description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to portable emergency lights, and more particularly, to a self-contained, water activated, hand-held strobe light and distress marker which may be used with various light filters to alert emergency rescue personnel in a combat or non-combat water environment.
2. Description of the Prior Art
Strobe lights have been used for many years in order to make persons or objects more visually detectable. The strobing effect of the light, particularly at night, draws an observer's attention directly to the light. In nighttime emergency situations, this effect is very beneficial since persons in need of rescue often require prompt response from rescue personnel. Locating a person at night in the open sea is difficult, often because of the sheer size of the area that must be searched. The use of a strobe light enables emergency personnel to reach persons much more quickly since a bright, flashing strobe is very noticeable no matter what the conditions.
Portable strobe lights have been used by aviators for many years. Military aviators, often operating over large ocean expanses, have found the use of small strobe lights extremely effective in locating downed personnel. However, because the strobe light is visible in all directions, the use of such a light in a combat environment in enemy or hostile territory would also direct enemy forces to a downed aviator. Additionally, a bright flash might also be misinterpreted as a gun muzzle flash which could draw aircraft or ground fire. All of these disadvantages have indicated that there is a need for a small, lightweight, watertight, water activated, portable strobe light which may be used with one or more filters and which can be operated from a single, self-contained battery-operated source.
An example of an emergency strobe light is U.S. Pat. No. 5,490,050, (the '050 patent) the disclosure of which is incorporated herein by reference. The '050 patent was issued to Clark et al., and is assigned to the owner of this application. As can be seen by the disclosure, the device of the '050 patent has some of the features of the present invention, with the present invention being an improvement thereto.
The present invention provides a portable, water activated, hand-held emergency strobe light that can be used in both combat and non-combat water-born environments. If water activated in daylight, the strobe light will not turn on until darkness to conserve battery power. A special infrared (IR) strobe filter and circuit provides for daytime shut off of the strobe light. The light is powered by alkaline batteries with an energy saving circuit to extend the useable battery life.
SUMMARY OF THE INVENTION
The present invention is directed to a portable strobe light for use in emergency or distress situations for locating personnel in both combat and non-combat water-born environments. The light includes a flashing xenon bulb and a transparent or clear, water-protective bulb cover contained at one end of a small, hand-sized housing. The xenon bulb emits a bright, white light through the clear cover, and flashes approximately one flash per second.
A self-contained power source (battery) within the housing powers the bulb and associated circuitry while a manually-actuated, sparkproof power on/off switch lever mounted outside the housing actuates a switch controlling the electronic strobe circuit inside the housing. Once armed by the manual switch, a second, water activated switch, turns the light on upon coming in contact with water. Once the water activated switch comes in contact with water, a latching circuit maintains the water activated switch in the on position. To insure the light is only activated at night, a third switch, consisting of a photo sensor and associated circuitry, prevents the light from being activated during the day.
Once activated, the light will remain on until the light is turned off by the manually-activated switch, or when daylight returns, or when the battery becomes exhausted.
Special power saving circuitry allows the use of alkaline batteries. In general, mercury batteries have a slower voltage drop over time than alkaline batteries, however, the use of alkaline batteries is preferred due to the reduced environmental harm caused by alkaline batteries verses mercury and other type batteries. Special power saving circuitry makes the alkaline battery voltage discharge over time appear similar to the slower discharge rate of the mercury batteries.
The light includes a flash guard slidably mounted to the exterior housing, having a positionable peripheral light shield and two different light filters, each of which may be positioned over the strobe light by manual manipulation of the flash guard to provide different light emission wave lengths and directional profiles. The flash guard is optionally removable.
The light has three different operating modes, i.e. white only, infrared only, or blue only. The first light filter acts to block all visible light below infrared wavelengths. The second filter inside the flash guard is used independently of the infrared filter to block all but blue light. When the blue filter is in use, the flash guard on the housing is positioned so that a peripheral light shield around the xenon bulb creates a tunnelling effect to block peripheral transmission of the blue light, in a line-of-sight manner, for manual aim in a desired direction.
The strobe light housing is constructed of a rigid plastic material that is watertight and can be any shape but is preferably substantially rectangular in shape, having the xenon bulb mounted at one end underneath a clear, watertight plastic bulb cover. A manually operated, slidable on/off switch actuator is mounted externally on one face of the housing, and is a waterproof switch that arms the battery and the strobe light bulb through internal circuitry.
A water activated switch, connected to a latching circuit, is mounted on another face of the housing to activate the light when in water. A photosensor is mounted near the bulb under the watertight plastic bulb cover to prevent activation in daylight. The sensor is a special photosensor that is sensitive to infrared light rays. A photosensor activated by visible light rather than infrared light rays would not prevent the light from becoming activated when the infrared filter is in place.
When the IR filter is manually positioned in place, the IR filter covers the light bulb and the sensor. The infrared filter blocks the transmission of light having wavelengths below the infrared region of the electromagnetic spectrum, which includes visible light. Therefore, if the photosensor were sensitive to visible light, the infrared filter would block the transmission of visible light, the sensor would receive no input, and allow activation of the strobe light during the day. By making the photosensor sensitive to infrared radiation, the filter will not permit activation of the strobe light during the day because sunlight contains infrared rays that penetrate the infrared filter and impinge upon the infrared sensor, thus preventing activation of the strobe light during the day.
In an alternate embodiment, the strobe can be supplied without the infrared or blue filter. In this embodiment, the photosensor can be sensitive to visible light and prevent activation during the day.
Without the flash guard, the strobe light would operate in a normal fashion, providing pulsed, high intensity white light in a 360° area, hemispherically surrounding the strobe light when activated.
The flash guard, in accordance with the present invention, is a rectangular, hollow body that fits slidably over the exterior portions of the strobe light housing while still exposing the on/off switch actuator and water switch. The flash guard, once installed on the housing, is optionally removable. The flash guard is normally kept in a storage or stored position in which the infrared filter forms a light seal over the clear protective cover of the strobe bulb and infrared sensor. If the light were activated in the storage position, only infrared rays would be emitted, unobservable by human beings. The shape and configuration of the infrared lens allows for a snug fit above and around the clear bulb cover in the storage position. The peripheral edges of the infrared filter overlap inwardly into the body of the flash guard, forming a light seal around the edges. In the flash guard storage position, the flash guard body and infrared filter is mechanically locked in place and can be moved only by deliberate manual manipulation to change operation modes.
The flash guard has an external, movable infrared filter that covers the clear bulb cover in the storage mode and allows only infrared light to pass from the strobe light, and an internal blue light filter that is positioned over the white strobe light when the flash guard body is moved to a particular position longitudinally relative to the strobe light housing. Thus, the flash guard body is moveable longitudinally to provide multiple positions for manually providing different light frequencies and area distribution, depending on the situation.
The present invention allows for three different light-emitting conditions for the strobe light viz. white, blue or infrared light. In the flash guard storage position, the exterior IR filter on the flash guard covers the white strobe light, bulb cover, and infrared sensor with an infrared filter, such that only infrared light is allowed to pass through the filter. In many military and combat environments, the use of infrared equipment is well known, including infrared detectors that are used at night for locating various objects radiating IR energy. The IR filter can be rotated manually 90° from the flash guard stored position to a position out of the way of the white strobe light to provide a white light operating condition. In the white light operating position, the white light is prominently displayed and exposed outside of the flash guard for normal operation emitting white light, 360° peripherally and 180° elevationally. The blue filter operating position is achieved by sliding the flash guard body relative to the strobe light housing, causing the blue filter to move into position over the white strobe light and bulb cover within the flash guard body passage which acts as a peripheral shield. In a combat situation, a downed aviator, for example, could use the infrared filter in the storage position and direct IR rays in the direction of a helicopter or other equipment known to have infrared detecting equipment. The infrared detector operator could then observe a pulsing, infrared signal, not visible to the human eye in the area. This could be useful in peacetime or combat situations. Inside the flash guard body, when moved to the blue filter position, a dark blue light filter allows only dark blue light to pass in a line-of-sight fashion from the top opening of the flash guard. This would be highly directional by the person holding the light, and could be directed in a known direction of friendlies, who could observe and expect to see a blue light, indicating friendly downed personnel. Such a line-of-sight method could also be directed at overhead aircraft if the downed person realized that they were friendly aircraft looking for the downed person. The blue light would positively identify the person and would not be confused with muzzle flashes from firearms. Also, surrounding personnel would not be able to see the blue light because of the shield formed by the flash guard.
Thus, the present invention is capable of peacetime and combat usage, can emit white, strobed light, or an infrared or blue light, shielded, depending on the circumstances, by mere manipulation of a flash guard contained on the strobe light housing.
It is an object of this invention to provide a portable emergency strobe light for locating downed personnel in water borne areas that is useful in both peacetime or combat environments that is water activated.
It is another object of this invention to provide a water activated strobe light for emergency location of downed personnel that includes a latching circuit that maintains the water activated switch in the on position after the water activated switch comes in contact with water.
A further objective of the present invention is a water activated emergency strobe light that includes a photosensor that permits activation of the strobe light only at night.
And yet a further object of this invention is to provide a water activated emergency strobe light that includes a power saving circuit that permits the use of alkaline batteries efficiently.
It is still another object of this invention to provide a water activated emergency strobe light having three different selectable modes of light transmission and emission, including white light, or infrared light that are directed hemispherically, or blue light that can be directed in a particular line of sight, all modes using the same strobe light source.
In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of the strobe light, including flash guard, showing the present invention.
FIG. 2a is a front elevational view of the strobe light with the flash guard in its retracted position, and the infrared lens pivoted to expose the white light.
FIG. 2b is a side elevational view of that shown in FIG. 2a.
FIG. 3a is a front elevational view of the strobe light, with the flash guard in a retracted position, with the infrared lens extended above the clear lens, an intermediate position.
FIG. 3b is a side elevational view of that shown in FIG. 3a.
FIG. 4a is a front elevational view of the strobe light and flash guard in the retracted position with the infrared lens retracted over the clear lens in the flash guard storage position and IR operation position.
FIG. 4b is a side elevational view of that shown in FIG. 4a.
FIG. 4c is a top plan view of that shown in FIG. 4a.
FIG. 4d is a bottom plan view of that shown in FIG. 4a.
FIG. 5a is a front elevational view of the strobe light and flash guard, shown with the flash guard in an extended position, with the infrared lens extended over the clear lens, a non-operable transition position while moving the infrared lens to an out of the way position.
FIG. 5b is a side elevational view of that shown in FIG. 5a.
FIG. 6a is a top view of the strobe light and flash guard, shown extended, with the infrared lens in a non-operable out of the way position.
FIG. 6b is a side elevational view of that shown in FIG. 6a.
FIG. 7a shows a side cross-sectional view, through lines 7a-7a shown in FIG. 7b, of the strobe light where the blue lens and spring are stored along a side of the lamp housing.
FIG. 7b shows a top view of that shown in FIG. 7a.
FIG. 7c shows a side cross-sectional view of the strobe light, through lines 7c-7c shown in FIG. 7d, in which the light is in an extended position and the blue lens is bent in a U-shape over the clear cover.
FIG. 7d shows a top view of that shown in FIG. 7c.
FIG. 8a and 8b is a schematic diagram of the strobe light operational circuitry.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, the invention 1 is shown comprising a strobe light 2, and depicts each of the components in an exploded format. The strobe light 2 is comprised of a main exterior housing 3, and a clear, watertight, transparent bulb cover 14. The housing 3 is manufactured of a durable, polycarbonate plastic, and may be colored brightly, such as bright orange or the like, for ease in detection. Alternatively, housing 3 may be colored black or olive to insure the unit's stealth. The main housing 3 includes a waterproof, manual light activating switch actuator 7 for activating an internal strobe light bulb electrical circuit shown in FIGS. 8a and 8b. Switch actuator 7 is a sparkproof magnetic switch which will neither spark nor ignite combustible gases or fuels when actuated. This feature is critical in the event of an aircraft or boating accident where a flammable gas or liquid may be on or near the user hand-held rescue light.
Housing 3 includes a switch guide and retainer channel 9 for sliding longitudinal movement of the switch actuator 7 therein between "on" and "off" positions of the light bulb. Four switch actuator detents 10 act to hold a retaining pin (not shown) attached to a lower portion of the switch actuator 7 within switch guide 9. These detents 10 hold switch actuator 7 into a respective on or off position. A lanyard 11 passes through an aperture at the lower end of switch guide 9 and is used to attach the strobe light 1 to the hand or other fixed object.
At the upper end of the strobe light housing 3, a flash lamp or xenon light bulb 13, as seen in FIG. 1, is connected to a fixed panel 3a, having a reflective surface. Flash lamp 13, when actuated by the flash circuit, emits approximately 250,000 peak lumens per flash at an initial flash rate of 60 FPM +10 FPM. Flash lamp 13 is a xenon bulb or the like, and emits a white, visible light at a frequency range between approximately 4,000 and 7,700 Å. The visibility of flash lamp 13 exceeds one nautical mile on a clear, dark night. At the top of flash lamp 13, a clear, transparent cover 14 allows light transmission through the cover 14 while guarding the bulb 13 against damage due to moisture or collision with foreign objects.
Also at the upper end of strobe light 2, located near bulb 13 and under cover 14, is photosensor 13'. Photosensor 13' is sensitive to infrared (IR) energy, and prevents the activation of strobe light 2 during daylight hours when light rays are received at sensor 13'. Sensor 13' prevents strobe 2 from wasting battery power by uselessly flashing during the day.
At the lower end of housing 3, water activated switch 7', upon coming in contact with water, activates strobe light 2's control circuitry, shown in FIGS. 8a and 8b. Water activated switch 7' is located in any suitable location such as that shown in FIG. 1. In the preferred embodiment, assuming manual switch 7 is in the "on" position, once water activated switch 7' comes into contact with water, strobe light 2 will remain "on" until deactivated. Strobe Light 2 can be deactivated by either infrared light rays reaching IR sensor 13', or switch 7 being turned to the "off" position.
Thus, strobe light 2 will only be activated if manual switch 7 is turned on, no infrared light rays are being received by IR sensor 13', and water activated switch 7' has come in contact with water.
A memory latch circuit, as shown in FIGS. 8a and 8b and fully described herein below, prevents strobe light 2 from becoming deactivated if water activated switch 7' comes in contact with water and is then removed from water. The memory latch circuit maintains activation on strobe light 2 until deactivated by one of the two methods described, or by exhaustion of the battery. In this manner, if a rescue victim crawls from the water into a raft or onto floating debris removing the emergency strobe light from contact with water, the strobe light will not turn off.
The strobe light housing 3 fits within the hollow passage 15 of flash guard 200 and flash guard body 5. The flash guard and its light filters are movable relative to the strobe light housing and bulb between three different operating positions, explained below. Switch guide 9 fits within a cut out area on one face of flash guard body 5, so that the switch actuator 7 protrudes above the flash guard body surface. The flash guard body 5 also has an internally mounted blue light filter 27' along with spring 23 that bends translucent plastic blue light filter 27' over cover 14. As best seen in FIGS. 7a-7d, spring 23 forces blue filter 27' downward over the top of clear cover 14. This occurs when the flash guard body 5 is longitudinally, manually pulled along strobe light housing 3 into an extended position. A second light filter, plastic infrared light filter 27, (hereinafter referred to as IR strobe filter 27) includes rigidly attached support members 29 and corresponding position holding apertures 31. A pair of mounting posts 21 are rigidly attached to the upper portion of the flash guard body 5, one on each side, which fit through and over apertures 31 and allow the IR strobe filter 27 to be manually pivoted about the posts 21 between an operable position when the flash guard is in a stored position, and pivoted to an out of the way position to expose the white or blue light modes.
In FIGS. 4a, 4b, and 4c, the strobe light with the IR strobe filter 27 is shown in the flash guard storage or stored position. In the stored position, IR strobe filter 27 rests on top of the flash guard body 5, above and covering bulb 13. As seen in FIG. 4b, IR strobe filter 27 and lower edge 27a is positioned to overlap below the top edge of the flash guard body 5 to act as a white light seal around the upper edge of the body 5. The flash guard body 5 is not extended. Position barrier tabs 12, extending from the switch guide 9 on each side, press against the upper position detent 19 so the flash guard body 5 cannot be moved toward the strobe light housing base. The IR filter can be used in this position by switching on the light. Only IR rays will be emitted.
In FIGS. 2a and 2b, the IR strobe filter 27 has been moved (pivoted) from the flash guard storage position and IR operating position to an out-of-the-way location that exposes white light bulb 13 and clear cover 14. This is the white light operating position.
FIGS. 3a and 3b show the longitudinal extent (manually) of the IR strobe filter 27. The IR strobe filter 27 can be moved from a side position (FIGS. 2a and 2b) upwardly into an IR operable position directly above, covering the clear cover 14, as shown in FIGS. 4a and 4b. FIG. 3b specifically shows that the mounting post 21 is at the rear of slot 31. Thus, in the IR operating position, the IR strobe filter 27 snaps downward over the clear cover 14. This is best seen in FIGS. 4a and 4b. FIG. 4b shows the mounting post 21 (one on each side) at the upper portion of slot 31 after the IR strobe filter 27 has been snapped into the IR emitting operating position. The IR strobe filter 27 perimeter 27a overlaps and fits snugly into a recess created by the junction of clear cover 14 and main housing 3. IR strobe filter 27 totally overlaps clear cover 14 to provide a completely leakproof light barrier. Support member 29 also holds IR strobe filter 27 by its frictional engagement with the outer surface of the flash guard body 5. A tight fit is required to prevent visible light emitted from the flash lamp bulb 13 from being emitted around the edges of the IR strobe filter 27.
The IR strobe filter 27 is made of durable plastic and acts to filter visible light below approximately 7,500 Å. As specified above, the IR strobe filter 27 is made generally of a concave shape, and is C-shaped in cross section. This allows a snug fit and overlap that conforms in shape over the clear bulb cover 14 to prevent any visible light from escaping around the edges of the cover 29.
Since the IR spectrum ranges from approximately 7,500 Å to above 36,000 Å, the IR strobe filter 27 filters out visible light below approximately 7,500 Å, allowing only IR frequencies to pass through the filter. Using an IR detection system (not shown), this IR light source can be readily detected. The IR is normally invisible and undetectable to the naked eye, useful in a combat situation. Hence, the strobe light 13, using IR strobe filter 27, can be used by the military or others who wish to avoid detection to all persons except those with IR detection equipment.
Photosensor 13' must be sensitive to infrared light above 7,500 Å to operate correctly when IR strobe filter 27 is in position covering bulb 13 and sensor 13'. A special infrared sensor can be used, or a standard photo sensor that is sensitive to light above 7500 Å can be used to form sensor 13'.
FIGS. 4a, 4b, 4c, and 4d show the IR strobe filter 27 in its operational position. This is also the compact stored position of the flash guard and the entire strobe light. Switch actuator 7 is shown in its "on" position. FIG. 4c shows the IR strobe filter 27 fitting completely over the flash lamp 13, infrared sensor 13', and clear cover 14. FIG. 4d shows the access door to the internal battery compartment (not shown) within strobe light housing 3. A screw member 33 includes an elongated, threaded shaft (not shown) which engages inside the strobe light housing 3 to hold the access door 35 to the battery housing. The battery housing typically holds two AA alkaline batteries, or in the alternative, two AA lithium iron sulfide batteries if a long shelf life is desired. The screw member 33 and rubber gasket (not shown) surrounding the access door 35 insure the battery compartment is tightly sealed and is both vibration proof and waterproof to a depth of approximately thirty meters.
FIGS. 5a, 5b and 6a, 6b show the flash guard body 5 in a longitudinally (manually) extended position relative to the strobe light housing 3 required to move the IR strobe filter 27 when it is desirous to use the blue filter 23 and to shield light emission laterally for line-of-sight transmission. The blue filter 23, when moved by a flexible spring, or bendable wire, over the flash lamp 13, acts to transmit light at approximately 5,500 Å. The blue filter 23 would be used during nighttime in a combat area for positive identification by a friendly and direct line-of-sight positioning by the user to aim the blue light beam at a friendly aircraft or position without detection by the enemy.
For a white flashing strobe light, the IR strobe filter 27 is manually extended and pivoted about its mounting posts 21 where it is moved out of the way of clear cover 14 and into its stored position as seen in FIGS. 6a and 6b. As seen in FIG. 6b, the IR strobe filter 27 may be positioned flat against the surface of flash guard body 5. The flash guard body 5 stays in the retracted position for use of the white strobe light. Lower position detent 17 prevents the strobe light housing 3 from being totally disengaged and removed from the flash guard body 5.
As seen in FIGS. 7a, 7b, 7c and 7d, when the strobe light housing 3 is extended relative to the flash guard body 5, bulb 13 and cover 14 are moved into a position behind blue filter 27'. Blue filter 27' is stored in an extended position along the side of strobe housing 3. Blue filter 27' is relatively thin and pliable, capable of bending and flexing into a U-shape repeatedly without damage. Spring 23 is also positioned adjacent and against the outer surface of blue filter 27'. The spring 23 may be approximately the same length as blue filter 27' and has a narrow dimension so a limited amount of filter area is covered. Spring 23 is typically positioned down the center of blue filter 27' in order to facilitate ease of movement. Alternatively, the spring may be placed at either side of blue filter 27'. FIG. 7a shows a side sectional view of blue filter 27', in a stored position, inside of the strobe housing 3. FIG. 7b shows a top view of blue filter 27' in its stored position. FIG. 7c shows a side sectional view of the extension of housing 3 relative to the flash guard body 5. As flash guard body 5 is moved into position, spring 23 is exposed at the upper portion of flash guard body 5 and tends to bend into its naturally U-shaped position. In turn, the spring 23 forces the pliable upper portion of blue filter 27', which is beneath spring 23, downward. As seen in the figure, blue filter 27' flexes and bends into a U-shape over the top of clear cover 14. FIG. 7d shows a top view of spring 23 providing a biasing force to bend blue filter 27' thereby covering flash lamp bulb 13 and clear cover 14. When retracting the flash guard body 5 back into the position shown in FIG. 7a, the surface of strobe housing 3 forces both spring 23 and blue filter 27' back into a straight position where it is again stored until its use is required.
When extending the strobe light housing 3 relative to flash guard body 5 to use blue filter 27', the upper portion of flash guard body 5 is moved so that the inner channel encompasses the blue filter to create a lateral peripheral light barrier or tunnel to effect line-of-sight directionality by manually pointing the light in a desired direction. This allows blue light which is emitted from blue filter 27' to be directed to a specific area. In a night combat environment, a friendly can identify the light source while the user can direct the light toward a known friendly aircraft, ship, or area. The IR strobe filter 27 is always moved out of the way when using the blue filter 27'.
As stated above, IR strobe filter 27 is used to generate an IR strobe from bulb 13 when water activated switch 7' is in contact with water. For IR operation, IR strobe filter 27 completely covers bulb 13 and sensor 13'. For sensor 13' to keep the strobe off during daylight hours, and, because only IR passes through IR strobe filter 27, sensor 13' must be IR sensitive. Daylight includes infrared (IR) radiation not visible to humans. The IR radiation in daylight passes through IR strobe filter 27 and impinges on sensor 13'. If IR strobe filter 27 is removed from the IR operation position and manually placed on the side of housing 5 for white light operation, sensor 13' continues to receive IR radiation from direct sunlight and will prevent activation of the strobe during daylight hours.
The present invention can be provided in an alternate embodiment without flash guard 200 which includes IR strobe filter 27 and blue filter 27'. In this embodiment, photosensor 13' will continue to receive IR radiation from direct sunlight. However, sensor 13' will not need to be sensitive to IR radiation if a water activated strobe is constructed without an IR filter, as any sensor that is sensitive to visible light will suffice.
FIGS. 8a and 8b shows the circuit diagram for strobe bulb 13 activation. Once switch actuator 7 is positioned to the "on" position, water activated switch 7' has been triggered, and infrared sensor 13' is not triggered, the strobe bulb 13 will pulse in accordance with the circuit parameters.
Operation of the memory latch circuit is best described by referring to FIG. 8a. When battery power is supplied to J1 and J2, switch S1 must first be closed to activate the circuit. When switch 7' is activated by a water path between J3 and J4, Q2 is turned on. This in turn activates Q7 which allows current to flow through Q3. The flow of current through Q3 to Q2, maintains Q2 in the "on" state, which maintains Q7 in the "on" state, which in turn maintains current to Q3. This sequence also supplies power to the collector of Q1, regardless of what now happens to water activated switch 7'. Hence, once manual switch 7 is on, and water activated switch 7' is engaged, Q2, in conjunction with Q3 and Q7, will latch on and provide current for the rest of the circuit to operate.
Q7 provides current to D5 and hence provides the input to pin 3 of U1. Q7 also provides current to the collector of Q8 through a divider consisting of R10 and R11. R5 can optionally be used in an alternate embodiment where there is no water activated switch. Current passing through Q8 is dependent upon activation by the operation of U1. The output of U1 is dependent upon the input on pins 2 and 3. The input to pin 3 is fed by the activation of Q7 via the above described latching of Q7, Q2, and Q3. However, the input of pin 2, and hence the output of U1, is dependent on whether Q1 is "on" or "off", which controls the state of Q4. Q4 in turn controls the input to pin 2.
When Q1 is turned "on" by reception of infrared or visible light rays, Q4 is turned "on" which supplies the input to pin 2 of U1. In this state, the output of U1 is low, and Q8 will be off. When Q1 turns off by removal of the infrared or light rays, Q4 turns off altering the input to pin 2, causing the output of U1 to go high, turning Q8 on. Q8 then passes current to the remainder of the strobe circuit, as shown in FIG. 8b.
The components comprised primarily of Q8, R10, and R11 provide compensation for the current flowing from Q8 to the reminder of the strobe circuit shown in FIG. 8b. The purpose of the compensation is to provide a constant current to the strobe circuit as the battery voltage drops over time. Typically, a plot of the voltage verses time characteristics of certain batteries, such as mercury type batteries, appears flat over time until it nears the end of the lifetime of the battery, where the voltage drops off rapidly. This is a desirable trait for supplying power to the strobe circuit so the light will continue to flash brightly. However, the use of mercury batteries can be harmful to the environment. Alkaline batteries are desired because they are less harmful to the environment.
The voltage characteristics of alkaline batteries, when plotted with respect to time, show a steady decline of battery voltage over time. This steady decrease in battery voltage can cause a corresponding decrease in strobe light brightness and/or frequency. The compensation components comprised primarily of Q8, R10, and R11 offset the decrease of voltage over time due to the use of alkaline batteries, such that the strobe circuit receives a constant current supply for a predetermined required time, as set by U.S. government operational requirements of 8 hours of continuous operation, and remains bright and at a steady pulse frequency until the end of the useful battery life.
The present invention provides efficient, manually-actuated strobe light filters and light guard to allow a white strobe light, used for emergency location purposes in a water environment, to be converted into a combat useful light that can emit light rays in both the infrared region of the spectrum and in the blue ray region, to allow a person in an emergency situation to be located when in enemy territory or a combat situation. Otherwise, the light can also be used as a normal water-activated survival light to find someone at night in remote locations with a strong, white, pulsed strobe light. Using the infrared spectrum in a combat situation, the device can transmit infrared light below the human visible spectrum to infrared detectors used by friendly forces to locate the downed person. Likewise, using a blue light and a tunnel-like shield around the strobe light, a highly directional line-of-sight emission of blue light rays can be transmitted at night in the direction of friendly forces or vehicles to attract attention, known by friendlies to look for a blue, pulsing light. The flash guard, in accordance with the present invention, can be affixed in conjunction with the housing of a white strobe light.
Other embodiments of the present invention are contemplated and included under the scope of the invention. For example, the light can be provided without a water activated switch, without a light sensor, with or without an IR filter, or in any combination of the features disclosed herein.
The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art. | A hand-held water activated strobe light which may be used in rescue or emergency operations in peacetime or in a combat zone. The light includes a watertight housing with a high intensity bulb which flashes white light. Interchangeable blue and infrared filters attached to a flash guard body can be used with the bulb for filtering various wave lengths of light spectrum in combat situations and for both 360 degree or line-of-sight transmission. The strobe light is water activated and includes a sensor that deactivates the light during daylight hours. A memory latch circuit maintains activation of the light once the water activated switch comes in contact with water. A power saving circuit permits the use of alkaline batteries in place of mercury batteries, which also provides for environmental protection. | 5 |
BACKGROUND OF THE INVENTION
The present invention concerns devices for allowing the user of a wheelchair to carry personal possessions along with him or her while moving in the wheelchair, and more particularly such a device for carrying such articles beneath the chair, so that the user of the wheelchair has hands free for the operations necessary in moving from place to place in the wheelchair.
Many thousands of people in our society engage in varied activities in wheelchairs, for which they are required to carry a number of possessions with them while moving from place to place. Students must carry books and notebooks. Shoppers must carry purses and shopping bags containing articles purchased. There is a need for an apparatus whereby the user of a wheelchair may carry such articles in a manner which leaves the user's hands free for rotating the wheels of the wheelchair, and for the other activities necessary for moving from place to place in the wheelchair. It is generally unsatisfactory to carry such articles in one's lap, since they may easily be dropped.
Since wheelchairs ordinarily do not come equipped with such carrying apparatus, there is also a need for such an apparatus which can be used with wheelchairs of varying sizes. Applicants' device satisfies this need by providing such a carrying device of the form of a platform of cross-linked cloth strips which can be mounted to the underframe of the wheelchair, which attaches to the frame by Velcro fasteners attached to the ends of cloth strips which make up the device, said Velcro fasteners having sufficient positions to accommodate a range of wheelchair frame sizes.
Although a platform located beneath the seat of the wheelchair can be used to carry personal articles, there is also a need for such a device to provide a means for carrying the articles securely when the wheelchair is moving in an upwardly inclined orientation, as when the user is going up a wheelchair ramp, or going up over a curb at the edge of a street, in which case the articles will naturally tend to slide and fall off the rear end of the platform, sometimes without the user of the wheelchair even being aware of the loss. Even when the user is aware that objects have fallen, there is the inconvenience and delay of having to turn around and go back to retrieve them.
Applicants' device deals effectively with this problem by providing at least one cloth strap at the rear of the support platform which is located above but parallel to the support platform, just slightly above the platform, which acts to stop personal objects from sliding off the rear of the platform.
SUMMARY OF THE INVENTION
The invention is a carrying device for carrying articles beneath a wheelchair, comprising in combination an array of cross-linked cloth straps for attachment to the underframe of a wheelchair; and attachment means for attachment of said array to the underframes of wheelchairs of varying width, which attachment means is, in the preferred embodiment, a plurality of Velcro fasteners on those of said straps which extend to the sides of said wheelchair; said array further comprising securing means for preventing articles carried on said array from being dislodged and falling from the rear of said array when the forward end of said wheelchair is inclined upward, as when proceeding up a wheelchair ramp or going upward over a curb, said securing means in the preferred embodiment comprising at least one of said straps for attachment to the rear of the underframe of said wheelchair at an elevation slightly above the elevation of the main portion of said array.
The purposes of Applicants' invention include the provision of a carrying apparatus allowing the user of a wheelchair to carry articles beneath the seat of the wheelchair, having advantages which include, but are not necessarily limited to, providing such an apparatus which, in the preferred embodiment: is easy for the user to quickly attach to or detach from the wheelchair; is inexpensive to manufacture; is light in weight, using a minimum of necessary material; is adjustable to fit wheelchairs of varying frame sizes; is flexible to accommodate articles of various shapes; will fold along with the wheelchair when it is folded; can be used to carry a variety of personal articles such as books and notebooks of students, purses, coats and shopping bags; and provides means to carry such articles securely so that they will not slip off the back of the support when the wheelchair is inclined upward as in jumping a curb.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the device attached to a wheelchair.
FIG. 2 is a plan view of the device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, in which like reference numbers denote like or corresponding elements, the device of the present invention provides a means for supporting articles beneath the seat 2 of the wheelchair 4. Said support means is an array 6 of cross-linked cloth strips, formed by a set of parallel strips 8, which are to extend from side to side beneath seat 2, and another set of parallel strips 10, at right angles to and interlocking with strips 8, said strips 10 extending from the front to the rear of wheelchair 4. For strength of support for the articles to be carried, the strips 8 and strips 10 are sewed, glued or otherwise attached to one another in any convenient, secure fashion, at each of the points at which one of strips 8 crosses one of the strips 10. The use of cloth strips for strips 8 and 10 offers the advantage of flexibility of the support means provided by array 6, which facilitates using the invention to carry articles of varied shapes on array 6, since array 6 can to some extent deform to accommodate the shapes of the articles carried. Seat belt strip material is used for the strips 8 and strips 10.
The invention also includes attachment means, for attaching the array 6 to the frame of wheelchair 4, for frames of varying sizes. Each of the strips 8 except the strip 12 has at each end thereof an end section 14, and each of said end sections 14 extends beyond the corresponding outermost one of the strips 10. For purposes of attachment of array 6 to the horizontal frame members 16 located at the sides of the base of wheelchair 4, and in order to allow such attachment to be made for a range of sizes of wheelchair 4, i.e. for a range of spacing distances between the two frame members 16, Velcro attachments are provided on strips 8, in a manner conducive to accommodating wheelchairs of various sizes. A velcro hook section 18 is attached near the outer end of each end section 14. Attached at various spaced locations along each of the strips 8, at locations between the crossing points of the strips 10, are a series of Velcro loop sections 20, to each of which the velcro hook section 18 at the end of the corresponding end section 14 may be attached. The lengths of the end sections 14, and the number of the Velcro loop sections 20, allow the end sections 14 to be looped around the frame members 16, and allow the velcro hook section 18 at the end of each end section 14 to be attached to an appropriate Velcro loop sections 20, so that array 6 is secured to frame members 16 of wheelchair 4. By suitable choice of the length of end sections 14, and the number of Velcro loop sections 20 spaced along strips 8, the apparatus may be made to be usable with wheelchairs having any desired range of spacing between frame members 16. The strip 12 at the rear of array 6 is not equipped with the Velcro fasteners, because of the proximity of frame joint 22 of the frame of wheelchair 4, at which frame members 16 join vertical frame members 24 on each side of wheelchair 4. The forwardmost strip 26 of the strips 8 has an additional velcro hook section 28 located a small distance inside each of the corresponding velcro hook sections 18. Because of the proximity of the forward wheel 30 of wheelchair 4, this extra velcro hook section 28 allows some latitude for fastening of strip 26 to frame members 16, which may be necessary depending upon the size of forward wheel 30.
The invention also provides securing means for preventing carried articles from sliding off of the rear of array 6 when wheelchair 4 is inclined with the front end thereof above the rear end thereof, as when the user is moving up a wheelchair ramp, or going up over a curb. The principal such securing means is provided by the combination of a strip 32, of the same material as the strips 8 and the strips 10, which in the operational configuration of the device is oriented with its plane vertical and with its longitudinal axis disposed horizontally a short distance above the plane of array 6, and end sections 34 of the strips 10, which are in the operational configuration oriented vertically at the back of wheelchair 4, extending up to and around strip 32, to which they are secured by means of velcro hook sections 36 attached to the outer end of each of end sections 34, and velcro loop sections 38 attached to each of end sections 34 at a suitable position further from the end of each of end sections 34 than the locations of velcro hook sections 36, with the spacing between velcro hook sections 36 and velcro loop sections 38 being sufficient to allow the endmost portion of each of end sections 34 to be looped around strip 32, to which each of the end sections 34 is secured by attachment of its velcro hook section 36 to its velcro loop section 38. The strip 32 has Velcro hook sections 40 at the ends thereof, and Velcro loop sections 42 located inside the positions of loop sections 42, so that strip 32 may be attached to the vertical frame members 24 of wheelchair 4. The loop sections 42 have sufficient length to allow strip 32 to be attached to the frames of wheelchairs of varying frame width, for the same range of frame widths as may be accommodated by the above-described Velcro fasteners for strips 8. In this manner the strip 32 and end sections 34 form a barrier at the rear of and above the plane of array 6, which acts to prevent carried articles from sliding off the rear of array 6, particularly when wheelchair 4 is inclined at an upward elevation. Another feature of the invention which acts to some extent to secure carried articles against falling from the platform formed by array 6, is simply the fact that strips 8 and 10 are made of cloth, rather than being formed of a rigid material, so that the flexibility of strips 8 and strips 10 allows the central portion of array 6 to deform downward under the weight of the carried articles. Thus the outer edges of array 6 will be at a higher elevation than the central portion, and will therefore form somewhat of a barrier against loss of articles, not only to the rear, but also in the other directions.
Those familiar with the art will appreciate that the invention may be employed in configurations other than the specific forms disclosed herein, without departing from the essential substance thereof.
For example, and not by way of limitation, Velcro fasteners need not be used for making the fastening connections described above. Other kinds of fasteners could be used instead, such as button-type snap fasteners. Similarly, although seat belt material is used to form the strips 8 and strips 10 in the preferred embodiment, numerous other kinds of cloth or flexible plastic materials of suitable strength could be used instead.
Although the preferred embodiment employs an array 6 of uniformly spaced strips 8 and strips 10, it should be recognized that the invention may be fabricated in forms which depart from such uniform strip spacing, in order to allow the invention to be used with particular wheelchairs. For example, in some older model wheelchairs made prior to about 1980, the frame members 16 have a curved portion near the front of the wheelchair 4, and it may be necessary or convenient to vary the spacing of the strips 8 at this portion of the frame members 16.
The scope of the invention is defined by the following claims, including also all subject matter encompassed by the doctrine of equivalents as applicable to the claims. | A device for carrying personal articles below the seat of a wheelchair, which may easily be attached to the underframe of the wheelchair, and is adjustable to fit the frames of wheelchairs of varying sizes. An array of cross-linked cloth strips is equipped with spaced velcro fasteners to allow ready attachment to the frames of wheelchairs of varying width. A vertical security barrier of cross-linked strips at the rear of the carrying platform prevents dropping of articles from the rear when the wheelchair is inclined upward as in ascending a wheelchair ramp. | 0 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to a device for shape-forming at least one recess in a film-type material, said device featuring a die with at least one opening, at least one shaping stem that can be introduced into the opening to create the recess by shape-forming and a clamping facility for holding the film-type material fast between the clamping facility and the die.
[0002] It is known to manufacture base parts of blister packs, also called push-through packs, or other packaging containers with recesses or cups to accommodate contents, by means of deep-drawing, stretch-drawing or thermo-forming methods. These types of packaging may be made from thermoplastics or film-type composites, or laminates such as aluminum foils laminated with plastic films, or extrusion-deposited layers of thermoplastics.
[0003] If the packaging is made from metal-containing laminates, the manufacturing process may be performed using tools comprising stems, dies and clamping facilities. During the shape forming operation, the laminate is clamped fast between the die and the clamping facility. In order to create the desired recess or cup, the laminate is pushed into the die opening by the stem, whereby the laminate is deformed by local elongation. The result is that a shaped part exhibiting one or more recesses is formed out of the originally flat laminate.
[0004] In order to be able to exploit the elongation properties of the material to be thus formed, and hence to achieve recesses with a good deepening ratio i.e. large depth and small diameter, it is known from EP-A-0779143 to carry out the cold-forming deepening of metal-containing laminates in two steps. Using a first stem with a shape-forming surface of high coefficient of friction, the metal-plastic composite is pre-formed and then formed into its final shape using a second stem with a shape-forming surface of low coefficient of friction. This procedure suffers the disadvantage that two different stems have to be employed one after the other and therefore calls for a high degree of precision with respect to the positioning of both stems. In another variant, a telescopic type of two part stem is employed instead of two different stems. These stems are however complicated in design and cannot be employed for forming all the standard kinds of laminate.
SUMMARY OF THE INVENTION
[0005] The object of the present invention is therefore to provide a device of the kind mentioned above by means of which two-stage forming can be employed for deepening purposes, achieving a good deepening ratio in a simple manner.
[0006] That objective is achieved by way of the invention in that counter-stems which are displaceable at least within the die openings are situated in the die, whereby shape-forming regions of the forming stems and the counter-stems for clamping the film-shaped material can, at least in part, be superimposed on each other.
[0007] The arrangement of a shaping stem and a counter-stem according to the invention offers the significant advantage over the state-of-the-art that, in a simple manner, using two successive forming steps to create a recess or cup, first the potential for forming the base part and then the potential for forming the side walls, or vice versa, can be exploited.
[0008] In a preferred device according to the invention the counter-stems are positioned on a piston that can be displaced into the die along the forming axis.
[0009] The surface of the forming region of the shaping stem and/or the counter-stem may locally exhibit different coefficients of friction. Because of this the friction between the shaping stem or the counter-stem and the film to be shape-formed can be adjusted such that the sliding behavior of the film on the shaping surface of the shaping stem and the counter-stem can be influenced during the forming process.
[0010] The coefficient of friction of the shaping surface of the shaping stem and the counter-stem can be adjusted such that either stem is made of the appropriate material or features a corresponding coating.
[0011] A low coefficient of friction is obtained e.g. using materials such as polytetrafluorethylene, polyoxymethylene (polyacetal, POM), polyethylene or polyethylene-terephthalate, or mixtures thereof. Other materials than plastics may be considered e.g. metals such as aluminum or chrome steel, in particular also with polished surfaces. Further usable materials are e.g. ceramic layers or coatings containing graphite, boron nitride or molybdenum-sulphide.
[0012] Materials that may be employed to produce surfaces with high coefficients of friction are e.g. metals such as steel, or plastics such as polyacetal (POM), polyethylene, rubber, hard rubber or caoutchouc, including acrylic polymers. The metal surfaces may be given higher coefficients of friction e.g. by roughening.
[0013] The outer part of the forming and counter stems in the regions of the surfaces effecting the forming may be different in shape depending on the desired shape of recess or cup. In the simplest case the shaping and counter-stems are cylindrical in shape and exhibit flat bases; however, other three-dimensional shapes such as e.g. conical, pyramid, blunted cone, blunted pyramid, segments of spheres or a drum-shape are possible. At the same time, the counter-stem may also have a corresponding shape that fits to the shaping stem.
[0014] The shaping stem and/or the counter-stem may also be in two parts with a hollow cylindrical outer stem part and an inner stem part that can be slid in a telescopic manner out of the outer stem part.
[0015] In a preferred version of the device according to the invention, near a clamping area at the edges of the openings of the die and the clamping device, both the die and the clamping device exhibit a substrate of material of low coefficient of friction for guiding the film. This insures that the edge of the recess is uniformly formed and pore-free.
[0016] The device according to the invention is particularly suitable for producing recesses in a plastic-coated metal foil by means of cold forming, for example for manufacturing the bases for blister packs.
[0017] For the purposes of shape-forming with the device according to the invention, suitable metal-plastic composite films have e.g. a metal foil of 8 to 150 μm, preferably 20 to 80 μm. Suitable metals are e.g. steel, copper and aluminum. Preferred foils of aluminum are e.g. of 98% purity or higher, whereby in particular one may employ aluminum foils of alloys of the AlFeSi or AlFeSiMn type.
[0018] The plastics employed may be e.g. layers, films or laminate films of thermoplastics of the polyolefin, polyamide, polyester and polyvinylchloride series, whereby the films and film laminates may also be uniaxially or biaxially stretched. Typical examples of thermoplastics from the polyolefin series are polyethylenes, such as MDPE, HDPE, uniaxially and biaxially stretched polyethylenes, polypropylenes such as cast polypropylenes and uniaxially or biaxially stretched polypropylenes, or polyethylene-terephthalate from the polyester series. The thickness of the thermoplastic layer, in the form of a layer, film or film laminate, in the metal-plastic composite film may be e.g. 12 to 100 μm, preferably 20 to 60 μm.
[0019] The metal foils and the thermoplastics may e.g. be joined together by laminate bonding, colandering or extrusion bonding into composites. To join the layers, one may employ, from case to case, laminate bonding and bonding agents, and the surfaces to be joined may be modified by a plasma, corona or flame pre-treatment.
[0020] Examples of metal-plastic composite films that can be employed may have a first layer e.g. a film or laminate made up of the above mentioned thermoplastics, a second layer in the form of a metal foil and a third layer, e.g. a film or film laminate or an extruded layer made of the above mentioned thermoplastics. Further layers such as sealing layers may be fore-seen.
[0021] The metal-plastic composite films may exhibit on at least one of its outer facing sides or on both outer facing sides a sealing layer in the form of a sealable film or sealing lacquer. The sealing layer is situated, for reason of its function, in the outermost layer of the composite laminate. In particular, a sealing layer may be on the outside of the composite, whereby in the case of a blister pack this sealing layer should be facing the contents side in order to perform the sealing on of the lid film or the like.
[0022] Typical examples in practice of metal-plastic composite films that are formable using the device according to the invention are:
[0023] oPA25/A145/PVC60
[0024] oPA25/A145/oPA25
[0025] A1120/PP50
[0026] oPA25/A160/PE50
[0027] oPA25/A160/PP60
[0028] oPA25/A145/PVC100
[0029] oPA25/A160/PVC60
[0030] oPA25/A145/PVC, PE-coated
[0031] oPA25/A145/cPA25
[0032] oPA25/A160/PVC100
[0033] oPA25/A160/oPA25/EAA50
[0034] where oPA stands for oriented polyamide, cPA for cast polyamide, PVC for polyvinylchloride, PE for polyethylene, PP for polypropylene, EAA for ethyl-acrylic acid and Al for aluminum, and the numbers represent the thickness in μm of the layers or films.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Further advantages, features and details of the invention are revealed in the following description of preferred exemplified embodiments and with the aid of the accompanying drawings which show schematically:
[0036] [0036]FIG. 1 a cross-section through a shaping station with a die with an opening;
[0037] [0037]FIG. 2 a cross-section through a forming station with a die having a plurality of openings;
[0038] [0038]FIG. 3 a plan view of the die in FIG. 2, viewed in direction A;
[0039] [0039]FIG. 4 a plan view of the clamping facility in FIG. 2, viewed in direction B;
[0040] [0040]FIG. 5 a longitudinal section through a version of a shaping stem with counter-stem;
[0041] [0041]FIG. 6 a longitudinal section through a further version of a shaping stem with counter-stem
[0042] [0042]FIG. 7 a sequence of process steps for manufacturing blister packs.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] In FIG. 1 a shaping station 10 features a die 12 with an opening 14 and a clamping device 16 with clamp opening 18 . Situated in the die 12 is a piston 20 which is sealed off in a fluid-tight manner against the inner wall 22 of the die 12 by means of seals 22 and delimits with respect to the base 25 of the die 12 a cylindrical space 26 , which can be filled with hydraulic fluid 28 via pipeline 30 . The movement of the piston 20 along the direction of its z axis is controlled via a valve 32 situated in the pipeline 30 . Depending on its function, the piston 20 can be pressure-controlled and/or distance-controlled by way of the valve 32 . The distance control is symbolized in the drawing by a distance display 34 . Of course the piston movement may also be effected by means of other means e.g. mechanical means instead of hydraulic means.
[0044] A distance-controlled shaping stem 36 penetrates the clamp opening 18 and can be moved in and out of the die opening 14 along a displacement axis z which coincides with the axis of the piston 20 . The base 42 of a counter-stem 40 mounted above the piston 20 lies facing the base 38 of the shaping stem along the direction of displacement z and can be advanced into the clamp opening 18 . The base 42 of the counter-stem 40 is covered with a coating 44 e.g. made of rubber.
[0045] A metal-plastic composite film 46 is held under force in a clamping region 48 between the die 12 and the clamping device 16 . Next to the clamping region 48 facing the openings 14 and 18 is a ring-shaped, stepped recess 50 and 52 respectively in the periphery of the die 12 and that of the clamping device 16 . In the recesses 50 , 52 is a ring-shaped insert 54 and 56 respectively made of a low-friction material. The film 46 slides between the inserts 54 , 56 .
[0046] The formation of a recess or cup 58 by shape-forming the film 46 clamped between the die 12 and the clamping device 16 is readily understood from FIG. 1. The film 46 , lying initially in a plane E in which it is clamped, is plastically deformed as it is pressed by the shaping stem 36 into the die opening 14 . In that process the recess 58 is formed with side wall 60 between shaping stem 36 and the inner wall 24 of the die and a base part 62 which corresponds to the base 38 and the shaping surface of the shaping stem 36 .
[0047] The shaping station shown in FIGS. 2 to 4 differ from that in FIG. 1 in that the die 12 and the clamping device 16 feature a plurality of openings 14 , 18 , in the present case 15 openings, and a pair of shaping stems 36 and counter-stems 40 facing each pair of openings 14 , 18 . The shaping stems 36 are mounted on a support plate 64 . Displacement of the support plate 64 in direction z leads to simultaneous displacement of all shaping stems 36 . In the same manner all counter-stems 40 are mounted on a common piston 20 with the result that, on displacing the piston in the direction z, the counter-stems 40 are also displaced simultaneously. This forming station enables therefore the simultaneous formation of a number of recesses or cups 58 in the metal-plastic composite, corresponding to the number of shaping stems 36 and counter-stems 40 .
[0048] The shaping stem 36 shown in FIG. 5 is made up of various parts 66 , 68 , 70 of materials of different friction coefficients. The surface 38 of the shaping stem 36 effecting the shape forming is comprised of the flat base 66 and the concentric, successively inclined side walls 68 , 70 . The surface 38 effecting the shaping extends over all of the parts 66 , 68 , 70 . The surface areas 66 , 68 , 70 effecting the shaping may therefore have different coefficients of friction. For example, the parts 66 , 68 , 70 are of materials with increasing friction coefficients, whereby the base part 66 exhibits the lowest coefficient of friction.
[0049] The shape of the base 42 of the counter-stem 40 coated e.g. with a rubber liner 44 matches that of the shape-effecting surface 38 of the shaping stem 36 .
[0050] The version of shaping stem 36 shown in FIG. 6 is telescopic in structure and exhibits a first hollow-cylindrical stem 36 a with a first ring-shaped shape-effecting surface 38 a. Sliding in this first stem 36 a is a moveable second stem 36 b with a second shape-effecting surface 38 b. This two part shaping stem 36 permits shaping with the shaping stem 36 in two steps. As in FIG. 5, the base 42 of the counter-stem 40 matches the shape-effecting surface of the shaping stem 36 , whereby a ring-shaped base part 42 a faces the ring-shaped surface 38 a of the shaping stem 36 and a further base 42 b faces the shape-effecting surface 38 b of the inner stem 36 b.
[0051] In a process for manufacturing blister packs illustrated in FIG. 7 the metal-plastic composite 46 is unrolled from a roll 106 and fed discontinuously into through a shape forming station 100 . In a subsequent filling station 102 the recesses 58 are filed with contents 108 such as e.g. tablets. On advancing the shaped and filled film 46 further, a lid film 112 made e.g. of plastic-coated aluminum foil, unrolled from a storage roll 110 , is laid on top of the metal-plastic composite film 46 and sealed to it, producing the finished blister pack. The blister packs made in the form of an endless strip can then be cut into packs of the desired size.
[0052] In the following, using the example shown in FIG. 1, the manner in which the shaping stem 36 and counter-stem 40 operate is explained in terms of four examples of shape-forming.
Shape-forming Example 1
[0053] The film 46 is held, clamped between the die 12 and the clamping device 16 . The shaping stem 36 is advanced until it makes contact with the film 46 at the level of clamping E. On the opposite side, the counter-stem 40 is likewise advanced until it meets the unstretched film 46 . Via the piston 20 a preselected pressure is applied, clamping the film 46 between the base 38 of the shaping stem 36 and the base 42 or rubber cover 44 of the counter-stem 40 . The force of the shaping stem 36 is chosen to be greater than the force applied by the counter-stem 40 . As a result the shaping stem 36 penetrates the die opening 40 and at the same time pushes back the counter-stem 40 . In this first shaping step the film is stretched in a controlled manner in the side wall part 60 of the recess 58 being formed, until the forming potential of the film in the side wall part 60 is exhausted. After the elongation of the side wall part 60 , the piston 20 is drawn back along with the counter-stem 40 into its original position. In a second shaping step, the base part 62 of the recess 58 being formed is shaped by advancing the shaping stem 36 against the film 46 which up to then had been clamped against the base 42 of the counter-stem 40 .
Shape-forming Example 2
[0054] The film 46 is held, clamped between the die 12 and the clamping device 16 . The piston 20 along with the counter-stem 40 is thereby withdrawn to its starting position. The shaping stem 36 is advanced into the die opening 14 up to a pre-selected position in which the full shape-forming potential in the base part 62 of the recess 58 being formed is reached. In this first shape-forming step the film 46 is stretched mainly in the base part 62 . In a second step the piston 20 along with the counter-stem 40 is advanced with pre-selected pressure towards the shaping stem 36 and onto the film 46 resting on the base 38 of the shaping stem 36 . Thereby, that part of the film 46 which forms the base part 62 of the recess 58 being formed is held, clamped between the base 38 of the shaping stem 36 and the base 42 or the rubber cover 44 of the counter-stem. The force of the shaping stem 36 is now chosen to be greater than that of the counter-stem 40 . The shaping stem 36 and the counter-stem 40 move therefore with the clamped film 46 towards the base 25 of the die 12 , whereby the side wall part 60 of the recess 58 being formed is stretched until the shaping potential of the film in the side wall part 60 has been fully exploited. When the shaping potential of the film 46 has been fully exploited, the shaping stem 36 and the counter-stem 40 move back to their starting positions.
Shape-forming Example 3
[0055] The film 46 is held, clamped between the die 12 and the clamping facility 16 . The shaping stem 36 is moved back to its starting position. The counter-stem 40 moves to that position in the clamping device opening 18 at which the potential for shape forming the film in the base part 62 of the recess being formed has been fully exploited. Thereby, the base 42 of the counter-stem 40 exhibits a surface with a high coefficient of friction, with the result that the shape-forming potential of the film in the side wall part 60 of the recess 58 being formed is fully exploited in this first shape-forming step. After exhausting the shape-forming potential of the film in the side wall part 60 , the piston 20 is drawn back again to the starting position along with the counter-stem 40 . In a second shape-forming step the shape-forming stem 36 is moved into the die opening 14 until the shape-forming potential of the film in the base part 62 of the recess 58 being formed has been exhausted. To this end the surface of the base 38 of the shaping stem 36 exhibits a low coefficient of friction. In the first shaping step the film 46 may also be clamped between the shaping stem 36 and the counter-stem 40 .
Shape-forming Example 4
[0056] The film 46 is held, clamped between the die 12 and the clamping facility 16 . The shaping stem 36 is moved back to its starting position. The piston 20 with the counter-stem 40 is moved to a pre-selected position in the clamping device opening 18 at which the shape-forming potential of the film 46 in the base part 62 of the recess 58 being formed has been fully exploited. To that end the surface of the base 42 of the counter-stem 40 exhibits a low coefficient of friction. After this first shape-forming step the piston with the counter-stem 40 is moved back to its starting position. In a second shape-forming step the shaping stem 36 , the base 38 of which has a surface with a high coefficient of friction is moved to a pre-selected position in the die opening 14 until the shape-forming potential of the film in the side wall part 60 has been exhausted. In the second shape-forming step the film 46 may also be clamped between the shaping stem 36 and the counter-stem 40 . | A device for shape-forming at least one recess in a film-type material features a die with at least one opening, at least one shaping stem that can be introduced into the opening to create the recess by shape-forming, and a clamping facility for holding the film-type material fast between the clamping facility and the die. Counter-stems which are displaceable at least within the die openings are situated in the die, whereby shape-forming regions of the shape forming stems and the counter-stems for clamping the film-shaped material are, at least in part, superimposed on each other. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a utility patent application based on applicant's provisional patent application serial number 60/008,551, which was filed on Dec. 18, 1995 and which is currently pending.
DESCRIPTION OF THE PRIOR ART
Applicant has an earlier issued U.S. Pat. No. 5,165,734 issued on Nov. 24, 1992 entitled Conduit Swivel Connector. The present application is an improvement over this patent.
BRIEF SUMMARY OF THE INVENTION
A connector or joint designed, for example, to connect an LP Gas filler hose to a delivery nozzle and permit swiveling between the delivery nozzle and the filler hose. The swivel connection enables complete full circle turning about the axis of the nozzle and the hose connection so as to obviate any twisting or kinking of the filler hose in use.
The connector is useful in liquefied petroleum gas (LPG) applications. Whenever an LPG tank has to be refilled, the LPG truck travels to the site of the stationary LPG tank. A flexible hose and nozzle have to be unreeled from the truck to the stationary tank. During the reeling and unreeling process, the hose twists and turns. The present invention is a linkage somewhere between the truck tank and the nozzle. The present invention allows the hose and other components to swivel back and forth or to rotate to prevent twisting and entanglement of the hose. Also, the present invention cannot allow any pressurized fluid to escape from it.
The present invention also has a unique feature, which includes a thrust plate and ball bearing pre-load spring positioned in the interior between the main housing and the rotatable nipple connection. The thrust plate cushions and absorbs the shock or an abrupt blow should the present invention be dropped on the ground by the delivery man or falls off the reel and is accidently dragged on the pavement behind the delivery truck. All are common occurrences in actual use.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the present invention.
FIG. 2 is a longitudinal medial section of the present invention taken along the line 2--2 in FIG. 1.
FIG. 3 is a perspective view of the present invention showing the external threaded nipple in the foreground.
FIG. 4 is a perspective view of the present invention showing the internal threaded end in the foreground.
FIG. 5 is an exploded perspective view showing the components and the proper arrangement of the components which form the present invention.
FIG. 6A is the front view, FIG. 6B is a side view and FIG. 6C is an end view of the main housing, which is a component of the present invention.
FIG. 7 is a front and side elevational view of the stationary seal without the O-ring, along with a view of the retaining balls.
FIG. 8 is a front and side elevational view of the pre-load spring.
FIG. 9 is a front and side elevational view of the bearing thrust plate.
FIG. 10A is a front view and FIG. 10B is a side elevational view of the rotating metallic seal without the O-ring.
FIG. 11A is a front view and FIG. 11B is a side elevational view of the wave spring.
FIG. 12A is a front view, FIG. 12B is a side view, and FIG. 12C is an end elevational view of the combined ball bearings and rotatable nipple.
FIG. 13A is a front view, FIG. 13B is a side view, and FIG. 13C is an end elevational view of the bearing plate with lip seal and groove for O-ring.
FIG. 14A is a front view and FIG. 14B is a side elevational view of the spiral retaining ring.
DETAILED DESCRIPTION
The present invention includes nine major components. They are shown in correct sequence in the exploded perspective view in FIG. 5 and individually in the remaining Figures. The nine major components are; the main housing 10, the four individual balls 90, the annular stationary sealing member or seal ring 100, the ball bearing pre-load spring 150, the thrust plate 200, the rotatable metallic seal 250, the wave spring 300, the rotatable nipple 350 with ball bearing holder, the bearing retaining plate 400, and the spiral retaining spring 450. This is the correct sequence of the components from left to right after the present invention is assembled using the previously identified components.
The seal 250 will now be described and discussed in detail. The front and side views of the rotating metallic seal 250 are illustrated in FIGS. 10A and 10B. The seal 250 is provided with a circular groove 252 into which is fitted a sealing O-ring 254, which is not shown in FIGS. 5 or 10A, but which is shown in the medial longitudinal sectional view in FIG. 2 of the drawings. The O-ring blocks axial passage of fluid from the left end of the housing 10 (connected to the hose) into the interior of the housing. The left end of the seal 250 has a sealing face 256 and a flange 258 with a key way 260. The seal 250 is held stationary using the single key way pin 360 extending from the left end of the rotating nipple 350 which pin 360 is positioned in the key way 260 on the seal 250. The seal 250 is held stationary relative to the ball bearing 355. In this manner the metallic seal 250 is allowed to rotate relative to the ball bearing and holder 355. The diameter of the bore 262 passing through the seal 250 is of the same diameter as the bore 365 in the rotating nipple 350, which is about 7/8 inch. The seal 250 consists of a continuous-cast grey-iron seal. The face 256 of the seal is mated to the face of the seal ring 100 located in the main housing 10. The face 256 of the seal is lapped to three light bands. The face 256 of the seal is an annular ring or circular band about 1/8 inch in width. The keying arrangement of the key pin 360 and the key way 260 also allows the seal 250 limited axial movement relative to the other components that comprise the present invention.
The second conduit means comprising a rotating nipple 350 and a ball bearing holder 355 with internal ball bearings 357 is shown in the perspective view in FIG. 5. The left front, the side, and the right front of the nipple 350 are shown in FIGS. 12A, 12B and 12C repsectively. The nipple 350 and ball bearing 357 and the bearing holder 355 are independently rotatable relative to each other. They form one unit. The nipple has a left flange 370 from which extends the key pin 360 previously discussed. The bearing holder 355 is ring-shaped and fits around the outside of the nipple 350 and is permanently pressed against the right side of the flange 370 on the nipple 350 and around the outer wall of the nipple 350. The nipple 350 has an externally threaded right end portion 352 for threadably connecting to an LP gas delivery nozzle, which is not shown in any of the Figures. The nipple has a main annular bore 365 running therethrough. The left end of the main bore transitions to a larger stepped bore. The diameter of the main bore 365 is the same as the diameter of the annular bore 262 in the rotating seal 250. Both bores are in axial and concentric alignment. The transition between the main bore and the larger stepped bore results in an annular seat 375 or shoulder which can be seen in the left front view in FIG. 12A. The seat can also be seen in the sectional view in FIG. 2, and in the perspective view of the nipple 350 in FIG. 5. The seat 375 or shoulder acts as a stop for the wave or compression spring 300. The depth of the larger bore is about 1/2 inch. The thickness of the wave spring 300 in the uncompressed position is about 3/8 inch. The wave spring also has a bore therethrough of the same diameter as the main bore 365 in the nipple 350. The wave spring 300 is placed in the larger bore. The remaining space between the left face of the spring 300 and the flange 370 allows for the right hand portion of the body of the metallic seal 250 to be slidably positioned adjacent the left face of the spring 300. This arrangement can be seen in the sectional view in FIG. 2. The wave spring 300 allows limited axial movement of the metallic seal independently of the other components. The wave spring also maintains the sealing pressure between the two faces of the two seals 100 and 250. The wave spring 300 has the appearance of a miniature Slinky® toy. The wave spring has the appearance of a coiled flat ribbon of metal. The ribbon undulates like a wave to form the wave spring. The spring can be stretched apart as a Slinky® toy can be. It is also compressible to a limited extent. The wave spring 300 is compressed between the annular seat 275 and the metallic seal 250 to keep the latter continually biased to the left to maintain the sealing pressure between the two faces of the two seals 100 and 250.
The main housing 10 will now be described and discussed in detail. The housing 10 and the nipple 350 are both made of durable stainless steel. The present invention is corrosion-resistant. The housing 10 at its right hand end is bell-shaped, as shown at 15 in FIGS. 5 and 6. The bell-shaped portion 15 of the housing is used to encompass the left hand portion of the nipple 350 and to provide an annular space for the bearing holder 355, the ball bearing pre-load spring 150, the thrust plate 200, the bearing retaining plate 400, and the spiral retaining spring 450. The bell-shaped portion 15 with these components placed therein is illustrated in the sectional view in FIG. 2. The main housing 10 has five axial concentric stepped annular bores arranged in sequence. The left hand first bore 20 that terminates at the left end of the housing is female threaded for receiving the hose end of an LP gas hose. The threaded portion terminates at the right to a second small diameter bore 25 which is the same diameter as the main bore 365 in the nipple 350, the bore in the metallic seal 250, and the annular space in the wave spring 300. To the right of the small bore 25 is a somewhat larger diameter third bore 30 which acts as a seat for the stationary annular sealing member 100. The transition between the first small bore 25 and the second larger bore 30 results in a first annular shoulder 35, which is visible in the end view in FIG. 6. The next or fourth stepped bore 40 is a larger diameter than the seal seat bore 30. This fourth bore 40 is used for receiving the flange 258 end of the seal 250. The fourth bore 40 transition to the smaller third bore 35 results in a second annular shoulder 45, which is visible in the end view of the housing in FIG. 6C. The flange 258 of the metallic seal 250 mates with the second annular shoulder 45. The fifth stepped bore 50 is of much larger diameter than all of the other bores and is used as a seat for the ball bearing pre-load spring 150 and the face of the thrust plate 200. The fifth bore 50 transition to the smaller fourth bore 40 results in a third annular shoulder 55, which is visible in the housing end view in FIG. 6C. The large ball bearing pre-load spring 150 rests against the third annular shoulder 55. The overall diameter of the thrust plate 200 is the same as the overall diameter of the spring 150 and of the same the diameter of the fifth large bore 25. The thrust plate 200 is annular in shape and the width of the ring is the same as the width of the third shoulder 55. The left 5 side of the thrust plate 200 has a ring-shaped projection 155 so 6 that the spring 150 can fit around the projection 155 to keep the spring in place relative to the third annular shoulder 55 in the housing and the thrust plate 200. The spring 155 is a wave spring and compressible, and the combination spring 155 and thrust plate 200 serve a very important function in the present invention. After the components are assembled to form the present invention, the thrust plate abutting against the spring 150 in the housing allows the nipple 350, or male threaded portion of the present invention to absorb shock or an abrupt blow should the present invention be dropped on the ground while in use in actual field conditions where the present invention is used. The nipple 350 is allowed to move about 0.008-inch into the largest bore 50 of the main housing 10 before the thrust plate 200 bottoms out. In this way, the thrust plate cushions any abrupt blows and prevents damage to the seals and the other components in the present invention. The housing 10 also has a bleed screw 11 illustrated as an allen head screw. The screw can be unthreaded to release moisture or trapped fluid in the sealed housing, and then rethreaded to seal the interior of the present invention. The present invention can be serviced in the field with only a screwdriver if repairs are necessary.
The seal 100 will now be described and discussed in detail. The seal 100 is stationary in the sense it does not rotate relative to the main housing. The seal 100 is not keyed as the rotatable metallic seal 250 is keyed. The seal 100 is prevented from rotating in the seat by four small balls 90 that are equally spaced in the annular shoulder 35 in the main housing. The seat 35 of the second bore in the housing where the seal 100 is seated is an annular shoulder. Four hemispherical indentations 60 are drilled into the seat 35 and are equally spaced apart at 90 degree increments. The four hemispherical indentations are used for permanently holding each one of the bottom halves of the four balls 90. The annular stationary seal 100 has four complementary hemispherical indentations 105 for receiving each one of the top halves of the four balls 50. This spatial arrangement of the four balls 90, the seal 100 and the 4 indentations 105 is clearly illustrated in the perspective view in FIG. 5. The seal is slightly larger than the bore 30 into which it is seated. The seal is pressed into the bore and forms a tight fit. Also the face 256 of the metallic seal continuously presses against the face of the seal to prevent the seal 100 from dislodging or moving in its seat in the bore 30. The seal 100 is provided with a circular groove 110 into is fitted a sealing O-ring 115, which is not shown FIGS. 5 or 7, but which is shown in the medial sectional view in FIG. 2 of the drawings. The O-ring 115 is used to seal the exterior cylinder wall portion of the annular stationary seal 100 and is used to block axial passage of fluid from the left end of the housing 10 into the interior of the housing 10. The stationary seal ring 100 is made of a monomeric thermoplastic material. The sealing face 115 of the seal ring 100 is lapped to three light bands just as the sealing mating face 256 of the rotatable seal 250 is lapped to three light bands.
The bearing retaining plate 400 will now be described and discussed in detail. As shown in exploded perspective view 8, the plate has an annular shape. The front side and rear views of the plate 400 is shown in FIGS. 13A, 13B and 13C respectively. The plate is fitted over the nipple 350 and is positioned against the right hand face of the ball bearing holder 355. The plate is a one-piece metal ring. The plate 400 is provided with a circular groove 410 into which is fitted a sealing O-ring 415, which is not shown FIGS. 5 or 13, but which is shown in the medial sectional view in FIG. 2 of the drawings. The O-ring 415 is used to seal the exterior cylinder wall portion of the annular bearing plate 400 and is used to block axial passage of fluid from the left end of the housing 10 into the interior of the housing 10 and also to prevent contamination of soil and water from the exterior into the housing from the right end. An elastomeric annular seal 420 is fitted into the interior rim of the plate 400 for additional sealing.
The spiral retaining ring 450 will now be described and discussed in detail. Immediately interior of the end of the large bore in the housing is cut an internal circular groove 80. This is for receiving the spiral retaining ring 450. The thickness and outside diameter of the ring 450 are the same as the groove 80. After all of the eight major components are assembled together, the spiral ring is contracted and placed into the groove 80, and allowed to expand to near its normal shape, which causes it to lock itself in the groove 80, and in turn keeps the other components in place in the housing even though the wave spring 300 and the pre-load spring 150 are permanently biasing against the components placed together in the housing to expand. The retaining ring 450 prevents this. It also keeps the two sealing faces 256 and 115 in frictional sealing engagement with each other.
OPERATION
In use the left hand of the main housing 10 is secured to a flexible LP gas delivery hose, and a nozzle is threaded onto the right hand end of the nipple 350. In unreeling the hose there is a tendency for the hose to twist, which would kink and disrupt the filling operation were it not for the swivel connection between the nipple 350 and the main housing 10. With the swivel connection, however, such twisting is ameliorated and there is no disturbance to the filling operation.
In the filling operation the fluid under pressure flows freely through the internal diameter of the main housing, the annular stationary sealing member 100, the rotating metallic seal 250, into the inside diameter of the nipple 350 and thence into the filler nozzle. There is limited adjusting movement between the rotatable metallic seal 250 and the housing 10. There is virtually no leakage past the outside diameters of the stationary sealing member 100 and the rotating/rotatable metallic seal 250. As relative rotation between the nipple 350 and the housing 10 takes place there is a corresponding rotative sliding between the stationary sealing member annular sealing face 115 and the rotating metallic seal annular sealing face 256.
These sealing faces are carefully and precisely lapped so as to block leakage radially across the engaging faces.
Sealing pressure at the annular sealing faces 256 and 115 is provided by the wave spring 300, and the ball bearing pre load spring 150.
Obviously, many modifications and variants of the present invention are possible in light of the above teachings. It is therefore to be understood that the full scope of the invention is not limited to the details disclosed herein, but may be practiced otherwise than as specifically described. | The hose end conduit swivel connector consists of a first conduit, adapted to be connected for example to a filler hose, and terminating in a bell-like housing within which resides a nipple with ball bearing rotation permitted between the two. Thus a pair of aligned conduits are provided with relative 360 degree rotation between the nipple and the housing. Leakage of fluid being transmitted through the connector is prevented by two sealing faces, one being located on a annular stationary seal member retained in the housing, which cooperates with a corresponding sealing face on an opposed rotating metallic seal. The sealing faces are carefully lapped so that leakage is substantially prevented from the interior of the conduits. A thrust plate and wave spring are interposed between the swivel connector and the nipple to cushion shock to the connector should the connector be accidently dropped or otherwise misused to prevent damage to the seals and the other components comprising the connector. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for bleaching a long cloth continuously, with particular in tension to give an excellent result in saving energy, and an apparatus therefor.
2. Description of the Related Art
In a conventional method for bleaching a long cloth produced industrially with the use of sodium chlorite, an aqueous bleaching solution comprising sodium chlorite together with an organic acid such as formic acid and acetic acid or an inorganic acid such as phosphoric acid and sulfuric acid, is applied to a cloth to be bleached at tile ordinary temperature, and the resultant cloth is subjected to wet heat treatment in a treating chamber in gaseous or liquid medium for carrying out the bleaching treatment in object continuously.
To describe said method for bleaching a long cloth continuously for practical use in detail, the pH of the aqueous treating solution is controlled to 3-4, and after the cloth is soaked with said bleaching solution at the ordinary temperature by transporting the cloth continuously therethrough, the cloth is squeezed by using a squeeze roll in order to render its solution content appropriate (about 100%), and then the resultant cloth is transported through a bleaching chamber in gaseous or liquid medium continuously. In the bleaching chamber, the cloth is folded to form piles in succession, and subjected to the bleaching at a temperature in the range of 80°-90° C. for about 40-60 minutes. After a sufficient treating time, the piles of the thus treated cloth are taken out of the chamber in succession, and thus the continuous bleaching of a long cloth is ended.
However, in such an instance, since the cloth is piled in succession in this way, the temperature distribution of the interior and the outside of the cloth thus piled is not uniform, and the temperature of the interior of the pile is unavoidably low. Accordingly, the reaction velocity, i.e., the bleaching speed, is low at the interior of the piles. This is the reason why it needs a long time of about 40-60 minutes as above mentioned in order to complete the bleaching up to the interior of the piles sufficiently. Moreover, since the treating degree differs place after place, uniformly bleached product can hardly be obtained, and further, since the treating time is unavoidably long as above mentioned, it is unavoidable that creases are formed in the cloth due to folding, particularly at the bottom part of the piles owing to the weight of the cloth itself. The formation of creases is especially remarkable in a high density cloth and the one with a fine yarn number.
Separately, to avoid the defect of forming piles of cloth, in bleaching a long cloth continuously, a method has been proposed to transport a cloth to be bleached continuously through a wet heat treating chamber with no tension continuously by using a plurality of guide rolls or a piler. However, since it needs a long treating time of about 40-60 minutes thereby for the bleaching of each part of a long cloth uniformly, the length of the cloth staying in a chamber becomes unavoidably very long, and accordingly the number of guide rolls necessary for transporting the cloth continuously becomes very numerous and the size of the piler becomes very large. In calculating, for trial, the length of a cloth necessary to stay in the wet heat treating chamber under the condition that the passing speed of a cloth therethrough is 100 m/min as usual in the similar treatment in a wet heat treating chamber, the length of the cloth staying in the treating chamber becomes unavoidably very long as 4,000-6,000 meters when the bleaching time is so long as 40-60 minutes as in the above-mentioned case. Therefore, it is obvious that such a proposal is by no means practical.
SUMMARY OF THE INVENTION
Under such circumstances, the present inventors have recently filed Japanese Patent Application Nos. Hei 2-125880 and Hei 2-125881 on this matter, and the present invention is a continuation of them.
The technical thought of the present invention is based on the consideration that, when the reaction time of bleaching a cloth with the use of an aqueous sodium chlorite solution can be shorten, it may be possible to apply the method of transporting a cloth continuously in a wet heat treating chamber by using limited number of guide rolls on a small size piler, with which the defect of the formation of creases in the cloth as in the case of piling the cloth as above mentioned can be prevented. Accordingly, the essential point of the present invention is to shorten the reaction time of bleaching a cloth with the use of sodium chlorite as a bleaching agent in a wet heat treating chamber remarkably by improving the means for applying the bleaching agent to the cloth.
As a method for shortening the treating time in the bleaching of a cloth with the use of a sodium chlorite solution, such means can be considered as to lower the pH of the treating solution, to use a concentrated treating solution, to use a large quantity of the treating solution, to elevate the treating temperature and so on. However, in any one of these means, it is impossible to shorten the bleaching time sufficiently low, for instance, to 2 minutes. It needs at least about 10 minutes thereby.
Differing from these considerations, the principle of shortening the bleaching time of a cloth in using sodium chlorite in the present invention is to make the atmosphere of the wet heat treating chamber acidic with the use of an activation agent for making the atmosphere containing sodium chlorite acidic. The term will frequently be called in short as "activation agent" hereinafter. In an acidic atmosphere, sodium chlorite (NaClO 2 ) is decomposed at a sufficiently high temperature, via free chlorous acid (HClO 2 ), to form chlorine dioxide (ClO 2 ), and indeed, chlorine dioxide is effective for the bleaching of a cloth and others due to the effect of oxidation.
As the preferred embodiments of the present inventive method will be described together with the apparatuses thereof in detail in the following, it is proved thereby that, in such a condition, the bleaching of a cloth with the use of an aqueous sodium chlorite solution can be done satisfactorily in a very short time of 30-60 seconds or at least in 2 minutes at a temperature within 100° C. Therefore, it becomes possible to carry out the continuous bleaching of a long cloth for practical use in a small size ordinary pressure wet heat treating chamber fitted with a limited number of guide rolls or a small size piler for transporting a long cloth with no tension continuously therethrough in a short time satisfactorily and effectively by eliminating the defect of folding the cloth to form piles in the conventional art as above mentioned.
As an activation agent for making the atmosphere containing sodium chlorite acidic so as to form chlorine dioxide from sodium chlorite in this instance, an inorganic acid such as sulfuric acid and hydrochloric acid, an organic acid such as formic acid and acetic acid, and further, a carbonyl compound such as formaldehyde and acetaldehyde can satisfactorily be used.
In this connection, as already mentioned, an inorganic or organic acid is added to a sodium chlorite solution also in said prior art, However, its addition is done at the ordinary temperature prior to the bleaching. Therefore, it is considered that, while such an acid is effective to decompose sodium chlorite to form chlorine dioxide at the ordinary temperature, the thus formed chlorine dioxide has no effect to bleach a cloth and escapes in vain in such a cold state, and even when the thus treated mixture is subjected to the bleaching of a cloth at a higher temperature in the range of 80°-90° C. as in said prior art, no satisfactory bleaching can be done in a short time.
As above mentioned, it is possible in the present invention to perform the continuous bleaching of a long cloth by using a small size wet heat treating chamber and by eliminating the defects in the prior art. Accordingly, the product thus obtained is quite excellent, particularly having no such defect as the creases of which formation can by no means be avoided in the conventional art. Thus, the effect of the present invention is quite distinguished.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an example of the present inventive apparatus in general for bleaching a long cloth continuously in the present invention by using an ordinary pressure wet heat treating chamber fitted with a plurality of guide rolls for transporting the cloth.
FIG. 2 is another example thereof in the case of using a carbonyl compound as an activation agent.
FIG. 3 is an example of the present inventive apparatus in which a piler is added next to the guide rolls in the wet heat treating chamber.
Finally, FIG. 4 is to show an apparatus for carrying out the wet heat treatment in two steps in succession.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The examples of the preferred embodiment of the invention will be described in detail in the following with reference to the examples of the inventive apparatus in the drawings.
EXAMPLE 1
In FIG. 1, 1 is a long cloth, for instance, a cotton cloth or a blended yarn cloth containing cotton, to be bleached. 2 is a bleaching solution tank in which sodium chlorite solution is to be introduced at the ordinary temperature. 3 is a squeeze roll for squeezing the cloth soaked with the bleaching solution appropriately. 4 is an ordinary pressure wet heat treating chamber of the cloth coming from the bleaching solution tank 2. In the wet heat treating chamber 4, 5 is a means such as a spray or an ultrasonic atomizer for supplying a volatile activation agent in order to make the interior of the chamber 4 acidic. 6 are a plurality of guide rolls provided up and down alternately for transporting the cloth 1 with no tension by forming snaky undulations through the chamber 4 continuously. 7 are heating means to heat the interior of the chamber up to a temperature nearly to 100° C.
The construction of the apparatus in this example is as above described. Now, the function of this apparatus will be stated in the following.
In the first place, a cloth to be bleached 1 is immersed in a bleaching solution comprising a slightly alkaline sodium chlorite solution with a concentration of about 0.5-1.0% in the bleaching solution tank 2 at the ordinary temperature. The cloth soaked with the sodium chlorite solution is squeezed by means of the squeeze roll 3 appropriately, and the thus squeezed cloth is transferred into the wet heat treating chamber 4 which has been heated to a temperature nearly 100° C. previously by using the heating means 7.
In the wet heat treating chamber 4, a volatile activation agent, for instance acetic acid, is supplied in the state of mists by using the means 5 so as to make the atmosphere in the chamber acidic with a pH of 3-4. Instead of acetic acid, such activation agent as an inorganic acid and a carbonyl compound as already mentioned may also be used. The cloth is transported continuously therethrough zigzag forming snaky undulations with no tension by means of the guide rolls 6 at a temperature in the range of 90°-95° C., and thus the continuous bleaching of a long cloth in object is done in a short time of within 2 minutes. The cloth is bleached uniformly and excellently, and particularly with no formation of creases of which formation can by no means be avoided in the conventional art.
EXAMPLE 2
This example is to show the process in the present invention in which a carbonyl compound is used as an activation agent for making the atmosphere of the wet heat treating chamber acidic. In FIG. 2, 1 is a long cloth to be bleached, 2 is a bleaching solution tank to introduce a sodium chlorite solution at the ordinary temperature similarly as in FIG. 1. In this instance, an activation agent tank 8, which is to introduce an activation agent comprising a carbonyl compound, is provided next to the bleaching solution tank 2. 3 and 3' are squeeze rolls respectively for squeezing the cloth. 9 is an exit of chlorine dioxide gas accidentally formed in the activation agent tank 8. 4 is a wet heat treating chamber, which is divided in two parts, a heating chamber 10 and a reaction chamber 11. 6 are a plurality of guide rolls provided up and down alternately for transporting the cloth 1 forming snaky undulations continuously with no tension. Among the guide rolls 6, those with the numerical 6' placed fittingly are water cooled ones for forming water droplets easily on the surface thereof. 7 are a plurality of heating means comprising heating pipes. 12 is a neutralization tank containing a reducing agent solution for neutralizing and removing the solution contained in the cloth bleached. 13 is a sensor for measuring the concentration of chlorine dioxide gas formed from sodium chlorite for the use of bleaching the cloth in the reaction chamber 11. When the concentration of chlorine dioxide gas determined by said sensor 13 becomes too high, its concentration is controlled by opening the exhaust pipe 14.
In carrying out the bleaching of a cloth by using this apparatus, the cloth 1 is immersed in the first place in a sodium chlorite solution in the bleaching solution tank 2 at the ordinary temperature, then the cloth is squeezed by using the squeeze roll 3 and passed, in this instance, further through an activation agent tank containing a carbonyl compound as an activation agent also at the ordinary temperature. The resultant cloth is squeezed again by using the squeeze roll 3', and supplied into the heating chamber 10 of the wet heat treating chamber 4 for heating and beginning the wet heat treatment. The thus heated cloth sufficiently to 70°-90° C. is transferred to the reaction chamber 11, where the cloth is transported continuously by guiding with the use of the guide rolls 6 for continuing the bleaching further. In the reaction chamber, the cloth is contacted occasionally with the guide rolls 6' having dews on the surface thereof. Thus, the dews are transferred to the cloth, and the wet heat treatment of the cloth for the bleaching thereof proceeds more effectively. The cloth bleached sufficiently in this way is neutralized in the neutralization tank 12, and thus a cloth sufficiently bleached is obtained.
In this example, a carbonyl compound is used as an activation agent for making the atmosphere of a wet heat treating chamber acidic, but a carboxyl compound is not an acid in itself. It acts as an activation agent for the first time at a sufficiently elevated temperature, so that a carbonyl compound can be applied to a cloth to be bleached conveniently at the ordinary temperature before the cloth is supplied in a wet heat treating chamber. Therefore, the continuous bleaching of a cloth by using a carbonyl compound as an activation agent can be done more effectively in a wet heat treating chamber at a temperature of 70°-90° C. in a short time of about 30-60 seconds as in this instance.
The practical merit of the present invention will be described in this occasion. Since the bleaching time of a cloth is very short as 30-60 minutes, when the passing speed of the cloth in a practical apparatus is 100 m/rain as already mentioned, it is sufficient that the capacity of the wet heat treating chamber is to introduce 50-100 meters of the cloth therein, and such an apparatus can beneficially be applied for the practical use commercially. In the case even when the bleaching time reaches to 2 minutes as in the case of Example 1, the length of a cloth necessary to stay in a wet heat treating chamber is still only 200 meters, and such a wet heat treating chamber can also be applied for practical use. Therefore, the present inventive apparatus can be applied eminently commercially.
EXAMPLE 3
The apparatus in FIG. 3 is for the use of Example 3, in which a piler is provided further next to a series of guide rolls 6 in the wet heat treating chamber 4 for the purpose to carry out the wet heat treatment of the cloth further. Unless otherwise stated, the numerals indicating the parts in the figure are corresponding to the parts with similar numerals in FIGS. 1 and 2 previously mentioned. In addition, 15 is a heating pipe provided in the bleaching solution tank 2 in this example for heating sodium chlorite solution therein previously. 16 is a piler for transporting the cloth 1 further in succession to the guide rolls 6, and 17 is an exhaust pipe provided at the cloth inlet part of the wet heat treating chamber 4.
In tire bleaching solution tank 2, a cloth to be bleached 1 is passed through a sodium chlorite solution with a concentration of 0.5-1.0% at a temperature of 80°-95° C. The cloth is squeezed by using the squeeze roll 3 so as to control the bleaching solution content thereof to about 100%, and then supplied into the wet heat treating chamber 4. In the wet heat treating chamber, an activation agent solution comprising an acid, a carboxyl compound, or a mixture of them is added to the cloth by the use of such means as a spray or an ultrasonic atomizer 5 in an amount 0.2-0.5% to the cloth. The cloth is then transported continuously through the chamber by using a plurality of guide rolls 6 and the piler 16. Thus, the bleaching of a cloth in object is accomplished in a short time of 30-60 seconds satisfactorily.
EXAMPLE 4
This example is to show an case in which the bleaching is done in two steps with the use of two wet heat treating chambers in succession in an apparatus as shown in FIG. 4.
In FIG. 4, a first wet heat treating chamber 4 fitted with a bleaching solution tank 2 is connected to a second wet heat treating chamber 4' also fitted with a bleaching solution tank 2'. The numerals indicating the parts in this figure are corresponding to the parts with similar numerals in the previous figures, and boosters 18 and 18' are attached to each one of the guide rolls respectively in the two wet heat treating chambers. The number of the wet heat treating chamber is not limited to two, and more than two chambers may also be applied.
In carrying out the bleaching of a cloth 1 in this example, a cloth to be bleached 1 is immersed in a slightly alkaline sodium chlorite solution at a temperature of 60°-95° C. heated by means of the heating pipe 15, and squeezed by using the squeeze roll 3 for removing excess solution. The cloth is then supplied into the first wet heat treating chamber 4 maintained at a temperature of about 100° C. by using the heating means 7. In the wet heat treating chamber 4, the cloth receives an activation agent solution to make the atmospheric of the chamber acidic by using the means for supplying the same 5, and is transported through the chamber similarly as in the preceding examples. In this example, particularly, moisture is supplemented to the cloth always by means of the boosters 18 and 18' so as to accelerate the bleaching more effectively. The cloth is then transferred to the second wet heat treating chamber 4', and treated as before.
In this example, the total amount of sodium chlorite consumed is about 0.6-0.8% per the cloth treated, and the bleaching time is only about 1-2 minutes in total even when the cloth is hardly bleachable. Therefore, this apparatus is particularly suitable for the bleaching of such a hardly bleachable cloth. | A method for bleaching a cloth comprising subjecting a cloth soaked with an aqueous bleaching solution comprising sodium chlorite to wet heat treatment at a temperature nearly to 100° C., particularly subjecting a long cloth soaked with the bleaching solution to wet heat treatment continuously in an ordinary pressure wet heat treating chamber of which atmosphere being acidified to a pH of 3-4 by the use of an activation agent for making the atmosphere containing sodium chlorite acidic comprising an inorganic acid such as sulfuric acid and hydrochloric acid, an organic acid such as formic acid and acetic acid, and a carbonyl compound such as formaldehyde and acetaldehyde so as to form chlorine dioxide active for the bleaching of a cloth by the decomposition of sodium chlorite, and apparatuses for carrying out the method. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority under 35 U.S.C. §119(e) on U.S. Provisional Application No. 60/833,154 entitled STABILIZED SUSTAINED-RELEASE BUPROPION AND BUPROPION/MECAMYLAMINE TABLETS, filed Jul. 25, 2006 the entire disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to pharmaceutical dosage forms, and more particularly to controlled-release tablets.
BACKGROUND OF THE INVENTION
Bupropion is used as an antidepressant. It has also been used either alone or in combination with other drugs as a smoking cessation aid. Bupropion is highly hygroscopic and susceptible to decomposition. Various techniques have been employed to overcome the stability issues with bupropion. These techniques have included combining bupropion hydrochloride with a stabilizing agent, typically a pharmaceutically acceptable acid, e.g., hydrochloric acid, phosphoric acid, nitric acid, sulfuric acid, malic acid, citric acid, tartaric acid, ascorbic acid, isoascorbic acid, etc. Other attempts to stabilize bupropion hydrochloride in pharmaceutical dosage forms include application of coating films or barriers, either on the bupropion hydrochloride or on excipients utilized in preparation of bupropion hydrochloride pharmaceutical dosage forms. It has also been proposed to stabilize bupropion hydrochloride in pharmaceutical dosage forms by forming complexes between the bupropion hydrochloride and an ion exchange resin, or by occluding the bupropion hydrochloride with cyclodextrin. Others have reported that bupropion hydrochloride is stable by itself under normal storage conditions, but can easily degrade in the presence of conventional excipients used in commercial formulations. It has been theorized that small amounts of impurities in the excipients, typically residual impurities such as peroxides, superoxides, hypochlorites and formic acid introduced during the manufacturing processes, can interact with the bupropion hydrochloride to cause decomposition during storage. Accordingly, it has been proposed that one possible strategy to eliminate or reduce decomposition of bupropion hydrochloride in pharmaceutical dosage forms is to pretreat the excipients to remove or neutralize impurities that can induce oxidation, add chelating agents to formulations to prevent metal induced oxidation, and/or add antioxidants such as L-cysteine hydrochloride to pharmaceutical dosage forms containing bupropion hydrochloride.
Commercially available sustained-release oral formulations of bupropion hydrochloride have been prepared by mixing the bupropion hydrochloride with a stabilizing agent and with various celluloses, alkyl celluloses and hydroxyalkylcelluloses, carboxyalkylcelluloses, polyalkylene glycols and acrylic acid polymers. It has also been proposed that complexes formed between bupropion hydrochloride and an ion exchange resin may be used for achieving a sustained-released effect.
The utility of pharmaceutical therapies and compositions involving the combination of mecamylamine hydrochloride and bupropion hydrochloride in the treatment of tobacco addiction or nicotine addiction, for palliating nicotine withdrawal symptoms, and/or facilitating smoking sensation is disclosed in U.S. Pat. No. 6,197,827, which is incorporated by reference in its entirety herein. This patent generally describes the concept of administering mecamylamine and bupropion either individually or in a single tablet, but does not disclose any particular formulation, or provide details as to how stable sustained-release tablet formulations comprising a therapeutically effective combination of mecamylamine hydrochloride and bupropion hydrochloride can be prepared. There is only a relatively general suggestion that time-release formulations may be prepared “as is known in the art and disclosed in U.S. Pat. Nos. 4,690,825 and 5,005,300,” and that “conventional means with pharmaceutically acceptable excipients such as binding agents . . . ; fillers . . . ; disintegrants . . . ; or wetting agents . . . ; glidants, artificial and natural flavors and sweeteners; artificial or natural colors and dyes; and stabilizers” may be employed. This teaching does not recognize potential interactions between mecamylamine hydrochloride and bupropion hydrochloride, and does not address the known stability issues with bupropion hydrochloride.
SUMMARY OF THE INVENTION
In accordance with an aspect of this invention, an alternative solution to providing controlled release of a pharmaceutically active agent in a tablet dosage form is provided. In accordance with this aspect of the invention, a granulation comprising a pharmaceutically active agent is distributed in a sustained-release matrix. More particularly, the pharmaceutical tablets in accordance with this aspect of the invention comprise a granular phase composed of a pharmaceutically active agent, and a hydroxyalkylcellulose. The granular phase is distributed within an extragranular phase comprising a particulate material that provides a sustained-release effect, such as by providing a diffusion barrier and/or controlled erosion.
In accordance with a related aspect of the invention, a controlled-release pharmaceutical tablet is prepared by granulating a pharmaceutically active agent with a hydroxyalkylcellulose. The resulting granulation is dried to an acceptable moisture content, and the dried granulation may optionally be milled and/or screened to achieve a desired granulation particle size. Thereafter, the dried granulation is dry blended with a particulate material capable of forming a sustained-release matrix in which the granules are distributed. The resulting blend is then compressed into a tablet form.
In accordance with another aspect of the invention, there is provided a single tablet dosage form providing controlled release of both bupropion and mecamylamine in which the bupropion is stabilized against decomposition, and bupropion and mecamylamine are stabilized against interactions with each other. More particularly, the invention provides a combination controlled-release bupropion, controlled-release mecamylamine pharmaceutical tablet in which mecamylamine and a bupropion granulation are distributed in an extragranular phase comprising a particulate material capable of providing a controlled-release matrix.
In accordance with a related aspect of the invention, a combination controlled-release bupropion, controlled-release mecamylamine pharmaceutical tablet is prepared by granulating bupropion with a hydroxyalkylcellulose and an optional pharmaceutically acceptable stabilizing agent; drying the bupropion granulation; optionally milling and/or screening the dried granulation; dry blending the dried granulation with mecamylamine or mecamylamine granules; blending the combined granulations of bupropion and mecamylamine with a suitable extragranular phase; and compressing the resulting blend into a tablet form.
These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification and claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the various embodiments of the invention, a pharmaceutically active agent is incorporated in a granular phase that is distributed within an extragranular phase which provides a sustained-release matrix for the active agent.
The invention is illustrated herein with respect to bupropion and/or mecamylamine. However, the invention has broad application in the formulation of dosage forms for achieving controlled release of a variety of pharmaceutically active agents, particularly those that are susceptible to hydrolytic degradation. It is further contemplated that the invention may have utility for administering one or more pharmaceutically active agents in which one or more of the active agent(s) is available, at least in part, in an immediate release form.
The term “bupropion” is, unless otherwise indicated, intended to encompass bupropion in its base form, as well as various acid addition salts of bupropion, including bupropion hydrochloride, and enantiomers thereof in either pure form or in any ratio. Conventional wet granulation techniques may be employed for preparing the stabilized bupropion granules. The terms “granule”, “granulation” and “granular phase” refer to particulate agglomerates or aggregates, such as those formed by combining the components of the granulation in the presence of a liquid to bind individual particles into aggregated clumps or clusters comprising the individual components of the granulation. Depending on the granulation techniques employed, the selected ingredients, and the desired release properties, the granules, after being dried, can be milled and/or sieved to achieve a desired granule size.
The term “therapeutically effective amount” refers to an amount of a pharmaceutically active agent, which when administered to a particular subject, considering the subject's age, weight and other relevant characteristics, will attenuate, ameliorate, or eliminate one or more symptoms of a disease or condition that is treatable with the pharmaceutically active agent.
The term “controlled release” is meant to encompass delayed and/or sustained release.
Suitable optional bupropion stabilizing agents may be selected from those known in the art, including various inorganic acids, such as hydrochloric acid, phosphoric acid, nitric acid, and sulfuric acid, organic carboxylic, dicarboxylic and polycarboxylic acids such as malic acid, citric acid, tartaric acid, ascorbic acid, isoascorbic acid, oxalic aid, succinic acid, adipic acid, fumaric acid, benzoic acid, and phthalic acid; sulfites such as sodium metabisulfite and potassium metabisulfite; and organic esters such as L-ascorbic acid palmitate. Other examples of bupropion stabilizers include L-cystine dihydrochloride, L-cysteine hydrochloride, and glycine hydrochloride. Preferred bupropion stabilizing agents include generally any pharmaceutically acceptable acid that maintains the granulated bupropion at an acidic pH when contacted with water. In general, suitable acids include those that lower the pH of an aqueous solution to a value in the range from about 0.5 to about 4.0 when added to the neutral solution at a concentration of about 0.003 parts by weight to 100 parts by weight of the solution. An example of a suitable acidic neutralizer for bupropion hydrochloride is hydrochloric acid.
Suitable hydroxyalkylcellulose polymers that may be employed for preparing the bupropion granulation include hydroxymethycellulose, hydroxyethylcellulose, and hydroxypropylcellulose. The term “hydroxyalkylcellulose” is also intended to encompass hydroxypropylmethylcellulose.
The amount of bupropion may be selected to provide conventional therapeutic amounts in the range from about 25 milligrams to about 500 milligrams, such as 50, 75, 100, 150, 225, and 450 milligrams.
Surprisingly, the amount of hydroxyalkylcellulose needed in the bupropion granules to achieve effective stabilization of the bupropion in the tablet dosage forms of the invention, and to prevent degradative interactions between bupropion and mecamylamine for tablets containing these two pharmaceutically active compounds, is relatively low. The term “mecamylamine” is, unless otherwise indicated, intended to encompass mecamylamine in its base form, as well as acid addition salts of mecamylamine, including mecamylamine hydrochloride, and enantiomers and/or diastereomers thereof, in either pure form or in any ratio. Typically, a suitable and effective amount of hydroxyalkylcellulose in the granular phase is from about 10 to about 30% by weight of the granular phase, with the remaining 70% to 90% of the weight of the granular phase being primarily bupropion, the stabilizing component typically comprising substantially less than 1% by weight of the bupropion granular phase. The preferred hydroxyalkylcellulose is hydroxypropylcellulose. Other excipients and/or adjuvants may be present in the granular phase, typically in relatively minor amounts, if at all.
For sustained-release bupropion tablets which do not contain mecamylamine, the relative amount of granular phase to extragranular phase may vary considerably, depending on the selected tablet dose and the desired release properties. However, the granular phase typically and generally comprises 30% to 70% of the combined weight of the granular phase and the extragranular phase. In the case of tablets providing both sustained release of bupropion and mecamylamine, the mecamylamine need not, but may be granulated with a hydroxyalkylcellulose, preferably hydroxypropylcellulose, to effectively reduce or eliminate potential interactions between bupropion and mecamylamine. However, because pharmaceutically effective doses of mecamylamine are substantially lower than those of bupropion, the total amount of bupropion granules and mecamylamine granules (when mecamylamine is incorporated into the dosage form in a granular phase) may be in a range of from about 30% to about 75% of the combined weight of the two granular phases and the extragranular phase.
Therapeutically effective amounts of mecamylamine are well known in the art, and generally range from about 1 to about 10 milligrams per tablet, with specific examples being 3 milligrams, 6 milligrams, and 9 milligrams.
The extragranular phase may be comprised of generally any particulate material that can be compressed into a tablet form and that provides a sustained-release matrix. Materials having suitable sustained-release properties are generally well known in the art, and typically provide sustained release by providing a diffusion barrier for the active or active ingredients and/or by eroding at a desired controlled rate, with the result being a relatively uniform or constant rate of release of the active ingredient or active ingredients over an extended period of time, such as 4, 8, 16 or 24 hours. Such sustained release is desirable for maintaining therapeutically effective blood plasma levels of the drug over an extended period of time without requiring administration of multiple tablets over the extended period. Examples of suitable extragranular particulate materials that may be used for providing a sustained-release matrix include poly(vinylacetate), polyvinylpyrrolidone, blends of poly(vinylacetate) and polyvinylpyrrolidione, copolymers of vinylpyrrolidone such as copolymers of vinylacetate and vinylpyrrolidone, polyethylene oxides, modified starches, and hydroxyethylcellulose.
The extragranular phase may also contain small amounts of conventional additives such as colorants, opacifiers, glidants, etc.
Suitable extragranular excipients include water-swellable and/or water-erodible polymers, with suitable examples including polyvinylpyrrolidone, poly(vinylacetate), copolymers of vinylpyrrolidone and vinylacetate and blends thereof. The blends may further comprise a polyalkylene oxide, such as polyethylene glycol, in an amount effective to adjust the hydrophilicity of the sustained-release matrix provided by the extragranular phase, and thereby adjust the rate of sustained release.
In addition to sustained release, it may be desirable to provide bupropion and bupropion/mecamylamine tablet dosage forms having delayed-release properties. The term “delayed release” as used herein refers to release of the pharmaceutically active compound or compounds that is delayed until after the dosage form has passed through the stomach and into the intestine. As is well known in the art, such delayed-release can be achieved by coating the compressed tablet with a polymer coating composition that remains intact in the upper part of the gastrointestinal tract while in contact with acidic gastric fluids, but which readily decomposes or solubilizes at the higher pH in the intestine, i.e., an enteric coating.
It may be beneficial to incorporate a lubricant in the extragranular phase to aid tableting. While common tableting lubricants such as magnesium stearate may be employed, it has been discovered that stearic acid, in addition to providing the desired lubricating effect, also imparts enhanced storage stability to the resulting tablets.
The enteric coating generally comprises components soluble in a liquid at a pH of about 5 or more and includes components that impart resistance to gastric conditions, as is known in the art. Some examples of the components for an enteric coating include anionic acrylic resins, such as methacrylic acid/methyl acrylate copolymer and methacrylic acid/ethyl acrylate copolymer (for example, Eudragit® L, Eudragit® S (Rohm, Germany), hydroxypropylmethylcellulose acetate succinate, hydroxypropylmethylcellulose phthalate, cellulose acetate phtalate, carboxymethylcellulose acetate phthalate, shellac and so forth. Mixtures of those compounds also may be used. The enteric coating can comprise from about 1 to about 10% of the combined weight of the tablet.
Other auxiliary components such as a minor amount of a plasticizer, such as acetyltributylcitrate, triacetin, acetylated monoglyceride, rape oil, olive oil, sesame oil, acetyltriethylcitrate, glycerin sorbitol, diethyloxalate, diethylmalate, diethylfumarate, dibutylsuccinate, diethylmalonate, dioctylphthalate, dibutylsebacate, triethylcitrate, tributylcitrate, glyceroltributyrate, polyethyleneglycol, propylene glycol and mixtures thereof in combination with an antisticking agent which may be a silicate such as talc, can be used. Titanium oxide also can be included in the coating, as well as known cellulosic materials. A flavorant or colorant may be included. The auxiliary components may be added to the enteric coating composition in combination with appropriate solvents.
It has been surprisingly discovered that bupropion can be effectively stabilized by developing a sufficiently thick or complete enteric coating on a compressed tablet core containing bupropion. In particular, it has been discovered that an enteric coating that constitutes at least 6% of the weight of the compressed tablet core containing bupropion substantially reduces or eliminates hydrolytic degradation of bupropion during storage at room temperature for 6 months. Higher levels such as 10% of the weight of the core may be used. It is believed that a stabilizing effect is surprisingly achieved, either with or without a stabilizing agent in the compressed tablet core containing bupropion, when a suitably thick and/or complete enteric coating is applied to the core. Further, it is believed that a stabilizing effect is achieved using a suitably thick or complete enteric coating regardless of whether the core comprises a granular and extragranular phase as described herein with respect to other aspects of the invention, or comprises a more conventional compressed tablet core, with or without mecamylamine.
The following examples are illustrative of the invention, but do not define the limits of the invention.
EXAMPLE 1
Examples of formulations for sustained-release bupropion hydrochloride tablets and bupropion hydrochloride/mecamylamine hydrochloride tablets are summarized in the following Table 1. The tablets were made using a wet granulation method where 0.3N HCl was used as the granulation liquid. The active and HPC were homogenized for two minutes in a high shear mixer. The mixer was set at 500 rpm and the chopper motor was set at 1000 rpm. The bupropion wet granules were air dried briefly and then passed through a 2.36 mm sieve and then through a 1.18 mm sieve. The wet granulation of mecamylamine was performed with water. The mecamylamine wet granules were dried overnight at 50° C. and then passed through a 1.18 mm sieve. The one or two granules were blended and then mixed with Kollidon SR and polyethylene oxide previously passed through a 0.60 mm sieve. All excipients were blended for 5 minutes in a V blender. Following the addition of lubricant and other excipients, blending was continued for another minute. The tablet was compressed on a rotary press. The tablets were coated using a solution of Eudragit® L30D-55 and other additives as shown in Table 2. The coating was applied using a fluid bed drier at a temperature of 40° C. at 0.8 bar, with a flow rate of 2.5 g/min, to provide a weight gain of 4%. The illustrated exemplary tablet formulations (1-5) prevent potential interactions between bupropion hydrochloride and mecamylamine hydrochloride for those tablets containing both active ingredients in a single tablet dosage form. The tablet were stable, which means that at least 80% of the initial potency of the bupropion hydrochloride in each tablet was maintained after storage for at least 10 weeks at 40° C. and 75% relative humidity.
TABLE 1
Bupropion/Mecamylamine Current Formulation (Dry Basis)
Dosage Bupropion/Mecamylamine (mg)
Example
Weight (mg per tablet)
1A
1B
1C
1D
1E
Active Granulations:
Bupropion HCl
225.00
225.00
225.00
225.00
450.00
Hydroxypropylcellulose Klucel GXF
40.00
40.00
40.00
40.00
80.00
0.3 N Hydrochloric acid
Mecamylamine HCl
—
3.00
6.00
9.00
—
Hydroxypropylcellulose Klucel GXF
—
0.67
1.33
2.00
—
Water
External phase:
Poly(vinylacetate) povidone blend Kollidon SR
101.00
101.00
101.00
101.00
101.00
Polyethylene oxide N60K
58.00
58.00
58.00
58.00
58.00
Stearic acid
7.50
7.50
7.50
7.50
7.50
Colloidal silicon dioxide
2.50
2.50
2.50
2.50
2.50
Coating:
Methacrylic acid copolymer dispersion
10.42
10.50
10.63
10.68
16.84
Talc
4.17
4.20
4.21
4.27
6.67
Polyethylene glycol 8000
1.39
1.40
1.40
1.42
2.22
Titanium dioxide
1.04
1.05
1.05
1.07
1.67
Carboxymethylcellulose sodium Hercules 7LF
0.35
0.35
0.35
0.36
0.56
Water
Total Tablet weight (mg)
451.37
455.17
458.97
462.80
726.96
EXAMPLE 2
A tablet containing 225 mg of bupropion as provided in Example 1A was compared to Wellbutrin XL 150 in a dissolution study using USP 26 App. (basket) or the two paddle test for extended release tablets. In the paddle test, at 50 rpm, the tablets were exposed to two paddles in 900 ml of water for 8 hours. In the basket test, tablets were exposed to 0.1 N HCl for two hours to mimic gastric conditions. After the two hours, the tablets were moved to simulated intestinal fluid at pH 6.8 at 100 rpm for 22 hours. At one hour time points throughout the incubation in the basket or paddle tests, beginning at time 0, a fluid sample was obtained and tested for presence and amount of bupropion. The simulated intestinal fluid (SIF) comprises 0.05 M tris hydroxymethylaminomethane adjusted to pH 6.8 with 2N sodium hydroxide solution.
Throughout the 24 hour period, at the 24 hour time point, all tablets had released about 95% of the bupropion dose contained in the tablet, the tablet of the instant invention released nearly the same percentage of bupropion as did the name brand product, including a two hour lag at the onset wherein essentially no bupropion was released from the tablets.
The same results were obtained with tablets containing 450 mg of bupropion. In one set of experiments, some tablets did not contain an enteric coating. That tablet released about 45% of the carried bupropion at the two hour time point, and about 70% at the four hour time point. In another set of experiments, two other tablets with 450 mg of bupropion contained a 4.68% enteric coating. One tablet also included a lubricant, magnesium stearate, in the formulation. Both of those tablets demonstrated a nearly identical dissolution profile as observed for Wellbutrin XL 150. In this set of experiments, the initial two hour incubation was done not in 0.1; N HCl but in simulated gastric fluid (SGF) which comprises 12 g of sodium chloride and 42 ml of hydrochloric acid, diluted to 6 liters and pH adjusted to 1.2.
EXAMPLE 3
Stability of bupropion HCl 225 mg extended release tablets and release profile were examined. Tablets were made as described in Example 1. Tablets were then stored at two different conditions, 25° C./60% RH and 40° C./75% RH. Samples were obtained at 0 and 1 month, and for the lower temperature regimen, also at 3 months, and then tested for bupropion, content uniformity, dissolution and related compounds. The results were compared to the specification of related approved drugs.
Throughout the lower temperature regimen, the instant tablets conformed with the standard parameters. At the higher temperature regimen, the instant tablets conformed at the 0 and one month sampling periods.
EXAMPLE 4
In vitro dissolution was compared to in vivo absorption, the amounts absorbed in vivo were calculated using the Wagner/Nelson method and plotted against the amounts released in vitro at equivalent time points using a Levy plot, practicing known methods. The tablet of interest contained 225 mg of bupropion, and was compared to Wellbutrin XL 300 mg.
Selected patients screened to meet parameters established in the approved protocol at a VA hospital, were provided with a single tablet after a nine hour fast. Blood samples were obtained, serum separated and the amount of bupropion was determined by liquid chromatography and mass spectrometry. A blood sample was also take prior to administration of the tablet.
Over a 36 hour period, nearly 100% of the bupropion was absorbed. The two hour lag period was noted. Overall, the profiles were the same, with the instant tablet identical to the Wellbutrin up through six hours, and then demonstrating an absorption profile that paralleled that of Wellbutrin, although at a level about 5% lower. The Wagner/Nelson method used assumes a one compartment, one body model for the drug. On the other hand bupropion has been reported to follow a two compartment, one body model. The Lou Riegelman method provides a suitable two compartment model. Nevertheless, the Wagner/Nelson method provides a sufficiently accurate approximation of the true absorption profile.
The Levy plots were substantially identical, the data best fit a second degree polynomial relationship. Hence, the absorption of the drug is nearly quantitative during the first eight hours after administration but is reduced as the dosage from enters the lower parts of the intestine. The pattern was observed for both Wellbutrin and the instant tablet. Thus, the absorption rate is dependent on the drug and not on the dosage.
The overall amount of drug released was about 5% lower than that of Wellbutrin. However, the maximum concentration was the same and was obtained at the same time.
EXAMPLE 5
Tablet cores are prepared as described above in Example 1A, and subsequently coated with an enteric coating solution having the formula set forth in the following Table 2.
TABLE 2
Coating solution
Eudragit ® L30 D55 (305 Dispersion)
39.76%
Talc
4.77%
Polyethylene glycol 8000
1.59%
Titanium dioxide
1.20%
Carboxymethyl cellulose sodium
0.40%
Water
52.28%
Solid percentage
20%
Polymer percentage
12%
Conventional coating techniques are employed to develop a dried coating on the compressed tablet cores that has a weight per tablet equal to either 4% or 6% of the weight of the tablet cores. Samples of the coated tablets are initially analyzed for the hydrolytic degradation product m-chlorobenzoic acid, and samples are subsequently analyzed after storage at room temperature for 6 months. The results show that the tablets (both 4% and 6% coatings) do not initially contain a quantifiable amount of m-chlorobenzoic acid (e.g., less than 0.05% based on the total weight of bupropion hydrochloride). After 6 months of storage at room temperature, the tablets (4 batches) with a 4% coating (weight of coating as a percentage of the weight of the compressed tablet core prior to coating) exhibit a small amount of degradation. More specifically, 0.1 to 0.3% conversion of bupropion hydrochloride to m-chlorobenzoic acid is found. Accordingly, a 4% coating appears to provide marginally acceptable stability for 6 months. The USP requirement is no more than 0.3%. Tablets (4 batches) having the 6% coating (weight of the coating as a percentage of the weight of the compressed tablet core) did not exhibit any quantifiable degradation (as characterized by quantitative analysis for m-chlorobenzoic acid) after 6 months of storage at room temperature.
The above description is considered that of the preferred embodiments only. Modifications of the invention will occur to those skilled in the art and to those who make or use the invention. Therefore, it is understood that the embodiments described above are merely for illustrative purposes and not intended to limit the scope of the invention, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents. | Controlled-release tablets exhibiting excellent storage stability are achieved by granulating a pharmaceutically active agent with a hydroxyalkylcelluose, blending the resulting granules with an extragranular phase composed of a particulate material that provides a sustained-release matrix, and compressing the blend into a tablet form, which may be optionally coated, such as with an enteric coating composition, to provide delayed release and/or to enhance stability of the active agent. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of co-pending U.S. Provisional Application Ser. No. 61/031,966, filed Feb. 27, 2008, the full disclosure of which is hereby incorporated by reference herein.
BACKGROUND
1. Field of Invention
The invention relates generally to the field of oil and gas production. More specifically, the present invention relates to a perforating system. Yet more specifically, the present invention relates to a perforating gun coupled to a plug.
2. Description of Prior Art
Perforating systems are used for the purpose, among others, of making hydraulic communication passages, called perforations, in wellbores drilled through earth formations so that predetermined zones of the earth formations can be hydraulically connected to the wellbore. Perforations are needed because wellbores are typically completed by coaxially inserting a pipe or casing into the wellbore. The casing is retained in the wellbore by pumping cement into the annular space between the wellbore and the casing. The cemented casing is provided in the wellbore for the specific purpose of hydraulically isolating from each other the various earth formations penetrated by the wellbore.
FIG. 1 illustrates one example of a known operation for cementing a casing within a wellbore. As shown, a vertical wellbore 5 lined with casing 7 is formed through a subterranean formation 9 . An annulus 8 exists in the space between the wellbore 5 and casing 7 ; cement 11 is forced into the annulus 8 to bond the casing 7 within the wellbore 5 . This typically involves first injecting cement 11 into the casing 7 and landing a wiper plug 13 in the casing 7 above the cement 11 . The wiper plug 13 shown includes a textured outer surface that seals against the casing 7 inner diameter preventing cement 11 flow between the wiper plug 13 and the casing 7 .
Completion fluid 15 is pumped from an injection system 17 in the wellbore 5 above the wiper plug 13 . Pressure from the fluid 15 forces the wiper plug 13 and cement 11 toward the wellbore 5 bottom. Sufficient applied pressure forces the cement 11 past the end of the casing 7 and to the wellbore 5 bottom. There the cement 11 enters the annulus 8 bottom and flows upward in the annulus 8 forced by the continued inflow of the pressurized completion fluid 15 . Ultimately, the wiper plug 13 reaches the wellbore 5 bottom and couples with a float collar (not shown), where the plug 13 will likely remain indefinitely, unless the wellbore 5 depth is later increased. The cement 11 flowed into the annulus 8 is allowed to cure and set before further downhole operations are commenced.
SUMMARY OF THE INVENTION
Disclosed herein is a method of wellbore operations. In an embodiment a method includes injecting cement into casing that is circumscribed by a wellbore and an annulus formed between the casing and wellbore, deploying an assembly into the wellbore that includes a perforating gun, shaped charges in the perforating gun, and a plug attached to the perforating gun, forcing the plug with the attached assembly down the wellbore with fluid so that the cement exits the casing bottom and flows into the annulus to bond the casing to the wellbore, and activating the perforating gun. The plug and gun can be attached by a line, a tubular member, wireline, slickline, a chain, tubing, or combinations thereof, optionally; the plug can be on the perforating gun itself. The method can include adding a second perforating gun in the wellbore. Plug embodiments include a cylindrically shaped body having an outwardly radially extending ridge in sealing contact with the casing.
Also provided herein is a method of perforating a subterranean formation that includes deploying a perforating gun system having a perforating gun with shaped charges into a wellbore, forming a pressure differential across a portion of the gun system to force the perforating gun within the wellbore, locating the perforating gun system at a location in the wellbore, and detonating the shaped charges in the wellbore. This embodiment can further comprise attaching a plug to the perforating gun system that can sustain a pressure differential along its length. A flexible member can be used for attaching the plug and gun system.
An example of a perforating system is included herein. In an embodiment the system is moveable along a bore of a casing disposed in a wellbore and includes a perforating gun freely deployable in the casing bore without an attached deployment member, shaped charges in the perforating gun, a plug connected to the perforating gun, a higher pressure side on the side of the plug proximate to the wellbore entrance, and a lower pressure side on the side of the plug proximate to the wellbore bottom, so that a force is generated by a difference in pressure between the higher pressure side and the lower pressure side to move the perforating system in the casing. The plug can include ridges on its lateral sides radially extending outward into sealing contact with the casing. The system may further include a float collar selectively attachable to the plug. The system may further have a first fluid in the casing and a second fluid in the casing, wherein the first and second fluids are separated by the plug.
BRIEF DESCRIPTION OF DRAWINGS
Some of the features and benefits of the present invention having been stated, others will become apparent as the description proceeds when taken in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a sectional view of a prior art example of a casing cementing operation.
FIG. 2 is a cutaway view illustrating a combined perforating and wiper plug operation in accordance with the present disclosure.
FIGS. 3 and 4 illustrate embodiments of a combination perforating and wiper plug operation in a deviated wellbore.
FIG. 5 illustrates a side view of an alternative embodiment of a system for perforating and cementing.
While the invention will be described in connection with the preferred embodiments, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications, and equivalents, as may be included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF INVENTION
The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. For the convenience in referring to the accompanying figures, directional terms are used for reference and illustration only. For example, the directional terms such as “upper”, “lower”, “above”, “below”, and the like are being used to illustrate a relational location.
It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials, or embodiments shown and described, as modifications and equivalents will be apparent to one skilled in the art. In the drawings and specification, there have been disclosed illustrative embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for the purpose of limitation. Accordingly, the invention is therefore to be limited only by the scope of the appended claims.
FIG. 2 illustrates in cross-sectional view one embodiment of a system and method for cementing and for perforating. In this embodiment, a wiper plug 20 is shown contacting a float collar 21 provided at the casing 7 end. The system and method described herein is not limited to the embodiments of wiper plug 20 and float collar 21 illustrated herein, but can include any now developed or later known apparatus for cementing a casing 7 within a wellbore 5 . A perforating system 24 is shown coupled to the wiper plug 20 . The perforating system 24 comprises a perforating gun 26 with shaped charges 27 for creating perforations 29 through the casing 7 and into the surrounding formation 9 . In the embodiment shown, a line 22 couples the perforating gun 26 to the wiper plug 20 .
An optional wireline 28 may be used to deploy the perforating gun 26 into the wellbore 5 and to convey an initiation signal for detonating the shaped charges 27 . The wireline 28 can also be used to remove the perforating gun 26 from the wellbore 5 . However, as discussed below, the perforating gun 26 can also be free floating in the wellbore 5 attached to a wiper plug 20 without being suspended from a deployment member, such as a wireline 28 . Additionally, the shaped charge 27 detonation signal may be from a timer circuit, telemetry, or other communication means. After shaped charge 27 detonation, the gun 26 can remain in the wellbore 5 , or retrieved using fishing techniques. A fishing neck (not shown) may be included on the perforating gun 26 for later retrieval. To ensure the perforating gun 26 can be detached from the wiper plug 20 , a frangible link may be included in the connection between the perforating gun 26 and the wiper plug 20 . Alternatively, the coupling between the perforating gun 26 and the wiper plug 20 may include a detachment mechanism automatically activated upon shaped charge 27 initiation, after a programmed delay, or manually on a command from the surface.
In one mode of operation of the embodiment illustrated in FIG. 2 , a typical cementing operation may take place by applying completion fluid 15 from an injection system 30 to the upper or high pressure side of the wiper plug 20 . Alternatively, the substance added into the wellbore 5 above the wiper plug 13 may be something other than completion fluid and optionally it may be pressurized. Examples of such a substance include brine, acidizing fluids, alcohols, mud based fluids, polymeric compounds, other completion fluids, and combinations thereof. As discussed above, the continued application of completion fluid 15 urges the cement 11 into the bottom portion of the wellbore and up the annulus 8 formed between the casing 7 and wellbore 5 . After the wiper plug 20 engages the float collar 21 the cement 11 may be given time to cure within the annulus 8 . It is believed that it is well within the capabilities of those skilled in the art to determine an appropriate and/or method for establishing the time period to allow a proper set or setting of the cement 11 .
The shaped charges 27 may be initiated after the cement 11 has set where the resulting detonation creates the perforations 29 . Optionally, shaped charge 27 detonation can occur before the cement 11 has set or been cured. In an alternative, the shaped charges 27 are detonated as the perforating gun 26 is being drawn downward within the borehole 5 . Eliminating a downhole tool removal/deployment step is an advantage of combining cementing with perforating. A control module 25 is shown optionally provided with the perforating gun 26 . Perforating gun 26 operations can be maintained by the control module 25 . In an example, the control module 25 can include a control module for receiving and sending control commands. The module 25 can also include a firing head, an initiator, and an initiator module.
FIG. 3 is a side view of a deviated wellbore 5 a with casing 7 a and an annulus 8 a filled with cement 11 between the wellbore 5 a and casing 7 a . The wellbore 5 a is shown extending through a formation 9 having a generally horizontal section. As shown, the perforating gun 26 is in the generally horizontal portion having been pulled into position by the wiper plug 20 and line 22 . Thus utilizing the present method deviated wellbores can be perforated with perforating guns not on tubing. Additionally, the wellbore 5 a can be perforated and cemented without removing/redeploying a downhole tool. Additionally, it should be pointed out that the line 22 length can be tailored to accommodate specific perforating situations and is not limited to a specified length. Attaching the perforating gun 26 to the wiper plug 20 is not limited to the use of the line 22 , but includes any other mode of attachment, including a rigid or flexible member attaching device. Examples include direct attachment (see FIG. 5 ), a tubular member, a rod, chain, slickline, and combinations of these. The tubular member includes tubing, tubulars, as well as deployed members referred to in the art as “subs”.
FIG. 4 illustrates another embodiment of a perforating and/or cementing system disclosed herein shown disposed in a wellbore 5 a lined with casing 7 a . In this embodiment an additional perforating gun 32 is included with a perforating system 24 a . It should be pointed out; however, that the number of perforating guns is not limited to those illustrated herein, but can include any number of individual perforating guns and/or a number of perforating strings.
Purposes of the wiper plug include: (1) acting as a barrier between the cement slurry and the completion fluid; (2) to clean the wellbore; (3) preventing backflow of the cement slurry by being locked in place. Optionally, the perforating system may be included with a sensor circuit 31 having a timer that recognizes setting of the wiper plug 20 onto its associated float collar 21 . After the wiper plug 20 with the sensor circuit 31 contacts the collar 21 contact timer can then initiate a countdown sequence that when finished would initiate detonation of the shaped charges 27 .
FIG. 5 provides in side view an optional embodiment of a system for perforating and cementing. The system 24 a comprises a perforating gun 26 a coupled to a wiper plug 20 a . The perforating gun 26 a can be directly attached to the wiper plug 20 a upper surface; alternatively a single body of material can be used to form the perforating gun 26 a and wiper plug 20 a . Yet further optionally, wiper plug elements, i.e. radial members extending outward into sealing contact with the wellbore inner surface, may be included on the perforating gun outer surface thereby integrating a perforating gun with a wiper plug.
The scope of the embodiments discussed herein is not limited to systems disposed on wireline, but any type of deployment member, such as slickline, tubing, and any other form of deploying a tool within a wellbore. A timing circuit can be used for perforating gun detonation in either a wireline/slickline deployment or in a freely deployed scenario. The timing circuit may be initiated upon deployment of the system into the wellbore, on landing at the float collar, contact with a timing rod 23 extending from the wiper plug 22 ( FIG. 4 ), or anytime between. Perforating gun detonation may also take place by pressure, memory based, or telemetry. Alternatives to the embodiments discussed may include a wiper plug assembly behind the cement wiper plug. Additionally, the timing circuit can be electrical, mechanical, or ballistic.
The present invention described herein, therefore, is well adapted to carry out the objects and attain the ends and advantages mentioned, as well as others inherent therein. While a presently preferred embodiment of the invention has been given for purposes of disclosure, numerous changes exist in the details of procedures for accomplishing the desired results. These and other similar modifications will readily suggest themselves to those skilled in the art, and are intended to be encompassed within the spirit of the present invention disclosed herein and the scope of the appended claims. | A method and system for cementing and perforating a wellbore in a single step by coupling a perforating gun with a wiper plug. The method includes injecting cement in a wellbore having casing therein and an annulus between the casing and wellbore. A wiper plug is dropped on the cement having a perforating gun attached to the wiper plug. The plug is forced downward pulling the perforating gun along. The downward motion of the plug in turn pushes the cement out the bottom end of the casing and into the annulus. The cement in the annulus is allowed to set and the perforating gun is activated. | 4 |
TECHNICAL FIELD
This disclosure relates to heterostructure field effect transistors (HFET), which are also known as high electron mobility transistors (HEMTs), and in particular to normally-off type HFET transistors.
BACKGROUND
GaN-based transistors are typically of the normally-on type due to the spontaneous formation of a polarization-doped two dimensional electron gas (2DEG) at the AlGaN/GaN interface. However, normally-off type devices are desirable in a number of applications and particularly in high voltage power-switching applications, where the normally-off functionality reduces power consumption and improves safety. High-voltage power-switching devices also require a high breakdown voltage in addition to a low on-resistance. Methods of making AlGaN/GaN transistors normally-off include gate recess etching, fluorine plasma exposure, the use of thin or low Al-composition AlGaN barrier layers, p-type depletion layers, etc. Any method for fabrication of a normally-off device should ideally not compromise the breakdown voltage of the device and should maintain a low on-resistance. Another issue is charge trapping at the drain side of the gate, which can result in a phenomenon known as “current collapse” under high-voltage operation. To avoid current collapse, the surface of the device must be passivated by a dielectric material that has a high-quality interface with GaN (typically SiN).
The prior art includes flourine-treated normally-off type GaN devices, as described by K. S. Boutros, S. Burnham, D. Wong, K. Shinohara, B. Hughes, D. Zehnder, and C. Mcguire, “Normally-off 5 A/1100V GaN-on-Silicon Device for high Voltage applications”, International Electron Devices Meeting 2009; and hybrid MOS-HFET devices which utilize a single dielectric layer as a gate insulator and surface passivation layer as described by H. Kambayashi, Y. Satoh, S. Ootomo, T. Kokawa, T. Nomura, S. Kato, and T. P. Chow, “Over 100 A normally-off AlGaN/GaN hybrid MOS-HFET on Si substrate with high-breakdown voltage”, Solid State Elec., vol. 54 issue 6 pp. 660-664 (2010), and T. Oka and T. Nozawa, “AlGaN/GaN recessed MIS-Gate HFET with high threshold voltage normally-off operation for power electronics applications”, IEEE Elec Dev. Lett. vol. 29 no. 7 (2008).
The disadvantages of Flourine-treated devices include poor threshold voltage uniformity and reliability. The disadvantages of prior art MOS-HFET devices, which use a thick SiO 2 or SiN layer as both a gate dielectric and a passivation layer, include poor channel mobility and on-resistance due to a poor quality, thick, low k dielectric under the gate, as well as poor surface passivation by SiO 2 , and threshold voltage hysteresis due to a poor quality interface between the gate dielectric and underlying epitaxial material.
These types of “hybrid” MOS- or MIS-HFET devices are known to result in a normally-off device with a high breakdown voltage. However, these hybrid MOS-HFET devices have the disadvantage of low electron mobility in the active region under the gate due to a poor quality interface between the gate dielectric and the underlying GaN, resulting in increased on-resistance compared to a traditional GaN HFET.
What is needed is a device with a normally-off operation with low gate current, high breakdown voltage, and low on-resistance, as well as low threshold voltage hysteresis and current collapse. The embodiments of the present disclosure answer these and other needs.
SUMMARY
In a first embodiment disclosed herein, a field effect transistor (FET) comprises a source electrode, a drain electrode, a channel layer, a barrier layer over the channel layer and coupled to the source and drain electrodes, a passivation layer over the barrier layer for passivating the barrier layer between the gate electrode and the source electrode and between the gate electrode and the drain electrode, a gate electrode extending through the barrier layer and the passivation layer, and a gate dielectric surrounding the portion of the gate electrode that extends through the barrier layer and the passivation layer, wherein the passivation layer is a first material and the gate dielectric is a second material, and wherein the first material is different than the second material.
In another embodiment disclosed herein, a method of fabricating a field effect transistor comprises forming a channel layer, forming a barrier layer over the channel layer, forming a passivation layer over the barrier layer, etching away a first area of the passivation layer for a source electrode and a second area of the passivation layer for a drain electrode, forming a source electrode and a drain electrode on the barrier layer, etching away a third area of the passivation layer and a fourth area extending through the barrier layer for a gate electrode, forming a gate dielectric on the surface of the third area and the fourth area, and forming a gate electrode in the third area and in the fourth area, wherein the passivation layer is a first material and the gate dielectric is a second material, and wherein the first material is different than the second material.
These and other features and advantages will become further apparent from the detailed description and accompanying figures that follow. In the figures and description, numerals indicate the various features, like numerals referring to like features throughout both the drawings and the description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an elevation sectional view of a hybrid MOS-HFET with a layer used as both a gate dielectric and a passivation layer in accordance with the prior art;
FIG. 2 shows an elevation sectional view of a hybrid MOS-HFET in accordance with the present disclosure;
FIG. 3 shows transfer curves comparing characteristics with and without a post deposition anneal (PDA) of the Al 2 O 3 gate dielectric for a hybrid MOS-HFET in accordance with the present disclosure;
FIG. 4 shows a 200 ns pulsed common-source current voltage measurement of an annealed Al 2 O 3 hybrid MOS-HFET in accordance with the present disclosure;
FIG. 5 shows a common-source DC current voltage and zero-bias breakdown measurement of an annealed Al 2 O 3 hybrid MOS-HFET in accordance with the present disclosure;
FIG. 6 shows a comparison of a prior art normally-off GaN power device with a hybrid MOS-HFET in accordance with the present disclosure;
FIG. 7 shows a common-source DC current voltage measurement of an annealed hybrid Al 2 O 3 MOS-HFET with a gate periphery of 20 mm with the gate biased from +3V in −0.5V steps in accordance with the present disclosure; and
FIG. 8 is a flow diagram of a method of fabricating a hybrid MOS-HFET in accordance with the present disclosure.
DETAILED DESCRIPTION
In the following description, numerous specific details are set forth to clearly describe various specific embodiments disclosed herein. One skilled in the art, however, will understand that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well known features have not been described so as not to obscure the invention.
FIG. 1 shows an elevation sectional view of a hybrid MOS-HFET 10 with a layer 12 used for both surface passivation of the AlGaN layer 14 between the gate 16 and source 20 and drain 22 electrodes and as a gate dielectric beneath gate 16 in accordance with the prior art. In the prior art for hybrid AlGaN/GaN MOS- or MIS-HFETs, the layer 12 may be a plasma enhanced chemical vapor deposition (PECVD) SiN or SiO 2 layer 12 and be greater than 20 nm thick. The result the use of the layer 12 as both a surface passivation layer and a gate dielectric is a low-mobility channel with high on-resistance and low g m . In addition, prior art MIS-HFETs can suffer from threshold voltage hysteresis related to a poor quality interface between the layer 12 and the GaN epi layer 18 .
The prior art method of fabricating a normally-off low on-resistance GaN HFET, involves etching completely through the AlGaN barrier layer 14 in the gate 16 region of the device and depositing a gate dielectric material 12 , which forms an MOS-type interface in the channel under the gate, as described in H. Kambayashi, Y. Satoh, S. Ootomo, T. Kokawa, T. Nomura, S. Kato, and T. P. Chow, “Over 100 A normally-off AlGaN/GaN hybrid MOS-HFET on Si substrate with high-breakdown voltage”, Solid State Elec., vol. 54 issue 6 pp. 660-664 (2010), and T. Oka and T. Nozawa, “AlGaN/GaN recessed MIS-Gate HFET with high threshold voltage normally-off operation for power electronics applications”, IEEE Elec Dev. Lett. vol. 29 no. 7 (2008). Away from the gate 16 the AlGaN barrier layer 14 induces a high-density high-mobility 2DEG 24 , which results in low on-resistance. Although the prior art “hybrid” MOS- or MIS-HFET devices have been shown to result in normally-off operation with high breakdown voltage, the prior art hybrid MOS-HFET devices have the disadvantage of a low electron mobility in the active region under the gate due to a poor quality interface between the gate dielectric 12 and the underlying GaN layer 18 , resulting in increased on-resistance compared to a traditional GaN HFET. The performance of such “hybrid” MOS-HFET devices therefore is extremely sensitive to the quality of the gate dielectric 12 and its interface with the underlying channel layer. As shown in FIG. 1 the GaN layer 18 may be doped with magnesium (Mg).
FIG. 2 shows an elevation sectional view of a hybrid MOS-HFET 30 in accordance with the present disclosure. The AlGaN barrier layer 32 , which also may be formed of AlN, AlInN, a combination of AlN spacer and AlGaN barrier, or a combination of AlN spacer and InAlN barrier, in the gate 34 region of the device is completely etched, resulting in normally-off operation, while a low on-resistance is maintained by the presence of a polarization-induced 2DEG 36 in the access regions between the AlGaN barrier layer 32 and the GaN channel layer 38 , and away from the gate 34 . The channel layer 38 may also be formed of InN, or InGaN, may be a 0001 oriented GaN layer, and in a preferred embodiment is not doped with magnesium. A passivation layer 44 , which may be PECVD SiN, SiO 2 , Al 2 O 3 , HfO 2 , TiO 2 , amorphous AlN, or polycrystalline AlN, and which may be about 20-100 nm thick, is used to passivate the AlGaN layer 32 between the gate 34 and source 40 and drain 42 .
A gate dielectric 46 , which may be Al 2 O 3 , or may be hafnium oxide (HfO 2 ), titanium oxide (TiO 2 ), SiN, SiO 2 , amorphous AlN, or polycrystalline AlN, surrounds the gate 34 and also covers the passivation layer 44 in the embodiment shown in FIG. 2 . In another embodiment the gate dielectric 46 only surrounds the gate 34 and does not cover the passivation layer 44 . Having a separate passivation layer 44 and gate dielectric 46 is in contrast to prior art devices which use the same thick layer 12 , as shown in FIG. 1 , as both a passivation layer and gate dielectric.
In the present disclosure the gate dielectric and surface passivation layers are different materials, and may be deposited by different deposition techniques, allowing independent optimization of gate characteristics and current collapse, respectively. The gate dielectric 46 may be deposited using atomic layer deposition (ALD), which has advantages compared to PECVD, and may consist of a high-k material such as Al 2 O 3 . Al 2 O 3 has a higher dielectric constant of approximately 9-10, compared to SiO 2 , which has a dielectric constant of approximately 6-7. In addition Al 2 O 3 has a larger bandgap of approximately 7 eV, compared to approximately 5 eV for SiO 2 , making Al 2 O 3 a superior gate dielectric material.
As further described below, hybrid MOS-HFETs in accordance with the present disclosure have been fabricated and tested with a SiN surface passivation layer 44 in combination with an ALD Al 2 O 3 gate dielectric 46 , with the Al 2 O 3 gate dielectric 46 annealed after deposition for improved oxide/epi interface quality. The test results indicate that hybrid MOS-HFETs in accordance with the present disclosure are normally-off with low gate current, high g m , high drain current, low current collapse, low hysteresis, low on-resistance, and high breakdown voltage. Together the results indicate that hybrid MOS-HFETs in accordance with the present disclosure have an approximately seven times (7×) improvement in Vb 2 /R on figure-of-merit over the prior art hybrid MOS-HFET structures.
As described above, the hybrid MOS-HFETs in accordance with the present disclosure have gate dielectric and surface passivation layers that are different materials and that may be deposited by different deposition techniques, allowing independent optimization of gate characteristics and current collapse, respectively. The characteristics which make good surface passivation layers and good gate dielectrics are very different. Due to uncontrolled oxidation of the epi surface during deposition, oxygen-containing materials such as SiO 2 typically result in inferior surface passivation of GaN devices and poor current collapse suppression compared to oxygen-free materials, such as SiN, as described by X. Hu, A. Koudymov, G. Simin, J. Yang, and M. Asif Khan, “Si3N4/AlGaN/GaN metal-insulator-semiconductor heterostructure field-effect transistors”, Applied Phys. Lett., vol. 79 no. 17 p. 2832 (2001).
Optimal surface passivation layers are typically at least 30-50 nm thick in order to remove the surface of the dielectric, which can be a source of charging due to ionization of air, from the active region of the device as described by Y. Pei, S. Rajan, M. Higashiwaki, Z. Chen, S. P. DenBaars, and U. K. Mishra, “Effect of dielectric thickness on power performance of AlGaN/GaN HEMTs”, IEEE Elec Dev. Lett. vol. 30 no. 4 (2009).
Finally, low dielectric constants are desired for surface passivation layers in order to reduce parasitic capacitances, particularly for high-frequency applications. Gate insulator dielectrics, on the other hand, ideally have high dielectric constants and low thickness to achieve high device transconductance, in addition to a large bandgap and large band offset with the channel layer in order to reduce gate current. Uniformity, thickness control, and a low interface density of states (Dit) are critical gate insulator properties—especially for MOS-type devices, in which the conduction electrons are confined directly by the dielectric. For low leakage current, gate insulator dielectrics should be amorphous, as grain boundaries have been shown to act as leakage paths. Suitable high-k dielectrics with large bandgaps for electron confinement include amorphous oxides such as Al 2 O 3 , HfO 2 , and TiO 2 , which have been studied extensively for GaAs III-V and Si MOSFETs. The atomic layer deposition (ALD) deposition technique is ideally suited to deposition of gate dielectrics due to excellent conformality, thickness control, low deposition temperature (thermal processing budget), and plasma-free deposition, which avoids plasma-induced damage of the underlying epi. The extremely low deposition rates in ALD (˜1 A/cycle) make it suitable for very thin (<20 nm thick) films. In contrast, typically, SiO 2 and SiN passivation layers are deposited by plasma-enhanced CVD techniques (PEVCD), which result in much high deposition rates but relatively poor film quality due to the high-energy plasma environment during deposition. Other techniques for deposition include metal-organic chemical vapor deposition (MOVCD), atomic layer deposition (ALD), molecular beam epitaxy (MBE), e-beam evaporation, and sputtering.
In the hybrid MOS-HFET of the present disclosure, the AlGaN barrier layer 32 may be etched away to the channel layer 38 in the gate region using an atomic layer etching (ALE) technique, eliminating the polarization-induced 2DEG 36 under the gate electrode 34 only. The atomic layer etching (ALE) technique is described in U.S. patent application Ser. No. 12/909,497 filed Oct. 21, 2010, which is incorporated herein as though set forth in full. The lack of a 2DEG 36 at zero-bias conditions on the gate 34 results in normally-off operation, while surface passivation 44 in the access region between the gate 34 and the source 40 and between the gate 34 and the drain 42 results in low current collapse. The high density 2DEG 36 remains in the access regions of the device under the AlGaN barrier layer 32 , resulting in a low on-resistance. The gate 34 is insulated from the channel by an amorphous gate dielectric layer 46 . The device is considered a “hybrid” MOS-HFET structure because the electrons under the gate 34 and in the GaN 38 channel are directly in contact with the gate dielectric 46 as in a MOS device, while the electrons in the access regions away from the gate are confined by the wide bandgap AlGaN layer 32 and form a high-mobility 2DEG 36 , as in an HFET device.
In one embodiment of the hybrid MOS-HFET of the present disclosure, the gate dielectric 46 may be 2-20 nm-thick ALD Al 2 O 3 , and the passivation layer may be 20-100 nm-thick PECVD SiN. An optimized post-deposition anneal process, in which the Al 2 O 3 is annealed immediately following deposition may be used. The anneal process improves the Al 2 O 3 /GaN interface and results in reduced electron trap density and increased channel mobility compared to unannealed Al 2 O 3 . Test results show a normally-off with low on-resistance, high breakdown voltage, very low current collapse, low gate current, and drain current and transconductance, and a figure of merit Vb 2 /R on,sp , where Vb is the breakdown voltage and R on,sp is the on-resistance normalized by the area of the transistor, equal to 260 MW/cm2, which as discussed above is approximately a 7-fold improvement over prior art hybrid MOS-HFET devices, which typically use a 60 nm-thick PECVD SiO 2 as both a gate dielectric and surface passivation layer.
FIGS. 3A and 3B show transfer curves for hybrid MOS-FETs according to the present disclosure. FIG. 3A shows transfer curves for hybrid MOS-FETs fabricated without the post-deposition anneal process described above. FIG. 3B shows transfer curves for hybrid MOS-FETs which underwent a post-deposition anneal (PDA) immediately following the Al 2 O 3 deposition. The PDA significantly reduced the interface trap density, reflected in reduced threshold voltage hysteresis, as indicated in the up and down arrows in FIGS. 3A and 3B , and also increased the gm and maximum drain current due to an increase in the channel electron mobility.
FIG. 4 shows the resulting pulsed and DC current voltage for hybrid MOS-FETs according to the present disclosure. The device has very low current collapse at a quiescent bias of Vds=+30V, Vgs=−2V, indicating successful suppression of surface charge trapping by the SiN passivation layer. Common-source DC current voltage and breakdown measurements are shown in FIG. 5 . In the embodiment tested the gate periphery was 200 μm and the gate-drain spacing was 12 μm. The on-resistance was measured at Vgs=+3V was 16.6 ohm-mm, while the off-state three-terminal breakdown (measured at zero gate bias) was 1132V. The specific on-resistance was 4.9 mohm-cm 2 , leading to a high-voltage device figure-of-merit, Vb 2 /R on,sp , of 261 MW/cm 2 , which is a good figure of merit for a normally-off GaN device, and is an excellent figure of merit for a normally-off insulated-gate GaN device.
FIG. 6 compares this result with results for prior art normally-off GaN devices. The result 50 for a hybrid MOS-HFET of the present disclosure significantly out-performs the result 52 for a prior art hybrid MOS-HFET device with a SiO 2 layer used for both a gate dielectric and a passivation layer, as described in H. Kambayashi, Y. Satoh, S. Ootomo, T. Kokawa, T. Nomura, S. Kato, and T. P. Chow, “Over 100 A normally-off AlGaN/GaN hybrid MOS-HFET on Si substrate with high-breakdown voltage”, Solid State Elec., vol. 54 issue 6 pp. 660-664 (2010).
FIG. 7 shows common-source DC current and voltage measurements for a larger-periphery (20 mm gate width) device. In these measurements, the maximum drain current is greater than 3 A at a gate bias of +3V, while the gate current is on the order of 10 uA/mm. This demonstrates that large area devices with an ALD Al 2 O 3 gate dielectric 46 and passivation layer 44 are also feasible. The gate periphery, which is the perimeter of the gate, may range from about 200 μm to as large as 5 meters in length for power electronic applications.
FIG. 8 is a flow diagram of a method of fabricating a hybrid MOS-HFET in accordance with the present disclosure. In step 100 a channel layer 38 is formed. Then in step 102 a barrier layer 32 is formed over the channel layer. Next in step 104 a passivation layer 44 is formed over the barrier layer. Then in step 106 a first area of the passivation layer is etched away for a source electrode 40 and second area is etched away for a drain electrode 42 . Next in step 108 a source electrode 40 and a drain electrode 42 is formed on the barrier layer. Then in step 110 a third area 47 of the passivation layer and a fourth area 48 extending through the barrier layer for a gate electrode 34 is etched away. Next in step 112 a gate dielectric 46 is formed over the surface of the third and fourth area. Then in step 114 a gate electrode 34 is formed in the third area and in the fourth area. In this method, as described in step 116 , the passivation layer is a first material and the gate dielectric is a second material and the first material is different than the second material.
Having now described the invention in accordance with the requirements of the patent statutes, those skilled in this art will understand how to make changes and modifications to the present invention to meet their specific requirements or conditions. Such changes and modifications may be made without departing from the scope and spirit of the invention as disclosed herein.
The foregoing Detailed Description of exemplary and preferred embodiments is presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive nor to limit the invention to the precise form(s) described, but only to enable others skilled in the art to understand how the invention may be suited for a particular use or implementation. The possibility of modifications and variations will be apparent to practitioners skilled in the art. No limitation is intended by the description of exemplary embodiments which may have included tolerances, feature dimensions, specific operating conditions, engineering specifications, or the like, and which may vary between implementations or with changes to the state of the art, and no limitation should be implied therefrom. Applicant has made this disclosure with respect to the current state of the art, but also contemplates advancements and that adaptations in the future may take into consideration of those advancements, namely in accordance with the then current state of the art. It is intended that the scope of the invention be defined by the Claims as written and equivalents as applicable. Reference to a claim element in the singular is not intended to mean “one and only one” unless explicitly so stated. Moreover, no element, component, nor method or process step in this disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the Claims. No claim element herein is to be construed under the provisions of 35 U.S.C. Sec. 112, sixth paragraph, unless the element is expressly recited using the phrase “means for . . . ” and no method or process step herein is to be construed under those provisions unless the step, or steps, are expressly recited using the phrase “comprising the step(s) of . . . .” | A field effect transistor (FET) includes source and drain electrodes, a channel layer, a barrier layer over the channel layer, a passivation layer covering the barrier layer for passivating the barrier layer, a gate electrode extending through the barrier layer and the passivation layer, and a gate dielectric surrounding a portion of the gate electrode that extends through the barrier layer and the passivation layer, wherein the passivation layer is a first material and the gate dielectric is a second material, and the first material is different than the second material. | 7 |
The present invention generally relates to a compress garment, and more specifically is directed to a compress garment for positioning medical electrodes against a body.
Monitoring electrodes are well known for their use in determining a multitude of body conditions.
Transcutaneous electrical nerve stimulation is used for example, in post-operative and chronic pain control.
On the other hand, muscle stimulation is useful for example, in maintenance and development of muscle tissue and is a particularly important function in sports medicine.
While significant advantages afforded through the use of electrical stimulation of nerves and muscles, its effectiveness can be enhanced when used in combination with a supporting compress, band or brace, which may not only provide for immobilization of the body part, but also proper placement and positioning of electrical stimulation electrodes with respect to the body part. Reference is made to U.S. patent application entitled “ELECTRICAL STIMULATION COMPRESS” Ser. No. 09/428,196 filed Oct. 27, 1999. This patent application is to be incorporated herewith in its entirety, including all specifications and drawings by this specific reference thereto. The referenced patent application is limited to relatively small supports, bands, or braces because of the difficulty in placement of electrodes thereunder. For large compresses, or garments, such as for example, sleeves and torso garments, it is difficult to effect proper placement of the electrodes because the “skin tight” nature of the garment. Such garments must be rolled, pulled over, strapped or slid into position in order to effect proper compress or bracing for the patient. It is also evident that electrode placement, or the means therefore, should not interfere with the purpose of the garments.
The present invention provides for the use of difficult to don compress garments in combination with accurate placement of one or more medical electrodes without interfering with the garment placement or function.
SUMMARY OF THE INVENTION
A compress garment in accordance with the present invention for application to a body generally includes a garment member sized and shaped for positioning onto a body, and when in position, conforming to and supporting a body shape. The positioning may be by sliding, rolling or strapping the garment member onto the body. Typically the garment member is elastic and of sufficient elasticity to not only conform to the body part but act also as a brace or compress. Such garment members cover a large area of body and are custom made and fitted to a patient in order to apply compress, or support, to selected body parts as noted hereinabove.
In accordance with the present invention, at least one access window is disposed in the garment member for enabling dermal application and removal of a medical electrode. The access window is located on the garment member at a position enabling access to a pre-selected dermal area.
In one embodiment of the present invention, the access window comprises a slit in the garment member and the slit is sized and shaped for enabling the insertion and removal of a medical electrode therethrough. Further, an electrical contact for example, an eyelet of a snap assembly, is disposed in the garment member and passes through the garment member proximate the slit for establishing electrical connection with the medical electrode. In this embodiment, the medical electrode has no separate electrical lead wires extending therefrom.
In another embodiment of the present invention, the access window comprises at least one hinged flap with the hinged flap being sized and shaped for enabling insertion and removal of the medical electrode thereunder. In addition, an electrical contact, passing through the hinged flap is provided for establishing electrical connection with the medical electrode.
In yet another embodiment of the present invention, the access window may comprise an opening in the member with the opening being sized and shaped for enabling insertion and removal of a medical electrode. The garment further comprises a cover for covering the opening and the medical electrode. In addition, an electrical contact passing through the cover, may be provided for establishing electrical connection with the medical electrode.
A carrier, for example, a pocket, may be provided in the garment for supporting an electrical/electronic module for connection to the medical electrode. In this instance electrical connection between the electrode and the module may be through wires embedded in the garment.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will be better understood by the following description when considered in conjunction with the accompanying drawings in which:
FIG. 1 is a perspective view of a compress garment in accordance with the present invention showing a plurality of access windows and slits with electrical contact snaps extending therethrough;
FIG. 2 is a compress garment similar to that shown in FIG. 1 also featuring a pocket for supporting an electrical module and a plurality of electrodes disposed through access windows with wires integral with or beneath the garment for attachment to the electronic module (not shown) which may be disposed in the pocket;
FIG. 3 is a cross-section exploded view of an access window flap in accordance with the present invention;
FIG. 4 is a plan view of the flap access window as shown in FIG. 3 illustrating a variety of electrode positions;
FIG. 5 is a cross-sectional view of an alternative flap access window in accordance with the present invention;
FIG. 6 is a plan view of the flap access window shown in FIG. 5;
FIG. 7 is a cross-sectional exploded view of an access window and cover in accordance with the present invention sized for accommodating two electrodes, for example, an anode and cathode electrode, as may be desired in certain treatments or applications;
FIG. 8 is a plan view of the cover access window shown in FIG. 7 utilizing attachment tabs disposed in an asymmetric position around a window opening or alternately, an index for orienting the electrode beneath the cover;
FIG. 9 is a cross-sectional exploded view of an alternative embodiment of an access window and cover in accordance with the present invention;
FIG. 10 is a plan view the embodiment shown in FIG. 9 along with an index marking for properly orienting the electrode within the access window;
FIG. 11 is an alternative embodiment of a cover window access in accordance with the present invention;
FIG. 12 is a plan view of the embodiment shown in FIG. 11;
FIG. 13 is a cross-sectional exploded view of a slit access window in accordance with the present invention; and
FIG. 14 is a plan view of the slit access window shown in FIG. 13 .
DETAILED DESCRIPTION
With reference to FIG. 1, there is shown a compress garment 10 , specifically a lower torso garment, for application to a body. It should be appreciated that while a lower torso garment 10 is shown, other garment such as sleeves, leggings, upper torso garments or any garment covering large areas of the body are to be considered within the scope of the present invention.
Such garments are typically custom fitted to a patient and even light adhesion to the skin hampers donning and doffing of such garments. Prior art garments, not shown, utilizing stimulation electrodes, see for example the referenced patent application Ser. No. 09/428,196, further hamper the donning and doffing of the garments. The prior art has attempted to solve this problem though the use of sliding electrodes, however, the manufacture of such electrodes is difficult, and further, when sliding over the skin such slidable electrodes leave an undesirable “snail trail”.
With further reference to FIG. 1, the garment 10 includes a sized member 12 which is shaped for slidable positioning onto a body, and when in position conforming to an supporting the body shape. In the present described embodiment 10 , the shape is for the lower torso.
Various access windows 16 , 18 , 20 , 22 , 24 are shown disposed in the garment member 12 for enabling dermal application and removal of a medical electrode (not shown in FIG. 1) with the access window 16 , 18 , 20 , 22 , 24 being located on the garment member at positions enabling access to a preselected dermal area (disposed beneath the access windows). The positioning of the window 16 , 18 , 20 , 22 , 24 shown in the Figure is only intended to be a representation and not limiting the present invention to such limited positions. Fixed art positions are determined by a professional in the art of electrode placement. Also shown, are electrical snap connectors 26 described hereinafter in greater detail.
An alternative compress garment embodiment 30 is shown in FIG. 2 including a garment member 32 along with a pocket 34 for supporting an electrical module for connection to medical electrodes 40 shown in dashed line beneath access windows 42 and directly interconnected to the pocket through embedded wires 44 to a plug 46 for connecting with an electronic module (not shown). It should be appreciated that the electrodes 40 may be monitoring or stimulation electrodes, accordingly, a corresponding electronic module (not shown) is utilized.
With reference to FIG. 3, there is shown the flap window access 18 which includes a flap 44 with a hinge 46 integral with the garment member 12 . The flap 18 may be cut from the garment member 12 and a circumferential band 48 disposed therearound, which may include an attachment system for providing a positive coupling between the flap 18 and the garment member 12 . Any suitable attachment system, for example Velco® may be used in accordance with the present invention. In addition, a separate flap closure tab 50 may be included to provide tension and a smooth surface between the flap 18 and the garment member 12 , see FIG. 4 .
The flap 18 is sized and shaped for enabling insertion and removal of a medical electrode 54 which preferably includes a highly conductive gel 56 , a conductive layer 58 and a skin specific gel 60 . The electrode 54 is fully described in the referenced patent application Ser. No. 09/428,196 which is incorporated herewith, and accordingly, further specific details of the electrode 54 construction are omitted herewith for brevity.
The electrode 54 is electrically connected through the flap 44 by means of an electrical connector 64 passing through the hinged flap 44 and including a snap eyelet 66 and a snap stud 68 .
As shown in FIG. 4 within the flap 18 area, the electrode 54 may be oriented in various positions as shown in a broken line.
With reference to FIG. 5, there is shown the access window 20 which includes, alternatively, two flaps 72 , 74 having integral hinges 76 , 78 symmetrical with the garment member 12 . Common reference numerals shown in FIG. 5 being identical or substantially equivalent to the elements referenced to hereinbefore with the same reference characters.
FIG. 6 is a plan view of the window access 20 as shown in FIG. 5 .
With reference to FIG. 7 and 8, there is shown the access window 22 which includes an opening 84 in the garment member 12 with the opening 84 being sized and shaped for the insertion or removal of a plurality of medical electrodes 54 and a cover 86 for covering the opening 84 and electrodes 54 . Common reference numbers, particularly with regard to the snap eyelets 66 and snap stud 68 are identical to hereinbefore referenced elements having the same character reference. In the embodiment shown, the electrodes 54 may be cooperating electrodes, such as an anode and cathode, or be independent, such as a stimulation electrode, monitoring electrode or drug delivery electrode.
In the embodiment 22 fastener tabs 90 are utilized for securing the cover 86 directly to the member 12 . An asymmetric pattern of the tabs 90 may be used to orient the cover 86 , with the electrodes 54 attached thereto, within the opening 84 . Alternatively, an indexed tab 92 and index 94 may be used for orientation.
With reference to FIGS. 9 and 10, there is shown alternative embodiment access window 24 , that includes a removable cover 96 and an attachment system 98 . As shown in FIG. 10, indicia 102 , 104 disposed on the cover 98 and the garment member 12 may be utilized for alignment of the electrode 54 when the cover 96 is removed and replaced on to the garment member 12 .
With reference to FIGS. 11 and 12, there is shown an alternate embodiment of window access 100 (which generally includes a cover 102 ) which is secured to the garment member 12 by an attachment system 104 . Common reference numerals refer to identical or substantially similar elements as hereinbefore described.
As shown in FIG. 12, the arrangement facilitates manufacture through the use of rectangular attachment pieces.
With reference to FIGS. 13 and 14, the slit window access 16 , which includes a slit 108 in the garment member, is disclosed. The elastic nature of the garment member 12 enables a stretching as indicated by the bend 112 in FIG. 13 enables the insertion of the electrode 54 . The electrical connecter 64 comprising the eyelet 66 and snap stud 68 pass through the garment member 12 proximate the slit 108 for establishing electrical contact with the electrode 54 . Again, reference numerals represent identical or substantial component as hereinabove described.
Although there has been hereinabove described a compress garment in accordance with the present invention, for the purpose of illustrating the manner in which the invention may be used to advantage, it will be appreciated that the invention is not limited thereto. Accordingly, and all modifications, variations or equivalent arrangements which may occur to those skilled in the art, should be considered to be within the scope of the invention as defined in the appended claims. | A compress garment for application to a body generally includes a member sized and shaped for positioning onto a body when in position conforms to and supports a body shape. A least one, preferably a multiple number of access windows disposed in the garment member for enabling dermal application and removal of a medical electrode. The access windows are located on the garment member at positions enabling access to pre-selected dermal areas. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an evaluation method for polycrystalline silicon. More specifically, the present invention relates to an evaluation method for polycrystalline silicon which may be used as a material for pulling single crystal silicon.
2. Description of Related Art
As a method for producing single crystal silicon, the Czochralski method (hereinafter referred to as the CZ method) is well-known. The CZ method has the advantages that single crystals of a large diameter and high purity can easily be obtained with no transition state or a small number of little lattice defects.
In the CZ method, after washing a polycrystalline silicon piece of extremely high purity, the polycrystalline silicon piece is put into a quartz crucible and melted in a heating furnace. At that time a necessary amount of a conductive impurity (e.g., an additive or a dopant) is added to control, for example, the type of crystal to be prepared. For instance, a P-type crystal is obtained if boron (B) is added whereas an N-type crystal is obtained if phosphorus (P) or antimony (Sb) is added. Also, the resistivity of the crystal may be controlled by changing the amount of the conductive impurity added.
After that, a seed crystal (a single crystal) which is hung by a wire is immersed in the melted silicon and the single crystal is grown by gradually pulling the wire while rotating the single crystal. Single crystal silicon having various diameters and characteristics may be produced by controlling the temperature, the pulling speed and so forth. The crystal grown in this manner becomes a perfect single crystal. The lower the amount of contaminants contained in the polycrystalline silicon used as the material, the less likely that the single crystal produced is subjected to a transition.
However, even if the purity of the polycrystalline silicon is extremely high at first, contaminants, such as metal particles, may attach to the surface of silicon when the polycrystalline silicon is crushed into pieces having a certain particle size. Also, a fine resin particle may attach to the surface of the polycrystalline silicon while being transported. Accordingly, there are cases where fine particles of a metal or a resin are already attached to the surface of polycrystalline silicon pieces when, for instance, a manufacturer of single crystal silicon purchases the polycrystalline silicon from a supplier. For this reason, although the manufacturer washes the polycrystalline silicon beforehand, not all of the contaminants are washed away and some may still remain on the surface.
Since the contaminants attached to the surface of polycrystalline silicon pieces may cause problems, such as crystal defects, in single crystal silicon prepared by the pulling method, it is naturally required to use as clean a polycrystalline silicon piece as possible. However, because the number of particles of contaminants attached to the surface of polycrystalline silicon differ depending on the supplier or product lot, it is necessary to determine the number of particles attached to the polycrystalline silicon before its use, so that it becomes possible to select usable polycrystalline silicon, or use the polycrystalline silicon for a suitable purpose.
Conventionally, the evaluation of the quality of polycrystalline silicon has been carried out by actually preparing single crystal silicon from purchased polycrystalline silicon and measuring, for instance, the density of defects, such as crystal defects, of the single crystal silicon obtained. Accordingly, it takes time to carry out the evaluation procedure and it is difficult to flexibly apply the evaluation results to actual practice, such as the above-mentioned selection of polycrystalline silicon or use for a suitable purpose.
The present invention was achieved in consideration of the above problems and its objectives include providing a method for effectively evaluating the level of contaminants contained in polycrystalline silicon which may be used as a material.
SUMMARY OF THE INVENTION
The present invention provides an evaluation method for polycrystalline silicon including the steps of immersing the polycrystalline silicon in an agent which is capable of dissolving the polycrystalline silicon, and counting the number of foreign particles in the agent.
In accordance with another aspect of the invention, the polycrystalline silicon is used as a material for pulling single crystal silicon.
In yet another aspect of the invention, the polycrystalline silicon immersed in the agent is aggregated or in pellet shape.
According to the evaluation method for polycrystalline silicon, when the polycrystalline silicon of aggregated or pellet shape is immersed in the agent, the surface of the polycrystalline silicon is dissolved and foreign matter attached to or contained in the polycrystalline silicon is dispersed in the agent. Accordingly, a part of the agent which contains the foreign matter may be taken as a sample and the number of the foreign matter particles in the sample may be counted by using such a measuring device as a particle counter.
According to the above evaluation method of the present invention, the amount of foreign matter contained in polycrystalline silicon may be predetermined without actually pulling a single crystal from it. Thus, the evaluation results may be more rapidly used in practice as compared with a conventional technique and, for instance, it becomes easy to select polycrystalline silicon to be used as a material for pulling single crystals, or to use the polycrystalline silicon for a suitable application.
In yet another aspect of the invention, the evaluation method further includes a step of analyzing the composition of the foreign particles.
According to the above evaluation method for polycrystalline silicon, not only the evaluation of the particle number but also the determination of the kind or origin of the particles may be carried out. Hence, clues for the cause of the attachment of the foreign matter to the polycrystalline silicon may be obtained. Accordingly, if the cause is detected, it may become possible to obtain clean polycrystalline silicon which is not contaminated by the foreign matter by taking appropriate precautions.
In yet another aspect of the invention, the evaluation method further includes a step of subjecting the agent to a circulation filtering process prior to the immersion of the polycrystalline silicon in the agent.
According to the above evaluation method for polycrystalline silicon, since the agent is subjected to the circulation filtering process prior to the immersion of the polycrystalline silicon in the agent, it is possible to maintain the agent in a clean state and, hence, the number of foreign particles in the agent may be accurately counted.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the features and advantages of the invention have been described, and others will become apparent from the detailed description which follows and from the accompanying drawings, in which:
FIGS. 1A to 1 D are diagrams for explaining an evaluation method for polycrystalline silicon according to an embodiment of the present invention;
FIGS. 2A to 2 C are diagrams for explaining an evaluation method for polycrystalline silicon according to another embodiment of the present invention;
FIG. 3 is a graph showing the results of measuring the number of particles contained in each sample in accordance with the embodiment of the present invention; and
FIG. 4 is a graph showing the results of measuring the free ratio of each single crystal silicon obtained from polycrystalline silicon corresponding to the respective sample described in FIG. 3 .
DETAILED DESCRIPTION OF THE INVENTION
The invention summarized above and defined by the enumerated claims may be better understood by referring to the following detailed description, which should be read with reference to the accompanying drawings. This detailed description of a particular preferred embodiment, set out below to enable one to build and use one particular implementation of the invention, is not intended to limit the enumerated claims, but to serve as a particular example thereof.
An evaluation method for polycrystalline silicon according to an embodiment of the present invention will be described with reference to FIGS. 1A through 1D .
First, as shown in FIG. 1A , a certain amount (for instance, 5 kg) of polycrystalline silicon pieces 1 to be evaluated are prepared. The shape of the polycrystalline silicon pieces 1 is not particularly limited and they may be aggregated or pellet shaped.
Then, as shown in FIG. 1B , the polycrystalline silicon pieces 1 are put into a container 2 made of, for instance, polyethylene or polytetrafluoroethylene. Since the container 2 is immersed in an etchant in the next step, it is necessary to use a material having a resistance to the etchant for the container 2 .
After that, as shown in FIG. 1C , the container 2 , in which the above-mentioned polycrystalline silicon pieces 1 are placed, is immersed in an etchant 3 contained in an etching vessel 4 . The kind of etchant 3 used in this embodiment is not particularly limited as long as it is capable of dissolving the polycrystalline silicon pieces 1 . Examples of such an etchant include hydrofluoric and nitric acids. Note that the etching vessel 4 used in this embodiment is provided with circulation filtering equipment, such as a pump 5 or a filter 6 , so that the etchant 3 may be filtered by circulation to reach a particle free state before the container 2 is immersed in the etchant 3 .
Next, the circulation filtering process is stopped and, after the container 2 is put into and taken out of the etching vessel 4 a few times, the container 2 is pulled out from the etching vessel 4 . After that a portion of the etchant 3 is taken as a sample by using an arbitrary container 8 made of, for instance, polyethylene or polytetrafluoroethylene. At that time, fine particles or a powder of polycrystalline silicon are contained in the sampled etchant. As a method for taking the sample of the etchant 3 , the container 8 may be placed in a sealed chamber 9 , and the chamber 9 evacuated by using a vacuum pump 10 so that the sample of the etchant 3 is drawn into the container 8 as shown in FIG. 1C (i.e., a clean sampling method).
The collected sample solution is left for a certain period (e.g., a couple of days) so that all of the fine particles or powder of the polycrystalline silicon are dissolved in the solution, and then the number of particles of foreign matter in the sample solution per unit volume is measured by using a particle counter 7 . Since the fine particles or powder of the polycrystalline silicon have been dissolved in the solution, only the particles of foreign matter attached to or contained in the polycrystalline silicon are counted. By using this counting method, it becomes possible to improve the efficiency of the measurement.
In addition, the composition of the foreign particles may be analyzed by using such methods as Scanning Electron Microscopy (SEM), or Energy Dispersive X-ray spectroscopy (EDX). By using such analytical methods, not only the evaluation of the particle number but also the determination of the kind or origin of the particles may be carried out. Accordingly, the composition of the particles may be detected as, for instance, alumina, carbon, a vinyl chloride type resin, a polyethylene type resin, a polytetrafluoroethylene type resin, or a hard metal.
It is also possible to directly measure the etchant 3 in the etching vessel 4 by using the particle counter 7 as shown in FIG. 2C , after immersing the container 2 , in which the polycrystalline silicon pieces I are placed, into the etchant 3 in the etching vessel 4 as shown in FIGS. 2A and 2B and allowing to stand for a certain period in the same manner as described above.
According to the embodiment of the present invention, as mentioned above, the amount of foreign matter contained in polycrystalline silicon may be predetermined without actually pulling a single crystal from it. Accordingly, by using the evaluation method of the present invention, the evaluation result may be more rapidly used in practice as compared with a conventional technique and, for instance, it becomes easy to select polycrystalline silicon to be used as a material for pulling single crystals, or to use the polycrystalline silicon for a suitable application.
Also, if the analysis of components of foreign matter is conducted, clues for the cause of attachment of the foreign matter to the polycrystalline silicon may be obtained. Accordingly, if the cause is detected, it may become possible to obtain clean polycrystalline silicon which is not contaminated by foreign matter. Moreover, according to the embodiment of the present invention, since the etchant 3 is subjected to the circulation filtering process prior to the immersion of the polycrystalline silicon pieces I in the etchant 3 , it is possible to maintain the etchant 3 in a clean state and, hence, the number of foreign particles in the etchant 3 can be accurately counted.
Note that the scope of the present invention is not limited to the above-described embodiment and various alterations, modifications, and improvements may be made within the sprit and scope of the invention. For example, although hydrofluoric and nitric acids are used as the etchant 3 in the above embodiment, other agents may be employed as the etchant 3 as long as the agent is capable of etching polycrystalline silicon. Also, such factors as the configuration of the etching vessel 4 or a concrete evaluation manner are not limited and any suitable adjustments may be made thereto.
Next, evaluation data which was actually obtained by using the method according to the embodiment of the present invention will be explained.
Three kinds of samples (A, B and C) of polycrystalline silicon were prepared as evaluation objects. The number of particles contained in each sample counted in accordance with the method described in the above embodiment are shown in FIG. 3 . The particle counter used is capable of counting the number of particles in accordance with particle size and in this case the comparison was made within a particle size range of between 0.2 and 5 μm. As shown in FIG. 3 , the number of particles contained in samples A-C of 1×10 −2 L was 8,000 for the sample A; 2,500 for the sample B; and 15,000 for the sample C.
On the other hand, polycrystalline silicon pieces corresponding to the samples A, B, and C, respectively, were used as the material and the pulling method was actually carried out to measure the free ratio of each single crystal silicon prepared. The results are shown in FIG. 4 . The free ratio of the single crystal silicon samples A-C per unit volume is 70% for the sample A, 77% for the sample B, and 60% for the sample C. Note that the term “free ratio” means the ratio of no transition single crystals.
That is, it was confirmed that the number of particles in each of the samples A-C corresponds to the free ratio (defect density) in the single crystal silicon prepared. Accordingly, it is demonstrated that polycrystalline silicon may be assuredly evaluated by using the method according to the present invention.
Having thus described an exemplary embodiment of the invention, it will be apparent that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements, though not expressly described above, are nonetheless intended and implied to be within the spirit and scope of the invention. Accordingly, the foregoing discussion is intended to be illustrative only: the invention is limited and defined only by the following claims and equivalents thereto. | An evaluation method for polycrystalline silicon including the steps of immersing the polycrystalline silicon in an agent which is capable of dissolving the polycrystalline silicon, and counting the number of foreign particles in the agent. The polycrystalline silicon thus evaluated may be used as a material for pulling single crystal silicon. The evaluation method may further include a step of analyzing the composition of the foreign particles. In yet another aspect, the evaluation method may further include a step of subjecting the agent to a circulation filtering process prior to the immersion of the polycrystalline silicon in the agent. | 6 |
BACKGROUND OF THE INVENTION
In the assembly of an automobile, numerous connectors are used to hold various panels and trim strips in position. It is common practice in the assembly of the door of an automobile to use plastic connectors to hold the trim panels on the inside of the door. Since water can enter a door separate rubber washers have been used in combination with the connectors to prevent the water from entering the interior of the automobile where it would stain a cloth trim panel on a door. When it was necessary to service the inside of a door, for example the mechanisms for raising and lowering the window or for latching and locking the door, the interior trim panels had to be removed. A common connector used to support trim panels is of the so-called christmas tree-type Which, when once put in place, has to either be broken or seriously damaged to the point that it is no longer reusable in order to remove the door panel. If the Christmas tree connector was molded to the door panel, the door panel would have to be replaced in order to have usable connectors. This resulted in an unnecessary expense in that an entire door panel had to be replaced in order to replace several inexpensive plastic connectors.
SUMMARY OF THE INVENTION
In accordance with the present invention, a connector is provided which has an integral water seal thereby eliminating the need for separate rubber washers. The connector is also serviceable in that it will tightly hold the door panels together while at the same time is capable of being removed with a door panel without damage to the connector which would render the connector unserviceable . In the unlikely event that the portion of the connector used to connect the door panel becomes broken or seriously damaged, that portion of the connector can be replaced by sliding a new connecting piece into the anchor portion of the connector.
The connector of the present invention is made of two major parts. The first part is a hollow retainer or anchor member which has a closed end with a shaped slot. The retainer member is intended to be molded into plastic molding material on a surface of a door panel with the slot adjacent the surface of the molding material. The second member of the connector is a hook member which has an outwardly turned hook extending from the center portion of a base. A supporting stud projects from the opposite side of the base. A sealing flange extends about the edge of the supporting base and is dished toward the hook with the hook at the center of the dish and with the edge of the dish projecting in the direction of the hook. The bottom of the hook member has a compound camming surface with a curved entry surface leading to a sharply inclined surface which terminates at the supporting base. The projecting supporting stud has a substantially flat head in the center of which is positioned an alignment member having spaced parallel sides. A plug is provided for the open end of the hollow retainer member. The plug is adapted to be press fitted into the retainer member and is used to prevent the plastic molding material from entering into the retainer member. A pair of spaced, substantially parallel projections extend from the inner surface of the plug and cooperate with the alignment member on the head of the supporting stud to preclude rotation of the hook.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the hook member of the connector;
FIG. 2 is a side elevational view of the hook member;
FIG. 3 is a front elevational view of the retainer member or anchor member of the connector with the rear plug in place;
FIG. 4 is a side elevational view of the closed retainer member;
FIG. 5 is a side elevational view showing the retainer member supported by plastic molding material and with the hook member gripping a sheet of metal;
FIG. 6 is a rear perspective view of the hook member;
FIG. 7 is a perspective view showing the retainer supported in a plastic molding material and with the hook member aligned with the retainer; and
FIG. 8 is a schematic sectional view of a pair of connectors holding a metal panel in place.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1-4, the connector of the present invention has two major components, the retainer member 10 and the hook member 12. Retainer member 10 is of substantially hollow circular configuration with a raised stepped end portion 11 and a cap portion 13. Retainer member 10 has a circumferential sidewall 15 supporting a first flat surface 17. Substantially centrally disposed on surface 17 is another sidewall 19 which supports a slotted end wall 21. End wall 21 has a substantially keyhole-shaped slot 23 which extends across surface 21 to an open portion 25 in sidewall 19. Sidewall 19 is cut out at 25 to receive the supporting head of hook member 12 and has spaced parallel edges to pass an alignment member on the supporting head of the hook member. Sidewall 15 has spaced projecting members 27 which prevent retainer member 10 from rotating when it is supported in the plastic molding material.
Since retainer member 10 is intended to be molded in place and since it is hollow, a cap 13 is provided to prevent the molding material from entering into the interior of the retainer member. The cap is preferably attached to the retainer member by a living hinge 14 enabling the retainer member and cap to be molded in a single operation. The bottom of the cap is reinforced by a pair of ribs 37 from which a pair of substantially parallel upstanding members 39 project. When cap 13 is snap-fitted into place in the bottom of retainer member 10, projecting alignment members 39 align with slot 25 in edge 19 and also with the center with keyhole slot 23 in surface 11.
Hook member 12 has an enlarged, thickened supporting portion 41 from which a shaped hook 43 extends. Hook 43 is enlarged where it joins base 41 to provide maximum strength at that point. Hook 43 can be of solid molded plastic or, and more preferably, can be made of three substantially identical spaced supporting ribs (FIGS. 1 and 7) with outer ribs 45 forming the side of the hook and with a central rib 47 forming the center of the hook with the inner edges of the hooks being joined by a continuous plastic web.
Hook 43 is turned outwardly and has a tapered distal end 49 for easy entrance into an aperture in a metal panel or part. The bottom surface of hook 43 has a compound camming surface which has a smoothly curved portion 51 proximate distal end 49, which leads to a sharply inclined camming surface 53, which can be at approximately 45°, which ends or abuts the surface of supporting washer or flange 41. The compound camming surface provides easy entry of the hook into an aperture and then, once in place, leads an edge of the metal panel sharply into the crux of the hook where the panel can be held pressed against the face of support 41. Since the connector is primarily intended for use in the assembly of automobile doors, it has an integral sealing flange 55 supported about hook 43. The sealing flange is dished with the base of hook 43 being at the bottom of the dish and with the projecting edge 57 of the sealing flange surrounding hook 43 and extending away from support 41 in the same direction as hook 43. When hook member 12 is used in the assembly of a door (FIG. 5) hook 43 is passed through an aperture 60 in the door, preferably a square aperture, and sealing flange 55 is forced tightly about the edge of the aperture sealing out any water which might come from the interior of the door and attempt to pass through into the interior of the automobile.
Hook member 12 is supported in retainer member 10 by means of a flat headed stud 61 which is spaced from the back of base member 41 by a shaped stud 63. Stud 63 is shaped to be complementary to slot 23 in retainer member 10 and can be characterized as a key-shaped stud, the slot in the surface of the retainer member being keyhole-shaped. On the outer or end surface of flat headed stud 61 is an alignment portion 65. Alignment portion 65 has spaced parallel sides 67 which cooperate with the edges of projecting members 39 on cap 13 to prevent hook member 12 from rotating when it is supported in retainer member 10.
The two components of the hook member are preferably made of an organic polymeric material such as Nylon; however, other engineering plastic materials which can be molded, and which will resist cutting or being cut by the edge of the metal panels, and which will also not fracture in cold weather, can be used. With these physical characteristics in mind, numerous suitable plastic materials can be selected.
As shown in FIG. 8, retainer or anchor member 12 is shown supported in a layer of plastic molding material 71 on one side of a door panel 70. The lower surface 17 is substantially in alignment with the surface of the plastic molding material with raised surface 21 projecting above the surface. The plastic molding material can also cover the closed sides of wall 19 of the retainer member so long as opening 25 in the wall is not obstructed. Cap member 13 is snapped in place in the open end of the retainer member before it is molded into the plastic material. Retainer member 10 is positioned so that slots 25 and 21 face downwardly. Hook member 12 is then slid lockably upwardly into the slot until it is snapped in place with alignment member 65 positioned between the edges of projecting members 39 which extend from cap 13.
Hook member 12 has its distal end 49 passed through the aperture in the door panel 73 so that the metal edge will slide along compound camming surfaces 51 and 53. Metal panel 73 is held tightly between base 41 and camming surface 53 on hook 43. When hook member 12 is forced into place against panel 73, water sealing flange 55 will be tightly pressed against the surface of panel 73 sealing the aperture in the panel and preventing any water from passing through the door into the interior of the vehicle.
When it is desired to remove door panel 70 from metal panel 73, the door panel is raised to lift hook members 12 out of the apertures in the metal panel. Hook members 12 remain supported by retainer or anchor members 10. In the event a hook member is badly damaged or broken in separating the panels, the remainder of the hook members can be knocked out of the holding slot in the retainer member. A new hook member can then be slid into the holding slot and the door panels are again ready to be connected. The expensive door panel is reusable by the mere replacement of an inexpensive plastic connector part. Panel 70 can be replaced by merely reversing the aforedescribed procedure.
While it is preferred to use both the anchor and hook parts of the connector, there may be occasions where only the hook part is needed, for example, in supporting a small panel which will almost never have to be removed once put in place. In this situation the head and projecting stud portion on the back of the hook can be embedded in the plastic molding material up to the base of sealing flange 55. The hook is then used as previously described with the sealing flange closing the aperture about the hook.
From the above description it can be seen that a reusable, serviceable connector is provided having an integral water seal. The connector can be used in the assembly of door panels. Through the use of the plastic connector the door panels on the inside of the vehicle can be removed for servicing of the door and be easily replaced without damaging the connector. If a connector is damaged, the broken portion of the connector can easily be replaced saving the door panel for reuse.
Though the invention has been described with respect to a specific preferred embodiment thereof, many variations and modifications will become apparent to those skilled in the art. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications. | A connector for joining automobile panels. A retainer member having a shaped slot is molded into a door panel and receives a flat headed stud for supporting a hook surrounded by a sealing flange for hooking over an edge of an opening in a sheet metal door panel for fastening the panels together. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for recording information in which the recording medium is excited optically or thermally and physical properties of the recording medium are changed locally, a method for reproducing the information, an information recording head having a function of recording, an information recording and reproducing head having functions of recording and reproducing, and an information recording and reproducing apparatus having any of the above-listed properties and/or functions.
2. Description of the Related Art
In “the conventional information recording medium on which both magneto-optical reproducing and magnetic reproducing can be performed and the conventional recording and reproducing apparatus for the same” (a first conventional technology) that is disclosed by JP-A No. 21598/1998, recording is performed by irradiating a magneto-optical recording film formed on the recording medium with recording light through a substrate to heat the recording film and form reversed magnetic domains therein. Further, reproduction of the information is performed by irradiating the aforesaid magneto-optical recording film with the recording light from a light source through the substrate and detecting rotation of a polarization plane of reflected light and by forming a second magnetic layer on the magneto-optical recording film and reproducing leakage flux from this second magnetic layer.
Further, “a magnetic head and a manufacturing method of the same” (a second conventional technology) is described in Japanese Patent No. 2665022 which discloses a method in which a magnetoresistance effect element, whose recording sensitivity distribution is curved, is used to accommodate an approximately crescentic recorded magnetic domain formed by light pulse magnetic-field modulation recording etc.
Moreover, “an information recording and reproducing apparatus” (a third conventional technology) is described in JP-A No. 353301/2000 which discloses an information recording and reproducing apparatus that uses a recording medium in which information is stored through the use of a recorded magnetic domain on a perpendicular magnetic recording film formed on the surface of a substrate member. Such substrate member has a rugged structure on the surface, wherein a center of a track is placed on a land, the magnetic domain whose width in a direction perpendicular to the track is not less than a land width is formed, hence improving recording density.
Furthermore, “a magneto-optical recording medium, a manufacturing method for the same, and a magneto-optical recording and reproducing apparatus” (a fourth conventional technology) is taught by JP-A, No. 126385/1999 which describes that a domain wall formed in a magnetic layer by a magnetic-field modulation recording method is formed in the shape of a circular arc that extends along a rear part of an isothermal line for the Curie temperature of a magnetic material and the shape of a magnetized region becomes crescent.
FIG. 7 is a view illustrating a recording process in detail where the recording is performed on the perpendicular magnetic recording film by a prior-art light pulse magnetic-field modulation recording method with a recording and reproducing head that uses a conventional single-peaked light spot, i.e., a light spot that is focused to a diffraction limit with a lens. The light pulse magnetic-field modulation recording method is a well-known recording method using the light pulse magnetic-field modulation recording that is a kind of thermomagnetic recording. Since in the light pulse magnetic-field modulation recording, the size of the recorded magnetic domain (spacing of domain walls in a scanning direction) is less prone to be limited by the size of a region of the magnetic medium excited by a light spot, as will be explained below, it is an advantageous method especially in forming a minute recorded magnetic domain. Note that in the explanation in this description, formation of the recorded magnetic domain by the light pulse magnetic-field modulation recording is taken as an example to explain the present invention, but it is not intended to limit the recording method to be used for the invention to the light pulse magnetic-field modulation recording method. The present invention is also effective in other thermomagnetic recording methods such as the DC magneto-optical magnetic-field modulation method and the light modulation recording method.
Referring to FIG. 7 , the recording data 700 is given at the time of recording. The recording data 700 generates a recording bias magnetic field 702 in the vicinity of a heating position by the light spot on the recording film. This recording bias magnetic field 702 is applied normal to the recording film. Simultaneously, as shown by the diagram of laser emission intensity 701 , the light source is driven in a pulsed manner in synchronization with a minimum change unit (detection window width) of a recorded magnetic domain length along the recording track and is applied on the recording film. In the region heated by the light irradiation, coercive force of the recording film is reduced to lower than an absolute value of the recording bias magnetic field 702 , and magnetization of the region follows a direction of the recording bias magnetic field 702 ; thus one shot of light pulse irradiation determines a magnetization direction in an approximately circular region as shown by the diagram of a recorded magnetic domain 703 . With the light spot scanning over the recording film, the center of the heated region is moved at certain intervals, and consequently the recording film is heated for that region and cooled intermittently. If the interval of the light pulse irradiation is being shortened, the approximately circular regions come to overlap each other partially, and the recording is performed as if a crescentic recorded magnetic domain were formed by each shot of the light pulse irradiation. The diagram of the recorded magnetic domain 703 in FIG. 7 shows schematically the shape of this recorded magnetic domain, as viewed from directly above the recording film, that is formed on the recording film when performing a recording operation as illustrated by the diagrams of the laser emission intensity 701 and the recording bias magnetic field 702 . In FIG. 7 , the light spot is scanned from the left to the right. When the recording bias magnetic field is positive, formed is a magnetic domain whose magnetization directs upwards off the sheet of the drawing (meshed domain); when the recording bias magnetic field is negative, formed is a magnetic domain whose magnetization directs downwards off the sheet of the drawing (colorless domain).
It is generally understood that in the case where thermomagnetic recording is performed by use of a light spot focused to a diffraction limit with a lens, a method employing the light pulse magnetic-field modulation recording is advantageous because a recording power margin can be secured to a large degree. In this light pulse magnetic-field modulation recording, if an approximately circular light pulse of a single peak focused to a diffraction limit with a lens is used, since the magnetization direction of the approximately circular region is determined in each single shot of light pulse irradiation, the recorded magnetic domain becomes crescent consequently. However, in the case where the crescent magnetic domain is reproduced by use of normal magnetic-flux detecting means (i.e., GMR element) that has a linear sensitivity distribution, there exist a problem that reproducing resolution decreases. This is because the time when the magnetic-flux detecting means passes over the domain wall differs depending on the distance from the center of the track and hence the response waveform from the recorded magnetic domain is enlarged. Moreover, in the top of the crescentic recorded magnetic domain, the domain walls become close to each other. See FIG. 11 of JP-A, No. 126385/1999 described above. Formation of the magnetic wall, therefore, becomes unstable, and an unexpected domain wall shape is likely to develop. Since a response from this portion is a noise (recording, noise) that is different from user data originally recorded, it becomes a hindrance against normal reproducing of the user data. Thus, with the first or fourth conventional technology, the recording density could not be fully improved due to problems of the resolution of the reproduced signal and the noise, and as a result it was disadvantageous in several respects: increased size of the information recording and reproducing apparatus, increased manufacturing costs of the information recording and reproducing apparatus, and poor reliability, etc.
Further, with respect to the second conventional technology, since considerable decrease in the resolution occurs when the center of the magnetoresistance effect element offsets from the center of the recorded magnetic domain sequence, it has become necessary to control track offset between the recording time and the reproducing time to an extremely small value. Moreover, it was difficult to form the magnetoresistance effect element that has a curved sensitivity distribution and, consequently, it was very disadvantageous in respect of the manufacturing cost of such an information recording and reproducing apparatus.
Further, with respect to the third conventional technology, the process of manufacturing the medium becomes complicated because the rugged structure is formed on the surface of the substrate member of the recording medium. Hence, it was disadvantageous in respect of the cost of the information recording medium. Moreover, in the case where the recording and reproducing head is made to be afloat at a position very close to the surface of the recording medium using dynamic pressure, air film rigidity between the recording medium and the head slider decreases and crash of the slider is likely to occur. Accordingly, such third conventional technology was disadvantageous in respect of the reliability of the information recording and reproducing apparatus.
Referring to FIG. 7 , in a point area of the crescentic magnetic domain, the domain walls are in very close vicinity to each other and become unstable, and accordingly the unexpected domain wall shape that does not reflect a heat distribution at the time of recording is likely to develop. When the information is reproduced from the recorded domain walls, the response from a portion of such an unexpected domain wall shape will become a noise different from the originally recorded information (recording noise) which is a hindrance to the normal reproduction of the user data. The diagram of a GMR reproduced signal 704 shows a reproduced signal waveform obtained when the recorded magnetic domain 703 is reproduced using a magnetic detection device such as a normal GMR element. When the recorded magnetic domain like the recorded magnetic domain 703 is reproduced in such manner, since the domain wall is curved on the whole, a track center region and track edge regions contribute to the reproduced signal with different phases, respectively, which gives rise to a problem that the resolution of the reproduced signal is decreased.
SUMMARY OF THE INVENTION
According to at least one preferred embodiment, the present invention provides an information recording and reproducing head comprising: a slider for scanning the surface of a recording medium; a light source that is installed on the slider and supplies recording energy; and a scatterer that is formed in the vicinity of the surface of the slider so as to oppose the recording medium and that receives irradiation of the light from the light source, causes local physical properties to change by exciting the recording medium optically or thermally, and thereby records information therein, wherein a fringe part or perimeter of the scatterer, that generates intense near-field light capable of causing the physical properties to change in the recording medium, comprises at least two adjacent vertices and the distance between the vertices is shorter than the recording track width on the recording medium.
In another preferred aspect, the information recording and reproducing head of the present invention comprises: a slider for scanning the surface of a recording medium; a light source that is installed on the slider and supplies recording energy; a scatterer that is formed in the vicinity of the surface of the slider so as to oppose the recording medium and that receives irradiation of light from the light source, causes local magnetic properties to change by exciting the recording medium optically or thermally, and thereby records information; and a magnetic flux detecting element that is installed on the slider and detects leakage flux from the surface of the recording medium locally; wherein a perimeter of the scatterer, at which the intense near-field light for causing the physical properties to change in the recording medium is generated, comprises at least two adjacent vertices where the distance between the vertices is shorter than the recording track width on the recording medium.
Another preferred aspect of the present invention resides in an information recording and reproducing apparatus that uses a recording medium storing information by means of a local change in the physical properties caused by optical or thermal excitation, wherein the apparatus comprises: a recording and reproducing head; recording-signal processing means that drives the light source according to a transformed result obtained by performing predetermined transformation on the user data and thereby forms a magnetic domain array corresponding to the user data on the recording medium; reproduced-signal processing means that performs inverse transformation that is inverse to the transformation on a signal from the magnetic-flux detecting means and thereby restores the user data; and a scanning mechanism for placing the slider in an arbitrary position of the recording medium.
Another aspect of the present invention resides in a method for recording information comprising the steps of:
encoding user data to obtain recording data;
sending the recording data to a recording-coil drive circuit via a recording-waveform generation circuit, and generating a recording bias magnetic field in the vicinity of a heating region on an information recording medium using intense near-field light from a scatterer disposed between a semiconductor laser and said information recording medium;
applying the recording bias magnetic field perpendicular to the recording medium, and simultaneously driving, via a laser drive circuit, said semiconductor laser in a pulsed manner in synchronization with minimum change units of a recorded magnetic domain length along a recording track;
reducing the coercive force of the recording medium to lower than an absolute value of the recording bias magnetic field in the region heated by the near field light so that the magnetization of the region follows a direction of the recording bias magnetic field whereby one shot of a light pulse irradiation determines a magnetization direction in said region having an approximately rectangular shape;
moving the center of the heated region at predetermined intervals by moving the scatterer over the recording track so that a plurality of said regions in the recording medium are heated and cooled intermittently; and
shortening the interval of the light pulse irradiation so that the approximately rectangular regions partially overlap each other to form an elongated, approximately rectangular recorded magnetic domain.
At the time of reproducing the information, a GMR element is made to scan over the medium on which the information was recorded by the preferred method, and the reproduced signal is obtained. The reproduced signal reflects the recording data obtained by transformation of the user data in the encoder, and is restored to the user data after being subjected to such processing as amplification, equalization, binary conversion, decoding, etc., if needed.
By the foregoing method, even when the light pulse magnetic-field modulation recording that is advantageous especially for high linear-density recording is used, increase in the recording noise accompanied by malformation of a minute magnetic domain structure can be suppressed. In addition, the bend of the domain wall of the recorded magnetic domain near the recording track center region is reduced, and decrease in the reproducing resolution at the time of magnetic reproducing resulting from the bend can be suppressed. For this reason, it becomes unnecessary to use the magnetic-flux detecting means that is hard to manufacture or the like and to control the allowable amount of track offset between the recording time and the reproducing time to an extremely small value. At the same time, it becomes possible to improve the recording density. The preferred method of the present invention becomes extremely advantageous in several respects: the size of the information recording and reproducing apparatus, the manufacturing cost of the information recording and reproducing apparatus, the reliability, etc.
Other and further objects, features and advantages of the invention will appear more fully from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
For the present invention to be clearly understood and readily practiced, the present invention will be described in conjunction with the following figures, wherein like reference characters designate the same or similar elements, which figures are incorporated into and constitute a part of the specification, wherein:
FIG. 1 is a view showing an example of a construction of a preferred recording and reproducing head according to the present invention;
FIG. 2 is a view showing another preferred recording and reproducing head according to the present invention;
FIG. 3 is a view showing a further preferred recording and reproducing head according to the present invention;
FIG. 4 is a view showing yet another preferred recording and reproducing head according to the present invention;
FIG. 5A is a view illustrating a preferred shape of the metal scatterer;
FIG. 5B is a view illustrating the near-field light generated by the metal scatterer of FIG. 5A ;
FIG. 5C is a view illustrating how the recording medium is heated in a preferred recording and reproducing head according to the present invention;
FIG. 6 is a view showing a preferred information recording and reproducing apparatus using the preferred recording and reproducing head of FIG. 1 ;
FIG. 7 is a view illustrating in detail an example of a recording process in which the light pulse magnetic-field modulation recording is performed on the perpendicular magnetic recording film using a conventional recording and reproducing head that uses a light spot of a single peak; and
FIG. 8 is a view illustrating an example of operation of the preferred information recording and reproducing apparatus of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood that the figures and descriptions of the present invention have been simplified to illustrate elements that are relevant for a clear understanding of the present invention, while eliminating, for purposes of clarity, other elements that may be well known. Those of ordinary skill in the art will recognize that other elements are desirable and/or required in order to implement the present invention. However, because such elements are well known in the art, and because they do not facilitate a better understanding of the present invention, a discussion of such elements is not provided herein. The detailed description of the present invention and the preferred embodiment(s) thereof is set forth in detail below with reference to the attached drawings.
FIG. 1 is a view showing an example of the construction of the recording and reproducing head according to the present invention. A semiconductor laser 100 acting as a recording light source is installed on the top face (i.e., the face opposite to a face directly opposing the recording medium) of a slider 101 for scanning the surface of the recording medium comprising a substrate 106 and a recording film 107 formed on the substrate 106 with a predetermined distance between the top surface of the recording film 107 and the bottom surface of the slider 101 . The oscillation light wavelength of the semiconductor laser 100 is 785 nm. Laser beam 109 emitted from this semiconductor laser is applied on a metal scatterer 102 formed on the slider bottom (a face opposing the recording film). When the metal scatterer 102 receives irradiation of light, plasmons are excited in it and consequently intense near-field light 108 is generated in the vicinity of the metal scatterer 102 . The metal scatterer 102 is an Au thin film of a thickness of 20 nm, is in the shape of a pentagon as viewed from the semiconductor laser 100 side, and comprises two convex vertices 102 a, 102 b and a concave vertex 102 c. The angle, α, that is formed by two equal-length sides 102 d, 102 e of the metal scatterer 102 , as viewed from the semiconductor laser side, preferably is set to 30 degrees and the lengths of the two sides 102 d, 102 e preferably are set to 200 nm. The portion of the metal scatterer 102 where the intense near-field light 108 is generated for exciting the recording film 107 optically or thermally comprises the three adjacent vertices 102 a, 102 b and 102 c where the concave vertex 102 c preferably is arranged between the two convex vertices 102 a, 102 b. The radii of curvature of the vertices 102 a, 102 b and 102 c preferably are set to about 20 nm. Note that in this description, the “vertex” indicates “a part corresponding to a region where the radius of curvature of the fringe (or perimeter) of the scatterer 102 is small as compared with those of adjacent parts in a projected figure obtained by projecting the shape of the scatterer 102 on a plane perpendicular to a traveling direction of the light from the light source,” and the “side” indicates “a portion corresponding to a continuous region where the radius of curvature of the fringe is large as compared with those of adjacent regions in the projected figure obtained by projecting the shape of the scatterer on a plane perpendicular to the traveling direction of the light from the light source.” Incidentally, in FIGS. 1–4 , in order to show an internal structure of the recording and reproducing head more clearly, part of depiction of the front of slider's backside is omitted. On the bottom of the slider 101 , a recording coil 104 comprising Cu wiring is formed so as to surround the metal scatterer 102 . This recording coil. 104 is used to generate a recording bias magnetic field that is necessary to perform thermomagnetic recording on the recording medium in a direction perpendicular to the surface of the recording medium. A recording coil electrode 105 is a pull-out terminal for injecting a driving current in the recording coil 104 . Further, on the side of the slider 101 , a GMR element 103 that is the magnetic flux detecting element is provided.
Although only some examples of the construction of the recording and reproducing head wherein the semiconductor laser acting as the recording light source is mounted directly on the slider, are shown in this application, the light source can be disposed not only on/in the slider, but at an outside of the slider. And the laser light emitted from the light source can be guided from by means such as an optical fiber or an optical waveguide, etc., and applied on the metal scatterer. The disposition explained above can be applicable to all of the construction shown in this application.
FIG. 2 is a view showing one of examples of the construction of the recording and reproducing head according to the present invention, wherein the metal scatterer 202 takes another preferred form. In this embodiment, the metal scatterer 202 comprises an Au thin film of a thickness of 20 nm in the shape of a heptagon, as viewed from the side of the semiconductor laser 200 . The portion of the scatterer 202 at which intense near-field light 208 , for exciting the recording film 207 optically or thermally is generated comprises five adjacent vertices, 202 a, 202 b, 202 c, 202 d and 202 e, in the fringe of the metal scatterer 202 . The three convex vertices, 202 a, 202 c and 202 e, and two concave vertices, 202 b and 202 d, are arranged alternately. The radii of curvature of these vertices of scatterer 202 are set to about 20 nm.
FIG. 3 and FIG. 4 are views each showing one of examples of the construction of the recording and reproducing head according to the present invention, wherein the metal scatterer takes further another arrangement and/or shape. FIG. 3 is a view showing the example in which the same metal scatterers as that in FIG. 1 are provided therein and are arranged with one set of vertex portions for generating near-field light 308 opposing the other set of vertex portions; FIG. 4 is a view showing the example in which the same metal scatterers as that in FIG. 2 are provided therein and are arranged with one set of vertex portions for generating near-field light 408 opposing the other set of vertex portions. In the preferred embodiments shown in FIGS. 3 and 4 , the distance between the metal scatterers is 30 nm. It should be noted that in this description the metal scatterers whose shapes approximate a pentagon or heptagon are described by way of examples, but the shape of the scatterer shall be appropriately adjusted depending on the shape of a desired recorded mark (recorded magnetic domain), that is, a shape of a generation region of the near-field light that causes local physical properties to change by exciting the recording medium optically or thermally, and is not necessarily limited to polygons. Note also that the metal scatterer is not limited in material, size, thickness, etc. as long as the metal scatterer is capable of exciting plasmons inside the metal scatterer under application of the exciting light from the semiconductor laser as a light source. Similarly, although the semiconductor laser is a common single longitudinal-mode type device, the semiconductor laser is not particularly limited in optical output, emission wavelength, internal structure, etc. as long as the semiconductor laser is capable of exciting plasmons inside the metal scatterer to generate the intense near-field light in the vicinity of the metal scatterer. Further, although the recording head according to the present invention is one that can achieve better effects when being combined with the magnetic reproducing method in such a way that the magnetic-flux detecting means etc. are installed on the same slider and the like; the recording coil 104 , the recording coil electrode 105 , and the GMR element 103 are constituents required for an example of an embodiment that is specified for the thermomagnetic medium (necessity of these constituents will be described below). Therefore, none of these constituents has direct connection with a low-noise recording operation with the near-field light obtained with the metal scatterer according to the present invention.
FIG. 5 is a view illustrating the near-field light generated by the metal scatterer and how the recording medium is heated thereby in the recording and reproducing head according to the present invention. FIG. 5A is a view of geometries of the metal scatterer as viewed from the positive z-axis direction (from above in vertical direction off the sheet of the drawing) The metal scatterer is an Au thin film having a thickness of 30 nm in the z-axis direction and its peripheral part is composed of a combination of: a concave vertex of a radius of curvature of 15 nm, two convex vertices of radii of curvature of 25 nm that are adjacent to each other to sandwich the concave vertex, straight line segments connecting to these convex vertices, two convex part of radii of curvature of 25 nm, and a circular arc of a radius of curvature of 150 nm. The numerals in the figure indicate radii of curvature of the indicated portions of the perimeter of the metal scatterer. The angle that is formed by the straight line segments is 60 degrees and the length of the scatterer in the x-axis direction is 150 nm. Note that, in the explanatory examples of embodiments referring to FIGS. 1 to 4 , the shapes of the metal scatterers are specified to be approximately polygons, respectively, but it is not necessarily an essential condition of the metal scatterer in the present invention that the peripheral part is composed exactly of a polygon, as shown in FIG. 5A .
FIG. 5B is the diagram showing results of a simulation of a near-field light distribution on the surface of the TbFeCo recording medium when the metal scatterer of FIG. 5A is placed 10 nm above the surface of the TbFeCo recording film of a thickness of 15 nm and the x-y plane is irradiated with a plane wave of a wavelength of 785 nm parallel. The solid lines in the figure are isointensity lines of the near-field light, a dashed line represent a fringe shape of the metal scatterer, and the numerals indicate the intensity ratio of the near-field light to incident light. By excitation of plasmons inside the metal scatterer caused by the irradiation of exciting light from the light source, the intense near-field light whose intensity is 200 times higher than the incident light is generated at two convex vertices pointing in the positive x-axis direction (facing to the right of the figure).
FIG. 5C is a diagram showing results of a simulation of a surface temperature distribution of the TbFeCo recording film under the foregoing conditions. It was assumed that the metal scatterer moved at a relative speed of 1 m/s in a positive x-axis direction to the TbFeCo recording film and that the light pulses of an irradiation duration time of 100 nsec were applied. The solid lines are isothermal lines, the dashed line represents a fringe shape of the metal scatterer, and each numeral shows a temperature rise from the room temperature. A shape of the recorded magnetic domain formed in the TbFeCo recording film by the thermomagnetic recording agrees mostly with the isothermal line at a predetermined recording temperature determined according to the recording film composition. Assuming that the recording temperature is room temperature plus 150° C., with the light pulse irradiation, a bean-shaped or approximately rectangular recorded magnetic domain (recorded mark) having the same shape as the isothermal line at the +150° C. is formed.
FIG. 6 is a view showing an example of the preferred construction of the information recording and reproducing apparatus that uses the preferred recording and reproducing head of the present invention shown in FIG. 1 . First, acquisition of recording/reproducing position information that is done in parallel with a recording or reproducing operation is described below. That is, on a recording medium 620 consisting of a substrate 616 and a recording film 615 formed on the substrate 616 , information that indicates a physical location on the recording medium 620 (address information) is recorded beforehand at the time of the manufacture as the magnetic domain array in which the information is indicated according to a fixed conversion rule. Therefore, when a GMR element 613 acting as the magnetic-flux detecting means is made to scan the surface of the recording medium 620 , a signal that reflects the magnetic domain array in that surface, i.e., a signal indicating the address information, is outputted from the GMR element 613 . This output signal of the GMR element 613 is amplified to a required level by an amplifier 610 , and subsequently is inputted into a decoder 606 , an actuator drive circuit 609 , and an address recognition circuit 605 . The address recognition circuit 605 analyzes a scanning position of the slider 614 from a signal sent from the GMR element 613 , and transmits it to the system controller 604 . According to position information of the GMR element 613 and a request for recording/reproducing from an external apparatus, the system controller 604 properly performs control of the actuator drive circuit 609 , the recording-coil drive circuit 607 , and the laser drive circuit 608 . According to directions from the system controller 604 and signals from the GMR element 613 , the actuator drive circuit 609 drives a VCM (Voice Coil Motor) 611 so that a metal scatterer 617 and the GMR element 613 may scan desired positions on the recording medium 620 . In accordance with this driving signal, the VCM 611 moves the slider 614 that is fixed on the top of a gimbal arm 619 and places it in an arbitrary position on the recording medium 620 . A semiconductor laser 612 , the metal scatterer 617 , the GMR element 613 , and the recording coil 618 are installed on the slider 614 , as described above.
At the time of recording information, user data 600 to be recorded is fed into the system controller 604 via an interface circuit 601 for an external apparatus, and is sent to an encoder 603 after error detection, addition to error correction information, etc., if needed. The encoder 603 puts the user data 600 through ( 1 , 7 ) modulation, performs NRZT conversion on it, and thereby generates a signal that reflects the array of recorded magnetic domains on the recording medium 620 . By referring to this signal, the recording-waveform generation circuit 602 generates both a control signal for the recording bias magnetic field and a control signal for the laser emission intensity. The recording coil drive circuit 607 receives directions from the system controller 604 , drives the recording coil 618 according to the control signal for the recording bias magnetic field, and generates the recording bias magnetic field in a portion of the recording film 615 where the intense near-field light is generated by the metal scatterer 617 . Further, the laser drive circuit 608 also receives directions from the system controller 604 , and according to a control signal for the laser emission intensity, drives the semiconductor laser 612 serving as the recording energy source. Laser beam 621 emitted from the semiconductor laser 612 is applied on the metal scatterer 617 ; and the metal scatterer 617 generates the intense near-field light in the vicinity that is determined by the shape of the metal scatterer 617 , and heats the recording film 615 therewith. Here, it is assumed that the heated region by the near-field light is wider than a region where the recording bias magnetic field is applied by the recording coil 618 . The recording film 615 is the perpendicular magnetic recording film having an easy axis in a direction normal to the film surface (for example, a TbFeCo amorphous alloy film, a Pt/Co multilayer, etc.), whose coercive force at normal temperatures is higher than the recording bias magnetic field applied externally, and whose coercive force at the time of recording, being heated by the laser beam, is lower than the recording bias magnetic field. Adopting this configuration makes it possible to form a desired recorded magnetic domain on the recording film 615 by controlling the heating by the laser beam and the recording bias magnetic field, as described below.
At the time of reproducing the information, the surface of the recording film 615 is scanned with the GMR element 613 , and a signal that reflects the array of recorded magnetic domains is generated. The output signal of the GMR element 613 that reflects the array of recorded magnetic domains is amplified to a required level by the amplifier 610 , and subsequently is inputted into the actuator drive circuit 609 , the decoder 606 , and the address recognition circuit 605 . The decoder 606 restores the recording data by performing a transformation that is inverse to the transformation by the encoder 603 , and transmits a restored result to the system controller 604 . The system controller 604 conducts such processing as error detection, error correction, etc., if needed, and sends out the reproduced user data 600 to an external apparatus via the interface circuit 601 .
Incidentally, in this description, examples of constructions of the information recording and reproducing apparatus using a preferred recording and reproducing head according to the present invention, as shown in FIGS. 2–4 , will not be shown particularly, but it may be understood that the examples of constructions for these recording and reproducing apparatus are ones in which the recording and reproducing head part of FIG. 6 is appropriately replaced with any of such recording and reproducing heads.
FIG. 8 is a view illustrating in detail an example of operation of a preferred information recording and reproducing apparatus of the present invention, as shown in FIG. 6 . It is assumed herein that the user data 600 has been transformed by the encoder 603 at the time of recording, and recording data 800 has been obtained. The recording data 800 is sent to the recording-coil drive circuit 607 via the recording-waveform generation circuit 602 , and generates a recording bias magnetic field 802 in the vicinity of the heated position by the intense near-field light on the recording film 615 . This recording bias magnetic field 802 is applied normal to the recording film 615 . Simultaneously, the laser drive circuit 608 drives the semiconductor laser 612 in a pulsed manner, as shown by the diagram of laser emission intensity 801 , in synchronization with minimum change units (detection window width) of the recorded magnetic domain length along the recording track. In the region heated by the intense near-field light, the coercive force of the recording film 615 is reduced to lower than an absolute value of the recording bias magnetic field, and the magnetization of that region flows in a direction of the recording bias magnetic field. Thus, one shot of the light pulse irradiation determines the magnetization direction in a bean-shaped or approximately rectangular region as shown by the diagram of a recorded magnetic domain 803 . With the metal scatterer scanning over the recording film 615 , the center of the heated region is moved at certain intervals, and consequently the recording film is heated for that region and cooled intermittently. If the interval of the light pulse irradiation is being shortened, the bean-shaped or approximately rectangular regions come to overlap each other partially, and the recording is performed as if an elongated, bean-shaped or approximately rectangular recorded magnetic domain were formed by each shot of the light pulse irradiation.
The diagram of the recorded magnetic domain 803 in FIG. 8 shows schematically the shape of this recorded magnetic domain, as viewed from directly above the recording film 615 , that is formed on the recording film 615 when performing a recording operation in such a way as illustrated by diagrams of the laser emission intensity 801 and the recording bias magnetic field 802 . As shown in FIG. 8 , a bean-shaped or approximately rectangular recorded magnetic domain 803 has a shape such that a side in a direction perpendicular to the track direction is longer than a side in the track direction. Note here that a line connecting the domain wall near the track center and the domain wall near the track edge of the bean-shaped recorded magnetic domain 803 is approximately perpendicular to the track direction. In FIG. 8 , the near-field light generation region (slider) is made to scan from the left to the right. When the recording bias magnetic field is positive, a magnetic domain whose magnetization directs upwards off the sheet of the drawing (meshed domain) is formed; when the recording bias magnetic field is negative, a magnetic domain whose magnetization directs downwards off the sheet of the drawing (colorless domain) is formed. In the recording that uses a preferred recording and reproducing head according of the present invention, since a generation region of the intense near-field light is a row of plural near-field light sources, curvature of the isothermal line at the time of recording in the recording film in the track center region can be made small (average radius of curvature being made large) as compared with a case where the recording and reproducing head with the single-peaked light spot previously mentioned is used. At the time of, reproducing the information, the GMR element 613 is made to scan over the recording medium 620 , and the reproduced signal is obtained. The reproduced signal reflects the recording data 800 obtained by transformation of the user data 600 in the encoder 603 , and is restored to the user data 600 after being subjected to such processing as amplification, equalization, binary conversion, decoding, etc., if needed. The diagram of a GMR reproduced signal 804 shows the reproduced signal waveform obtained when the magnetic domain 803 is magnetically-reproduced by use of the GMR element 813 . The recording according to the present invention has a feature that the bend of the recorded magnetic domain in the middle of the track is small as compared with the recording by the conventional technology previously described referring to FIG. 7 . Consequently, edges of the GMR reproduced signal 804 show steep build-up and steep falling as compared with the edges of the GMR reproduced signal 704 . That is, as compared with the GMR reproduced signal 704 , the GMR reproduced signal 804 has high resolution, and thereby becomes extremely advantageous in several respects: the size of the information recording and reproducing apparatus, the reliability of the information recording and reproducing apparatus, etc. In addition, the amount of track offset that is allowed between the time of recording and the time of reproducing is mitigated because a large decrease in the resolution does not occur even when the center of the GMR element is offset from the center of the recording track. Further, less noise is generated, even at the time of high-density recording because the domain walls do not get too close to each other on both edges of the track. Therefore, the present invention is extremely advantageous in the size of the information recording and reproducing apparatus, its reduced manufacturing cost, and high reliability.
Since the present invention aims at reducing the curvature of the isothermal line at the time of recording in the track center region of the recording film to as small a value as possible, necessarily, it is preferable that the scanning direction of the recording and reproducing head to the recording medium, i.e., the direction of the recording track R, is largely perpendicular to the line T tangent to the convex vertices of the scatterer where the intense near-field light capable of causing the physical properties to change in the recording medium is generated, as is shown in the schematic diagram of the metal scatterer in the recorded magnetic domain 803 in FIG. 8 . Further, in this case, since the width of the recording track is equal to the width of the magnetic domain that is apparently formed for each shot of the light pulse irradiation, the distance, D, between the vertices of the scatterer at which the intense near-field light capable of causing the physical properties to change in the recording medium becomes necessarily shorter than the width of this recording track.
According to the present invention, in the recording head, the recording and reproducing head, and the information recording and reproducing apparatus, all of which use the recording medium that stores information by means of a local change in the physical properties caused by being subjected to optical or thermal excitation, increase in the recording noise that accompanies malformation of a minute recorded mark structure can be suppressed. In addition, since the shape of the recorded mark in the recording track center region can be controlled to match reproducing characteristics of a reproduced-signal detecting element, it also becomes possible to enhance the capability of reproducing information from the recording medium. With the forgoing capabilities, the present invention makes possible the following features: (1) to improve the recording density without using the reproduced-signal detecting element that is extremely hard to manufacture etc., (2) to prevent the increase in the size of the information recording and reproducing apparatus and the increase in the manufacturing cost of the information recording and reproducing apparatus, and at the same time (3) to realize high reliability.
The foregoing invention has been described in terms of preferred embodiments. However, those skilled, in the art will recognize that many variations of such embodiments exist. Such variations are intended to be within the scope of the present invention and the appended claims.
Nothing in the above description is meant to limit the present invention to any specific materials, geometry, or orientation of elements. Many part/orientation substitutions are contemplated within the scope of the present invention and will be apparent to those skilled in the art. The embodiments described herein were presented by way of example only and should not be used to limit the scope of the invention.
Although the invention has been described in terms of particular embodiments in an application, one of ordinary skill in the art, in light of the teachings herein, can generate additional embodiments and modifications without departing from the spirit of, or exceeding the scope of, the claimed invention. Accordingly, it is understood that the drawings and the descriptions herein are proffered by way of example only to facilitate comprehension of the invention and should not be construed to limit the scope thereof.
Our invention also includes the following method.
1. An information recording method comprising the steps of:
encoding user data to obtain recording data;
sending the recording data to a recording-coil drive circuit via a recording waveform generation circuit, and generating a recording bias magnetic field in the vicinity of a heated region on an information recording medium using intense near-field light from a scatterer disposed between a semiconductor laser and said information recording medium;
applying the recording bias magnetic field perpendicular to the recording medium, and simultaneously driving, via a laser drive circuit, said semiconductor laser in a pulsed manner in synchronization with minimum change units of a recorded magnetic domain length along a recording track;
reducing the coercive force of the recording medium to lower than an absolute value of the recording bias magnetic field in the region heated by the near field light so that the magnetization of the region follows a direction of the recording bias magnetic field whereby one shot of a light pulse irradiation determines a magnetization direction in said region having an approximately rectangular shape;
moving the center of the heated region at predetermined intervals by moving the scatterer over the recording track so that a plurality of said regions in the recording medium are heated and cooled intermittently; and
shortening the light pulses so that the approximately rectangular regions partially overlap each other to form an elongated, approximately rectangular recorded magnetic domain.
2. The information recording method of above 1 wherein said scatterer has a perimeter defining a plurality of vertices and a distance between a first vertex and a last vertex of said plurality of vertices is shorter than a width of said recording track. | A recording head for decreasing recording noise accompanying malformation of a recorded mark and to form the recorded mark capable of increasing reproduction resolution at the time of magnetic reproduction. The head has a light source and a scatterer for recording information on a recording medium by generating near-field light by application of light from the light source and forming a magnetic domain array on the recording medium, a perimeter of the scatterer defines a plurality of vertices and a distance between a first vertex and a last vertex is shorter than the width of the recording track on the recording medium. The recording head improves recording density and can be used to manufacture a highly reliable information recording and reproducing apparatus having a reduced cost per capacity. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Application No. 103 42 659.0 filed Sep. 16, 2003, which is herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an industrial truck, such as a counterweight fork-lift truck, having a vehicle frame comprising a frame portion with a lateral frame opening configured for receiving a battery block. A door is provided for covering the frame opening. The door can be pivoted outwardly about a substantially vertical axis of rotation.
[0004] 2. Technical Considerations
[0005] DE 101 45 991 A1 discloses a generic industrial truck. In order to remove the battery block from the side of the truck, the door is opened and the battery block is withdrawn laterally, such as by a crane with a loading gear. It is installed in the reverse order. If the door is in an open position that is at right angles to the closed position, it can help to insert the battery block suspended from the loading gear.
[0006] If the battery block is to be installed or removed by the fork prongs of a second fork-lift truck, it is important that this second fork-lift truck moves as close as possible with its fork bracket, to which the fork prongs are attached, to the side wall of the first vehicle frame. A door in a 90° open position is an impediment here. The door can only be pivoted beyond 90° to a 180° open position if the rear-side counterweight does not protrude laterally. Otherwise, the door can strike the counterweight prematurely and thus obstruct a laterally approaching second fork-lift truck.
[0007] Therefore, it is an object of the invention to provide an industrial truck of the general type described above but that allows the door provided for the lateral frame opening to be opened by approximately 180°.
SUMMARY OF THE INVENTION
[0008] According to the invention, this object can be achieved in that the door is connected to the vehicle frame by a double hinge. This provides a second axis of rotation set apart and parallel to the first axis of rotation and alterable in its position when the door pivots about the first axis of rotation.
[0009] The invention uses a double hinge, instead of the single hinge that has been used in the past, to attach the door to the vehicle frame.
[0010] A double hinge allows the door to pivot in a pivoting range between the closed position and an open position that is approximately at right angles about the first axis of rotation and, in the pivoting range beyond this, about a second axis of rotation. The position of the second axis of rotation allows the door to be opened to an angle of 180°, even if the counterweight protrudes laterally. In other words, the position of the second axis of rotation, set apart from the first axis of rotation, can prevent the door from colliding with the counterweight (or other laterally protruding components) of the industrial truck.
[0011] According to an advantageous development of the invention, it is proposed that the first axis of rotation is arranged within the vehicle contour. When closed, the door is thus fitted flush with the lateral vehicle contour, i.e., it does not protrude laterally.
[0012] If means for obstructing a rotational motion of the door about the second axis of rotation are provided, which means are active in the pivoting range between the closed position and an open position that is approximately at right angles, there is a defined course of motion when the door is opened and closed.
[0013] When the door is opened, it is initially pivoted about the first axis of rotation, wherein the position of the second axis of rotation changes. When the door pivots beyond 90°, this takes place solely about the second axis of rotation. In principle, a different sequence of the course of motion is also possible, i.e., the door pivots first about the second axis of rotation, then about the first axis of rotation.
[0014] According to one configuration of the invention, the means for obstructing the rotational motion about the second axis of rotation can comprise a locking rod, by means of which a rigid connection can be produced between the door and the portion of the double hinge that is delimited by the two axes of rotation.
[0015] The locking rod, which between the closed position and the 90° open position of the door ensures that the door cannot pivot about the second axis of rotation, can be disengaged (in the simplest case, manually) in the 90° open position. In this position, the second axis of rotation is located outside the vehicle contour. The door can now be pivoted farther to the 180° open position, wherein the door pivots about the second axis of rotation.
[0016] According to a further advantageous configuration of the invention, the means for obstructing the rotational motion about the second axis of rotation can comprise a cam control device, which can be incorporated into the double hinge.
[0017] The obstructing and releasing process therefore takes place automatically when the door pivots. No particular manual intervention is required, as is the case when a locking rod is used. When the door is opened, the second axis of rotation is initially obstructed, and it is only released, owing to the design of the cams, when the 90° open position is reached.
[0018] A defined course of motion, when opening and closing the door, can also be obtained by providing means for generating simultaneous, coordinated pivoting movements of the door about both axes of rotation.
[0019] These means can comprise a gear unit incorporated into the double hinge, such as a star wheel gear, for example.
[0020] In one development of the invention, the double hinge comprises a device for guiding the battery block, which device can be oriented at right angles to the lateral vehicle contour when the door is in a 180° open position.
[0021] This allows the battery block of the industrial truck according to the invention to be installed and/or removed in a wide variety of ways. If a crane with a loading gear is available, the double hinge can optionally help to insert the battery block suspended from the loading gear. If a second fork-lift truck is provided for changing the battery (because a crane with a loading gear is not available), this second fork-lift truck is able, as a result of the door being in a 180° open position, to move relatively close to the lateral vehicle contour of the fork-lift truck according to the invention because the guiding device, which protrudes at right angles, is substantially shorter than a door provided for guiding purposes that also protrudes at right angles (90° open position).
[0022] Although the door, in this embodiment of the invention, has only a single open position, namely a 180° open position, the guiding device that is incorporated into the double hinge provides a means for helping to insert the battery block.
[0023] In the operating position, the guiding device is expediently supported on the vehicle frame by an articulated brace. A damping device can be incorporated into the articulated brace.
[0024] It can be advantageous, in a development of the invention, if the door and the double hinge are constructed so as to reinforce the frame and can be locked in the closed position by a force-transmitting locking unit.
[0025] In the closed position, the door then acts as part of the vehicle frame, provided that the relevant elements (e.g., the door, the double hinge and the locking unit) are sufficiently stable in their construction. Owing to the frame-reinforcing function of the door and the double hinge, the vehicle frame can be provided with a plurality of frame openings, which may also merge with one another. Nevertheless, when the door is closed, the vehicle frame of the industrial truck according to the invention hardly deforms.
[0026] In conjunction with the use of the door and the double hinge as elements for reinforcing the frame, the devices that are provided for obtaining a specific course of motion when opening and closing the door, such as the locking rod, for example, serve to prevent buckling when the door is closed.
[0027] In their capacity as frame-reinforcing components, the door, the locking unit, and the double hinge absorb at least tractive and compressive forces. Advantageously, torsional forces are also absorbed.
[0028] A further configuration of the invention provides that, viewed in the direction of travel, the door is attached to the back of the vehicle frame. In principle, however, it is also possible to attach the door to the front.
[0029] If means for locking the battery block in the lateral direction are provided on the vehicle frame, the door, the double hinge, and the locking unit are not subjected to inertial forces acting in the transverse direction of the battery block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Further advantages and details of the invention will be described in greater detail with reference to the embodiment illustrated in the schematic figures, in which:
[0031] FIG. 1 shows a perspective view of an industrial truck of the invention, with the door in the closed position;
[0032] FIG. 2 shows an enlarged view of the double hinge in FIG. 1 , in the closed position;
[0033] FIG. 3 shows a perspective view of an industrial truck of the invention, with the door in the 90° open position;
[0034] FIG. 4 shows an enlarged view of the double hinge in FIG. 3 , with the door in the 90° open position;
[0035] FIG. 5 shows a perspective view of an industrial truck of the invention, with the door in the 180° open position;
[0036] FIG. 6 shows an enlarged view of the double hinge in FIG. 5 , with the door in the 180° open position;
[0037] FIG. 7 shows a plan view of a double hinge with a cam control device;
[0038] FIG. 8 shows a plan view of the double hinge according to FIG. 7 , with the door in the 90° open position;
[0039] FIG. 9 shows a plan view of the double hinge according to FIG. 7 , with the door in the 180° open position;
[0040] FIG. 10 shows a perspective view of an industrial truck of the invention, with a gear unit incorporated in the double hinge;
[0041] FIG. 11 shows a plan view of the gear unit according to FIG. 10 ;
[0042] FIG. 12 shows a perspective view of an industrial truck of the invention, with a gear unit incorporated in the double hinge and a device for guiding the battery block;
[0043] FIG. 13 shows a plan view of the gear unit and the guiding device according to FIG. 12 , with the door in the closed position; and
[0044] FIG. 14 shows a plan view of the gear unit and the guiding device according to FIG. 12 , with the door in the open position.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] The exemplary industrial truck shown in the drawings is configured as a counterweight fork-lift truck, which comprises a vehicle frame 1 with a rear-side counterweight G (the counterweight G can be part of the vehicle frame 1 or can be suspended therefrom). A central frame portion 2 , which is configured to receive a battery block (not shown in the figures), is located upstream of the counterweight G, in the direction of travel.
[0046] In order to allow the battery block to be installed and removed, the frame portion 2 has an upper frame opening 2 a and a lateral frame opening 2 b . The battery block can be removed upwardly out of the frame opening 2 a by a crane with a loading gear. Alternatively, the battery block can be installed and/or removed laterally through the frame opening 2 b , with the loading gear suspended from the crane.
[0047] A lower frame opening 2 c adjoins the lateral frame opening 2 b . The lower frame opening 2 c allows the fork prongs of a second industrial truck to travel underneath the battery block located in the industrial truck and move it laterally out of the central frame portion 2 of the vehicle frame 1 .
[0048] The lateral frame opening 2 b can be closed by a door 3 , which is shown in the illustrated embodiment as an open profile construction without cladding. A closed configuration, i.e., a profile construction with a sheet metal or plastics material cladding or a sheet metal shell construction with incorporated reinforcement profiles, is, however, preferred.
[0049] In the closed position, the door 3 can be brought into active engagement with a locking unit 4 . The door 3 is attached to the vehicle frame 1 (or the counterweight G) by means of a double hinge 5 , which in the present embodiment is arranged in the region of transition from the counterweight G to the central frame portion 2 . Viewed in the direction of travel of the truck, the door 3 is thus attached to the back of the opening. It is, however, in principle also possible to attach the door to the front, if this appears expedient.
[0050] The double hinge 5 has two vertical axes of rotation A 1 and A 2 , set apart and parallel to each other. A first axis of rotation A 1 is fixed relative to the frame or counterweight, and can be located within the lateral vehicle contour, i.e., in the present case, in a recess in the vehicle frame 1 or the counterweight G that is displaced, with respect to the lateral delimitation of the counterweight G, toward the vehicle longitudinal central plane.
[0051] The construction of the double hinge 5 may be seen in FIG. 2 . The double hinge 5 comprises upper and lower hinge elements 5 a and 5 b , respectively, each of which comprises an outer hinge frame 6 , an inner hinge frame 7 , and two hinge pins 8 and 9 . The first axis of rotation A 1 extends through the hinge pins 8 , while the second axis of rotation extends through the hinge pins 9 .
[0052] The two hinge pins 8 are attached to the vehicle frame 1 or the counterweight G by brackets H 1 (top and bottom). The hinge pins 9 are located in brackets H 2 (top and bottom) of the door 3 . In order to obtain a defined course of motion when opening and closing the door, it can be beneficial to obstruct the second axis of rotation A 2 occasionally.
[0053] For this purpose, a locking rod 10 can be provided, with which the door 3 can be fixed relative to the portion of the double hinge 5 that is enclosed between the axes of rotation A 1 and A 2 . The locking rod 10 penetrates a vertical brace 11 of the door 3 , in the horizontal direction, and a vertical brace 12 , connecting the inner hinge frames 7 of the two hinge elements 5 a and 5 b of the double hinge 5 .
[0054] Accordingly, when the locking rod 10 is engaged, the door can be pivoted only about the first axis of rotation A 1 . The first axis of rotation A 1 remains constantly fixed relative to the frame, while the second axis of rotation A 2 varies its position and, when the door is in the 90° open position (see FIGS. 3 and 4 ), for example, it is located outside the lateral vehicle contour.
[0055] Only when the locking rod 10 is removed, or at least disengaged, may the door 3 be pivoted about the second axis of rotation A 2 , allowing the door 3 to be opened beyond 90°, for example to 180° (see FIGS. 5 and 6 ), without the door 3 prematurely striking the counterweight G.
[0056] As an alternative to the locking rod 10 , it is also possible to incorporate a cam control device into the double hinge 5 (see FIGS. 7, 8 , and 9 ). In this case, a longitudinally movable cam body 13 is arranged between a cam track 14 and a cam track 15 . The cam track 14 is attached to the door 3 , e.g., to the bracket(s) H 1 ( FIG. 2 ), and can comprise a moulded-on entraining element 14 a . The cam track 15 is located on the vehicle frame 1 , on the bracket(s) H 2 , for example, and can comprise a moulded-on stop 15 a.
[0057] When the door 3 is in the closed position, the cam body 13 abuts both cam tracks 14 and 15 , substantially free from clearance. When it is opened, the door 3 , which is guided by the entraining element 14 a and by the design of the cam track 14 and the cam body 13 (freedom from clearance), performs a pivoting movement only about the first axis of rotation A 1 (hinge pins 8 ), but not about the second axis of rotation A 2 (hinge pins 9 ). The cam body 13 travels along the cam track 15 of the double hinge 5 (see FIG. 7 ), up to the stop 15 a of the cam track 15 .
[0058] When the door 3 is in the 90° open position (see FIG. 8 ), there is sufficient clearance (S) between the cam body 13 and the cam track 15 to allow the door 3 to be pivoted farther about the second axis of rotation A 2 (see FIG. 3 ), the cam body 13 being pressed from the rotating cam track 14 toward the cam track 15 .
[0059] Instead of the cam device for controlling the defined course of motion when opening and closing the door 3 , it is also possible to use a gear unit that is incorporated into the double hinge (shown in FIGS. 10 to 14 as a star wheel gear).
[0060] The effect of gearing 16 on the door 3 and gearing 17 on the vehicle frame 1 (or on cantilevers attached thereto) and of an even-numbered quantity of gear wheels 18 , 19 arranged therebetween cause coordinated pivoting movements of the door 3 about both axes of rotation A 1 and A 2 . These pivoting movements, in contrast to the successive pivoting movements described above in conjunction with the cam control device and the locking rod, take place simultaneously. There is no need for a locking rod to prevent buckling.
[0061] In the embodiment according to FIGS. 12 to 14 , not only the gear unit shown in FIGS. 10 and 11 but also a rod-shaped device 20 ( FIGS. 12 and 14 ) for guiding the battery block is incorporated into the double hinge 5 , which device 20 is oriented at right angles to the lateral vehicle contour when the door 3 is in a 180° open position. The guiding device 20 , which includes a rod attached to the upper end of the double hinge 5 and a rod attached to the lower end of the double hinge 5 , can be substantially (200 mm, for example) shorter than a door protruding at right angles (90° open position), provided for guiding purposes, would be.
[0062] In the operating position, the guiding device 20 is supported by an articulated brace 21 , which is attached in a pivoting manner to the vehicle frame 1 (or to the counterweight G), so that impacts of the battery block suspended from the loading gear are directed into the vehicle frame. The articulated brace 21 may also be configured to have a damping effect.
[0063] In all of the described variants, the door 3 , together with the locking unit 4 and the double hinge 5 , can be constructed so as to reinforce the frame. In this case, the described devices with which a defined course of motion is obtained when opening and closing the door 3 , such as the locking rod 10 , for example, can serve to prevent the double hinge 5 from buckling.
[0064] In order to prevent the door 3 , the locking unit 4 and the double hinge 5 from being subjected, in the transverse direction, to inertial forces of the integrated battery block and possibly becoming damaged, delimiters 22 , 23 can be arranged in the base region of the vehicle frame 1 (see FIG. 1 , for example).
[0065] It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. | An industrial truck has a vehicle frame ( 1 ) with a frame portion ( 2 ) having a lateral frame opening ( 2 b ) for receiving a battery block. A door ( 3 ) covers the frame opening ( 2 b ) and may be pivoted outwardly about a substantially vertical axis of rotation (A 1 ). To allow the door ( 3 ) to be opened approximately 180°, the door ( 3 ) is connected to the vehicle frame ( 1 ) by a double hinge ( 5 ). A second axis of rotation (A 2 ) is set apart and parallel to the first axis of rotation (A 1 ) and is alterable in its position when the door ( 3 ) pivots about the first axis of rotation (A 1 ). A device for obstructing a rotational motion of the door ( 3 ) about the second axis of rotation (A 2 ) can be provided, which device can be active in the pivoting range between the closed position and an open position that is approximately at right angles. | 4 |
BACKGROUND OF THE INVENTION
The invention concerns a device for coating a web of material traveling around a backing roller, with a flexible doctor having a foot secured in a clamping beam and a point supported by a supporting strip and with pressure-adjusting mechanisms positioned above the width of the doctor and acting independently of each other on individual points on the doctor. Devices of this kind are employed in particular to coat paper and cardboard.
They have a coating-application system with rollers or nozzles that apply a surplus of coating to the web. Downstream of the coating-application system is a doctor that reduces the coating to the desired thickness. The quality of the coating is decisively affected by the geometry of the area of the doctor that rests against the backing roller. The coating density is established by the pressure of the doctor against the backing roller, which is dictated by the tension on the doctor. To prevent sacrificing coating quality, one version of the method of applying pressure demands that the geometry of the point of the doctor be kept essentially constant.
When webs of paper or cardboard are coated, production-dictated fluctuations in the transverse cross-section of the web occur and make it necessary to vary the pressure of the doctor locally at various points along the operating width in order to obtain a uniform coating. The supporting strip in the generic device disclosed in German Pat. No. 2 825 907 is to a certain extent flexible and can be adjusted for this purpose by tension and compression screws along its line of support depending on whether the coating density is too high or too low at the point in question.
This known coating device has two serious drawbacks. First, local correction of the coating density along the operating width by means of the pressure of the doctor is impossible without simultaneously varying the geometry of the point of the doctor. This can result in local and temporary variations in quality and in a delay in the initiation of the desired effect. Second, it is impossible to automatically control the local distribution of pressure while the web is being coated.
OBJECT OF THE INVENTION
The object of the invention is to improve the generic device and eliminate these drawbacks.
SUMMARY OF THE INVENTION
This object is attained in accordance with the invention by the improvement wherein the pressure-adjusting mechanisms below the supporting strip act on the doctor. The transverse cross-section can accordingly be automatically corrected while the web is being coated independently of the particular tension established before the beginning of the operation. Another advantage is that the tension, which determines the line of support can be left unchanged, with the result that the geometry of the point of the doctor will hardly change at all while the cross-section is being corrected.
The device can have a clamping beam that is flexible across the web of material and is subject to pressure-adjusting mechanisms that are separated along the operating width and can be activated independently. The device can have pressure-adjusting mechanisms in the form of spindle-based thrusters. The pressure-adjusting mechanisms can be separately engaged in order to establish the tension on the doctor. The doctor can be secured in the clamping beam in such a way that it can be moved toward the backing roller, and the position of individual areas of the doctor can be adjusted independently in relation to the clamping beam by means integrated into the clamping beam. The doctor can be secured in the clamping beam between a flexible strip that extends over the operating width and a resilient tensioning element, whereby pressure-adjusting mechanisms in the form of pneumatic or hydraulic mechanisms engage the flexible strip. The tensioning element can be a hose that extends over the operating width and can be charged with air.
The transverse cross-section is accordingly corrected in this embodiment by adjusting the foot of the doctor in the clamping beam and accordingly at a maximal distance from the supporting strip, and the geometry of the point of the doctor does not change while the cross-section is being corrected.
The pressure-adjusting mechanisms in another embodiment of the invention can consist of several adjacent chambers that extend over the operating width and can be independently pressurized, each with an elastic wall that faces the doctor.
This embodiment can have a resilient compensation strip that rests against the doctor with the elastic wall of the pressurized chambers resting against the surface that faces away from the doctor.
The elastic walls in this embodiment can rest against a supporting strip that constitutes the resilient compensation strip.
Each pressurized chamber in this embodiment can have a compressed-air supply line with an independently controlled valve that communicates with a joint distribution line that has its own pressure-regulation unit.
The cross-section can accordingly be corrected automatically in this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be specified with reference to the drawings, wherein
FIG. 1 is a section along the direction that the web travels in through a device with a flexible and locally adjustable clamping beam,
FIG. 2 is a perspective view across the web illustrated in FIG. 1,
FIG. 3 is a section through a coating device with a mechanism for correcting the cross-section integrated into the clamping beam,
FIG. 4 is a schematic representation illustrating how the coating-density cross-section is corrected in the device illustrated in FIG. 3, and
FIG. 5 is a schematic representation of a device with pressure-adjusting mechanisms in the form of pressurized chambers.
DETAILED DESCRIPTION OF THE INVENTION
With reference now to FIGS. 1 and 2, the embodiment includes a flow-control system consisting of a pivoting doctor beam 1, in which a clamping beam 2 that is flexible across the web is mounted in such a way that it can be shifted toward a backing roller 3. Secured in clamping beam 2 in such a way that it can be released at its foot, is a doctor 4.
The point 5 of doctor 4 rests against backing roller 3. Below the point, a supporting strip 6 engages doctor 4 and is secured to doctor beam 1 in such a way that it can move back and forth more or less parallel to clamping beam 2. Supporting strip 6 extends over the operating width, and the side of the strip opposite the line of support is slotted at regular intervals and is accordingly flexible to a certain extent. Uniformly distributed setscrews 7 engage the same side and allow manual establishment of a locally variable pressure over the width of doctor 4.
Flexible clamping beam 2 can be locally shifted toward backing roller 3 by means of spindle-based thrusters 8 distributed at regular intervals (of approximately 50-100 mm) along the operating width. Each thruster 8 has for this purpose a drive mechanism 8.1 that is governed by unillustrated controls, which include a measuring instrument that determines the cross-section of the coating. The drive mechanism can also be engaged in order to vary all the spindle-based thrusters 8 together and establish the tension at the beginning of the coating process. Pneumatic or hydraulic mechanisms or thermally expanding structures, expansion rods for example, can be employed instead of spindle-based thrusters 8.
The mechanism that corrects the transverse cross-section of the coating in the embodiment illustrated in FIG. 3 is integrated into a clamping beam that can be shifted approximately 20 mm more or less horizontally. The foot of doctor 4 is for this purpose tensioned between the more or less vertical leg 9 of an angled strip and a counterpressure-generating hose 10 secured in clamping beam 2. The more or less horizontal leg 11 of the angled strip, which is positioned below a counterpressure-generating hose 10, has regularly spaced slots along the operating width at its end and terminates, when doctor 4 is tensioned in, at a certain distance away from clamping beam 2. This measure allows a more or less horizontal motion on the part of the foot of the doctor to a limited extent (approximately 3-4 mm) relative to clamping beam 2. This motion is generated by bellows 12 positioned adjacent to one another along the operating width with the side that faces away from doctor 4 resting against the vertical leg 9 of the angled strip. Since each bellows 12 has its own supply line 13 for air or liquid, the pressure in each bellows can be regulated individually. The counterpressure-generating hose 10 that extends over the operating width has a compressed-air supply line that generates a prescribed and constant counterpressure. Associated controls that regulate the distribution of pressure in bellows 12 in accordance with the cross-section of the coating are not illustrated in FIG. 3.
FIG. 4 illustrates how the device illustrated in FIG. 3 operates. The geometry and pressure of the point of the doctor is adjusted to the desired coating density at the beginning of the coating process (line a). The tension of doctor 4 that dictates the pressure is established by moving supporting strip 6 and clamping beam 2 toward each other in doctor beam 1. A uniform coating cross-section is attained by adjusting the setscrews 7 on supporting strip 6. A measuring instrument constantly measures the coating density at separate transverse areas of the web of paper during the coating process. The permissible range of coating density is demarcated by the lines b and c in FIG. 4. If the coating becomes too thick in one or more areas (area d), the controls will increase the pressure in the bellows 12 that act on doctor 4 in those areas. The increased pressure elastically deforms the tensioned section of doctor 4 toward counterpressure-generating hose 10 in these areas, decreasing the pressure on the point 5 of doctor 4 and accordingly reducing the thickness of the coating to the intended level. Region d represents the distribution of pressure in the individual bellows 12 that is necessary to compensate for the impermissibly thick coating in area b. The pressure in individual bellows 12 is similarly reduced when the coating in the associated areas is too thin.
The areas of clamping beam 2 in which the flow of coating is too high are shifted away from backing roller 3 by spindle-based thrusters 8. Since the foot of the doctor is secured immovably in flexible clamping beam 2, it is also adjusted, decreasing the coating density in the associated area.
In the cross-section correction mechanism illustrated in FIG. 5, the individual areas of doctor 4 are adjusted by means of several adjacent pressurized chambers 14 distributed over the operating width. The wall 15 of each chamber that faces doctor 4 is elastic. Elastic walls 15 are attached to a resilient compensation strip 16 that rests against doctor 4.
Each pressurized chamber 14 has its own compressed-air supply line 17 with a regulating valve 18 that communicates with a joint distribution line 19. The pressure in distribution line 19 is regulated by a manometer 20 and a regulating valve 21. A computer 22 also controls the pressure in each individual pressurized chamber 14.
Ancillary compressed-air supply lines 23, each with its own manually operated valve 24 communicating with a joint distribution line 25, make it possible to adjust the pressure in each chamber 14 manually.
This system of correcting the cross-section of the coating is especially appropriate for re-equipping existing coating devices because it can be employed instead of a manually adjusted supporting strip. It is not necessary to change the design of clamping beam 2.
At the beginning of the coating process, pressure is generated in distribution line 19 to ensure sufficient pressure on the part of the point of the doctor. A mean pressure is established in each pressurized chamber 14 by way of regulating valves 18. Once the coating process is under way, computer 22 opens or closes the individual regulating valves in accordance with the detected cross-section of the coating. The computer simultaneously controls the pressure in distribution line 19 in accordance with the demand in each chamber 14.
The pressures in the separate pressurized chambers 14 are corrected at regular intervals, with the actual value of the pressure in one chamber being stored in the computer as a reference for the next correction.
It will be appreciated that the instant specifications and claims are set forth by way of illustration and not limitation, and that various modifications and changes may be made without departing from the spirit and scope of the present invention. | A device for coating a web of material traveling around a backing roller, with a flexible doctor having a foot secured in a clamping beam and a point supported by a supporting strip and with pressure-adjusting mechanisms positioned above the width of the doctor and acting independently of each other on individual points on the doctor. The pressure-adjusting mechanisms below the supporting strip act on the doctor. In another embodiment, the pressure-adjusting mechanisms consist of several adjacent chambers that extend over the operating width and can be independently pressurized, each with an elastic wall that faces the doctor. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a current source device, an oscillator device and a pulse generator used in a semiconductor integrated circuit or the like.
A current source device configured as a basic circuit block is used in a semiconductor integrated circuit. The current source device supplies a predetermined current determined according to circuit constants to other circuit blocks or the like. A circuit example of a conventional current source device 100 is shown in FIG. 1 . The current source device 100 comprises a reference voltage generating unit 110 , a drive unit 120 and an output unit 130 . The reference voltage generating unit 110 generates a reference voltage VREF for determining an output current by dividing a source voltage V CC with resistors. Incidentally, the reference voltage VREF is VREF=V CC ·R 12 /(R 11 +R 12 ) in the circuit shown in FIG. 1 . The reference voltage VREF is supplied to an inversion input terminal of an operational amplifier OP 1 of the drive unit 120 . An output terminal of the operational amplifier OP 1 is connected to the gate of a PMOS transistor P 11 . The source of the PMOS transistor P 11 is connected to the source voltage V CC and the drain thereof is connected to a resistor R 13 whose one end is grounded. A potential developed at a connecting point of the drain of the PMOS transistor P 11 (first FET) and the resistor R 13 is connected to a non-inversion input terminal of the operational amplifier OP 1 . A PMOS transistor P 12 (second FET) is connected to a gate line of the PMOS transistor P 11 . The source of the PMOS transistor P 12 is connected to the source voltage V CC and the drain thereof is connected to its corresponding drain of an NMOS transistor N 12 (third FET). Namely, the NMOS transistor N 12 is connected in series with the PMOS transistor P 12 . The gate and drain of the NMOS transistor N 12 are short-circuited to each other and the source thereof is grounded. Here, a current Ill that flows through the PMOS transistor P 11 can be represented as I 11 =VREF/R 13 . On the other hand, if each transistor is used in a saturated region, then a relationship of I 12 ∝I 11 is established between the current I 11 and a current I 12 that flows through the PMOS transistor P 12 and the NMOS transistor N 12 . A voltage V BP developed at a gate line for the PMOS transistors P 11 and P 12 is used as a gate voltage of a PMOS transistor P 13 of the output unit 130 , and a voltage V BN developed at a gate line for the NMOS transistor N 12 is used as gate voltage of an NMOS transistor N 13 of the output unit 130 . The source of the PMOS transistor P 13 of an output stage is connected to the source voltage V CC and the drain thereof serves as an output terminal OUT 1 . The source of the NMOS transistor N 13 of the output stage is grounded and the drain thereof serves as an output terminal OUT 2 . With the connection of anther circuit block or the like between the output terminals OUT 1 and OUT 2 in the current source device 100 having such a configuration, a drive current corresponding to the reference voltage VREF can be supplied to the corresponding circuit block or the like. The current source device referred to above can be used as, for example, a drive current source of an oscillator device having a ring oscillator circuit comprised of inverter circuits of odd-numbered stages. In this case, drive currents are supplied from the current source device every plural inverter circuits constituting the ring oscillator circuit. The current source device can also be used as, for example, a drive current source of a pulse generator including a delay circuit comprised of inverter circuits of plural stages. Even in this case, drive currents are supplied from the current source device every plural inverter circuits constituting the delay circuit.
The above prior art refers to a patent document 1 (Japanese Unexamined Patent Publication No. 2000-78510).
In the above current source device, the condition for its normal operation is that the drive voltages V BP and V BN for driving the PMOS transistor P 13 and NMOS transistor N 13 of the output stage are respectively set to predetermined potentials. On the other hand, the setting of an output current in a halt state of the current source device to zero might be required depending on specs. In this case, however, it is considered that the drive voltage V BP of the PMOS transistor P 13 of the output stage is set to the source voltage V CC to cut off the output current. Further, in this case, it is considered that V BN is set to a ground potential to avoid that the drive voltage V BN of the NMOS transistor N 13 of the output stage reaches an indefinite voltage. Thus, there is a need to change the drive voltages V BP and V BN of the transistors of the output stage from the source voltage V CC or ground potential to predetermined potentials when the current source device is started from its halt state. It cannot be however expected that a desired output current is obtained during a period of transition made until V BP and V BN reach a predetermined voltage respectively. Namely, the period during which the required output current cannot be obtained exists immediately after the start-up of the current source device. Thus, in the oscillator device using the current source device as the drive current source as described above, a normal frequency output cannot be expected during a period taken until the output current reaches a predetermined value, after the start-up of the current source device. In the pulse generator using the current source device as the drive current source as mentioned above, a normal pulse output cannot be expected during a period taken until the output current reaches a predetermined value, after the start-up of the current source device.
SUMMARY OF THE INVENTION
The present invention has been made in view of the foregoing points. An object of the present invention is to provide a current source device capable of cutting off an output current at its stop and obtaining a desired output current immediately at its start-up.
Another object of the present invention is to provide an oscillator device which does not consume current at its stop and is capable of obtaining a desired frequency output at once after its start-up.
A further object of the present invention is to provide a pulse generator which does not consume current at its stop and is capable of obtaining a desired output pulse at once after its start-up.
According to one aspect of the present invention, for attaining the above object, there is provided a current source device comprising a first series circuit comprising a first FET and a resistor connected in series with the first FET and having both ends between which a source voltage is applied, a second series circuit which comprises a second FET and a third FET connected in series with the second FET and which includes a connecting point of the second and third FETs and a gate of the third FET both being short-circuited to each other and includes both ends between which the source voltage is applied, a drive circuit which supplies a common drive voltage to both gates of the first and second FETs, and first and second current source circuits operated in response to first and second drive voltages with gate voltages of the second and third FETs as the first and second drive voltages, wherein the first and second current source circuits respectively include first and second current source FETs respectively operated with the first and second drive voltages as gate voltages, and a start-up circuit which changes the first and second drive voltages forcedly when the first and second current source FETs are brought into conduction, and wherein output currents are supplied from sources or drains of the first and second current source FETs. Incidentally, a series connection of plural FETs means a connection configuration that the source or drain of one FET and the source or drain of the other FET are connected to each other.
According to another aspect of the present invention, for attaining the above object, there is provided an oscillator device having the above current source device including a ring oscillator circuit comprising a plurality of inverter circuits respectively operated with output currents supplied from the first and second current source FETs as drive current sources.
According to a further aspect of the present invention, for attaining the above object, there is provided a pulse generator having the above current source device, comprising a delay circuit comprising a plurality of inverter circuits respectively operated with the output currents supplied from the first and second current source FETs as drive current sources, and an AND circuit which receives both input and output signals of the delay circuit as input signals.
According to the current source device of the present invention, it is possible to stop a current output upon a circuit stop and obtain a desired output current at once from immediately after its start-up upon a circuit start-up.
According to the oscillator device of the present invention, it is possible to suppress power consumption upon a circuit stop and obtain a desired frequency output at once from immediately after its start-up upon a circuit start-up.
According to the pulse generator of the present invention, it is possible to suppress power consumption upon a circuit stop and obtain a desired pulse output at once from immediately after its start-up upon a circuit start-up.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
FIG. 1 is an equivalent circuit diagram showing a configuration example of a conventional current source device;
FIG. 2 is an equivalent circuit diagram illustrating a configuration of a current source device according to a first preferred embodiment of the present invention;
FIG. 3( a ) is a diagram showing operation waveforms of respective parts in the conventional current source device, and FIG. 3( b ) is a diagram showing operation waveforms of respective parts in the current source device according to the first preferred embodiment of the present invention;
FIG. 4 is an equivalent circuit diagram illustrating a configuration of an oscillator device according to a second preferred embodiment of the present invention;
FIG. 5 is an equivalent circuit diagram depicting a configuration of a pulse generator according to a third embodiment of the present invention;
FIG. 6 is an equivalent circuit diagram showing a configuration of an oscillator device according to another embodiment of the present invention;
FIG. 7 is an equivalent circuit diagram illustrating a configuration of a pulse generator according to another embodiment of the present invention; and
FIG. 8 is an equivalent circuit diagram showing a configuration of a pulse generator according to a further embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will hereinafter be described with reference to the accompanying drawings. In the drawings shown below, the same reference numerals are respectively attached to substantially identical or equivalent constituent elements or parts.
First Preferred Embodiment
FIG. 2 is an equivalent circuit diagram showing a configuration of a current source device 200 of the present invention. The current source device 200 includes a reference voltage generating unit 140 , a drive unit 150 and an output unit 130 in a manner similar to the conventional circuit. A V BN start circuit 160 and a V BP start circuit 170 are respectively connected to a V BN line and a V BP line that connect the drive unit 140 and the output unit 130 . The current source device 200 of the present invention sets the potential of the V BP line to a source voltage V CC and sets the potential of the V BN line to a ground potential when it is held in a halt state. In this state, the current source device 200 brings transistors P 13 and N 13 of an output stage to an OFF state respectively to stop the supply of current. Upon its start-up, the current source device 200 is capable of causing both lines to reach a predetermined voltage momentarily and forcedly through the V BN start circuit 160 and the V BP start circuit 170 thereby to obtain a desired output current at once from immediately after the start-up. Detailed configurations of respective parts of the current source device 200 of the present invention will be explained below.
In a manner similar to the conventional circuit, the reference voltage generating unit 140 generates a predetermined reference voltage VREF by dividing the source voltage V CC by resistors R 11 and R 12 . The reference voltage generating unit 140 of the present embodiment includes a PMOS transistor P 30 inserted between the resistor R 11 and the source voltage V CC . The gate of the PMOS transistor is supplied with a start-up or enable signal ENB from outside, whereby ON/OFF control is done. Incidentally, the method of generating the reference voltage VREF is not limited to the resistance-division of the source voltage V CC . The reference voltage VREF may be generated by, for example, a bandgap circuit or the like. In this case, a reference voltage stable with respect to the temperature can be obtained without depending on the source voltage V CC . The reference voltage VREF generated by the reference voltage generating unit 140 is supplied to an inversion input terminal of an operational amplifier OP 1 of the drive unit 150 .
While the basic configuration of the drive unit 150 is similar to the conventional circuit, the drain of an NMOS transistor N 20 (fourth FET) is connected to a connecting point of a PMOS transistor P 12 and an NMOS transistor N 12 , i.e., the V BN line. The source of the NMOS transistor N 20 is grounded and the gate thereof is supplied with the enable signal ENB from outside, whereby ON/OFF control is performed.
The V BN start circuit 160 comprises four transistors of PMOS transistors P 14 and P 15 and NMOS transistors N 14 and N 15 . The gate of the NMOS transistor N 14 is connected to the V BN line, the source thereof is grounded and the drain thereof is connected to the gate of the NMOS transistor N 15 and the drain of the PMOS transistor P 14 at a point A in the drawing. The source of the NMOS transistor N 15 is connected to the V BN line and the drain thereof is connected to the drain of the PMOS transistor P 15 . The source of the PMOS transistor P 14 is connected to the source voltage V CC and the gate thereof is supplied with an enable signal EN from outside, whereby ON/OFF control is conducted based on the enable signal EN. The source of the PMOS transistor P 15 is connected to the source voltage V CC and the gate thereof is supplied with the enable signal ENB, so that ON/OFF control is done based on the enable signal ENB. Incidentally, the PMOS transistor P 14 corresponds to a second gate potential fixing FET of the present application, the PMOS transistor P 15 corresponds to a second current control FET of the present application, the NMOS transistor N 14 corresponds to a second gate control FET of the present application, and the NMOS transistor N 15 corresponds to a second drive voltage start-up FET of the present application.
The V BP start circuit 170 comprises four transistors of PMOS transistors P 16 and P 17 and NMOS transistors N 16 and N 17 . The source of the PMOS transistor P 16 is connected to the source voltage V CC , the gate thereof is connected to the V BP line and the drain thereof is connected to the gate of the PMOS transistor P 17 and the drain of the NMOS transistor N 16 at a point B in the figure. The source of the PMOS transistor P 17 is connected to the V BP line and the drain thereof is connected to the drain of the NMOS transistor N 17 . The source of the NMOS transistor N 16 is grounded and the gate thereof is supplied with the enable signal ENB, so that ON/OFF control is performed based on the enable signal ENB. The source of the NMOS transistor N 17 is grounded and the gate thereof is supplied with the enable signal EN, so that ON/OFF control is done based on the enable signal EN. Incidentally, the PMOS transistor P 16 corresponds to a first gate control FET of the present application, the PMOS transistor P 17 corresponds to a first drive voltage start-up FET of the present application, the NMOS transistor N 16 corresponds to a first gate potential fixing FET of the present application, and the NMOS transistor N 17 corresponds to a first current control FET of the present application.
The source of a PMOS transistor P 13 of the output unit 130 is connected to the source voltage V CC , the gate thereof is connected to the V BP line and the drain thereof serves as an output terminal OUT 1 . The source of an NMOS transistor N 13 of the output unit 130 is grounded, the gate thereof is connected to the V BN line and the drain thereof serves as an output terminal OUT 2 .
Connecting other circuit blocks or the like between the output terminals OUT 1 and OUT 2 in the current source device 100 having such a configuration makes it possible to supply a drive current corresponding to the reference voltage VREF to the corresponding circuit block or the like. The operation of the current source device 200 will be explained below.
When the current source device 200 is in a halt state, the enable signal EN is set to a Low level and the enable signal ENB is set to a High level in order to bring an output current to zero. Here, the Low level is of a ground potential level and the High level is of a source voltage V CC level.
When the enable signal ENB is brought to the High level, the PMOS transistor P 30 of the reference voltage generating unit 140 becomes an OFF state. Therefore, the reference voltage VREF assumes the ground potential, the output voltage of the operational amplifier OP 1 assumes the source voltage V CC level, and the V BP line assumes the source voltage V CC level. Hence, the PMOS transistor P 13 of the output unit 130 is brought to an OFF state so that the output current is brought to zero. When the enable signal ENB is brought to the High level, the NMOS transistor N 20 of the drive unit 150 is brought to an ON state. Therefore, the V BN line is brought to the ground potential level and the NMOS transistor N 13 of the output unit 130 is also brought to an OFF state. Thus, when the current source device 200 is in the halted state, the PMOS transistor P 13 and NMOS transistor N 13 of the output unit 130 are respectively driven to an OFF state, so that the supply of the output current is stopped.
In the V BN start-up circuit 160 , the PMOS transistor P 14 is brought to an ON state when the enable signal EN reaches the Low level, whereas when the enable signal ENB is brought to the High level, the PMOS transistor P 15 is brought to an OFF state. Since the V BN line is of the ground potential level as mentioned above, the NMOS transistor N 14 is brought to an OFF state so that the potential at the point A assumes the source voltage V CC level. Therefore, since the PMOS transistor P 15 is in the OFF state while the NMOS transistor N 15 is brought to an ON state, no current flows.
In the V BP start-up circuit 170 , the NMOS transistor N 17 is brought to an OFF state when the enable signal EN reaches the Low level, whereas when the enable signal ENB is brought to the High level, the NMOS transistor N 16 is brought to an ON state. Since the V BP line is of the source voltage V CC level as mentioned above, the PMOS transistor P 16 is brought to an OFF state so that the potential at the point B assumes the ground potential level. Therefore, since the NMOS transistor N 17 is in the OFF state while the PMOS transistor P 17 is brought to an ON state, no current flows.
Next, when the current source device 200 is started, the enable signal EN is set to the High level and the enable signal ENB is set to the Low level. When the enable signal ENB is brought to the Low level, the PMOS transistor P 30 of the reference voltage generating unit 140 is brought to an ON state, so that the reference voltage VREF determined by a resistance division ratio of the resistors R 11 and R 12 occurs at a connecting point of these resistors. This is supplied to the inversion input terminal of the operational amplifier OPI . Thus, the potential of the V BP line that has been maintained at the source voltage V CC level in the halt state starts to drop. With its drop, the PMOS transistors P 11 and P 12 are brought to an ON state so that currents I 11 and I 12 start to flow. On the other hand, when the enable signal ENB is brought to the Low level, the NMOS transistor N 20 of the drive unit 150 is brought to an OFF state. Therefore, the potential of the V BN line that has been maintained at the ground potential level in the halt state starts to rise.
With its drop, the PMOS transistors P 11 and P 12 are brought to an ON state so that currents 111 and 112 start to flow. On the other hand, when the enable signal ENB is brought to the Low level, the NMOS transistor N 20 of the drive unit 150 is brought to an OFF state. Therefore, the potential of the V BN line that has been maintained at the ground potential level in the halt state starts to rise.
When the enable signal EN is brought to the High level and the enable signal ENB is brought to the Low level in the V BN start-up circuit 160 , the PMOS transistor P 14 is brought to an OFF state and the PMOS transistor P 15 is brought to an ON state. Since the V BN line is at the ground potential level immediately after the start-up of the current source device 200 , the NMOS transistor N 14 is held in an OFF state and the potential at the point A is maintained at the source voltage V CC level. Thus, since the NMOS transistor N 15 is continuously held in the ON state immediately after the start-up, and the PMOS transistor P 15 is brought to the ON state by the enable signal ENB as described above, a current I 15 flows and the potential of the V BN line rises suddenly. With the sudden rise in the potential of the V BN line after the start-up, the NMOS transistor N 13 of the output unit 130 is transitioned to an ON state rapidly and brought to a state of being capable of supplying a predetermined output current from immediately after the start-up of the current source device 200 . Incidentally, when the NMOS transistor N 14 is brought to an ON state with the rise in the potential of the V BN line, the potential at the point A reaches the ground potential level and the NMOS transistor N 15 is brought to an OFF state. Therefore, the potential that the V BN line reaches is in the neighborhood of the threshold voltage of the NMOS transistor N 14 by the operation of the V BN start-up circuit 160 .
When the enable signal EN is brought to the High level and the enable signal ENB is brought to the Low level in the V BP start-up circuit 170 , the NMOS transistor N 16 assumes an OFF state and the NMOS transistor N 17 assumes an ON state. Since the V BP line is placed in the source voltage V CC level immediately after the start-up, the PMOS transistor P 16 is brought to an OFF state and the potential at the point B is maintained at the ground potential level. Thus, since the PMOS transistor P 17 is continuously held in the ON state and the NMOS transistor N 17 is brought to the ON state by the enable signal EN as described above, a current I 17 flows and the potential of the V BP line drops suddenly. With the sudden drop in the potential of the V BP line after the start-up, the PMOS transistor P 13 of the output unit 130 is transitioned to an ON state rapidly and assumes a state of being capable of supplying a predetermined output current from immediately after the start-up of the current source device 200 . Incidentally, when the PMOS transistor P 16 is brought to an ON state with the drop in the potential of the V BP line, the potential at the point B reaches the source voltage V CC level and the PMOS transistor P 17 is brought to an OFF state. Therefore, the potential that the V BP line reaches is in the neighborhood of the threshold voltage of the PMOS transistor N 16 by the operation of the V BP start-up circuit 170 .
FIG. 3( a ) shows changes in voltages of V BN and V BP lines at the start-up of the conventional current source device with no V BN start-up circuit 160 and V BP start-up circuit 170 . On the other hand, FIG. 3( b ) shows changes in voltages of the V BN and V BP lines at the start-up of the current source device 200 according to the present invention, including the V BN start-up circuit 160 and the V BP start-up circuit 170 . In the conventional current source device, a certain amount of time is required until V BN and V BP reach a predetermined voltage after its start-up as shown in FIG. 3( a ). Therefore, the transistors of the output stage operated with V BP and V BN as drive voltages are not capable of passing predetermined output currents immediately after the start-up. On the other hand, in the current source device 200 according to the present invention, including the V BN start-up circuit 160 and the V BP start-up circuit 170 , as shown in FIG. 3( b ), the potential of the V BP line maintained at the source voltage V CC level at its stop drops suddenly from immediately after the start-up thereof due to the operations of these start-up circuits and reaches a predetermined voltage level rapidly. The potential of the V BN line maintained at the ground potential level upon its stop rises suddenly from immediately after the start-up and reaches a predetermined voltage level rapidly. Thus, the PMOS transistor P 13 and NMOS transistor N 13 of the output unit 130 , which have been held in the OFF state in the halt state, are respectively transitioned to an ON state rapidly, and are capable of passing desired output currents momentarily. Incidentally, while the potential that the V BN line reaches is in the neighborhood of the threshold voltage of the NMOS transistor N 14 by the operation of the V BN start-up circuit as described above, and the potential that the V BP line reaches is in the neighborhood of the threshold voltage of the PMOS transistor P 16 by the operation of the V BP start-up circuit, the changes in the voltages of the V BN and V BP lines are greatly speeded up compared with the conventional or prior art circuit even in such a case, and the current source device can be enabled or started up at a high speed.
Second Preferred Embodiment
FIG. 4 is an equivalent circuit diagram showing a configuration of an oscillator device 300 illustrative of a second preferred embodiment of the present invention to which the current source device 200 shown in the first preferred embodiment is applied. The oscillator device 300 has a configuration in which a ring oscillator circuit 180 is added to the current source device 200 . That is, the ring oscillator circuit 180 is operated in response to the supply of drive currents from the current source device 200 .
The ring oscillator circuit 180 comprises inverter circuits 180 - 1 through 180 -n of n stages (where n: odd number) coupled to one another. Each of the inverter circuits 180 - 1 through 180 -n comprises a PMOS transistor P 40 and an NMOS transistor N 40 . Each inverter circuit is supplied with drive currents by output-stage transistors P 13 and N 13 of the current source device. Incidentally, the output-stage transistors P 13 and N 13 are increased according to the number of stages of the inverter circuits. The output of the final-stage inverter circuit 180 -n is taken out as the final output voltage of the oscillator device 300 . The output of the inverter circuit 180 -n is connected to the input of the first-stage inverter circuit 180 - 1 . The inverter circuits comprised of the odd-numbered stages assume a logical NOT of the input as a whole. Since the inverter circuits have finite delay times respectively, the final-stage inverter circuit 180 -n outputs a logical NOT of the first-stage input after the finite delay times have elapsed from the input to the first-stage inverter circuit 180 - 1 , and the logical NOT thereof is inputted to the first-stage inverter circuit 180 - 1 again. This process is repeated, thereby making it possible to obtain an oscillation signal from an output terminal OUT. Since the current source device 200 is similar in configuration and operation to the first preferred embodiment, their explanations are omitted.
Thus, according to the oscillator device of the present invention, the ring oscillator circuit 180 is configured so as to be supplied with the drive currents from the current source device 200 according to the present invention. Therefore, when the entire circuit is in a halt state, the supply of the drive currents therefrom is not conducted and power consumption can hence be reduced. Since desired drive currents are supplied from the current source device 200 to the ring oscillator circuit 180 rapidly from immediately after its start-up upon start-up of the circuit, an output signal having a stable oscillation frequency can be obtained from immediately after the start-up. The oscillator device 300 according to the present invention can be used in, for example, an internal clock circuit of a semiconductor memory circuit requiring that a standby current prior to the start-up is zero.
Third Preferred Embodiment
FIG. 5 is an equivalent circuit diagram showing a configuration of a pulse generator 400 illustrative of a third preferred embodiment of the present invention to which the current source device 200 illustrated in the first preferred embodiment is applied. The pulse generator 400 comprises the current source device 200 , a delay circuit 190 made up of inverter circuits 190 - 1 through 190 -n of n stages (where n: odd number), and an AND circuit 191 . Each of the inverter circuits 190 - 1 through 190 -n is operated in response to the supply of drive currents from the current source device 200 . The output of the final-stage inverter circuit 190 -n is connected to one input of the AND circuit 191 . The input of the first-stage inverter circuit 190 - 1 is connected to the other input of the AND circuit 191 . An output of the AND circuit 191 is taken out as a final output of the pulse generator 400 . With the supply of an input signal of a Low level to an input terminal IN connected to the first-stage inverter circuit 190 - 1 in the pulse generator 400 having such a configuration, a Low level is supplied to the one input of the AND circuit 191 and thereby the AND circuit 191 outputs the Low level therefrom. Since, at this time, the final-stage inverter circuit 190 -n outputs a High level, the High level is supplied to the other input of the AND circuit 191 . On the other hand, when the High level is supplied to the input terminal IN, the High level is temporarily supplied to both inputs of the AND circuit 191 . Therefore, the AND circuit 191 outputs the High level therefrom. Since the final-stage inverter circuit 190 -n outputs the Low level when a predetermined delay time determined according to the number of stages of the inverter circuits has elapsed, the output of the AND circuit 191 is brought to the Low level after the delay time has elapsed. Namely, the pulse generator 400 changes the input signal from the Low level to the High level thereby to generate an output pulse having a pulse width corresponding to a delay in propagation by the delay circuit 190 comprised of the inverter circuits of plural stages. Incidentally, since the current source device is similar to the first preferred embodiment in configuration and operation, their explanations are omitted.
Thus, according to the pulse generator of the present invention, each of the inverter circuits of the plural stages constituting the delay circuit 190 is configured so as to be supplied with the drive currents from the current source device 200 according to the present invention. Therefore, when the whole circuit is in a halt state, the supply of the drive currents therefrom is not conducted and power consumption can hence be reduced. Since desired drive currents are supplied from the current source device to the respective inverter circuits rapidly from immediately after its start-up upon start-up of the circuit, an output pulse having a stable pulse width can be obtained from immediately after the start-up. The pulse generator 400 according to the present invention can be used in, for example, a pulse generator with an address transition as a trigger in a semiconductor memory circuit requiring that a standby current prior to the start-up is zero.
First Modification
FIG. 6 is an equivalent circuit diagram showing a modification of the ring oscillator device 300 shown in the second preferred embodiment. In a ring oscillator device 300 a according to the present embodiment, the drains of potential fixing PMOS transistors P 60 are connected to their corresponding outputs of odd-numbered inverter circuits of inverter circuits 180 - 1 through 180 -n of n stages (where n: odd number). The sources of the PMOS transistors P 60 are connected to a source voltage V CC and the gates thereof are supplied with an enable signal EN from outside. On the other hand, the drains of potential fixing NMOS transistors N 60 are connected to their corresponding outputs of the even-numbered inverter circuits. The sources of the NMOS transistors N 60 are connected to a ground potential and the gates thereof are supplied with an enable signal ENB from outside. Since the present embodiment is similar to the second preferred embodiment in other constituent parts, their explanations are omitted. Incidentally, descriptions about the constituent parts of the current source device 200 are omitted in FIG. 6 .
When the ring oscillator device 300 a having such a configuration is in a halt state, the enable signal EN is set to a Low level and the enable signal ENB is set to a High level. Thus, the potential fixing PMOS transistors P 60 and the NMOS transistors N 60 are both brought to an ON state, so that the outputs of the odd-numbered inverter circuits are fixed to the High level and the outputs of the even-numbered inverter circuits are fixed to the Low level. Namely, when the oscillator device 300 a is in the halt state, the potential is fixed in such a manner that the High and Low levels alternately appear at connecting points of the respective inverter circuits. Incidentally, the input and output of the first-stage inverter circuit 180 - 1 are both fixed to the High level. Since the potential of a V BN line is of a ground potential level in the halt state as described above, N 13 are held in an OFF state and hence no through current flows. By fixing the input and output voltages of the respective inverter circuits in the halt state of the oscillator device 300 a , a stable frequency output can be obtained from immediately after the start-up of the oscillator device. Namely, the state of the potential at the input/output point of each inverter circuit in the halt state corresponds to a momentary state in which the input of the first-stage inverter circuit 180 - 1 is inverted to the High level upon the normal operation of the oscillator device. That is, since the potential of each part is fixed in such a manner that the oscillator device takes one state at the time that it is already in the normal operation, from the time when the oscillator device is in the halt state, and the supply of drive currents is started by the operation of the current source device 200 from immediately after the start-up thereof, a desired frequency output is obtained promptly from immediately after the start-up. Incidentally, when the oscillator device is started, the enable signal EN is set as the High level, the enable signal ENB is set as the Low level and the potential fixing transistors P 60 and N 60 are respectively brought to an OFF state. In this state, the fixing of each potential is released.
FIG. 7 is an equivalent circuit diagram showing a modification of the pulse generator 400 illustrated in the third preferred embodiment. The above-described potential fixing transistors can be applied even to the pulse generator 400 shown in the third preferred embodiment. Namely, in a pulse generator 400 a according to the present embodiment, potential fixing PMOS transistors P 60 and NMOS transistors N 60 are alternately disposed at respective outputs of inverter circuits 190 - 1 through 190 -n constituting a delay circuit 190 in a manner similar to the above oscillator device 300 a.
Incidentally, the constituent parts of the current source device 200 have not been described in FIG. 7 . In the pulse generator having such a configuration, an enable signal EN is set to a Low level and an enable signal ENB is set to a High level when the pulse generator is in a halt state. Thus, the potential fixing PMOS transistors P 60 and NMOS transistors N 60 are both brought to an ON state, so that the outputs of the odd-numbered inverter circuits are fixed to a High level and the outputs of the even-numbered inverter circuits are fixed to a Low level. Further, an input terminal IN is set to a Low level in the halt state. Thus, the potentials of the inputs and outputs of all the inverter circuits become opposite in phase. The output of an AND circuit 191 becomes a Low level because the input terminal IN is set the Low level. The state of the potential of each part at the stop of the pulse generator corresponds to a state at the time that the input terminal IN is of the Low level upon the normal operation of the pulser generator. Thus, it corresponds to a state prior to the input of a trigger for pulse generation. Namely, since the potential of each part is fixed in such a manner that the pulse generator 400 a takes one state at the time that it is already in the normal operation, from the time when the pulse generator is in the halt state, and the supply of drive currents is started by the operation of the current source device 200 from immediately after the start-up thereof, a desired pulse output is obtained promptly from immediately after the start-up. Incidentally, when the pulse generator is started, the enable signal EN is set as the High level, the enable signal ENB is set as the Low level and the potential fixing transistors P 60 and N 60 are respectively brought to an OFF state. In this state, the fixing of each potential is released.
Second Modification
FIG. 8 is an equivalent circuit diagram showing a second modification of the pulse generator 400 shown in the third preferred embodiment. A pulse generator 400 b according to the present embodiment is different from the third preferred embodiment in terms of a configuration of an output unit 130 a of a current source device. Namely, in the pulse generator 400 b according to the present embodiment, PMOS transistors P 50 that constitute odd-numbered inverter circuits of inverter circuits 190 - 1 through 190 -n of n stages (where n: odd number) are respectively connected directly to a source voltage V CC without via output-stage PMOS transistors P 13 of the current source device. On the other hand, NMOS transistors N 50 that constitute even-numbered inverter circuits are respectively connected directly to a ground potential without via output-stage NMOS transistors N 13 of the current source device. Incidentally, descriptions about the constituent parts of the current source device 200 are omitted in FIG. 8 .
In the pulse generator 400 b having such a configuration, an input terminal IN is set to a Low level when the pulse generator is in a halt state. Thus, the PMOS transistor P 50 that constitutes the first-stage inverter circuit 190 - 1 assumes an ON state, so that its output is brought to a High level. As a result, the High level is inputted to the second inverter circuit 190 - 2 thereby to bring the NMOS transistor N 50 to an ON state. Therefore, the inverter circuit 190 - 2 outputs a Low level therefrom. Thus, when the pulse generator is in the halt state, the potentials of the inputs and outputs of all the inverter circuits become opposite in phase. The output of an AND circuit 191 assumes a Low level because the input terminal IN is set to the Low level. The state of the potential of each part at the stop of the pulse generator corresponds to a state at the time that the input terminal IN is of the Low level upon the normal operation of the pulser generator. Thus, it corresponds to a state prior to the input of a trigger for pulse generation. Namely, since the potential of each part is fixed in such a manner that the pulse generator takes one state at the time that it is already in the normal operation, from the time when the pulse generator is in the halt state, and the supply of drive currents is started by the current source device from immediately after the start-up thereof, a desired pulse output is obtained promptly from immediately after the start-up.
While the preferred forms of the present invention have been described, it is to be understood that modifications will be apparent to those skilled in the art without departing from the spirit of the invention. The scope of the invention is to be determined solely by the following claims. | A current source device that cuts off an output current when stopped and obtains a desired output current upon start-up includes a first circuit having a first FET and resistors in series, a second circuit having second and third FETs in series with a point between the second and third FETs and a gate of the third FET connected, a drive circuit supplying a common drive voltage to gates of the first and second FETs, and first and second current source circuits responsive to first and second drive voltages that are gate voltages of the second and third FETs. The first and second current source circuits respectively include first and second current source FETs having the first and second drive voltages as gate voltages, and a start-up circuit changing the first and second drive voltages forcedly when the first and second current source FETs are made conductive. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This patent application is a continuation-in-part of U.S. application Ser. No. 08/594,758, filed Jan. 31, 1996 now U.S. Pat. No. 5,840,023 issued Nov. 24, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the fields of imaging, thermotherapy, and cryotherapy. More specifically, the present invention relates to a method and system utilizing optoacoustic imaging to monitor, in real time, tissue properties during therapeutic or surgical treatment.
2. Description of the Related Art
Various types of therapeutic agents (radiation, heating, cooling, drugs, surgical tools) are being used for treatment. It is necessary to monitor tissue physical properties during treatment to provide selective damage to diseased tissues. This will result in better outcome of any treatment procedure. It is highly desirable to develop an imaging technique which will be capable of monitoring tissue physical parameters in real time during treatment. Such an imaging technique will provide feed-back information which will be used to optimize treatment procedure. All conventional imaging techniques have limitations such as low contrast (ultrasound and X-ray imaging), high cost (MRI, PET), poor resolution (PET). Some of them are not capable of providing imaging information in real time. Due to these limitations, these conventional techniques are not being widely applied for monitoring tissue physical properties in real time during treatment.
It has been demonstrated that thermally treated tissues possess optical properties that are significantly different from normal untreated tissues. For example, the optical properties of coagulated and normal tissues are different. It was also demonstrated that different regimes of coagulation may yield different end values of tissue optical properties. A hemorrhage ring was observed at the boundary between coagulated and normal tissue in vivo.
The prior art is deficient in the lack of effective means of monitoring of tissue parameters in real time during therapeutic or surgical treatment. The present invention fulfills this long-standing need and desire in the art.
SUMMARY OF THE INVENTION
The present invention is directed to a method/system of real-time optoacoustic monitoring of tissue physical properties with the purpose of providing selective damage of diseased tissues and assuring minimal damage to surrounding normal tissues during therapy.
In one embodiment of the present invention, there is provided a method of monitoring tissue properties in real time during treatment using a laser optoacoustic imaging system, comprising the steps of administering a treatment agent to the tissue and applying the optoacoustic imaging system to the treated tissue. Preferably, the tissue can be selected from various organs with tumors or other lesions, and the tissue properties are referred to physical dimension, optical absorption, optical scattering, optical attenuation coefficient, temperature, thermal expansion coefficient, speed of sound or heat capacity. Representative treatment agents include optical radiation, electromagnetic radiation, ultrasonic radiation, electrical current, heating, cooling, a drug or a surgical tool.
In another embodiment of the present invention, there is provided a system of monitoring tissue properties in real time during treatment, comprising a system for administering a treatment agent to the tissue; an optoacoustic imaging system for providing images; an exogenous molecular probe for reflecting the treatment; and a feed-back electronic system for adjusting parameters of the treatment agent.
Other and further aspects, features, and advantages of the present invention will be apparent from the following description of the presently preferred embodiments of the invention given for the purpose of disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the matter in which the above-recited features, advantages and objects of the invention, as well as others which will become clear, are attained and can be understood in detail, more particular descriptions of the invention briefly summarized above may be had by reference to certain embodiments thereof which are illustrated in the appended drawings. These drawings form a part of the specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and therefore are not to be considered limiting in their scope.
FIG. 1 shows an optoacoustic image obtained in vitro from two pieces of liver tissue simulating tumors with increased absorption embedded in a tissue with lower absorption (1 pixel=0.1 mm).
FIG. 2 shows an example of utility for laser optoacoustic imaging system for monitoring of laser coagulation of a tumor within large volume of normal tissue.
FIG. 3 shows experimental schematics for optoacoustic monitoring of laser interstitial coagulation in real-time.
FIG. 4 shows optoacoustic pressure profiles recorded during coagulation of ex vivo canine liver at the laser power of 7 W for 6 minutes.
FIG. 5 shows optoacoustic pressure profiles recorded during coagulation of the canine liver at the laser power of 10 W.
FIG. 6 shows optoacoustic signals recorded from bovine liver samples before and after coagulation by microwave radiation.
FIG. 7 shows the optoacoustic signal amplitude measured in aqueous solution of potassium chromate as a function of temperature (circles), and the Grüuneisen coefficient theoretically calculated based on published thermomechanical properties of water (solid curve).
FIG. 8 shows the amplitude of optoacoustic pressure induced in freshly excised canine liver as a function of temperature during hyperthermia and coagulation.
FIG. 9 shows the amplitude of optoacoustic pressure induced in the canine liver as a function of temperature during hyperthermia between 36 and 50° C. without coagulation.
FIG. 10 shows optoacoustic pressure profiles recorded in real time from the normal and coagulated canine liver during coagulation.
FIG. 11 shows optical attenuation coefficients of the coagulated and normal canine liver as a function of temperature.
FIG. 12 shows the amplitude of optoacoustic pressure as a function of temperature during heating of freshly excised canine myocardium.
FIG. 13 shows a laser-induced pressure profile measured with an optoacoustic transducer from a chicken breast muscle slab covered with skin (solid curve) and the same tissues where the top layer of the muscle slab was coagulated (dashed curve).
DETAILED DESCRIPTION OF THE INVENTION
Laser optoacoustic imaging is an imaging technique recently proposed for medical diagnostics (screening). Laser optoacoustic imaging has potential to become an imaging technique with high contrast, sensitivity and resolution, and of moderate cost.
In the present invention, application of laser optoacoustic imaging is proposed for tissue physical properties monitoring during treatment in real time. Application of radiation, heating, or cooling induces changes in tissue temperature and optical and thermophysical properties. Optoacoustic technique is sensitive to changes in tissue temperature, optical properties (absorption, scattering and effective attenuation coefficient), and the following thermophysical parameters: Gruneisen coefficient, thermal expansion coefficient, speed of sound, and heat capacity at constant pressure.
In the present invention, laser interstitial coagulation is used for treatment of malignant tumors, which is based on heating of tumors by laser radiation resulting in coagulation and death of cancer cells. There is a need to monitor the degree of coagulation and the dimensions of the coagulation zone to avoid unwanted thermal damage to normal tissues surrounding the tumor.
The present invention demonstrates that optoacoustic signals measured in normal and coagulated tissues are different. In particular, the absorption and scattering coefficient of coagulated tissue is higher than that of normal tissue. Experiments were conducted demonstrating that the changes in the optical properties can be detected during laser coagulation in real time. This technique can be applied if any other type of radiation (microwave, radiofrequency, ultrasonic, etc.) is used for tissue heating. The invention can potentially be used for precise monitoring of interstitial coagulation of tumors in various organs such as breast, prostate, etc. It is proposed that laser optoacoustic can also be used for monitoring of interstitial coagulation during treatment of benign lesions. One of the most important applications is monitoring prostate tissue coagulation during treatment of benign prostatic hyperplasia.
Also disclosed in the present invention is laser optoacoustic monitoring of tissue temperature during hyperthermia. Hyperthermia has a great potential for treatment of malignant lesions in many organs. Temperature monitoring during these procedures is vital for successful treatment. Laser optoacoustic imaging is capable of non-invasive detection of 1° C. temperature change at the depth of up to several centimeters in some tissues. All the conventional imaging techniques fail to detect a temperature change at this depth in tissue.
Further disclosed in the present invention are applications of laser optoacoustic monitoring for other types of therapy. For example, cryotherapy is being widely used for treatment. There is a need to monitor dimensions of frozen zone during the cryotherapy to avoid unwanted damage to normal tissues. Optical and thermophysical properties of normal and frozen tissues are different providing high contrast in optoacoustic images. The movement of boundary between normal and frozen tissues should be clearly seen. Therefore, the optoacoustic monitoring can be used for monitoring physical properties of tissue during cryotherapy in real time.
Administration of drugs can change optical properties of tissue. For instance, application of photosensitizers for photodynamic therapy increases optical absorption coefficient of tissue. This can be used to study pharmacokinetics of the photosensitizers before, during, and after treatment.
Surgical tools have optical and acoustic properties substantially different from tissue properties. Along with optical contrast between normal and tumor tissue, it is possible to use this technique for navigation during surgery or biopsy.
In one embodiment of the present invention, there is provided a method of monitoring tissue properties in real time during treatment using an laser optoacoustic imaging system, comprising the steps of administering a treatment agent to the tissue and applying the optoacoustic imaging system to the treated tissue.
In a preferred embodiment, the tissue can be selected from various organs with tumors or other lesions. Representative organs which can be examined using this technique include liver, kidney, breast, prostate, brain, heart, eye and blood vessels. Alternatively, the tissue is from mucosa of a hollow organ, such as oral cavity, gastrointestinal tract, intestine, colon, rectum, bladder and vagina.
In another preferred embodiment, the tissue properties are referred to physical dimension, optical absorption, optical scattering, optical attenuation coefficient, temperature, thermal expansion coefficient, speed of sound or heat capacity. Specifically, the optical radiation is generated from a laser or non-laser source and is in the spectral range from about 0.2 μm to about 200 μm. More specifically, the optical radiation and optical pulses for imaging are delivered through the same fiber-optic delivery system. Still specifically, the electromagnetic radiation is in radiofrequency, or in microwave spectral range, or simply a X-ray radiation, or a gamma radiation.
In still another preferred embodiment, the treatment agent can be an optical radiation, an electromagnetic radiation, an ultrasonic radiation, an electrical current, heating, cooling, a drug or a surgical tool.
In another embodiment of the present invention, there is provided a system of monitoring tissue properties in real time during treatment, comprising a system for administering a treatment agent to the tissue; an optoacoustic imaging system for providing images; an exogenous molecular probe for reflecting the treatment; and a feed-back electronic system for adjusting parameters of the treatment agent.
The following examples are given for the purpose of illustrating various embodiments of the invention and are not meant to limit the present invention in any fashion.
EXAMPLE 1
Monitoring of Interstitial Coagulation of Tumors
Liver samples simulating tumors were placed between two pieces of chicken breast muscle tissue. Pulsed Nd:YAG laser radiation is used to obtain the image (see FIG. 1 ). A blood vessel in the chicken breast tissue is also visible. The data demonstrates capability of an optoacoustic technique to reconstruct images in tissue on the basis of the contract in optical and thermophysical properties between these two tissues. This allows monitoring of the tissue properties during treatment because application of a treatment agent (heating, freezing, etc.) will induce changes in optoacoustic images.
FIG. 2 demonstrates an example of utility for laser optoacoustic imaging in monitoring of tissue optical properties during coagulation of a breast tumor by a continuous wave laser radiation. An optical fiber is used to deliver interstitially the laser radiation to the tumor. The fiber can be introduced into the breast tissue using a needle. The needle can be removed from the breast before the continuous wave laser irradiation. The continuous wave irradiation results in coagulation and changes in optical properties of the irradiated volume of the tissue. To obtain optoacoustic images, the large volume of normal tissue is irradiated by laser pulses with short duration. The pulsed laser radiation penetrates sufficiently deep to heat the volume of the breast tissue with the tumor. Instant heating by short laser pulses produces acoustic (stress) wave with a profile resembling distribution of optoacoustic sources in the tissues. The laser-induced stress wave propagates to the normal tissue surface where it is detected by an acoustic transducer (or transducer array) with sufficient temporal resolution. The transducer signal resembling amplitude and temporal profile of the laser-induced stress wave is recorded via an interface to a computer for signal processing and image reconstruction. The optoacoustic images of the part of the breast with the tumor are displayed in real time. Changes in optical properties due to coagulation result in changes in the optoacoustic images. Dimensions of the coagulation zone are monitored during the continuous wave irradiation. The continuous wave irradiation is blocked, if the tumor is coagulated. This results in accurate coagulation of the tumor with minimal damage to normal breast tissues.
Similar procedures can be used for monitoring of physical properties during coagulation by other types of radiation (microwave, radiofrequency, ultrasonic radiation) as well as treatment by other treatment agents.
EXAMPLE 2
Scheme for Monitoring of Liver Coagulation in Real-time
An experimental scheme for optoacoustic monitoring of liver coagulation in real time is shown in FIG. 3 . Freshly excised liver was used in the experiments. Slabs with the dimensions of 50×50 mm were cut from the liver. Thickness of the slabs was varied from 20 to 30 mm. Continuous wave Nd:YAG laser was used to induce coagulation in the liver samples. The continuous wave laser radiation was delivered through a quartz fiber with a specially designed diffusing tip with the length of 25 mm. The diffusing tip scattered radiation in 360° resulting in uniform distribution with cylindrical symmetry. The diffusing tip was introduced into the samples through a needle which was removed from the liver before continuous wave irradiation. Such a scheme allowed coagulation only of a central part of the samples. A Q-switched Nd:YAG laser (pulse duration −14 ns) was employed for optoacoustic wave generation. The pulsed laser radiation was delivered from above with the use of a prism. Energy of incident laser pulses was 15 mJ. Laser beam diameter was 6 mm providing incident laser fluence of 53 mJ/cm 2 . The pulsed laser radiation with such parameters induced insignificant temperature rise less than 10 −3 ° C. in the samples. A specially designed sensitive (2.5 V/mbar) acoustic transducers was used to detect optoacoustic pressure waves in a wide spectral range. The samples were placed on the transducer. Data acquisition was performed each 30 s during 1 s. Repetition rate of the pulsed laser radiation was 10 Hz and allowed averaging of 10 pressure wave profiles during this time. The pressure profiles were recorded by a digital scope and stored with a computer.
EXAMPLE 3
Pressure Profiles during Laser Power Induced Coagulation of Liver Tissue
Pressure profiles recorded during coagulation of canine liver at the laser power of 7 W for 6 minutes are shown in FIG. 4 . The first pulse in the profiles was caused by generation of pressure in the acoustic transducer and indicated position of its surface. The pressure profile represents distribution of absorbed pulsed laser energy in the sample. The second pulse was induced in blood accumulated around the diffusing tip after the liver perforation. This pulse indicated the diffusing tip position. The sharp edge at 14 μs represents the position of the irradiated air-liver interface. It is clearly seen that the profiles change during continuous wave irradiation that indicates changes in optical properties in the sample. The formation of a sharp edge occurs between 8 and 11 μs during continuous wave irradiation. The delay between the edge and the signal from the diffusing tip is equal to 4.5 μs at the irradiation time of 6 min. One can calculate the distance between the diffusing tip and the edge by multiplying 4.5 μs by speed of sound. The speed of sound measured in the normal and coagulated samples is 1.52 and 1.54 mm/μs, respectively. The calculated value of 6.9 mm is in good agreement with the coagulation zone diameter of 7.0 mm measured after the experiment.
Pressure profiles upon continuous wave irradiation with the laser power of 10 W were also recorded and are shown in FIG. 5 . The upper profile is measured from a liver sample before the continuous wave irradiation. The lower profile is recorded after 1.5 min. of continuous wave irradiation. The changes in the profile indicates coagulation of the liver tissue near the diffusing tip.
EXAMPLE 4
Monitoring of Microwave Radiation Induced Liver Coagulation
Pulsed Nd:YAG laser radiation with the wavelength of 1064 nm was used to generate the thermoelastic pressure waves. No continuous wave laser radiation was applied to the samples. Optoacoustic signals recorded from bovine liver samples before and after coagulation by microwave radiation for 1 min. (see FIG. 6 ). There is a noticeable difference between these two signals. The pressure amplitude detected from the coagulated tissue is higher than the one recorded from the normal tissue. In addition, the exponential slope for the coagulated tissue is sharper in comparison with the one for the normal one. This indicates that both the absorption and the attenuation coefficient of coagulated tissue is substantially higher than that of the normal one.
Table 1 contains values of optical properties of normal and coagulated liver calculated from experimentally measured pressure profiles. The absorption coefficient of the coagulated tissue is about 2 time higher than that of the normal one. The value of the scattering coefficient increases 2.4 times due to coagulation. The changes in the absorption and scattering coefficients result in 2.2-fold increase of the attenuation coefficient.
TABLE 1
Normal
Coagulated
Optical Property
Liver
Liver
Absorption coefficient (cm −1 )
0.42
0.82
Scattering coefficient (cm −1 )
6.35
15.3
Attenuation coefficient (cm −1 )
2.92
6.3
The increase in the attenuation coefficient yields stronger attenuation of Nd:YAG laser radiation in the coagulated zone. This means that this radiation cannot deeply penetrate into the coagulated tissue and that laser fluence in the coagulated zone is substantially lower. Since generated thermoelastic pressure is proportional to the laser fluence, the pressure detected from the coagulated zone is lower than the pressure detected before coagulation from the same zone. This results in the optoacoustic contrast between normal and coagulated tissues.
EXAMPLE 5
Monitoring of Temperature in Aqueous Medium
The optoacoustic signal amplitude was obtained as a function of temperature measured in aqueous solution of potassium chromate (circles), and the Grüineisen coefficient theoretically calculated based on published thermomechanical properties of water (solid curve) (see FIG. 7 ). This experiment was performed to demonstrate capability of the laser optoacoustic monitoring technique to measure absolute temperature in aqueous medium. The water solution of potassium chromate was chosen for experiments because optical properties of this solution are not affected by the temperature variations. Therefore, only the Grüneisen coefficient, Γ=βC S 2 /C P , was influenced by the temperature changes. Thermomechanical properties of the solution, such as β(T), the thermoelastic expansion coefficient; C S (T), the speed of sound; and C P (T), the heat capacity at constant pressure, are the temperature dependent factors. Laser irradiation wavelength was 355 nm. The temperature rise resulted from laser irradiation was insignificant compared with the base temperature of the solution. A piezoceramic transducer with a 40 MHz bandwidth was used for detection of pressure profiles. The exponential slope of the measured optoacoustic signals was defined by the optical absorption coefficient and was found to be independent on the temperature. Good correlation between theoretical curve and experimental data is evident that temperature measurements in biological tissues may be performed at temperatures below the level of protein coagulation. At temperatures below 54° C. coagulation does not occur and therefore, the changes in the optoacoustic signal amplitude associated with changes in tissue optical properties may be excluded from the consideration.
EXAMPLE 6
Monitoring of Tissue Temperature Change during Hyperthermia
Amplitude of optoacoustic pressure induced in freshly excised canine liver during hyperthermia and coagulation was measured and shown to be temperature dependent (see FIG. 8 ). The measurements were performed in real time during heating and cooling of the tissue. The tissue was heated by hot air for 30 min. To avoid desiccation, the tissue was covered by a plastic film. It is clearly seen that the amplitude is increasing linearly with the increase of the temperature from 22 to about 54° C. Changes in optical properties induced by coagulation result in the sharp increase of the pressure amplitude at the temperature above 52° C. Subsequent cooling leads to gradual decrease of pressure amplitude.
Amplitude of optoacoustic pressure induced in the canine liver during hyperthermia between 36 and 54° C. without coagulation was also measured (see FIG. 9 ). The data shows that the amplitude of optoacoustic pressure was also temperature dependent. The relative increase in pressure amplitude amounts approximately 1.5% per 1° C. that results in about 9% pressure amplitude increase if the liver is heated from 36 to 54° C. This temperature rise is normally applied for hyperthermia. These results indicate that by detecting the pressure wave amplitude with sufficient accuracy, one can monitor temperature rise in tissues. The accuracy of temperature measurements was about 3% in this experiment and was limited by instability of laser energy (10%). Current laser systems with stabilized pulse energy available on the market have 1%-stability, therefore the accuracy of temperature measurement of about 0.3% can be achieved. The increase of pressure amplitude with the increase of temperature is noticeable and substantially greater than changes in acoustic properties (speed of sound and density) and chemical content of the tissue. This results in exceptional contrast of optoacoustic images compared with the contrast of ultrasound and MRI images.
EXAMPLE 7
Comparison of Tissue Properties between Normal and Coagulated Liver Tissue
Optoacoustic pressure profiles from the normal and coagulated canine liver were recorded (see FIG. 10 ). Pressure profiles recorded from coagulated liver differ dramatically from those recorded from the normal liver. Due to an increase i n attenuation coefficient, the profiles recorded from the coagulated tissue were substantially sharper than the profiles recorded from the normal one.
The optical attenuation coefficient of the coagulated and normal canine liver was shown to be temperature dependent (see FIG. 11 ). The attenuation coefficient of coagulated tissue at the temperature of about 70° C. was 4 times greater than the one of normal liver at this heating conditions. Data analysis indicates that these changes are due to approximately 4-fold increase of absorption and scattering coefficient of the liver induced by coagulation. These results explain formation of the sharp edge in the detected pressure profiles. The edge is caused by strong attenuation of laser radiation in the coagulated zone. The movement of the edge from the diffusing tip indicates an increase of coagulation zone dimensions during continuous wave laser irradiation.
EXAMPLE 8
Monitoring of Myocardium Coagulation during Heating
The amplitude of optoacoustic pressure was measured in real time from freshly excised canine myocardium during heating by hot air for 30 min. (see FIG. 12 ). The data shows that the amplitude is temperature dependent. To avoid desiccation, the tissue was covered by a thin plastic film. The pressure amplitude was shown to increase linearly with the increase of the temperature from 26° C. to about 55° C. Changes in optical properties induced by coagulation resulted in a sharp increase of the pressure amplitude at the temperature above 55° C. Optical attenuation coefficients of normal and coagulated myocardium calculated from pressure profiles equal 3.32 cm −1 and 4.29 cm −1 , respectively. These data demonstrate that real-time measurements of pressure amplitude and attenuation coefficient can be used for monitoring myocardium coagulation.
EXAMPLE 9
Laser-Induced Pressure Profile Measured with an Optoacoustic Transducer
A laser-induced pressure profile was measured with an optoacoustic transducer from a chicken breast muscle slab covered with skin (solid curve) and the same tissues where the top layer of the muscle slab was coagulated (dashed curve) (see FIG. 13 ). Laser irradiation wavelength was 532 nm. Lithium niobate front-surface optoacoustic transducer with a 100 MHz bandwidth was used for detection of pressure profiles.
The optoacoustic profile was first measured in a fresh chicken breast muscle covered with skin. The measured optoacoustic signal shows two layers: skin and muscle tissues. The optical absorption of chicken breast is slightly higher than that of the chicken skin. This allows optoacoustic imaging of the two layers. Acoustic diffraction that occurs in the prism of the optoacoustic transducer converts the intrinsic signal into its derivative. That is why originally positive pressure signals were measured as bipolar signals.
The top layer of the breast muscle was then placed for 1 minute in water heated to 100° C., and therefore, coagulated. The protein coagulation process dramatically increased tissue optical scattering. The increased tissue scattering resulted in enhanced amplitude of the measured optoacoustic signal. Three layers of optoacoustically different tissue can be detected after coagulation. The optoacoustic signal amplitude sharply increased at the boundary between skin and coagulated chicken breast. The optoacoustic signal amplitude decreased at the boundary between coagulated and normal chicken breast. The thickness of the top layer of skin and the coagulated layer can be measured from the presented profiles with a 30-μm accuracy. The result demonstrates capability of the optoacoustic imaging system to monitor tissue coagulation zone with the accuracy of tens of microns.
Discussion
The obtained results demonstrate that the optoacoustic technique can be successfully applied for monitoring of interstitial tissue temperature and coagulation in real time. The optoacoustic technique has such advantages compared with conventional imaging techniques as: (1) high contrast, (2) high sensitivity, (3) moderate cost, (4) minimal invasiveness, (5) capability of monitoring in real time. Currently investigated optical imaging techniques based on contrast in optical properties can also provide high contrast. However, they are not capable of monitoring tissue optical properties at the depth of the order of centimeters.
The following references were referred to herein.
1. Kruger, R. A. U.S. Pat. No. 5,713,356.
2. Tauc, J., et. al. U.S. Pat. No. 4,710,030.
3. Bowen, T. U.S. Pat. No. 4,385,634.
4. Oraevsky, A. A., et al., In: “Advances in Optical Imaging and Photon Migration”, vol. 21, ed. by Robert R. Alfano, Academic Press, 1994, pp.161-165.
5. Thomsen, S., et al., SPIE Proc. 1994, v. 2134, pp. 106-113.
6. Oraevsky A. A., et al., SPIE Proc. 1994, v. 2134, pp. 122-128.
7. Motamedi M., et al., Laser Surg. Med., 1995, v. 17, pp. 49-58.
8. Oraevsky A. A., et al., SPIE Proc. 1995, v. 2389, pp. 198-208.
9. Agah, et al., IEEE Trans. Biomed. Eng. 1996, 43 (8), pp. 839-846.
10. Oraevsky A. A., et al., SPIE Proc. 1996, v. 2676, pp. 22-31.
11. Esenaliev R. O., et al., SPIE Proc. 1996, v. 2676, pp. 84-90.
12. Oraevsky A. A., et al., In: “Trends in Optics and Photonics”, 1996, vol. II, ed. by R R Alfano and J G Fujimoto, OSA Publishing House, pp. 316-321.
13. Kim B., et al., IEEE J. Quant. Electr., 1996, v. 2 (4), pp. 922-933.
14. Karabutov A. A., et al., Appl. Phys. B, 1996, v.63, pp.545-563.
15. Oraevsky A. et al., Applied Optics, 1997, v. 36 (1), pp. 402-415.
16. Oraevsky A. A., et al., SPIE Proc. 1997, v. 2979, pp. 59-70.
17. Esenaliev R. O., et al., SPIE Proc. 1997, v. 2979, pp. 71-82.
18. Esenaliev R. O., et al., SPIE Proc. 1998, v. 3254, pp. 294-301.
Any patents or publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. These patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The present examples along with the methods, procedures, treatments described herein are presently representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention as defined by the scope of the claims. | The present invention is directed to a method/system of for monitoring tissue properties in real time during treatment using optoacoustic imaging system. Optoacoustic monitoring provides a control of the extent of abnormal tissue damage and assures minimal damage to surrounding normal tissues. Such technique can be applied for monitoring and controlling during surgical, therapeutic, and cosmetic procedures performed in various tissues and organs. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a system for washing elongated objects. More particularly, it relates to a system for washing sticks or rods which have been used for cooking and/or chilling food products.
[0005] 2. Background of the Art
[0006] In the processed meats industry, products such as hotdogs and sausages are typically suspended in link form from stainless steel sticks or rods for cooking and chilling. The sticks are usually three to four feet long and are either tubular or have a V-shaped cross-section. Following removal of the product from the sticks, the sticks must be cleaned before being reused.
[0007] Typically, such sticks are cleaned using large drum-type washing machines. Such washers usually consist of a round or octagonal shaped drum with a side access door. The drum can be supported in a vessel by a drive shaft. The sticks are manually placed in the drum and the drum is rotated in a cleaning solution. This produces some tumbling action between the sticks but tends to confine and block cleaning solution from effectively penetrating the core of the stick load in the drum. Further, the sticks with the V-shaped cross-section are prone to bunching and nesting which limits any mixing or migration of the sticks through the drum. Also, cleaning solution must be dumped after the wash cycle to allow refilling the unit with rinse water.
[0008] Another prior art apparatus for treating rods and pipes is disclosed in J. Moltrup, U.S. Pat. No. 1,393,633. The system disclosed in this patent includes a machine divided into separate pickling and washing compartments. The rods are organized into bundles or bunches and each bundle is inserted into a carrier. The carriers are placed on a runway which conveys the carrier into each compartment. As each carrier reaches the lower end of the runway, it is caught by a conveyor with flights and conveyed out of the first compartment. The carrier is passed through subsequent compartments, each with its own conveyor. One drawback of this system is the need for multiple conveyor assemblies. Another problem is that the rods must be placed in individual carriers and must be moved therefrom after exiting the apparatus. Also, there is no provision in the individual carriers for insuring that the rods and sticks are well mixed.
[0009] Another washing apparatus is disclosed in W. Morgan, U.S. Pat. No. 1,751,838. This apparatus is used for preparing cane stalks. The cleaning tank is provided with a hopper having inclined ends which direct the cane stalks onto a looped-shaped conveyor located adjacent to the bottom of the hopper. Another conveyor which shares a shaft with the loop-shaped conveyor conveys the cane stalks out of the hopper. Each of the conveyors is provided with a series of fingers which positively moves the cane stalks from the infeed of the hopper to the outfeed of the hopper. Like the previously described prior art washer, this system requires multiple conveyors. Another drawback of this system is that the cane stalks can short circuit the desired tumbling action in the circular conveyor by being removed too soon by the outfeed conveyor.
[0010] Another washing apparatus is disclosed in Ransley et al., U.S. Pat. No. 5,778,907, which is assigned to the assignee of the present invention and hereby incorporated by reference as though fully set forth herein. This patent discloses a conveyor washer specifically designed to improve the efficiency of washing the sticks or rods used by the food processing industry. Here, two conveyors are used, each with two spaced apart continuous loop chains. An infeed conveyor slopes down from one end of the tank toward the bottom of the tank where an outfeed conveyor slopes upwardly toward the other end of the tank. The conveyors run simultaneously and are positioned at a prescribed included angle so that the infeed conveyor drives the pile of sticks toward the outfeed conveyor which has pusher flights that carrying the sticks upward individually. A flip back plate strips the sticks from the outfeed conveyor so that the objects circulate in the wash tank. When the wash cycle is complete, the flip back plate can be retracted so the sticks can be conveyed by the outfeed conveyor to a rinse tank. This system provides for efficient loading and unloading of the sticks as well as promotes effectively cleaning by separating and recirculating the sticks during the wash cycle. However, the disclosed system requires two separate conveyors, like the other prior art washers described above, and must be placed relative to each other at the proper angle. If the angle is too large, the infeed conveyor will not effectively deliver the sticks to the outfeed conveyor and if the angle is to small the sticks may become lodged and jam one or both of the conveyors, particularly since the infeed and outfeed conveyors act on the stick pile in opposite directions. This two conveyor system thus adds to the complexity, cost and maintenance of the washer.
SUMMARY OF THE INVENTION
[0011] The present invention provides a washing system that effectively cleans elongated objects without the stagnant zones common in the prior art. It provides efficient loading and unloading of the elongated objects and allows the cleaning solution to be reused for subsequent loads. The present invention provides such a system with reduced cost and complexity compared to multi-conveyor systems.
[0012] In particular, one aspect of the present invention provides an apparatus for cleaning elongated objects having a cleaning tank, of the size necessary to hold the elongated objects in a cleaning solution, defining a feed end and an exit end formed by a top, a bottom and side walls and containing a back stop and an inclined conveyor. The back stop is mounted inside the tank at the feed end and extends in the direction between the top and bottom of the tank. The conveyor is mounted inside the tank with its lower end adjacent the back stop and so it slopes upwardly in the direction from the tank bottom to the exit end so as to convey the elongated objects from the feed end to the exit end.
[0013] During a cleaning cycle several elongated objects are loaded into the tank. The elongated objects pile up between the back stop and the conveyor. The conveyor strips off the lower, adjacent layer of elongated objects in the pile one at a time and circulates them through the cleaning solution. The elongated objects are thus pulled from the bottom side of the pile and returned to the top side. While piled and as they are beginning up the conveyor, a jet manifold provides a pressure spray that agitates and cleans the elongated objects. The weight of the pile holds the sprayed elongated objects down somewhat so that a forceful spray can be directed at the elongated objects without them being pushed away from the conveyor. While the true dynamics of the pile of elongated objects is somewhat unclear, the inventors have realized that it is important for the elongated objects to pile up as well as be circulated from bottom to top of the pile in order to achieve proper cleaning. The angle of incline of the conveyor and the included angle between the conveyor and the back stop are critical to avoid pockets of stagnation and achieve proper circulation of all the elongated objects.
[0014] Preferably, the back stop is essentially perpendicular and the conveyor is essentially at a 45° angle to the tank bottom. The back stop and conveyor thus extend along intersecting planes defining an angular section therebetween. Preferably, the included angle is between about 35° to about 60°, or more preferably of about 40° to about 50°, and even more preferably of about 45°, with the small angle between the conveyor and the tank bottom being preferably no less than 35°.
[0015] In other preferred forms, the tank includes separate wash and rinse basins and utilizes a single overflow sump, disposed between the basins, to limit disparate maximum water levels in each. A load ramp is mounted inside the tank at the feed end and slopes downwardly so that objects can readily slide down between the back stop and the conveyor. The conveyor itself preferably has two spaced apart chains. The chains include sets of aligned pusher flights extending from the conveyor at an angle. A flip back plate is mounted between the chains of the conveyor and is movable between a retracted position and an extended position. In the extended position, the plate is above the conveyor, and preferably, above a maximum fill level of the cleaning solution, which is regulated by an overflow.
[0016] In another aspect the invention provides a method of cleaning elongated objects comprising: feeding the elongated objects to the above described apparatus; operating the conveyor with the plate in the extended position for a predetermined time; and delivering the elongated objects to a rinse tank at the exit end of the tank by placing the plate in the retracted position; and removing the elongated objects from the rinse tank.
[0017] The objects and advantages of the present invention will be apparent from the description which follows. The following description is merely of a preferred embodiment. Thus, the claims should be looked to in order to understand the full scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a side elevational view of the single conveyor washer apparatus according to the present invention;
[0019] FIG. 2 is a top plan view thereof;
[0020] FIG. 3 is another side elevational view thereof opposite the side shown in FIG. 1 ;
[0021] FIG. 4 is an exit end view thereof;
[0022] FIG. 5 is a typical longitudinal cross-sectional view thereof;
[0023] FIG. 6 is a partial cross-sectional view thereof taken along the line 6 - 6 of FIG. 5 ;
[0024] FIG. 7 is a fragmentary enlarged detail of the flip back plate assembly; and
[0025] FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] The present invention provides an apparatus and method of washing elongated objects, such as tubular and V-shaped food processing sticks, that is an improvement over the drum and multi-conveyor type machines of the prior art. The washer of the present invention can clean and rinse the objects as well as or better than prior art machines with less complex sub-assemblies, thereby saving cost and reducing maintenance.
[0027] Referring to FIGS. 1-5 , in this washer 10 , a tank vessel 12 defining a top, a bottom and side walls, in general constructed of 304 stainless steel, contains a single conveyor 14 that circulates the elongated objects (“sticks”) 16 loaded into the vessel 12 from an open feed end 18 within a wash basin 20 for a period of time before carrying the objects to a shallower rinse basin 22 at an open exit end 24 . The opening at the exit end 24 is preferably shielded by a strip curtain 25 depending from the top of the vessel 12 to retain heat and steam during the wash and rinse cycles. If desired, a second curtain (not shown) could be similarly mounted at the feed end 18 . The vessel 12 is designed to accommodate sticks 16 having a typical length of 36-48 inches long. However, the apparatus can be modified in obvious ways to accommodate sticks of any size. The top of the washer 10 is equipped with a cover 26 which may be removed for easy access to the internals of the vessel 12 . The level of the cleaning solution in the wash basin 20 and the level of rinse water in the rinse basin 22 is maintained by respective wash 28 and rinse 30 fill nozzles and an overflow sump 32 formed between the basins 20 and 22 and drained through a drain 34 leading to an exterior drain (not shown). If desired, the wash basin 20 may be drained via drain 36 (see FIG. 2 ). Sticks 16 are discharged into the rinse basin 22 by falling off the conveyor 14 and onto a rinse rack 40 , which sits on the bottom of the rinse basin 22 . The rinse basin has a drain 42 at its bottom. A removable perforated stainless steel filter 44 is disposed inside of a box 46 at the exterior feed end of the vessel 12 . The interior of the box 46 is in communication with the interior of the wash basin 20 by a triangular cut out in the side of the vessel 12 . The filtered water is then pumped back into the wash basin 20 via line 48 . The filter 44 can be accessed for cleaning via removable lid 50 , and the box 46 can be drained by opening drain valve 52 . The filter 44 and the bottoms of the box 46 and the wash basin 20 are sloped to facilitate filtering and draining, respectively. Also, the bottoms of the rinse basin 22 and the overflow sump 32 are also sloped toward their respective drains.
[0028] Referring to FIGS. 5 and 8 , proper agitation and circulation of the objects 16 using only a single conveyor 14 is facilitated by a planar back stop 54 extending within the wash basin 20 . The back stop 54 is preferably formed of a single stainless steel panel that bends to also define a load ramp 56 , sloping downwardly at about a 45° angle from the open feed end of the vessel 12 to facilitate loading of the sticks 16 . Below the bend, the back stop 54 extends straight down to be essentially vertical and perpendicular to the bottom of the vessel 12 . The back stop 54 has a cut-out bottom side through which the lower end of the conveyor 14 protrudes.
[0029] Referring to FIGS. 1, 5 and 6 , the conveyor 14 includes a set of two closed loop conveyor chains 58 spaced apart and installed around sprockets 60 preferably mounted via adjustable bearings to a drive 62 and follower 64 conveyor shafts. The conveyor chains 58 are preferably polymeric but may be any acceptable material which is compatible with the cleaning solution. Each chain 58 has pusher flights 66 which act to engage the sticks 16 and both circulate them within the cleaning solution in the wash basin 20 and move them one at a time from the wash basin 20 to the rinse basin 22 . Each chain 58 is supported by a channel 68 which is in turn supported by an angle member 70 and a jet manifold 72 , which is part of the liquid circulation system described below. The channels 68 preferably include one or more slots or openings 69 for the cleaning solution to pass through. If necessary, an adjustable tensioner (not shown) can be included for each chain. Such tensioners can be in the form of spring loaded arms with a roller in contact with its respective chain, or the tensioners can have adjustable arms secured with a nut and bolt, as is known in the art. The conveyor 14 is propelled by applying power to the drive shaft 62 via motor 74 (see FIG. 2 ) mounted at the exterior of the vessel 12 , which preferably has a variable speed so that the conveyor speed may be adjusted to suit the particular washing application. Operation of the motor 74 is controlled by a logic controller (not shown) contained in an electronics cabinet 76 mounted to the exterior of the vessel 12 (see FIGS. 2 and 4 ). The control cabinet 76 houses other the electrical components associated with the conveyor shaft motor, a pump motor and other electrical subsystems.
[0030] The conveyor shafts are preferably arranged so that the plane of the conveyor 14 and the back stop 54 form an angular section having an included angle of about 35° to about 60°. More preferred is an angle at or about has an angle of about 45°. And, preferably the conveyor 14 is about 35° to 50° degrees from the horizon, or the bottom of the vessel 12 , the most preferred being about 45°. When the included angle between the back stop 54 and the conveyor 14 is significantly less than about 45°, the space for the stick pile is reduced thereby, not only making the pile smaller, but also making it narrower and taller and therefore less suitable for circulating the sticks properly. When the included angle is significantly more than about 45°, then the pile flattens too much and can cause the sticks to at the back of the pile (near the back stop 54 ) to stagnate rather than be circulated by the conveyor. Also, the reduction in depth of the stick pile diminishes the ability of the pile to hold the sticks on the conveyor against the force of the water from the jet manifold. Furthermore, the flattened stick pile may begin to move up the conveyor 14 collectively, rather than as individual sticks, thereby causing erratic mixing of the sticks and potential jamming at the flip back plate 78 . When the angle of inclination of the conveyor 14 is significantly less than about 45°, such as below 35°, the sticks ejected from the conveyor 14 by the flip back plate 78 may fall short and land on the conveyor 14 rather than at the back of the pile as preferred, thus also causing erratic circulation and cleaning of the sticks.
[0031] Previously, it was thought that a separate infeed feed conveyor was necessary to pull the sticks 16 ejected from the conveyor 14 by the flip back plate 78 down toward the bottom the pile to ensure the sticks did not stagnate at the top of the pile. However, the inventors of the present invention have determined through empirical study that proper circulation of the sticks 16 could be achieved using only a single conveyor in combination with the back stop 54 of the disclosed configuration and location such that all of the sticks 16 could be adequately de-nested and cycled through the cleaning solution prior to rinsing.
[0032] Referring now to FIGS. 5-7 , a movable flip back plate 78 is used to eject the sticks from the conveyor 14 during the washing cycle. The flip back plate 78 has a bent upper lip 80 to prevent the sticks 16 from riding up over the flip back plate 78 . The flip back plate 78 is mounted via linkage to a flip back plate shaft 82 , which is bounded by the chains 58 of the conveyor 14 . Specifically, a handle 84 is fixedly connected to a crank arm 86 which is in turn pivotally connected to a connecting link 88 fixedly attached the flip back plate 78 . Rotating the handle 84 (clockwise in FIG. 7 ) until the arm 86 hits angle 70 moves the flip back plate 78 to the extended position in which it protrudes above an upper plane formed by the chains 58 of the conveyor 14 . In this position, the pivot point of the arm 86 and the arm 88 is located above a centerline 91 connecting the axis of the flip back plate shaft 82 and the pivot axis of the handle 84 such that the arm 86 and link 88 resist incidental retraction of the flip back plate 78 from contact with the sticks 16 . In the retracted position, in which further rotation is prevented by contact of an upper part of the flip back plate 78 against angle 70 , the flip back plate 78 is just below the upper plane of the conveyor chains 58 . A lower bent down edge 89 is welded to another shaft 93 rotatably mounted to the conveyor support frame. The angle between the pusher flights 66 and the extended flip back plate 78 can be of any size as long as the sticks can be efficiently peeled off the conveyor 14 without the sticks hopping over the flip back plate 78 . Preferably, the flip back plate 78 is essentially vertical when deployed and the face of the pusher flight 66 is beveled at about 30° so that the included angle is about 75°. These parameters have been determined to provide suitable operation without jamming of the sticks.
[0033] Referring again to FIGS. 1 and 2 , the circulation system of the washer 10 includes a pump 90 located in the dry part of the vessel 12 beneath the bottom wall of the rinse basin 22 . The pump 90 is connected by the suction line 48 to the exit of the strainer box 46 and by a discharge line 92 to the elongated jet manifold 72 . The jet manifold 72 is bounded by the conveyor chains 58 and has a plurality of openings directed at the angular section between the conveyor 14 and the back stop 54 . The jet manifold 72 directly impinges the cleaning solution near the lower adjacent side of the stick pile. Directing the jetstream near the bottom sticks provides for more effective cleaning because the weight of the pile of sticks holds the sticks against the force of the spray thereby allowing them to be sprayed forcefully without being pushed away from the conveyor.
[0034] Referring to FIGS. 2-4 , a thermometer (not shown) is provided on the side of the vessel 12 which directly measures the temperature of the cleaning solution in the wash basin 20 . Temperature control of the cleaning solution is accomplished by thermowell 102 which is operably connected to steam regulator 104 . When the temperature of the cleaning solution falls below the desired set point, the steam regulator 104 will open allowing steam to be introduced into a steam mixer 106 mounted inside the vessel 12 and thereby heat the cleaning solution.
[0035] In use, the sticks 16 are loaded into vessel 12 through the open feed end 18 . If not already done, the wash 20 and rinse 22 basins are filled with water and liquid cleanser is injected into the wash basin 20 through an injection port in a side wall of the vessel 12 . Based on the temperature of the water, steam may also be injected into the wash basin 20 . During operation of a wash cycle, the conveyor motor 74 is energized to turn the chains 58 . The pusher flights 66 on the chains 58 pull sticks 16 off the bottom of the pile and conveys them upwards until they reach the flip back plate 78 , which is placed in the extended position by manually rotating the handle 84 . The extended flip back plate 78 peels the sticks 16 off the conveyor 14 and directs them back through the cleansing solution toward the back stop 54 and to the top of the pile of sticks 16 between the back stop 54 and the conveyer 14 . The shearing action at the bottom of the pile tends to separate and de-nest the sticks. At the end of the timed wash cycle, the flip back plate 78 is retracted, by rotating the handle 84 in the opposite direction, and the sticks are conveyed out of the wash basin 20 by the conveyor 14 into the rinse basin 22 . When all of the sticks have been transferred from the wash basin 20 , the conveyor 14 is stopped. The washed and rinsed sticks are then removed from the vessel 12 by lifting the rinse rack 40 through the open exit end 24 . Preferably, the cleaning solution is saved for the next batch of sticks. Overflowing wash or rinse water exits the vessel through the overflow sump 32 and out through its drain. Preferably, the wash basin 20 is topped up with water and possibly additional cleanser and the rinse basin 22 is drained and refilled prior to the next wash cycle.
[0036] An illustrative embodiment of the present invention has been described above in detail. However, the invention should not be limited to the described embodiment since many modifications and variations to the preferred embodiment, apparent to those skilled in the art, will be within the spirit and scope of the invention. For example, the washer could be supplied with an inlet hopper and inlet hopper door assembly (not shown) to better facilitate loading of the sticks. Also, the washer preferably includes a close out assembly having plates mounted to the vessel so as to close off the space between the chains of the conveyor to reduce the likelihood for sticks passing between the chains and beneath the conveyor. Therefore, to ascertain the full scope of the invention, the following claims should be referenced. | A system for cleaning elongated objects uses a single inclined conveyor with a lower end adjacent a back stop disposed inside a tank containing cleaning solution. The elongated objects pile up between the back stop and the conveyor and a jet manifold sprays a lower side of the pile where pusher flights on the conveyor pick off the objects one at a time. A flip back plate strips the objects from the conveyor to continuously circulate the objects in the cleaning solution from the bottom to the top of the pile. The plate is retracted to allow the conveyor to deliver the objects to a rinse water basin where the clean objects are rinsed and then removed. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of International Patent Application No. PCT/US2016/032292 filed on May 13, 2016 entitled “Synthetic tissue structures for electrosurgical training and simulation” which claims priority to and benefit of U.S. Provisional Patent Application No. 62/161,322 filed on May 14, 2015 entitled “Synthetic tissue for electrosurgical training and simulation”, and U.S. Provisional Patent Application No. 62/257,877 filed on Nov. 20, 2015 entitled “Synthetic tissue training for electrosurgical training and simulation” all of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
[0002] This application relates to synthetic tissue for practicing electrosurgical procedures and, in particular, to conductive synthetic tissue material made from a cross-linked hydrogel and methods of manufacturing such material and synthetic tissue models.
BACKGROUND OF THE INVENTION
[0003] Advances in technology have led to an increased use of energy devices in surgical procedures. There is a need for synthetic tissue that closely resembles the response of human tissue to electrosurgery. The synthetic tissue would be advantageous to surgeons and residents for training purposes. The synthetic tissue requires several characteristics to closely resemble human tissue including the ability to be cauterized, cut, and fused when manipulated with energy devices. Additionally, the tissue needs to emulate the mechanical properties of real tissue such as elasticity, toughness, suturability, tactility, color and texture. Furthermore, the material needs to be moldable into a structure that mimics various human organs or membranes for simulating human anatomy. The synthetic tissue may also need to be bondable to a variety of thermoplastics and silicones. The present invention addresses these needs.
SUMMARY OF THE INVENTION
[0004] According to one aspect of the invention, a surgical simulator for surgical training is provided. The surgical simulator includes a synthetic tissue structure formed at least in part of a hydrogel including an ionically cross-linked alginate network cross-linked with a covalently cross-linked acrylamide network. The synthetic tissue structure includes at least one of an artificial liver or artificial gallbladder. The at least one of the artificial liver or artificial gallbladder includes at least one lumen substantially formed of a hydrogel including an ionically cross-linked alginate network cross-linked with a covalently cross-linked acrylamide network.
[0005] According to another aspect of the invention, a surgical simulator for surgical training is provided. The surgical simulator includes a synthetic tissue structure substantially formed of a hydrogel including an ionically cross-linked alginate network cross-linked with a covalently cross-linked acrylamide network. The synthetic tissue structure includes a first layer formed of the hydrogel having a first ratio of acrylamide to alginate by weight and a second layer formed of the hydrogel having a second ratio of acrylamide to alginate by weight. The second layer is adjacent to the first layer.
[0006] According to another aspect of the invention, a surgical simulator for surgical training is provided. The surgical simulator includes a simulated organ model. The simulated organ model includes a first tube having an outer surface and an inner surface defining a first lumen. The first tube is made of a hydrogel comprising a dual interpenetrated network of ionically cross-linked alginate and covalently cross-linked acrylamide having a first ratio of acrylamide to alginate. The simulated organ model includes a second tube having an outer surface and an inner surface defining a second lumen. The second tube is made of a hydrogel comprising a dual interpenetrated network of ionically cross-linked alginate and covalently cross-linked acrylamide having a second ratio of acrylamide to alginate. The first tube is coaxially located inside the second lumen such that the outer surface of the first tube is in contact with the inner surface of the second tube.
[0007] According to another aspect of the invention, a method of making a surgical simulator for the practice of electrosurgical techniques is provided. The method includes the steps of providing an acrylamide polymer, providing alginate polymer, providing water, mixing the water with the acrylamide and alginate to form a solution, adding ammonium persulfate to the solution, adding N,N-methylenebisacrylamide to the solution, adding calcium sulfate after the steps of adding ammonium persulfate and adding N,N-methylenebisacrylamide to the solution, casting the solution into a shape representative of an anatomical structure, and curing the solution to form a simulated electrosurgery model made of hydrogel for practicing and simulating electrosurgery.
[0008] According to another aspect of the invention, a method of making a surgical simulator for the practice of electrosurgical techniques is provided. The method includes the step of providing an uncured hydrogel including an ionically cross-linked alginate network cross-linked with a covalently cross-linked acrylamide network. The method includes the step of providing a polymer bag, pouring the uncured hydrogel into the polymer bag, sealing the polymer bag, curing the uncured hydrogel inside the polymer bag to form a cured hydrogel, and removing the cured hydrogel. The resulting structure is substantially planar sheet of hydrogel that can be used in building a larger procedural-based surgical training model.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is an exploded, top perspective view of an organ model according to the present invention.
[0010] FIG. 2 is a side, cross-sectional view of a rectum model with a simulated prostate system according to the present invention.
[0011] FIG. 3A is posterior, partial, cross-sectional view of two collagen layers located between a second tube and a third tube of a rectum model with according to the present invention.
[0012] FIG. 3B is a posterior, partial, cross-sectional view of a second tube, third tube and a thin hydrogel layer of a rectum model according to the present invention.
[0013] FIG. 3C is a posterior, partial, cross-sectional view of a second tube, third tube and a collagen layer of a rectum model according to the present invention.
[0014] FIG. 4A is an anterior, partial, cross-sectional view of two collagen layers located between a second tube and simulated prostate system of a rectum model according to the present invention.
[0015] FIG. 4B is an anterior, partial, cross-sectional view of a thin hydrogel layer located between a second tube and simulated prostate system of a rectum model according to the present invention.
[0016] FIG. 4C is an anterior, partial, cross-sectional view of a collagen layer between a second tube and a simulated prostate system of a rectum model according to the present invention.
[0017] FIG. 5 is a top perspective view of a multi-layered hydrogel according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The material of the present invention is made from a dual interpenetrated cross-linked hydrogel network. The hydrogel is a mixture of two cross-linked polymers: an ionically cross-linked alginate network and a covalently cross-linked polyacrylamide network. The gel material is prepared by mixing an 8:3 ratio of acrylamide to alginate and water. In order to make the organ or tissue parts that are more realistic, color can be incorporated into the process. The colorant is added prior to deionized water being mixed with the acrylamide and alginate solids. Half the water being used to form the gel is used to make the colorant. A wash is created with the water and drops of acrylic paints. The amount and color of paint used varies depending on the organ See Table 1 below for organ color ratios that show how many parts of each color need to be mixed together for a particular organ and/or tissue part. The colored wash is then combined back with the other half of water and mixed with the acrylamide and alginate. Water content of the gel is approximately 86 weight percent. Ammonium persulfate (0.003 the weight of the acrylamide) and N,N-methylenebisacrylamide (0.006 the weight of acrylamide) are added to the solution as a photo initiator and a cross-linker respectively, for the acrylamide. Further, the solution is flushed with argon gas and N,N,N′N′-tetramethylethylenediamine (0.003 the weight of acrylamide) is added under an argon atmosphere as a cross-linking accelerator for the acrylamide. The final additive, calcium sulfate (0.136 weight of alginate), is an ionic cross-linker for the alginate. The slurry is constantly stirred throughout each step until the solution is homogeneous. The gel solution is cast into organ shaped molds and placed in an 85° C. oven for 30 minutes to cure. See the Example below for a specific hydrogel procedure example. To obtain hollow organs, the gel solution can be painted onto a mandrel and placed under a heat lamp to cure. The cured product is a tough, clear hydrogel or colored replica of the organ or tissue. The application of hydrogel organs makes the organ trays for surgical training more dynamic, the trays become more life-like as well as energy device compatible.
[0019] In another variation, the material of the present invention is made from a dual interpenetrated cross-linked hydrogel network. The hydrogel is a mixture of two cross-linked polymers: an ionically cross-linked alginate network and a covalently cross-linked polyacrylamide network. The gel material is prepared by mixing an 8:3 ratio of acrylamide to alginate and water. In order to make organs or tissue parts that are more realistic, color can be incorporated into the process. A colorant solution is prepared separate from the acrylamide and alginate mixture to allow for accessibility of different pigments while molding various tissue or organs. The colorant solution is prepared by dissolving acrylic paints in deionized water. The amount and color of paint used varies depending on the organ. See Table I for organ color ratios that show how many parts of each color need to be mixed together for a particular organ and/or tissue part. From the total amount of water used to create the hydrogel, half the water comes from the colorant solution. The colored solution is then combined back with the other half of water which is mixed with the acrylamide and alginate. The total water content of the gel is approximately 86 wt %. Ammonium persulfate (approximately 0.3% the weight of the acrylamide) and N,N-methylenebisacrylamide (approximately 0.6% the weight of acrylamide) are added to the solution as a photoinitiator and a cross-linker respectively, for the acrylamide. Further, the solution is flushed with argon gas for approximately 10-15 minutes in order to displace the air with an inert gas, and then N,N,N′N′-tetramethylethylenediamine (approximately 0.3% the weight of acrylamide) is added under an argon atmosphere as a cross-linking accelerator for the acrylamide. The final additive, calcium sulfate (approximately 13.6% weight of alginate), is an ionic cross-linker for the alginate. The slurry is constantly stirred throughout each step until the solution is homogeneous. The gel solution is cast into organ shaped molds and placed in an 85° C. oven for 60 minutes to cure. See Example below for a specific hydrogel procedure example. To obtain hollow organs, the gel solution can be painted onto a mandrel and placed under a heat lamp to cure. The cured product is a tough, clear hydrogel or colored replica of the organ or tissue. The application of hydrogel organs makes the organ trays for surgical training more dynamic, the trays become more life-like as well as energy device compatible.
[0020] Organs and/or tissue made of the hydrogel of the present invention closely resemble and react to manipulation with energy devices similar to the way human organs do. The synthetic tissue made of the hydrogel of the present invention can be cut, cauterized and fused. Two layers of the hydrogel tissue according to the present invention can be separated along a plane using various monopolar and bipolar devices. Furthermore, vessels of the hydrogel can be fused and transected like real blood vessels. Mechanical devices such as scissors, graspers, and sutures can also be used on synthetic tissue made from the hydrogel of the present invention. The tissue has the strength to accommodate sutures and can be further reinforced with mesh to allow additional strength to accommodate sutures in a manner used for actual surgeries without concern for the suture tearing through the synthetic tissue and coming undone. In addition, when wetted the material becomes lubricious and slick making for a life-like feel. The compatibility of the hydrogel with other materials becomes useful when making large assemblies, such as organ trays comprising multiple tissue components for simulators because the synthetic organs not only need to bond to each other, but also are able to bond to the plastic base of the tray. The synthetic organs and tissues made of the hydrogel material should be stored in closed containers with minimal exposure to the atmosphere until ready for use. Due to being predominantly water, the hydrogel material can dry out over time if not stored properly. However, advantageously, the hydrogel of the present invention has the ability to reabsorb water allowing for it to rehydrate after losing moisture and to be used.
[0021] In another variation of the present invention, synthetic tissue is made as follows. Sodium metabisulfite is added as an additive to the above mentioned hydrogel. The sodium metabisulfite is added to the solution prior to the calcium sulfate. The amount utilized is equivalent to the amount of ammonium persulfate present in the gel solution. The addition of the sodium metabisulfite allows the gel to be cured at room temperature. Once cast, the hydrogel begins to instantly cure, thus the need for a secondary oven cure is no longer necessary. This process shortens the time required for producing the gel. However, the resulting tissue lacks the same tear strength, elongation, and work time as its oven-cured counterpart.
[0022] Another approach utilizes adjusting the ratios of ingredients already present in the hydrogel solution. The two polymers of the hybrid hydrogel are what allow the gel to be elastic and still hold its shape. The 8:3 polymer ratio of acrylamide to alginate in the gel can be adjusted to enhance different properties of the gel. The amount of acrylamide can be increased to increase flexibility and elasticity of the gel; inversely, if the amount of alginate is increased, brittleness is amplified and tear resistance is decreased. The cross-linkers are further responsible for certain characteristics. The cross-linkers essentially entangle the polymer strands together forming a polymer network. Increasing the amount of cross-linkers causes the hydrogel to cure faster and lack elasticity and an insufficient amount of cross-linkers causes the formation of a jelly rather than a gel. The amount of water can also be varied, with the amount of water being inversely proportional to hardness. Gel with higher water content will be softer and will have the formation of a jelly. Ultimately, the ingredients of the hybrid hydrogel can be utilized to enhance different physical and mechanical properties.
[0023] Two other examples of replacement hydrogels are an acrylic acid based gel and a clay-based gel. In the acrylic acid hydrogel, an acrylate polymer is created through the polymerization of acrylic acid in an aqueous solution neutralized by sodium hydroxide. A sodium metabisulfite-ammonium persulfate redox reaction acts as an initiator for the polymerization process. The clay based hydrogel is a solution of sodium polyacrylate and clay nanosheets. A dendritic molecular binder (G3-binder) is added to the solution to initiate bonding. The resulting product is a clear, moldable hydrogel.
[0024] Besides hydrogel materials semiconductive silicones can be utilized to produce synthetic organs. Semiconductive silicones are silicone rubbers that have been doped with small particles of metal, commonly, nickel-graphite or aluminum. These metal particles essentially make a non-conductive silicone semiconductive by providing a medium for electricity to flow through. Semiconductive silicones are expensive and difficult to bond to other materials. In addition, the silicone needs to contain large amounts of metal particles to provide a short enough arcing distance for the electric current. The above materials and processes can similarly be engaged to manufacture organ trays that are energy compatible.
[0025] An exemplary organ model made of hydrogel material compositions described in this specification is shown in FIGS. 1-3 . The organ model is a simulated rectum model 100 . The simulated rectum model 100 includes a first tube 102 made of any one of the hydrogel compositions described herein and dyed to have a pink color. In one variation, the hydrogel is selected to have a ratio of approximately 8:1 acrylamide to alginate and approximately 86% water. The first tube 102 defines a first lumen 103 extending between a proximal end and a distal end.
[0026] The simulated rectum model 100 further includes a second tube 104 defining a second lumen 105 and extending between a proximal end and a distal end. The second tube 104 is made of yellow dyed hydrogel of any one of the hydrogel compositions described herein. In one variation, the hydrogel is selected to have a ratio of approximately 8:1 acrylamide to alginate and approximately 86% water. The second lumen 105 is dimensioned to receive the first tube 102 inside the second lumen 105 in a concentric-like fashion. The second tube 104 is adhered to the first tube 102 using cyanoacrylate glue. Alternatively, the second tube 104 is cured onto the first tube 102 and no glue is employed. The yellow color of the second tube 104 is selected such that the second tube 104 represents the mesorectum of a human colon.
[0027] The model 100 further includes a third tube 106 . The third tube 106 defines a third lumen 107 . The diameter of the third lumen 107 is dimensioned to receive the second tube 104 inside the third lumen 107 in a concentric fashion. The third tube 106 is adhered to the second tube 104 by being cured on top of the second tube 104 . The third tube 106 is made of any one of the hydrogel compositions described herein and dyed to have a yellow and/or orange color to represent a presacral fat layer. In one variation, the hydrogel is selected to have a ratio of approximately 8:1 acrylamide to alginate and approximately 86% water.
[0028] The simulated rectum model 100 further includes a fourth tube 108 . The fourth tube 108 defines a fourth lumen 109 . The diameter of the fourth lumen 109 is dimensioned to receive the third tube 106 inside the fourth lumen 109 in a concentric-like fashion. The fourth tube 108 is made of any one of the hydrogel compositions described herein and dyed to have a pink color. In one variation, the hydrogel is selected to have a ratio of approximately 8:1 acrylamide to alginate and 86% water. The fourth tube 108 is adhered to the third tube 106 with adhesive such as cyanoacrylate glue such as LOCTITE® 401 or 4902 cyanoacrylate glue manufactured by LOCTITE® of Westlake, Ohio. Alternatively, the fourth tube 108 is cured onto the third tube 106 and no adhesive is employed.
[0029] In one variation of the simulated rectum model 100 , the simulated rectum model 100 further includes a simulated prostate system 110 located and embedded between the third tube 106 and the fourth tube 108 . In one variation, the simulated prostate system 110 is located and embedded inside the third tube 106 . The simulated prostate system 110 is located at the anterior side of the model 100 . The simulated prostate system 110 includes any one or more of the following simulated anatomical structures: simulated prostate, simulated seminal vesicles, simulated bladder, simulated urethra, and simulated vas deferens. The simulated urethra and simulated vas deferens are made of silicone formed into a solid tube or other polymer. The simulated seminal vesicles are made of urethane or other foam overmolded onto the simulated vas deferens. The simulated prostate is made of urethane or other foam overmolded onto the simulated urethra.
[0030] In one variation of the simulated rectum model 100 , the simulated rectum model 100 further includes one or more collagen layer (not shown) located in any one or more of the following locations: (1) between the second tube 104 and the first tube 102 , (2) between the third tube 106 and the second tube 104 . The collagen layer is wetted and placed onto the cured hydrogel tube which is then placed in an oven to adhere it. In one variation, the second tube 104 is covered with a thin layer of collagen and the third tube 106 is covered with a thin layer of collagen and electrosurgical dissection takes places between the two adjacent layers of collagen. In another variation, a thin collagen layer is applied to the third tube 106 only and dissection is between the second tube 104 and the collagen layer on the third tube 106 . In another variation, a thin first collagen layer is applied to the second tube 104 , a thin second collagen layer is applied to the first collagen layer. The prostate system 110 is adhered to the second collagen layer and care is taken to dissect around the prostate system between the first collagen layer and the second collagen layer. In another variation, a thin collagen layer is applied to the prostate system 110 and care is taken to dissect between the second tube 104 and the thin collagen layer to avoid the prostate system 110 .
[0031] The simulated rectum model 100 is fantastically suited for practicing transanal total mesorectal excision (TaTME) for cancer located in the lower rectum using electrosurgical devices and electrosurgery techniques. In such a surgical procedure, the cancerous rectum is approached through the anus into the first lumen 103 via a sealable port that is connected to channel. A purse-string suture is tied to seal off the cancerous location of the rectum that includes the tumor. In order to practice this suture technique, the first tube 102 is optionally provided with an embedded mesh layer so that sutures would be held in the first tube 102 and not tear through the hydrogel when pulled. In another variation, the purse-string suture is pre-made during the manufacturing process so that the surgeon can visually locate the suture and only practice techniques subsequent to purse-string suture placement. In the practice of the procedure, the surgeon will commence to dissect in the posterior direction and electrosurgically cut down through first tube 102 and into the second tube 104 which represents the mesorectum and circumferentially around the second tube 104 between the second tube 104 and the third tube 106 being careful not to penetrate into the simulated prostate system 110 and not to penetrate into the fourth tube 108 as can be seen in FIG. 2 . Care is also taken not to enter the simulated mesorectum (second tube 104 ) nor enter into the first tube 102 . The user carefully practices to dissect circumferentially around the first tube 102 . Exemplary posterior dissection locations and dissection pathways are illustrated in FIGS. 3A-3C . FIG. 3A illustrates a posterior dissection location between the second tube 104 and the third tube 106 and a dissection plane 111 in between two collagen layers 113 if they are employed. FIG. 3B illustrates a posterior dissection location with a dissection pathway between the second tube 104 and the third tube 106 , and in particular, between the second tube 104 and a thin hydrogel layer 112 located between the third tube 106 and the second tube 104 . FIG. 3C illustrates a posterior dissection location with a dissection pathway 111 between the second tube 104 and a collagen layer 113 adhered to the third tube 106 . After dissecting posteriorly, anterior dissection begins by dissecting through the thinner layer of the second tube 104 , visible in FIG. 2 , until the third tube 106 is reached. Dissection proceeds between the second tube 104 and the third tube 106 along a dissection plane 111 until the posterior dissection is encountered. Exemplary anterior dissection locations and dissection pathways 111 that correspond to posterior dissection pathways 111 of the models configured as shown in FIGS. 3A, 3B and 3C are illustrated in FIGS. 4A, 4B and 4C , respectively. FIG. 4A illustrates an anterior dissection location with a dissection plane 111 lying between two collagen layers 113 if they are provided. FIG. 4B illustrates an anterior dissection location with a dissection plane 111 lying between the second tube 104 and the thin layer of hydrogel 112 . FIG. 4C illustrates an anterior dissection location with a dissection plane 111 lying between the second tube 104 and collagen layer 113 if one is provided. Care is taken not to enter the third tube 106 to avoid risk damaging the prostate system 110 .
[0032] The proximal end of the simulated rectum model 100 may be attached to a transanal adapter. The transanal adapter is a support used to space apart the top cover from the base of a surgical trainer to provide access into the model from the side of the surgical trainer. An example of a surgical trainer is described in U.S. Pat. No. 8,764,452 incorporated by reference herein in its entirety. The transanal adapter includes an opening that is connected to the first lumen of the first tube 102 . Surrounding the opening of the transanal adapter, soft silicone is provided to simulate an anus. The practice of the surgical TaTME procedure is performed through the opening of the transanal adapter into the first lumen 103 as described above.
[0033] In one variation, the first tube 102 and the second tube 104 are made of hydrogel having a ratio of approximately 8:1 acrylamide to alginate and approximately 86% water and the third tube 106 and the fourth tube 108 are made of hydrogel having a ratio of approximately 8:3 acrylamide to alginate and approximately 86% water. Whereas the intersection of layers/tubes having the same ratio are substantially indistinguishable, the intersection of layers/tubes having different ratios are distinguishable making the intersection plane discernible and more easily separable, leading the practitioner along the correct dissection plane and making dissection easier than if the correct dissection plane was the intersection of layers/tubes having the same ratio.
[0034] The simulated rectum model 100 is assembled by first casting the material into hollow tube-like molds that are provided with mandrels. The casting of layers may begin from the innermost layer and proceed to the outermost layer or vice versa. For example, if the casting is to start from the innermost layer, a small tube is filled with material and allowed to cure in an oven. When removed from the small tube mandrel, the cured innermost layer is inserted into a larger diameter tubular mandrel of the desired diameter and the next layer is poured and allowed to cure. The combination is then removed and placed into a tubular mandrel having a larger diameter and the next layer is poured and so forth. Similarly, the model 100 may be constructed beginning with the outer layer and sequentially proceeding to the inner layer. Tubing is placed inside of a larger hollow tubing and the outermost space in between is filled with material until the desired layers is achieved working progressively until the innermost layer is poured. Any layer can be offset from the longitudinal axis to achieve a thicker or thinner layer posteriorly or anteriorly as needed such as for the second tube. If a purse-string suture is to be pre-made, the outer-to-inner manufacturing process would be employed. On the last innermost layer, instead of placing a mandrel in all of the way, material would be cast to completely fill in the rectum except for the top portion. On the top, a small mandrel would be placed allowing only the very top to be hollow. The mandrel could be designed to look like a purse-string, giving the user a visual cue that the purse-string suture has been already completed. To apply a collagen layer, synthetic or natural collagen casing is employed in the form of a sheet or cylinder. If provided in the form of a cylinder, it is cut into sheets. The collagen layer is then soaked in water and water is brushed onto the desired layer of application. The soaked collagen layer is then placed onto the layer of hydrogel. More layers are added as needed and the hydrogel layer and collagen layer are baked together in an oven to adhere the hydrogel to the collagen or the collagen to itself when multiple layers are employed side-by-side. The model 100 is held together by over molding the layers or with cyanoacrylate glue. Silicone components of the model 100 such as the prostate system 110 are adhered to the hydrogel or collagen using cyanoacrylate glue. Urethane molds are employed and the molds may be surface treated with in a variety of ways including but not limited to plasma treating and flame treating to make the mold hydrophilic and improve spreading of hydrogel material into the mold, especially for a hydrogel formulation that does not include sodium metabisulfide. Certain model organ parts, especially thin sheet-like parts such as a simulated peritoneum, are formed by polybag casting. In polybag casting, the hydrogel material is poured into a bag. Any air pockets are pressed out and the bag is sealed and placed between two flat trays. Weights of approximately 2.5-5.0 pounds were laid on top of the trays and allowed to cure into a flat sheet to create an artificial peritoneum or omentum. Artificial vasculature also made of hydrogel may be embedded by arranging the artificial vasculature inside the polybag. Also, smaller hollow molds are utilized to manufacture simulated hollow vessels.
[0035] In another variation, the model 100 does not have a cylindrical shape to represent a rectum. Instead, the model 100 simply includes four layers 102 , 104 , 106 , 108 from top to bottom in the shape of a rectangular or square block as if the cylinder were to be cut open and laid flat as shown in FIG. 5 . The block configuration of the layers permits the user to practice the procedures without being confined to a lumen configuration with the procedures performed transluminally. The block allows practitioners to simply practice the electrosurgical techniques in a laparoscopic environment such with the model 100 placed inside a cavity of a surgical trainer between a top cover and a base. In such a variation, the first layer 102 and the second layer 104 are made of hydrogel having a ratio of approximately 8:1 acrylamide to alginate and approximately 86% water and the third layer 106 and the fourth layer 108 are made of hydrogel having a ratio of approximately 8:3 acrylamide to alginate and approximately 86% water.
[0036] Any one of the hydrogels disclosed in this specification can be used to form at least part of a simulated tissue structure for the practice of surgical techniques, especially laparoscopic electro-surgical procedures wherein the simulated tissue structure is disposed inside an enclosure substantially enclosing the simulated tissue structure. An example of an enclosure includes a laparoscopic trainer in which a laparoscope is utilized to visualize the surgical field. The simulated tissue structure is not limited to artificial vessels, arteries, veins, one or more organs and tissues, hollow or solid, associated with the human lower rectum as described above and suitable for practicing a TaTME procedure. Also, the TaTME model described above may be made with two layers of hydrogel instead of four layers. In such a model the two layers made of hydrogel include the rectum layer and mesorectum layer, the first tube 102 and the second tube 104 , respectively, if the model is formed to have a tubular shape. A variation of such a TaTME model having two layers includes a mesh layer located between the two layers 102 , 104 . Of course, the TaTME model need not have a tubular shape. Any of the TaTME models may include artificial polyps to be practiced for removal using energy. A gallbladder model may include one or more of an artificial liver, artificial gallbladder, artificial peritoneum, artificial fascia, artificial duct(s), and one or more artificial artery. In an alternative variation of the gallbladder model, the artificial liver is excluded from being made of hydrogel and instead made of silicone or KRATON in order to localize the surge areas to the locations where a simulated procedure would be performed. A simulated tissue structure is substantially made of any one of the hydrogels described herein. In one variation, the simulated tissue structure includes an artificial human ovarian organ that includes one or more of a simulated ovary portion, a uterine horn portion, uterus, ovary, fallopian tube, vagina, cervix, bladder, omentum, and peritoneum. The peritoneum and omentum may further include embedded simulated vasculature, hollow or solid, also made of hydrogel. Other artificial organs that are made of hydrogel and form at least part of a simulated tissue structure include an artificial stomach, kidney, rectum, aorta, tumor, and polyp. Any of the simulated tissue structures made of hydrogel described herein may include a mesh layer. Also, the simulated tissue structure may include two different hydrogels forming different parts of the simulated tissue. For example, as described above, part of a simulated tissue structure may be made with a hydrogel having an 8:3 formulation and another part having an 8:1 formulation. Also, part of a simulated tissue structure may be formed of a hydrogel according to the present invention and part made of silicone or other material and attached, connected, adjacent or in juxtaposition to the part made of hydrogel. For example, in a simulated appendectomy model, an artificial colon is made of silicone and an artificial peritoneum and vessels are made of hydrogel having one or more formulation described herein. In another example, in a simulated gallbladder model the artificial liver is made of silicone or KRATON and all other parts of the gallbladder model are made of hydrogel having one or more formulation described herein. In another example, an artificial rectum is made of silicone and artificial polyps of hydrogel described herein are adhered to the silicone rectum using cyanoacrylate glue.
[0037] In use, the simulated tissue structure according to the present invention is configured for use with electrosurgical units, including but not limited to monopolar, bipolar, harmonic or other devices employed in electrosurgery, in order to provide a realistic medium configured into an anatomical portion for the practice of using electrosurgical units, electrosurgical techniques, surgical procedures employing electrosurgical units alone and with other instruments encountered in surgery. The handling of electrosurgical units requires practice as does employing surgical techniques and learning specific procedures performed with the electrosurgical units. When an electrosurgical unit is applied, heat is generated by the electrical current traveling between two polarities in a bipolar system or from one electrical polarity to a ground in a monopolar system. Typically, in a monopolar system, the artificial tissue structure is located above and in contact with a grounding plate/pad which is connected to a ground. In one variation of the simulated tissue structure according to the present invention, that portion of the structure that is composed of hydrogel is placed in direct contact with the grounding pad/plate or other conductive surface. In the event, the entirety of the simulated tissue structure is configured such that the hydrogel is not in direct contact with the grounding pad, a conductive pathway, such as a wire or the like, is provided to contact the hydrogel portion and then pass across non-conductive portions of the model to contact the grounding pad. For example, in a gallbladder model such as the model described in U.S. Patent Application Publication No. US 2014/0370477 to Applied Medical Resources Corporation in California, the anatomical portion is connected to a support in order to permit the model to stand upright. If any one of the liver, peritoneum, gallbladder, vasculature, fascia, duct system or other component of the model is made of hydrogel, a wire is passed into that portion and then fed to contact a metallic frame which is set inside the stand with the frame legs extending all the way through the stand to be exposed at the bottom surface of the stand which then can be place atop a grounding pad. When the hydrogel structure is contacted with an electrosurgical unit, the temperature of the hydrogel structure will increase to a temperature that begins to vaporize the water content of the hydrogel in the location of contact. Because the hydrogel contains approximately 86% water by weight of the hydrogel structure, the model will generate steam that mimics the smoke created during electrosurgery performed on human tissue. Advantageously, the water vapor of the hydrogel structure is not odiferous compared with the smoke produced by real tissue. With prolonged contact with the electrosurgical unit, the water content will be reduced in the location of contact advantageously creating a simulated fusion or seal of tissue typically encountered in real surgery. Hence, the present invention not only advantageously simulates the look and feel of tissue structures that would undergo procedures that employ electrosurgery, but also, responds in manner that mimics real electrosurgery when electrosurgery is applied to the simulated tissue structures. The hydrogel of the present invention can be utilized to simulate dissection of tissue in addition to sealing and/or fusion via an electrosurgical unit.
[0000]
TABLE 1
ORGAN
COLOR RATIO
Liver
4 red:1 black
Gallbladder
3 yellow:1 blue
Cystic duct
3 yellow:1 blue
Kidney
4 red:1 blue
Spleen
4 red:1 blue
Pancreas
4 yellow
Omentum
4 yellow:1 white
Mesentery
4 yellow:1 white
(serial diluted 8 times)
Veins
3 blue:0.5 black
Arteries
5 red:0.25 black
Aorta
4 red
Example
[0038] The following is an example procedure for making a simulated hydrogel liver according to the present invention. In a large glass beaker, add 33.75 g alginate and 90 g acrylamide. Dry mix the two solids until the mixture is uniform. Measure out 614 ml of deionized (DI) water. Add 307 ml (about half) of the 614 ml of DI water to the beaker with the powder mixture. Mix the solution to break apart any alginate adhered to the sides or bottom of the beaker. Once a homogenous solution is formed, maintain the mixing by placing the beaker under an overhead mixer or insert a stir bar and place on stir plate to continue mixing. The remaining 307 ml of water are added to a different beaker and used to prepare the colorant. For a simulated liver, 4 drops of red acrylic paint and 1 drop of black acrylic paint are added to the second jar of DI water and stirred on a stir plate until the water is a uniform color. The now colored 307 ml of DI water is combined back with the other half in the beaker of gel solution. The beaker of gel solution remains mixing on the overhead mixer or stir plate to dissolve all solids and allow for uniform mixing of the colorant. Keep solution stirring and add 0.250 g of ammonium persulfate (APS) and add 0.050 g N,N′-methylenebisacrylamide. Allow the APS and N,N′-MBAA to dissolve in the gel solution prior to proceeding. Hand mix as necessary, since the solution is viscous and the lighter additives will not readily mix with the mixers.
[0039] While on the overhead mixer or stir plate, insert a thin hose into the bottom of the beaker of gel solution, the hose should be connected to the argon gas tank. Bubble in a stream of argon gas into the beaker for approximately 15 minutes. Afterwards, remove the hose from the solution and allow hose to sit above the surface and blow a stream of argon gas on top of the gel solution for another 5 minutes. After flushing the solution with argon gas remove the thin hose from the jar. The following step is also completed under argon conditions. Flush the headspace of the N,N,N′,N′-tetramethylethylenediamine (N,N,N′,N′-TMEDA) bottle with argon. Using a micropipette, pipette 0.290 milliliters of argon gas from the N,N,N′,N′-TMEDA bottle head space and eject the gas off to the side, this should be done twice in order to flush the interior of the micropipette. Now, extract 0.290 ml of N,N,N′,N′-TMEDA from the bottle using the same micropipette tip and eject into the gel solution. The N,N,N′,N′-TMEDA bottle should be sealed quickly after use and stored in a dark area, away from moisture.
[0040] Continue stirring, make a slurry of calcium sulfate dihydrate (CaSO4.2H2O) and DI water. Add approximately 25 ml of DI water to 4.59 g of CaSO4.2H2O. Mix thoroughly and add slurry to the hydrogel solution. Wash the remains of the CaSO4.2H2O slurry with DI water and add to the hydrogel solution. Some white clouds may still remain from the addition of the CaSO4.2H2O. These clouds will disappear once hydrogel is cured. Allow gel slurry to mix at medium speed for approximately 1 minute. The gel slurry can now be poured into a liver mold and placed in an oven at 85° C. for 60 minutes to cure the gel. After 1 hour, the mold is removed from the oven and allowed to cool to room temperature. Once cool, the hydrogel liver can be removed from the mold. The final product is a life-like synthetic liver capable of being manipulated with energy devices in addition to mechanical devices.
[0041] It is understood that various modifications may be made to the embodiments of the synthetic tissue disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the spirit and scope of the present disclosure. | A surgical simulator for electrosurgical training and simulation is provided. The surgical simulator includes one or more simulated tissue structures made substantially of a hydrogel comprising a dual interpenetrating network of ionically cross-linked alginate and covalently cross-linked acrylamide. Combinations of different simulated tissue structures define procedural-based models for the practice of various electrosurgical procedures including laparoscopic total mesorectal excision, transanal total mesorectal excision, cholecystectomy and transanal minimally invasive surgery. Methods of making the simulated tissue structures are also provided. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based on, and claims domestic priority benefits under 35 USC §119(e) from, U.S. Provisional Application Serial No. 60/334,963 filed on Dec. 4, 2001, the entire content of which is expressly incorporated hereinto by reference.
FIELD OF THE INVENTION
[0002] The present invention is related generally to chemical wood pulping processes and systems. In particular, the present invention relates to processes and systems for handling of knots in such chemical wood pulping processes.
BACKGROUND OF THE INVENTION
[0003] Screw-type chip meters are typically used to determine the chip feed rate to a digester employed in chemical wood pulping processes. The chip meters therefore are employed to feed uncooked wood chips in a controlled manner to the downstream pre-cooking and cooking operations, for example, chip steaming, impregnation vessels and/or digester vessels. A chip chute typically is employed to convey the uncooked wood chips to such downstream operations.
[0004] Conventionally, knots present in the wood chips are typically removed by screening following at least some cooking. Thus, in many pulp mills, a drainer is provided so as to remove the knots from the pulp, such as the system suggested in U.S. Pat. No. 3,886,035 1 . Such knots may then be refined or re-cooked so as to minimize waste and to recover any fiber content that may be present therein. (See, U.S. Pat. No. 4,002,528.) Conventional knot recovery techniques typically involve returning the knots separated from the pulp to the chip bin which requires expensive recycling equipment. Alternatively, knot drainers may be located at the top of the chip bin, but such an arrangement requires excess energy to be used to pump all the filtrate carrying the knots recovered after cooking back to the chip bin for reprocessing.
[0005] Another knot-recycling technique has recently been proposed in U.S. Pat. No. 5,672,245. In this regard, the '245 patent proposes to separate knots by means of a screen downstream of the pulp digesters and then redirect such separated knots, following their treatment in a knot bin with black liquor, to the chip chute upstream of the high pressure feeder.
SUMMARY OF THE INVENTION
[0006] According to the present invention, novel processes and systems are provided for the return of knots removed by conventional means, such as screening in the knotter or screen room, to an essentially atmospheric pressure feed system prior to being cooked in the digester operations associated with a chemical wood pulping process. More specifically, according to the present invention, a flow of uncooked wood chips is metered into a chip chute upstream of the digester operations. The processes and systems of the present invention will therefore allow the return of the knots to the chip feed system by feeding the knots into the chip handling system operating at essentially atmospheric pressure, instead of the conventional technique of returning the knots to a pressurized, higher elevation chip bin. Knots from the knotter or screen room are most preferably returned to the chip feed system through a knot drainer associated operatively with the chip screw.
[0007] The present invention is therefore especially well suited for use with current Lo-Level® Feed Systems commercially available from Andritz Inc. of Glens Falls, N.Y. (See also, U.S. Pat. Nos. 5 , 476 , 572 ; 5,700,355; 5,968,314; 5,766,418; 6,368,453, and 6,436,233.) The use of the present invention should result in lower energy costs by allowing the knot drainer to be placed at a lower elevation (e.g., attached physically to the chip screw instead of the higher elevation top of the chip bin). Additional energy savings are incurred by eliminating the need for the pressurization of the knot stream to the pressure of the conventional feed system.
[0008] These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0009] Reference will hereinafter be made to the accompanying drawing FIGURE which is depicts one particularly preferred system for treating knots in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0010] As shown in the accompanying drawing FIGURE, one particularly preferred system in accordance with the present invention includes a feed system 10 for introducing, steaming, slurrying and pressurizing comminuted cellulosic fibrous material, for example, hardwood or softwood chips, and feeding the slurry to a continuous digester system (not shown). These systems are disclosed in U.S. Pat. Nos. 5,476,572; 5,622,598; 5,635,025; 5,766,418; and 5,968,314 and are marketed under the trademark LO-LEVEL® by Andritz Inc. of Glens Falls, N.Y.
[0011] Though comminuted cellulosic fibrous material may take many forms, including sawdust; grasses, such as straw or kenaf; agricultural waste, such as bagasse; recycled paper; or sawdust, for the sake of simplicity, the term “chips” will be used when referring to comminuted cellulosic fibrous material; but any and all of the listed materials, and others not listed, may be processed by the present invention. Also, though a continuous digester may be referenced below and in the accompanying FIGURE, it is understood that the present invention as also applicable to feeding several continuous digesters or one or more discontinuous or batch digesters.
[0012] As shown in the FIGURE, chips 13 are introduced to the system, for example, via a conveyor (not shown) from a chip storage facility, for example, a woodyard, via an isolation and metering device 14 . For example, the FIGURE illustrates a screw-type isolation device 14 as described in U.S. Pat. No. 5,766,418. The device 14 , driven by an electric motor (not shown), introduces the chips to chip retention and streaming vessel 16 . Though various types of vessels are known in the art, vessel 16 is preferably a DIAMONDBACK® Steaming vessel as marketed by Andritz Inc. and described in U.S. Pat. Nos. 5,500,083; 5,617,975; 5,628,873; and 4,958,741, or a CHISELBACK™ vessel marketed by Andritz Inc. as described in U.S. Pat. No. 6,199,299. This vessel typically includes a gamma-radiation level-detection system, a regulated vent for discharging gases which accumulate in the vessel and one or more steam introduction conduits 16 ′. The pressure in the vessel 16 may be slightly below atmospheric pressure or slightly above atmospheric pressure, that is, the pressure in vessel 16 may vary from about −1 to 2 bar gage (that is, about 0 to 3 bar absolute).
[0013] During treatment with steam in vessel 16 , the air that is typically present in the chips is displaced by steam and the heating of the chips is initiated. The removal of air from the cavities within the chips permits the more efficient diffusion of cooking chemical into the chip and minimizes the buoyant forces on the chip during subsequent processing.
[0014] The steamed material is discharged from the bottom of the vessel 16 to a metering device 17 , for example, a star-type metering device or Chip Meter as sold by Ahlstrom Machinery, though any type of metering device may be used. The metering device 17 is typically driven by an electric motor (not shown) and the speed of rotation of the metering device is typically controlled by operator input to define a set rate of introducing chips to the system. The chips discharged by the metering device 17 are introduced to a vertical conduit or pipe 18 , for example, a Chip Tube sold by Ahlstrom Machinery. Cooking chemical and other liquids are typically first introduced to the chips in conduit 18 by means of one or more conduits 19 such that a level of liquid is established in conduit 18 and a slurry of chips and liquid is present in the bottom of conduit 18 . This level of liquid is typically monitored and controlled by a level detection device, for example, a gamma-radiation level detection device or a “d-p” cell. The metering device 17 typically does not act as a pressure isolation device, though it may, and the pressure in conduit 18 typically varies from 0 to 2 bar gage (or 1 to 3 bar absolute).
[0015] Conduit 18 discharges the slurry of chips and liquid by means of a radiused section 20 to the inlet of slurry pump 21 . Though any slurry pump can be used, pump 21 is preferably a Hidrostal® screw centrifugal pump sold by Wemco Pump of Salt Lake City, Utah or a pump provided by Lawrence Pumps Inc. of Lawrence, Mass. Slurry pump 21 , driven by electric motor 21 ′, pressurizes and transfers the slurry in conduit 18 via conduit 22 to the low pressure inlet 23 of a high pressure transfer device 24 . This high pressure transfer device is preferably a High-pressure Feeder as sold by Andritz Inc. High-pressure feeder 24 includes a pocketed rotor mounted in a housing typically having a low-pressure inlet 23 , a low-pressure outlet 25 , a high-pressure inlet 26 and a high-pressure outlet 27 . The low-pressure outlet 25 typically includes a screen plate (not shown) which minimizes the passage of chips out of low-pressure outlet 25 while allowing the liquid in the slurry to pass out outlet 25 to conduit 28 , though as disclosed in U.S. Pat. No. 6,199,299, the screen in the low-pressure outlet of feeder 24 may be omitted. The chips which are retained in the feeder by the screen are slurried with high-pressure liquid provided by pump 29 , preferably a Top Circulation Pump (TCP) provided by Andritz Inc., to inlet 26 via conduit 30 . The slurry is discharged out of high-pressure outlet 27 into conduit 31 and to the digester 32 of digester system 12 at a pressure of between about 5 and 15 bar gage, typically between about 7 to 12 bar gage.
[0016] The digester (not shown) may be a single or multiple-vessel digester and may be a hydraulic or steam-phase digester. The digester may also consist or comprise one or more batch digesters. The cellulose material with added cooking chemical is treated under temperature and pressure in the digester and essentially fully-treated chemical cellulose pulp is discharged into a conduit at the bottom of the digester. Though many types of processes may be performed in the digester, one preferred process is the process described in U.S. Pat. Nos. 5,489,363; 5,536,366; 5,547,012; 5,575,890; 5,620,562; 5,662,775; 5,824,188; 5,849,150; and 5,849,151 and marketed by Andritz Inc. under the trademark LO-SOLIDS®. The process performed in the digester may also be one of the processes disclosed in U.S. Pat. Nos. 5,635,026 or 5,779,856 and marketed under the name EAPC™ cooking by Andritz Inc.
[0017] As shown in the FIGURE, excess liquor in the slurry in conduit 31 at the top of the digester is separated from the slurry by a liquor separator and returned to the feed system 10 by means of conduit 34 . The liquid in conduit 34 is pressurized by pump 29 , driven by electric motor 29 ′, and provides the pressurized slurrying liquid introduced to the high-pressure inlet 26 of feeder 24 via conduit 30 . Feeder 24 is typically driven by an electric motor (not shown), the speed of which is monitored and controlled.
[0018] As shown in the FIGURE, the liquid discharged from the low-pressure outlet 25 of high-pressure feeding device 24 passes via conduit 28 to a cyclone-type separator 35 which isolates undesirable material and debris, such as sand, stones, etc., from the liquid in conduit 28 . Separator 35 is preferably a Sand Separator as sold by Andritz Inc. Liquid having little or no undesirable material or debris is discharged from separator 35 and is passed through a liquor separating device 37 via conduit 36 . At least some liquid is removed from the liquid separator 35 , which is preferably an Inline Drainer as sold by Andritz Inc., via conduit 38 and sent to vessel 39 . Vessel 39 is preferably a Level Tank as sold by Andritz Inc. Liquid is discharged from vessel 39 to conduit 40 and pump 41 and is supplied to the digester as liquor make-up as needed via conduit 42 . Pump 41 is preferably a Make-Up Liquor Pump (MLP) as sold by Andritz Inc. The sand separator 35 , level tank 36 , and in-line drainer 37 can be omitted without interfering with the ultimate function of the feed system 10 .
[0019] The liquid discharged from separator 37 into conduit 43 may be supplemented with cooking chemical, for example, kraft white, green, orange (that is, liquid containing polysulfide additives) or black liquor, prior to being introduced to tank 45 . Tank 45 is preferably a Liquor Surge Tank as sold by Andritz Inc. and described in U.S. Pat. No. 5,622,598. The cooking chemical may be heated or, preferably, cooled as needed by a heat exchanger (not shown). Some of the liquid in conduit 43 may bypass tank 45 and be introduced via conduit 19 to conduit 18 as described above. Tank 45 communicates with conduit 18 and the inlet of pump 21 via conduits 47 and 20 . As disclosed in U.S. Pat. No. 6,368,453, tank 45 may comprise or consist of an integral vessel concentric with conduit 18 .
[0020] Important to the present invention, a knot separator 50 is provided so as to supply knots via conduit 52 to the conduit 18 downstream of the metering device 17 . Most preferably the knot separator 50 is a Model KW Secondary Knotter from Andritz Inc. The knot separator 50 separates knots from the inlet supply of slurried knots and liquor pumped from a primary knotter or a knot screener introduced via inlet conduit 54 . Within the knot separator 50 , a vertically oriented screw-type conveyor is driven by motor 55 and lifted into the discharge chute 56 connected to the conduit 52 . The separated liquor is transferred via chute 58 to chamber 60 and thereafter discharged via conduit 62 . Gas may be vented from the chamber 60 via conduit 64 .
[0021] The present invention therefore allows the return of the knots to the chip feed system 10 by feeding the knots into the conduit 18 at under essentially atmospheric conditions instead of the conventional technique of returning the knots to a pressurized, higher elevation chip bin.
[0022] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | Processes and systems are provided for cooking wood chips containing knots in a digester to produce a chemical pulp. Specifically, a low pressure slurry of comminuted cellulosic fibrous material is formed in a vessel operating at essentially atmospheric pressure by mixing therein a liquid and the comminuted cellulosic fibrous material. The low pressure slurry is thereafter supplied to a low pressure inlet of a high pressure transfer device while liquid is removed from the slurry through a low pressure outlet thereof. A high pressure liquid is supplied to the transfer device (e.g., via a slurry pump) so as to form a high pressure slurry of the comminuted cellulosic material which is then discharged from a high pressure outlet of the transfer device. Knots are removed via a knot separator from a slurry of uncooked knot-containing cellulosic material at essentially atmospheric pressure. The removed knots are thereafter transferred to the vessel so that the knots become part of the low pressure slurry supplied to the low pressure inlet of the transfer device. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the dispersing of fluidized solids into a vessel. More specifically, this invention relates to a method and apparatus for distributing a stream of spent fluidized cracking catalyst particles into a regenerator for carbon removal.
2. Description of the Prior Art
There are a number of continuous cyclical processes employing fluidized solid techniques in which carbonaceous materials are deposited on the solids in a contacting zone and the solids are conveyed during the course of the cycle to another zone where carbon deposits are at least partially removed by combustion in an oxygen-containing medium. The solids from the latter zone are subsequently withdrawn and reintroduced in whole or in part to the contacting zone.
One of the more important processes of this nature is the fluid catalytic cracking (FCC) process for the conversion of relatively high boiling point hydrocarbons to lighter boiling hydrocarbons in the heating oil or gasoline (or lighter) range. In the FCC process, hydrocarbon feed is contacted in one or more reaction zones with a particulate cracking catalyst maintained in a fluidized state under conditions suitable for the conversion of hydrocarbons. The heavy hydrocarbons in the feed crack to lighter hydrocarbons. During cracking carbonaceous hydrocarbons or “coke” deposit on the catalyst to yield “coked” or “spent” catalyst. The cracked products are then separated from the coked catalyst. The coked catalyst is then stripped of volatiles, usually by steam, and then is regenerated in a catalyst regenerator. In the regenerator, the coke is burned from the catalyst with oxygen containing gas, usually air. Flue gas formed by burning the coke in the regenerator may be treated for removal of particulates and conversion of carbon monoxide, after which the flue gas is normally discharged into the atmosphere.
Emphasis on the environmental importance of reduced NO x formation in flue gas has prompted much work in various areas. NO x , or oxides of nitrogen, comes mainly from the oxidation of nitrogen compounds in the hydrocarbon feed, with perhaps some slight additional nitrogen fixation, or conversion to NO x of nitrogen in regenerator air.
Although all FCC regenerators produce some NO x , the problem is more severe in bubbling bed regenerators, as opposed to high efficiency regenerators. High efficiency regenerators burn most of the coke in a fast-fluidized bed coke combustor. Such regenerators have few poorly fluidized regions. Bubbling bed regenerators may have poorly fluidized regions and will have large bubbles of air passing through the bed, leading to localized areas of high oxygen concentration. Although the reasons for the different NO x emissions in these two types of regenerators are perhaps not completely understood, all agree that NO x emissions are usually significantly higher, frequently twice as high, from bubbling bed regenerators.
One area of work on NO x reduction pertains to flue gas treatment methods that are isolated from the FCC process unit. With flue gas treatment, it is known to react NO x in flue gas with NH 3 . NH 3 is a selective reducing agent, which does not react rapidly with the excess oxygen, which may be present in the flue gas. Two types of NH 3 processes have evolved—thermal and catalytic. Thermal processes, such as the Exxon Thermal DENOX process, generally operate as homogeneous gas-phase processes at very high temperatures, typically around 840° to 1040° C. The catalytic systems that have been developed operate at much lower temperatures, typically at 150° to 450° C. These temperatures are typical of flue gas streams. Unfortunately, the catalysts used in these processes are readily fouled, or the process equipment plugged, by catalyst fines that are an integral part of FCC regenerator flue gas. U.S. Pat. No. 521,389 and U.S. Pat. No. 434,147 disclose adding NH 3 to NO x -containing flue gas to catalytically reduce the NO x to nitrogen. U.S. Pat. No. 5,015,362 taught reducing NO x emissions by contacting flue gas with sponge coke or coal, and a catalyst effective for promoting reduction of NO x in the presence of such carbonaceous substances.
Flue gas treatment methods are effective, but the capital and operating costs are high. Therefore, the alternative areas within the FCC process unit itself should be examined, which include feed treatment, catalytic approaches, and process approaches.
First, some refiners now go to the expense of hydrotreating feed. This is usually done more to meet sulfur specifications in various cracked products, or a SO x limitation in regenerator flue gas rather than a NO x limitation. Hydrotreating will reduce to some extent the nitrogen compounds in FCC feed, and this will help reduce the NO x emissions from the regenerator. Again, there is typically a high cost for this procedure and it can usually only be justified for sulfur removal.
Second, there are catalytic approaches to NO x control. These approaches are generally directed at special catalysts which promote CO afterburning, but which do not promote formation of as much NO x . U.S. Pat. Nos. 4,300,997 and 4,350,615 are both directed to use of a Pd—Ru CO-combustion promoter. The bimetallic CO combustion promoter is reported to do an adequate job of converting CO to CO 2 , while minimizing the formation of NO x . U.S. Pat. No. 4,199,435 suggests steam treating a conventional metallic CO combustion promoter to decrease NO x formation without impairing too much the CO combustion activity of the promoter. U.S. Pat. No. 4,235,704 indicates too much CO combustion promoter causes NO x formation, and calls for monitoring the NO x content of the flue gases, and adjusting the concentration of CO combustion promoter in the regenerator based on the amount of NO x in the flue gas. As an alternative to adding less CO combustion promoter, the patent suggests deactivating it in place, by adding something to deactivate the Pt, such as lead, antimony, arsenic, tin or bismuth. U.S. Pat. No. 5,002,654 taught the effectiveness of a zinc-based additive in reducing NO x . Relatively small amounts of zinc oxides impregnated on a separate support having little or no cracking activity produced an additive which could circulate with the FCC equilibrium catalyst and reduce NO x emissions from FCC regenerators. U.S. Pat. No. 4,988,432 taught the effectiveness of an antimony-based additive at reducing NO x.
However, many refiners are reluctant to add additional metals to their FCC units out of environmental concerns. One concern is that some additives, such as zinc, may vaporize under some conditions experienced in FCC units. Many refiners are concerned about adding antimony to their FCC catalyst inventory. Such additives would also add to the cost of the FCC process and would dilute the FCC equilibrium catalyst to some extent.
Thirdly and finally, there are process approaches. Process modifications are suggested in U.S. Pat. Nos. 4,413,573 and 4,325,833 directed to two-and three-stage FCC regenerators, which reduce NO x emissions. U.S. Pat. No. 4,313,848 teaches countercurrent regeneration of spent FCC catalyst, without backmixing, to minimize NO x emissions. U.S. Pat. No. 4,309,309 teaches adding a vaporizable fuel to the upper portion of a FCC regenerator to minimize NO x emissions. Oxides of nitrogen formed in the lower portion of the regenerator are reduced in the reducing atmosphere generated by burning fuel in the upper portion of the regenerator. U.S. Pat. No. 4,542,114 minimized the volume of flue gas by using oxygen rather than air in the FCC regenerator, with consequent reduction in the amount of flue gas produced.
In U.S. Pat. No. 4,828,680, NO x emissions from a FCC unit were reduced by adding sponge coke or coal to the circulating inventory of cracking catalyst. The carbonaceous particles selectively absorbed metal contaminants in the feed and reduced NO x emissions in certain instances. Many refiners are reluctant to add coal or coke to their FCC units; such carbonaceous materials will burn and increase the heat release in the regenerator. Most refiners would prefer to reduce, rather than increase, heat release in their regenerators. U.S. Pat. No. 4,991,521 showed that a regenerator could be designed so that coke on spent FCC catalyst could be used to reduce NO x emissions from an FCC regenerator. The patent taught the use of a two stage FCC regenerator. Flue gas from a second regenerator stage contacted coked catalyst in a first stage. Although effective at reducing NO x emissions, this approach is not readily adaptable to existing units. Another use of coke on spent catalyst to reduce NO x was reported in U.S. Pat. No. 5,006,495. The incoming spent catalyst, or at least a portion of it, was added to the dilute phase region of a bubbling bed regenerator, so that the coke on catalyst could reduce NO x species in the dilute phase flue gas. This approach is interesting, but may increase dilute phase catalyst loading, and would require considerable unit modification.
We have found a simple, direct, and economical solution in that the apparatus and method of distributing catalyst into the regeneration vessel can dramatically affect the quality of the flue gas emissions produced upon coke combustion.
Previous art regarding catalyst distribution has focused on improved catalyst mixing in the regenerator to provide more complete and efficient catalyst regeneration. Better distribution and mixing also avoid dilute phase CO combustion or afterburning in the offgas. U.S. Pat. No. 5,773,378 disclosed a spent catalyst distributor apparatus and retrofit method to radially discharge spent catalyst and 10-50% of the regeneration air into the dense phase of the catalyst. U.S. Pat. No. 5,635,140 showed a self-aerating spent catalyst distributor to discharge catalyst radially and downwardly from a centerwell via lipped trough arms into the catalyst bed. U.S. Pat. No. 4,150,090 disclosed a similar system but included an aeration means in the trough arms to assist in fluidization and expulsion from the troughs.
An article disclosed an extension to a spent catalyst standpipe that directs catalyst into a fluidized trough located below the catalyst bed level. Joseph Wilson and Chris Ross, FCC Revamp Improves Operations at Australian Refinery , OIL & GAS JOURNAL, Oct. 25, 1999, at 63.
U.S. Pat. No. 4,615,992 disclosed a process for regeneration which included a horizontally placed baffle located below the catalyst bed level, and a concentric well pipe extending around a vertical standpipe.
U.S. Pat. No. 5,156,817 disclosed additional devices for discharging catalyst admixed with gas into a regeneration bed.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method and apparatus that simplifies the reducing or eliminating of non-uniformity in the delivery of particles into a fluidized particle bed within a vessel.
It is a further object of this invention to provide an apparatus and method for distributing spent catalyst uniformly onto a catalyst bed within a fluidized regenerator.
It is a further object of this invention to provide a method and apparatus that is susceptible to simple repair, replacement, or modification that provides a well dispersed spent catalyst layer across the top of a catalyst dense bed within a fluidized catalytic cracking regenerator.
It is a further object of this invention that the spent catalyst delivered to the top of the regenerator dense bed provide a curtain of coke that acts to reduce NO x to N 2 and CO 2 .
The objects of this invention are achieved by a specific form of a catalyst distributor arrangement that places coked catalyst horizontally into regenerator and onto the surface of the dense phase bed. The surface of the catalyst bed is considered to be within the upper and lower fluctuations of the transition boundary from a dense fluidized catalyst phase to a dilute flue gas phase with entrained catalyst. A hydraulic head of accumulated catalyst in a fluidized hopper vessel acts to provide the driving force for catalyst transport and flow. Dispersion onto a catalyst bed takes place through a header connected with multiple outlet arms. An aeration means can assist flow within the header by providing additional fluidization gas.
Other mechanical and operational advantages can result from the incorporation of this invention. Such advantages include FCC unit debottlenecking. Since the delivery of spent catalyst is more uniform, it is possible to contain more CO burning within the catalyst bed. This reduces the amount of afterburn in the dilute phase which often limits the effectiveness or capacity of many FCC units. This allows oxygen to be used more effectively, thus increasing the coke burning capacity at the same air flow rate. An additional mechanical advantage is the ease of installation into existing regeneration vessels, which allows revamps to be accomplished within a typical existing unit turnaround schedule.
Accordingly, in one embodiment, this invention is a method of regenerating FCC catalyst in a regenerator having a spent catalyst inlet for receiving spent catalyst from a stripper and an air distribution system at a lower end of the regenerator; wherein the method comprises the following steps. First, collecting catalyst from the spent catalyst inlet in a hopper and fluidizing the collected catalyst to provide a hydraulic head to assist catalyst flow. The next step is passing the catalyst to multiple points near a surface of a dense phase catalyst bed using a horizontally extended header having a plurality of horizontally extended outlet arms. Catalyst may also be passed through an opening in the hopper to a point near the surface of the catalyst bed. The next step is contacting the catalyst with fluidization gas in the regenerator to burn off at least part of the coke present on the spent catalyst. Finally, a regenerated catalyst is produced which then can be recovered from a dense phase of the catalyst bed. In preferred embodiments the hopper is fluidized with an air distributor located at the bottom of the hopper, and the header is fluidized with a means for aeration such as an aeration lance inserted into the header to further assist catalyst flow. The fluidization gas preferably comprises air. The top of the hopper is open to the regenerator. The method further preferably includes the step of producing a recovered off gas, or regenerator flue gas, containing reduced NO x as a result of the improved catalyst distribution.
In an apparatus embodiment, this invention has a hopper, an air distributor located at the bottom of the hopper, and a horizontally extended header having a plurality of horizontally extended outlet arms for placing catalyst near the top surface of the catalyst bed within a FCC regenerator. The header is in communication with the hopper. When this apparatus is installed in a regenerator having a spent catalyst standpipe, the hopper is in communication with the spent catalyst standpipe and the header is fixed with respect to the wall of the regenerator. The hopper also contains an outlet on its side in order to pass a portion of the catalyst near the top surface of the bed. In preferred embodiments, the header further comprises a means for aeration, which can be further characterized as an aeration lance with a plurality of orifices. The hopper is open at the top to provide an alternate contingency means for catalyst transport into the regenerator. The outlet arms may be arranged at various angles and places on the header, with a preferred angle range being 30 to 150 degrees, and an especially preferred angle range being 55 to 100 degrees. Drains may also be placed in the header to permit additional alternative pathways for catalyst flow to the regenerator.
Additional objects, embodiments, and details of this invention can be obtained from the following “detailed description”.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic elevational view of an FCC process incorporating the present invention.
FIG. 2 is a schematic elevational view of the regenerator of the present invention.
FIG. 3 is a cross-sectional view of the regenerator taken along segment 3 — 3 in FIG. 2 .
FIG. 4 is an enlarged bottom view of the hopper air distributor.
FIG. 5 is an enlarged side view of the header aeration lance.
DETAILED DESCRIPTION OF THE INVENTION
An FCC process unit, generally referred to with reference numeral 1 and shown schematically in FIG. 1, generally comprises two main zones for reaction and regeneration. A reaction zone is usually comprised of a vertical conduit, or riser 9 , as the main reaction site, with the effluent of the conduit emptying into a large volume process vessel, which may be referred to as a separation vessel 7 . In the reaction zone, a feed stream 91 is contacted with a finely divided fluidized catalyst at an elevated temperature and at a moderate positive pressure. The feed stream 91 to the FCC unit consists of a mixture of hydrocarbons having boiling points above about 232° C. In the riser, feed is contacted with a relatively large fluidized bed of catalyst. The residence time of catalyst and hydrocarbons in the riser needed for substantial completion of the cracking reactions is only a few seconds. The flowing vapor/catalyst stream leaving the riser 9 passes from the riser to a solids-vapor separation device, known as a cyclone 25 , normally located within and at the top of the separation vessel 7 . The products of the reaction are separated from a portion of catalyst which is still carried by the vapor stream by means of the cyclone 25 and the products are vented from the cyclone 25 and separation vessel 7 via line 92 . The spent catalyst falls downward to a stripper 27 located in a lower part of the separation vessel 7 . Catalyst is transferred to a regeneration vessel 5 by way of a conduit 21 connected to the stripper 27 .
The reaction zone is maintained at high temperature conditions which generally include a temperature above about 427° C. and a pressure of from about 69 to 517 kPa (gauge). The catalyst/oil ratio, based on the weight of catalyst and feed hydrocarbons entering the bottom of the riser, may range between about 4:1 and about 20:1. The average residence time of catalyst in the riser is preferably less than about 5 seconds. The type of catalyst employed in the process may be chosen from a variety of commercially available catalysts. A catalyst comprising a zeolitic base material is preferred, but the older style amorphous catalyst can be used if desired. Further information on the operation of FCC reaction zones may be obtained from U.S. Pat. No. 4,541,922 and U.S. Pat. No. 4,541,923 and the patents cited above.
In the FCC process again as illustrated in FIG. 1, the catalyst is continuously circulated from the reaction zone to the regeneration vessel 5 and then again to the reaction zone. The catalyst therefore acts as a vehicle for the transfer of heat from zone to zone as well as providing the necessary catalytic activity. Catalyst employed in the reaction zone which is being transferred to the regeneration zone for the removal of coke deposits is referred to as “spent catalyst”. The term “spent catalyst” is not intended to be indicative of a total lack of catalytic activity by the catalyst particles. Catalyst, which is being withdrawn from the regeneration vessel 5 , is referred to as “regenerated” catalyst. The spent catalyst being charged to the regeneration zone via conduit 21 may contain from about 0.2 to about 5 wt-% coke. This coke is predominantly comprised of carbon and can contain from about 5 to 15 wt-% hydrogen, as well as sulfur and other elements. The catalyst charged to the regeneration zone enters a regeneration vessel in which it is brought into contact with an oxygen-containing regeneration gas 15 such as air or oxygen-enriched air under conditions which result in combustion of the coke.
The regeneration vessel 5 is normally operated at a temperature of from about 500° to about 900° C., more usually between 600° to 750° C. The operating pressure is preferably from about 34 to about 517 kPa (gauge). Additional information on the operation of FCC regeneration zones may be obtained from U.S. Pat. Nos. 4,431,749, 4,419,221 and 4,220,623.
Combustion of coke raises the temperature of the catalyst and produces regenerated catalyst which exits via a withdrawal conduit 6 and a flue gas which exits via line 17 containing carbon monoxide, carbon dioxide, water, nitrogen, and perhaps a small quantity of oxygen. Flue gas is separated from entrained regenerated catalyst by the cyclone 23 separation device located within the regeneration vessel 5 and exits the regeneration vessel 5 by line 17 . Regenerated catalyst which was separated from the flue gas is returned to the lower portion of the regeneration zone which typically is maintained at a higher catalyst density. A stream of regenerated catalyst leaves the regeneration zone via the withdrawal conduit 6 and, as previously mentioned, contacts the feed stream 91 in the reaction zone.
As known to those skilled in the art, the regeneration vessel 5 may take several configurations, with regeneration being performed in one or more stages. Further variety is possible due to the fact that regeneration may be accomplished with the fluidized catalyst being present as either a dilute phase or a dense phase within the regeneration zone. The term “dilute phase” is intended to indicate a catalyst/gas mixture having a density of less than 320 kg/m 3 . In a similar manner, the term “dense phase” is intended to mean that the catalyst/gas mixture has a density equal to or more than 320 kg/m 3 . Representative dilute phase operating conditions often include a catalyst/gas mixture having a density of about 16 to 160 kg/m 3 .
FIGS. 2 and 3 show regeneration vessel 5 of the FCC unit 1 in detail. Discussion of the regeneration vessel will first proceed with reference to FIG. 2 . Cyclones 23 with connecting diplegs normally positioned in the upper portion of a regeneration vessel 5 are not shown to simplify the drawing. A catalyst inlet conduit 4 is provided for introducing spent catalyst containing carbonaceous deposits from the stripper 27 to the regeneration vessel via the conduit 21 . A valve in the standpipe controls catalyst flow. The conduit 4 may be positioned to provide for tangential introduction of the finely divided catalyst particles to the regeneration vessel 5 . The wavy line indicates a top surface of a dense phase catalyst bed 19 . The top surface of the dense phase catalyst bed 19 is within the upper and lower fluctuations of the transition boundary from a dense fluidized catalyst phase to a dilute flue gas phase with entrained catalyst. A conduit 6 extending upwardly into the vessel and terminating in a conical inlet 8 above a regenerator gas distributor grid 13 provides means for withdrawing regenerated catalyst from the vessel 5 . The regeneration vessel 5 is provided with a conical bottom 10 . A regeneration gas inlet conduit or manifold 12 concentrically extends upwardly through the conical bottom of the vessel and terminates at a level substantially coinciding with the lowest vertical wall portion of the vessel 5 . A plurality of conduits 14 extends substantially horizontally outwardly from the concentric manifold 12 to provide the distributor grid 13 . Support conduits 16 in open communication with conduits 12 and 14 provide structural support to the grid means in addition to providing additional regeneration gas to outer portions of each segment of the distributor grid 13 . Pipes 18 horizontally extend substantially at right angles to conduits 14 .
In the apparatus of FIG. 2, the regeneration gas enters the bottom of the vessel by vertically extending manifold 12 and passes out through conduits 16 and 14 to distributor pipes 18 . The regenerating gas passed to pipes 18 then passes out through holes or nozzles along the bottom surface of the pipes and then upwardly through the bed 19 of catalyst to be regenerated under dense fluid phase regeneration conditions. Regenerated catalyst is withdrawn from the vessel above the grid by the inlet 8 communicating with conduit 6 . The inlet to withdrawal conduit 6 may be as shown in FIG. 2 or it may be extended upwardly into the vessel so that regenerated catalyst is withdrawn from an upper portion of the dense fluid bed 19 of catalyst rather than a lower portion thereof as shown. Regeneration gas after passing through suitable cyclone separators not shown and positioned in an upper portion of the regenerator passes into a plenum chamber not shown and then out the top of the regeneration vessel through opening 24 to line 17 .
The catalyst distributor of the present invention is generally referenced with numeral 22 . Spent catalyst is collected in a vertically extending hopper 26 from catalyst inlet conduit 4 and fluidized with an air distributor 28 . FIG. 4 illustrates enlarged details of the air distributor 28 . The hopper air distributor 28 receives gas from through a conduit 31 that passes through the regenerator wall 47 and the side of the hopper 26 . A plurality of conduits 33 may extend horizontally from the conduit 31 to provide a grid located at the bottom of the hopper 26 . Gas may then pass out through holes 103 or nozzles along the bottom surface of the conduits 33 and then upwardly through the hopper 26 . The holes 103 or nozzles may also be configured by any means known to the art, for example as alternating recessed angled jets, dual offset jet nozzles, or single nozzles descending linearly from any angle desired, such that the main function of transferring fluidization gas occurs with a minimum of catalyst damage. The hopper 26 provides a hydraulic head to pass catalyst down a horizontally extended header 34 and out a plurality of horizontally extended outlet arms 36 and 46 and thereby onto multiple points on the surface of a dense catalyst bed 19 . The hopper 26 can be affixed to a wall 47 of the regenerator with a support 32 . The hopper 26 may also contain an outlet 29 which also allows catalyst to pass to a point near the top of a surface of the dense phase bed. The top of the hopper is open and in communication with the regeneration vessel. The hopper top provides an alternative contingency path into the regenerator as well as provides pressure equalization between the catalyst conduit 21 and the regeneration vessel 5 . The header 34 may also be fixed to the regenerator wall 47 , as shown by header support bracket 38 . In a preferred embodiment, the header is fluidized by an aeration lance 40 shown in dashed lines in FIG. 3 . Furthermore, FIG. 5 illustrates enlarged details of the aeration lance 40 . The lance is shown within the header 34 , which has been shown in dashed lines for illustrative purposes in FIG. 5 . The aeration lance 40 contains a plurality of orifices or nozzles 111 to introduce fluidization gas to further assist in catalyst transport from the hopper to the outlet arms. These orifices or nozzles 111 may be configured by any means know to the air distribution art, which allows fluidization gas to pass through. Alternating nozzle jets may be used to effect the gas transfer from the bottom side of the lance, where every other nozzle 111 typically contains a small downwardly angled jet insert. Gas is passed through conduit 115 which goes through the regenerator wall 47 and into the header 34 . The header support bracket 38 and brackets 113 that support the aeration lance are also shown in FIG. 5. A control valve in line 42 also regulates airflow to the header aeration lance 40 . In an alternate preferred embodiment, means for aeration of the header may be achieved by extending the hopper air distributor conduit 31 into the header 34 , and providing the conduit extension with at least one orifice or nozzle to introduce fluidization gas directly into the header. Finally, downwardly projecting drains 44 are located in the header beneath the outlet arms.
FIG. 3 illustrates a cross-sectional view of the catalyst distributor. The drawing has been simplified by eliminating the regenerator gas distributor grid 13 . Three outlet arms 36 , 46 are shown which intersect the header 34 at an angle of 90 degrees from the direction of catalyst flow. An alternative angle of 60 degrees also would provide excellent flow in an alternative preferred embodiment. The outlet arms 36 , 46 are shown as tubular piping conduits similar to the header 34 . One set of outlet arms 36 is symmetrically branched occupying both sides of the header. Another outlet arm 46 is placed only on one side of the header 34 in an asymmetric manner opposite to the axial location of the inlet 8 for the regenerated catalyst withdrawal This configuration allows for uniform mixing when the inlet 8 for regenerated catalyst withdrawal is located beneath the other side of the header 34 as shown.
The operation of the catalyst distributor proceeds via the steps of collecting catalyst from the spent catalyst inlet 61 in the hopper 26 . The air distributor 28 fluidizes the catalyst and passes the catalyst into the header 34 . The catalyst passes through the plurality of outlet arms 36 and 46 of the header 34 onto multiple points on or near a surface of a dense phase catalyst bed 19 . Catalyst may also be passed from the hopper 26 through the outlet 29 onto or near the surface of the dense phase catalyst bed 19 . The catalyst then contacts regeneration gas to produce a regenerated catalyst along with an off gas having reduced NO x content.
This invention has been presented with reference to the drawings. These depict particular embodiments of the invention and are not intended to limit the generally broad scope of the invention as set forth in the claims. | An distributor arrangement introduces spent FCC catalyst more uniformly across the dense bed of the regenerator to provide more even contact with regeneration gas in order to avoid hot spots and zones of incomplete combustion. The invention forms a fluidized hopper to collect spent catalyst and a horizontally extended header with multiple horizontally extended outlet arms to place catalyst into the regenerator. The invention may use an aeration means to fluidize the header to further assist catalyst flow. Furthermore, the spent catalyst delivered to the top of the regenerator dense reduces NO x emissions in the flue gas. | 1 |
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to the cooling of vacuum devices. More particularly, the present invention relates to a method and apparatus for cooling a thermal load in a vacuum device that results from such factors as gas flow from a vacuum chamber to an exhaust pump.
2. Description of the Prior Art
A vacuum pump, such as the cryopump 3 shown in FIG. 1, is used in the prior art to evacuate a process gas from a vacuum chamber 2 and thereby maintain a stable, selected vacuum in the interior of the vacuum chamber, while constantly purging the chamber of expended process gases. Because the cryopump requires specific operating conditions, it is usually necessary to reduce the thermal load on cryopump. For example, heat transfer to the cryopump from the process gas may be prevented by a heat shield 41, which absorbs heat from the gas, as well as any radiation heat. The heat shield 41 is cooled by a flow of cooling water, thereby increasing the heat shield cooling efficiency.
It is necessary to position a cooling pipe 42 within the vacuum chamber to provide a flow of coolant to cool the heat shield 41 because the heat shield is located within the vacuum chamber. Consequently, it is necessary to provide openings in the outer wall of the vacuum chamber to allow the cooling pipe 42 to be admitted into the vacuum chamber. The openings must be airtight under vacuum conditions and therefore must include a seal 43 to maintain the vacuum within the vacuum chamber interior. Because the vacuum chamber is used for extended periods of time, the seal 43 is subjected to repeated stress and is easily damaged, such that ambient air leaks through the openings, preventing maintenance of a vacuum in the vacuum chamber.
Because a seal 43 is needed, the vacuum chamber configuration can become complicated. For example, even when it is only necessary to repair the vacuum chamber heat shield 41 and cooling pipe 42, it is still necessary to exchange the entire vacuum chamber. Furthermore, if the cooling pipe is damaged, then cooling water may leak into the vacuum chamber, damaging both the chamber and any work in progress.
It would be advantageous to provide a simple, high integrity system for cooling a vacuum system that did not suffer from the above limitations.
SUMMARY OF THE INVENTION
The present invention solves the problems of prior art vacuum cooling systems by providing a new cooling structure for vacuum equipment. The invention provides a cooling structure for a vacuum system, including a vacuum chamber having a vacuum chamber flange; a suction pump having a suction pump flange; an external frame, which is also used as a fixing seal, having at least a portion of its peripheral surface exposed; a cooling panel, positioned in a partition that surrounds the external frame, and having an opening formed therethrough to allow a fluid flow between the vacuum chamber and the suction pump; and a cooling means which is adapted to cool the cooling panel. The external frame portion of the cooling panel is positioned between the vacuum chamber flange and the suction pump flange, such that the vacuum chamber is readily sealed under high vacuum operating conditions. The fluid flow opening formed through the partition promotes cooling of a fluid passing therethrough.
The cooling means preferably consists of a cooling pipe arranged to make contact with the exposed peripheral cooling panel frame surface, and a coolant circulating means for supplying coolant to the cooling pipe. The cooling means may alternatively consist of a pipe having an opening inside the cooling panel. The cooling pipe is arranged on the outside of the vacuum chamber. Thus, if the cooling pipe is broken, no coolant can leak into the vacuum chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially cut oblique view illustrating the cooling structure of a prior art vacuum device;
FIG. 2 is an exploded view illustrating a cooling structure of a vacuum device in accordance with the invention;
FIG. 3 is a top plan view illustrating a cooling panel for use with a vacuum chamber in accordance with the invention;
FIG. 4 is a side view of the cooling panel of FIG. 3;
FIG. 5 is an oblique view illustrating an alternative cooling panel for use with a vacuum chamber in accordance with the invention; and
FIG. 6 is an oblique view of another alternative cooling panel for use with a vacuum chamber in accordance with the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 is an exploded view of the cooling structure of a vacuum device in accordance with the invention. As shown in the figure, a cooling panel 1 is sandwiched between a vacuum chamber 2 flange 21 and a cryopump 3 flange 31. A cooper cooling pipe 61 is positioned in intimate contact with a cooling panel peripheral surface. The cooling pipe 61 is connected via a circulating pump 62 to coolant tank 63. A heat exchanger (not shown in the figure) that dissipates heat collected by the coolant fluid is positioned between the circulating pump 62 and the cooling pump 61.
It should be appreciated that the cooling pipe need not be made of copper, but may be made of any other thermally conductive material. While copper is also used in manufacturing the external frame portion and partition portion of the cooling panel, other materials may be used as well. The materials used in manufacturing the external frame portion and partition portion of the cooling panel and the cooling pipe may be different from each other. Additionally, although the coolant in the exemplary embodiment of the invention is water, other coolant fluids, including gases and liquids, such as nitrogen gas, and freon, may be used when practicing the invention.
FIG. 3 is a top plan view of a cooling panel for use with a vacuum chamber in accordance with the invention. As shown in FIGS. 2 and 3, the cooling panel 1 is made from a circular copper plate which is processed to leave an external frame portion 11 in contact with the vacuum chamber flange 21 and cryopump flange 31, a central panel 12, and four supporting bars or spokes 16 that connect the central panel to the external flange 11. The cooling panel defines four fan-shaped windows 13 that are formed therethrough. The central panel 12 is configured such that it does not contact the flanges 21 and 31. Thus, the four supporting bars 16 form a partition. In this configuration, the partition defines openings that allow a fluid flow therethrough, such that the fluid is cooled as it passes through the openings, and comes into contact with the surfaces of the partition.
FIG. 4 is a side view of the cooling panel of FIG. 3. Ring-shaped bumps 14 that act as gaskets are formed on the outer surface and inner surface of the cooling panel external frame 11. The bumps 14 are adapted for complementary engagement with a groove (not shown on the figure) formed on the vacuum chamber flange 21, and with a groove 32 formed on the cryopump flange 31. Such engagement seals the cooling panel frame to the vacuum chamber and cryopump, and thereby prevents penetration of the ambient into the vacuum chamber interior, while also preventing leakage of the fluid within the vacuum chamber to the ambient. Thus, the cooling panel external frame 11 form a seal between the cooling panel and vacuum chamber flange 21 and cryopump flange 31.
The fluid inside the vacuum chamber 2 is exhausted from the chamber by the cryopump 3. The fluid flows through an opening 13 arranged on the cooling panel. As the fluid flows through the window 13, heat is removed from the fluid by contact between the fluid and the cooling panel, especially from the partition comprising the central panel 12 and the four supporting bars or spokes 16. Heat is removed from the cooling panel by a coolant that is circulated in the cooling pipe 61 which is arranged on the cooling panel peripheral surface. Accordingly, ca fluid flowing through the opening in the cooling panel is continuously cooled.
The coolant flows from a water tank 63 to a circulating pump 62, and thereafter through the cooling pipe 61. Heat is released from the coolant when the coolant flows through the heat exchanger. The coolant is then recirculated to remove heat from cooling panel. This operation is repeated, the fluid is exhausted by the cryopump 3 from the vacuum chamber 2 and cooled. Radiated heat is also removed from the vacuum chamber in this way. Because the gas can be cooled and radiated heat can also be removed from the vacuum chamber, this configuration is particularly useful in applications having a high thermal load.
The cooling panel external frame 11 also functions as a fixing seal. It is therefore possible to circulate the cooled fluid to the cryopump 3, while preventing entry of the ambient into the vacuum chamber. Because the cooling panel 1 is arranged between the vacuum chamber flange 21 and the cryopump flange 31, it is easily installed between the vacuum chamber and the cryopump. Accordingly, if it is necessary to service the cooling panel, or if the cooling panel is to be mounted from a rear side, the cooling panel is easy to install, remove, and reinstall without exchanging or modifying the vacuum chamber. There is no need to arrange a heat shield or other unit in the vacuum chamber as is necessary in prior art cooling systems. Accordingly, the invention provides a vacuum system in which the configuration of vacuum chamber itself is simple. Finally, because the cooling pipe 61 is arranged on the peripheral surface of the cooling panel/fixing seal 1, in the event of a broken cooling pipe 61, the coolant will not leak into vacuum chamber.
The profile of the cooling panel is not limited to that shown in FIGS. 2, 3, and 4. For example, FIG. 5 is an oblique view of an alternative cooling panel for use with a vacuum chamber in accordance with the invention. In FIG. 5, a cooling panel is shown having an external flange 11 that is in contact with the end surfaces of the flanges 21 and 31, and having a partition portion 17 that is not in contact with the end surfaces of the flanges 21 and 31. The partition 17 has multiple apertures 15 formed therethrough that function in much that same way as the openings of the embodiment of the invention that is discussed above.
In another embodiment of the invention, the cooling panel has an external frame that is in contact with the end surfaces of the flanges 21 and 31, and that has a partition that is not in contact with the end surfaces of the flanges 21 and 31. Apertures of a selected size are formed through the partition. Multiple dips and bumps are formed on the inner peripheral surfaces of the apertures to increase the heat-dissipating area. Accordingly, the invention is not limited to a particular opening shape.
FIG. 6 is an oblique view of another alternative cooling panel for use with a vacuum chamber in accordance with the invention. As described above, a cooling pipe is arranged on the peripheral surface of the cooling panel 1 and a coolant is circulated in the cooling pipe to remove heat from cooling panel. In the embodiment of FIG. 6, holes are drilled in the cross-shaped partition 18 inside the cooling panel to form an integrated cooling pipe that is connected to a pipe 64 through which a coolant is circulated. Heat is transferred from the fluid that flows between the vacuum chamber and the cryopump to the cooling panel, and the heat thus collected is removed from the interior of cooling panel partition 18 by the coolant flowing within the cooling panel.
Although the invention is described herein with reference to the preferred embodiment, one skilled in the art will readily appreciate that other applications may be substituted for those set forth herein without departing from the spirit and scope of the present invention. For example, the invention is not limited to a cryopump, and may also be used when the vacuum chamber is evacuated by other types of pumps. Accordingly, the invention should only be limited by the claims included below. | A cooling structure for a vacuum device includes an external frame portion positioned between vacuum chamber flange and cryopump flange; a cooling panel formed in a partition surrounded by said external frame, the cooling panel having an opening that allows a fluid flow between said vacuum chamber and said cryopump; a cooling means positioned in contact with an exposed peripheral cooling panel surface for cooling said cooling panel; and a coolant feeding means for supplying coolant to the cooling means. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a method of controlling the placement of a cross-linked polymer gel in a subterranean formation for reducing permeability and improving sweep control. More specifically, it is concerned with the sequential injection of a slug of a cross-linkable polymer, a cross-linking agent and sequestering agent to achieve deeper polymer placement.
For many decades, the oil and gas industry has recognized the desirability, especially in enhanced oil recovery operations, of being able to selectively control the permeability of hydrocarbon bearing formations in order to reduce unwanted water production and to optimize oil and gas production by reducing the "fingering" of enhanced oil recovery fluids through porous reservoir regions. Thus, concepts such as permeability control, formation plugging, selective fluid placement, mobility control and the like are an integral part and significant feature in many aspects of oil and gas production processes including waterflooding, miscellar flooding and other related processes. In particular, the oil and gas industry has generically suggested and commercially used a variety of water soluble polymer-forming reactants which after being injected into the water bearing portion of the formation are polymerized or gelled such as to reduce the permeability of the previous water producing region. One specific technique involves the placement in the formation of a cross-linkable polymer solution which is followed by a cross-linking agent. In actual commercial implementation, the most frequently suggested polymers are polyacrylamides, polysaccharides, cellulosic polymers and lignosulfonates. Similarly, the most frequently used cross-linking agents are aluminum in the 3+ valence state and the dichromate species.
The process which is of particular relevance to the present invention involves the sequential cyclic injection scheme of introducing an aqueous cross-linkable polymer solution into the subterranean formation followed by a slug of a cross-linking agent made up of a multivalent cation accompanied by a sequestering anion. In U.S. Pat. No. 3,762,476, a process for reducing the quantity of water recovered from a subterranean formation involving the in situ cross-linking of a partially hydrolyzed polyacrylamide with aluminum citrate is disclosed. The claimed process involves the injection of the aqueous polymer solution followed by a slug of complexing ionic solution of multivalent cations and retarding anions capable of gelling the polymer solutions, and then the injection of brine, followed by a second injection of the polymer solution. The brine serves to prevent premature polymer cross-linking in the injection lines prior to actual injection into the formation. In U.S. Pat. No. 3,833,061, the polymer/cross-linking agent/polymer injection sequence is improved by preflushing the formation with a solution containing an oxidizing agent to remove hydrocarbons from the surface of the formation prior to in situ gelation of the polymer. In U.S. Pat. No. 3,926,258, a single slug injection scheme is proposed wherein the cross-linkable polymer is placed in solution with a multivalent cation cross-linking agent at a valence state above the lower valence state which promotes cross-linking, plus a complexing agent and a reducing agent, thus achieving a delayed gelation and extended gel time for deeper formation penetration. In U.S. Pat. No. 3,981,363, the basic two-step sequential injection of polymer/cross-linking agent is modified in that the polymer is partially cross-linked prior to injection.
Although these processes have been commercially implemented and have met with at least partial success, a still-unresolved problem, prior to the present invention, involved the tendency for excessive polymer retention at the face of the formation in the wellbore where injection occurs, particularly after repeated injection cycles. This excessive polymer retenion led to severely limited penetration of the polymer through the formation, and reduced the effectiveness of the polymer in reducing formation permeability.
SUMMARY OF THE INVENTION
A method for treating a subterranean formation involving the sequential injection of, first, an aqueous solution of a cross-linkable polymer solution (e.g., polyacrylamide) followed by an aqueous solution of a cross-linking agent consisting of a multivalent cation and a retarding anion (e.g., aluminum citrate) and thereafter injecting an aqueous salt solution of an alkaline metal cation and a sequestering anion. Repeated injection cycles of this three-step scheme alleviates the problem of formation plugging at the wellbore due to excessive polymer retention previously experienced during a two-step scheme of polymer solution injection followed by a cross-linking agent. The present invention permits controlled deep penetration of the cross-linked polymer into the formation without formation plugging at the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphic representation of a prior art polymer injection sequence as disclosed in U.S. Pat. No. 3,762,476.
FIG. 2 is a graphic representation of the injection sequence of an embodiment of the present invention.
FIGS. 3(A)-3(B) is a schematic view of reservoir response to the injection sequence of an embodiment of the present invention.
FIG. 4 represents the effect of reservoir discontinuities on fluid floods of reservoirs.
DETAILED DESCRIPTION OF THE INVENTION
It is believed that a better appreciation of the significance of the present invention may be gained if the approach disclosed in U.S. Pat. No. 3,762,476 is first reviewed. As used herein, "resistance factor" (RF) is defined as the permeability reduction achieved during the polymer cross-linking treatment or polymer injection, and "residual resistance factor" (RRF) is defined as the retained permeability reduction after water injection subsequent to the polymer/cross-linking agent treatment.
The procedure disclosed in U.S. Pat. No. 3,762,476 to achieve in situ cross-linking involves the sequential injection of aqueous solutions of polymer and cross-linking agents. An initial injection of polymer is thought to provide the absorbed or retained polymer for succeeding cycles of the cross-linker and polymer solutions. Under this theory the injection of the cross-linking solution attaches a metal ion (as described in greater detail below) to the retained polymer and prepares the retained polymer molecules to cross-link with the next injected polymer slug, resulting in a layer of cross-linked polymer which has a greater RF and RRF than does the polymer alone. The next slug of polymer cross-links with the retained polymer at the sites of retained metal ions and plugs off a portion of the permeable area to flow. After successive injections of polymer, flow through the porous zones can be substantially reduced.
While numerous different polymers can be used herein (and which are noted hereinafter), unless noted otherwise, the core tests reported herein were performed with a mildly sheared and filtered Dow Pusher 700 solution, a polyacrylamide manufactured by Dow Chemical Company. The purpose in using a mildly sheared polymer is to simulate polymer behavior in a field situation. The Pusher 700 was produced by forcing the unsheared, diluted polymer through a 7 micron stainless steel filter (NUPRO SS 4FE 7) by applying 25 psi air pressure to a transfer vessel containing the polymer. The approximate shear rate was 3500 sec -1 .
A core resistance profile performed in accordance with known technology is shown in FIG. 1. In this test, a saturation flood was performed and each injection sequence was terminated when no change in pressure was detected throughout the core. After two cycles of the aluminum citrate-polymer sequence, essentially all of the flow resistance occurred in the first few inches of the core. As can be seen in FIG. 1, the line representing the initial polymer injection has a maximum RF of about 14.0, whereas after the first full injection cycle, the RF has increased to approximately 100, and after the second full injection cycle the RF has increased to approximately 400. The downstream RF values, especially after the second injection sequence, are markedly reduced because, it is thought, of the inability of the polymer to penetrate the cross-linked polymer plug in the first few inches of the core. The decrease in the downstream RF after each additional injection sequence may be due to the penetration of the aluminum citrate slug which further delinks and dilutes a portion of the polymer that has penetrated. In order to overcome this effect, it is thought that a significantly greater volumes of polymer need to be injected as the number of cycles increases.
Two methods proposed for obtaining deeper polymer propagation are using shear degraded polymers or hydrating the polymer in a high salinity brine. Each of these methods reduces the physical volume of the polymer molecules and results in lower resistance level increases for each cross-linking cycle. Each of these is undesirable due to the concurrent decrease in effective molecular size (occupied volume) of the polymer and consequent decrease in porosity reduction.
Therefore, the present invention contemplates the use of a spacer consisting of an alkaline metal cation and a sequestering anion between the cycles of polymer+ cross-linker solution (multivalent cation and sequestering anion). It is thought that the anion of the spacer of the present invention will remove a portion of the multivalent cations previously injected into and retained by the polymer network near the injection site in the wellbore and therefore permit subsequently injected polymer to propagate deeper into the formation (without being cross-linked at the face of the formation). The in situ formation of a polymer network requires that the cross-linker solution contact the polymer molecules, so that when the solutions are injected alternately, the cross-linker must interact with the adsorbed polymer portion of the previously injected polymer solution. Therefore, more effective permeability modifications can be obtained with water soluble polymers that possess the property of residual resistance.
Suitable polymers for use herein are not limited to, but can be selected from the group comprising of polyacrylamides, partially hydrolyzed polyacrylamides, polysaccharides, carboxymethylcellulose, polyvinyl alcohol, polystyrene sulfonates, polyacrylonitriles, partially hydrolyzed polyacrylonitriles, polyacrylic acid, polyvinylpyrrolidone, copolymers of acrylonitrile with acrylic acid or 2-acrylamido-2-methyl-1-propane sulfonic acid, and the like.
Additional polymers for use in the present invention include copolymers of acrylamide and acrylic acid or other vinylic or polyolefinic monomers, partially hydrolyzed copolymers of acrylamide and acrylic acid or other vinylic monomers, copolymers of acrylonitrile and acrylic acid or other vinylic or polyolefinic monomers, partially hydrolyzed copolymers of acrylonitrile and acrylic acid or other vinylic or polyolefinic monomers, copolymers of acrylic acid and other vinylic or polyolefinic monomers, partially hydrolyzed copolymers of acrylic acid and other vinylic or polyolefinic monomers methylolated or sulfomethylolated forms of the above.
While the molecular weight of the polymer will probably vary with the particular formation characteristics, it is anticipated that a molecular weight of from 500,000 to 1 million is acceptable. The permeability of the formation and composition of the formation brine will determine what molecular weight polymer is used.
The polymer solutions can be prepared in either fresh water or formation brine. However, because formation brines may cause some shortening of the polymer molecule, it may be desirable to prepare the polymer solutions in fresh water using a presheared polymer. The concentration of the polymer in the solution can range from about 100 to about 10,000 ppm, more usually from about 250 to about 1,000 ppm.
The cross-linking agents useful in the present invention are prepared by reacting a multivalent cation selected from the group comprising, but not limited to, Fe 2+ , Fe 3+ , Al 3+ , Ti 4+ , Zn 2+ , Sn 4+ , Ca 2+ , Mg 2+ , and Cr 3+ and a retarding anion selected from the group comprising, but not limited to, ethylenediamine-tetracetic acid (EDTA) acetate nitrilotriacetate, tartrate, citrate, tripolyphosphate, metaphosphate, gluconate, and orthophosphate.
The novel spacers of the present invention comprise an alkali metal or ammonium cation and a sequestering anion. A multivalent cation complexing agent such as citric acid, tartaric acid, maleic acid or the alkaline salt of these acids provides an economical method of maintaining a high level of aluminum ion in solution. The alkali metal cation useful herein can be chosen from the group comprising, but not limited to, potassium or sodium. The sequestering anion suitable for use in the spacer herein includes, but is not limited to, EDTA, acetate nitrilotriacetate, tartrate, citrate, tripolyphosphate, metaphosphate, gluconate, and orthophosphate.
The injection of the polymer and cross-linker can be done sequentially or the polymer and cross-linker can be mixed prior to injection, although the latter can result in a much greater change of filtering out substantial amounts of polymer at the formation face thereby resulting in plugging. The cross-linking process can be controlled somewhat and plugging reduced by adjusting the solution pH, temperature and concentration of the multivalent metal cation. However, the process is preferably performed sequentially with alternate injections of polymer and cross-linking agents.
A novel spacer which Applicant has found to give acceptable results is sodium citrate. It is thought that citrate ion from the novel spacer forms a water soluble complex with the multivalent cation as, for example, aluminum, and releases a portion of the polymer previously cross-linked to a prior layer of polymer of the cation. The citrate-aluminum complex is then forced deeper into the formation where it reacts with the the polymer and provides future cross-linking potential. Assuming appreciable shear or breakage of the polymer does not occur, the previously cross-linked polymer can be driven deeper into the formation to provide future cross-linking potential.
The method of the present invention can be practiced in a saturation flood (wherein the polymer and multivalent cation are injected until injected solution is detected at a core exit, with a sodium citrate spacer therebetween) or a progressive small slug flood (wherein volumes of injected blends are gradually increased in successive cycles). The expense involved in injecting the large quantities of a saturation flood militate against its use and the experiments conducted by applicant have indicated the use of a progressive small slug flood to be more cost effective. The progressive small slug flood uses less than one pore volume quantity of each solution in a cycle. By gradually increasing the injected pore volume per cycle, the entire core (or formation) pore volume can be exposed to an RF greater than about 20 as compared to a polymer RF of about 12 to 14. As shown in FIG. 2, the polymer and aluminum citrate slug sizes were increased by 0.14 pore volume (the fluid volume of the pay zone in the formation under consideration) for each injection cycle. The sodium citrate spacers were increased by 0.14 pore volumes to provide increasing penetration of uncrosslinked polymer solutions. The approximate maximum RF for the uncrosslinked polymer is about 7 and the maximum RF range for the cross-linked polymer is 20-30.
The mole ratio of aluminum ion to citrate ion in the cross-linking solution can be from about 1:1 to about 4:1. The preferred mole ratio of aluminum:citrate is 2:1. It has been found that a mole ratio of 1:1 or less results in insufficient polymer cross-linking due to the unavailability of aluminum ions, while a ratio of 4:1 may result in aluminum hydroxide precipitation in the formation due to insufficient citrate.
Increasing the salinity of the polymer solution will tend to reduce the observed viscosity, RF and RRF, as well as reducing the degree to which the polymer is cross-linked. Increasing the salinity of the brine will decrease the effectiveness of the process due to the lower RF and RRF, but should increase the depth of penetration of the cross-linked polymer.
The method of the present invention can be useful when it is desired to move a bank of high flow resistance through a formation or reservoir. Extremely high RF's can be generated in localized portions of formations which may be utilized to increase oil recovery under appropriate conditions. As shown in FIG. 3(a), a highly permeable formation 20 is bounded by one or more oil-bearing formations 22, 24, having relatively lower permeability. After primary recovery of the formations has ceased and the reservoir is undergoing waterflooding, the water 26 injected in wellbore 28 has a tendency to preferentially enter formation 20, due to its high permeability, as opposed to less permeable formations 22, 24. The polymer "block" 30 injected into formation 20 tends to divert water 26, which is injected under pressure, into adjacent oil-bearing formations 22, 24, thereby recovering oil from formations 22, 24, which would otherwise not be recovered by waterflooding. By injecting subsequent cycles of polymer+cross-linker+spacer, the polymer plug 30 can be moved through the reservoir, as in FIG. 3(b), to permit recovery of oil from formations, as at 32, 34. In this manner, the wellbore region is maintained unplugged with low permeability reduction (equal to the polymer RF) and as each cross-linked cycle is completed, the injected polymer slug will progressively invade deeper into the formation.
When undergoing waterfloods, noncommunicating fractures may rob a waterflood of much of its effectiveness. As shown in FIG. 4, a fracture 40 through reservoir 42 may divert a substantial portion of the water 50 injected through injection well 44, thereby reducing the oil produced at production well 46.
By propagating a polymer slug or "block" through the reservoir as described above, and by emplacing the block upstream of the fracture in the object formation, the fracture 40 can be sealed off. Subsequent water-flooding bypasses the fracture and oil recovery from reservoir 42 is increased.
An additional effect of increasing the aluminum citrate, polymer and sodium citrate slug pore volume in successive cycles is that the RF maximum is broadened for each successive cycle. As shown in FIG. 2, approximately 80% of the core is exposed to an RF of greater than 10 after a total of only 3.85 pore volume total fluids in the method of the present invention. Without the use of the sodium citrate, applicant has found that at least six pore volumes polymer and four pore volumes aluminum citrate would be necessary to complete three cross-linked cycles in the formation while resulting in a much narrower RF coverage. Therefore, the injection time and chemical costs are substantially reduced using the method of the present invention.
Reasonable variation and modification are possible within the scope of the foregoing disclosure and the appended claims, and it should be understood that this invention is not to be unduly limited thereby. | A method and fluid for selectively reducing the permeability of an oil-bearing subterranean formation is disclosed, wherein a cross-linkable polymer, a cross-linking agent and a spacer fluid are alternately injected. The spacer, such as sodium citrate, permits repeated injection cycles of the polymer and cross-linking agents without excessive polymer retention at or near the formation face. Such retention filters out polymers and inhibits polymer propagation throughout the formation. The present invention also permits controlled deep penetration of the cross-linked polymer into the formation to increase oil recovery. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of German utility model application DE 20 2016 101 368.2, filed Mar. 11, 2016, wherein the entire content of this application is incorporated herein by reference.
BACKGROUND
[0002] The above-mentioned invention relates to a luminaire arrangement, in particular for providing lighting in or near buildings, the luminaire arrangement having a luminaire which includes a body and a lamp arrangement.
[0003] The lamp arrangement preferably includes one or more lamps having a low power consumption, such as an LED lamp arrangement. The lamp arrangement can be constructed in particular in the form of an array of lamps of this type. The luminaire also includes a body, to which the lamp arrangement is fixed.
[0004] Luminaire arrangements of this type are known as wall, table, ceiling or floor luminaires, to name a few examples. The lamp arrangement is generally electrically operated. Here, it is known to connect the lamp arrangement to a main power supply or another power source. For this purpose, suitable electrical lines can be laid in the body. However, it is also known to operate lamp arrangements of this type using rechargeable, secondary batteries or using primary batteries.
SUMMARY
[0005] On this basis, an object of the design is to specify an improved luminaire arrangement, an improved luminaire, an improved charging device, and also an improved method for operating a luminaire arrangement of this type.
[0006] The above problem is achieved by a luminaire arrangement, in particular for lighting in or near buildings, the luminaire arrangement containing one or more of the following components:
at least one portable luminaire, which has a body and a lamp arrangement, at least one energy store, which is connected to the luminaire, is rechargeable, and is designed to supply electrical power to the lamp arrangement of the luminaire, and at least one charging device, which is designed to recharge the energy store,
[0010] wherein the energy store being attachable by means of an interface arrangement to the charging device in order to recharge the energy store and/or in order to supply power to the lamp arrangement, and being separable from the charging device in order to take the luminaire as necessary to any target location to be lit.
[0011] With the luminaire arrangement according to the present design, a completely new type of lighting concept is provided. The basic concept lies in designing a luminaire so as to be portable and either attaching the luminaire to a charging device in order to recharge an energy store connected to the luminaire, or separating the luminaire from the charging device in order to take the luminaire as necessary to any location to be lit.
[0012] Consequently, by means of the portable luminaire, lighting can be provided in a mobile manner wherever it is currently required, for example for reading, for playing, for doing handicrafts, for activities performed by craftsmen, etc.
[0013] The portable luminaire here can be, in particular, a freestanding luminaire, but also a wall luminaire, a table luminaire, or a ceiling luminaire, to name a few examples. At the location to be lit, the portable luminaire can assume a normal operational position or operating position, which for example is a standing position, a leaning position, a plugged-in position or a hanging position. The charging process can be performed in the normal operational position. In a variant, however, it is preferably for the portable luminaire to be removed from the normal operational position in order to carry out a charging process. The normal operational position is preferably a position in which there is no main power supply connection provided by means of which the portable luminaire could be supplied with power.
[0014] The portable luminaire can be arranged in an indoors space for charging and can be taken outside to light a location, for example in a garden.
[0015] The lamp arrangement preferably has a power consumption that is less than 15 watts, in particular less than 10 watts. The lamp arrangement is preferably also designed to generate a luminous flux in a range of from 200 Im to 2,000 Im.
[0016] The rechargeable energy store preferably has a capacity in a range of from 2,000 mAh to 20,000 mAh.
[0017] The charging device can preferably be attached to a main power supply, such as a 220-volt grid, but can also be connected to a photovoltaic arrangement as power source.
[0018] The portable luminaire preferably has a weight in a range of from 500 g to 8,000 g, in particular in a range of from 1,000 g to 5,000 g. The luminaire also preferably has dimensions similar to conventional furniture luminaires.
[0019] The luminaire, in one embodiment, has dimensions such that it cannot be placed in a pocket of an item of clothing.
[0020] The body of the portable luminaire can be a housing of which the walls can be at least partially permeable to light. The body can be a one-piece rigid body, but can also be a multi-part body. In particular, the body can include a foot, which is connected to a main body, such as an arm or the like. The body can also have a head, which for example is connected to an arm or a pillar. It is particularly preferred if an arm or a pillar of a freestanding luminaire is rigidly connected to a foot, wherein a head can be mounted in an articulated manner on the arm or the pillar, the lamp arrangement being fixed to the head.
[0021] An interface of the interface arrangement is preferably also provided on the body. The interface on the body can be a standard interface, in particular a standard computer interface, such as a USB interface, a mini USB interface, or the like. Standard interfaces of this type generally include at least two DC contacts for providing a DC voltage, which can be used, preferably directly, to charge an electrical energy store inside the body, for example a voltage in a range of from 4 volts to 24 volts, i.e. a voltage as is also used for example to charge rechargeable batteries for mobile telephones.
[0022] The rechargeable electrical energy store of the luminaire arrangement preferably provides a DC voltage in a similar value range, this DC voltage being converted, where appropriate, by means of a converter circuit provided in the body to a voltage that is suitable for LED lamps, i.e. in particular a voltage of 12 volts or a voltage of 24 volts. In some embodiments the energy store can also provide a voltage of this type on the output side as standard.
[0023] A switching arrangement is preferably also provided on the body, by means of which switching arrangement the lamp arrangement can be switched on and switched off. The switching arrangement preferably includes a dimming device so as to be able to adjust the power consumption as necessary. The switching arrangement can include a contactless switch with or without dimmer.
[0024] The luminaire arrangement can include an individual portable luminaire, but can also include a plurality of portable luminaires.
[0025] The above object is also achieved by a method for operating a luminaire arrangement which comprises a portable luminaire having a lamp arrangement, an energy store, and a charging device, which can be connected to the energy store in order to charge the energy store, in particular in order to operate a luminaire arrangement of the type according to the present design, said method having the following steps: recharging the energy store by means of the charging device whilst the charging device is coupled to the energy store; detecting whether the energy store is coupled to the charging device; and, if the energy store is decoupled from the charging device, controlling the luminaire in such a way that power is supplied to the lamp arrangement.
[0026] In the present method according to the invention it is consequently detected whether the portable luminaire is connected to the charging device. As soon as the luminaire is decoupled from the charging device, power is supplied to the lamp arrangement so that the lamp arrangement can be used for lighting. Consequently, the luminaire can light up already on the way to a location to be lit and consequently can light the way for the person carrying the luminaire, for example.
[0027] The luminaire is switched on here preferably automatically once decoupled from the charging device, such that it is not necessary to actuate a switch of a switching arrangement or the like in order to switch on the luminaire.
[0028] The lamp arrangement is preferably switched off when the luminaire is coupled again to the charging device. On the other hand, it is preferable during a charging process if it is possible, during such a charging process (or when such a charging process is complete, but the luminaire is still connected to the charging device), to switch the luminaire on or off by means of a switching arrangement.
[0029] It is also conceivable for the luminaire to always be supplied with a small amount of power during a charging process so as to thus indicate that a charging process is underway. Only when the energy store is fully recharged can the power supply to the lamp arrangement be interrupted in this case. However, it is generally possible to also separate the luminaire from the power supply already prior to complete recharging. In an alternative embodiment it is possible to integrate a charge indicator in the body of the luminaire, for example on the upper side of a foot of the luminaire body, and/or on a head of the body.
[0030] If a state of charge indicator of this type is integrated, the following functions can also be provided in addition: By way of example, the state of charge or state of recharge indicator can be activated for a predetermined period of time (for example ranging from 2 seconds to 30 seconds) as soon as a user switches on the luminaire. The state of charge can thus be displayed to the user directly. Furthermore, provision can be made for the state of charge indicator to appear whenever the energy store is connected to the charging device, such that the state of charge indicator is activated during the entire charging process. The state of charge indicator can include, for example, a plurality of individual light-emitting diodes of different colors, which indicate the particular state of charge, more specifically preferably at least three LEDs for displaying a full energy store, a practically discharged energy store, and an energy store which is still sufficiently charged.
[0031] The above object is also achieved by a method for operating a luminaire arrangement which comprises a portable luminaire having a lamp arrangement, an energy store, and a charging device, which can be coupled to the energy store in order to charge the energy store, in particular a luminaire arrangement of the type according to the present design, said method having the following steps: detecting the state of charge of the energy store and reducing the light output of the lamp arrangement when the state of charge falls below a predetermined threshold value (for example 15% to 40% of a full charge), such that a power-saving mode is established; and/or detecting the state of charge of the energy store and gradually reducing the light output when the state of charge falls below a predetermined threshold value (for example 5% to 15% of a full charge), such that the nearing end of the energy store charge is displayed to a user; and/or providing a boost mode, by means of which the amount of light can be temporarily increased to approximately 101% to 150%, in particular 120% to 150% of a nominal power, the boost mode being automatically limited to a predetermined operating period, which is preferably shorter than 8 minutes.
[0032] With the luminaire according to the present design it is possible to provide a charging interface on the body for charging another mobile device, for example a smartphone or another USB device. A capacity of the energy store of the luminaire can thus be used to recharge another electronic device. If the state of charge falls below a specific threshold value, this function can preferably be switched off for reasons of self-protection of the energy store.
[0033] On the whole, a new type of luminaire concept is consequently provided, with which it is possible, as necessary, to grasp a luminaire which is provided in the region of a charging device and which is generally fully recharged, to separate said luminaire from the charging device, and then to carry it to any location at which lighting is desired. On the one hand this allows an unlimited flexibility with regard to providing lighting at a wide range of different locations. On the other hand a lighting plan can be designed from the outset such that power outlets for luminaires do not have to be provided everywhere. In addition, it can still be possible to provide lighting in spaces or at places where there are no power outlets provided.
[0034] In the case of the above-described electrical parameters of capacity for the energy store and energy consumption of the lamp arrangement, it is possible to provide sufficient lighting for a wide range of different activities for a number of hours without recharging. The lighting period at full light output lies preferably in a range of from half an hour to a week, in particular in a range of from two hours to ten hours. The energy store is preferably based on available secondary battery technologies, such as lithium-ion secondary batteries or the like. A portable luminaire can use for example one or more secondary batteries, as are also used in modern mobile telephones or the like. In a variant the energy store is fixedly integrated in the body of the luminaire. In an alternative preferred embodiment a compartment which is to be opened by a user is provided, within which compartment the energy store(s) is/are received, such that a user can exchange the energy store independently. The energy store can be an LiPO secondary battery for example, which is preferably provided with a protection circuit and housing. The compartment for receiving the energy store can preferably be provided on the underside of a foot of the luminaire.
[0035] By way of example, a USB socket or USB micro socket can be formed on the body of the luminaire and is connected to the energy store in order to recharge this. Alternatively or additionally, a charging station can be provided, which includes an adapter from USB or mini USB to a magnetic contact arrangement. Such a charging station can include, for example, a USB socket or a mini USB socket, into which a conventional USB cable or mini USB cable is inserted, for example on a charging device housing, which can form such a charging station. The magnetic contact can produce, for example, an independent connection to corresponding contacts on a foot of the luminaire when the charging station approaches the luminaire foot (or vice versa). The magnetic connection should be sufficiently strong here for the luminaire to be positioned without separation (within the cable length of the attached USB cable). To release the connection, the user can stand with his/her foot on the projecting end of the charging station in order to fix this on the floor whilst he/she releases the luminaire from the magnetic coupling.
[0036] The above object is also achieved by various types of luminaires which can be used for the above-described luminaire arrangement.
[0037] The object stated in the introduction is achieved in full overall.
[0038] It is generally conceivable to provide the interface arrangement between the energy store and the charging device as a conventional electrical plug connection.
[0039] However, it is particularly preferred when the charging device and the energy store can be coupled by means of an inductive interface arrangement such that the energy store can be charged inductively.
[0040] In this embodiment the charging device and energy store or luminaire can be coupled and decoupled without the need to establish or release mechanical plug connections.
[0041] By way of example, an inductive charging station can be formed as a flat module, which is arranged on a flooring surface. A flat inductive charging device of this type can also be integrated for example in a flooring surface, for example instead of a tile or the like, or can be arranged beneath a non-conductive flooring surface, such as a wood flooring surface or the like.
[0042] Here, it is particularly preferred when the inductive charging device has a coil which is flat and which is oriented, within a charging device housing, substantially parallel to a horizontal. Accordingly, a corresponding inductive charging coil can be arranged on the body of the luminaire, for example in the region of a foot or the like, which charging coil is preferably likewise oriented horizontally in a charging position of the luminaire.
[0043] In accordance with a further embodiment the interface arrangement alternatively or additionally includes an electrical connection arrangement, the connection arrangement being held magnetically in a connection position, such that a separation of the connection arrangement is facilitated.
[0044] In this embodiment the electrical connection between charging device and luminaire can be provided such that the electrical contact is made by magnetically attracting the interface elements of the charging device on the one hand and luminaire on the other hand. If the luminaire and the charging device are forcibly separated from one another, this occurs in a facilitated manner by overcoming the magnetic force of attraction. Damage in the region of the interface arrangement on account of such a forcible separation, as could occur for example in the case of mechanical plug connections, is avoided as a result.
[0045] In accordance with a further preferred embodiment the luminaire arrangement includes a plurality of portable luminaires, which each have a control arrangement, each control arrangement including a wireless communications device, the communications devices of at least two luminaires being able to communicate with one another such that the luminaires can be switched jointly.
[0046] In other words, in this embodiment a plurality of luminaires of this type can be switched synchronously with one another. The term “switch” is to include in the present case in particular a switching on and off, but can also include dimming.
[0047] Here, it can be advantageous if, with operation of just one of the luminaires, the other luminaires are then switched synchronously hereto. Alternatively, is also conceivable to switch a plurality of luminaires by means of a control arrangement, such as a remote control, a mobile telephone, a tablet computer, or the like. Here, it is conceivable for a connection to be established between a control arrangement of this type and one of the portable luminaires so as to then synchronously switch a plurality of luminaires.
[0048] The wireless communications device can be an infrared network or a radio network. The transmission standard can be, for example, an LAN standard, a Bluetooth standard, Zigbee, NFC, or the like.
[0049] When a luminaire has a body with a foot, on which luminaire contacts of an interface arrangement for charging an integrated energy store are provided, luminaire contacts of this type can be provided on one side in such a way that a connection axis of an electrical connection arrangement has a connection axis which is oriented parallel to a horizontal, in particular parallel to a supporting plane. The supporting plane can be a plane parallel to a floor in the case of a freestanding luminaire or a plane parallel to a wall in the case of a wall luminaire. The supporting plane is preferably a plane which is formed parallel to a base area of a foot of a freestanding luminaire.
[0050] It is particularly preferred when the body of the luminaire defines a supporting plane of this type and when the interface arrangement has an electrical connection arrangement with a connection axis which is oriented transversely to the supporting plane.
[0051] In the case of a foot of a freestanding luminaire, the connection axis consequently is not oriented horizontally, but transversely hereto, in particular perpendicularly hereto.
[0052] Here, the connection axis is preferably the axis along which contacts of the electrical connection arrangement of the charging device on the one hand and the body of the luminaire on the other hand are moved toward one another or are aligned with one another.
[0053] The embodiment of an electrical connection arrangement with a connection axis which is oriented transversely to the supporting plane makes it possible, when the luminaire contacts are formed on a foot of a freestanding luminaire, for the connection axis to extend perpendicularly. Here, the luminaire can be moved substantially transversely to the horizontal in order to release the electrical connection arrangement. This can be combined with an embodiment as described hereinafter in which a charging device has a housing which has, on its upper side, a foot placement surface and of which the charging interface is likewise formed on the upper side, so as to in this way provide a substantially perpendicular connection axis.
[0054] In accordance with a preferred embodiment the body here of the luminaire has a recess, in which at least a portion of a charging device housing can be inserted, the shape of the recess and the shape of the charging device housing being coordinated with one another such that the charging device housing can be pivoted relative to the body of the luminaire parallel to the supporting plane by an angle which lies in a range of from 10° to 90°.
[0055] The angle preferably lies in a range of from 15° to 45°, in particular from 20° to 35°.
[0056] Here, the pivot potential can be provided in particular about the above-mentioned connection axis.
[0057] This has advantages in particular with regard to the process of coupling the body of the luminaire to the charging device housing. Here, the charging device housing can rest on a flooring surface, for example. Due to the relatively large pivot angle, it is possible to move the body of the luminaire toward the charging device housing at different angular positions in order to perform the coupling process.
[0058] The recess on the body preferably has an insertion bevel which defines the above-mentioned angle.
[0059] In this embodiment it is also advantageous when the interface arrangement includes a magnetic holding device or coupling device, such that the electrical connection arrangement is electrically coupled substantially automatically as soon as the body approaches the charging device housing.
[0060] The recess is formed here preferably on an underside of a foot of the body of the luminaire in such a way that the luminaire can be brought not only from the side toward the charging device housing in order to carry out the coupling process. Rather, it is also possible to place the foot from above onto the charging device housing, the coupling process being implemented again preferably via magnetic coupling means, by means of which charging contacts on the charging arrangement housing and luminaire contacts on the body are electrically contacted with one another.
[0061] This magnetic connection is preferably sufficiently strong here, as mentioned above, for the luminaire to be positioned without separation, unless the user places a foot on the charging device housing or the user removes the luminaire, beyond the cable length of an attached cable, from a main plug to which the charging device is connected. In this case the magnetic coupling or magnetic connection is forcibly released, however this can be implemented without damaging the interface arrangement.
[0062] It may also be preferable if the recess has a recess cone, which is preferably oriented concentrically to the connection axis. In this case it is likewise preferred if a housing cone is provided on the charging device housing, which housing cone is likewise oriented concentrically to the connection axis. In other words, the cones of the recess on the one hand and charging device housing on the other hand are arranged concentrically to a particular electrical contact arrangement.
[0063] Consequently, it is preferred when the electrical connection arrangement has two concentric luminaire contacts on the body of the luminaire and two corresponding concentric charging contacts on the charging device housing.
[0064] The charging contacts are preferably provided on an upper side of the charging device housing. The luminaire contacts are also preferably provided on an upper side or ceiling of the recess, which is preferably open to the underside.
[0065] The present design also relates to a luminaire of a luminaire arrangement which is to be protected independently of the charging device. Here, the luminaire preferably has a handle, which is mounted and/or formed on the luminaire such that the luminaire, when grasped, assumes an equilibrium position which deviates from a normal operational position by no more than ±30°.
[0066] The handle is preferably shaped such that it can be grasped by hand. The term “grasped” in the present case is intended to mean that, for example, a finger is held centrally beneath the handle, such that the luminaire can freely come to a rest with respect to this suspended position. Compared with a normal operational position, in which the luminaire is placed for example on a floor, an equilibrium position is provided here which deviates from the normal operational position by no more than ±30°. Superior ergonomics and a high level of safety when carrying the luminaire can be achieved as a result.
[0067] As already mentioned, the handle is preferably a handgrip having a length in the range of from 5 cm to 20 cm and a diameter in the range of from 1 cm to 7 cm. In the case of a normal operational position of the luminaire, the handle extends preferably approximately in the horizontal direction, but can also be oriented perpendicularly hereto.
[0068] In any case a center of gravity of the handle is preferably oriented vertically with a center of gravity of the luminaire and/or a center of gravity of a foot of the luminaire, in such a way that the center of gravity of the handle in a vertical projection is distanced by no more than 10 cm, in particular by no more than 5 cm, from the center of gravity of the luminaire or the foot.
[0069] A further embodiment of such a luminaire, which is to be protected independently, includes a foot from which a pillar-like main body extends upwardly, a luminaire head being mounted on the main body, and a handle for carrying the luminaire being mounted on the main body.
[0070] In the case of this luminaire the pillar-like main body is preferably rigidly connected to the foot. The handle is preferably oriented horizontally and/or extends transversely to a longitudinal axis of the pillar-like main body. In particular, is preferred if a handle extends in the manner of a cantilever from the pillar-like main body, in such a way that the handle can be grasped for example from above in order to carry the luminaire.
[0071] It is particularly preferred if the main body has a longitudinal axis which is oriented at an angle in the range between 45° and 80° with respect to a horizontal.
[0072] Here, the main body is preferably connected to a foot in the region of a horizontal end of the foot and is inclined such that it extends over the foot. The handle preferably extends in a projection plane defined in this way and/or extends from the main body on a rear side of the main body averted from the foot. The handle is preferably arranged, in vertical projection, within a peripheral line of the foot.
[0073] In all embodiments in which the luminaire has a foot, the electrical energy store is preferably integrated therein. A recess is also preferably provided on the foot, as has been described above in a preferred embodiment, and serves to receive at least a portion of a charging device housing.
[0074] A further embodiment of such a luminaire, which is to be protected independently, has a control arrangement arranged on the body, said control arrangement having a switching arrangement which comprises a first switching device for switching the lamp arrangement and a second switching device, the first switching device preferably being contactless and/or dimmable, and/or the second switching device preferably being connected in series with the first switching device and/or being capacitive.
[0075] The lamp arrangement can preferably be switched in this embodiment via two control devices. The second control device is preferably closed during operation. By way of example, the second switching device can be closed when the luminaire is decoupled from a charging device.
[0076] The second switching device is preferably connected in series with the first switching device, the first switching device preferably being able to be switched and/or dimmed contactlessly. For this purpose, a contactless sensor such as a reflex light barrier is used, which for example can receive light reflected back from an operating member (for example a finger). The contactless sensor is preferably a contactless IR sensor, which for example can receive reflected-back IR light.
[0077] A reflex light barrier of this type is supplied here continuously with power during operation in order to emit a light beam and detect any reflections hereof. Although the consumption is very low, it is still preferred in the case of a portable luminaire separable from a charging device if this type of power consumption is not permanent. Consequently, it is preferred when the second switching device, which is preferably connected in series with the first switching device, opens once a predetermined period of time has elapsed, for example after a period of time ranging from one minute to ten minutes. A renewed closing of the second switching device is then only possible for example via a mechanical switch which operates the second switching device. However, it is particularly preferred when the second switching device is capacitive, in such a way that a housing or body of the luminaire for example must be contacted in order to close the second switching device again following a sleep mode of this type and in order to consequently wake the luminaire from the sleep mode. The first switching device can then be activated again, a light beam of a reflex light barrier being emitted.
[0078] A capacitive design of the second switching device generally means that a body of the luminaire is electrically conductive at least in a region to be contacted, or that an electrically conductive capacitive sensor portion is formed behind a housing portion, similarly to a hob that is to be capacitively operated.
[0079] In accordance with a further embodiment of such a luminaire, which is to be protected independently, the lamp arrangement and the energy store are fixed to the body, the body being provided with holding or supporting means in order to temporarily hold or support the body at the location to be lit.
[0080] The holding means can be mechanical holding or supporting means, for example a hook for hanging the luminaire. However, in the simplest case, the holding means could also be a foot by means of which the luminaire can be set down on a floor.
[0081] It is particularly preferred when the holding means are formed as magnetic holding means. In this case it is possible for example to hold the luminaire magnetically at a location to be lit. The magnetic holding means can consist of the fact that the luminaire has a ferromagnetic portion which can be magnetized. Alternatively, the luminaire can have a magnet by means of which the luminaire can be temporarily fixed to another magnet or to a ferromagnetic material.
[0082] By way of example, a magnetic counter piece can be secured to a wall in order to secure a luminaire to a wall in a simple manner, even if there is no main outlet provided there.
[0083] A fastening to a ceiling is also possible via such magnetic holding means.
[0084] The magnetic holding means can be standardized for different luminaires. In particular, it is possible to provide a holding magnet arrangement on the body, which arrangement has a centering feature, such as a circular protrusion. The magnetic holding means can also comprise a counter piece having a centering recess, which is substantially circular. Here, the counter piece can be secured for example to a wall, but can also be secured to a ceiling or to an end of a suspension. The counter piece is preferably produced at least in part from a ferromagnetic material, such that the counter piece can be produced comparatively economically.
[0085] In an alternative embodiment the counter piece can include a magnet, with corresponding ferromagnetic portions of the magnetic holding means being provided on the body of the luminaire. Luminaires having magnetic holding means of this type preferably do not have a magnetic charging interface, and vice versa.
[0086] As described above, a luminaire according to the present design can be formed as a freestanding luminaire, as a wall luminaire, or as a hanging or pendant luminaire. A design as a ceiling luminaire is also possible.
[0087] In a particularly preferred variant the luminaire can have a body which has a foot and a head connected thereto via a rotational joint. The lamp arrangement can be formed on the head. The lamp arrangement can be connected via a cable in the rotational joint to an energy store in the foot. By way of example, the energy store can be a lithium-ion secondary battery, as is also used in mobile radio devices. An on/off switch can be integrated in the foot, in particular on the underside thereof. It is also preferred if magnetic holding means, in particular one or more magnets, are integrated in the foot. In this case, it is preferred when an underside of the foot is produced from a plastics material. It is particularly preferred if the foot has an upper shell and a lower shell, the upper shell preferably being produced from metal, in particular an aluminum alloy, and the lower shell preferably being produced from plastic. In this case the effect of the magnets is improved if a luminaire of this type is secured to a magnetic counter means, for example to a ferromagnetic portion, such as a refrigerator door, a metal plate, a vehicle body, etc.
[0088] In the variant in which a foot and a body are connected via a rotational joint, a charging interface in the form of a standard interface or computer interface can be formed, such as a USB interface. A luminaire of this type is particularly portable and can be charged at any location. The same is also true for luminaires which are formed for example as wall luminaires, as ceiling luminaires, or as pendent luminaires.
[0089] In accordance with a further embodiment of a luminaire, which is to be protected independently, the luminaire includes a body to which the lamp arrangement and the energy store are fixed and which defines a supporting plane, which for example can be a resting plane of a foot, the interface arrangement comprising an electrical connection arrangement having a connection axis formed transversely to the supporting plane.
[0090] As explained above, a luminaire of this type is preferably formed as a freestanding luminaire, in which the luminaire contacts of the electrical connection arrangement are formed in a recess in the foot, which is open on a side of the foot and on an underside of the foot, as described above.
[0091] A further embodiment of a luminaire, which is to be protected independently, includes a body which defines a body plane and in which a rechargeable electrical energy store is received, the luminaire also including a lamp arrangement which has a light input portion and a luminous panel with a side edge, into which light from the light input portion is coupled, the luminous panel being oriented at an angle of greater than 3° and less than/equal to 90° to the body plane.
[0092] In this embodiment the light input portion can be formed for example by a light strip having a plurality of adjacently arranged LEDs, the light strip being arranged in the region of an interface between the body and the luminous panel.
[0093] A luminaire of this type is suitable for example as a wall or ceiling luminaire, the body then preferably being mounted parallel to the wall or ceiling, and the body plane thus simultaneously forming a supporting plane of the above-described type.
[0094] In this case the luminous panel protrudes relative to the wall or ceiling and consequently can be used advantageously for lighting.
[0095] The luminous panel is preferably opaque or has scattering elements, such that light is coupled out from at least one surface of the luminous panel, said surface being oriented perpendicularly to the side edge, in particular from two opposite surfaces. On account of the angled embodiment of the luminous panel, light can be irradiated both directly, for example downwardly, and indirectly upwardly.
[0096] A luminaire of this type is also suitable as a pendant luminaire.
[0097] Magnetic holding means are preferably also formed on the body in order to secure the body temporarily to a wall, to a ceiling or also to a pendant.
[0098] An interface for charging the energy store is preferably provided on the body. The interface is preferably a standard interface, in particular in the form of a standardized computer interface, such as a USB interface.
[0099] The present design also relates to a charging device for a luminaire arrangement of the type disclosed herein and/or for a luminaire of the type disclosed herein, the charging device having a flat charging device housing, which has an underside, which can be placed on a floor, an upper side, and a side face connecting the underside and the upper side, a holding surface, for example in the form of a foot placement surface, being formed on the upper side, and/or a charging interface for connection to a rechargeable energy store being arranged on the upper side and/or on the side face.
[0100] In this embodiment the housing can be fixed by way of example by means of a foot or a hand, and the luminaire can then be separated from the interface at the side face of the charging device housing. Here, is particularly preferred when the coupling between charging device and luminaire has magnetic means, which facilitates a separation of the interface or the connection.
[0101] The flat housing of the charging device can include here charging electronics, such that the housing is connected to a main plug. Here, by way of example, the charging electronics can convert a main voltage of 220 volts into a suitable charging voltage or a charging current in the form of a direct current.
[0102] In a particularly preferred variant, however, charging electronics are provided in a separate housing, which for example can be part of a charging plug which can be plugged into a power outlet. A cable connected to a charging plug of this type, via which cable the charging DC voltage or the charging direct current is already provided, can then be a USB cable or a mini USB cable for example, as is known in the case of smart phones and other devices of this type. The flat housing of the charging device can in this case include a passive adapter which connects a USB connector or a mini USB connector to suitable contacts, which for example cooperate with a magnetic coupling between the housing and the luminaire. In this case, the flat housing preferably does not contain any active electronics, but is formed in the manner of a charging station or a magnet dock and preferably includes merely a socket for the connector of a cable providing a DC voltage, such as a USB cable, and contact means for making electrical contact with the luminaire so as to thus supply power for charging to the energy store in the luminaire.
[0103] Consequently, it is preferred when the charging device is equipped such that a standard interface is formed on the charging device housing, via which standard interface an electrical charging DC voltage can be provided, the electrical standard interface in the charging device housing being electrically connected to charging contacts on the outer side of the charging device housing, in particular on the upper side thereof, the charging contacts being electrically connectable to luminaire contacts on a body of a luminaire.
[0104] For charging, a conventional USB charging device can be used alternatively, for which purpose a USB mini socket or USB micro socket is preferably provided on the body of the luminaire.
[0105] As explained above, a charging device housing in the form of a dock is preferably provided when the luminaire is a freestanding luminaire. In all other cases, it is generally preferred when a standard interface, such as a USB socket, is provided on the body.
[0106] In accordance with a further preferred embodiment, which is to be protected independently, a charging device includes a charging station, to which a plurality of luminaires can be fixed temporarily and which has a plurality of interfaces, corresponding to the plurality of luminaires, for simultaneously charging the luminaires fixed to the charging station.
[0107] The basic concept of a charging device of this type having a charging station consequently lies in the fact that a plurality of luminaires can be charged simultaneously. Here, the charging station preferably has a plurality of luminaire mounts, which are preferably each identical so as to be able to receive identical types of luminaires. Alternatively, however, different luminaire mounts for receiving different types of luminaires can also be provided on the charging station.
[0108] The charging station preferably has a base by means of which the charging station can be placed on a horizontal surface. The charging station also includes a power supply interface, via which charging power can be fed. It is indeed conceivable for a converter for converting a main voltage into a charging DC voltage to be contained in the charging station itself, for example in a base hereof. However, a charging interface which is connected by means of wiring provided in the charging station to the plurality of interfaces for simultaneous charging of a plurality of luminaires is preferably provided on a housing of the charging station, preferably on the base.
[0109] In this case, the central charging interface at the charging station can be either a standard interface, such as a USB port. Alternatively, a recess can be provided on the charging station, into which recess at least a portion of a charging device housing can be inserted, the merits of which have been described above in similar form for the foot of a particular embodiment of a luminaire according to the present design.
[0110] A charging device housing of this type can be identical to that described above, specifically with concentric charging contacts which can be electrically connected to concentric “luminaire” contacts on the charging station. The charging device housing can again be formed such that, on an upper side hereof, a foot placement surface or hand resting surface or the like is formed, such that the charging device housing can be fixedly held by the part protruding from the recess of the charging station in order to separate a magnetic coupling between the charging device housing and the charging station.
[0111] The charging device housing can also have a standard interface in the form of a USB interface or the like, via which the charging device housing can be connected to a standard charging converter. In this case the charging device housing does not have its own converter provided therein, but instead merely electrical wiring between the standard interface and charging contacts.
[0112] The charging device housing can consequently be used to recharge a luminaire which has a foot on the underside of which a recess is provided for receiving a portion of the charging device housing. However, the charging device housing can also be used to charge a plurality of luminaires which are temporarily fixed in a charging station of the above-described type. The charging station is preferably formed such that it has a base, on which at least two, preferably four or more luminaire mounts for a corresponding number of luminaires are provided. The luminaires are preferably luminaires in which a luminous panel extends at an angle from a body. The luminaire mounts can be provided here in order to receive the corresponding bodies of these luminaires. The mounts are preferably arranged here such that in each case two luminaires can be received directly adjacently via their bodies, in such a way that their luminous panels extend in opposite directions.
[0113] It goes without saying that the above-mentioned features and the features yet to be explained hereinafter can be used not only in the specified combinations, but also in other combinations or in isolation without departing from the scope of the present invention.
DRAWINGS
[0114] Exemplary embodiments of the invention are illustrated in the drawing and will be explained in greater detail in the following description. In the drawing:
[0115] FIG. 1 shows a schematic illustration of a luminaire arrangement according to the present design;
[0116] FIG. 2 shows schematic illustrations of further luminaire arrangements in a building;
[0117] FIG. 3 shows a further embodiment of a luminaire arrangement according to the present design in a charging position and in a lighting position;
[0118] FIG. 4 shows an illustration comparable to FIG. 3 of a further embodiment of a luminaire;
[0119] FIG. 5 shows a detailed view of the luminaire of FIG. 4 ;
[0120] FIG. 6 shows a schematic illustration of a further embodiment of a luminaire arrangement;
[0121] FIG. 7 shows a plan view of a charging device of the luminaire arrangement of FIG. 6 ;
[0122] FIG. 8 shows a schematic illustration of a control arrangement of a luminaire;
[0123] FIG. 9 shows a perspective illustration of a further embodiment of a luminaire;
[0124] FIG. 10 shows a perspective illustration of the luminaire of FIG. 9 from below;
[0125] FIG. 11 shows a schematic illustration of an interface arrangement with vertical connection axis for an embodiment of a luminaire arrangement, more specifically obliquely from above;
[0126] FIG. 12 shows an illustration comparable to FIG. 11 obliquely from below;
[0127] FIG. 13 shows an illustration of the interface arrangement from below prior to a coupling of charging device housing and body;
[0128] FIG. 14 shows an illustration comparable to FIG. 13 once the coupling has been established;
[0129] FIG. 15 shows a schematic perspective view of a charging device housing in accordance with a further embodiment;
[0130] FIG. 16 shows the charging device housing of FIG. 15 from above;
[0131] FIG. 17 shows a perspective illustration of a further embodiment of a luminaire obliquely from the front;
[0132] FIG. 18 shows a perspective illustration of the luminaire of FIG. 17 obliquely from behind;
[0133] FIG. 19 shows an operating device for luminaires;
[0134] FIG. 20 shows a perspective view of a further embodiment of a luminaire in the form of a pendant luminaire;
[0135] FIG. 21 shows a schematic illustration of a magnetic securing part for magnetic holding means from the front;
[0136] FIG. 22 shows the magnetic securing part of FIG. 21 in a sectional view;
[0137] FIG. 23 shows a schematic illustration of a luminous panel and of a light input for the luminaires shown in FIGS. 17, 18 and 20 ;
[0138] FIG. 24 shows a luminaire arrangement having a plurality of luminaires and a central operating device;
[0139] FIG. 25 shows a further embodiment of a charging device comprising a charging station for charging a plurality of luminaires.
DESCRIPTION
[0140] FIG. 1 schematically illustrates a luminaire arrangement designated generally by 10 . The luminaire arrangement 10 includes a luminaire 12 . The luminaire 12 comprises a lamp arrangement 14 , which is incandescent lamp-based or halogen-based, but in particular is formed as an LED lamp arrangement, in particular in the form of an array formed from a plurality of individual LEDs.
[0141] The luminaire 12 also has a body 16 , which can be formed in one or more parts. The body 16 can be a housing, can be an arrangement formed from a foot, pillar and head, but can also be a light-permeable, opaque or otherwise scattering surface. In some cases the body can be a closed sleeve formed from a light-permeable or light-scattering material. In other variants the body can be a housing not permeable to light, which for example includes a slot or another opening for the exit of light of the lamp arrangement 14 . In many cases the lamp arrangement 14 can include a flat element formed from a light-scattering plastics material which is provided with holes, for example with countersunk points for each LED of an LED array. The rear side of a plastic or glass arrangement of this type can be covered by a housing which covers the rear side of the LED array arrangement and, where applicable, control electronics assigned to this arrangement.
[0142] Examples of luminaires of this type can be found on the webpage www.nimbus-lighting.com, with reference being made to the full content thereof.
[0143] The luminaire 12 also includes a control arrangement 18 , which is designed to control the lamp arrangement 14 . The luminaire 12 also has an electrical energy store 20 , which is fixedly connected to the body 16 , in particular is received in a housing portion of the body. It is particularly preferred when the electrical energy store 20 , which for example can be formed as a secondary battery and consequently can be recharged, is received in a foot of the luminaire 12 .
[0144] The luminaire arrangement 10 also has a charging device 22 , which converts energy from a power source 24 , for example a main power supply 24 , into a suitable DC voltage for charging the electrical energy store 20 and/or for supplying power to the lamp arrangement 14 .
[0145] An interface arrangement 26 serves to connect the charging device 22 to the luminaire 12 . The interface arrangement 26 can include an electrical connection device, for example a mechanical plug connector device. However, the interface arrangement 26 can also be an inductive interface arrangement. The interface arrangement 26 can also be assigned a magnet arrangement 28 , which serves to electrically contact the interface elements of the luminaire 12 and the charging device 22 with one another on the basis of magnetic attraction, such that a release of the interface arrangement 26 or separation of the interface arrangement 26 can be facilitated.
[0146] The control arrangement 18 has a circuit arrangement 30 , which preferably can be operated by means of an operating object 32 , such as a finger. The switching arrangement 30 can be a mechanical switching device, but can also be a capacitive switching device, a contactless switching device with reflex light barrier, or the like. The switching arrangement 30 can be integrated for example in a head of the body 16 of the luminaire 12 .
[0147] The luminaire 12 also includes a supporting or holding portion 34 , by means of which the luminaire 12 can be supported or held at a location to be lit. In the simplest case, the supporting or holding portion 34 can be a foot, by means of which the luminaire 12 is placed on a floor. The supporting/holding portion 34 , however, can also be a magnetic portion, a hook, or the like.
[0148] In some embodiments the control arrangement 18 includes a communications device 36 , by means of which the luminaire 12 can be connected for communication to another luminaire 12 in order to switch the luminaires in a synchronized manner. However, the communications device 36 can also be designed to be connected to an operating device, for example a remote control, a mobile telephone, a tablet computer, etc. The communications device 36 is preferably a wireless communications device, based for example on one of the following standards: WLAN, Bluetooth, Zigbee, NFC, etc.
[0149] Lastly, the luminaire 12 can include a handle 38 , by means of which the luminaire 12 can be carried, more specifically to a location to be lit, the luminaire 12 for this purpose being separated from the charging device 22 , preferably beforehand, in such a way that the luminaire arrangement 14 is supplied with power exclusively from the electrical energy store 20 .
[0150] FIG. 2 illustrates different types of luminaires or luminaire arrangements, more specifically with respect to a building 40 , which includes a floor 42 , a ceiling 44 and at least one vertical wall 46 .
[0151] FIG. 2 thus shows a wall luminaire 12 A having a supporting/holding portion 34 A, by means of which the luminaire 12 A can be connected to an interface arrangement 26 A in a region of the wall 46 , a charging device 22 which is connected to a power source 24 , such as a main power supply, being integratable in the wall. In this case the wall luminaire 12 A can be grasped for example at a vertically extending part of a body and can be separated from the interface arrangement 30 so as to then be placed on a table, for example by means of a foot 48 , so as to be able to carry out a lighting function in the region of the table independently of the main power supply.
[0152] An alternative embodiment of a luminaire 12 B for example has a light-permeable or light-scattering body and also a hook 50 , which forms a supporting or holding portion and for example is connectable to a hook eyelet, which hangs from a ceiling 44 . With a hook 50 of this type, the luminaire 12 B, which in this case is formed as a ceiling luminaire, can also be hung at other locations, for example also in the garden, on a terrace, or the like. Here, a charging device 22 can likewise be provided in the region of the hook eyelet, by means of which charging device an energy store contained in the luminaire 12 B can be charged.
[0153] A further luminaire in the form of a freestanding luminaire is shown at 12 C. The freestanding luminaire 12 C has a foot 48 , from which a rod-shaped or pillar-shaped main body 52 protrudes upwardly. The main body 52 can be oriented at an incline to a horizontal, as is illustrated schematically in FIG. 2 . A head 54 can be supported at a free end of the main body 52 , more specifically for example via a joint 56 , which can be formed as a single joint or as a multiple joint. A lamp arrangement 14 can in this case be integrated in the head 54 , as is illustrated schematically in FIG. 2 .
[0154] It can be seen that an interface arrangement 26 C is formed in the region of the foot in order to connect the luminaire 12 C to a charging device 22 , which for example has a flat housing and is set down on the floor 42 . The charging device 22 can be connected via a cable (not illustrated in greater detail) to a power outlet 58 of a power source 24 .
[0155] A ceiling luminaire is shown at 12 D which includes a flat lamp arrangement 14 , on the rear side of which a body 16 is formed. The body 16 can cooperate in this case with a magnet 60 , which is secured to the ceiling 44 . Consequently, following a charging process at a charging station (not illustrated), the ceiling luminaire 12 D can be secured upwardly to the ceiling 44 , more specifically by means of the magnet 60 , which in this case serves as a supporting or holding portion.
[0156] A similar concept is shown for a floor-lighting luminaire 12 E 1 , which can be secured by means of a magnet 60 in a region of a wall 46 close to the floor 42 by means of a magnet 60 .
[0157] In FIG. 2 a further luminaire 12 E 2 , in addition to the luminaire 12 E 1 , is illustrated on a further wall, the luminaires 12 E 1 and 12 E 2 preferably being of identical construction. The luminaires 12 E 1 , 12 E 2 can each serve to light a floor, for example in the region of stairs or the like. In a preferred variant the luminaires 12 E 1 , 12 E 2 can communicate wirelessly with one another via communications devices (not presented in greater detail), as is shown schematically in FIG. 2 at 62 . The luminaires 12 E 1 , 12 E 2 can each be switched, for example switched on and off or dimmed, synchronously as a result.
[0158] An operating device is shown at 66 which can be formed as a remote control, as a mobile telephone, as a tablet computer, etc. Communication between the operating device 66 and at least one of the luminaires 12 E 1 , 12 E 2 is illustrated at 64 . The operating device 66 can also be formed, however, so as to control all luminaires 12 E 1 , 12 E 2 in parallel and to switch these in parallel.
[0159] The concept of the communication between luminaires is also conceivable for other of the above-described luminaire types, as is shown schematically for example at 62 between the luminaires 12 A and 12 C. The operating device 66 is also designed, as appropriate, to also switch other luminaires, for example the luminaire 12 B, as is also indicated in FIG. 2 by an arrow 64 .
[0160] FIG. 3 shows a further embodiment of a luminaire 12 F which corresponds in terms of structure and operating principle to the luminaire 12 C of FIG. 2 . Like elements are therefore characterized by like reference signs.
[0161] The luminaire 12 F includes a body having a pillar-like main body 52 , at the end of which a head 54 is supported via a joint 56 . The joint 56 can be a joint movable about three axes. A switching arrangement 30 is provided on an upper side of the head 54 , by means of which switching arrangement a lamp arrangement 14 arranged on the underside of the head 54 can be switched.
[0162] The foot 48 is formed such that it accommodates the energy store 20 . An inductive charging process can also take place between the foot 48 and a charging device 22 integrated in the floor 42 . For this purpose, the charging device 22 , in the case of a tiled floor, can be integrated in the floor instead of a tile 70 , for example. Joins of tiles 70 of this type are illustrated schematically at 72 . In other words, an upper side of the charging device 22 can be flush with the floor 42 so that the luminaire 12 F can be placed onto the charging device 22 in order to carry out an inductive charging process. For this purpose, the charging device 22 includes a schematically illustrated coil 74 , and a further coil 76 is integrated in the foot 48 . The coils 74 , 76 cooperate magnetically during the inductive charging process, the merits of which are known per se. It goes without saying that a further part of the control arrangement 18 can preferably also be integrated in the foot 48 in order to conduct energy received via the interface arrangement 26 F to the energy store 20 and/or to the lamp arrangement 14 .
[0163] As it is also illustrated in FIG. 3 on the left-hand side, the luminaire 12 F has a handle 78 . The handle 78 extends in a cantilever-type manner from the pillar-like main body 52 . The main body 52 is rigidly connected to foot 48 at a lateral end thereof and extends at an angle α to the horizontal, more specifically such that the main body 52 extends in a vertical projection transversely above the foot 48 . The angle α can lie in a range of from 45° to 80°, in particular in a range of from 60° to 80°. The handle 78 is fixed to the main body 52 preferably on a side averted from the foot 48 . The handle 78 , as is illustrated in FIG. 3 , has a length L G and a diameter D. The length L G can lie for example in the range of from 5 cm to 20 cm. The diameter D can lie for example in the range of from 1 cm to 7 cm.
[0164] The handle 78 can be grasped easily from above in order to carry the luminaire. The handle 78 can be fixed in a region of an upper half of the main body 52 and can extend substantially in the horizontal direction.
[0165] An axial center of the handle 78 is preferably arranged above a center of gravity of the luminaire 12 F or of the foot 48 , as is illustrated by a vertical dashed line in FIG. 3 . If the handle is consequently grasped from below by means of an operating member, such as a finger 32 , the luminaire 12 F assumes an equilibrium position, which deviates from the normal operational position shown on the left in FIG. 3 by no more than ±30°, preferably by no more than ±15°.
[0166] FIG. 3 also shows that the luminaire can be removed from the location LP of the charging device 22 by means of the handle 78 , more specifically to a location to be lit BP, which is schematically indicated in FIG. 3 by a sofa 80 , such that the luminaire 12 F can serve as a reading luminaire. An axial length L S of the main body 52 can lie for example in the range of from 35 cm to 150 cm.
[0167] Although in FIG. 3 an inductive charging device 22 is shown, it goes without saying that the luminaire 12 F can also be formed such that an electrical interface device is formed on a side of the foot 48 , similarly to that illustrated at 26 C in FIG. 2 .
[0168] FIG. 4 shows a further luminaire 12 F′, which illustrates a modification of the luminaire shown in FIG. 3 . The luminaire 12 F′ corresponds generally in terms of structure and operating principle to the luminaire 12 F of FIG. 3 , and therefore like elements are provided with like reference signs.
[0169] The luminaire 12 F′ has a main body 52 with a shorter length L S ′ than the luminaire 12 F. The length L S ′ can lie for example in a range of from 15 cm to 50 cm. In this case, the handle 78 can be arranged in the region of the free end of the main body 52 averted from the foot 48 . In this case, a position of the handle 78 lying above the center of gravity can lie closer to the main body 52 for example, as is schematically illustrated in FIG. 4 .
[0170] FIG. 5 shows the luminaire 12 F shown in FIG. 3 in the region of its head 14 . It can be seen that the head 54 is rectangular in plan view and has a greater extension over both side lengths than over height. The lamp arrangement 14 is provided on the underside of the head 54 . A switching arrangement 30 F can be formed on the upper side of the head 54 , which for example works contactlessly in the manner of a gesture control, the switching arrangement 30 F possibly including a reflex light barrier.
[0171] It can also be seen in FIG. 5 that the joint 56 is rotatable about three axes which are independent of one another, such that a practically arbitrary adjustment of the head 54 with respect to the main body 52 is possible.
[0172] FIG. 6 shows a further variant of a luminaire 12 F in combination with a charging device 22 . The charging device 22 and the luminaire can be connected to one another via an electrical connection arrangement 82 . The charging device 22 has a housing 83 , which is formed as a flat housing and on which a plug 84 with charging contacts of the electrical connection arrangement 82 is provided. Accordingly, an electrical socket 86 with luminaire contacts is provided on the foot 48 of the luminaire 12 F, in which socket the plug 84 can be inserted in order to couple the luminaire 12 F to the charging device 22 .
[0173] It can be seen that the foot 48 and/or the housing 83 can have a magnet arrangement 28 in order to hold the electrical connection arrangement 82 in electrical contact substantially on the basis of magnetic forces. In this way, the electrical connection arrangement 82 can be easily released, more specifically against the magnetic force of attraction of the magnet arrangement 28 .
[0174] The housing 83 has an upper side 88 and an underside 90 . The underside 90 can be set down on the floor 42 . The plug 84 is formed in the region of a side face 92 connecting the upper side 88 and the underside 90 .
[0175] When the luminaire 12 F is brought into the vicinity of the charging device 22 , a magnetic force of attraction 94 causes the electrical connection arrangement 82 comprising the plug 84 and the socket 86 to be closed. The plug 84 and the socket 86 are illustrated in an exaggerated manner in FIG. 6 . In both cases the elements may also be much shorter, such that separation at an angle does not cause any mechanical damage either.
[0176] The upper side 88 of the housing 83 is formed as a foot placement surface. Consequently, a foot 96 can be placed thereon in order to fix the position of the charging device 22 by means of a vertical fixing force 98 . The luminaire 12 F can thus be released from the charging device 22 in a simple manner against the force of attraction 94 of the magnet arrangement 28 and can be brought to a location to be lit.
[0177] FIG. 7 shows the charging device 22 from above, with the upper side 88 of the housing 83 and one or more plugs 84 on a side face 92 .
[0178] FIG. 8 shows a control arrangement 18 of a luminaire 12 in a schematic exemplary form. The control arrangement 18 includes a switching arrangement 30 , which can be provided on a body 16 , for example in the region of a head 54 .
[0179] The switching arrangement 30 includes a first switching device 102 . The first switching device 102 includes a contactless sensor 104 , which comprises an emitter 106 for light and a receiver 108 , the contactless sensor 104 possibly being formed as a reflex light barrier. The emitter 106 and the receiver 108 can be formed in a wall region of the body 16 or the head 54 such that the first switching device 102 can be actuated by the approach of an operating member, such as a finger 32 .
[0180] The first switching device 102 can be connected here to a dimming device 110 , which connects the energy store 20 to the lamp arrangement 14 .
[0181] The switching arrangement 30 also includes a second switching device 112 . The second switching device 112 comprises a contact sensor 114 , which for example can be formed as a capacitive sensor and can be triggered by contact with an operating member 32 , such as a finger. The second switching device 112 also includes a sleep control unit 116 , which is connected to the contact sensor 114 . The sleep control unit 116 is also connected to a time-delay member 118 , which is connected to the first switching device 102 . The sleep control unit 116 serves to actuate a switch 120 of the second switching device 112 , which is connected in series with the first switching device 102 .
[0182] Since the first switching device 102 consumes power during operation on account of the emitter 106 , the switch 120 is opened via the time-delay member 118 a certain period of time after the last detection of a switching operation, so as to set the luminaire or the control arrangement 18 to a sleep mode. When contact is detected at the contact sensor 114 , the sleep control unit 116 is initiated so as to cancel the sleep mode by closing the switch 120 . The lamp arrangement now lights up again, and the contactless sensor 104 is supplied with power again, such that the luminaire can be dimmed again.
[0183] The time-delay member 118 can be set up to switch off the luminaire in an automated manner after a predetermined time.
[0184] In an embodiment illustrated in a dashed manner in FIG. 8 the sleep control unit 116 can also be designed to open or close a switch 122 , which supplies power to the contactless sensor 104 . By way of example, the switch 112 can be opened after the last actuation of the contactless sensor 104 after a predetermined period of time of, for example, one minute (preferred range 30 seconds to 5 minutes), such that power is no longer supplied to the contactless sensor 104 . The switch 120 can remain closed in this variant, such that power continues to be supplied to the lamp arrangement 14 , more specifically at the output level set by the dimming device 110 .
[0185] When an operator wishes to then switch off the luminaire or change the output, he/she must first cancel the sleep mode via the contact sensor 114 , whereby the switch 122 is closed, such that a contactless dimming of the lamp arrangement is possible again, and/or the lamp arrangement can be switched off.
[0186] The two variants can also be combined with one another such that the sleep control unit 116 can be used both for long-term switch-off of the lamp arrangement 14 and for short-term deactivation of the contactless sensor 104 .
[0187] FIGS. 9 and 10 show a further embodiment of a luminaire 12 G. The luminaire 12 G has a body 16 with a foot 48 and a head 54 , the head 54 being connected to the foot 48 via a joint 56 . The head 54 can be constructed identically to the luminaire 12 F of FIGS. 3 to 5 . The rotational joint 56 can also be formed identically. The foot 48 preferably has dimensions similar to those of the head. The foot 48 and the head 54 can be oriented in a plane via the rotational joint 56 , such that the luminaire 12 G can be placed flat in a pocket.
[0188] The foot 48 constitutes a supporting/holding portion 34 , since the luminaire 12 G can be placed via the foot 48 on any surface. An interface arrangement 26 G can also be formed on the foot 48 in order to charge an energy store 20 received in the foot 48 . The interface arrangement 26 G can be a micro USB interface, for example.
[0189] The head 54 has an upper side, on which the switching arrangement 30 is formed. The upper side is preferably formed from metal, in particular from an aluminum alloy. The lamp arrangement 40 can include an opaque panel, which is formed with holes, through which an array of LEDs illuminates.
[0190] The foot 48 has an upper shell 130 , which is likewise preferably produced from a metal, in particular from the same type of metal as the upper part of the head 54 . The foot 48 also has a lower shell 132 , which is preferably produced from plastic. The upper shell 130 and the lower shell 132 preferably have an identical basic shape and enclose a volume, within which the energy store is received. One or more magnets can also be received within this volume so as to not only be able to set down the foot on a horizontal surface, but so as also to be able to secure the foot to a magnetizable or magnetic counter means.
[0191] An on/off switch 134 can also be formed on the lower shell 132 , which switch interrupts the power supply between the lamp arrangement 14 and the energy store 20 . The on/off switch 134 is formed in the present case is a mechanical switch, but could also be formed as a contact sensor 114 , similar to that illustrated in FIG. 8 .
[0192] A further embodiment of a luminaire 12 H is shown in figures in 11 to 14 which can correspond in general in terms of structure and operating principle to the luminaires 12 d in FIGS. 12 and 12F in FIGS. 2 to 5 , a body 16 H of the luminaire having a pillar-like main body 52 , on which a handle 78 can be formed, as shown for example in FIG. 4 , and at the upper end of which a luminaire head 54 can be fixed, in particular via a hinged connection 56 .
[0193] Elements similar to those in the above-described embodiments are therefore designated by the same reference signs. Primarily the differences will be explained hereinafter.
[0194] It can be seen in FIG. 11 that a charge indicator or state of charge indicator is formed on the upper side of the foot 48 H. The state of charge indicator 140 can indicate a state of charge of an electrical energy store 20 which is received in the foot 48 H, as indicated schematically in FIG. 12 . There, it can also be seen that an energy store cover 138 can be formed on the underside of the foot 48 H, via which energy store cover the energy store 20 , which can be formed in the manner of a rechargeable mobile telephone battery, can be replaced.
[0195] The state of charge indicator 140 can also have further features as have been described in the introduction.
[0196] The foot 48 H has an underside 142 , which defines a supporting plane, that is to say a plane over which the luminaire 12 H is supported. Since the luminaire 12 H is a freestanding luminaire, the supporting plane is oriented parallel to a horizontal.
[0197] An electrical connection arrangement 82 H of an interface arrangement 26 H of a charging device 22 H is also illustrated in FIGS. 11 to 14 . The connection arrangement 82 H serves in this case to connect charging contacts 146 on a charging device housing 83 H to luminaire contacts 148 , which are formed on the foot 48 H of the luminaire 12 H. The connection arrangement 82 can also include one or more magnets in order to magnetically hold the connection arrangement 82 H in the coupled position so that, on the one hand, a separation of the connection arrangement 82 H is facilitated, but, on the other hand, a coupling can also be facilitated.
[0198] The connection arrangement 82 H defines a connection axis 144 , which in the present case is oriented transversely, in particular perpendicularly, to the supporting plane 142 .
[0199] The connection axis 144 is defined by the direction in which the charging contacts 146 and the luminaire contacts 148 are brought into contact with one another or are to be aligned.
[0200] In the present case a recess 150 is provided on the foot 48 H of the luminaire 12 H, which recess is preferably formed below the region of the foot 48 H from which the pillar-like main body 52 extends upwardly. The recess 150 is open to a side face 92 H of the foot 48 H and is also open to the underside 142 of the foot 48 H.
[0201] The recess 150 has a recess cone 152 , which is arranged concentrically with the connection axis 144 . The recess cone 152 has a large diameter in the region of the underside 142 and tapers toward the upper side of the foot 48 H. The recess cone 152 extends in the peripheral direction about the connection axis 144 over an angle of approximately 180°, more specifically on the side of the recess 150 arranged opposite the side face 92 H. The luminaire contacts 148 lie within the recess cone 152 .
[0202] The recess 150 also has an insertion bevel 154 , which in particular can be seen in FIG. 14 and which starts from the side face 92 H and tapers toward the recess cone 152 .
[0203] The insertion bevel 154 , in conjunction with the recess cone 152 and the fact that the charging contacts 146 and the luminaire contacts 148 are oriented concentrically with the connection axis 144 , makes it possible for a charging device housing 83 H extending in part into the recess 150 to pivot parallel to the underside 142 (supporting plane) through an angle 156 which lies in a range of from 10° to 90°, in particular in a range of from 15° to 45°. This makes it possible to produce the connection arrangement or the coupling of the contacts 146 , 148 in a large number of different relative positions between foot 48 H and charging device housing 83 H.
[0204] As is shown in FIGS. 15 and 16 , the charging device housing 83 H preferably has a substantially cuboidal base 160 , which at one longitudinal end has a cone extension 162 , which defines a housing cone 164 which conically tapers from an underside of the charging device housing 83 H and extends over an angle of greater than 180° and preferably less than 270°. The housing cone 164 is adapted in terms of dimensions and cone pitch to the recess cone 152 of the recess 150 .
[0205] The cone extension 162 has, on its upper side, a flat circular face 166 , which preferably protrudes toward an upper side of the base 160 . As is shown in FIG. 16 , a housing magnet part 168 can be provided on the circular face 166 and can cooperate with a soft-magnetic portion of the recess 150 in order to magnetically hold the connection arrangement in the manner of a magnetic dock.
[0206] A first charging contact 170 of the charging contacts 146 is also preferably provided on the circular face 166 . The first charging contact 170 is formed as a circular central contact. A second charging contact 172 , which is formed as a ring contact, is also formed on the circular face 166 , more specifically concentrically with the first charging contact 170 and radially distanced herefrom.
[0207] The charging contacts 170 , 172 form the above-described charging contacts 146 and correspond in terms of shape and arrangement to the luminaire contacts 148 . One of the charging contacts 170 , 172 can be a positive pole. The other charging contact can be a negative pole. A DC voltage can be provided via the charging contacts 170 , 172 and is suitable for charging the energy store 20 , for example a voltage in a range of from 4 to 24 volts.
[0208] An electrical standard interface 174 , which can be formed as a computer interface, in particular as a USB interface, is formed on the longitudinal end of the base 160 opposite the cone extension 162 . A plug of a standard charging cable 176 can be inserted into the interface 174 , which in particular can be formed as a socket. The other end of the standard charging cable 176 can be connected to a standard charging converter 178 , which for example can be inserted into a power outlet 58 . The standard charging converter 178 converts the AC voltage provided at the power outlet 58 into a DC voltage, which can be guided via the standard charging cable 176 to the electrical standard interface 174 . This charging voltage is tapped within the charging device housing 83 H by contacts of the electrical standard interface 174 and can then be electrically connected to the charging contacts 170 , 172 .
[0209] The charging device housing 83 H in this embodiment preferably does not have its own charging electronics. Rather, a standard charging converter 178 can be used to charge the energy store 20 .
[0210] The charging device housing 83 H is formed in particular so as to be arranged on a floor or flooring surface. An upper side of the base 160 , which is designated in FIGS. 15 and 16 by 88 H, can serve as a foot placement surface, similarly to that illustrated in FIG. 6 .
[0211] In order to dock the luminaire 12 H at the charging device housing 83 H located on the floor, the luminaire is moved such that the recess 150 is approximately aligned with the cone extension 162 . Due to the fact that the insertion bevel 154 is provided, and due to the fact that the housing cone 164 can cooperate with the recess cone 152 , a centering is provided with respect to the connection axis 144 , even if there is initially a certain misalignment. The cone extension 162 is also drawn magnetically against the “ceiling” of the recess 150 along the connection axis 144 on account of the housing magnet part 168 so as to thus electrically connect the charging contacts 146 to the luminaire contacts 148 .
[0212] The dimensions of the recess 150 and of the cone extension 162 can be such that the charging device housing 83 H still rests on a floor when the contacts 146 , 148 are coupled. However, the charging device housing 83 H can also be lifted slightly with respect to the floor, more specifically on account of the magnetic holding forces of the housing magnet part 168 .
[0213] In order to separate the connection arrangement 82 H, the luminaire can be lifted up, a foot preferably being placed on the base 160 so as to overcome the magnetic forces of the housing magnet part 168 during this process. If the luminaire is removed unintentionally from the power outlet 58 beyond the length of the standard charging cable 176 , the unintentional forces occurring here can likewise release the magnetic holding forces, the connection arrangement being separable in this way without resulting in destruction. A separation of the connection arrangement 82 H can thus likewise be facilitated.
[0214] The charging device housing 83 H and foot 48 H or recess 150 thereof can be coupled either by sliding the foot parallel to the underside 142 in the direction of the housing cone 164 , or vice versa. Here, the contacts 146 , 148 are firstly aligned in a direction parallel to the underside 142 or the supporting plane. However, contact is again made parallel to the connection axis 144 , since the housing cone 164 is drawn into the recess cone 152 on account of the magnetic forces, more specifically parallel to the connection axis 144 . A lateral approaching movement, which only at the end leads to the movement of charging device housing 83 H and foot 48 H along the connection axis 144 , is indicated schematically in FIG. 13 by an arrow.
[0215] Of course, the foot 48 H and charging device housing 83 H can also be coupled and decoupled purely vertically, as is indicated schematically in FIGS. 11 and 12 .
[0216] The luminaire arrangement shown in FIGS. 11 to 16 with the luminaire 12 H and the charging device housing 83 H, which is formed in the manner of a magnet dock, can be combined with any of the above-described embodiments. In particular, in addition to the electrical connection arrangement, an inductive interface arrangement can be provided. A wireless communications device can also be integrated, via which the portable luminaire can be switched or dimmed jointly with other luminaires. Lastly, a switching arrangement for actuating the luminaire can be constructed in a similar manner to that described with reference to FIG. 8 .
[0217] The pillar-like main body 52 can be coupled to a luminaire head 54 , as is illustrated in FIG. 5 .
[0218] A luminaire family for a further embodiment of a luminaire arrangement is shown in FIGS. 17 to 24 . The luminaires of FIGS. 17 to 24 correspond generally in terms of structure and operating principle to the above-described luminaires, more specifically in particular the luminaires 12 B, 12 D and 12 E of FIG. 2 . The luminaires of the luminaire family of FIGS. 17 to 24 are preferably wall luminaires, ceiling luminaires or pendant luminaires. The luminaires of FIGS. 17 to 24 preferably share magnetic holding technology in order to secure the luminaires to the wall, to the ceiling, or to a pendant.
[0219] In FIGS. 17 and 18 a first luminaire of this luminaire family is illustrated schematically and designated generally by 12 I.
[0220] The luminaire 12 I has a flat cuboidal body 180 , which has a body front side 182 ( FIG. 17 ) and a body rear side 184 ( FIG. 18 ). The body rear side 184 forms a supporting plane, which lies parallel to a securing plane (wall or ceiling or the like).
[0221] A switching arrangement 30 I, which can correspond in terms of structure and operating principle to the switching arrangement 30 as has been described with reference to the luminaire of FIG. 5 and the luminaire of FIGS. 9 and 10 , can be provided on the body front side 182 . A charge indicator 140 I, via which a state of charge of an energy store 120 I integrated in the body 180 can be queried or displayed, is also arranged on the body front side 182 .
[0222] An electrical standard interface 174 I is formed on a side face 92 I and can be identical to the standard interface 174 of the charging device housing 83 H of FIGS. 15 and 16 or to the interface 26 G indicated schematically in FIGS. 9 and 10 . In the present case the standard interface 174 forms part of an electrical interface 26 I of this type.
[0223] The body 180 is connected on a longitudinal end opposite the side face 92 I to a planar lamp or a luminous panel 186 . The luminous panel 186 can be an opaque Plexiglas plate, for example, but can also be a glass plate with interspersed particles.
[0224] The luminous panel 186 is fed via a feed portion 182 . In particular, light is coupled into a side edge (not shown) of the luminous panel 186 . The feed portion 188 is arranged in the manner of a strip in the region between the body 180 and the luminous panel 186 . The feed portion 188 preferably has a plurality of LEDs arranged along a strip form, which are fed from the energy store 20 I.
[0225] The body 180 has a frame 190 , which surrounds the luminous panel 186 . In some cases, however, the frame 190 can also be omitted.
[0226] The luminous panel 186 with the frame 190 is angled relative to the body front side 182 and/or the body rear side 184 by an angle 192 . The angle 192 can lie in a range of from 3° to 90°, in each case inclusive, and preferably lies in a range of from 15° to 45°, in each case inclusive.
[0227] The feed portion 188 can also be inclined with respect to the side face 92 I by an angle (not specified in greater detail) in a range of from 5° to 60°. The feed portion 188 , however, can also be oriented parallel to the side face 92 I and/or perpendicularly to side faces arranged therebetween (not specified in greater detail).
[0228] Due to the angling of the luminous panel 186 relative to the body 180 , it is possible, when the luminaire 12 I is mounted on a wall or ceiling, for light to irradiate both from the surface of the luminous panel 186 facing toward the body front side 182 and from the opposite surface of the luminous panel facing toward the body rear side 184 . Consequently, a lighting effect in the manner of direct and indirect light can be obtained, to name just one exemplary application for this.
[0229] A communications module 194 is also integrated in the body 180 . The communications model can be, in particular, part of a wireless communications device 36 K, as shown in FIG. 24 . The communications module 194 can be connected for communication to other luminaires and/or to an operating device 66 . It is preferably possible, via the communications device 36 K, to switch and/or to dim a plurality of luminaires synchronously.
[0230] As can be seen in FIG. 18 , the luminaire 12 I also has, in the region of the body rear side 184 , an on/off switch and a holding magnet arrangement 196 .
[0231] The magnet holding arrangement 196 in the present case forms a magnet 60 I for mounting the luminaire 12 I on a wall or a ceiling. The holding magnet arrangement 196 here has a centering feature 198 , by means of which the holding magnet arrangement 196 can be centered with respect to a magnetic securing part, which will be described hereinafter. The centering feature 198 can be, for example, a circular protrusion, which protrudes relative to the holding magnet arrangement 196 .
[0232] In one embodiment the luminaire 12 I can be set via the switching arrangement 30 I to a master mode, in which the communications module 194 synchronizes all changes of the state of the luminaire 12 I with a plurality of “slave” luminaires. Generally, however, the communications model 194 of the luminaire 12 I is always a “slave” module, which can be controlled by means of a master in the form of an operating device 66 K, as shown in FIG. 19 .
[0233] The operating device 66 K has an operating device body 202 , which likewise can be formed as a flat, planar body, with a body rear side illustrated in FIG. 19 , on which a holding magnet arrangement 196 K can be formed, which is identical to the holding magnet arrangement 196 of FIG. 18 .
[0234] An electrical energy store 20 K can also be arranged in the operating device body 202 . A standard interface 174 K can also be provided on the operating device body 202 so as to be able to charge the energy store 20 K in this way.
[0235] A communications module 194 K is also formed in the operating device body 202 and is preferably formed as a “master” module and can be connected for communication to a plurality of luminaires (such as a plurality of luminaires 12 I or also any other of the above-described luminaires) so as to control these synchronously.
[0236] A charge indicator 140 K can be arranged on the front side (not shown in greater detail) of the operating device body 202 , as can also a switching arrangement 30 K. The switching arrangement 30 K and the charging indicator 140 K can be formed identically to the corresponding elements 30 I and 140 I of FIG. 17 .
[0237] FIG. 20 shows a further embodiment of a luminaire 12 L, which generally corresponds in terms of structure and operating principle to the luminaire 12 I. Like elements are therefore designated by like reference signs. Primarily the differences will be explained hereinafter.
[0238] The luminaire 12 L can preferably be temporarily secured to a pendant 206 , more specifically preferably by means of a holding magnet arrangement 196 L, which is formed on a rear side or upper side of the luminaire 12 L, which is not visible in FIG. 20 .
[0239] The luminaire 12 L has a body 180 L, which is preferably formed as a semi-circular plate. A switching arrangement 30 L and a charge indicator 140 L can be formed on an underside 182 L of the body 180 L and can correspond to the elements 30 I and 140 I of FIG. 17 .
[0240] An electrical energy store 20 L is also integrated in the body 180 L, as is also a communications module 194 L, which can be generally comparable in terms of structure and operating principle to the corresponding elements 20 I, 194 I of the luminaire of FIG. 17 .
[0241] The luminaire 12 L also preferably has a semi-circular luminous panel 186 L, which is shaped such that the body 180 L and the luminous panel 186 L together define a circle, for example. Similarly to the embodiment of FIGS. 17 and 18 , however, the luminous panel 186 L is angled relative to the body 180 L by an angle 192 L, which can lie in an angular range similar to the above-described angle 192 .
[0242] A semi-circular frame 190 L can also be provided around the luminous panel 186 L.
[0243] A feed portion 188 L is provided between the body 180 L and the luminous panel 186 L, by means of which feed portion light can be coupled into a side edge of the luminous panel 186 L. Light is preferably again emitted from a surface of the luminous panel 186 L facing toward the underside 182 L, and preferably also from a surface of the luminous panel 186 L facing toward the upper side (not illustrated).
[0244] The pendant 206 can be formed for example by a single cable, which at its upper end is secured purely mechanically to a ceiling, for example. A magnetic securing part can be secured to the underside or the free end of the pendant, which magnetic securing part can cooperate with the holding magnet arrangement 196 L (not shown in greater detail in FIG. 20 ). The holding magnet arrangement 196 L is preferably secured to the upper side of the body 180 L concentrically with a circle shape, which circle shape is defined by the body 180 L and the luminous panel 186 L. Consequently, the luminaire 12 L can be secured to the pendant 206 such that the body 182 L is preferably oriented horizontally.
[0245] FIGS. 21 and 22 show a magnetic securing part 210 , as can be secured for example to a wall or to an end of a pendant 206 . The magnetic securing part 210 has a main body formed from a soft-magnetic material, which is approximately circular and has a centering means 212 in the form of a circular axial indentation. The centering feature 198 of the holding magnet arrangement 196 can engage in this indentation or in this centering means 212 , for example.
[0246] The magnetic securing part 210 preferably has a securing portion centrally, which for example can be formed by a bore, via which a screw 218 can be passed through. FIG. 22 shows that a screw of this type passes through the securing portion 214 and is fixed in a wall 46 at a wall plug (not specified in greater detail).
[0247] The magnetic securing part 210 can also preferably have a holding magnet mount 216 , in which the holding magnet arrangement 196 can be completely received. An aesthetically pleasing magnetic connection can be established in this way.
[0248] FIG. 23 shows, in schematic form, a feed portion 188 , which is formed in a strip-like manner with a plurality of LEDs (not specified in greater detail), which couple their light into a side face 220 of a luminous panel 186 . By way of example, the luminous panel 186 can be formed as an opaque panel so that total internal reflection within the panel is avoided. However, particles can also be integrated in the panel 186 in order to be able to couple light out via the surfaces oriented perpendicularly to the side face 220 .
[0249] FIG. 24 shows, in schematic form, a luminaire arrangement 10 M, which for example includes a plurality of luminaires 12 I and a luminaire 12 L. The luminaire arrangement 10 also includes an operating device 66 K, as shown in FIG. 19 .
[0250] In FIG. 24 it can first be seen that, in the case of the luminaire 12 L, a magnetic securing part 210 is fixed at an end of a pendant 206 and is fixed to the upper side of the body 180 L by means of a holding magnet arrangement 196 L. An on/off switch 200 L can also be arranged on the upper side of the body 180 L.
[0251] As indicated schematically by arrows 64 , the luminaires 12 I and 12 L can be controlled synchronously by means of the operating device 66 K.
[0252] In FIG. 24 the operating device 66 K is shown attached to a standard charging cable 176 . However, the operating device 66 K can also be decoupled from a charging cable 176 of this type and can be temporarily fixed to a wall merely via its holding magnet arrangement 196 K ( FIG. 19 ).
[0253] The luminaires 12 I, 12 L of FIG. 24 and also the operating device 66 K can each be removed from their place of temporary mounting by means of the magnetic securing part 210 and holding magnet arrangement 196 and can each be charged at a central charging location, more specifically via a standard charging converter 178 and a plurality of standard charging cables 176 .
[0254] FIG. 25 shows a preferred embodiment of a luminaire arrangement 10 M with a charging device 22 M, which has a charging station 240 .
[0255] The charging station 240 includes a base 242 , which example can be placed on a flat surface. A plurality of luminaire mounts 244 (in the present case four) for temporarily receiving a corresponding plurality of luminaires are also formed on an upper side of the base 242 . In the present case the charging station 240 is designed to charge luminaires 12 I, as are shown in FIGS. 17 and 18 and also in FIG. 24 . The charging station 240 is preferably also suitable for recharging an operating device 66 K, as is shown in FIG. 19 . However, the charging station 240 can also be adapted such that it is suitable for recharging other types of luminaires, in particular luminaires which are formed as wall, ceiling, or pendant luminaires.
[0256] In the present case, four luminaire mounts 244 are formed on the base 242 and are designed to receive four luminaires 12 I 1 , 12 I 2 , 12 I 3 and 12 I 4 of the luminaire type shown in FIGS. 17 and 18 .
[0257] Here, interface arrangements 26 M 1 , 26 M 2 , etc. are formed in the region of the luminaire mounts 244 and are designed to cooperate with the interfaces 174 I 1 , 174 I 2 , etc. provided on the luminaires 12 I.
[0258] Wiring 246 is provided inside the base 242 and is designed to connect these interfaces 174 I 1 , 174 I 2 , etc. to a central charging interface, which is formed in the present case by “luminaire” contacts 148 M on the upper side of a recess 150 M formed in the bottom of the base 242 .
[0259] The recess 150 M corresponds in terms of structure and operating principle to the recess 150 shown in figures in 11 to 14 (in that case for the foot of a freestanding luminaire). The same recess with the identical contacts 148 M is provided in the present case on the base 242 , such that the charging device housing 83 H can be slid into the recess 150 M via the cone extension 162 . The charging device housing 83 H is preferably structured identically to the charging device housing 23 H of FIGS. 15 and 16 .
[0260] Consequently, a standard interface 174 is provided at an end of the charging device housing 83 H opposite the cone extension 162 , into which standard interface a plug of a standard charging cable 176 can be inserted, said charging cable being connected at the other end to a standard charging converter 178 .
[0261] Alternatively to the embodiment in which a recess 150 M for receiving a portion of the charging device housing 83 H is formed on the charging station 240 , a standard charging interface 174 M could also be provided on the charging station 240 , into which standard charging interface a plug of the standard charging cable 176 could be directly inserted. In this case, this interface 174 M would be connected in parallel with the interfaces 174 I 1 , 174 I 2 , etc. via a corresponding wiring.
[0262] Retaining struts 250 can be provided in order to mechanically fix the luminaires 12 I to the charging station 240 and extend upwardly starting from the base 242 and form a mechanical part of the luminaire receptacles 244 .
[0263] Furthermore, the recess 150 M can be formed at any point in the region of the base 242 . However, the recess 150 M is preferably provided at an axial end of the base 242 .
[0264] The axial direction of the base 242 preferably lies parallel to the body front sides 182 1 , 182 2 , etc. of the luminaires 12 I 1 , 12 I 2 , etc. inserted into the charging station 240 .
[0265] The charging station 240 preferably also has a hoop or handle 248 , which extends in a U-shaped manner above the base 242 and is connected to the axial end of the base. The hoop 248 is preferably longer than the height of the luminaires 12 I inserted into the charging station 240 so that the charging station 240 with the luminaires 12 I inserted therein can be easily carried by means of the hoop 248 .
[0266] For coupling to the charging device housing 83 H, the charging station 240 can be moved such that the mount 150 M is moved into the vicinity of the cone extension 162 , where the contacts 146 and 148 M are contacted with automatic centering on account of the housing magnet part 168 . To separate the charging station 240 from the charging device housing H, the upper side 88 H of the charging device housing 83 H can then be pressed by hand or by means of a foot in order to fix this and facilitate a removal of the charging station 240 from the charging device housing 83 H.
[0267] It is to be understood that the foregoing description is not a definition of the invention, but is a description of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.
[0268] As used in this specification and claims, the terms “for example,” “e.g.,” “for instance,” “such as,” and “like,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation. | A luminaire arrangement for providing lighting in or near buildings. The luminaire arrangement may contain one or more of the following components: (i) at least one portable luminaire, which has a body and a lamp arrangement, (ii) at least one energy store, which is connected to the luminaire, is rechargeable, and is designed to supply electrical power to the lamp arrangement of the luminaire; and (iii) at least one charging device, which is designed to recharge the energy store. The energy store is attachable by means of an interface arrangement to the charging device in order to at least one of recharge the energy store and supply power to the lamp arrangement. The energy store is separable from the charging device in order to take the luminaire as necessary to any target location to be lit. | 5 |
This is a divisional of copending application Ser. No. 08/980,781 filed on Dec. 1, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to calendering systems. Such structures of this type, generally, employ the use of hard or soft nips to provide excellent smoothness without gloss mottle.
2. Description of the Related Art
It is well known in calendering systems, particularly heated soft roll calendering systems, to employ a soft roll at high pressures. Exemplary of such prior art is U.S. Pat. No. 4,624,744 ('744) to J. H. Vreeland, entitled “Method of Finishing Paper Utilizing Substrata Thermal Molding”. While the '744 patent does achieve calendering, the use of the high nip pressures, namely, pressures above 2000 psi, reduce the bulk of the paper. Consequently, such use of a calendering device is, typically, employed when calendering fine papers. Consequently, a more advantageous calendering system, then, would be employed if calendering could be done at lower nip pressures in order to reduce bulk loss.
It is apparent from the above that there exists a need in the art for a calendering system which is able to calender as well as the known calendering systems, while providing excellent smoothness without gloss mottle (an uneven pattern of gloss or reflectance), but at the same time is able to calender at lower nip pressures.
It is a purpose of this invention to fulfill this and other needs in the art in a manner more apparent to the skilled artisan once given the following disclosure.
SUMMARY OF THE INVENTION
Generally speaking, this invention fulfills these needs by providing a substantially gloss mottle-free calendered paper with significantly increased smoothness consisting of a coated paper produced by a method comprising, passing the coated paper through a first nip formed between a substantially harder calendering roll and a heated roll means, passing the coated paper through a second nip formed between a substantially softer calendering roll and the heated roll means to produce a substantially gloss mottle-free calendered paper having significantly increased smoothness and operating the method at nip pressures between the first and second nip of substantially less than 2000 psi.
In certain preferred embodiments, the harder calendering roll has a surface hardness of greater than 80 shore D. The heated roll is a polished metallic roll. The softer calendering roll has a surface hardness of less than or equal to 80 shore D. Also, calcium carbonate (CaCO 3 ) is added to the coating placed upon the paper. The coating is applied at a coat weight of approximately 8-24 lbs/3900 ft 2 . The coating contains at least 40% solids and at least 30% CaCO 3 .
In another further preferred embodiment, the use of the harder-softer roll combination allows one to produce a paper which is substantially gloss mottle-free and has a significantly increased smoothness.
The preferred calendering system, according to this invention, offers the following advantages: good stability; good durability; substantially reduced gloss mottle; significantly increased smoothness; reduced operating nip pressures; increased operating capacity; reduced converting problems; and excellent economy. In fact, in many preferred embodiments, these factors of improved gloss mottle, improved smoothness, reduced nip pressures, increased capacity, and reduced converting problems are optimized to an extent that is considerably higher than heretofore achieved in prior, known calendering systems.
BRIEF DESCRIPTION OF THE DRAWING
The above and other features of the present invention, which will become more apparent as the description proceeds, are best understood by considering the following detailed description in conjunction with the accompanying FIGURE, in which the FIGURE is a schematic illustration of a calendering system using hard and soft rolls, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As discussed earlier, the '744 patent adequately calenders fine papers, but at higher nip pressures. Typically, these nip pressures are greater than 2000 psi as measured by Equation (1) below as set forth by H. L. Schmidt, Rubber Roll Hardness-Another Look, Pulp and Paper, Mar. 18, 1968, pp 30-32. The Equation (1) is: nip width , n = ( 4 LTD 1 D 2 E ( D 1 + D 2 ) ) 1 m ( 1 )
m=exponent which is dependent on roll diameter
L=line load (pli)
T=thickness of cover (inches)
D 1 =diameter of harder roll (inches)
D 2 =diameter of softer roll (inches)
E=elastic modulus
However, in today's modern paper manufacturing machines, it is desirable to run at lower nip pressures, i.e., substantially less than 2000 psi. These lower nip pressures reduce bulk loss of the calendered paper and allow paper with greater caliper or thickness to be produced. Using Equation (1), nip pressures in the present invention have been measured from 900 to 1400 psi.
Along with reducing bulk loss, there are several other desired qualities that a paper manufacturer wants the paper to achieve after calendering. From past studies, it has been determined that a Parker Print-Surf (a measurement of surface roughness) of 1.0 or less and a gloss (or reflectance) of greater than or equal to 60 based upon a 75° Hunter gloss are currently acceptable parameters for determining whether or not a paper is calendered to achieve the best results.
With reference first to the FIGURE, there is illustrated an advantageous environment for use of the concepts of the invention. In particular, as shown in the FIGURE, there is illustrated calendering system 2 . System 2 , includes in part, harder or backing roll 4 having a hard resiliently yieldable surface, conventionally treated, polished metal roll 6 , softer or backing roll 8 having a soft resiliently yieldable surface, conventional paper 10 , coating 12 , and nips 14 and 16 . It is to be understood that softer roll 8 may also be located ahead of harder roll 4 . Also, roll 6 may be a series of heated rolls such that substrate 10 does not wrap around roll 6 and nips 14 and 16 located in a series.
Harder roll 4 , preferably, is any roll constructed of natural or synthetic materials having a surface hardness of greater than 80 shore D measured by conventional techniques. Softer roll 8 , preferably, is any suitable roll constructed of natural or synthetic materials having a surface hardness of less than or equal to 80 shore D.
Paper substrate 10 of the present invention is coated by coating 12 on at least one side surface and frequently on both sides. The paper trade characterizes a paper web or sheet that has been coated on one side as C1S and C2S if sheet coated on both sides.
Compositionally, coating 12 is a fluidized blend of coating clay, calcium carbonate (CaCO 3 ), and/or titanium dioxide with binders and additives which is smoothly applied to the traveling web surface. In particular, CaCO 3 is added to the fluidized blend of minerals such that the CaCO 3 comprises greater than 30% by weight of the minerals. Also, the mixture includes at least 40% by weight of solids in order to reduce gloss mottle and increase smoothness.
Coating 12 is applied to paper 10 at a rate of 8-24 lbs/3000 ft 2 by conventional techniques. Preferably, coating 12 is applied by a means of a rod coater, air knife or blade by conventional techniques.
The following test results prove the novelty of the present invention and its application as a desired calendering system.
Using coated basestock with a starting Parker Print-Surf value of 1.9 and a caliper value of 0.012″, the following results were achieved as shown below in TABLE 1:
TABLE 1
Caliper
Load (pli)
Roll Hardness
(in)
PPS
Sheffield
Gloss
348
Softer
11.9
1.4
15
61
417/417
Harder/Softer
11.9
1.2
6
68
348
Harder
12.0
1.1
8
68
where PPS = Parker Print-Surf, Softer = Softer roll 8, and Harder = Harder roll 4
The above data demonstrate a more profound effect of the harder polymer roll (88 Shore D) on the larger scale roughness (Sheffield) than on the fine scale roughness (measured by PPS). There was an obvious visual improvement in surface uniformity of the harder/softer roll combination condition as compared to the harder roll only condition.
Using coated basestock with a starting PPS value of 2.4 and a caliper value of 0.11″, the following results were achieved as shown below in TABLE 2:
TABLE 2
Caliper
Load (pli)
Roll Hardness
(in)
PPS
Sheffield
Gloss
348
Harder
10.9
1.9
10
64
417/417
Harder/Harder
10.7
1.7
10
71
417/417
Harder/Softer
10.8
1.7
13
71
Again, the harder/softer roll combination provides reduced PPS values and higher gloss values than a single hard roll. Also, the harder/softer roll combination gives better gloss uniformity than the harder/harder roll combination.
Based upon the favorable results from TABLE 1 and TABLE 2, calendering system 2 was placed on a conventional papermaking machine. The paper was calendered using a harder roll (Shore D hardness of greater than 80), two softer rolls (Shore D hardness of less than or equal to 80) and the harder/softer roll combination of the present invention. The results of the three runs are shown below in TABLE 3:
TABLE 3
Roll Hardness
PPS
Sheffield
Gloss
Mottle
Harder
1.2
N/A
62
Unacceptable Gloss
Uniformity
Softer/Softer
1.3
6
56
Acceptable Gloss Uniformity
Harder/Softer
0.8
4
68
Acceptable Gloss Uniformity
Clearly, the use of the harder/softer calendering roll combination creates a paper having a Parker Print-Surf of 1.0 or less, a gloss of greater than or equal to 60, and reduced gloss mottle.
Once given the above disclosure, many other features, modifications or improvements will become apparent to the skilled artisan. Such features, modifications or improvements are, therefore, considered to be a part of this invention, the scope of which is to be determined by the following claims. | This invention relates to calendering systems. Such structures of this type, generally, employ the use of hard and soft nips to provide excellent smoothness without gloss mottle. | 3 |
BACKGROUND OF THE INVENTION
[0001] I. Field of the Invention
[0002] This invention relates generally to equipment for compacting waste material, and more particularly to the design of a trash compactor for use in fast food restaurants and other food vending establishments where the patron is expected to deposit his/her waste paper products in a trash receptacle upon leaving the establishment.
[0003] II. Discussion of the Prior Art
[0004] Many fast food restaurants and cafeterias typically provide a refuse or waste container near the exit doors of the establishment and at other convenient locations so that at the conclusion of a meal, the patron's tray containing napkins, paper cups, food wrappers, placemats, etc. can be dumped into the waste receptacle by the patron rather than by restaurant staff. However, it is up to the restaurant staff to periodically empty these trash receptacles, bag the waste materials in polyethylene bags, and then deposit the bagged waste in a dumpster for pick-up by a refuse removal service.
[0005] Because the waste material is merely allowed to fall by gravity in the conventional waste receptacles currently used, it is not particularly dense and frequent emptying of the waste receptacles by staff personnel is required to prevent overflow and attendant lack of patron compliance. The need to frequently empty the refuse receptacles can be a significant cost item for a restaurant operation. Moreover, since refuse haulers generally charge by volume and not by weight, bagged, loosely-compacted refuse takes up an inordinate amount of space in a dumpster and also adds to the cost of refuse disposal.
[0006] Trash compactors intended to meet these needs have been designed to effectively reduce this problem. One such compactor is fully described in my earlier U.S. Pat. No. 6,925,928 which is hereby incorporated by reference. However, those trash compactor designs typically utilize an internal support structure formed from steel I-beams or rectangular tubing that is independent of sheet metal or plastic panels comprising the outer housing or “skins” of the trash compactor. It would be beneficial if such an independent supporting structure were not necessary to provide the rigidity and strength for the hydraulic ram based compaction processes utilized in the prior art trash compactor designs. Eliminating support structures within the compactor would be greatly beneficial in terms of space savings and manufacturing costs.
[0007] A need, therefore, exists for an improved and more efficiently designed refuse compactor capable of compressing fast food restaurant trash so that less frequent emptying is required and a greater mass of waste material can be contained in a smaller volume. The present invention provides a unique solution to this problem.
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention, there is provided a refuse compactor especially designed for use in a restaurant facility that comprises a structurally supportive housing frame having a horizontal, rectangular base and four upwardly extending sheet metal cabinet panels referred to herein as “skins” affixed to the base around its four perimeter edges. Extending across the width dimension of the compactor between its side wall proximate the top thereof is a horizontal tray member. Supported on the tray member is a hydraulic ram along with an electric motor and a hydraulic pump used to drive a hydraulic ram. A compaction plate assembly that includes a one-piece platen pivotally affixed to a support member for rotation about a horizontal axis, is coupled to the piston rod of the hydraulic ram. The piston rod is joined to the support member for driving the compaction plate in a vertical direction toward and away from the base. A pair of guide rods extends through sleeve bearings mounted on the tray member for maintaining alignment of the compaction plate assembly during its operational stroke. A biasing spring is disposed between the support member and the compaction plate for urging the platen from a first position that is inclined to the vertical, to a second horizontal position during a downward movement of the compaction plate assembly when the hydraulic ram is actuated. On a return stroke of the compaction plate assembly, the platen is returned to its inclined position.
[0009] Extending between the refuse compactor's sidewalls and mounted on the base is a front panel that includes a door which can be opened about a vertical hinge to withdraw a wheeled cart containing compacted trash. Located above this door is a refuse receiving opening. Mounted relative to the opening is a hinged panel that is pivotable about a horizontal axis for selectively blocking the refuse-receiving opening. In that the compaction plate is inclined to the vertical when in its raised disposition, it does not interfere with the opening of the hinged panel by a patron wishing to deposit refuse into the compactor. Means are provided for automatically swinging the hinged panel to its open position upon detection of the approach of a patron toward the compactor.
DESCRIPTION OF THE DRAWINGS
[0010] The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment, especially when considered in conjunction with the accompanying drawings in which like numerals in the several views refer to corresponding parts.
[0011] FIG. 1 is an isometric view of the trash compactor comprising a preferred embodiment of the present invention;
[0012] FIG. 2 is a cross-sectional right side view of the trash compactor of the present invention;
[0013] FIG. 3 is a top view of the present invention;
[0014] FIG. 4 is rear view of the invention, where the back panel is removed;
[0015] FIG. 5 is rear view of the invention, where the back panel is removed and the compaction plate is in the open position; and
[0016] FIG. 6 is rear view of the invention, where the back panel is removed and the compaction plate is in the closed position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Certain terminology will be used in the following description for convenience in reference only and will not be limiting. The words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the device and associated parts thereof. Said terminology will include the words above specifically mentioned, derivatives thereof and words of similar import.
[0018] Shown in FIG. 1 is an isometric view of a trash compactor specifically designed for use in fast food restaurants. It is indicated generally by number 10 . In this figure, the compactor cabinet 12 comprises an enclosure having four mutually perpendicular sidewalls joined to one another. The four sidewalls include a front panel 14 , a back panel 16 , and two side panels 18 and 20 . An opening 22 is found in the top half of the front metal skin panel 14 . Restaurant waste or the like can be deposited through this opening 22 . As in my earlier '928 patent, the compactor is designed such that deposited waste falls into a polyethylene refuse bag (not shown) used to line the box of a removable cart assembly when the lower door 24 of the front skin panel is closed and locked. A removable plastic top panel 26 is attached to the top of the device. The top panel has upwardly projecting ribs 27 adjacent the side and rear perimeters of the top panel. The space between these ribs provides a convenient place for serving trays to be stacked once the waste has been deposited into the cart 28 (See FIG. 2 ) through the opening 22 .
[0019] During use, the door 24 will be closed and locked. The door is only open to remove the cart 28 once it is filled with compacted waste material. A motor-operated hinged panel 30 normally blocks the opening 22 , but swings to an open position when a proximity sensor detects the approach of a patron. An audio message is also played. The manner in which this is accomplished will be explained in considerably more detail as the description of the preferred embodiment continues.
[0020] Referring then to FIG. 2 , there is shown a cross-sectional right side view of the waste compactor 10 constructed in accordance with the present invention. The framework differs significantly from what is shown in my aforementioned '928 patent in that instead of utilizing heavy square tubes (labeled 18 , 20 , an 24 in the '928 patent), in the construction of the present invention the compactor force is resisted only by the sheet metal skins comprising side panels 18 and 20 ( FIG. 1 ). The framework for the compactor includes a flat, generally rectangular steel base 32 that is mounted on four caster wheels, as at 34 , to facilitate moving and positioning of the compactor. Extending between the upper ends of the side panels or vertical skins 18 and 20 is a steel plate 38 that spans the width of the opening between the metal skins found above the cabinet. The sides of that plate are bent perpendicular and are welded to the opposite side panels 18 and 20 comprising the sheet metal cabinet skins. The plate 38 conveniently supports electronic circuit boards comprising the compactor's controls.
[0021] FIG. 3 shows a steel plate 42 spanning the width of cabinet 12 . This component is also welded to the opposed side panels 18 and 20 about the steel plate's perimeter. There is a large key hole shaped aperture 37 in the center of the plate 42 through which the piston rod of the hydraulic ram 80 may extend when the cylinder thereof is bolted vertically in place with fasteners (not shown) that pass through the four apertures 41 . Additionally found in plate 42 are a pair of holes 39 for accommodating passages of the guide rods 84 . These holes 39 are disposed on either side of the keyhole shaped aperture 37 . Extra rigidity and support is supplied by the steel plate 42 .
[0022] Referring now to FIG. 4 , the back of the device is seen with a back cover panel removed so that the device's internal features can be readily viewed. First, located above the large upper opening in the back of the device, is the steel tray 38 welded to the edges of the wall skins, on which is supported an electronic control board assembly. (Not shown) Electrical power is delivered to the compactor 10 by way of a power cord 40 that is adapted to plug into a connector on the rear of the tray 38 . Residing on the support plate 42 are an electric motor 44 that is coupled in driving relation to a hydraulic pump 46 for powering the ram 80 .
[0023] Referring again to the frame assembly shown in FIG. 2 , also welded to the vertical skins 12 at a location proximate the upper ends thereof, is a steel tray indicated generally by numeral 50 . It has a vertical rear wall 52 welded at each side edge to the vertical skins 12 and a vertical front wall 54 . To add additional rigidity to the steel tray 50 , a steel partition plate 58 located approximately midway across the width dimension of the steel tray 50 is welded to the rear plate 52 , the front plate 54 and the floor plate 48 .
[0024] Referring momentarily to FIG. 5 , there is indicated generally by numeral 70 a compaction plate assembly. It includes a cast aluminum plate or platen 72 that is pivotally mounted to a steel channel support member 74 . The pivot connection includes a pair of compactor plate bearings 76 , disposed midway along the side edges of the compaction plate 72 , through which a cylindrical hinge rod (not shown) extends to allow rotation of the platen 72 about a horizontal axis. A pair of strong, helical springs 78 is mounted on the pivot pin. They are operatively disposed between the channel support member 74 and the compaction plate 72 so as to apply a biasing force thereto tending to rotate the compaction plate 72 so that it becomes parallel to the top surface of the channel support member 74 , i.e., horizontal, during a compaction stroke, all as will be further described.
[0025] With continued reference to the compaction plate assembly 70 of FIG. 5 , affixed to the top surface of the channel support member 42 is the hydraulic ram 80 . It is centrally disposed between a pair of guide rods 82 and 84 . Guide sleeves, as at 86 , fit into openings formed through the support plate 42 from which the compaction plate assembly 70 is suspended and serve as bearings for the guide rods 82 and 84 . The ram attaches to the steel plate 42 and is vertically oriented such that when pressurized by hydraulic fluid from the pump 46 causes the compaction plate to execute a compaction stroke whereby trash deposited in the cart 28 is crushed and compressed.
[0026] As in my earlier '928 Patent, to avoid having trash deposited on the top surface of the compaction plate 72 , it is imperative that the compaction plate be inclined as shown in FIG. 5 as waste is being deposited through the door opening 22 . However, in order to effect compaction, the plate must assume a horizontal disposition during its downward compaction stroke (as seen in FIG. 6 ) and return to its inclined disposition at the end of the compaction stroke. To achieve this result, there is provided an assembly structure holding two non-axially aligned large diameter rollers 88 and 90 that are suspended from a tube 94 of rectangular cross section that is welded to the undersurface of the support plate 42 . The roller 90 is journaled for rotation in a U-shaped bracket 96 having a rectangular tube 98 welded to it. Also protruding out the side of rectangular tube 98 is a rod 100 , thereby providing an axis for rotation of roller 88 . The rectangular tube 98 is dimensioned to telescopingly fit within the tubular bracket 94 and is held in place by setscrews whereby the degree of extension can be adjusted.
[0027] Also attached to the top surface of the compaction plate is a compactor plate latch assembly 102 . It is used to releasably lock the platen in a horizontal position during the downward compaction stroke of the platen 72 . As shown in FIG. 5 , the compactor plate latch assembly comprises a rectangular base 108 pivotally supporting a rearwardly protruding, spring-loaded platform 104 . Bolts, as at 110 extend through base 108 to permit attachment to the compaction plate 72 . The platform assembly is set up such that as the compaction plate descends from the disposition shown in FIG. 5 , the roller 88 will move out of contact with platform 104 and its spring will rotate the plate 104 so that a hook thereon will engage member 74 to latch the compaction plate. It will be latched in its horizontal disposition during the downward movement of the compaction plate assembly, assuring that any objects that may be in the trash being compacted cannot tilt the compaction plate away from its desired horizontal disposition.
[0028] During upward travel of the compaction plate, a point in the cycle is reached where the roller 88 again comes into contact with the latch plate 104 to disengage the latch from member 74 and, at this point, roller 90 riding on its cam surface 91 will cause the compaction plate to tilt against the force of spring 93 .
[0029] Returning again to FIG. 2 , the hinge panel 30 comprising the waste entry door is pivotally mounted to a pair of door hinge arms 112 which fasten by screws to the floor 48 of the steel tray 50 . Fastened to the inside surface of the hinge panel 30 is a door motion arm that has an arcuate cam profile formed therein along its length dimension. Also mounted on the floor plate tray 48 is a door actuating motor 114 which is coupled through a gear box to one end of an arm supporting a cam follower roller on the free end thereof. The arm is joined to an output shaft of the gear box, as is a further cam (not shown). This further cam cooperates with Microswitches® which are connected in circuit with the motor 114 to cause the arm to be rotated 180° upon each actuation of the motor.
[0030] The roller is positioned to cooperate with the arcuate surface 116 on the arm 112 so as the arm moves through 180°, the waste entry door swings open to the position, allowing waste to be dumped into the cart 28 . Because the platform of the compaction plate assembly is inclined, it does not interfere with the opening of the hinged panel waste entry door 30 .
[0031] The actuation of the motor 114 is controlled by a commercially available motion sensor on the front panel 14 , all as is further explained in my '928 patent. Thus, when the door 24 is closed and locked, as a patron approaches the waste compactor 10 , the motion is detected and a signal is sent to the motor 114 to initiate a 180° swing of arm 112 to first open the waste entry door 30 . As the patron moves away after depositing refuse into the compactor, the action is again sensed and the motor 114 is triggered to rotate the arm an additional 180°, allowing the waste entry door 30 to reclose.
[0032] A programmable logic array comprising the electronic circuit is configured to initiate a compaction cycle after a predetermined number of openings of the waste entry door 30 . For example, and without limitation, the electronic circuit may be programmed such that ten patrons approaching and depositing refuse into the cart 28 will initiate a compaction cycle whereby that refuse is compressed into a cube defined by the side walls of the cart 28 . To prevent the waste entry door 30 from opening during the compaction cycle, which might expose a patron to injury, an interlock is provided to block the waste entry door 30 from opening during a compaction cycle.
[0033] The door lock for securing the door 24 preferably comprises a bolt assembly 118 that is designed to pass through the door 24 . The bolt 118 is sufficiently long to project through the thickness dimension of the door 24 and into a threaded block (not shown) within the device. Bolt 118 additionally has an enlarged plastic knob on the exterior of the front panel to enable easy opening and closing of the device.
[0034] The cart 28 includes a base tray 120 mounted on wheels 122 and supported on the base tray is a separable trash-receiving chamber 124 . The chamber 124 has four mutually perpendicular sidewalls, an open top and an open bottom. For convenience, a polyethylene bag may be inserted into the chamber 124 for ultimately containing the trash once impacted. A pull handle may be pivotally attached to the base 120 to facilitate removing a filled and compacted mass of waste material through the open door 24 and to a temporary storage site. Once at the storage site, the tube-defining chamber 124 can be lifted free of the tray 120 , leaving a compacted trash-filled bag for ultimate disposal by a trash hauling company.
[0035] It has also been found desirable to mount an audible speaker inside the front panel 14 where the speaker is coupled by wires to a voice chip integrated circuit on the electronics panel. Holes 126 are placed in the front panel 14 to aid those using the device in hearing this speaker. As in many telephone answering machines, these voice chips may be used to store several short audio messages that are played each time a patron causes the waste entry door 30 to swing open as a marketing tool. The messages may thank the patron for visiting the restaurant or for dumping his/her trash, etc.
[0036] It can be seen then that the trash compactor of the present invention provides all of the functionality of my earlier embodiment described in U.S. Pat. No. 6,925,928 while obviating the need for heavy I-beam or square tubing frame elements to withstand the forces applied to the waste during the compaction stroke.
[0037] This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself. | A refuse compactor especially designed for use in fast-food restaurant environments includes a hydraulic pump driven by an electric motor for actuating a hydraulic ram to compress restaurant waste materials. The compactor includes a unique outer support structure that derives strength from the outer housing skins to support a compaction plate assembly. The compaction plate assembly maintains the platen inclined at a predetermined angle to the vertical when the platen is elevated and which forces the platen to a horizontal disposition during a downward compaction stroke. A motor operated closure member selectively blocks and unblocks a refuse-receiving opening formed in a front door of the compactor unit and with a motion detector controlling the opening and closing of the refuse entry door panel. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an imaging system useful in medical and industrial x-ray imaging, including classical and digital radiography, and CT scanning. The imaging system of the present invention provides an increased spatial resolution over imaging systems of the prior art by angulating an x-ray detector or detector array with respect to a radiation source.
2. Description of the Prior Art
A number of prior art systems and devices exist for x-ray imaging. The resolution of prior art imaging systems is limited by a variety of different factors. In conventional x-ray detectors, resolution limitations arise from the ranges of electrons and reabsorbed, scattered x-ray photons released in the x-ray detection media.
In imaging systems which use x-ray intensifying screens and in image intensifiers, further resolution limitations arise from lateral light propagation in the detection media. In clear intensifying screen plus lens imaging systems, resolution limitations arise from optical aberrations which depend upon the x-ray absorption position.
In discrete scintillator plus photodetector systems, resolution limitations arise from finite cell dimensions. In gas ionization detectors, resolution limitations arise from finite cell or electrode size and from effects which disperse the ion positions during collection.
The apparatus of the present invention provides significantly improved resolution over x-ray imaging systems of the prior art. The x-ray imaging system of the present invention further provides information on the energy of detected photons. Such information is useful in differentiating component tissues and other materials in the subject based, not only on, gross x-ray absorption, but also on absorption vs. photon energy. The energy discriminating capabilities of the present system provide information allowing isolation of subject components according to atomic number, thereby allowing for chemical identification of components such as calcium, water, fat, and any contrast agents used.
SUMMARY OF THE INVENTION
The present invention is directed toward an imaging system for providing an image of a target body. The invention comprises a radiation source capable of emitting a beam of electromagnetic radiation. The source is aimed at a target body. Depending upon the size of the target body, the invention may also comprise a collimator positioned between the radiation source and a target body so as to control the lateral dimension of the beam within a preselected range.
The invention further comprises a linear first detector array comprising a multiplicity of detectors. The detector array may comprise a multiplicity of scintillator crystals and photodiodes. Alternatively, the detector may comprise a continuous detection medium. The first detector array is oriented such that a radiation beam from a radiation source strikes the detector array at a tilt angle sufficient to define a field of view of sufficient size to image a target body. Because of the angulation of the detector array, the detector cells appear closer in projection as viewed from the radiation source, thereby proportionately increasing the spatial resolution. The detector array is capable of generating a signal indicative of integrated or counting data.
The invention further comprises a signal receiving and storage device connected to receive a signal indicative of integrated or counting data. The signal receiving and storage device is further capable of storing integrated or counting data from the detector array.
The invention further comprises an image display system coupled to the receiving and storage device and capable of displaying images derived from integrated or counting data in the receiving and storage device.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a first embodiment of the present invention.
FIG. 2 is a top view of a second embodiment of the present invention.
FIG. 3 is a top view of a third embodiment of the present invention.
FIG. 4 is a top view of a first detector array embodiment of the present invention.
FIG. 5 is a top view of a second detector array embodiment of the present invention.
FIG. 6 is a top view of the rotatable gantry of the present invention.
FIG. 7 is a block diagram of a signal receiving and storage device of the present invention.
FIG. 8 is a top view of a detector array embodiment of the present invention.
FIG. 9 is a top view of a detector array embodiment of the present invention.
FIG. 10 is a top view of another detector array embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment of the present invention is shown in FIG. 1 . This embodiment comprises a radiation source 10 capable of emitting a beam of electromagnetic radiation. In a preferred embodiment the electromagnetic radiation may be x-rays. The source is aimed at a target body 11 .
This embodiment further comprises a linear first detector array 12 comprising a multiplicity of detector cells 26 . The first detector array is oriented such that the radiation beam strikes the detector array at a tilt angle sufficient to define a field of view of sufficient size to image a target body. The first detector array is capable of generating a signal indicative of integrated or accounting data. In a preferred embodiment each detector cell in the first detector array comprises a scintillator crystal 73 and photomultiplier tube 74 as shown in FIG. 7 .
This embodiment of the invention further comprises a signal receiving and storage device 32 connected to receive a signal indicative of integrated or counting data and to store the integrated or counting data from the detector array. This embodiment further comprises an image display system 34 coupled to the receiving and storage device. The image display system is capable of displaying images derived from integrated or counting data stored in the signal receiving and storage device.
A second embodiment of the present invention is shown in FIG. 2 . This embodiment of the invention further comprises a collimator 20 positioned between the radiation source 10 and the target body 11 so as to control the lateral dimension of the beam within a preselected range, as shown in FIG. 2 .
In a preferred embodiment, the signal receiving and storage device further comprises an energy discriminating device 70 and a multiplicity of bins 72 such that the received signals can be stored according to their energy level, as shown in FIG. 7 . One example of an energy discriminating device suitable for use in the present invention is a pulse height analyzer.
In a preferred embodiment, the invention further comprises a rotatable gantry 60 having a first side 62 affixed to the radiation source and the collimator, as shown in FIG. 6 . The rotatable gantry further has a second side 64 affixed to the detector, as shown in FIG. 6 . In a preferred embodiment, an antiscatter collimator 66 is affixed to the second side of the gantry and positioned between the detector array and the radiation source, as shown in FIG. 6 .
This second embodiment of the invention further comprises a first detector array 12 comprising a proximal end 12 a and a distal end 12 b . The proximal end is closer to the radiation source then the distal end. The first detector array is oriented such that a radiation beam strikes it at an angle within the range of 0.0005-90 degrees. The first detector array is capable of generating a signal indicative of integrated or counting data. This second embodiment of the invention further comprises a signal receiving and storage device and an image display system, as described for the first embodiment, above.
A third embodiment of the present invention is shown in FIG. 3 . This embodiment of the present invention comprises all of the elements depicted in FIG. 1 of the present invention. Additionally, this embodiment of the present invention comprises a second detector array 24 comprising a proximal end 24 a and a distal end 24 b . The proximal end of the second detector array is closer to the radiation source then the distal end.
The second detector array is capable of generating a signal indicative of integrated or counting data. The second detector array is positioned with respect to the first detector array such that the distal ends of the first and second arrays are substantially in contact and the proximal ends of the first and second arrays are spaced apart such that they form an opening approximately the same size as the radiation beam. The opening formed by the proximal ends of the first and second detector arrays face the radiation beam.
In a preferred embodiment of the invention, as shown in FIG. 2, each detector array comprises a multiplicity of cells 26 wherein each cell comprises a center and is placed against at least one other adjacent cell. In another preferred embodiment, the invention may also comprise a collimator, as shown in FIG. 3 . The need or desirability of having a collimator is a function of the size of the target body. In general, the probability of needing a collimator is proportional to the size of the target.
In a preferred embodiment, the distal ends of the first and second arrays are spaced apart a distance that is less than or equal to 20% of the distance between the centers of adjacent cells within each detector array. In a preferred embodiment, each detector array comprises a continuous medium for detecting electromagnetic radiation 29 .
Another preferred embodiment of a detector array of the present invention is shown in FIG. 10 . In this embodiment, each detector array comprises a multiplicity of scintillation crystals 80 . Each of said crystals has a first end 81 a second end 82 and two sides 83 .
This detector array embodiment further comprises a spacer medium 84 positioned between the sides of the scintillation crystals. This medium has low x-ray absorbing and high light reflecting properties. The term “low x-ray absorbing”, as used herein, means that less than approximately 20% of incident x-ray photons are absorbed in the material. The term “high light reflecting”, as used herein, means that more than approximately 80% of the light photons produced in a crystal are reflected back into the crystal by the material.
This detector array embodiment further comprises a substrate 86 extending across the first end of the scintillation crystals. This embodiment further comprises a multiplicity of light sensitive elements 87 mounted on the substrate such that each element faces the first end of a respective crystal as shown in FIG. 10 .
In a preferred embodiment, the spacer medium comprises magnesium oxide power suspended in a binder. In another preferred embodiment, the light sensitive elements are photodiodes.
In another preferred embodiment, the invention further comprises an x-ray absorbing septum 43 placed between the first and second detector arrays as shown in FIG. 3 . In a preferred embodiment, the x-ray absorbing septum is a plate comprising tungsten.
In a preferred embodiment each detector array comprises at least two linear subarrays 27 each of which comprises a mulplicity of detector cells 26 , as shown in FIG. 8 . In a preferred embodiment, each subarray is positioned at an angle with respect to its adjacent subarray such that the first detector array is arranged in an arched configuration, as shown in FIG. 9 .
In a preferred embodiment, as shown in FIG. 4, the first detector array comprises a multiplicity of cells 26 arranged in an arcuate geometry. In a preferred embodiment, the cells are arranged in a stairstep configuration, as shown in FIG. 5 . The first detector array is oriented such that the radiation beam strikes the array at an angle within a range of 0.0005-90 degrees.
In a preferred embodiment, each detector array comprises a multiplicity of cells arranged in an arcuate geometry, as described above. In a preferred embodiment, the cells are arranged in a stairstep configuration, as shown in FIG. 5 .
The foregoing disclosure and description of the invention are illustrative and explanatory. Various changes in the size, shape, and materials, as well as in the details of the illustrative construction may be made without departing from the spirit of the invention. | This invention relates to an imaging system useful in medical and industrial x-ray imaging, including classical and digital radiography, and classical CT scanning. The imaging system of the present invention provides an increased spatial resolution over imaging systems of the prior art by angulating an x-ray detector or detector array with respect to a radiation source. | 0 |
BACKGROUND OF THE INVENTION
Rotating heat exchanger drums such as used in the manufacture of paper and fabric utilize rotary joints for establishing communication between the drum and a heating or cooling medium such as steam or cold water. Such rotary joints usually include an elongated pipe or nipple which is concentrically affixed to an end of the heat exchanger drum, and an end of the nipple is located within a chamber defined by the joint housing or body. The pressurized medium communicates with the stationary body and passes through the nipple into the drum. Seal structure within the joint body prevents loss of fluid between the relatively rotating nipple and body. Typical examples of rotary joints for drums are shown in U.S. Pat. Nos. 2,352,317; 2,385,421; 2,700,558; 2,911,234; 3,594,019; 3,874,707 and 4,262,940.
Pressurized fluid mediums, such as steam, impose forces upon the joint seals which accelerate seal wear, and various constructions have been proposed to compenstate for such internal pressures on the seals, and typical examples of pressure compensated rotary joints owned by the assignee are shown in U.S. Pat. Nos. 2,700,558; 3,874,707 and 4,262,940. Rotary joints wherein seal pressures are compensated by externally mounted apparatus, such as in U.S. Pat. Nos. 2,700,558 and 3,874,707 are expensive and bulky, and it is an object of the invention to provide a rotary joint for heat exchanger drums wherein the seals thereof may be internally compensated with respect to fluid pressures and the need for externally located compensating apparatus is eliminated. In the assignee's application No. 739,862 filed May 31, 1985 a double seal internally pressure compensated rotary joint is disclosed, but this rotary joint requires very precise installation and is not self aligning.
Another object of the invention is to provide a rotary joint for heat exchanger drums wherein the seals of the joint are internally compensated with respect to internal pressurized medium forces, the joint may be rigidly mounted, and wherein limited misalignment between the nipple and joint body may be accommodated and the alignment of the joint is automatically achieved.
Yet another object of the invention is to provide a rotary joint for heat exchanger drums wherein the joint seals are internally compensated with respect to fluid pressures, the joint structure may be readily assembled and serviced, and wherein the components may be manufactured by conventional rotary joint machining techniques.
In the practice of the invention a tubular nipple includes an outer end affixed to the end of a heat exchanger drum for rotation therewith, and the nipple inner end is located within a chamber defined within a rotary joint body. The body chamber is partially enclosed by annular wear and assembly plates attached to the body having central openings and inner flat seal surfaces lying in planes perpendicular to the length of the nipple, and annular carbon graphite seal rings engage the plates' seal surfaces. The nipple inner end includes an enlarged cylindrical portion having a collar in the form of a nipple body axially displaced thereon and the nipple body includes a spherical segment seal surface defined thereon engaging a complementary spherical surface on an adjacent seal ring. The nipple body is sealingly axially displaceable upon the nipple inner end enlarged portion and its axial movement is limited by transverse pins mounted on the nipple extending within axially defined slots formed in the nipple body.
A thrust collar having a spherical segment sealing surface is also mounted upon the nipple inner end enlarged portion within the body chamber in sealing engagement with a carbon graphite seal ring associated with the assembly plate and a compression spring is interposed between the nipple body and thrust collar biasing these components away from each other in the axial direction of the nipple. Key pins mounted on the nipple rotate the thrust collar with the nipple.
The geometric relationship and dimensions of the engaging sealing surfaces of the nipple body and associated seal ring, and the thrust collar and associated seal ring, and the faces of these components exposed to the pressure within the chambers are such that the forces imposed upon the nipple body and thrust collar and seal rings within the body chamber are generally balanced preventing excessive axial forces existing between the relatively moving sealing surfaces. In this manner internal seal balancing is achieved.
Ports are defined within the nipple for establishing communication between the interior of the nipple and the joint chamber, and a port within the body communicating with the chamber permits supply of pressurized medium to the nipple. Additionally, a syphon pipe may extend through the nipple and a gland threaded into the thrust collar seals the syphon pipe with respect to the thrust collar permitting communication of the syphon pipe with a head affixed to the assembly plate for permitting steam condensate to be removed from the associated dryer drum.
The desired geometrical relationship between the collars and seal rings can be achieved because of the enlarged cylindrical portion defined on the nipple inner end upon which the collars are mounted. The spherical surface of the nipple body extends over a nipple end transition shoulder and the spherical surface on the thrust collar extends over the nipple terminal end. These relationships permit the outer radial dimension of the collars' spherical surfaces to be greater than the outer diameter of the seal rings and the inner radial dimension of the spherical surfaces of the collars are less than the diameter of the nipple inner end enlarged portion, yet sufficient seal areas of contact between the collars and seal rings is achieved to prevent excessive seal area pressures. The result of these structural and geometrical relationships permits substantial balancing and compensation of the fluid pressures imposed on the collars and seal rings, and in a joint constructed in accord with the inventive concepts seal wear is substantially extended as compared with noncompensated joints. The joint components may be readily assembled within the body cavity and the spherical configuration of seal surfaces of the nipple body and thrust collar permit accommodation of limited misalignment between the body support and the axis of drum rotation while mounting the joint body on a relatively rigid support bracket.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is an elevational, diametrical, sectional view of a rotary joint in accord with the invention,
FIG. 2 is a reduced scale end elevational view of the joint of FIG. 1 as taken from the left thereof,
FIG. 3 is a side elevational view of the joint as taken from the right of FIG. 2, and
FIG. 4 is a perspective view of the nipple and nipple body, per se.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A rotary joint in accord with the invention includes a cast iron body 10 having mounting surfaces 12 defined thereon and includes a mounting boss 14. The mounting surfaces and the boss permit the joint body to be mounted upon a fixed support bracket 16 which is shown in dotted lines and which is attached to support structure for a rotating heat exchanger drum, not shown. The support bracket 16 includes flanges through which bolts 18 extend and which thread into holes defined in the mounting surfaces 12, and bolt 20 extends through the mounting boss 14, and into the bracket 16. In this manner the joint body 10 may be substantially rigidly affixed adjacent to the heat exchanger drum wherein the axis of the body chamber is substantially coaxial with the drum axis of rotation.
The body 10 includes generally cylindrical chamber 22 which intersects the body flat sides 24 and 26, and the axis of the chamber 22 is substantially coaxial with the axis of heat exchanger drum rotation. A threaded inlet port 28 is defined in the body communicating with the chamber.
A tubular nipple 30 includes an outer end 32 upon which a known mounting flange 34 is located for cooperation with the nipple groove by means of wedge collar and the mounting flange is used to attach the nipple to a drum as shown in assignee's U.S. Pat. No. 2,911,234.
The inner end 36 of the nipple 30 extends into the body chamber 22 and includes an enlarged cylindrical portion 38 having an exterior cylindrical surface defining a transitional shoulder 40 with the smaller diameter portion of the nipple, and the nipple inner end includes several transverse ports 42 which establish communication between the interior of the nipple and the body chamber 22. Additionally, the nipple terminal end 44 includes four axially extending blind holes 46 as will be appreciated from FIGS. 1 and 4.
An annular collar or nipple body 48 is mounted upon the nipple portion 38 for axial displacement thereon, and the nipple body includes a spherical segment seal surface 50, a hub portion 52 and an internal groove in which O-ring 54 is located for sealing the nipple body to the nipple portion 38. Additionally, four slots 56 are defined in the nipple body hub 52 and each slot receives a transversely extending spring pin 58 pressed within a hole in the nipple and received within an associated slot wherein axial movement of the nipple body 48 on the nipple is limited by engagement of the pins with the ends of the slots 56.
A thrust collar 60 is also located upon the nipple portion 38 adjacent its end 44, and the thrust collar includes a spherical segment sealing surface 62 and an internally threaded cylindrical extension 64. A plurality of blind holes 66 are located within the thrust collar for receiving axially extending pins 68 which are received within the four nipple holes 46 and serve as keys for assuring rotation of the thrust collar 60 with the nipple.
A compression spring 70 is interposed between radial shoulders defined upon the nipple body 48 and the thrust collar 60 biasing these components in an axial direction away from each other for a purpose later described.
An annular cast iron wear plate 72 is attached to the joint body side 24 by bolts 74 and includes a central opening 76 through which the nipple 30 extends, and an inner flat sealing surface 78 lying in a plane perpendicular to the length of the nipple. An annular seal ring 80 of carbon graphite is interposed between the nipple body surface 50 and the wear plate seal surface 78, and the seal ring includes a concave spherical segment sealing surface 82 for engaging the nipple body surface 50, and a flat sealing surface 84 engaging the wear plate surface 78.
An annular assembly plate 86 is attached to the body side 26 by screws 88 and the assembly plate includes an annular central opening through which the thrust collar extension 64 extends. The assembly plate 86 includes a flat seal surface 90 perpendicular to the axis of the nipple, and an annular seal ring 92 of carbon graphite is interposed between the assembly plate 86 and the thrust collar 60 having a concave spherical surface 94 complementary to and engaged by the thrust collar spherical surface 62, and having a flat seal surface 96 engaging the assembly plate surface 90.
In the embodiment shown in FIG. 1 a syphon pipe 98 associated with drum syphon structure is illustrated, and the syphon pipe extends through the nipple 30 and through a gland 100 threaded into the end of the thrust collar extension 64 for compressing packing 102 to establish a sealed relationship between the thrust collar 60 and the syphon pipe. A head 104 is attached to the joint body 10 to establish communication with the end of the syphon pipe 98 and the head engages complementary interfitting surfaces defined on the assembly plate 86 and is affixed to the joint body by bolts 106. The head 104 includes an outlet port 108 to which a syphon conduit discharge system may be attached, and condensate flowing through the syphon pipe 98 is removed through the head 104.
The compression spring 70 will initially maintain engagement between the spherical surfaces of the nipple body 48 and the seal ring 80 and the thrust collar 60 and the seal ring 92, and also initially maintain engagement between the flat surfaces of the seal ring 80 and the wear plate 72, and the seal ring 92 and the assembly plate 86.
The nipple body 48 and the thrust collar 60 include a plurality of surfaces or faces which are subjected to the fluid pressure within the chamber 22. For instance, the radial shoulders which engage the ends of the spring 70 and the inner ends of the nipple body and thrust collar adjacent nipple portion 38 form pressure faces which produce axial forces tending to separate the nipple body and thrust collar. Conversely, as the outer diameter dimension of the spherical surfaces 48 and 62 as represented at 110 is greater than the outer diameter of the associated seal rings 80 and 92, respectively, and are spaced from the seal rings these spherical surfaces will be exposed to the chamber fluid pressure and exert axial forces on the nipple body 48 and thrust collar 60 tending to force these components toward each other.
As the spherical surface 50 of the nipple body extends inwardly over the transition shoulder 40, and as the thrust collar spherical surface 62 extends inwardly over the nipple end 44 the inner diametrical dimension of these spherical surfaces as represented at 112 is less than the diameter of the nipple portion 38.
The aforedescribed geometrical relationships permit the engaged portions of surfaces 50 and 82, 78 and 84, 62 and 94, and 90 and 96 to be located radially inwardly with respect to the pressure faces defined on the nipple body and thrust collar to a greater degree than known rotary joints using collars having spherical surfaces permitting an effective balancing of sealing forces to be achieved.
The reception of the spring pins 58 within the nipple body slots 56 will permit the necessary axial displacement of the nipple body on the nipple to compensate for wear of the seal rings 80 and 92, but engagement of the spring pins with the ends of the slots will limit the nipple body axial movement to prevent the nipple body from engaging and damaging the wear plate 72 as the seal ring 80 wears and "thins". Upon extensive leaking occurring due to wear of the seal rings new seal rings 80 and 92 may be readily installed by removing the wear plate 72 and assembly plate 86, respectively.
The spherical configuration of the surfaces 50 and 62 permits effective sealing to take place between the nipple 30 and the joint body 10 even though the body 10 is rigidly mounted by bracket 16 and though misalignment may be present with respect to the axis of the chamber 22 and the axis of rotation of the nipple. Thus, it will be appreciated that the aforedescribed rotary joint configuration permits internal balancing of fluid pressures to provide maximum seal wear, and also accommodates limited misalignment of axes of rotation.
It is appreciated that various modifications to the disclosed embodiment may be apparent to those skilled in the art without departing from the scope of the invention. For instance, the inventive concepts may be practiced in a rotary joint not utilizing a syphon pipe 98 and head 104 and in such instance the assembly plate extension 64 will be plugged. | A rotary joint for establishing communication of a pressurized medium with a rotating heat exchanger drum wherein the joint seals and associated structure are of such configuration to permit internal balancing with respect to fluid pressures imposed thereon. A rotating nipple within the joint body utilizes spherical seal surfaces engaging annular seal rings to achieve self alignment and the nipple includes spring biased collars which automatically compensate for wear and retaining structure limits collar displacement to prevent joint damage. | 8 |
RELATED APPLICATIONS
[0001] This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 60/716,774, entitled “BEARING CAP WITH WEIGHT RESUCTION FEATURE,” filed Sep. 13, 2005, which is hereby incorporated by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates generally to engine components and their manufacture, and relates particularly to a bearing cap with features that reduce the weight of the bearing cap.
BACKGROUND
[0003] In reciprocating piston engines, vibrational forces are produced due to the movement and mass of reciprocating parts. To offset such vibrational forces, engines are often equipped with balance shafts, which include balancing weights. Such balancing weights act to counterbalance and offset vibrational forces produced by reciprocal parts during the operation of the engine. Typical reciprocal engines often utilize pairs of balance shafts. Such pairs of balance shafts are supported on casings disposed in an oil pan below the engine cylinder block. The balance shafts are linked to each other and a to an engine crankshaft to transfer the rotational forces from the crankshaft to the balance shafts. Balance shafts are typically linked to the crankshaft via a chain, belt, or the like, such that the balance shafts rotate at twice the rotational speed and in the opposite direction of the crankshaft. The resultant vibrational forces of the balance shafts counterbalance and offset the vibrational forces of the engine.
[0004] In general, such balance shafts are supported at a plurality of positions to secure the balance shafts to the engine. Since a substantial amount of balancing torque is produced when the balance shafts rotate, the shafts must be supported by a sufficiently rigid bearing structure to remain secured to the engine during operation of the engine. Typically, balance shafts are supported and secured by bearing caps having journal portions designed to capture a portion of the balance shaft. Bearing caps known in the art are generally solid bodies fabricated from cast iron and split into upper and lower halves, as disclosed in U.S. Pat. No. 5,535,643.
[0005] As is known in the art, one method of increasing the strength of the journal portion is to manufacture bearing caps from billet steel or other such rigid material through a casting or machining process. Secondary operations often accompany such processes, such as the drilling of journal portions through the cast or machined bearing cap. The journal portions are drilled to accommodate the insertion of the balance shafts into the journal portions.
[0006] There is a constant need in the art to reduce the weight of automotive components, increase the strength and machinability of such components, and reduce costs. Any such improvements are constantly sought in the automotive industry.
SUMMARY OF INVENTION
[0007] These needs and others are addressed by the invention disclosed herein. An apparatus and methods are provided for reducing the weight of a bearing cap. Such bearing caps are utilized for securing a balance shaft to an engine. Methods and features for reducing the weight of a bearing cap retain the structural integrity of the bearing cap. The apparatus and methods further provide for cost reductions by limiting the amount of post-forming machining needed to finish a bearing cap.
[0008] As such, an apparatus for a bearing cap is disclosed herein. The bearing cap includes a body that comprises an abutment surface, a bearing surface, an exterior surface, and a recess portion. The abutment surface provides for the bearing cap to be coupled to an engine along a flat and even surface. The bearing surface provides for the bearing cap to at least partially capture the bearing shaft to secure the bearing shaft when the bearing cap is abutted to the engine. The recess portion extends into the body of the bearing cap from the exterior surface to reduce the weight of the bearing cap. The recess portion can be located anywhere along the exterior surface and be any shape and dimension that provides sufficient structural integrity to the bearing cap for securing the balance shaft to the engine.
[0009] Furthermore, a method for forming a bearing cap is disclosed herein. The bearing cap is formed in a mold. The mold includes a cavity into which material is place. A die is used to compress the material in the cavity to form the bearing cap. A protrusion in the cavity produces a recess in a portion of the bearing cap. Such recess reduces the weight of the bearing cap. In addition, a contact surface of the die may form an abutment surface of the bearing cap.
BRIEF DESCRIPTION OF THE DRAWING
[0010] In the accompanying drawings, which are incorporated in and constitute a part of this specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below serve to illustrate the principles of this invention. The drawings and detailed description are not intended to and do not limit the scope of the invention or the claims in any way. Instead, the drawings and detailed description only describe embodiments of the invention and other embodiments of the invention not described are encompassed by the claims.
[0011] FIG. 1 is a perspective view of a bearing cap arranged in accordance with an embodiment of the present invention;
[0012] FIG. 2 is a front elevational view of the bearing cap of FIG. 1 ;
[0013] FIG. 3 is a top plan view of the bearing cap of FIG. 1 ;
[0014] FIG. 4 is a bottom plan view of the bearing cap of FIG. 1 ;
[0015] FIG. 5 is a cross-sectional view of the bearing cap of FIG. 1 taken along the line 5 - 5 of FIG. 2 ; and
[0016] FIG. 6 is a perspective view of a bearing cap arranged in accordance with another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] This invention and disclosure are directed to apparatus and methods for providing a bearing cap for securing a balance shaft to an engine. Such bearing caps include features that reduce the weight of bearing caps. Such features include recesses extending into the bearing cap from exterior surfaces of bearing caps. Such features are arranged such that the structural integrity of the bearing cap is not compromised with regard to securing the balance shaft to the engine.
[0018] An exemplary bearing cap 10 in accordance with an embodiment of the invention is illustrated in FIGS. 1 though 5 . The bearing cap 10 includes a body 12 formed from metal or other such rigid material. The body 10 includes abutment surfaces 14 A and 14 B (best seen in FIG. 4 ), a bearing surface 16 , and a plurality of exterior surfaces. As illustrated in the figures, the exemplary embodiment includes a pair of side surfaces 18 and 20 and a top surface 22 .
[0019] Additionally, the bearing cap 10 includes four apertures 24 , 26 , 28 , and 30 . The apertures 24 , 26 , 28 , and 30 pass though the body 10 from the top surface 22 to the abutment surfaces 14 A and 14 B. The apertures 24 , 26 , 28 , and 30 are arranged to accommodate bolts or other such fasteners. The body 12 also includes a number of weight reducing features. For example, a weight reducing recess 32 extending into the body 12 from the top surface 22 , and a plurality of weight reducing recesses 34 , 36 , 38 , and 40 extending into the body 12 from the side surfaces 18 and 20 . As illustrated, the recesses 32 , 34 , 36 , 38 , and 40 are areas that are lower than the surrounding surfaces 18 , 20 , and 22 due to the elimination of material that would normally be present to complete an even exterior surface. The elimination of material from exterior surfaces of the bearing cap 10 allows for a multitude of embodiments for the reduction of overall weight of the bearing cap 10 without compromising the structural integrity of the bearing cap 10 .
[0020] The bearing cap 10 is designed to be coupled to the engine, either directly or indirectly. Bolts or other such fasteners are passed through the apertures 24 , 26 , 28 , and 30 and fastened in threaded holes (not shown) in an engine. Alternatively, the bolts may be fastened to an intermediate component, which is secured to the engine, to couple the bearing cap 10 to the engine. When the bearing cap 10 is coupled to the engine, the bearing cap 10 abuts or otherwise contacts the engine or intermediate component along the abutment surfaces 14 A and 14 B. The abutment surfaces 14 A and 14 B are flat and coplanar, such that the surfaces 14 A and 14 B may effectively contact opposing surfaces on the engine or intermediate component. The bearing surface 16 is arranged to capture a balance shaft (not shown) when the bearing cap 10 is coupled to the engine. The bearing surface 16 cooperates with a similar bearing surface on the engine or other intermediate component to form a bearing to contain a journal portion of the balance shaft and secure the balance shaft to the engine. Coupled as used herein is defined as connected, either directly or indirectly. Two components that are coupled, may have one or more intermediate components that are used to connect the components together.
[0021] As previously described, the body 12 includes a number of recesses 32 , 34 , 36 , 38 , and 40 to reduce the weight of the bearing cap 10 . Preferably, the recesses 32 , 34 , 36 , 38 , and 40 are arranged to offer the maximum reduction of weight without affecting the structural integrity of the bearing cap 10 , which is needed to secure balance shafts to the engine. Although the preference is to achieve a maximum reduction of bearing cap weight, any reduction of weight through the weight reduction features as described herein is included in the present invention.
[0022] The exemplary embodiment as illustrated includes a recess 32 in the top surface 22 . The recess 32 is a groove or channel located along an end 42 of the top surface 22 . Although the recess 32 in the top surface 22 is illustrated and described as a groove or channel along an end 42 of the top surface 22 , it will be understood by those skilled in the art that a recess of any size or shape that extends into the body 12 from the top surface 22 is included in the present invention. Indeed, the invention is not limited to one recess or weight reduction feature on the top surface 22 , any number of recesses or other weight reduction features may be incorporated into the top surface 22 , provided the structural integrity of the bearing cap 10 is not compromised.
[0023] The exemplary embodiment as illustrated, includes four recesses 34 , 36 , 38 , and 40 in the side surfaces 18 and 20 . Each recess 34 , 36 , 38 , and 40 is an elongated channel extending from the intersections of the top surface 22 and the side surfaces 18 and 20 towards the abutment surfaces 14 A and 14 B and terminating a short distance from the abutment surfaces 14 A and 14 B. Each recess 34 , 36 , 38 , and 40 in the side surfaces 18 and 20 , includes a ledge 44 at the end of the channel 34 , 36 , 38 , and 40 that terminates proximate to the abutment surfaces 14 A and 14 B. Each ledge 44 is generally perpendicular to the side surfaces 18 and 20 . The purpose for terminating the channels 34 , 36 , 38 , and 40 a short distance from the abutment surfaces 14 A and 14 B is to maintain a maximum footprint or profile for the abutment surfaces 14 A and 14 B. If a channel 34 , 36 , 38 , and 40 were to extend to the intersection between the side surfaces 18 and 20 and an abutment surface 14 A and 14 B, the surface area of the abutment surface 14 A and 14 B would be reduced. Such reduction in surface area may enhance contact fatigue between the abutment surface 14 A and 14 B and a mating surface on the engine, which may lead to premature failure of the bearing cap 10 .
[0024] As best seen in FIGS. 1 and 3 , each elongated channel 34 , 36 , 38 , and 40 in a side surface 18 , 20 is located between a pair of apertures 24 , 26 and 28 , 30 . When a recess in a side surface 18 and 20 is an elongated channel 34 , 36 , 38 , and 40 , locating the channel 34 , 36 , 38 , and 40 between a pair of apertures 24 , 26 and 28 , 30 is preferred. Such a location does not affect the structural integrity of the bearing cap 10 . Each channel 34 , 36 , 38 , and 40 is arranged such that the amount of material surrounding the perimeter of each aperture 24 , 26 , 28 , and 30 is as large or larger than the amount of material surrounding the perimeter of each aperture 24 , 26 , 28 , and 30 when a weight reducing feature is not located near an aperture. Therefore, whether a weight reducing feature is located near an aperture or not, the structural integrity of the bearing cap 10 , specifically the area surrounding apertures, is unaffected.
[0025] Although the recesses 34 , 36 , 38 , and 40 in the side surfaces 18 and 20 are illustrated and described as channels extending from the top surface 22 to a short distance from the abutment surfaces 14 A and 14 B, it will be understood by those skilled in the art that a recess or other weight reduction feature of any shape or size that extends from a side surfaces 18 and 20 into the body is included in the present invention. Indeed, the invention is not limited to the four recesses 34 , 36 , 38 , and 40 shown on the side surfaces 18 , 20 , any number of recesses or other weight reduction features may be positioned on the side surfaces 18 , 20 , provided the structural integrity of the bearing cap 10 is not compromised.
[0026] Bearing caps as described herein may be formed or manufactured through a molding process that utilizes a mold and a die. The mold typically includes a cavity that generally defines the shape of the bearing cap. Material is placed into the cavity through an open end of the cavity. The die, which includes a contact surface that defines one exterior surface of the bearing cap, enters the cavity though the open end and compresses the material in the cavity to form the bearing cap. A common material used to mold bearing caps is a powder metal material. Such powder metal can be placed into the cavity, the die can enter the cavity to compress the powder metal, and the powder metal can be sintered upon compression of the material to form a solid bearing cap. Such a process may produce a near-net-shape part, i.e., a part that needs little or no machining to achieve a final form.
[0027] Typically, a bearing cap is molded with the cavity forming the abutment surfaces 14 A and 14 B, the bearing surface 16 , and the side surfaces 16 and 18 . The contact surface of the die forms the top surface 22 . That is to say, bearing caps are normally molded in the upright position, with reference to FIG. 1 . However, with the embodiment shown in the figures, the bearing cap would not be able to be removed from the cavity of a standard mold. Each channel 34 , 36 , 38 , and 40 includes a ledge 44 formed just above the abutment surfaces 14 A and 14 B. The outer dimensions of the abutment surfaces 14 A and 14 B are larger than the outer dimensions of the channels 34 , 36 , 38 , and 40 . Thus, the exemplary bearing cap 10 , as illustrated in the figures, cannot be manufactured in the upright position. As such, the exemplary bearing cap 10 may be manufactured in a reversed, or upside down position, with reference to FIG. 1 . In this arrangement the cavity forms the side surfaces 18 and 20 , any weight reduction features in the side surfaces 18 and 20 , the top surface 22 , and any weight reduction features in the top surface 22 . The contact surface of the die forms the abutment surfaces 14 A and 14 B and the bearing surface 16 . The arrangement of the contact surface of the die, along with the alignment of the die is such that the abutment surfaces 14 A and 14 B are coplanar and generally flat upon the forming of the bearing cap 10 .
[0028] Molding the bearing cap in a reversed position provides flexibility in designing and molding weight reduction features into bearing caps. As most designs that include weight reducing features will seek to maintain the largest possible footprint or profile for the abutment surfaces, the outer dimensions of the side surfaces and top surface will typically be less than the outer dimensions of the abutment surfaces footprint. Therefore, molding the bearing cap in the reversed position may reduce concerns over removal of the bearing cap from the cavity once the bearing cap is formed. Weight reduction features, such as channels and groove, can be formed by including protrusions on an inner wall of the cavity. Such protrusions reduce the amount of material needed to mold a bearing cap, and thus, reduce the overall weight of the bearing cap.
[0029] An alternative to molding a bearing cap in a reversed position is to utilize a split mold, which includes two halves. In such an arrangement, the bearing cap can be molded in either the upright or reversed positioned. Once the bearing cap is formed, the two halves of the mold can be separated to remove the formed bearing cap.
[0030] Referring to FIG. 6 , another exemplary bearing cap 100 in accordance with an embodiment of the invention is illustrated. The bearing cap 100 includes a rigid frame 102 coupled to a sintered bearing cap body 104 . The bearing cap body 104 includes weight reduction features 106 . For example, the bearing cap body 104 may include channels or grooves as described herein. | Bearing caps and methods for manufacturing bearing cap are disclosed. Bearing cap includes a body that comprises an abutment surface, a bearing surface, an exterior surface, and a recess portion. The abutment surface provides for the bearing cap to be coupled to an engine along a flat and even surface. The bearing surface provides for the bearing cap to at least partially capture the bearing shaft to secure the bearing shaft when the bearing cap is abutted to the engine. The recess portion extends into the body of the bearing cap from the exterior surface to reduce the weight of the bearing cap. The recess portion can be located anywhere along the exterior surface and be any shape and dimension that retains sufficient structural integrity of the bearing cap to secure the balance shaft to the engine. | 5 |
RELATED APPLICATIONS
The present application is a Divisional of U.S. patent application Ser. No. 12/193,054, filed Aug. 18, 2008, now U.S. Pat. No. 8,051,871, which claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application 60/935,571 filed Aug. 20, 2007. The contents of the aforementioned applications are incorporated by reference in their entirety.
FIELD
The invention relates to systems and apparatus for controlling irrigation systems.
BACKGROUND OF THE INVENTION
Irrigation systems that deliver water, often containing plant nutrients, pesticides and/or medications, to plants via networks of irrigation pipes are very well known. In some irrigation systems, external sprinklers, emitters or drippers, are connected to the irrigation pipes to divert water from the pipes and deliver the water to plants. In many such irrigation networks, water from the pipes is delivered to the plants by emitters or drippers that are installed on or “integrated” inside the irrigation pipes. For convenience, any of the various types of devices used in an irrigation system to divert water from an irrigation pipe in the system and deliver the diverted water to the plants is generically referred to as an emitter. Spacing between emitters, and emitter characteristics are often configured to respond to different irrigation needs of plants that the irrigation system is used to irrigate.
For a given configuration of irrigation pipes and emitters, quantities of water delivered by the irrigation system may be controlled by controlling any of various water flow control devices, such as water pumps, flow valves and check valves, and/or combinations of flow control devices known in the art. Flow control devices may operate to control water from a source that provides water to all of, or a portion of, irrigation pipes in an irrigation system or to control water from individual emitters in the irrigation system.
Israel Patent Application 177552 entitled “Irrigation Pipe” filed Aug. 17, 2006, the disclosure of which is incorporated herein by reference, describes an irrigation system having irrigation pipes comprising integrated emitters having different pressure thresholds at which they open to deliver water from the pipes. Which emitters open to deliver water, is controlled by changing pressure in the irrigation pipes. U.S. Pat. No. 5,113,888, “Pneumatic Moisture Sensitive Valve”, the disclosure of which is incorporated herein by reference, describes a spray device having its own valve that is opened and closed to control amounts of water that the device sprays on plants.
Various automatic and/or manual methods and systems are used to determine when and how much water to supply to plants irrigated by an irrigation system and to control water flow devices in the system accordingly. U.S. Pat. No. 5,113,888 noted above, controls the water flow valve in the spray device described in the patent responsive to soil moisture. The spray device comprises an element located in the soil that has pores, which are blocked when soil water moisture is above a predetermined amount and that are open when soil moisture is below a predetermined amount. When the pores are open, air is released from a chamber in the valve relieving pressure that keeps the flow valve closed to allow the valve to open and water to flow to and be sprayed from the spray device. U.S. Pat. No. 6,978,794, the disclosure of which is incorporated herein by reference, describes controlling an irrigation system responsive to soil moisture determined by at least one time domain reflectometry sensor (“TDRS”) located in the soil. The patent describes using multiple TDRS's at a different soil depth to provide measurements of soil moisture content. U.S. Pat. No. 6,314,340, the disclosure of which is incorporated herein by reference, describes controlling water responsive to diurnal high and low temperatures.
For many agricultural and scientific applications, soil water matric potential is used as a measure of soil moisture content and suitability of soil conditions for plant growth and irrigation systems are often controlled responsive to measurements of soil matric potential. Water matric potential, conventionally represented by “ψ”, is a measure of how strongly particulate soil matter attracts water to adhere to the particulate surfaces. The drier a soil, the stronger are the forces with which soil particles attract and hold water to their surfaces and the greater is the water matric potential. As matric potential of a soil increases, the more difficult it is for plants to extract water from the soil. When soil gets so dry that plants cannot extract water from the soil, plant transpiration stops and plants wilt.
Matric potential has units of pressure, is typically negative, and is conventionally measured using a tensiometer. A tensiometer usually comprises a porous material that is connected by an airtight seal to a sealed reservoir filled with water. The porous material is placed in contact with soil whose matric potential, and thereby moisture content, is to be determined and functions to couple the reservoir to the soil to allow water but not air to pass between the reservoir and soil. The forces that attract water to soil particles draw water through the porous material from the reservoir and generate a vacuum in the reservoir. The drier the soil, the greater are the forces that draw water from the reservoir through the porous material and the greater is the vacuum, i.e. the pressure of the vacuum decreases. As soil moisture increases, the forces that attract water to the soil particles decrease and water is drawn from the soil through the porous material into the reservoir and pressure of the vacuum increases. The vacuum increases (pressure decreases) or decreases (pressure increases) as water content of the soil respectively decreases or increases. A suitable pressure monitor is used to determine pressure of the vacuum and thereby provide a measure of the soil matric potential.
The porous material in a tensiometer is usually a ceramic and is often formed having a cuplike or test tube-like shape. However, U.S. Pat. No. 4,068,525, the disclosure of which is incorporated herein by reference, notes that the porous material “may be formed from any of a wide variety of materials, including ceramics, the only requirement being that the ‘bubbling pressure’, the pressure below which air will not pass through the wettened pores of the material, must be greater than normal atmospheric pressure, to prevent bubbles of air from entering the instrument”. It is noted that bubbling pressure is generally maintained only when the porous material is saturated with water.
Additionally, the porous material should provide good hydraulic contact between the soils and the water reservoir. The latter constraint with respect to soil contact generally requires that the porous material be in relatively intimate mechanical contact with soil particles. Whereas such contact can usually be provided by a surface of a ceramic, for coarse soils or gravels, such mechanical and resulting hydraulic contact can be difficult to obtain using a ceramic material. Gee et al, in an article entitled “A Wick Tensiometer to Measure Low Tensions in Coarse Soils”; Soil Sci. Soc. Am. J. 54:1498-1500 (1990) describes a tensiometer for use in coarse soils in which the porous material “is constructed from paper toweling or other comparable wicking material rolled tightly into a cylinder (.about.0.7 cm in diameter and .about.7 cm long).” The authors note that the tightly rolled wicking material when wetted was pressure tested for suitable bubbling pressure.
U.S. Pat. No. 5,156,179, the disclosure of which is incorporated herein by reference, describes an irrigation system that is controlled using a tensiometer responsive to water matric potential. The system comprises a “flow controller device” that includes a valve assembly connected with the tensiometer to “provide automatic control of flow of water for irrigation”. Changes in pressure in the tensiometer move a piston in the valve to provide “variable control of the rate of flow” through the valve assembly “according to the matric tension of the soil for water”.
SUMMARY OF THE INVENTION
An aspect of some embodiments of the invention relates to providing a tensiometer for measuring matric potential of a soil, for which functions of providing hydraulic contact with the soil and sealing a water reservoir used with or comprised in the tensiometer against ingress of air through the hydraulic contact are provided by different components of the tensiometer.
According to an aspect of some embodiments of the invention, a septum, hereinafter a “sealing septum” interfaces the tensiometer water reservoir with a component of the tensiometer formed from a porous material that provides hydraulic contact between the tensiometer reservoir and the soil and when wet substantially seals the reservoir against ingress of air through the porous material. For convenience of presentation, the component formed from the porous material is referred to as a “hydraulic coupler”.
In an embodiment of the invention, because the sealing septum substantially provides appropriate sealing of the water reservoir, the porous material of the hydraulic coupler is generally not required when wet to have a bubbling pressure greater than an absolute value of a minimum matric potential of the soil in which the tensiometer is to be used. (As noted above, matric potential is usually a negative pressure, and a minimum matric potential is negative pressure having a greatest absolute value. Bubbling pressure of a material is the negative of a minimum matric potential at which air will not pass through the material, generally when the material is properly wetted.) By substantially separating the function of providing hydraulic contact with a soil and the function of sealing against passage of air, a relatively broad spectrum of materials can be used for the hydraulic coupler and a tensiometer can advantageously be configured for specific agricultural applications while also providing relatively improved hydraulic contact with the soil.
For example, according to an aspect of some embodiments of the invention, the hydraulic coupler comprises a porous material in which plant roots are able relatively easily to grow. Optionally, the porous material comprises a woven and/or non-woven geotextile and/or fiberglass. Practice of the invention is not however, limited to such materials and a tensiometer in accordance with an embodiment of the invention may, for example, comprise any hydrophilic material characterized by suitable porosity and may of course comprise relatively rigid materials such as ceramics.
It is noted that the roots of many plants are able to generate hydraulic pressure equivalent to about 15 atmospheres in order to extract water from soil. Such pressure can cause relatively steep gradients in soil moisture for which soil in a near neighborhood of a plant's roots is substantially drier than soil outside of the near neighborhood. Since plant growth and health are generally relatively sensitive to the soil environment near to their roots, a tensiometer for which plant roots are able to grow inside the tensiometer's hydraulic coupler can provide water matric potential measurements advantageously sensitive to soil conditions in the near neighborhoods of plant roots. Such measurements can be particularly advantageous for use in controlling an irrigation system that provides water to the plants.
An aspect of some embodiments of the invention relates to providing a tensiometer that is relatively inexpensive and simple to make and use.
In an embodiment of the invention, a tensiometer comprises a housing having a first housing part formed having an inlet orifice for communication with a sealed water reservoir and a second housing part formed to mate with the first part. The mated parts are assembled sandwiching a sealing septum between the orifice and a first region of a porous hydraulic coupling material that is located in the tensiometer housing when the tensiometer is assembled. A second region of the hydraulic coupling material is located outside of the assembled housing and provides hydraulic coupling of the tensiometer to soil for which the tensiometer provides matric potential measurements. Optionally the first and second housing parts are formed by injection molding plastic. Optionally, the sealing septum is formed from materials readily available in the market such as a plastic, ceramic, or sintered metal characterized by a porosity having suitable uniformity and pore size. Optionally, the pore size has a characteristic dimension having an average between about 0.5 micron and about 1 micron. Optionally, the hydraulic coupling material comprises a geotextile. The tensiometer may rapidly be assembled by any of various methods known in the art, such as by ultrasonic welding, gluing, or snap locking the first and second housing parts together.
An aspect of some embodiments of the invention, relates to providing a configuration of tensiometers that provides a measurement of water matric potential responsive to water matric potential conditions over a relatively large area.
According to an aspect of some embodiments of the invention, a plurality of tensiometers is distributed over the area and the tensiometers in the plurality are coupled to a same common water reservoir. Pressure of a partial vacuum in the common reservoir is responsive to the water matric potential at each of the locations at which a tensiometer of the plurality of tensiometers is located. At equilibrium, pressure of a partial vacuum in the common water reservoir provides a measure, hereinafter a “representative matric potential”, of water matric potential in the area that is intermediate a highest and lowest value for water matric potential provided by the tensiometers. A suitable pressure or vacuum gauge is used to provide a measurement of pressure in the reservoir and thereby a measure of the representative matric potential.
An aspect of some embodiments of the invention relates to providing an improved water management algorithm for controlling irrigation of a field responsive to water matric potential.
In an embodiment of the invention, an irrigation cycle defined by the algorithm comprises a period of active irrigation during which the algorithm controls an irrigation system to provide pulses of water to a field responsive to measurements of water matric potential in the field. Optionally, the cycle is a diurnal cycle. Optionally pulses of water are provided responsive to comparing measurements of water matric potential to a calibration water matric potential measurement. In an embodiment of the invention, the calibration water potential measurement is acquired prior to the active irrigation period at a time for which plants in the field have a relatively small demand for water. Generally, plants exhibit a minimum in water demand at night, often in the early dawn hours and it is at such hours that calibration matric potential measurements are, optionally, acquired. Optionally, the water matric potential measurements are acquired using a tensiometer.
In an embodiment of the invention, an algorithm controls an irrigation system to provide water to a field continuously during an active irrigation period. The duration of the active irrigation period is determined by the algorithm responsive to a comparison of a measurement of water matric potential for the field with a calibration water matric potential.
There is therefore provided in accordance with an embodiment of the invention, a tensiometer for use in determining matric potential of a soil comprising: a water inlet; a hydraulic coupler comprising a porous material for providing hydraulic coupling between water that enters the inlet and the soil; and a septum that seals water that enters the inlet against ingress of air via the porous material. Optionally, the porous material comprises a geotextile. Additionally or alternatively, the porous material is adapted to enable growth of plant roots therein.
In some embodiments of the invention, the septum comprises a septum surface, at least a part of which is contiguous with water that enters the inlet. Optionally, the tensiometer comprises a water labyrinth having baffles. Optionally, a portion of the septum surface contacts the baffles.
In some embodiments of the invention, the septum comprises a membrane and the septum surface is a surface of the membrane. Optionally, the membrane comprises a plurality of layers. Optionally, the layers comprise a first layer having a bubbling pressure greater than about a maximum absolute value of the matric potential of the soil in which the tensiometer is used. Optionally, the first layer is supported by at least one support layer. Optionally, the first layer is sandwiched between two support layers.
In some embodiments of the invention, the septum has a bubbling pressure greater than about a maximum absolute value of the matric potential of the soil in which the tensiometer is used.
In some embodiments of the invention, the bubbling pressure is about equal to one atmosphere.
In some embodiments of the invention, a tensiometer comprises an elastic member that resiliently presses the porous material to the septum.
In some embodiments of the invention, a tensiometer comprises a water reservoir coupled to the water inlet.
In some embodiments of the invention, a tensiometer comprises a device for providing a measure of pressure in the water reservoir.
There is further provided in accordance with an embodiment of the invention, an irrigation system comprising: an irrigation pipe having at least one output orifice for outputting water from the pipe; at least one tensiometer according to an embodiment of the invention coupled to the irrigation pipe so that water output from an orifice of the at least one orifice is constrained to pass substantially directly from the orifice through the hydraulic coupler. Optionally, the irrigation pipe comprises at least one emitter and an output orifice is an orifice of the at least one emitter. Additionally or alternatively, the at least one emitter is an integrated emitter. Additionally or alternatively, the at least one emitter comprises a plurality of emitters.
In some embodiments of the invention, each of the at least one tensiometer is coupled to a same water reservoir.
There is further provided in accordance with an embodiment of the invention, apparatus for use in determining matric potential of a soil comprising: a plurality of tensiometers; and a same water reservoir to which all the tensiometers are hydraulically coupled. Optionally, the plurality of tensiometers comprises a tensiometer in accordance with an embodiment of the invention. Additionally or alternatively, the apparatus comprises a valve adapted to connect the irrigation system to a water source and operable to enable water from the water source to enter the reservoir and remove air therefrom.
There is further provided in accordance with an embodiment of the invention, an irrigation system comprising: an irrigation pipe having at least one output orifice for outputting water from the pipe; at least one tensiometer comprising a hydraulic coupler for coupling the tensiometer to soil irrigated by the irrigation system; and a valve adapted to connect the irrigation system to a water source and operable to enable water from the water source to enter the at least one tensiometer and flush air from the tensiometer and coupler.
There is further provided in accordance with an embodiment of the invention, a tensiometer for use in determining matric potential of a soil comprising: a water inlet; a hydraulic coupler comprising a porous material for providing hydraulic coupling between water that enters the inlet and the soil; a valve adapted to connect the tensiometer to a water source and operable to enable water from the water source to enter the tensiometer and flush the hydraulic coupler.
There is further provided in accordance with an embodiment of the invention, a method of irrigating a field, the method comprising: acquiring a calibration water matric potential for the field; and irrigating the field with an amount of water responsive to the value of the calibration matric potential. Optionally, irrigating a field comprises performing an irrigation cyclically. Optionally, irrigating the field cyclically comprises irrigating the field in diurnal cycles. Optionally, acquiring a calibration water matric potential comprises acquiring a calibration water matric potential at least once a day.
In some embodiments of the invention, the field comprises plants and acquiring the calibration water matric potential comprises acquiring the matric potential when the plants exhibit relatively small water demand.
In some embodiments of the invention, providing an amount of water comprises providing a pulse of water. Optionally, providing an amount of water comprises acquiring a water matric potential measurement for the field in addition to the calibration water matric potential, comparing the additional water matric potential measurement to the calibration water matric potential, and providing an amount of water responsive to the comparison. Optionally, comparing the additional water matric to the calibration matric potential comprises determining their difference. Optionally, providing a pulse of water comprises providing the pulse responsive to the difference.
In some embodiments of the invention, providing water comprises providing water continuously. Optionally, providing water continuously, comprises determining an irrigation period responsive to the calibration water matric potential and providing water continuously for the determined irrigation period. Optionally, determining the irrigation period comprises determining the irrigation period responsive to a difference between the calibration water matric and a previously determined calibration water matric.
There is further provided in accordance with an embodiment of the invention, an irrigation system comprising: an irrigation pipe having at least one output orifice for outputting liquid from the pipe; at least one hydraulic coupler coupled to the irrigation pipe so that liquid output from an orifice of the at least one orifice passes through the hydraulic coupler; and at least one sensing means coupled to the hydraulic coupler to sense a property associated with liquid in the hydraulic coupler, responsive to which property output of water via the at least one orifice is controlled. Optionally, the sensed property comprises matric potential. Additionally or alternatively, the sensed property comprises moisture content of the hydraulic coupler.
Optionally, the irrigation system comprises a controller that controls output of water via the at least one orifice responsive to the sensed property.
BRIEF DESCRIPTION OF FIGURES
Non-limiting examples of embodiments of the invention are described below with reference to figures attached hereto and listed below. Identical structures, elements or parts that appear in more than one figure are generally labeled with a same numeral in all the figures in which they appear. Dimensions of components and features shown in the figures are chosen for convenience and clarity of presentation and are not necessarily shown to scale.
FIG. 1A schematically shows an exploded view of a tensiometer, in accordance with an embodiment of the invention;
FIG. 1B schematically shows details of a top housing part of the tensiometer shown in FIG. 1A , in accordance with an embodiment of the invention;
FIG. 1C schematically shows a plan view of the top housing part shown in FIG. 1B , in accordance with an embodiment of the invention;
FIG. 1D schematically shows a perspective view of a bottom housing part of the tensiometer shown in FIG. 1A , in accordance with an embodiment of the invention;
FIG. 2 schematically shows an assembled view of the tensiometer shown in FIGS. 1A-1B , in accordance with an embodiment of the invention;
FIG. 3 schematically shows a side cross-sectional view of the tensiometer shown in FIG. 1A and FIG. 2 connected to a sealed water reservoir, in accordance with an embodiment of the invention;
FIG. 4 schematically shows a configuration of tensiometers distributed in the soil of an agricultural field in which plants are grown, in accordance with an embodiment of the invention;
FIGS. 5A and 5B show a flow diagram of an algorithm for controlling irrigation of a field responsive to water matric potential in accordance with an embodiment of the invention; and
FIG. 6 shows a flow diagram of another algorithm for controlling irrigation of a field responsive to water matric potential in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
FIG. 1A schematically shows an exploded view of a tensiometer 20 for measuring water matric potential in a soil, in accordance with an embodiment of the invention. FIGS. 1B-1D schematically show enlarged views of components of tensiometer 20 shown in FIG. 1A . FIG. 2 schematically shows an assembled view of tensiometer 20 . For convenience of presentation, apparatus 20 is referred to as a tensiometer, even though, as shown in FIGS. 1A-1D , it optionally, does not comprise a water reservoir and apparatus for providing a measure of pressure in the reservoir.
Tensiometer 20 optionally comprises a housing 22 having first and second housing parts 30 and 50 , hereinafter referred to for convenience as housing top 30 and housing bottom 50 , a sealing septum 60 , a hydraulic soil coupler 70 formed from a porous material and a resilient element 80 .
Hydraulic coupler 70 is formed having a soil-coupling region 72 that extends outside of housing 22 when tensiometer 20 is assembled ( FIG. 2 ) and is a part of tensiometer 20 that contacts soil for which the tensiometer provides water matric potential measurements and hydraulically couples the tensiometer to the soil. Optionally soil-coupling region 72 enlarges with distance from tensiometer housing 22 . Hydraulic coupler 70 optionally comprises a neck region 74 and an optionally circular reservoir-coupling region 76 that are discussed below and are located inside housing 22 . Hydraulic coupler 70 is optionally formed from a flexible porous material and is optionally such that plants that are to be grown in a soil for which tensiometer 20 is to be used to monitor water matric potential can intrude their roots. Optionally, hydraulic coupler 70 is formed from a material comprising a geotextile.
Housing top 30 comprises a tubular stem 31 having a lumen for connecting tensiometer 20 to a sealed tensiometer water reservoir and is formed having a septum recess 33 , shown in a perspective view of first housing part 30 from a side opposite that of stem 31 in FIG. 1B , that seats sealing septum 60 . A bottom surface 34 of septum recess 33 is formed having an inlet hole 35 , clearly shown in a plan view of housing top 30 in FIG. 1C , through which water from a reservoir connected to stem 31 enters tensiometer 20 . Bottom surface 34 of septum recess 33 is optionally formed having a water flow labyrinth 36 comprising an entrance, “detour” baffle 37 that covers portions of inlet hole 35 and a plurality of raised cylindrical baffles 38 . Detour baffle 37 is optionally “starfish shaped” comprising five angularly, equally spaced arms 39 . Labyrinth 36 is surrounded by an annular, optionally planar surface 40 devoid of labyrinth components. Housing top 30 optionally comprises a neck 41 formed having a channel 42 for receiving neck region 74 of hydraulic coupler 70 and optionally comprises an assembly ridge 44 for mounting housing top 30 to housing bottom 50 .
Sealing septum 60 optionally comprises a porous septum membrane 61 supported by an annular septum frame 62 , which optionally protrudes on either side of the plane of the septum membrane. When tensiometer 20 is assembled, the annular septum frame seats on annular region 40 of bottom surface 34 and septum membrane 61 optionally rests on and is supported by detour and cylindrical baffles 37 and 38 .
Septum membrane 61 transmits water but is characterized by a bubbling pressure, hereinafter referred to as an “operating bubbling pressure”, when wet that is equal to a maximum water matric potential, typically between about ≦0.2 bar to about −0.7 bar, expected to be encountered in a soil in which tensiometer 20 is to be used. Optionally, the operating bubbling pressure of porous membrane 61 is equal to about 1 atmosphere. As a result, water can pass through membrane 61 relatively easily, but for a pressure differential across the membrane less than or equal to about a maximum water matric potential of soil in which tensiometer 20 is used, membrane 61 is substantially impervious to air. Optionally, membrane 61 is a layered structure, schematically shown in an inset 66 in FIG. 1A , and optionally comprises a porous layer 63 , which transmits water but when wet is impervious to air for pressures less than an appropriate operating bubbling pressure, sandwiched between two support layers 64 . Optionally, porous layer 63 is formed by way of example from a ceramic, and/or a sintered metal and/or a suitable woven or non-woven fabric having suitable porosity. Support layers 64 are optionally meshed, or screen-like layers formed from any suitably rigid and strong material. Optionally, porous layer 63 is characterized by an average pore size from about 0.5 to about 1 micron. Optionally, support layers are formed from a metal and/or plastic.
Housing bottom 50 is formed to mate with housing top 30 and is optionally formed having a mating ridge 51 that is matched to fit inside recess 33 ( FIG. 1B ) formed in housing top 30 so that it aligns the housing top and bottom. Mating ridge 51 defines a portion of a boundary of a recess 52 that seats reservoir-coupling region 76 ( FIG. 1A ) of hydraulic coupler 70 . The housing bottom also comprises a neck 54 formed having a channel 55 that matches neck 41 and channel 42 respectively of housing top 30 . A bottom surface 56 of recess 52 is optionally formed having a cavity 57 for receiving resilient element 80 , optionally in a shape of a sphere, formed from an elastic material. An outer, optionally planar peripheral border 58 surrounds mating ridge 51 and channel 55 .
When tensiometer 20 is assembled, assembly ridge 44 of housing top 30 contacts and is bonded to peripheral border 58 of housing bottom 50 and mating ridge 51 presses annular septum frame 62 to annular surface 40 of housing top 30 to secure septum 50 in septum recess 33 of the housing top. Resilient sphere 80 is slightly compressed and urges reservoir-coupling region of hydraulic coupler 70 to resiliently press on septum membrane 61 and the septum membrane to rest securely on water labyrinth baffles 37 and 38 . Because of the secure contact between septum membrane 61 and labyrinth baffles 37 and 38 , water that enters tensiometer 20 is distributed substantially equally over the surface of septum membrane 61 that contacts the labyrinth baffles. Starfish detour baffle 37 operates to direct substantially equal portions of water that enters inlet hole 35 to flow radially in each of five different sectors defined by the starfish baffle arms 39 . Cylindrical baffles 38 disperse radially flowing water azimuthally. As a result, water that enters tensiometer 20 through inlet hole 35 wets substantially equally all regions of septum membrane 61 and the membrane becomes substantially impervious to passage of air for the bubbling pressure for which it is intended.
FIG. 3 schematically shows a side cross-sectional view of tensiometer 20 shown in FIG. 1A and FIG. 2 connected to a sealed water reservoir 100 partially filled with water 120 and being used to determine a value for the water matric potential ψ of a soil region 130 , in accordance with an embodiment of the invention. It is noted that whereas water reservoir 100 is shown above the surface of soil region 130 , in practice, the water reservoir is generally located below the surface of soil for which the tensiometer is used to measure water matric potential.
Tensiometer 20 is positioned in soil region 130 so that soil-coupling region 72 of hydraulic coupler 70 is in contact with soil in the soil region. A pressure gauge 102 is coupled to water reservoir 100 to measure pressure in the reservoir. In FIG. 3 , by way of example, the pressure gauge is shown as a manometer having a left hand branch 103 coupled to water reservoir 100 and a right hand branch 104 exposed to atmospheric pressure. The manometer is assumed to comprise mercury 125 as a manometer fluid, and left hand branch 103 between the mercury and water 120 in reservoir 100 is filled with water. Whereas in FIG. 3 pressure gauge 102 is shown as a manometer, in practice any suitable pressure gauge or sensor known in the art may be used to provide a measure of pressure in reservoir 100 .
Hydraulic coupler 70 provides a hydraulic coupling between soil in soil region 130 and water in water reservoir 100 via contact between reservoir-coupling region 76 ( FIG. 1A ) of the hydraulic coupler and sealing septum 60 . The soil draws water from or introduces water into water reservoir 100 via the hydraulic coupler depending on whether the water matric potential of soil region 130 is greater than or less than the pressure in water reservoir 100 . Equilibrium is established for which there is substantially no water flow from or into the reservoir when pressure in the reservoir is equal to the soil water matric potential. Since the matric potential is almost always negative, there is a vacuum in reservoir 100 above a waterline 121 of water 120 in the reservoir. In FIG. 3 mercury 125 , is higher in left hand branch 103 of the manometer connected to water reservoir 100 than in right hand branch 104 of the manometer exposed to atmospheric pressure. A difference between the height of mercury in the left and right hand branches provides a measure of the partial vacuum in water reservoir 100 and thereby of the matric potential ψ.
In order to operate reliably, advantageously, septum membrane is maintained properly wetted and does not have air trapped in its pores. However, during operation, air might leak through hydraulic coupler 70 or seep through water 120 and be trapped by the membrane or in spaces between baffles 37 and 38 of labyrinth 39 . In order to purge septum 61 and/or labyrinth 36 of air that they may trap, a purge valve 105 is optionally connected to reservoir 100 . Purge valve 105 is connected to a suitable source of water (not shown) and in accordance with an embodiment of the invention is periodically opened to flush water from the water source through the reservoir, septum membrane 61 , and labyrinth 36 to purge the septum and labyrinth of air they may have trapped. Advantageously, the space above waterline 121 is substantially a vacuum and water provided via purge valve 105 is used to remove air from reservoir 100 . Thus, as seen in FIG. 3 , the tensiometer 20 is connected to the water source via the sealed water reservoir 100 ; and the purge valve 105 is adapted to connect the water source to the sealed water reservoir 100 at a point below the waterline 121 of the sealed water reservoir 100 .
In an embodiment of the invention, to provide a measure of matric potential ψ in a region of a field, a plurality of tensiometers, optionally of a type shown in FIGS. 1A-3 , is positioned in soil at different locations in the field and coupled to a common sealed water reservoir. Pressure in the common water reservoir provides a measure, i.e. “representative matric potential”, of water matric potential in the field that is intermediate a highest and lowest value for water matric potential provided by the tensiometers. Optionally, the field is an agricultural field for growing plants and the plurality of tensiometers and representative matric potential is used to control irrigation of the plants in the field.
FIG. 4 schematically shows a configuration of tensiometers 200 distributed in the soil of an agricultural field 240 in which plants 242 are grown, in accordance with an embodiment of the invention. The tensiometers are connected to a same water reservoir 202 connected to a pressure gauge 204 used to provide a measure of a partial vacuum in the reservoir and thereby of a representative matric potential of the region of agricultural field 240 in which the tensiometers are located.
By way of example, in FIG. 4 plants 242 are irrigated using an irrigation pipe 210 , comprising integrated emitters 212 and tensiometers 200 are of a type shown in FIGS. 1A-3 having hydraulic couplers 70 formed from a geotextile in which roots 244 of plants 242 are able to grow. In accordance with an embodiment of the invention, each tensiometer 200 coupled to water reservoir 202 is located in a neighborhood of a plant 242 and has its hydraulic coupler 70 wrapped around a region of irrigation pipe 210 in which an emitter 212 is located. Some roots 244 of plants 242 are shown growing into the geotextile fabric of hydraulic couplers 70 of tensiometers 200 . Because of the close proximity of emitters 212 and plant roots 244 to hydraulic couplers 70 , each tensiometer 200 is responsive to soil water matric potential to which plants 242 are relatively sensitive and to changes in the matric potential produced by water emitted by emitters 212 .
In an embodiment of the invention, measurements of changes in pressure in reservoir 202 , and thereby of changes in representative water matric potential of field 240 , provided by pressure gauge 204 are used to control water emitted by emitters 212 . When the representative water matric potential provided by pressure gauge 204 falls below a desired lower threshold for water matric potential, emitters 212 are controlled to release water to the soil. When the representative water matric potential rises above a desired upper threshold, the emitters are prevented from delivering water to the soil.
Optionally, emitters 212 release water to soil region 240 only after pressure in irrigation pipe 210 rises above a release water threshold pressure and water released by emitters 212 is controlled by controlling pressure in the irrigation pipe. In some embodiments of the invention, water release is controlled by pulsing pressure in irrigation pipe 210 above the emitter threshold pressure. In some embodiments of the invention, pressure pulses are periodic and are characterized by a pulse length. The period and pulse length of the pressure pulse are optionally determined responsive to a “hydration” relaxation time of soil in soil region 240 characteristic of a time it takes the soil to reach a limiting water matric potential following release of a quantity of water to the soil by an emitter 212 during a pressure pulse. Controlling release of water in accordance with an embodiment of the invention by pulsing water pressure responsive to a soil hydration relaxation time can be advantageous in providing relatively accurate control of irrigation. For example, it can be advantageous in preventing over irrigation of plants 242 .
The inventors of embodiments of the invention have carried out irrigation experiments in which plants were irrigated responsive to a representative matric potential in accordance with an embodiment of the invention. The inventors found that they were able to achieve relatively improved crop yields with relatively smaller quantities of water than would normally be provided to the plants.
Under some conditions, a representative water matric potential provided by a plurality of tensiometers in accordance with an embodiment of the invention is substantially equal to an average of the measurements provided by the tensiometers. For example, assume that at a location of an “i-th” tensiometer 200 , for convenience represented by “T i ”, in soil region 240 , the water matric potential is ψ i . At equilibrium, a partial vacuum in water reservoir 202 settles down to a pressure equal to that of a representative matric potential “ψ o ”. At the representative matric potential, as much water enters water reservoir 202 from tensiometers T i at locations for which matric potentials ψ i >ψ o as exits the water reservoir from tensiometers T i at locations for which ψ i <ψ o . Assume that water flow into or out of a tensiometer T i is proportional to (ψ i −ψ o )/R where R is a resistance to water transport of soil in soil region 240 , which is the same for all locations of tensiometers T i , and is independent of (ψ i −ψ o ). Then at equilibrium,
∑ i N ( ψ i - ψ o ) R = 0 and ψ o = ( 1 N ) ∑ i N ψ i
so that ψ o is an average of all the ψ i . However, it is expected that, in general, R will not only not be the same for all locations of soil region 130 but will be dependent on (ψ i −ψ o ). As a result, it is expected that a given representative water matric potential will in general be some sort of weighted average of the matric potential at the locations of each of tensiometers 200 .
In some embodiments of the invention, provision of water to an agricultural field by an irrigation system, such as agricultural field 240 and the irrigation system shown in FIG. 4 , which provides measurements of soil water matric potential ψ is controlled in accordance with an algorithm 300 having a flow diagram similar to that shown in FIGS. 5A and 5B . The flow diagram delineates an optionally diurnal water provision cycle in which the irrigation system provides pulses of water to the field subject to certain “trigger” conditions, described below, prevailing.
In a block 301 , optionally values for parameters that control the water provision cycle T cal , T diff , T B and T E are determined. T cal is a time during the diurnal cycle at which the irrigation system calibrates water matric potential measurements and acquires a calibration water matric potential measurement M o . M o is optionally acquired during night after a period of time during which irrigation was not provided and water demand by plants in the field is minimal. Optionally, T cal is about 0500. T diff is an optionally fixed, maximum time lapse allowed by algorithm 300 between provision of pulses of water to field 240 . Optionally, T diff is equal to about 5 hours. T B is a time following time T cal at which the irrigation system begins a period of “active irrigation” in which it provides a pulse of water to field 240 when a trigger condition occurs. T E is a time at which the active irrigation period ends. Optionally, T B is about an hour later than T cal and T E is a time at about dusk, for example about 1700.
In a step 302 , algorithm 300 checks a system clock (not shown) to acquire a reading of the time, “T clock ”. In a decision block 303 the time T clock is checked to see if it is about equal to T cal . If it is not, then the algorithm returns to block 302 to acquire a new reading for T clock . If on the other hand T clock is about equal to T cal , algorithm 300 advances to a block 304 and acquires a calibration reading, M o , of the soil matric potential ψ. The algorithm then proceeds to acquire another reading, T clock , of the system clock in a block 305 and then proceeds to a decision block 306 . In decision block 306 algorithm 300 determines if T clock is greater than or equal to time T B at which active irrigation of field 240 is to commence. If T clock is less than T B , the algorithm returns to block 305 to acquire another reading for T clock . If on the other hand T clock is greater than or about equal to T B , algorithm 300 advances to a block 307 and sets a variable time parameter T P equal to T clock , and in a block 308 optionally sets ΔT equal to (T clock −T P ), which initializes ΔT to zero.
Optionally, in a decision block 309 , algorithm 300 determines if ΔT is greater than T diff . If it is not, (which at this stage, immediately after initialization, is the case) algorithm 300 optionally skips to a block 313 . In block 313 algorithm 300 acquires a measurement M I of the water matric potential of field 240 , optionally responsive to readings from tensiometers 200 ( FIG. 4 ), and proceeds to determine in a decision block 314 if the absolute value of |M I | is greater than the absolute value |M o | acquired in block 304 . If |M I | is greater than |M o |, algorithm 300 optionally proceeds to a block 315 and controls the irrigation system to provide a pulse of water to field 240 .
In some embodiments of the invention, a pulse of water provided by the irrigation system is determined to provide about 0.6 liters of water per m 2 of field 240 . The inventors have determined that aforementioned amount of water per pulse is convenient to maintain appropriate irrigation, generally, if a time between pulses is greater than or about equal to 0.5 hours. In some embodiments of the invention, algorithm 300 increases an amount of water provided by an irrigation pulse if time between pulses decreases to less than about 0.5 hours. For example, if irrigation algorithm 300 “finds” that |M I | increases relatively rapidly, indicating a requirement for irrigation pulses every 0.25 hours, optionally the algorithm increases the mount of water provided by an irrigation pulse. Optionally, the algorithm increases water provided by a pulse to about 0.9 liters/m 2 if it finds that demand for irrigation pulses reaches a rate of about 4 pulses per hour.
Following provision of the pulse of water, algorithm 300 proceeds to a block 316 and acquires a new reading for T clock and resets T P to T clock in a block 317 . It is noted that in decision block 314 , if |M I | is less than |M o |, algorithm 300 skips blocks 315 to 317 , does not provide a pulse of water, and goes directly to a decision block 318 shown in FIG. 5B .
Returning to block 309 if ΔT is greater than T diff , algorithm 300 does not skip to block 314 where it measures M I , but rather, optionally, proceeds to a block 310 and provides a pulse of irrigating water to field 240 . Thereafter the algorithm proceeds to a block 311 , acquires a new reading for T clock , and in a block 312 resets T P to T clock . It proceeds to block 314 to measure M I and via blocks 315 - 317 eventually to decision block 318 .
In decision block 318 algorithm 300 determines if T clock is greater than or equal to T E , the time set in block 301 at which the active irrigation period ends and a new irrigation cycle begins. If T clock is less than T E , algorithm 300 returns to block 308 and resets ΔT, otherwise, the algorithm returns to block 302 to begin the cycle again.
In some embodiments of the invention, an agricultural field, such as field 240 ( FIG. 4 ) is irrigated in accordance with an algorithm 400 having a flow diagram shown in FIG. 6 . Algorithm 400 controls an irrigation system to continuously provide water to agricultural field 240 during an active irrigation period instead of by pulsing water provision.
In a block 401 of algorithm 400 , optionally parameters T B , T E , T diff , T irr , T cal , and M diff are set. As in algorithm 300 , T B and T E are begin and end times of active irrigation and T cal is a calibration time. T irr is an initial value for duration of the active irrigation period, and T diff is an adjustment to T irr , which algorithm 400 makes subject to certain water matric potential conditions of field 240 . M diff is an optionally fixed, maximum change in water matric potential for which algorithm 400 does not adjust T irr . Affects of the parameters set in block 401 on decisions of algorithm 400 are clarified below. In some embodiments of the invention, T irr and L diff have values equal to about 3 hours and 0.2 hours, respectively. M diff is optionally a positive number having value equal to a fraction less than one of a typical matric potential for the field being irrigated with the irrigation system. Optionally, M diff is equal to about 5% of a calibration matric potential acquired for the field. Optionally, for a given day, M diff is equal to 5% of a calibration matric potential for a previous day.
In a block 402 , algorithm 400 acquires a value for T clock , and optionally in a decision block 403 determines if T clock is equal to T cal . If it is not it returns to block 402 to acquire a new value for T clock . On the other hand, if T clock is equal to T cal the algorithm proceeds to a block 404 and acquires a reading “M n ” for the water matric potential ψ of field 240 . The subscript “n” refers to an “n-th” day, assumed a current day, of operation of the irrigation system in providing water to field 240 . In a block 404 , algorithm 400 stores the value for M n in a suitable memory. In a block 405 the algorithm optionally assigns a value to ΔM equal to a difference between of the current reading M n of the water matric potential and a value of a reading, M n-1 , of the water matric potential acquired for the day before the current day.
In a decision block 406 , algorithm 400 determines if an absolute value of ΔM is greater than or equal to M diff . If it is, the algorithm proceeds to a decision block 407 to determine if ΔM is greater than or equal to zero. If ΔM is greater than zero, the algorithm proceeds from block 407 to a block 408 where it decreases T irr by an amount T diff and then proceeds to a block 410 to acquire time T clock . If ΔM is less than zero, the algorithm proceeds from block 407 to a block 409 where it increases T irr by an amount T diff and then proceeds to a block 410 to acquire time T clock .
If in decision block 406 the absolute value of ΔM is less than M diff , then algorithm 400 skips directly from block 406 to block 410 to acquire T clock , skipping blocks 407 , 408 and 409 .
From block 410 , the algorithm proceeds to decision block 411 . In decision block 411 , algorithm 400 determines if T clock acquired in block 410 is greater than or equal to the active irrigation begin time T B . If it is not, it returns to block 410 to acquire a new value for T clock and then to block 411 to test the new T clock . If in block 411 the algorithm determines that T clock is greater than or equal to T B , the algorithm proceeds to a block 412 and begins continuous irrigation of field 240 .
From block 412 the algorithm continues to a block 413 to acquire a new value for T clock and in a decision block 414 determines if (T clock −T B ) is greater than or equal to T irr . If it is not, the algorithm returns to block 412 to continue continuous irrigation of field 240 . If on the other hand, (T clock −T B )>T irr then the algorithm ends continuous irrigation and returns to block 403 .
In the description and claims of the present application, each of the verbs, “comprise” “include” and “have”, and conjugates thereof, are used to indicate that the object or objects of the verb are not necessarily a complete listing of members, components, elements or parts of the subject or subjects of the verb.
The invention has been described with reference to embodiments thereof that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments comprise different features, not all of which are required in all embodiments of the invention. Some embodiments of the invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the described invention and embodiments of the invention comprising different combinations of features than those noted in the described embodiments will occur to persons of the art. The scope of the invention is limited only by the following claims.
Although the present embodiment has been described to a certain degree of particularity, it should be understood that various alterations and modifications could be made without departing from the scope of the disclosure as hereinafter claimed. | A tensiometer for use in determining matric potential of a soil includes a water inlet; a hydraulic coupler comprising a porous material for providing hydraulic coupling between water that enters the inlet and the soil; and a septum that seals water that enters the inlet against ingress of air via the porous material. | 8 |
CONTRACT ORIGIN OF THE INVENTION
The United States Government has rights in this invention pursuant to Contract No. DE-AC02-83CH10093 between the United States Department of Energy and the Solar Energy Research Institute, a Division of the Midwest Research Institute.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is generally related to processes and apparatus used in photochemical vapor deposition (photo-CVD) of materials on substrates, and more particularly to removing and preventing deposition on a transparent solid medium, such as a window, that is positioned between the photon source and the photolysis region, which film, if not prevented or removed, inhibits transmission of photon energy to the photolysis region during deposition processes.
2. Description of the Prior Art
It has been found recently that some materials that are already used, or having potential for use, in thin film semiconductor devices can be deposited on substrates with a photo-CVD technique. In processes using this technique, a substrate is placed in a vacuum chamber, and a reaction gas containing atoms or molecules of the material to be deposited on the substrate is injected into the vacuum chamber. The reaction gas is then exposed to light energy, such as ultraviolet (UV) light, visible light, or infrared radiation, which breaks the molecular bonds and leaves the desired atomic or molecular species to be deposited free to bond with the substrate or with other atoms or molecules of the deposited material already on the substrate. For example, solar cells composed of a thin film of hydrogenated amorphous silicon (a-Si:H) on a substrate can be fabricated by exposing disilane gas (Si 2 H 6 ) to UV light in a vacuum chamber containing the substrate. The photon energy from the UV light breaks Si-H or Si-Si molecular bonds in the Si 2 H 6 gas, thereby freeing Si atoms to bond with other silicon atoms deposited on the substrate to build up a film of a-Si:H.
Such a photo-CVD process for producing a-Si:H films has been shown recently to produce film properties and solar cell efficiencies similar to the best a-Si:H films produced by glow discharge processes. See M. Konagai, MRS SYMP. PROC. 70, 257 (1986). Further, since this process does not involve high voltage ion bombardment, as required by glow discharge deposition, there is no ion bombardment of the substrate surface, chamber walls, and RF electrodes that causes film structural damage and impurity contamination to the deposited film. Therefore, there are substantial reasons for developing the photo-CVD process for commercial production of thin films.
However, prior to this invention, there was still a significant problem associated with the photo-CVD process that precluded efficient commercial use. While depositing the film of the desired atomic or molecular species on the substrate, a film of that material also deposits on glass or other transparent materials through which the UV or other light is introduced into the vacuum chamber. For example, if UV source light bulbs or tubes are positioned in the chamber where photo-CVD of a-Si:H is being performed, a film of a-Si:H also builds up on the surfaces of the light bulbs or tubes. On the other hand, where a transparent window is provided in the side of the vacuum chamber, and the UV light source is positioned outside the window, an a-Si:H film builds up on the inside surface of the window. In either case, the thicker the film build-up, the more it inhibits transmission of the UV light to the Si 2 H 6 process gas, thus decreasing the photolysis and the efficiency of photo-CVD process and eventually effectively shutting down the process.
As a result, in order to continue the photo-CVD process, the vacuum chamber has to be opened to wipe or clean the deposited film from the window or bulbs, sometimes before the desired film on the substrate is even completed, particularly if a somewhat thicker film is desired. Such shut-down and opening of the vacuum chamber to clean the film off the window or bulbs is not only inefficient and labor intensive, but it is also detrimental to the integrity of the film being produced on the substrate. Specifically, impurities, such as oxygen, water vapor, aerosols, and other substances in the air degrade the desired film on the substrate. Even when one thin film can be completed before the deposition on the window or bulb totally blocks the light source, the chamber still has to be opened and cleaned before the next thin film on a substrate can be produced. Once the chamber is opened, it requires closure, pump down, and overnight heating to eliminate the impurities before another film can be produced. Therefore, it has still been a very inefficient, labor intensive process that is not conducive to commercial production. In order for photo-CVD to be a viable manufacturing technique, film deposition on the transparent window through which light is introduced to the vacuum chamber has to be eliminated.
There have been a number of attempts to solve this problem prior to this invention. All of the attempts have been effective to some extent, but also have created new problems or have not completely solved the existing problem. For example, a number of attempts have been made to solve the problem by blowing an inert purge gas, such as helium (He) on the interior surface of the transparent window in an attempt to keep the process gas away from the window. See, e.g., A. Yoshikwaw, et al., 23 JPN. J. APPL. PHYS. L91 (1984), H. Zarnani, et al., 60 J. APP. PHYS. 2523(1986), J. M. Jasinski, et al., 61 J. APPL. PHYS. 431 (1987), K. Kumata, et al., 48 APPL. PHYS. LETT. 1380 (1986), K. Tamagawa, et al., 25 JPN. J. APPL. PHYS. L728 (1986), and Y. Numasawa, et al., 15 J. ELECT. MAT. 27 (1986). The advantages of such an inert gas purge next to the window are that it does not introduce degrading impurities to the film being produced on the substrate and that it does not require moving parts. A significant disadvantage of this inert gas purge is that film deposition on the transparent window is only retarded and not prevented completely. Therefore, it does not always keep the film off the window long enough to complete a normal deposition process, especially where a thicker film on the substrate is desired, and the chamber still has to be opened, cleaned, reevacuated, and heated overnight between each substratecoating process. Also, in order to retard the film growth on the window enough to be beneficial, this inert purge technique requires large purge gas flows. Such large purge gas flows dilute the process gas, which is usually quite expensive, thus reducing efficiency of material usage. Such substantial dilution of the process gas can also adversely affect the film growth process on the substrate. This purge technique is better suited to laser photolysis because the beam can be focused to a small area at the window, as reported by A. Yoshikawa, et al., supra, H. Zarnani, et al., supra, and J. M. Jasinski, et al., supra. T. Saitoh, et al., 42 APPL. PHYS. LETT. 678 (1983), reported that a somewhat thicker film deposition on the substrate can be obtained by repetitively plasma etching the window and resuming the deposition. However, such plasma etching in the chamber requiring periodic interruption of the photo-CVD process is inefficient, can produce undesirable impurities, and detracts from the benefits of photo-CVD over normal plasma deposition.
Another approach to solve the problem, as reported by T. Inoue, et al., 43 APPL. PHYS. LETT. 744 (1983), and A. E. Delahoy, 77 & 78 J. NON-CRYST. SOLIDS 322 (1985), has been to coat the interior surface of the window with a transparent film of low vapor pressure oil, such as Fomblin, to reduce the sticking coefficient of the material being deposited. This oil coating technique has better success at retarding film growth on the window than the inner gas purge technique, but carbon from the oil is a source of degrading impurity that can have a deleterious effect on the film being grown on the substrate. Also, while the oil coating does retard film growth on the window, it still provides only enough time to deposit about a 3-μm film on the substrate. Thus, one successful substrate coating is still about all that can be expected before the chamber has to be opened again for cleaning. The U.S. Pat. No. 4,597,986, issued to R. Scapple, et al., describes an improvement whereby oil is continually applied to the window surface while the surface is wiped with a wiper blade. This latter improvement does enhance continuous production, but the carbon impurity problem renders this technique unsuitable for deposition of semiconductor films that require a high degree of purity.
U.S. Pat. No. 4,265,932, issued to Peters, discloses still another approach in which a movable UV transparent sheet is positioned between the process gas and the window so that a film is deposited on the movable sheet instead of on the window. The clean sheet is continuously unwound from a spool and drawn across the window, then wound onto another spool during the photo-CVD process so that no film build-up to inhibit UV light entering the chamber is allowed. This technique is quite effective for one substrate. Its only disadvantages are that it takes about 300 feet of sheet for the time it takes to accomplish one film deposition on a substrate, so the chamber still has to be opened after every run to change the roll of transparent sheet, and there is still the possibility of some contaminants that emanate or outgas from the sheet as it is unrolled. The U.S. Pat. No. 4,654,226, issued to R. Rochelea, et al., discloses an improvement on this movable sheet technique.
Another interesting approach illustrated by the U.S. Pat. No. 4,454,835, issued to P. Walsh, et al., is to avoid the problem by incorporating a UV light source right in the vacuum chamber without any intervening transparent windows, sheets, or bulbs. In this kind of apparatus, a lamp gas, such as argon or neon, is introduced directly into the vacuum chamber near some discharge electrodes while the process gas is introduced into the chamber near the substrate. The lamp gas is ionized right in the vacuum chamber to create a glow discharge along side the process gas by the electrodes to emit the required UV light, while the film is deposited from the process gas onto the substrate. Since the lamp and deposition regions are in a common vacuum chamber, it is difficult to distinguish between the effects of a remote plasma that may include at least some of the process gas and photolysis of the process gas. This type of system may yet become successful in producing high quality films, but the deposition mechanism is still uncertain, and since the lamp and process gases do mix in the vacuum chamber, the problem of impurities still has to be considered.
Consequently, while the actual photo-CVD process has great potential for producing at least some very commercially desirable thin film semiconductor devices, such as the a-Si:H solar cells discussed above, there has still been a critical need for an effective method and apparatus for eliminating the film build-up on the vacuum chamber window where UV light is introduced in order to make this photo-CVD process commercially viable. Such a solution should meet at least four criteria, as follows: (1) It should not reduce window transparency; (2) It should eliminate deposition on the window while not adversely affecting deposition on the substrate; (3) It should be inert or benign to the film deposition on the substrate and not introduce undesirable impurities into the chamber which would degrade the film deposited on the substrate; and (4) It should be continuously effective without requiring periodic opening of the chamber so that efficient, continuous production of film depositions on successive substrates can be accomplished.
SUMMARY OF THE INVENTION
Accordingly, it is a general object of the present invention to provide a method and apparatus for preventing deposition film build-up on the interior surface of a light-admitting window in a photo-CVD chamber.
A more specific object of the present invention is to provide a method and apparatus for preventing build-up of a deposition film on the light-admitting window of a photo-CVD chamber that does not reduce the transparency of the window.
Another specific object of the present invention is to provide a method and apparatus for preventing build-up of a deposition film on the light-admitting window of a photo-CVD chamber that does not adversely affect deposition on the substrate.
Still another specific object of the present invention is to provide a method and apparatus for preventing build-up of a deposition film on the light-admitting window of a photo-CVD chamber that does not introduce undesirable impurities into the vacuum deposit chamber that would degrade the film deposited on the substrate.
Yet another specific object of the present invention is to provide a method and apparatus for preventing build-up of a deposition film on the light-admitting window of a photo-CVD chamber that accommodates continuous deposition of films on successive substrates without having to open the chamber to the atmosphere after each deposition on a single or even on several substrates.
A still further object of this invention is to provide a method and apparatus for preventing build-up of a-Si:H on the UV-admitting window of a vacuum deposition chamber.
Additional objects, advantages and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by the practice of the invention. The object and the advantages of the invention may be realized and attained by means of the instrumentalities and in combinations particularly pointed out in the appended claims.
To achieve the foregoin and other objects and in accordance with the purposes of the present invention, as embodied and broadly described herein, the method of this invention may broadly comprise the steps of flowing an etchant capable of breaking bonds of the desired atomic or molecular species being deposited into the part of the photolysis region of the chamber immediately proximate to the interior surface of the window and remote from the substrate and from the point where the process gas is introduced into the chamber. The etchant eliminates deposition on the window surface and preferably creates a depletion zone next to the window where excess etchant is consumed by reaction and process gas is depleted.
To further achieve the objects and purposes described above. The apparatus of this invention may broadly comprise a photo-CVD vacuum chamber with a process gas inlet remote from the window and an etchant inlet nozzle adjacent the window and remote from the process gas inlet and from the substrate. Since opening and cleaning is not required after each substrate coating, a load-lock chamber can also be provided for continuous processing.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification illustrate preferred embodiments of the present invention together with the description, the drawing serve to explain the principles of the invention.
In the drawings:
FIG. 1 is a symbolic description of the UV photolysis reaction of Si 2 H 6 as known in the art;
FIG. 2 is a symbolic description of the photo-CVD deposition of a-Si:H as known in the art; and
FIG. 3 is a cross-sectional view of a photo-CVD chamber according to this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention includes a method of preventing deposition film build-up on a light-admitting window in a photo-CVD chamber by purging the interior window surface and the immediately adjacent photolysis region with an etching material. The apparatus of this invention, which will be described in more detail below, is used to implement this method.
In photo-CVD processes, a process gas bearing a desired atomic or molecular species to be deposited is exposed to photon energy. The photon energy breaks molecular bonds in the process gas either directly or indirectly via a sensitizing agent, thereby freeing the desired atomic or molecular species to bond with other atoms or molecules on a substrate. As the process continues, a film of the desired material grows on the substrate.
For example, as illustrated in FIG. 1, it is known that when a disilane gas (Si 2 H 6 ) is exposed to UV light, it breaks into Si X H y +H components, e.g., Si 2 H 5 . The free bond on the Si atom then bonds with other Si atoms on a substrate to grow a film of hydrogenated amorphous silicon (a-Si:H), as illustrated in FIG. 2. This process occurs in an enclosed, sealed, evacuated chamber, and the UV light rays are typically introduced into the chamber through a transparent window in a wall of the chamber.
A cross-section of photo-CVD apparatus 10 according to the present invention is illustrated in FIG. 3. The photo-CVD apparatus 10 includes a chamber 12 enclosed by sidewalls 14. A substrate mounting structure 16 extends into the chamber 12 from one side and is adapted to mount and hold a substrate 20 in stationary position in the chamber 12 during the film deposition process. A heater unit 18 is connected to the substrate mounting structure for heating the substrate 20, if desired, during the photo-CVD process in order to control film properties, such as adhesion and hydrogen content.
In the chamber sidewall 14 opposite the substrate mounting structure is a transparent window 30 with appropriate seals 32 around its perimeter to maintain the seal and vacuum integrity of the chamber 12. A photon light source 40, illustrated in FIG. 3 as comprising an Hg lamp 42 for producing UV light, is positioned adjacent the outside surface of the window 30. Of course other kinds of lamps or light sources for producing UV or other light, as needed for any particular photo-CVD process desired, can also be used as photon light source 40.
The substrate 20 is shown fastened on a carrier 22 that is adapted for mounting on the substrate mounting structure 16. The carrier 22 is also illustrated with a coupling component 24 adapted for releasable attachment to an extractor rod 26 which is mounted so that it can slide in a load-lock apparatus 80, which will be described below. A neck piece 32 connects the photo-CVD chamber 12 to a gate valve 34 positioned between the photo-CVD chamber 12 and a vacuum loading chamber 82 in the load lock apparatus 80. A process gas feeder pipe 44 is connected to the neck piece 32 for feeding process gas into the photo-CVD chamber 12.
An etch gas feeder line 50 is connected to a nozzle 52 positioned adjacent the inside surface of the window 30. An etch gas according to this invention is directed onto the inside surface of window 30 by this nozzle 52, as will be described in more detail below.
A vacuum pump 60 is connected to the end of the photo-CVD chamber 12 that is opposite the neck piece 32 where the process gas is introduced into the chamber 12. This vacuum pump 60 is used to produce and maintain a high quality vacuum in the photo-CVD chamber 12 and to maintain process gas flow. A turbo-type vacuum pump is preferred, though not necessarily essential, for this purpose. Chamber pressure can be controlled by an orifice or throttle valve 66 between the chamber 12 and the pump 60. A second vacuum pump 70 is connected to the load-lock chamber 82 for evacuating the load-lock chamber as substrates 20 are changed, as will be described below.
In operation, with the gate valve 34 closed, the vacuum pump 60 is actuated to pull a high quality vacuum in photo-CVD chamber 12. Once evacuated, the chamber 12 can also be heated for a sufficient time to eliminate any residual water vapor that may have been introduced into chamber 12 from the atmosphere. At the same time, a substrate 20 to the coated can be mounted on a carrier 22 and attached to the rod 26 in load-lock chamber 82 through a hatch 84. The hatch 84 is then closed and sealed, and the vacuum pump 70 is actuated to pull all air out of load-lock chamber 82 and to create a vacuum therein to match the vacuum in photo-CVD chamber 12.
When the chambers 12 and 82 are evacuated and purified as described above, the gate valve 34 can be opened, and the rod 26 can be manipulated from outside load-lock chamber 82 to mount the carrier 22 and substrate 20 in the substrate mounting structure 16. Appropriate channels or guides (not shown) or other suitable structures known in the art can be provided to retain the carrier 22 on the mounting structure 16. The rod 26 can then be manipulated to detach it from the coupler 24 of carrier 22. Once it is detached, the rod 22 can be withdrawn from the photo-CVD chamber 12, and the gate valve 34 can be closed to once again seal the photo-CVD chamber 12 from the lock-load chamber 82.
With the substrate 20 positioned on the mounting structure 16 in chamber 12, and with the vacuum pump 60 operating to maintain the vacuum in chamber 12, the process gas feed, etch gas feed and UV light source 40 can be turned on sequentially or simultaneously to start the photo-CVD process according to this invention. During this photo-CVD process, the process gas is fed into chamber 12 through the process gas feed line 44. The process gas flows through chamber 12 to the primary photolysis area 62 of the chamber 12 between the substrate 20 and the window 30. In this area 62, the process gas is exposed to the photon energy from the light source 40, which photolyzes or breaks molecular bonds and allows the desired atoms or molecules to bond with atoms or molecules on the substrate 20 to grow the desired film thereon.
Simultaneously, as the desired film is being grown on the substrate 20, the nozzle 52 directs etch gas onto the interior surface of the window 30. The etch gas not only tends to purge process gas away from the window 30, but more importantly, it breaks bonds between the desired atoms both in the process gas and in those that may have deposited on the surface of the window 30. The volume and pressure of this etch gas is adjusted so that it is just sufficient to prevent the desired atoms from the process gas from depositing and building a film on the surface of window 30 and to confine the reaction of the etch gas with the process gas to an area 64 adjacent the window 30 and not in the primary photo-reaction or photolysis area 62 adjacent the substrate 20. As this etch gas reacts with the process gas, it creates a depletion region in the area 64 adjacent the window where the process gas is essentially consumed in reaction with the etch gas.
In order to function as described above, the etch gas, of course, must be of a type chosen to react with and break bonding between the desired atoms or molecules that would otherwise deposit and build up a film on the window 30. However, it is also important that the etch gas not react with the window 30 or reduce its transparency. Further, the etch gas should react quickly and thoroughly enough with the process gas in the area 64 adjacent the window 30 so that it is substantially depleted in this area 64 and cannot migrate to any significant extent into the primary photolysis area 62 or to the desired film build up on the substrate 20. Finally, it is also important that the by-products of the etching reaction be inert or benign in the photo-CVD process.
To illustrate the principles of this invention, the desired film to be deposited on the substrate 20 can be a-Si:H. Such photo-CVD process utilizes Si 2 H 6 process gas exposed to UV light in chamber 12. The UV light can be generated by the Hg lamps 42 in light source 40 and introduced into the chamber 12 through window 30. Window 30 can be fabricated of UV grade quartz, which is primarily silicon dioxide (SiO 2 ), or it can be fabricated of Al 2 O 3 , or other Uv transparent materials. The primary photo-CVD reaction, as illustrated in FIGS. 1 and 2, occurs in the area 62 of chamber 12 adjacent the substrate 20 shown in FIG. 3.
The etch gas used in this example is Xenon difluoride (XeF 2 ), which is a white powder with vapor pressure of 3.8 Torr at 25° C. XeF 2 spontaneously etches Si with rates as large as 7000 Å/min without requiring the application of heat, a plasma, or ion bombardment, yet it will not etch the SiO 2 window in these conditions. XeF 2 also reacts very rapidly with silane (SiH 4 ) and disilane (Si 2 H 6 ). Therefore, with proper proportioning of this XeF 2 etch gas to the Si 2 H 6 process gas, this rapid reaction can create a process gas depletion zone 64 adjacent the window 30 while preventing the XeF 2 from reaching the substrate 20 or even from making any significant incursion into the primary photolysis zone 62.
The by-products of XeF 2 etching Si deposited on the interior surface of the quartz window 30 are SiF 4 , Xe, and HF gases. The SiF 4 gas by-product is a strong-bonded gas that does not dissociate in the UV wavelengths used. The Xe gas is, of course, inert. Also, the products of the reaction of XeF 2 with SiH 4 and Si 2 H 6 process gas are SiF 4 , Xe, and HF. While HF is a strong acid reactant with metals, it does not etch Si and is essentially benign in this situation. Therefore, the XeF 2 etchant in this a-Si:H photo-CVD process meets the requirements described above. A very small percentage of F from this process might end up incorporated in the film on the substrate, such as in the range of approximately 0.5 to 3 atomic percent. However, it has been reported that such small amounts of F in an a-Si:H film, i.e., an a-Si:H(F) film, actually enhances the electrical properties of the film. Therefore, it is not detrimental at all to the use of this process for fabricating semiconductor or solar cell devices.
The slight fluorination of the a-Si:H film deposited on the substrate 20 can be eliminated almost entirely, if desired, by drawing some vacuum through a secondary suction pipe positioned principally in the depletion region 64 adjacent the window 30. Such a secondary suction pipe 72 is shown in FIG. 3 connected to a secondary vacuum pump 74. An adjustable valve 76 is also provided in pipe 72 for metering the secondary vacuum drawn from region 64 to attain a balance with the primary vacuum drawn through throttle valve 66. In this manner the secondary vacuum drawn through pipe 72 can be optimized to draw the by-products of the etchant reaction, including F, directly from the region 64 without unnecessary interference with the flow of process gas to the primary photolysis region 62.
In the example described above, the substrate 20 was positioned about 2 cm from the window 30. The Si 2 H 6 process gas was introduced through line 44 into the chamber 12 upstream of the substrate 20. The XeF 2 etchant was introduced through nozzle 52 positioned adjacent the window 30. The nozzle 52 was a 1/8" O.D. tube opening about 2 mm from the quartz window 30. The photolysis source was a low pressure mercury lamp with 185 nm output of 6 mW/cm 2 at a distance of 3 cm. The lamp intensity was monitored with a calibrated thermopile detector and an interference filter to select the wavelength. The process gas was 100% Si 2 H 6 , and the etchant was XeF 2 with He as a gas carrier. The relative flow rates of the process and etchant gases were adjusted so the window 30 transparency was maintained and the XeF 2 was consumed in the region 64 near the window without etching the a-Si:H(F) film being deposited on the substrate 20. The deposition rate and material properties were examined as functions of the gas flow rates, pressure, temperature, and lamp intensity, as shown in Table I below. The films were characterized for thickness, light and dark conductivity, bandgap, activation energy, and infrared absorption X-ray photoelectron spectroscopy (XPS) for fluorine content.
TABLE I______________________________________Deposition parameter ranges. RangeParameter Low High Units______________________________________T.sub.subst. 240 315 °C.Si.sub.2 H.sub.6 flow 10 30 sccmXeF.sub.2 flow 0.1 0.3 sccmHe flow 5 50 sccmP.sub.total 0.5 3 TorrI.sub.185nm 3 6 mW/cm.sup.2______________________________________
The results confirmed that the window transparency was maintained effectively and continually throughout the photo-CVD of as many a-Si:H(F) films as desired, and the film characterizations show that the observed and measured properties are of sufficiently high quality for semiconductor device use. The photo to dark conductivity gain is in excess of 10 5 . The balance between maintaining effective etching at the window 30 and efficient deposition of a-Si:H(F) at the substrate 20 was quite easy to maintain over a wide range of parameters. At one extreme end of this range, with insufficient flow of XeF 2 , deposition of a-Si:H(F) film started around the edges of the window 30. Increasing the XeF 2 flow caused the diameter of the clear region on the window 30 to increase until the film disappeared. At the other extreme of this range, excessive XeF 2 etched the deposited a-Si:H(F) film off the substrate 20 as well.
Since it is quite easy to maintain the window 30 clear of film deposits according to this invention there is no problem with UV light blockage before a desired film thickness on the substrate 20 is obtained, regardless of how long it takes. Further, and perhaps equally as important, the ability to maintain the window clear of film build-up allows a continuous succession of substrates to be coated without having to open the chamber 12, thus eliminating the need to open the chamber to clean and then close it, pump it down, and heat it for an extended period to eliminate impurities between each substrate coating. Therefore, as shown in FIG. 3, the load-lock and the vacuum pump 70 can be used to pump down the load-lock chamber 82 to eliminate air and impurities and to match the vacuum in chamber 12. When the substrate 20 in chamber 12 is coated as desired, the process gas and etch gas are turned off, and the gate valve 34 is opened to allow insertion of the rod 26 into the photo-CVD chamber 12 to attach and remove the carrier 22 and substrate 20. The gate valve 34 is then closed, and the hatch 84 is opened to remove the finished substrate 20. Another substrate 20 is then mounted in carrier 22 and the hatch 84 is closed and sealed. The pump 70 again evacuates load-lock chamber 82, the gate valve 34 is opened, and the new uncoated substrate 20 is inserted into chamber 12 and mounted on mounting apparatus 16. The rod 26 is then uncoupled from carrier 22 and withdrawn so that gate valve 34 can then be closed again, and the photo-CVD process can be repeated immediately to deposit a film on the new substrate 20. This process can continue indefinitely without opening photo-CVD chamber 12 to the atmosphere, yet with assurance that the window 30 can be kept clear according to the present invention.
The method and apparatus of this invention to maintain window transparency in photo-CVD processes can be applied to a variety of materials and is not limited to the use of XeF 2 etchant in a-Si:H(F) photo-CVD described in the example above. Both the etchant and the depositing film can be varied while still fulfilling the requirements described above. For example, other materials that are spontaneously etched by XeF 2 include W and Nb. Also, photo-CVD of metals, while having many potential device applications, also has suffered from complications due to window blocking deposition. Other etchants, such as Cl 2 , will react spontaneously with metals, such as Al and Cu.
Further, because of the light present in photo-CVD processes, a new class of etchants that are activated by light are particularly suited to this application. For example, although NF 3 and SF 6 do not etch Si spontaneously, they do become effective etchants of Si when photolyzed with UV light. Other etch deposition pairs effective when photolyzed with UV light irradiation include NF 3 etchant with SiO 2 deposition and HCl etchant with GaAs deposition. Similarly, when photolyzed with visible light, NF 3 and Cl 2 become etchants for Mo, W, and Cr, and infrared irradiation makes COF 2 an etchant of SiO 2 . The combinations of such materials are particularly appropriate for use in accordance with this invention where the same photolysis light source can be used to induce the etching as well as the deposition.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to falling within the scope of the invention as defined by the claims which follow. | Unwanted build-up of the film deposited on the transparent light-transmitting window of a photochemical vacuum deposition (photo-CVD) chamber is eliminated by flowing an etchant into the part of the photolysis region in the chamber immediately adjacent the window and remote from the substrate and from the process gas inlet. The respective flows of the etchant and the process gas are balanced to confine the etchant reaction to the part of the photolysis region proximate to the window and remote from the substrate. The etchant is preferably one that etches film deposit on the window, does not etch or affect the window itself, and does not produce reaction by-products that are deleterious to either the desired film deposited on the substrate or to the photolysis reaction adjacent the substrate. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a child seat carrier and, more particularly, to a lightweight, compact child seat transport system, which transfers weight of the carrier and its contents to the waist of a user.
2. Description of the Prior Art
It is well known in the art to provide carriers for children or the like. Such carriers typically include a base or body coupled to a pivotal handle. In many embodiments, the base is specifically designed to attach and detach to an affixed base provided with a vehicle.
One drawback associated with such devices is the orientation of the body of the carrier and the handle pivotally coupled thereto. Prior art designs make it difficult and awkward to hold or transport the carrier by hand, especially for a substantial length of time. It is well known in the art to provide a sling or similar device to transfer the weight of the carrier to the shoulder of a user. Such prior art slings, however, have several drawbacks.
Some of these drawbacks include the carrying location of the body of the carrier being below the knee of the user. With this design the user must force the carrier outward to avoid contact of the carrier with the user's legs while walking. Another drawback associated with such prior art devices is the awkwardness in moving a sling over the user's head and the discomfort and awkwardness of the sling extending across the chest of the user. Extending the sling across the chest of a user could lead to wrinkling, staining or tearing of a shirt or blouse in contact with the sling, and discomfort to the chest area. It would, therefore, be desirable to provide a quick connect system for transferring the weight of a carrier to the body of a user in a manner which secured the carrier near waist level of the user, and which did not substantially interfere with the walking stride of the user. The difficulties encountered in the prior art discussed hereinabove are substantially eliminated by the present invention.
SUMMARY OF THE INVENTION
In an advantage provided by this invention, a child carrier transport system is provided which is of low-cost, lightweight and strong manufacture.
Advantageously, this invention provides a child carrier transport system which quickly connects and disconnects from both a user and child carrier.
Advantageously, this invention provides a child carrier transport system which maintains a child carrier near waist level of a user.
Advantageously, this invention provides a child carrier transport system which reduces contact with and degradation of a shirt or blouse of a user.
Advantageously, this invention provides a child carrier transport system which quickly adjusts to a plurality of various child carriers and a plurality of users of different heights and girths.
In an embodiment of this invention, a system is provided for transporting a child seat having a base, a front, a back, a first side and a second side. The system includes a belt having a first end and a second end, and means for attaching the belt to the base and lateral of the child seat. Means are provided for releasably securing the first end of the belt to the second end in a manner which defines a ring at least fifteen inches in circumference.
Preferably, the attaching means is a second ring provided around the base of the child seat and secured to the handle at the points at which the handle pivotally connects to the base. A pad is also preferably coupled to the belt to buffer pressure of the child seat against the user.
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 front perspective view of the child carrier transport system of the present invention, shown coupled to a child carrier and a user;
FIG. 2 illustrates a top elevation of the child carrier transport system of FIG. 1 ;
FIG. 3 illustrates a front perspective view in partial cutaway of the child carrier transport system of FIG. 1 ;
FIG. 4 illustrates a side perspective view of the child carrier, showing the latch and hook material applied to the base and handle of the child carrier;
FIG. 5 illustrates a side perspective view of the child carrier, showing the child carrier transport system attached thereto; and
FIG. 6 illustrates a front perspective view in partial cutaway of an alternative embodiment of the present invention utilizing a clip to secure the child carrier to a belt worn by the user.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, the child carrier transport system is shown generally as ( 10 ) in FIG. 1 . As shown in FIG. 2 , the child carrier transport system ( 10 ) includes a first belt ( 12 ). The belt is preferably constructed of two inch wide polypropylene webbing, such as that known in the art. The first belt ( 12 ) may, of course, be constructed of any suitably durable material. The first belt ( 12 ) preferably includes a first end ( 14 ) and a second end ( 16 ), coupled to one another by a buckle ( 18 ). Although the buckle may be of any type known in the art, in the preferred embodiment, the buckle is of the side release type, such as that generally known in the art to allow for quick adjustment of the side of the interior ring defined by the first belt ( 12 ) when the buckle ( 18 ) secures the first end ( 14 ) to the second end ( 16 ).
While the first belt ( 12 ) may be of any suitable length, in the preferred embodiment, the first belt ( 12 ) is preferably greater than ten inches in length, and less than one hundred inches in length; more preferably greater than twenty inches in length, and less than sixty inches in length; and most preferably, about forty-five inches in length. As noted above, the side release buckle ( 18 ) allows for quick adjustment of the side of the circumference ( 20 ) of the area defined by the first belt ( 12 ) when the buckle ( 18 ) is secured. For smaller individuals, the side release buckle ( 18 ) may be adjusted as desired and the extraneous lengths of the first belt ( 12 ) associated with the first end ( 14 ) and second end ( 16 ) of the first belt ( 12 ) can be tucked around the remainder of the first belt ( 12 ), cut off, or otherwise removed from the first belt ( 12 ).
As shown in FIG. 2 , secured to the interior circumference ( 20 ) of the first belt ( 12 ) is a pad ( 22 ). The pad ( 22 ) is secured to the first belt ( 12 ) by stitching, adhesive or any other similar attachment means known in the art. As shown in FIG. 3 , the pad ( 22 ) is preferably constructed of a tough outer covering ( 24 ) constructed of pliable vinyl or the like, and a resilient interior ( 26 ) constructed of urethane, silicone rubber, neoprene, thick polypropylene webbing, or any other similar resilient material known in the art. In the preferred embodiment, the pad ( 22 ) is a block five inches wide, four inches tall, and two inches thick.
As shown in FIG. 2 , also secured to the pad ( 22 ) is a first cuff ( 28 ). While the first cuff ( 28 ) may be constructed of any suitable material, in the preferred embodiment, the first cuff ( 28 ) is constructed of one inch thick polypropylene webbing, defining a first end ( 30 ) and a second end ( 32 ) coupled to one another by a side release buckle ( 34 ) such as that described above. While the first cuff ( 28 ) may be of any suitable dimensions, in the preferred embodiment, the first cuff ( 28 ) is six inches in diameter. The side release buckle ( 34 ), however, allows the first cuff ( 28 ) to be adjustable as desired.
As shown in FIG. 2 , the child carrier transport system ( 10 ) also includes a second belt ( 36 ). The second belt ( 36 ) is preferably constructed of one-inch wide polypropylene webbing, such as that described above. In the preferred embodiment, the second belt ( 36 ) is greater than twenty inches in length and less than one hundred inches in length; more preferably, greater than thirty inches in length and less than seventy-five inches in length; and, most preferably, seventy inches in length. The second belt ( 36 ) includes a first end ( 38 ) and a second end ( 40 ), coupled to one another by a side release buckle ( 42 ), such as that described above. Secured to the second belt ( 36 ) by stitching, adhesive or similar securement means is a second cuff ( 44 ). The second cuff ( 44 ) includes a first end ( 46 ) and a second end ( 48 ), secured to one another by a side release buckle ( 50 ). The dimensions of the second cuff ( 44 ) are similar to those described above in association with the first cuff ( 28 ).
As shown in FIG. 2 , the second belt ( 36 ) is secured to the pad ( 22 ) by a first strap ( 52 ) and a second strap ( 54 ). The straps ( 52 ) and ( 54 ) are secured to the pad ( 22 ) and second belt ( 36 ) by stitching, adhesive or similar securement means. The straps ( 52 ) and ( 54 ) are preferably constructed of one inch wide polypropylene webbing.
As shown in FIG. 4 , the child carrier ( 56 ) includes a base ( 58 ) and a handle ( 60 ). The handle ( 60 ) includes a first arm ( 62 ) and a second arm ( 64 ), coupled to one another by a grip ( 66 ). The first arm ( 62 ), second arm ( 64 ), and grip ( 66 ) are preferably integrally molded of a single piece of thermoplastic material, such as those well known in the art. As shown in FIG. 4 , the arms ( 62 ) and ( 64 ) are pivotally coupled to the base ( 58 ) by a pivot assembly ( 68 ) such as those well known in the art. The base ( 58 ) includes a front ( 70 ), a rear ( 72 ), a left side ( 74 ), a right side ( 76 ), a bottom ( 78 ) and an overhanging lip ( 80 ).
As shown in FIG. 4 , when it is desired to utilize the child carrier ( 56 ) in accordance with the present invention, strips of hook and latch material ( 82 ) are riveted or otherwise secured to the base ( 58 ) of the child carrier ( 56 ) just under the lip ( 80 ). The material ( 82 ) is provided around the entire circumference, except for a four-inch section between the arms ( 62 ) and ( 64 ) and the base ( 58 ). The size of the section devoid of material ( 82 ) may, of course, be of any suitable dimensions. The material is also provided around each of the arms ( 62 ) and ( 64 ) immediately above the pivot assemblies ( 68 ) and is similarly secured.
As shown in FIGS. 2 and 3 , lengths of hook and latch material ( 84 ) are provided along the interior circumferences of the second belt ( 36 ) and the cuffs ( 28 ) and ( 44 ). Accordingly, as shown in FIG. 5 , the hook and latch material ( 84 ) of the second belt ( 36 ) secures to the hook and latch material ( 82 ) secured to the base ( 58 ). The interior circumference defined by the second belt ( 36 ) is adjusted to the external circumference of the base ( 58 ) using the side release buckle ( 42 ), before the buckle ( 42 ) is actuated to secure the second belt ( 36 ) against inadvertent dislodgement from the child carrier ( 56 ).
Similarly, the side release buckle ( 34 ) associated with the first cuff ( 28 ) is released and the hook and latch material ( 86 ), stitched, adhesively secured, or otherwise secured to the interior defined by the first cuff ( 28 ), is secured around the first arm ( 62 ) of the handle ( 60 ), interlocking the hook and latch material ( 86 ) of the first cuff ( 28 ) with the hook and latch material ( 82 ) provided around the first arm ( 62 ) of the handle ( 60 ), just above the pivot assembly ( 68 ). The second cuff ( 44 ) is provided with similar hook and latch material ( 88 ) and is secured around the second arm ( 64 ) of the handle ( 60 ) in a similar manner.
Once the second belt ( 36 ) and cuffs ( 28 ) and ( 44 ) have been secured to the child carrier ( 56 ), the child carrier ( 56 ) is lifted with the handle ( 60 ) and the first belt ( 12 ) is provided around the user as shown in FIG. 1 . The buckle ( 18 ) is secured in front of the user retains the first arm ( 62 ) as shown in FIG. 1 . As shown in FIG. 1 , the first belt ( 12 ) preferably extends through a plurality of belt loops ( 90 ), sewn or otherwise secured to the user's pants ( 92 ). The circumference ( 20 ) defined by the first belt ( 12 ) may, of course, be adjusted by adjusting the buckle ( 18 ).
Once the child carrier transport system has been connected as described, the belts ( 12 ) and ( 36 ), and straps ( 52 ) and ( 54 ), transfer weight of the child carrier ( 56 ) to the user's waist ( 93 ). The hook and latch material ( 82 ), ( 84 ), ( 86 ) and cuffs ( 28 ) and ( 44 ), prevent the child carrier ( 56 ) from becoming inadvertently dislodged from the child carrier transport system ( 10 ). Additionally, when in use, the pad ( 22 ) lies between the user and child carrier ( 56 ) to reduce contact of the child carrier ( 56 ) with the user and prevent damage or injury associated therewith.
When it is desired to release the child carrier carrying device ( 10 ), the first belt ( 12 ) is simply unbuckled and removed from the user. If it is desired to completely remove the child carrier transport system ( 10 ) from the child carrier ( 56 ), the buckles ( 34 ), ( 42 ), ( 50 ) may all be released and the cuffs ( 28 ) and ( 44 ), and belt ( 36 ) are removed from the carrier ( 56 ). The buckles ( 34 ), ( 42 ) and ( 50 ) are all positioned facing forward to facilitate access.
An alternative embodiment of a connection system is shown generally as ( 94 ) in FIG. 6 . As shown in FIG. 6 , the alternative connection system includes a rigid plastic keeper ( 96 ), preferably two inches high and four inches wide, defining an interior ( 98 ), ¼ inch side, and 1⅞ inches tall. The keeper ( 96 ) may, of course, be constructed of any suitable material and of any suitable dimensions, but in the preferred embodiment is ⅛ inch in thickness. The keeper ( 96 ) is preferably provided with a back ( 100 ), curving into a long upper catch ( 102 ), and a short lower catch ( 104 ). The upper catch ( 102 ) is preferably at least ½ inch long and, more preferably, over one inch long, while the lower catch ( 104 ) is preferably no greater than ½ inch long, and, more preferably, no greater than ¼ inch long.
Adhesively secured or otherwise secured to the upper catch ( 102 ) of the keeper ( 96 ) is a pad ( 106 ), similar to the pad ( 22 ) described above. The pad ( 106 ) is not secured to the lower catch ( 104 ) which allows insertion of a user's belt ( 118 ) into the interior ( 98 ) of the keeper ( 96 ). Adhesively secured or otherwise secured to the back ( 100 ) of the keeper ( 96 ) are ends ( 108 ) and ( 110 ) of a pair of straps ( 112 ) and ( 114 ), similar to the straps ( 52 ) and ( 54 ) described above. Also secured to the back ( 100 ) of the keeper ( 96 ) is a second belt ( 116 ) similar to the second belt ( 36 ) described. In this embodiment, the cuffs (not shown) may be secured on the interior defined by the second belt ( 116 ), rather than on the exterior as described above.
When it is desired to utilize the alternative connection system ( 94 ), the second belt ( 116 ) is secured to the child carrier ( 56 ) in a manner such as that described above, and the child carrier ( 56 ) is lifted until the alternative connection system ( 94 ) is at approximately waist level with the user. The pad ( 106 ) is preferably pulled on its lower portion, biasing it away from the lower catch ( 104 ) associated with the keeper ( 96 ). Once the pad ( 106 ) has been pulled away a short distance, the user positions the upper catch ( 102 ) around the user's belt ( 118 ). Once the belt ( 118 ) has been forced fully within the interior ( 98 ) of the keeper ( 96 ), the lower catch ( 104 ) acts to maintain the belt ( 118 ) within the interior ( 98 ) of the keeper ( 96 ), and secure against inadvertent dislodgement. In this embodiment, the pad ( 106 ) rests between the user and the keeper ( 96 ), absorbing energy and shock from transmitting between the child carrier ( 56 ) and user.
Although the invention has been described with respect to a preferred embodiment thereof, it is to be understood that it is not to be so limited, since changes and modifications can be made therein which are within the full, intended scope of this invention as defined by the appended claims. | A child carrier transport system. The system has a belt releasably secured around a child carrier, and a belt releasably secured around the waist of a user. The belts are coupled to one another and coupled around the base of the handles provided on the child carrier. A pad is secured to the belts to buttress the transmission of potential injurious force between the child carrier and the user. The resulting system is low cost, strong, lightweight, and does not prohibitively restrict movement of the user. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is the US National Phase of PCT Application No. PCT/GB/2006/001052 filed 24 Mar. 2006 which claims priority to British Application No. 0506051.2 filed 24 Mar. 2005.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not Applicable
INCORPORATED-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0004] Not Applicable
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to the production of coatings which contain aldehyde functional groups.
[0007] 2. Description of the Related Art
[0008] The surface functionalization of solid objects is a topic of considerable technological importance, since it offers a cost effective means of improving substrate performance without affecting the overall bulk properties. For instance, the attachment of biomolecules such as DNA or proteins is of great technical interest, allowing the construction of biological arrays that are finding application in fields of study as diverse as computing (Aldeman, M. Science 1994, 266, 1021; Frutos, A. G. et al., Nuc. Acids Res. 1997, 25, 4748), drug discovery (Debouck, C. et al., Nature Genet. 1999, 1(suppl) 48), cancer research (Van't Veer, L. J. et al. Nature 2002, 415, 530) and the elucidation of the human genome (McGlennen, R. C. Clinical Chemistry 2001, 47, 393). In addition, silver can be deposited onto aldehyde surfaces via Tollens reaction to yield anti-bacterial properties (Manolache, S. et al., Journal of Photopolymer Science and Technology 2000, 13, 51; Hongquan, J. et al., J. Appl. Polym. Sci. 2004, 93, 1411).
[0009] Furthermore, an aldehyde surface offers a chemically versatile substrate that allows surface modification by the application of widely used solution-based chemistries including, but not limited to, the Aldol reaction; the Canizzarro reaction, the Mannich reaction, the Reformatsky reaction, the Tischenko reaction, the Wittig reaction, benzoin formation, bimolecular reduction to 1,2-diols, reductive alkylation/halogenation, conversion to acyls, anhydrides, γ-keto esters/nitriles or 1,4-diketones, acetals, amides, carboxylic esters, dihalides, epoxides, formats, halo alcohols and ethers, β-keto esters and ketones, ketones, nitriles, oximes, phenols, silyl enol ethers. Further reactions include the acylation of heterocyclic systems, photochemical cleavage, decarbonylation, halogenation, and the oxidation or reduction of the aldehyde functionality.
[0010] Aldehydes can also undergo molecular rearrangements to yield ketones (alkyl-interchange reaction) and indole compounds (upon treatment with phenylhydrazine and a catalyst, the Fischer indole synthesis).
[0011] Another application of aldehydes is in condensation reactions including, but not limited to, condensation with active hydrogen compounds, anhydrides, aromatic rings, carboxylic esters, halo esters, and phopsphoranes. Aldehydes are also known to react with species including, but not limited to alcohols, alkenes, amines (the Schiff-base reaction), ammonia, carbon dioxide, hydrogen cyanide, hydrazines, ketenes, metalated aldimines, organometallic compounds, sulfamide, sodium bisulfite, thiobenzilic acid, thiols (including hydrogen sulphide) and can undergo selenation or sulfonation (March, J., Advanced Organic Chemistry 4 th ed., Wiley-Interscience, New York 1992).
[0012] Existing methods of functionalizing solid surfaces with aldehyde groups include aldehyde-silane self-assembly (Zammateo, N. et al, Anal. Biochem. 2000, 280, 143), aldehyde-thiol self-assembly, the conversion of surface immobilized epoxide functionalities (Pitt, W. G. et al Journal of Biomedical Materials Research, Part A 2004, 68A, 95), and the immobilization of aldehyde containing linkers (typically glutaraldehyde) to other functionalised surfaces (Duman, M. et al., Biosensors and Bioelectronics 2003, 18, 1355; Yokoyama et al., WO 2003046562). All of these approaches suffer from drawbacks such as involving multistep processes, substrate specificity, and the requirement for solution phase chemistry.
[0013] Another method of forming aldehyde functionality on a surface involves treatment of a polymer surface, such as polyurethane, with a gas plasma, such as carbon dioxide. However, such approaches lead to the generation of a wide range of surface functions such as carboxylic acids or hydroxyl groups (Terlingen, J. G. A. et al., J. Appl Polym. Sci. 1995, 57, 969).
[0014] Surface functionalization by continuous wave plasma polymerization is an additional route by which aldehydes have been attached to solid surfaces. This approach suffers from the drawback of poor structural retention, with surfaces showing increased oxygenation and/or a loss of aldehyde functionality compared to their monomer precursors (Baumer et al. European Patent EP 1131359; Chow, et al. U.S. Pat. No. 6,528,291; Griesser, H. J. et al., Mat. Res. Soc. Symp. Proc. 1999, 544, 9; Gong, X. et al., Journal of Polymer Science B: Polymer Physics 2000, 38, 2323; Chen, Q. et al., J. Phys. Chem. B 2001, 105, 618; McLean, K. M. et al., Colloids and Surfaces B: Biointerfaces 2000, 18, 221).
[0015] Plasma polymers are hence often regarded as being structurally dissimilar compared to conventional polymers, since they possess high levels of cross-linking and lack a regular repeat unit (Yasuda, H. Plasma Polymerisation Academic Press: New York, 1985). This can be attributed to the plasma environment generating a whole range of reactive intermediates which contribute to the overall lack of chemical selectivity. However, it has been found that pulsing the electric discharge on the ms-μs timescale can significantly improve structural retention of the parent monomer species (Panchalingam, V. et al., Appl. Polym. Sci. 1994, 54, 123; Han, L. M. et al., Chem. Mater., 1998, 10, 1422; Timmons et al., U.S. Pat. No. 5,876,753) and in some cases conventional linear polymers have been synthesized (Han, L. M. et al., J. Polym. Sci., Part A: Polym. Chem. 1998, 36, 3121). Under such conditions, repetitive short bursts of plasma are understood to control the number and lifetime of active species created during the on-period, which then is followed by conventional reaction pathways (e.g. polymerization) occurring during the off-period (Savage, C. R. et al., Chem. Mater., 1991, 3, 575).
[0016] The preparation of aldehyde functionalized surfaces by pulsed plasma polymerization has been previously reported using benzaldehyde (Leich, M. A. et al., Macromolecules 1998, 31, 7618). However, the retention of monomer structure was poor and the coated surfaces exhibited low levels of usable aldehyde functionality. The observed inadequate level of sample performance was due to the structure of the monomer utilized. Benzadelhyde lacks a functional group, such as an acrylate or alkene functionality, that can be readily polymerized by conventional reaction pathways during the pulsed plasma off-time without damage to the desired aldehyde moiety. Plasma polymerization of benzaldehyde, even under mild pulsing conditions, must proceed via its aryl group resulting in unavoidable rupture of the monomer structure and potential damage to the neighbouring aldehyde functionality. Hence, to achieve the successful deposition of an aldehyde containing surface, a methodology combining both pulsed plasma techniques and the selection of a suitable polymerizable monomer structure must be utilised.
[0017] Applicants have found that pulsed plasma polymerisation of monomers containing aldehyde functionalities of general formula (I) can potentially overcome the limitations of existing techniques for forming aldehyde functionalized surfaces. Compounds of formula (I) possess unsaturated functional groups (such as alkene, acrylate and methacrylate) that can undergo conventional polymerization pathways during the pulsed plasma off-time with negligible impact on the desired aldehyde moiety. The resulting films, in comparison with the prior art, exhibit almost total retention of monomer functionality and have been found capable of the exacting levels of performance demanded by applications such as DNA microarray production.
BRIEF SUMMARY OF THE INVENTION
[0018] According to the present invention there is provided a method for applying a reactive aldehyde containing coating to a substrate. The method includes subjecting the substrate to a plasma discharge in the presence of a compound of formula (I):
[0000]
[0019] Where X is an optionally substituted straight or branched alkylene chain(s) or aryl group(s); R 1 , R 2 or R 3 are optionally substituted hydrocarbyl or heterocyclic groups; and m is an integer greater than 0.
[0020] As used herein, the term “hydrocarbyl” includes alkyl, alkenyl, alkynyl, aryl and aralkyl groups. The term “aryl” refers to aromatic cyclic groups such as phenyl or naphthyl, in particular phenyl. The term “alkyl” refers to straight or branched chains of carbon atoms, suitably of from 1 to 20 carbon atoms in length. The terms “alkenyl” and “alkynyl” refer to straight or branched unsaturated chains suitably having from 2 to 20 carbon atoms. These groups may have one or more multiple bonds. Thus examples of alkenyl groups include alkenyl and dienyl.
[0021] Suitable optional substituents for hydrocarbyl groups R 1 , R 2 , R 3 and alkylene/aryl groups X are groups that are substantially inert during the process of the invention. They may include halo groups such as fluoro, chloro, bromo and/or iodo. Particularly preferred halo substituents are fluoro.
[0022] In a preferred embodiment of the invention, X is a moiety comprising an ester group adjacent to an optionally substituted hydrocarbyl or heterocyclic group, R 4 . Thus, in a particular embodiment, the compound of formula (I) is a compound of formula (II):
[0000]
[0023] In particular, R 1 , R 2 , R 3 and R 4 are independently selected from hydrogen or alkyl, and in particular, from hydrogen or C 1-6 alkyl, such as methyl. Thus, in a particularly preferred embodiment, the compound of formula (II) is a compound of formula (III): the desired aldehyde functionality is connected to a readily polymerized acrylate group (CH 2 ═CH—CO 2 —) via a saturated alkyl hydrocarbon chain linker, R 4 , where n is an integer of from 1 to 20:
[0000]
[0024] A particular example of a compound of formula (III), where m=1 and n=1, is ethylaldehyde acrylate.
[0025] In another particularly preferred embodiment, the compound of formula (II) is a compound of formula (IIIa): the desired aldehyde functionality is connected to a readily polymerized methacrylate group (CH 2 ═C(CH 3 )—CO 2 —) via a saturated alkyl hydrocarbon chain linker, R 4 , where n is an integer of from 1 to 20:
[0000]
[0026] A particular example of a compound of formula (IIIa), where m=1 and where n=1, is ethylaldehyde methacrylate
[0027] In other particularly preferred embodiments of the invention, with reference to the compound of formula (I), R 1 , R 2 and R 3 are again independently selected from hydrogen or alkyl, and in particular, from hydrogen or C 1-6 alkyl, such as methyl. Thus, in another particular embodiment, the compound of formula (I) is a compound of formula (IV):
[0000]
[0000] where X is as defined above and m is an integer greater than 0.
Particularly preferred compounds of formula (IV) are vinylbenzenes of formula (V), where X is a di-substituted aromatic ring:
[0000]
[0000] where the ring can be ortho, meta or para substituted.
[0028] A particular example of a compound of formula (V) is 3-vinylbenzaldehyde.
[0029] In another particularly preferred example of the compound of formula (IV), X is a saturated alkyl hydrocarbon chain. Thus, the compound of formula (IV) is a compound of formula (V) where n is an integer of from 1 to 20, for example from 1 to 10 and preferably 8.
[0000]
[0030] A particular example of a compound of formula (Va), where m=1 and n=8, is 10-undecenal.
[0031] Precise conditions under which the pulsed plasma deposition of the compound of formula (I) takes place in an effective manner will vary depending upon factors such as the nature of the monomer, the substrate, the size and architecture of the plasma deposition chamber etc. and will be determined using routine methods and/or the techniques illustrated hereinafter. In general however, polymerization is suitably effected using vapors or atomized droplets of compounds of formula (I) at pressures of from 0.01 to 999 mbar, suitably at about 0.2 mbar. Although atmospheric-pressure and sub-atmospheric pressure plasmas are known and utilized for plasma polymer deposition in the art.
[0032] A glow discharge is then ignited by applying a high frequency voltage, for example at 13.56 MHz. The applied fields are suitably of an average power of up to 50 W.
[0033] The fields are suitably applied for a period sufficient to give the desired coating. In general, this will be from 30 seconds to 60 minutes, preferably from 1 to 15 minutes, depending upon the nature of the compound of formula (I) and the substrate etc.
[0034] Suitably, the average power of the pulsed plasma discharge is low, for example of less than 0.05 W/cm 3 , preferably less than 0.025 W/cm 3 and most preferably less than 0.0025 W/cm 3 .
[0035] The pulsing regime which will deliver such low average power discharges will vary depending upon the nature of the substrate, the size and nature of the discharge chamber etc. However, suitable pulsing arrangements can be determined by routine methods in any particular case. A typical sequence is one in which the power is on for from 10 μs to 100 μs, and off for from 1000 μs to 20000 μs.
[0036] In one embodiment of the invention, the pulsing regime is varied during the course of coating deposition so as to enable the production of gradated coatings. For example, a high average-power pulsing regime may be used at the start of sample treatment to yield a highly cross-linked, insoluble sub-surface coating that adheres well to the substrate. A low average-power pulsing regime may then be adopted for conclusion of the treatment cycle, yielding a surface layer displaying high levels of retained monomer aldehyde functionality on top of said well-adhered sub-surface. Such a regime would be expected to improve overall coating durability and adhesion, without sacrificing any of the desired surface properties (i.e. reactive surface aldehyde functionality).
[0037] Suitable plasmas for use in the method of the invention include non-equilibrium plasmas such as those generated by audio-frequencies, radiofrequencies (RF) or microwave frequencies. In another embodiment the plasma is generated by a hollow cathode device. In yet another embodiment, the pulsed plasma is produced by direct current (DC).
[0038] The plasma may operate at low, sub-atmospheric or atmospheric pressures as are known in the art. The monomer may be introduced into the plasma as a vapor or an atomized spray of liquid droplets (WO03101621 and WO03097245, Surface Innovations Limited). The monomer may be introduced into the pulsed plasma deposition apparatus continuously or in a pulsed manner by way of, for example, a gas pulsing valve
[0039] The substrate to which the aldehyde bearing coating is applied will preferentially be located substantially inside the pulsed plasma during coating deposition, However, the substrate may alternatively be located outside of the pulsed plasma, thus avoiding excessive damage to the substrate or growing coating.
[0040] The monomer will typically be directly excited within the plasma discharge. However, “remote” plasma deposition methods may be used as are known in the art. In said methods the monomer enters the deposition apparatus substantially “downstream” of the pulsed plasma, thus reducing the potentially harmful effects of bombardment by short-lived, high-energy species such as ions.
[0041] The plasma may comprise the monomeric compound alone, in the absence of other compounds or in admixture with for example an inert gas. Plasmas consisting of monomeric compound alone may be achieved as illustrated hereinafter, by first evacuating the reactor vessel as far as possible, and then purging the reactor vessel with the organic compound for a period sufficient to ensure that the vessel is substantially free of other gases. The temperature in the plasma chamber is suitably high enough to allow sufficient monomer in gaseous phase to enter the plasma chamber. This will depend upon the monomer and conveniently ambient temperature will be employed. However, elevated temperatures for example from 25 to 250° C. may be required in some cases.
[0042] In alternative embodiments of the invention, materials additional to the plasma polymer coating precursor are present within the plasma deposition apparatus. The additional materials may be introduced into the coating deposition apparatus continuously or in a pulsed manner by way of, for example, a gas pulsing valve.
[0043] The additive materials may be inert and act as buffers without any of their atomic structure being incorporated into the growing plasma polymer (suitable examples include the noble gases). A buffer of this type may be necessary to maintain a required process pressure. Alternatively the inert buffer may be required to sustain the plasma discharge. For example, the operation of atmospheric pressure glow discharge (APGD) plasmas often requires large quantities of helium. This helium diluent maintains the plasma by means of a Penning Ionization mechanism without becoming incorporated within the deposited coating.
[0044] In other embodiments of the invention, the additive materials possess the capability to modify and/or be incorporated into the coating forming material and/or the resultant plasma deposited coating. Suitable examples include other reactive gases such as halogens, oxygen, and ammonia.
[0045] In alternative embodiments of the invention, the additive materials may be other monomers. The resultant coatings comprise copolymers as are known and described in the art. Suitable monomers for use within the method of the invention include organic (e.g. styrene), inorganic, organo-silicon and organo-metallic monomers.
[0046] The invention further provides a substrate having an aldehyde containing coating thereon, obtained by a process as described above. Such substrate can include any solid, particulate, or porous substrate or finished article, consisting of any materials (or combination of materials) as are known in the art. Examples of materials include any or any combination of, but are not limited to, woven or non-woven fibres, natural fibres, synthetic fibres, metal, glass, ceramics, semiconductors, cellulosic materials, paper, wood, or polymers such as polytetrafluoroethylene, polythene or polystyrene. In a particular embodiment, the surface comprises a support material, such as a polymeric material, used in biochemical analysis.
[0047] In one embodiment of the invention, the substrate is coated by means of a reel-to-reel apparatus. This coating process can take place continuously. In one embodiment, the substrate is moved past and through a coating apparatus acting in accordance with this invention.
[0048] The pulsed plasma polymerization of the invention is therefore a solventless method for functionalizing solid surface with aldehyde groups.
[0049] Once the aldehyde functional coating has been applied to the substrate, the aldehyde group may be further derivatised as required. In particular, it may be reacted with an amine such as an amine terminated oligonucleotide strand. The derivatisation reaction may be effected in the gaseous phase where the reagents allow, or in a solvent such as water or an organic solvent. Examples of such solvents include alcohols (such as methanol), and tetrahydrofuran.
[0050] The derivatisation may result in the immobilization of an amine containing reagent on the surface. If derivatisation is spatially addressed, as is known in the art, this results in chemical patterning of the surface. A preferred case of an aldehyde surface patterned with amine containing biomolecules is a biological microarray. A particularly preferred case is one in which the amine containing biomolecule is a DNA strand, resulting in a DNA microarray. Another preferred embodiment is one in which the amine containing biomolecule is a protein or fragment thereof, resulting in a protein microarray.
[0051] Aldehyde functionalized surfaces produced in accordance with the invention were derivatized with a variety of amine-containing reagents (e.g. oligonucleotide strands, proteins, and derivatized sugars). Furthermore, these aldehyde functionalized surfaces produced in accordance with the invention enabled the construction of DNA microarrays by a procedure shown diagrammatically in Scheme 1.
[0052] In one embodiment, a solution of silver containing salt reacts with surface aldehyde groups, resulting in silver metallization of the polymer surface. The Tollens reaction can be used to generate metallic silver on the reactive aldehyde surface.
[0053] Thus in a further embodiment, the invention provides a method for the immobilization of an amine containing reagent at a surface. The method includes the application of a reactive aldehyde containing coating to the surface by a method described above, and then contacting the surface with a solution of the amine-containing agent under conditions such that the amine-containing agent reacts with the aldehyde groups.
[0054] Preferably, the amine solution is spatially addressed onto the reactive aldehyde containing surface, such that amine immobilization occurs only in given spatial locations. The spatial restriction can be achieved by plasma depositing the aldehyde functional coating through a mask or template. This produces a sample exhibiting regions covered with aldehyde functional coating juxtaposed with regions that exhibit no aldehyde functional coating.
[0055] Pulsed plasma polymerization in accordance with the invention has been found to be an effective means for functionalizing solid substrates with aldehyde groups. The resulting functionalized surfaces are amenable to conventional aldehyde derivatization chemistries.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] The invention will now be particularly described by way of examples with reference to the accompanying drawings in which:
[0057] FIG. 1 shows the FT-IR spectra of: (a) 3-vinylbenzaldehyde monomer; (b) 3-vinylbenzaldehyde pulsed plasma polymer (t on =50 μs, t off =4 ms); and (c) 5W continuous wave 3-vinylbenzaldehyde plasma polymer.
[0058] FIG. 2 shows the Fluorescence Intensity Variation with pulsed plasma on-time of: (a) Cy5 Tagged DNA immobilized onto 3-vinylbenzaldehyde plasma polymer surfaces (1% excitation laser intensity); and (b) the hybridisation of Cy5 tagged DNA to surface immobilised DNA strands (10% excitation laser intensity) on a 3-vinylbenzaldehyde plasma polymer surface (P p =40 W and t off =4 ms).
[0059] FIG. 3 shows Cy5 Tagged DNA hybridized to spots of surface immobilized DNA on a 3-vinylbenzaldehyde pulsed plasma polymer surface (t on =50 μs, t off =4 ms).
[0060] FIG. 4 shows Cy5 tagged ssDNA immobilised onto 3-vinylbenzaldehyde functionalized treated polystyrene beads. Examined by (a) fluorescence microscopy, and (b) visible microscopy.
[0061] FIG. 5 shows amine terminated Cy5-tagged DNA spatially addressed onto a 10-undecenal pulsed plasma polymer surface (t on =15 μs, t off =20 ms).
[0062] FIG. 6 shows the XPS spectra of (a) 3-vinylbenzaldehyde pulsed plasma polymer and (b) the 3-vinylbenzaldehyde plasma polymer following reaction with 1M ammonium hydroxide and 0.1M silver nitrate.
[0063] Scheme 1 shows a method of the invention for enabling DNA hybridization on surfaces: (a) Aldehyde surface functionalization by pulsed plasma polymerization of 3-vinylbenzaldehyde, (b) Immobilization of amine terminated ssDNA onto the pulsed plasma polymer surface by Schiff-base chemistry, and (c) Hybridization of complimentary Cy5 tagged ssDNA to surface immobilized ssDNA.
DETAILED DESCRIPTION OF THE INVENTION
[0064] The following examples are intended to illustrate the present invention but are not intended to limit the same:
Example 1
[0065] Plasma polymerization of 3-vinylbenzaldehyde (Aldrich, 97%, H 2 C═CH(C 6 H 4 )CHO, purified by several freeze-pump-thaw cycles) was carried out in an electrodeless cylindrical glass reactor (5 cm diameter, 520 cm 3 volume, base pressure 3×10 −2 mbar, leak rate=1×10 −9 mol s −1 ) enclosed in a Faraday Cage. The chamber was fitted with a gas inlet, a thermocouple pressure gauge and a 30 L min −1 two-stage rotary pump connected to a liquid nitrogen cold trap. All joints were grease free. An externally wound 4 mm diameter copper coil spanned 8-15 cm from the gas inlet with 9 turns.
[0066] The output impedance of a 13.56 MHz RF power supply was matched to the partially ionized gas load with an L-C matching network. In the case of pulsed plasma deposition,
[0067] the RF source was triggered from an external signal generator, and the pulse shape monitored with a cathode ray oscilloscope. The reactor was cleaned by scrubbing with detergent, rinsing in water, propan-2-ol and drying in an oven. The reactor was further cleaned with a 0.2 mbar air plasma operating at 40 W for a period of 30 min. Each substrate was sonically cleaned in a 50:50 mixture of cyclohexane and propan-2-ol for 10 min and then placed into the centre of the reactor on a flat glass plate.
[0068] A comparison of the infrared spectra obtained from low power (5 W) continuous wave and pulsed plasma deposited films shows that the distinctive aldehyde CHO stretch at 2815 cm −1 and 2723 cm −1 and the aldehyde C═O stretch at 1695 cm −1 are markedly reduced and broadened for the former, relative to the C—H stretches in the 2836-3030 cm −1 region, FIG. 1 and Table 1. The C═C stretch at 1650 cm −1 associated with 3-vinylbenzaldehyde monomer is absent. Bands from meta-substituted phenyl ring in the fingerprint region of the pulsed plasma polymer are also clearly discernible.
[0000]
TABLE 1
The Assignment of 3-vinylbenzaldehyde FT-IR absorbances.
Wavenumber (cm −1 )
Assignment
2836-3030
C—H stretches
2815
CHO stretch *
2723
CHO stretch *
1695
C═O stretch *
1650
C═C stretch □
1595
Di-substituted benzene quadrant stretch
1581
Di-substituted benzene quadrant stretch
1478
Meta-substituted benzene semicircle stretch
1446
Meta-substituted benzene semicircle stretch
1410
C═CH 2 scissors deformation
1386
Aldehyde CH rock
1309
C═CH rock
1145
Meta ring stretch
992
Meta in-phase CH wag
908
Meta single CH wag
* denotes aldehyde absorbances,
• denotes the polymerizable alkene C═C band in FIG. 1.
[0069] The XPS surface elemental compositions of both the low power (5W) continuous wave and pulsed 3-vinylbenzaldehyde plasma polymers appeared to be in good agreement with the theoretical composition based on the monomer structure, Table 2. Absence of any Si(2p) signal was indicative of a pinhole-free film, whilst the loss of Na(1s) and Cl(2p) signals corresponded to the complete removal of buffer salts during washing.
[0000]
TABLE 2
The XPS atomic composition of 3-vinylbenzaldehyde
plasma polymers.
% Carbon
% Oxygen
Theoretical
90
10
Pulsed Plasma Polymer
89 ± 2
11 ± 2
Continuous Wave Plasma Polymer
91 ± 2
9 ± 2
Example 2
[0070] DNA immobilization to pulsed plasma polymerized 3-vinylbenzaldehyde surfaces entailed immersing 3-vinylbenzaldehyde plasma polymer surfaces, prepared as described in example 1, into 1.0 μmol dm −3 of fluorescently tagged oligonucleotide (Sigma-Genosys Ltd., oligonucleotide sequence: 5′-3′ AACGATGCACGAGCA, desalted, reverse phase purified with 3′ terminal primary amine and 5′ terminal Cy5 fluorophore) at 42° C. for 16 h in saline sodium citrate buffer at pH=4.5 (citric acid 99%, Aldrich; NaCl 99.9%, Sigma). Subsequently 3.5 mg ml −1 NaCN(BH 3 ) (Aldrich, 99%) was added and the solution gently stirred for 3 h. Excess physisorbed probe oligonucleotides were removed by sequential washing in high purity water; saline sodium citrate buffer (SSC, 0.3 M Sodium Citrate, 3 M NaCl, pH=7, Sigma) with 1% sodium dodecyl sulphate (Sigma, 10% solution); high purity water; solution of 10% stock SSC buffer in high purity water with 0.1% (w/v) sodium dodecyl sulphate; and finally, high purity water; 5% stock SSC buffer in high purity water; high purity water.
[0071] Fluorescently labelled oligonucleotides attached to the surface were identified using a fluorescence microscope (Dilor Labram) fitted with a 10× lens, and a 20 mW HeNe laser (632.817 nm wavelength) which corresponds to the excitation range of the Cy5 fluorophore. A polarization of 500:1 was chosen, and the laser beam passed through a diffraction grating of 1800 lines mm −1 . Due to the high fluorescence of some surfaces, a filter permitting only 1% laser energy transmission was used unless otherwise stated. A low-level fluorescence background was present for the glass slides, with a broad shallow peak at approximately 2800 cm −1 .
[0072] For the hybridization studies, an oligonucleotide (sequence: 5′-3′ GCTTATCGAGCTTTC, desalted, reverse phase purified with 5′ terminal primary amine, Sigma-Genosys Ltd.) was attached onto 3-vinylbenzaldehyde plasma polymer surfaces as described above. These surfaces were then immersed in a solution of 50% pre-hybridization solution (Sigma, from 2× concentrate) and 50% formamide (Sigma, molecular biology grade) for 1 h. The treated polymer surface was removed from solution, rinsed in high purity H 2 O and immersed in a 50% high purity H 2 O/50% hybridization solution (Sigma, from 2× concentrate), with 200 nM of hybridizing oligonucletide (sequence: 5′-3′ GAAAGCTCGATMGC, desalted, reverse phase purified with 5′ terminal Cy5 fluorophore, Sigma-Genosys Ltd.) at 20° C. for 1 h. These hybridized surfaces were then washed sequentially as described previously.
[0073] Pulsed plasma deposition conditions corresponding to a duty cycle with t on =50 μs were shown by fluorescence intensity measurements to be efficient for both the immobilization of oligonucleotides and the subsequent hybridization of surface immobilized oligonucleotides, FIG. 2 .
Example 3
[0074] Similarly to the procedure described above, oligonucleotides were spatially addressed onto 3-vinylbenzaldehyde pulsed plasma polymer coated glass microscope slides using a robotic spotter (Genepak). Probe solutions were placed in a 384-well plate and the robot used a stainless steel pin to pick up and spot solution onto the functionalized slides. Typically, 4 identical 500 μm print pitch arrays were constructed onto the slide, using a pin pick-up time of 1 s and a 0.01 s dwell time. The spotted arrays were incubated in an oven at 42° C. over a saturated solution of K 2 SO 4 (96% relative humidity) for 16 h and cleaned as outlined above in order to remove non-covalently-bound material.
[0075] On examination, an array of DNA modified regions was clearly visible, FIG. 3 .
Example 4
[0076] 3-vinylbenzaldehyde was deposited onto polystyrene beads (Biosearch Technologies, Inc.) as described above. These aldehyde functionalized beads were then derivatised with fluorescently tagged DNA strands as described above. The derivatisation was confirmed by fluorescence microscopy, FIG. 4 .
Example 5
[0077] The methodology of Example 1 was utilized to effect the polymerization of undecenal (Aldrich, +99%).
[0078] The XPS surface elemental compositions of the pulsed 10-undecenal plasma polymer (t on =10 μs, t off =20 ms) appeared to be in good agreement with the theoretical composition based on the monomer structure. Low power (3 W) continuous wave polymerization resulted in a marked increase in oxygenation of the surface, Table 3.
[0000]
TABLE 3
The XPS atomic composition of 10-undecenal plasma polymers.
% Carbon
% Oxygen
Theoretical
91.7
8.3
Pulsed Plasma Polymer
92.0
8.0
Continuous Wave Plasma Polymer
86.3
13.7
[0079] This surface was suitable for derivatisation by amine modification as in Example 3. The successful attachment of fluorescently tagged amine-terminated DNA to a pulsed plasma polymerized undecanal surface is shown in FIG. 5 .
Example 6
[0080] Silver deposition was performed on a pulsed plasma polymerized 3-vinylbenzaldehyde surface. This firstly comprised plasma deposition as described in Example 1, followed by immersion in an aqueous solution of 1.0 M ammonium hydroxide (Aldrich) and 0.1 M silver nitrate (Apollo Scientific) for 24 hours. Samples were then washed under gentle stirring in high purity water for 16 hours before immersion in a fresh water solution for 7 days.
[0081] XPS of the plasma polymer surface prior to treatment showed only carbon and nitrogen present on the surface, FIG. 6 a . After silver deposition, XPS peaks at 374 eV and 368 eV were observed, corresponding to the Ag(3d 3/2 ) and Ag(3d 5/2 ) levels respectively. The intensity of the C(1s) envelope was also reduced relative to the O(1s) envelope, due to the expected oxidation of surface aldehyde functionality during the reaction, FIG. 6 a . | A method is provided for applying a reactive aldehyde containing coating to a substrate. The method includes subjecting a substrate to a plasma discharge in the presence of a compound of formula (I):
Where X is an optionally substituted straight or branched alkylene chain(s) or aryl group(s); R 1 , R 2 or R 3 are optionally substituted hydrocarbyl or heterocyclic groups, and m is an integer greater than 0. | 3 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 60/911,921, filed Apr. 16, 2007. The contents of the prior application are hereby incorporated by reference in their entireties.
BACKGROUND
Angiogenesis is a physiological process of growing new blood vessels from pre-existing vessels. It takes place in a healthy subject to heal wounds, i.e., restoring blood flow to tissues after injury or insult.
Excessive blood vessel growth may be triggered by certain pathological conditions such as cancer, age-related macular degeneration, rheumatoid arthritis, and psoriasis. As a result, new blood vessels feed diseased tissues and destroy normal tissues. In cancer, new blood vessels also allow tumor cells to escape into the circulation and lodge in other organs.
Vascular endothelial growth factor (VEGF), a homodimeric glycoprotein, and its receptors, e.g., kinase insert domain receptor (KDR), constitute an important angiogenic pathway. Studies have shown that inhibition of KDR resulted in endothelial cell apoptosis and, thus, suppression of angiogenesis. See Rubin M. Tuder, Chest, 2000; 117: 281. KDR inhibitors are therefore potential candidates for treating angiogenesis-related diseases.
SUMMARY
This invention is based on the discovery that a number of pyrimidine compounds inhibit the activity of KDR.
One aspect of this invention features pyrimidine compounds of the following formula (I):
in which each of X and Y, independently, is O, S, or NR, wherein R is H, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkylcarbonyl, alkoxycarbonyl, aminocarbonyl, or aminosulfonyl; Z is CR′ or N, wherein R′ is H, halo, nitro, cyano, hydroxyl, alkoxy, aryloxy, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, or heterocycloalkyl; V, U, and T together represent
each of R 1 , R 2 , R 3 , R 4 , and R 6 , independently, is H, halo, nitro, amino, cyano, hydroxy, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkoxy, alkylthio, alkylcarbonyl, carboxy, alkoxycarbonyl, carbonylamino, sulfonylamino, aminocarbonyl, or aminosulfonyl; R 5 is alkyl, cycloalkyl, heterocycloalkyl, aryl or heteroaryl; and R 7 is alkyl.
Referring to formula (I), one subset of the compounds features that R 1 , R 2 , R 3 , and R 4 is H and R 5 is aryl or heteroaryl, optionally substituted with halo, nitro, amino, cyano, hydroxy, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkoxy, alkylthio, alkylcarbonyl, carboxy, alkoxycarbonyl, sulfonyl, carbonylamino, sulfonylamino, aminocarbonyl, or aminosulfonyl. Another subset features that X is O or NH; Y is NH; V, U, and T together represent
in which R 6 can be H and R 7 can be methyl; or Z is CR′, in which R′ is H, halo, or alkyl.
The term “alkyl” herein refers to a straight or branched hydrocarbon, containing 1-10 carbon atoms. Examples of alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, and t-butyl. The term “alkoxy” refers to an —O-alkyl.
The term “aryl” refers to a 6-carbon monocyclic, 10-carbon bicyclic, 14-carbon tricyclic aromatic ring system wherein each ring may have 1 to 4 substituents. Examples of aryl groups include, but are not limited to, phenyl, naphthyl, and anthracenyl.
The term “cycloalkyl” refers to a saturated and partially unsaturated cyclic hydrocarbon group having 3 to 12 carbons. Examples of cycloalkyl groups include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclopentenyl, cyclohexyl, cyclohexenyl, cycloheptyl, and cyclooctyl.
The term “heteroaryl” refers to an aromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heteroaryl groups include pyridyl, furyl, imidazolyl, benzimidazolyl, pyrimidinyl, thienyl, quinolinyl, indolyl, and thiazolyl. The term “heteroaralkyl” refers to an alkyl group substituted with a heteroaryl group.
The term “heterocycloalkyl” refers to a nonaromatic 5-8 membered monocyclic, 8-12 membered bicyclic, or 11-14 membered tricyclic ring system having one or more heteroatoms (such as O, N, or S). Examples of heterocycloalkyl groups include, but are not limited to, piperazinyl, pyrrolidinyl, dioxanyl, morpholinyl, and tetrahydrofuranyl. Heterocycloalkyl can be a saccharide ring, e.g., glucosyl.
Alkyl, cycloalkyl, heterocycloalkyl, aryl, heteroaryl, and alkoxy mentioned herein include both substituted and unsubstituted moieties. Examples of substituents include, but are not limited to, halo, hydroxyl, amino, cyano, nitro, mercapto, alkoxycarbonyl, amido, carboxy, alkanesulfonyl, alkylcarbonyl, carbamido, carbamyl, carboxyl, thioureido, thiocyanato, sulfonamido, alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl, cycloalkyl, heterocycloalkyl, in which alkyl, alkenyl, alkynyl, alkyloxy, aryl, heteroaryl cycloalkyl, and heterocycloalkyl may further substituted.
The pyrimidine compounds described above include their pharmaceutically acceptable salts, hydrate and prodrug, if applicable.
Another aspect of this invention features a method of treating an angiogenesis-related disorder (e.g., cancer or age-related macula degeneration). The method includes administering to a subject having such an disorder an effective amount of one or more of the above-described pyrimidine compounds.
Still another aspect of this invention features a method of inhibiting the activity of kinase insert domain receptor by contacting the receptor with an effective amount of a pyrimidine compound of formula (II):
in which R 1 is H, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, or heteroaryl; each of R 2 and R 3 , independently, is H, halogen, nitro, amino, CN, hydroxy, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkoxy, alkylcarbonyl, carboxy, or alkoxycarbonyl; each of X and Y, independently, is O, S, or NR 4 , wherein R 4 is H, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkylcarbonyl, alkoxycarbonyl, aminocarbonyl, or aminosulfonyl; and Ar is aryl or heteroaryl.
Referring to formula (II), one subset of the compounds features that Ar is indolyl, indazolyl, benzoimidazolyl, or benzoxazolyl; X is O or NH and Y is NH; or R 1 is aryl or heteroaryl, optionally substituted with halo, nitro, amino, cyano, hydroxy, alkyl, alkenyl, alkynyl, aryl, cycloalkyl, heterocycloalkyl, heteroaryl, alkoxy, alkylthio, alkylcarbonyl, carboxy, alkoxycarbonyl, sulfonyl, carbonylamino, sulfonylamino, aminocarbonyl, or aminosulfonyl.
Exemplary compounds 1-317 are shown in the Detailed Description section below.
Yet another aspect of this invention features a method of inhibiting angiogenesis, or treating age-related macular degeneration, by administrating to a subject in need thereof an effective amount of a pyrimidine compound of formula (II) as described above.
Also within the scope of this invention are (1) a composition containing one or more of the pyrimidine compounds described above and a pharmaceutically acceptable carrier for use in treating an angiogenesis-related disorder (e.g., such cancer or age-related macular degeneration) and (2) use of one or more of the pyrimidine compounds for the manufacture of a medicament for treating the disorder.
The details of one or more embodiments of the invention are set forth in the description below. Other features, objects and advantages of the invention will be apparent from the description and from the claims.
DETAILED DESCRIPTION
The compounds described above can be synthesized from commercially available starting materials by methods well known in the art. As an example, one can replace leaving groups (e.g., chloride, p-TsO, MeS, or MeSO 2 ) at the active N2, N4-positions of a suitable pyrimidine compound with nucleophilic groups such as amino or hydroxyl via, e.g., Buchwald-Hartwig coupling reaction. The replacement can be first effected either at the N2 position or the N4 position.
The compounds thus obtained can be further modified at their peripheral positions to provide the desired compounds.
Synthetic chemistry transformations useful in synthesizing desirable pyrimidine compounds are described, for example, in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons (1999); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
Before use, the compounds can be purified by column chromatography, high performance liquid chromatography, crystallization, or other suitable methods.
The pyrimidine compounds described above, when contacting with KDR, inhibit this receptor's activity. An effective amount of one or more of these compounds can be therefore used to inhibit angiogenesis and treat a subject having an angiogenesis-related disorder.
The term “an effective amount” refers to the amount of a pyrimidine compound that is required to confer the intended effect in the subject. Effective amounts may vary, as recognized by those skilled in the art, depending on route of administration, excipient usage, and the possibility of co-usage with other agents. The term “treating” refers to administering one or more of the above-described pyrimidine compounds to a subject that has an angiogenesis-related disorder, or has a symptom of the disorder, or has a predisposition toward the disorder, with the purpose to cure, heal, alleviate, relieve, alter, remedy, ameliorate, improve, or affect the disorder, the symptoms of the disorder, or the predisposition toward the disorder.
To practice this method, a composition having one or more of the pyrimidine compounds of this invention can be administered orally, parenterally, by inhalation spray, or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional and intracranial injection or infusion techniques.
An oral composition can be any orally acceptable dosage form including, but not limited to, tablets, capsules, emulsions and aqueous suspensions, dispersions and solutions. Commonly used carriers for tablets include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added to tablets. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added.
A sterile injectable composition (e.g., aqueous or oleaginous suspension) can be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as, for example, Tween 80) and suspending agents. The sterile injectable preparation can also be a sterile injectable solution or suspension in a non-toxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or di-glycerides). Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long-chain alcohol diluent or dispersant, or carboxymethyl cellulose or similar dispersing agents.
An inhalation composition can be prepared according to techniques well known in the art of pharmaceutical formulation and can be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art.
A topical composition can be formulated in form of oil, cream, lotion, ointment and the like. Suitable carriers for the composition include vegetable or mineral oils, white petrolatum (white soft paraffin), branched chain fats or oils, animal fats and high molecular weight alcohols (greater than C12). The preferred carriers are those in which the active ingredient is soluble. Emulsifiers, stabilizers, humectants and antioxidants may also be included as well as agents imparting color or fragrance, if desired. Additionally, transdermal penetration enhancers may be employed in these topical formulations. Examples of such enhancers can be found in U.S. Pat. Nos. 3,989,816 and 4,444,762. Creams are preferably formulated from a mixture of mineral oil, self-emulsifying beeswax and water in which mixture the active ingredient, dissolved in a small amount of an oil, such as almond oil, is admixed. An example of such a cream is one which includes about 40 parts water, about 20 parts beeswax, about 40 parts mineral oil and about 1 part almond oil. Ointments may be formulated by mixing a solution of the active ingredient in a vegetable oil, such as almond oil, with warm soft paraffin and allowing the mixture to cool. An example of such an ointment is one which includes about 30% by weight almond and about 70% by weight white soft paraffin.
A carrier in a pharmaceutical composition must be “acceptable” in the sense that it is compatible with active ingredients of the formulation (and preferably, capable of stabilizing it) and not deleterious to the subject to be treated. For example, solubilizing agents, such as cyclodextrins (which form specific, more soluble complexes with one or more of active pyrimidine compounds of the extract), can be utilized as pharmaceutical excipients for delivery of the active ingredients. Examples of other carriers include colloidal silicon dioxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow #10.
Suitable in vitro assays can be used to preliminarily evaluate the efficacy of the above-described pyrimidine compounds in inhibiting the activity of KDR or inhibiting the activity of VEGF. The compounds can further be examined for its efficacy in treating an angiogenesis-related disorder by in vivo assays. For example, the compounds can be administered to an animal (e.g., a mouse model) having cancer and its therapeutic effects are then accessed. Based on the results, an appropriate dosage range and administration route can also be determined.
Without further elaboration, it is believed that the above description has adequately enabled the present invention. The following specific examples are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
Example 1
Synthesis of N4-(2-methyl-1H-indol-5-yl)-N2-phenylpyrimidine-2,4-diamine (Compound 1)
Et 3 N (1 mmol) was added to a solution of 2,4-dichloropyrimidine (1 mmol) and 5-amino-2-methylindole (1 mmol) in 5 ml EtOH. The reaction mixture was refluxed for 5 hours. After removal of the solvent in vacuo and addition of H 2 O, the mixture was extracted with EtOAc. The organic layers were combined, washed with saturated NaCl solution, dried over anhydrous Na 2 SO 4 , and concentrated in vacuo. The resulting residue was purified by column chromatography to give N-(2-chloropyrimidin-4-yl)-2-methyl-1H-indol-5-amine in a yield of 80%.
N-(2-chloropyrimidin-4-yl)-2-methyl-1H-indol-5-amine (0.1 mmol) and aniline (0.1 mmol) were dissolved in 0.5 ml DMF. To this was added p-TsOH monohydrate (0.2 mmol). The reaction mixture was stirred at 60° C. for 5 hours, diluted with water, and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The resulting residue was purified by column chromatography to provide the title product in a yield of 85%.
1 H NMR (CD 3 OD, 400 MHz): δ 7.831 (d, J=6.0 Hz, 1H), 7.633 (t, J=8.0-7.6 Hz, 3H), 7.262 (t, J=8.4-7.6 Hz, 3H), 7.064 (d, J=6.8 Hz, 1H), 6.995 ((t, J=7.6-7.2 Hz, 1H), 6.133 (t, J=6.4-2.0 Hz, 2H), 2.439 (s, 3H); MS (m/e): 384.2 (M+1).
Example 2-283
Synthesis of Compounds 2-283
Compounds 2-283 were each synthesized in a manner similar to that described in Example 1.
Com-
pound
Name/Structure
1 H NMR (400 MHz, δ ppm)/MS
2
N2-(3-ethynylphenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 7.848 (d, J = 6.8 Hz, 1 H), 7.730 (s, 1 H), 7.704 (d, J = 8.0 Hz, 1 H), 7.507 (s, 1 H), 7.275 (d, J = 8.0 Hz, 1 H), 7.200 (t, J = 8.0 Hz, 1 H), 7.093-7.036 (m, 2 H), 6.639 (m, 2 H), 2.425 (s, 3 H); MS (m/e): 340.4 (M + 1)
3
N2-(3-bromophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 7.879 (s, 1 H), 7.784 (d, J = 6.0 Hz, 1 H), 7.437 (br, 1 H), 7.373 (s, 1 H), 7.255 (d, J = 8.8 Hz, 1 H), 7.079 (br, 2 H), 6.968 (d, J = 8.4 Hz, 1 H), 6.133 (s, 1 H), 6.041 (d, J = 6.4 Hz, 1 H), 2.400 (s, 3 H); MS (m/e): 394.3 (M)
4
N2-(3-fluorophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 7.923 (s, 1 H), 7.759 (d, J = 6.0 Hz, 1 H), 7.641 (d, J = 8.0 Hz, 1 H), 7.397 (s, 1 H), 7.247 (d, J = 8.4 Hz, 1 H), 7.179-7.053 (m, 1 H), 6.963 (d, J = 8.4 Hz, 1 H), 6.575 (t, J = 8.0 Hz, 1 H), 6.125 (s, 1 H), 6.044 (d, J = 6.0 Hz, 1 H), 2.395 (s, 3 H); MS (m/e): 334.2 (M + 1)
5
N2-(3-chlorophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 7.838 (d, J = 6.8 Hz, 1 H), 7.746 (s, 1 H), 7.526 (br, 2 H), 7.298 (d, J = 8.4 Hz, 1 H), 7.212 (t, J = 8,0 Hz, 1 H), 7.102 (d, J = 8.4 Hz, 1 H), 7.001 (d, J = 8.0 Hz, 1 H), 6.217 (d, J = 6.0 Hz, 1 H), 6.133 (s, 1 H), 2.436 (s, 3 H); MS (m/e): 350.2 (M + 1)
6
N4-(2-methyl-1H-indol-5-yl)-N2-(3- (trifluoromethyl)phenyl) pyrimidine-2,4- diamine
(CD 3 OD): 8.045 (d, J = 7.2 Hz, 1 H), 7.788 (d, J = 6.0 Hz, 2 H), 7.529 (s, 1 H), 7.366 (d, J = 6.8 Hz, 1 H), 7.276 (d, J = 8.4 Hz, 1 H), 7.228 (d, J = 7.2 Hz, 1 H), 7.083 (d, J = 1.2 Hz, 1 H), 6.190 ((d, J = 6.4 Hz, 1 H), 6.115 (s, 1 H), 2.440 (s, 3 H). MS (m/e): 384.2 (M + 1)
7
N4-(2-methyl-1H-indol-5-yl)-N2-(3- (methylsulfonyl)phenyl) pyrimidine-2,4- diamine
(CD 3 OD): 11.471 (s, 1 H), 9.461 (s, 1 H), 9.364 (s, 1 H), 8.441 (s, 1 H), 8.236 (s, 1 H), 7.988 (d, J = 5.6 Hz, 1 H), 7.396 (M,, 5 H), 7.303 (d, J = 8.4 Hz, 1 H), 6.255 (d, J = 5.6 Hz, 1 H), 3.111 (s, 3 H), 2.456 (s, 3 H). MS (m/e): 393.2 (M + 1)
8
N2-(3-methoxylphenyl)-N4-(2-methyl- 1H-indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 8.050 (s, 1 H), 7.943 (d, J = 6.0 Hz, 1 H), 7.440-7.362 (m, 3 H), 7.293 (s, 1 H), 7.223 (t, J = 8.0 Hz, 2 H), 7.122 (d, J = 7.6 Hz, 1 H), 7.0211 (d, J = 6.8 Hz, 1 H), 6.808 (s, 1 H), 6.680 (d, J = 6.4 Hz, 1 H), 6.222 (s, 1 H), 6.068 (d, J = 5.6 Hz, 1 H), 3.790 (s, 3 H), 2.472 (s, 3 H); MS (m/e): 345.9 (M + 1)
9
ethyl 1-(3-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)benzyl)piperidine-4-carboxylate
(CD 3 OD): 8.019 (s, 1 H), 7.889 (d, J = 5.6 Hz, 1 H), 7.554 (s, 1 H), 7.399 (d, J = 8.0 Hz, 1 H), 7.328 (d, J = 8.4 Hz, 1 H), 7.278 (t, J = 8.0 Hz, 1 H), 7.101 (d, J = 8.0 Hz, 1 H), 7.002 (d, J = 7.2 Hz, 1 H), 6.180 (d, J = 6.0 Hz, 1 H), 6.141 (s, 1 H), 4.166 (q, J = 7.2 Hz, 1 H), 3.586 (s, 2 H), 2.973-2.943 (m, 2 H), 2.462 (s, 3 H), 2.316 (br, 1 H), 2.089 (m, 2 H), 1.939-1.885 (m, 2 H), 1.741-1.653 (m, 2 H), 1.272 (t, J = 7.2 Hz, 2 H); MS (m/e): 485.4 (M + 1)
10
N2,N4-bis(2-methyl-1H-indol-5- yl)pyrimidine-2,4-diamine
(CD 3 OD): 7.675 (d, J = 6.4 Hz, 1 H), 7.625 (s, 1 H), 7.577 (br, 1 H), 7.266-7.219 (m, 2 H), 7.068-7.051 (m, 1 H), 6.116 (d, J = 6.0 Hz, 1 H), 6.072 (s, 1 H), 6.014 (s, 1 H), 2.435 (s, 3 H), 2.425 (s, 3 H); MS (m/e): 369.3 (M + 1)
11
N2-(1H-indazol-5-yl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 12.385 (s, 1 H), 10.928 (s, 1 H), 9.120 (s, 1 H), 9.003 (s, 1 H), 8.259 (s, 1 H), 7.920 (d, J = 6.0 Hz, 1 H), 7.758 (s, 1 H), 7.667 (s, 1 H), 7.541 (d, J = 8.8 Hz, 2 H), 7.399 (d, J = 8.8 Hz, 1 H), 7.242 (d, J = 8.8 Hz, 1 H), 7.151 (d, J = 8.8 Hz, 1 H), 6.142 (d, J = 6.0 Hz, 1 H), 6.017 (s, 1 H), 2.389 (s, 3 H). MS (m/e): 356.3 (M + 1)
12
N2-(1H-benzo[d]imidazol-5-yl)-N4-(2- methyl-1H-indol-5-yl)pyrimidine-2,4- diamine
(CD 3 OD): 10.853 (s, 1 H), 9.033 (s, 1 H), 8.956 (s, 1 H), 8.077 (br, 2 H), 7.925 (d, J = 6.0 Hz, 1 H), 7.736 (s, 1 H), 7.533 (d, J = 8.0 Hz, 1 H), 7.444 (d, J = 8.8 Hz, 1 H), 7.214-7.144 (m, 2 H), 6.131 (d, J = 6.0 Hz, 1 H), 6.020 (s, 1 H), 2.372 (s, 3 H); MS (m/e): 356.3 (M + 1)
13
N2-(2-methoxyphenyl)-N4-(2-methyl- 1H-indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 8.496 (s, 1 H), 8.002 (d, J = 6.0 Hz, 2 H), 7.446 (s, 1 H), 7.047 (dd, J = 8.8 Hz, J = 2.4 Hz, 1 H), 6.981-6.957 (m, 2 H), 6.913-6.771 (m, 1 H), 6.889 (s, 1 H), 6.243 (s, 1 H), 6.083 (d, J = 6.0 Hz, 1 H), 3.910 (s, 3 H), 2.490 (s, 3 H). MS (m/e): 346.2 (M + 1)
14
N2-(2-chlorophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 8.385 (d, J = 6.0 Hz, 1 H), 7.914 (s, 1 H), 7.849 (s, 1 H), 7.325 (d, J = 7.6 Hz, 1 H), 7.237 (d, J = 8.4 Hz, 1 H), 7.182 (t, J = 7.6 Hz, 1 H), 6.945-6.870 (m, 2 H), 6.119 (s, 1 H), 6.070 (d, J = 6.0 Hz, 1 H), 2.397 (s, 3 H); MS (m/e): 350.1 (M + 1)
15
N2-(2-bromophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 10.860 (s, 1 H), 9.204 (s, 1 H), 8.140 (d, J = 8.4 Hz, 1 H), 7.916 (d, J = 5.6 Hz, 2 H), 7.651 (d, J = 7.6 Hz, 2 H), 7.334 (t, J = 7.6 Hz, 1 H), 7.184 (d, J = 8.8 Hz, 1 H), 7.038 (br, 2 H), 6.192 (d, J = 6.0 Hz, 1 H), 6.012 (s, 1 H), 2.369 (s, 3 H); MS (m/e): 394.3 (M)
16
N2-(4-fluorophenyl)-N4-(2-methyl-1H- indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 10.889 (s, 1 H), 9.256 (s, 1 H), 9.245 (s, 1 H), 7.966 (d, J = 5.6 Hz, 1 H), 7.752 (m, J = 8.4-3.6Hz, 2 H), 7.236 (d, J = 5.4 Hz 1 H), 7.133 (m, J = 8.4-3.6 Hz, 3 H), 6.086 (d, J = 5.6 Hz, 1 H), 6.050 (s, 1 H), 2.402 (s, 3 H); MS (m/e): 334.2 (M + 1)
17
methyl 2-(4-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)phenyl)acetate
(CD 3 OD): 10.907 (s, 1 H), 9.132 (s, 1 H), 9.015 (s, 1 H), 7.914 (s, 1 H), 7.713 (d, J = 6 Hz, 1 H), 7.498 (d, J = 6.8 Hz, 1 H), 7.217 (d, J = 7.2 Hz, 1 H), 7.127 (m, 4 H), 6.149 (d, J = 6 Hz, 1 H), 6.067 (s, 1 H), 2.384 (s, 3 H), 2.272 (s, 3 H), 1.288 (s, 2 H). MS (m/e): 387.2 (M + 1)
18
N4-(2-methyl-1H-indol-5-yl)-N2-(4- phenoxyphenyl)pyrimidine-2,4-diamine
(CD 3 OD): 10.855 (s, 1 H), 9.098 (s, 1 H), 9.065 (s, 1 H), 7.909 (d, J = 5.6 Hz, 1 H), 7.786 (d, J = 8 Hz, 2 H), 7.365 (t, J = 7.6 Hz, 2 H), 7.346 (s, 1 H), 7.201 (d, J = 8.8 Hz, 1 H), 7.086 (m, 2 H), 6.962 (d, 8 Hz, 2 H), 6.895 (d, J = 8 Hz, 2 H), 6.137 (d, J = 5.6 Hz, 1 H), 6.021 (s, 1 H), 2.331 (s, 3 H). MS (m/e): 407.5 (M + 1)
19
N2-(4-methoxyphenyl)-N4-(2-methyl- 1H-indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 11.097 (s, 1 H), 9.479 (s, 1 H), 9.243 (s, 1 H), 8.090 (d, J = 6 Hz, 1 H), 7.923 (s, 1 H), 7.822 (m, 2 H), 7.420 (d, 8.8 Hz, 1 H), 7.307 (s, 1 H), 7.025 (d, J = 8.8 Hz, 2 H), 6.340 (m, 1 H), 6.265 (s, 1 H), 3.941 (s, 3 H), 2.591 (s, 3 H); MS (m/e): 345.4 (M + 1)
20
N4-(2-methyl-1H-indol-5-yl)-N2-(4-(2- morpholinoethoxy)phenyl) pyrimidine- 2,4-diamine
(CD 3 OD): 10.899 (s, 1 H), 9.074 (s, 1 H), 8.823 (s, 1 H), 7.869 (d, J = 6 Hz, 1 H), 7.713 (s, 1 H), 7.621 (d, J = 8.8 Hz, 2 H), 7.200 (d, J = 8.4 Hz, 1 H), 7.080 (s, 1 H), 6.784 (m, 2 H), 6.101 (d, J = 5.6 Hz, 1 H), 6.025 (s, 1 H), 4.034 (t, J = 5.6 Hz, 2 H), 3.585 (t, J = 4.8 Hz, 4 H), 2.679 (t, J = 5.6 Hz, 2 H), 2.475 (t, J = 6.4 Hz, 4 H), 2.375 (s, 3 H); MS: 444.5 (M + 1)
21
N2-(3, 4-difluorophenyl)-N4-(2-methyl- 1H-indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 11.234 (s, 1 H), 9.886 (s, 1 H), 9.754 (s, 1 H), 7.966 (d, J = 5.6 Hz, 2 H), 7.752 (s, 1 H), 7.393 (m, J = 8.4-3.6 Hz, 3 H), 7.133 (d, J = 5.6 Hz, 1 H), 6.251 (d, J = 4.5 Hz, 1 H), 6.1.9 (s, 1 H), 2.402 (s, 3 H); MS (m/e): 352.2 (M + 1)
22
N2-(3,5-dimethylphenyl)-N4-(2-methyl- 1H-indol-5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 10.863 (s, 1 H), 9.051 (s, 1 H), 8.841 (s, 1 H), 7.905 (d, J = 6 Hz, 1 H), 7.633 (s, 1 H), 7.367 (s, 1 H), 7.207 (m, 2 H), 6.507 (s, 1 H), 6.118 (d, J = 5.6 Hz, 1 H), 6.032 (s, 2 H), 2.370 (s, 3 H), 2.171 (s, 6 H); MS (m/e): 343.4 (M + 1).
23
2-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2-ylamino)ethanol
(CD 3 OD): 7.939 (d, J = 8.0 Hz, 1 H), 6.923 (d, J = 6.8 Hz, 2 H), 6.437 (s, 1 H), 6.328 (d, J = 7.6 Hz, 2 H), 6.218 (s, 1 H), 6.231 (d, J = 5.6 Hz, 1 H), 5.726 (d, J = 7.2 Hz, 1 H), 3.735 (t, J = 7.2-6.4 Hz, 3 H), 3.225 (t, J = 6.8-5.6 Hz, 3 H), 2.247 (s, 3 H); MS (m/e): 384.1 (M + 1)
24
N4-(2-methyl-1H-indol-5-yl)-N2-(2- morpholinoethyl)pyrimidine-2,4-diamine
(CD 3 OD): 7.796 (d, J = 6.0 Hz, 1 H), 7.497 (s, 1 H), 7.246 (d, J = 8.8 Hz, 1 H), 7.076 (d, J = 2.8 Hz, 1 H), 6.148 (s, 1 H), 5.625 (d, J = 4.8 Hz, 1 H), 3.760 (m, J = 3.2-2.8 Hz, 4 H), 3.165 (t, J = 3.2-2.4, 2 H), 2.619 (t, J = 2.0-0.8 Hz, 2 H), 2.447 (m, J = 2.0-1.2 Hz, 4 H), 2.317 (s, 3 H). MS (m/e): 353.2 (M + 1)
25
N-cyclopropyl-2-(3-(4-(2-methyl-1H- indol-5-ylamino)pyrimidin-2- ylamino)phenyl)acetamide
(DMSO-d 6 ,): 7.920 (d, J = 5.6 Hz, 1 H), 7.700 (m, 2 H), 7.546 (s, 1 H), 7.220 (d, J = 8.0 Hz, 1 H), 7.120 (m, 2 H), 6.778 (d, J = 8.0 Hz, 1 H), 6.200 (d, J = 6.0 Hz, 1 H), 6.066 (s, 1 H), 3.027 (s, 2 H), 2.593 (m, 1 H), 2.380 (s, 3 H), 0.608 (m, 2 H), 0.404 (m, 2H). MS (m/e): 413.5 (M + 1).
26
N2-(3-(2- (dimethylamino)ethylsulfonyl)phenyl)- N4-(2-methyl-1H-indol-5-yl)pyrimidine- 2,4-diamine
(CD 3 OD): 8.237 (s, 1 H), 8.042 (d, J = 6.8 Hz 1 H), 7.867 (d, J = 6.0 Hz, 1 H), 7.477 (s, 1 H), 7.465 (br, 2 H), 7.253 (d, J = 8.8 Hz, 1 H), 7.028 (d, J = 8.0 Hz 1 H), 6.141 (d, J = 5.6 Hz 1 H), 6.088 (s, 1 H), 3.230 (t, J = 7.6 Hz, 2 H), 2.666 (t, J = 7.2 Hz, 2 H), 2.409 (s, 3 H) , 2.165 (s, 6 H); MS: 451.4 (M + 1).
27
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(1- (methylsulfonyl)piperidin-4- yloxy)phenyl)pyrimidine-2,4-diamine
(DMSO-d6): 10.976 (s, 1 H), 9.240 (s, 1 H), 9.036 (s, 1 H), 7.054-8.014 (m, 7H), 6.401-6.564 (m, 1 H), 6.114-6.278 (m, 1 H), 6.012-6.073 (m, 1 H), 4.224-4.383 (m, 1 H), 3.110-3.209 (m, 2 H), 2.770-2.886 (m, 2 H), 2.370(s, 3 H), 1.806-1.970 (m, 2 H), 1.578-1.712 (m, 1 H); MS (m/e): 493.5 (M + 1)
28
N-(3-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)phenyl)methanesulfonamide
(CD 3 OD): 7.856 (d, J = 6.0 Hz, 1 H), 7.652 (s, 1 H), 7.543 (s, 1 H), 7.432 (dd, J = 8.4 Hz, 1 H), 7.271 (d, J = 8.4 Hz, 1 H), 7.196 (t, J = 8.0 Hz, 1 H), 6.882 (dd, J = 8.0 Hz, 2 H), 6.130 (d, J = 6.0 Hz, 2 H), 2.440 (s, 3 H), 2.172 (s, 3 H); MS (m/e): 409.3 (M + 1)
29
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(2- morpholinoethoxy) phenyl) pyrimidine- 2,4-diamine
(DMSO-d 6 ): δ10.825 (s, 1 H), 9.023 (s, 1 H), 8.986 (s, 1 H), 7.927 (d, J = 5.6 Hz, 1 H), 7.703 (s, 1 H), 7.429 (s, 1 H), 7.351 (d, J = 2.4 Hz, 1 H), 7.208 (d, J = 8.8 Hz, 1 H), 7.076 (m, J = 8 Hz, 2 H), 6.469 (dd, J = 8, 2.4 Hz, 1 H), 6.118 (d, J = 2 Hz, 1 H), 6.057 (s, 1 H), 3.933 (t, J = 5.6 Hz, 2 H), 3.551 (t, J = 4.8 Hz, 4 H), 2.591 (t, J = 5.6 Hz, 2 H), 2.401 (t, J = 4.8 Hz, 4 H), 2.379 (s, 3 H); MS (m/e): 444.5 (M + 1).
30
N2-(3-(3-(dimethylamino) propoxy)phenyl)-N4-(2-methyl-1H-indol- 5-yl)pyrimidine-2,4-diamine
(CD 3 OD): 10.836 (s, 1 H), 9.021 (s, 1 H), 8.983 (s, 1 H), 7.926 (d, J = 6 Hz, 1 H), 7.691 (s, 1 H), 7.419 (s, 1 H), 7.345 (d, J = 8.4 Hz, 1 H), 7.212 (d, J = 8.4 Hz, 1 H), 7.079 (m, 2 H), 6.444 (dd, J = 8, 2.4 Hz, 1 H), 6.118 (d, J = 6 Hz, 1 H), 6.062 (s, 1 H), 3.835 (t, J = 6 Hz, 2 H), 2.317 (s, 3 H), 2.318 (t, J = 7.2 Hz, 2 H), 2.154 (s, 6 H), 1.767 (t, J = 7.2 Hz, 2 H); MS (m/e): 416.5 (M + 1).
31
2-(3-(4- (2-methyl-1H-indol-5-ylamino)pyrimidin- 2-ylamino) phenoxy)ethanol
(CD 3 OD): 10.902 (s, 1 H), 9.087 (s, 1 H), 8.986 (s, 1 H), 7.917 (d, J = 4 Hz, 1 H), 7.683 (s, 1 H), 7.405 (m, 2 H), 7.227 (m, 1 H), 7.104 (m, 1 H), 6.458 (d, J = 8 Hz, 1 H), 6.141 (s, 1 H), 6.050 (m, 2 H), 5.594 (m, 1 H), 3.873 (t, J = 5.6 Hz, 2 H), 3.653 (t, J = 6 Hz, 2 H), 2.376 (s, 3 H); MS (m/e): 375.4 (M + 1)
32
2-(2-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)phenoxy)ethanol
(CD 3 OD): 10.851 (s, 1 H), 9.117 (s, 1 H), 8.431 (d, J = 8.0 Hz 1 H), 7.938 (d, J = 6.0 Hz, 1 H), 7.869 (s, 1 H), 7.689 (br, 1 H), 7.228 (d, J = 8.8 Hz, 1 H), 6.983~7.053 (m, 2 H), 6.836-6.923 (m, 2 H), 6.147 (d, J = 6.0 Hz 1 H), 6.079 (s, 1 H), 5.137 (t, J = 5.6 Hz 1 H), 4.061 (q, J = 11.2 Hz, 1.2 Hz 2 H), 3.767 (q, J = 9.6 Hz , 5.6 Hz 2 H), 2.389 (s, 3 H); MS (m/e): 376.3 (M + 1).
33
N4-(2-methyl-1H-indol-5-yl)-N2-(2-(2- morpholinoethoxy)phenyl) pyrimidine- 2,4-diamine
(CD 3 OD): 10.845 (s, 1 H), 9.112 (s, 1 H), 8.377 (d, J = 7.6 Hz 1 H), 7.935 (d, J = 6.0 Hz, 1 H), 7.823 (s, 1 H), 7.647 (br, 1 H), 7.219 (d, J = 8.8 Hz, 1 H), 7.061 (d, J = 8 Hz , 2 H), 6.889~6.950 (m, 2 H), 6.147 (d, J = 6.0 Hz 1 H), 6.074 (s, 1 H), 4.182 (t, J = 6.0 Hz 2 H), 3.592 (t, J = 4.8 Hz, 4 H), 2.692 (t, J = 5.2 Hz, 2 H), 2.471 (br, 4 H), 2.388 (s, 3 H); MS (m/e): 445.3 (M + 1).
34
N-methyl-3-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2-ylamino)benzamide
(DMSO-d 6 ): δ 11.015 (s, 1 H), 10.776 (s, 1 H), 10.593 (s, 1 H), 8.493 (d, J = 4 Hz, 1 H), 7.938 (m, 2 H), 7.803 (d, J = 2 Hz, 1 H), 7.651 (m, 2 H), 7.374 (m, 1 H), 7.210 (m, 2 H), 6.467 (m 1 H), 6.046 (s, 1 H), 2.779 (d, 4.4 Hz, 3 H), 2.379 (s, 3 H); MS (m/e): 373.4 (M + 1).
35
3-(4-(2-methyl-1H-indol-5- ylamino)pyrimidin-2-ylamino)-N-(2- (piperidin-1- yl)ethyl)benzamide
(CD 3 OD): 10.832 (s, 1 H), 9.156 (s, 1 H), 9.056 (s, 1 H), 8.157 (s, 1 H), 8.054 (s, 1 H), 7.946 (m, 2 H), 7.700 (b, 1 H), 7.319 (m, 2 H), 7.199 (m, 2 H), 6.159 (s, 1 H), 6.052 (s, 1 H), 3.180 (t, J = 5.6 Hz, 2 H), 2.378 (s, 3 H), 1.480 (s, 6 H), 1.372 (s, 4 H), 1.229 (s, 2 H). MS (m/e): 469.6 (M + 1)
36
N-(2-(dimethylamino)ethyl)-3-(4-(2- methyl-1H-indol-5-ylamino)pyrimidin-2- ylamino)benzamide
(CD 3 OD): 10.846 (s, 1 H), 9.149 (s, 1 H), 9.077 (s, 1 H), 8.181 (t, J = 5.6 Hz, 1 H), 8.036 (m, 2 H), 7.934 (m, 1 H), 7.706 (b, 1 H), 7.340 (m, 1 H), 7.270 (m, 1 H), 7.203 (m, 1 H), 7.137 (m, 1 H), 6.160 (d, J = 5.6 Hz, 1 H), 6.054 (s, 1 H), 3.313 (t, J = 6.4 Hz, 2 H), 3.175 (t, J = 5.6 Hz, 2 H), 2.376 (s, 3 H), 2.175 (s, 6 H). MS (m/e): 429.5 (M + 1)
37
N2-(3-(4-methoxyphenyl)-1H-pyrazol-5- yl)-N4-(2-methyl-1H-indol-5- yl)pyrimidine-2,4-diamine
(DMSO-d 6 ): δ 12.354 (s, 1 H), 10.911 (s, 1 H), 8.985 (br, 2 H), 7.901 (s, 1 H), 7.599 (br, 2 H), 7.259 (d, J = 8.4 Hz, 1 H), 7.037 (s, 1 H), 6.941-6.913 (m, 2 H), 6.099 (br, 2 H), 3.787 (s, 3 H), 2.493 (s, 3 H); MS (m/e): 412.8 (M + 1).
38
N-(3-ethynylphenyl)-4-(2-methyl-1H- indol-5-yloxy)pyrimidin-2-amine
(CD 3 OD): 8.190 (d, J = 6.0 Hz, 1 H), 8.098 (s, 1 H), 7.612 (s, 1 H), 7.489 (d, J = 8.0 Hz, 1 H), 7.339-7.284 (m, 2 H), 7.053 (t, J = 8.4 Hz, 1 H), 6.937 (dd, J = 8.4 Hz, 2.0 Hz, 2 H), 6.294 (d, J = 6.0 Hz, 2 H), 6.262 (s, 1 H), 2.495 (s, 3 H); MS (m/e): 341.1 (M + 1)
39
N-(4-methoxyphenyl)-4-(2-methyl-1H- indol-5-yloxy)pyrimidin-2-amine
(CD 3 OD): 8.198 (d, J = 6.4 Hz, 1 H), 7.974 (s, 1 H), 7.363-7.283 (m, 2 H), 6.935 (m, 2 H), 6.742 (t, J = 8.4 Hz, 1 H), 6.260 (s, 1 H), 6.200 (d, J = 5.6 Hz, 1 H), 3.771 (s, 3 H), 2.493 (s, 3 H). MS (m/e): 347.2 (M + 1).
41
4-(2-methyl-1H-indol-5-yloxy)-N-(4- phenoxyphenyl)pyrimidin-2-amine
(CD 3 OD): 8.201 (d, J = 5.6 Hz, 1 H), 7.373 (m, J = 8.8-5.2 Hz, 4 H), 7.188 (d, J = 2.0 Hz, 1 H), 7.081 (t, J = 7.2-6.8 Hz, 1 H), 6.989 (d, J = 3.2 Hz, 2 H), 6.890 (d, J = 8.4 Hz, J = 2.0 Hz, 1 H), 6.644 (d, J = 9.2 Hz, 2 H), 6.323 (d, J = 6.4 Hz, 1 H), 6.137 (s, 1 H), 2.376 (s, 3 H). MS (m/e): 409.3 (M + 1).
42
N-(3-methoxyphenyl)-4-(2-methyl-1H- indol-5-yloxy)pyrimidin-2-amine
(CD 3 OD): 8.236 (d, J = 5.2 Hz, 1 H), 7.983 (s, 1 H), 7.314-7.283 (m, 2 H), 7.239 (br, 1 H), 7.063 (t, J = 8.0 Hz, 1 H), 6.981 (d, J = 8.0 Hz, 1 H), 6.981 (dd, J = 8.8 Hz, 2.0 Hz, 1 H), 6.528 (d, J = 8.0 Hz, 1 H), 6.278-6.253 (m, 1 H), 3.571 (s, 1 H), 2.493 (s, 3 H). MS (m/e): 347.2 (M + 1).
43
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(3- (thiomorpholino-1′,1′- dioxide)propoxy)phenyl)pyrimidin-2- amine
(CD 3 OD): 8.298 (s, 1 H), 7.996 (d, J = 5.6 Hz, 1 H), 7.385 (d, J = 8.4 Hz, 1 H), 7.197 (t, J = 8.0 Hz, 1 H), 7.094 (d, J = 8.4 Hz, 2 H), 6.791 (s, 1 H), 6.543 (d, J = 8.0 Hz, 1 H), 6.333 (s, 1 H), 5.995 (d, J = 6.0 Hz, 1 H), 5.321 (s, 1 H), 3.974 (t, J = 5.6 Hz, 1 H), 3.077 (m, 8 H), 2.699 (t, J = 6.8 Hz, 1 H), 2.468 (s, 3 H), 1.926 (t, J = 6.8 Hz, 2 H);
44
N-methyl-3-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2-ylamino)benzamide
(DMSO-d 6 ): 11.130 (s, 1 H), 9.631 (s, 1 H), 8.324 (d, J = 4.2 Hz, 1 H), 8.309 (s, 1 H), 7.994 (s, 1 H), 7.741 (s, 1 H), 7.308 (d, J = 9.2 Hz, 1 H), 7.219 (d, J = 1.6 Hz, 1 H), 7.052 (t, J = 2.0-0.8 Hz, 2 H), 6.932 (m, 1 H), 6.272 (d, J = 3.6 Hz, 1 H), 6.140 (d, J = 4.2 Hz, 1 H), 5.249 (s, 1 H), 2.801 (s, 3 H), 2.437 (s, 3 H), 2.401 (m, 2 H); MS (m/e): 374.3 (M + 1)
45
trifluoro-N-(4-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2- ylamino)phenyl)methanesulfonamide
(DMSO-d 6 ): 11.248 (s, 1 H), 9.304 (s, 1 H), 9.153 (s, 1 H), 7.960 (s, 1 H), 7.913 (d, J = 6.0 Hz, 1 H), 7.543 (d, J = 4.4 Hz, 2 H), 7.132 (d, J = 8.4 Hz 1 H), 7.063 (m, 1 H), 6.910 (t, J = 3.6 Hz, 2 H), 6.217 (s, 1 H), 6.106 (t, J = 1.6-2.4 Hz, 1 H), 2.411 (s, 3 H) MS (m/e): 464.4 (M + 1)
46
(S)-4-(2-methyl-1H-indol-5-yloxy)-N-(3- (pyrrolidin-3-yloxy)phenyl)pyrimidin-2- amine
( DMSO-d6): 11.122 (s, 1 H), 9.515 (s, 1 H), 8.306 (d, J = 5.6 Hz, 1 H), 7.156-7.332 (m, 4 H), 6.951 (t, J = 8.0 Hz, 1 H), 6.827 (dd, J = 8.4 Hz, 2.0 Hz, 1 H), 6.427 (dd, J = 8.4 Hz, 2.0 Hz, 1 H), 6.267 (d, J = 6.0 Hz, 1 H), 6.139 (s, 1 H), 6.639 (m, 2 H), 4.652-4.711 (m, 1 H), 2.964-3.154 (m, 4 H), 2.401 (s, 3 H), 1.958-1.993 (m, 1 H), 1.825-1.898 (m, 1 H); MS (m/e): 402.4 (M + 1)
47
N- methyl-3-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2- ylamino)benzenesulfonamide
(CDCl 3 ): 8.290 (d, 1 H), 8.115 (s, 1 H), 7.994 (s, 1 H), 7.504 (d, J = 8, 1 H), 7.409 (m, 2 H), 7.247 (d, J = 8, 1 H), 6.958 (m, J = 10.8), 6.403 (d, J = 5.6, 1 H), 6.254 (s, 1 H). 2.505 (s, 3 H), 2.478 (d, J = 5.6, 3 H). MS (m/e): 410.1 (M + 1)
48
N-(4-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2- ylamino)phenyl)methanesulfonamide
(CD 3 OD): 11.204 (s, 1 H), 9.120 (s, 1 H), 8.837 (s, 1 H), 7.959 (d, J = 5.6 Hz, 1 H), 7.791 (d, J = 6.8 Hz, 2 H), 7.144 (s, 1 H), 7.026 (d, J = 7.6 Hz, 2 H), 6.922 (d, J = 7.2 Hz, 1 H), 6.210 (s, 1 H), 6.115 (s, 1 H), 4.007 (s, 3 H), 2.405 (s, 3 H); MS (m/e): 358.2 (M + 1).
49
2-(3-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2-ylamino)phenyl)-N-(2- morpholinoethyl)acetamide
(CD 3 OD): 11.211 (s, 1 H), 8.935 (s, 1 H), 8.760 (s, 1 H), 7.959 (t, J = 8.8-5.6 Hz, 2 H), 7.376 (s, 1 H), 7.276 (d, J = 7.6 Hz, 1 H), 7.120 (t, J = 8.8-4.4 Hz, 1 H), 6.896 (t, J = 8.0 Hz, 2 H), 6.403 (t, J = 2.0-1.6 Hz, 1 H), 6.205 (s, 1 H), 6.004 (s, 1 H), 3.560 (s, 3 H), 2.405 (s, 3 H); MS (m/e): 364.2 (M + 1).
50
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2- (methylsulfonyl)ethoxy)phenyl)pyrimidin- 2-amine
(CD 3 OD): 8.345 (s, 1 H), 8.049 (s, 1 H), 7.915 (d, J = 6.0 Hz, 1 H), 7.826 (s, 1 H), 7.58 (d, J = 8.8 Hz, 1 H), 7.535 (m, J = 7.2-6.8 Hz, 1 H), 7.433 (d, J = 7.6 Hz, 2 H), 7.103 (d, J = 7.6 Hz, 1 H), 6.241 (s, 1 H), 2.460 (s, 3 H); MS (m/e): 402.2 (M + 1).
51
N-methyl(3-(4-(2-methyl-1H-indol-5- yloxy)pyrimidin-2-ylamino)phenyl) methanesulfonamide
11.217 (s, 1 H), 8.998 (s, 1 H), 8.789 (s, 1 H), 7.947 (d, J = 5.6 Hz, 1 H), 7.595 (m, J = 7.8-1.6 Hz, 2 H), 7.133 (d, J = 8.0 Hz, 2 H), 7.000,(s, 1 H), 6.721 (d, J = 2.8 Hz, 1 H), 6.211 (s, 1 H), 6.021 (s, 1 H), 2.403 (s, 3 H), 2.346 (s, 3 H); MS (m/e): 380.2 (M + 1).
52
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(3-fluorophenyl) pyrimidine-2,4- diamine
(CD 3 OD): 11.234 (s, 1 H), 9.256 (s, 1 H), 8.898 (s, 1 H), 7.966 (d, J = 5.6 Hz, 1 H), 7.752 (d, J = 8.4 Hz, 1 H), 7.393 (t, J = 8.4 Hz, 1 H), 7.133 (m, J = 8.4-3.6 Hz, 3 H), 6.612 (t, J = 7.6-1.2 Hz, 1 H), 6.239 (s, 1 H), 6.050 (s, 1 H), 2.402 (s, 3 H); MS (m/e): 352.2 (M + 1).
53
N2-(3-chlorophenyl)-N4-(4-fluoro-2- methyl-1H-indol-5-yl)pyrimidine-2,4- diamine
(CD 3 OD): 11.221 (s, 1 H), 8.965 (s, 1 H), 8.775 (s, 1 H), 7.927 (d, J = 6.0 Hz, 1 H), 7.619 (d, J = 8.0 Hz, 2 H), 7.128 (m, J = 8.0-7.6 Hz, 2 H), 6.958 (d, J = 7.8 Hz, 2 H), 6.210 (s, 1 H), 2.411 (s, 3 H); MS (m/e): 368.2 (m/e) (M + 1).
54
2-(4-(4-fluoro-2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)benzonitrile
(CD 3 OD): 11.248 (s, 1 H), 9.412 (s, 1 H), 8.959 (s, 1 H), 8.208 (s, 1 H), 7.936 (d, J = 7.2 Hz, 1 H), 7.562 (d, J = 5.6 Hz, 1 H), 7.287 (s, 2 H), 7.164 (d, J = 8.4 Hz, 2 H), 6.233 (s, 1 H), 6.075 (s, 1 H), 2.399 (s, 3 H); MS (m/e): 359.2 (M + 1).
55
N2-(3,5-dimethylphenyl)-N4-(4-fluoro-2- methyl-1H-indol-5-yl)pyrimidine-2,4- diamine
(CD 3 OD): 11.200 (s, 1 H), 8.806 (s, 1 H), 8.745 (s, 1 H), 7.911 (d, J = 6.0 Hz, 1 H), 7.216 (s, 2 H) 7.117 (t, J = 8.8-7.8 Hz, 2 H), 6.396 (s, 1 H), 6.181 (s, 1 H), 6.010 (s, 1 H), 2.381 (s, 3 H); 1.985 (s, 6 H); MS (m/e): 362.3 (M + 1).
56
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(2-(trifluoromethyl) phenyl)pyrimidine-2,4-diamine
(CD 3 OD): 11.211 (s, 1 H), 8.898 (s, 1 H), 8.209 (s, 1 H), 7.939 (t, J = 9.6-6.0 Hz, 2 H), 7.270 (t, J = 8.4-1.6 Hz, 1 H) 7.126 (s, 2 H), 6.998 (m, J = 2.0-1.2 Hz, 2 H), 6.225 (s, 1 H), 6.035 (s, 1 H), 2.402 (s, 3 H); MS (m/e): 402.2 (M + 1).
57
N2-(2-chlorophenyl)-N4-(4-fluoro-2- methyl-1H-indol-5-yl)pyrimidine-2,4- diamine
(CD 3 OD): 11.231 (s, 1 H), 8.922 (s, 1 H), 8.143 (d, J = 8.0 Hz ,1 H), 7.936 (s, J = 5.6 Hz, 1 H), 7.790 (s, 1 H), 7.424 (d, J = 8.4 Hz, 1 H), 7.101 (m, J = 8.4-7.2 Hz, 2 H), 6.993 (t, J = 8.8-7.2 Hz, 1 H), 6.216 (s, 1 H), 6.093 (m, J = 7.2-10.0 Hz, 1 H), 4.043 (s, J = 7.8 Hz, 1 H), 2.402 (s, 3 H); MS (m/e): 368.2 (M + 1).
59
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(4-methoxyphenyl) pyrimidine-2,4- diamine
11.222 (s, 1 H), 8.796 (s, 1 H), 8.729 (s, 1 H), (CD 3 OD): 7.959 (s, 1 H), 7.892 (d, J = 5.6 Hz, 1 H), 7.547 (d, J = 8.8 Hz, 2 H) 7.075 (s, 1 H), 6.646 (d, J = 7.6 Hz, 2 H), 6.222 (s, 1 H), 5.567 (s, 1 H), 3.658 (s, 3 H), 2.406 (s, 3 H); MS (m/e): 402.2 (M + 1).
60
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(4-phenoxyphenyl) pyrimidine-2,4- diamine
(CD 3 OD): 11.190 (s, 1 H), 9.046 (s, 1 H), 8.801 (s, 1 H), 7.959 (s, 1 H), 7.931 (d, J = 6.0 Hz, 1 H), 7.681 (d, J = 7.2 Hz, 2 H), 7.361 (t, J = 8.0-7.6 Hz, 2 H), 7.114 (m, J = 8.4-7.2 Hz, 3 H), 6.903 (d, J = 8.0 Hz, 2 H), 6.755 (d, J = 7.2 Hz, 2 H), 6.179 (s, 1 H), 6.024 (s, 1 H), 2.338 (s, 3 H). MS (m/e): 426.2 (M + 1).
61
2-(1-(3-(4-(4-fluoro-2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)benzyl)piperidin-4-yl)ethanol
(CD 3 OD): 7.932 (s, 1 H), 7.885 (d, J = 5.6 Hz, 1 H), 7.331 (m, 1 H), 7.204 (m, 3 H), 7.103 (t, J = 7.2 Hz, 1 H), 6.958 (d, J = 7.6 Hz, 1 H), 6.251 (s, 1 H), 6.176 (m,1 H), 3.603-3.572 (m, 4 H), 3.068-3.041 (m, 2 H), 2.454 (s, 3 H), (m, 2 H), 2.197 (br, 2 H), 1.783-1.750 (m, 2 H), 1.563 (br, 2 H), 1.477 (m, 2 H), 1.311-1.275 (m, 2 H). MS (m/e): 475.4 (M + 1)
62
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(3-(3- (methylsulfonyl)propoxy)phenyl)pyrimidine- 2,4-diamine
(DMSO-d 6 ): 7.932 (d, J = 6.0 Hz, 1 H), 7.399 (s, 1 H), 7.393 (d, J = 6.8 Hz, 1 H), 7.099 (m, 2 H), 6.97 (m, 1 H), 6.416 (d, J = 8.0 Hz, 1 H), 6.207 (s, 1 H), 6.088 (s,lH), 3.84 (m, 2 H), 3.196 (m, 2 H), 3.010 (s, 3 H), 2.400 (s, 3 H), 2.014 (m, 2 H). MS (m/e): 470.5 (M + 1).
63
2-(3-(4-(4-fluoro-2-methyl-1H-indol-5- ylamino)pyrimidin-2- ylamino)phenoxy)ethanol
(DMSO-d 6 ): 7.938 (d, J = 6.0 Hz, 1 H), 7.347 (m, 2 H), 7.104 (m, 2 H), 6.950 (m, 1 H), 6.410 (d, J = 8.0 Hz, 1 H), 6.206 (s, 1 H), 6.088 (s, 1 H), 3.788 (m, 2 H), 3.630 (m, 2 H), 2.401 (s, 3 H). MS (m/e): 394.4 (M + 1).
64
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(3-(piperidin-3- yloxy)phenyl)pyrimidine-2,4-diamine
(DMSO-d 6 ): 11.241 (s, 1 H), 8.966 (s, 1 H), 8.789 (s, 1 H), 7.929 (d, J = 5.6 Hz, 1 H), 7.378 (s, 1 H), 7.267 (d, J = 7.6 Hz, 1 H), 7.120-7.053 (m, 2 H), 6.964 (m, 1 H), 6.380 (d, J = 8.0 Hz, 1 H) 6.207 (s, 1 H) , 6.010 (s, 1 H), 4.010 (s, 1 H), 3.710 (m, 1 H); 3.554 (s, 2 H). 3.362 (m, 2 H) 2.506 (s, 3 H) 2.401 (m, 2 H) 1.234 (m, 2 H),MS (m/e): 433.2 (M + 1)
65
N4-(4-fluoro-2-methyl-1H-indol-5-yl)- N2-(3-((1-(methylsulfonyl)piperidin-4- yl)methoxy)phenyl)pyrimidine-2,4- diamine
(CD 3 OD): 8.021 (d, J = 5.6 Hz, 1 H), 7.418 (s, 1 H), 7.220-7.051 (m, 3 H), 6.998 (m, 1 H), 6.612 (d, J = 7.4 Hz, 1 H) 6.267 (s, 1 H) , 5.800 (d, J = 5.6 Hz , 1 H), 3.960 (d, J = 5.2 Hz, 2 H), 3.810 (m, 2 H); 3.362 (m, 2 H).2.826 (s, 3 H), 2.506 (s, 3 H) 1.556 (m, 2 H), 1.452 (m 1 H) 1.234 (m, 2 H)
66
1-(3-(4-(4-fluoro-2-methyl-1H-indol-5- yloxy)pyrimidin-2- ylamino)benzyl)piperidin-4-ol
(CD 3 OD): 8.247 (d, J = 5.6 Hz, 1 H), 7.378 (s, 1 H), 7.160-7.108 (m, 2 H), 6.956 (t, J = 8.0 Hz, 1 H), 6.895-6.825 (m, 2 H), 6.450 (d, J = 5.6 Hz, 1 H), 6.247 (s, 1 H), 3.031 (s, 1 H), 2.690-2.663 (m, 2 H), 2.455 (s, 3 H), 2.069-2.042 (m, 2 H), 1.815-1.716 (m, 2 H), 1.562-1.483 (m, 2 H); MS (m/e): 448.5 (M + 1)
67
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)- N-(3-(methylsulfonyl)phenyl)pyrimidin- 2-amine
(CD 3 OD): 8.292 (d, J = 5.6 Hz, 1 H), 8.005 (s, 1 H), 7.69 1 (d, J = 7.2 Hz, 1 H), 7.34 1 (d, J = 7.2 Hz, 1 H), 7.102 (d, J = 8.8 Hz, 1 H), 7.013 (t, J = 7.2 Hz, 1 H), 6.849 (t, J = 8.0 Hz, 1 H), 6.482 (d, J = 5.6 Hz, 1 H), 6.221 (s, 1 H), 2.900 (s, 3 H), 2.432 (s, 3 H); MS (m/e): 413.4 (M + 1)
68
N-cyclopropyl-2-(3-(4-(4-fluoro-2- methyl-1H-indol-5-yloxy)pyrimidin-2- ylamino)phenyl)acetamide
(DMSO-d 6 ): 7.947 (m, 2 H), 7.298 (m, 2 H), 7.154 (d, J = 8.4 Hz, 1 H), 6.947 (m, 1 H), 6.755 (m, 1 H), 6.775 (d, J = 8.0 Hz, 1 H), 6.441 (d, J = 5.6 Hz, 1 H), 6.240 (s, 1 H), 3.027 (s, 2 H), 2.593 (m, 1 H), 2.499 (s, 3 H), 0.596 (m, 2 H), 0.390 (m, 2 H). MS (m/e): 432.5 (M + 1)
69
(E)-3-(3-(4-(4-fluoro-2-methyl-1H-indol- 5-yloxy)pyrimidin-2-ylamino)phenyl)-N- methylacrylamide
(DMSO-d 6 ) 11.550 (s, 1 H) ,9.791 (s, 1 H), 8.385 (d, J = 5.2, 1 H), 8.114 (d, J = 4.8, 1 H), 7.432 (d, J = 7.2, 2 H), 7.214 (d, J = 10, 1 H), 7.184 (d, J = 3.2, 1 H), 7.083 (d, J = 8, 2 H), 6.942 (m, J = 16, 1 H), 6.533 (d, J = 5.6, 1 H, 6.402 (d, J = 15.6), 6.253 (s, 1 H), 2.687 (d, J = 4.8, 3 H), 2.440 (s, 3 H). MS (m/e): 418.2 (M + 1)
70
3-(3-(4-(4-fluoro-2-methyl-1H-indol-5- yloxy)pyrimidin-2-ylamino)phenyl)-N,N- dimethylpropanamide
(DMSO-d 6 ) 11.397 (s, 1 H), 9.420 (s, 1 H), 8.334 (d, J = 5.6, 1 H), 7.290 (s, 1 H), 7.241 (d, J = 7.2, 1 H), 7.152 (d, J = 8.8, 1 H), 6.919 (m, J = 15.2, 1 H), 6.803 (m, J = 15.6, 1 H), 6.652 (d, J = 6.8, 1 H), 6.451 (d, J = 5.6, 1 H), 6.218 (s, 1 H), 2.860 (s, 3 H), 2.795 (s, 3 H), 2.449 (m, J = 14.8, 2 H), 2.399 (s, 3 H), 2.338 (m, J = 14.8, 2 H). MS (m/e): 434.2 (M + 1)
71
N-methyl-3-(4-(2-methyl-1H-indol-5-
MS (m/e): 372.4 (M)
ylamino)pyrimidin-2-ylamino)benzamide
72
N2-(2-fluorophenyl)-N4-(2-methyl-1H-
MS (m/e): 350.1 (M + 1)
indol-5-yl)pyrimidine-2,4-diamine
73
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 341.2 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzonitrile
74
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 362.3 (M + 1)
(methylthio)phenyl)pyrimidine-2,4-
diamine
75
N,N-dimethyl-3-(4-(2-methyl-1H-indol-5-
MS (m/e): 423.5 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzenesulfonamide
76
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 465.4 (M + 1)
(morpholinosulfonyl)phenyl)pyrimidine-
2,4-diamine
77
N2-(3,4-dimethoxyphenyl)-N4-(2-methyl-
MS (m/e): 376.3 (M + 1)
1H-indol-5-yl)pyrimidine-2,4-diamine
78
N2-(4-chlorophenyl)-N4-(2-methyl-1H-
MS (m/e): 350.3 (M + 1)
indol-5-yl)pyrimidine-2,4-diamine
79
N2-(2,4-difluorophenyl)-N4-(2-methyl-
MS (m/e): 352.2 (M + 1)
1H-indol-5-yl)pyrimidine-2,4-diamine
80
N2-(3-chloro-2-fluorophenyl)-N4-(2-
MS (m/e): 368.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
81
N2-(1H-indol-4-yl)-N4-(2-methyl-1H-
MS (m/e): 355.3 (M + 1)
indol-5-yl)pyrimidine-2,4-diamine
82
N2-(4-(3-
MS (m/e): 417.4 (M + 1)
(dimethylamino)propoxy)phenyl)-N4-(2-
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
83
2-(4-(4-(2-methyl-1H-indol-5-
MS (m/e): 376.3 (M + 1)
ylamino)pyrimidin-2-
ylamino)phenoxy)ethanol
84
N2-(3-chloro-4-fluorophenyl)-N4-(2-
MS (m/e): 368.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
85
N2-(benzo[d][1,3]dioxol-5-yl)-N4-(2-
MS (m/e): 360.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
86
(1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 443.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperidin-4-yl)methanol
87
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(2-
MS (m/e): 521.2 (M)
(4-(methylsulfonyl)piperazin-1-
yl)ethoxy)phenyl)pyrimidine-2,4-diamine
88
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 437.3 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-
propylbenzenesulfonamide
89
N2-(2-chloro-4-fluorophenyl)-N4-(2-
MS (m/e): 368.1 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
90
2-chloro-4-fluoro-5-(4-(2-methyl-1H-
MS (m/e): 384.3 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenol
91
N2-(4-chloro-2-fluorophenyl)-N4-(2-
MS (m/e): 368.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
92
N2-(3-(2-
MS (m/e): 403.4 (M + 1)
(dimethylamino)ethoxy)phenyl)-N4-(2-
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
93
N2-(2-methyl-1H-indol-5-yl)-N4-(3-(3-
MS (m/e): 452.3 (M + 1)
(methylsulfonyl)propoxy)phenyl)pyrimidine-
2,4-diamine
94
2-(1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 457.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperidin-4-
yl)ethanol
95
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 429.4 (M + 1)
(piperidin-4-
ylmethoxy)phenyl)pyrimidine-2,4-
diamine
96
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 416.4 (M + 1)
(piperidin-3-yloxy)phenyl)pyrimidine-
2,4-diamine
97
1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 429.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperidin-4-ol
98
(S)-N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 401.4 (M + 1)
(pyrrolidin-3-yloxy)phenyl)pyrimidine-
2,4-diamine
99
(S)-N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 479.5 (M + 1)
(1-(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidine-2,4-diamine
100
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 415.5 (M + 1)
(piperidin-4-yloxy)phenyl)pyrimidine-
2,4-diamine
101
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(3-
MS (m/e): 536.6 (M + 1)
(4-(methylsulfonyl)piperazin-1-
yl)propoxy)phenyl)pyrimidine-2,4-
diamine
102
N4-(2-metbyl-1H-indol-5-yl)-N2-(3-(3-
MS (m/e): 459.6 (M + 1)
morpholinopropoxy)phenyl) pyrimidine-
2,4-diamine
103
(R)-N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 479.5 (M + 1)
(1-(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidine-2,4-diamine
104
(E)-N,N-dimethyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 413.2 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)acrylamide
105
4-(4-fluoro-2-methyl-1H-indol-5-yL)-N-
MS (m/e): 507.5 (M + 1)
(3-(3-(thiomorpholino-1′,1′-
dioxide)propoxy)phenyl)pyrimidin-2-
amine
106
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(2-
MS (m/e): 389.5 (M + 1)
(methylamino)ethoxy)phenyl)pyrimidine-
2,4-diamine
107
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 491.5 (M + 1)
N-(3-(3-(thiomorpholino-1′-oxide)
propoxy) phenyl) pyrimidin-2-amine
108
N-(2-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 453.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)phenoxy)ethyl)methanesulfonamide
109
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(3-
MS (m/e): 475.5 (M + 1)
thiomorpholinopropoxy)
phenyl)pyrimidine-2,4-diamine
110
trifluoro-N-(4-(4-(2-methyl-1H-indol-5-
MS (mfe): 463.4 (M-i-1)
ylamino)pyrimidin-2-ylamino)
phenyl)methanesulfonamide
111
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(2-
MS (m/e): 461.4 (M + 1)
thiomorpholinoethoxy)
phenyl)pyrimidine-2,4-diamine
112
N4-(2-methyl-1H-indol-5-yl)-N2-(3-(2-
MS (m/e): 429.4 (M + 1)
pyrrolidinethoxy)phenyl)pyrimidine-2,4-
diamine
113
N4-(2-metbyl-1H-indol-5-yl)-N2-(3-(2-
MS (m/e): 493.1 (M + 1)
morpholinoethylsulfonyl)
phenyl)pyrimidine-2,4-diamine
114
N4-(2-methyl-1H-indo1-5-yl)-N2-(3-(2-
MS (m/e): 477.1 (M + 1)
(pyrrolidin-1-yl)
ethylsulfonyl)phenyl)pyrimidine-2,4-
diamine
115
N4-(2-methyl-1H-indol-5-yl)-N2-(3-((4-
MS (m/e): 492.4 (M + 1)
(methylsulfonyl)piperazin-1-
yl)methyl)phenyl)pyrimidine-2,4-diamine
116
2-(4-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 458.5 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperazin-1-yl)ethanol
117
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 408.3 (M + 1)
(methylsulfonylmethyl)phenyl)pyrimidine-
2,4-diamine
118
N,N-dimethyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 415.5 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)propanamide
119
(E)-N-methyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 399.2 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)acrylamide
120
N4-(2-methyl-1H-indol-5-yl)-N2-(3-
MS (m/e): 416.4 (M + 1)
(tetrahydro-2H-pyran-4-
yloxy)phenyl)pyrimidine-2,4-diamine
121
N2-(3-(2-aminoethoxy)phenyl)-N4-(2-
MS (m/e): 375.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
122
N-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 423.4 (M + 1)
ylamino)pyrimidin-2-ylamino)
benzyl)methanesulfonamide
123
N-(2-hydroxyethyl)-3-(4-(2-methyl-1H-
MS (m/e): 403.2 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)benzamide
124
N-methyl-3-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 401.2 (M + 1)
ylamino)pyrimidin-2-
ylamino)phenyl)propanamide
125
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 430.2 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
(methylamino)-2-oxoethyl)benzamide
126
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 472.3 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
morpholinoethyl)benzamide
127
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 470.1 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
(piperidin-1-yl)ethyl)benzamide
128
trifluoro-N-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 463.0 (M + 1)
ylamino)pyrimidin-2-yl
amino)phenyl)methanesulfonamide
129
N-(2-methoxyethyl)-3-(4-(2-methyl-1H-
MS (m/e): 417.2 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)benzamide
130
N-(4-(4-(2-methyl-1H-indol-5-
MS (m/e): 409.1 (M + 1)
ylamino)pyrimidin-2-yl
amino)phenyl)methanesulfonamide
131
2-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 493.1 (M + 1)
ylamino)pyrimidin-2-ylamino)phenyl)-N-
(2-
morpholinoethyl)acetamide
132
N2-(6-methoxypyridin-3-yl)-N4-(2-
MS (m/e): 347.4 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
133
2-methyl-N-(4-(2-methyl-1H-indol-5-
MS (m/e): 370.3 (M + 1)
yloxy)pyrimidin-2-yl)-1H-indol-5-amine
134
N-(3-(3-
MS (m/e): 418.4 (M + 1)
(dimethylamino)propoxy)phenyl)-4-(2-
methyl-1H-indol-5-yloxy)pyrimidin-2-
amine
135
2-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 377.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)phenoxy)ethanol
136
N-(3-(2-(dimethylamino)ethoxy)phenyl)-
MS (m/e): 404.4 (M + 1)
4-(2-methyl-1H-indol-5-yloxy)pyrimidin-
2-amine
137
N-cyclopropyl-2-(3-(4-(2-methyl-1H-
MS (m/e): 414.4 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino)phenyl)acetamide
138
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(3-
MS (m/e): 453.4 (M + 1)
(methylsulfonyl)propoxy)phenyl)pyrimidin-
2-amine
139
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 448.2 (M + 1)
(piperidin-4-
ylmethoxy)phenyl)pyrimidin-2-amine
140
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 416.2 (M + 1)
(piperidin-3-yloxy)phenyl)pyrimidin-2-
amine
141
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 416.4 (M + 1)
(piperidin-4-yloxy)phenyl)pyrimidin-2-
amine
142
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(1-
MS (m/e): 494.5 (M + 1)
(methylsulfonyl)piperidin-4-
yloxy)phenyl)pyrimidin-2-amine
143
1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 430.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)piperidin-4-ol
144
(1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 444.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)piperidin-4-yl)methanol
145
2-(1-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 458.5 (M + 1)
yloxy)pylrimidin-2-
ylamino)benzyl)piperidin-4-yl)ethanol
146
N-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 409.12 (M + 1)
yloxy)pyrimidin-2-ylamino)phenyl)
methanesulfonamide
147
(S)-4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 480.5 (M + 1)
(1-(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
148
(E)-N,N-dimethyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 414.5 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino)phenyl)acrylamide
149
3-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 458.5 (M + 1)
yloxy)pyrimidin-2-ylamino) phenyl)-1-
morpholinopropan-1-one
150
N-(3-(2-methoxyethoxy)phenyl)-4-(2-
MS (m/e): 391.0 (M + 1)
methyl-1H-indol-5-yloxy)pyrimidin-2-
amine
151
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 465.1 (M + 1)
(morpholinosulfonyl)phenyl)pyrimidin-2-
amine
152
N-(2-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 454.2 (M + 1)
yloxy)pyrimidin-2-
ylamino)phenoxy)ethyl)methanesulfonamide
153
(R)-4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 480.5 (M + 1)
(1-(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
154
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 446.4 (M + 1)
morpholinoethoxy)phenyl)pyrimidin-2-
amine
155
N-(2-(dimethylamino)ethyl)-3-(4-(2-
MS (m/e): 431.4 (M + 1)
methyl-1H-indol-5-yloxy)pyrimidin-2-
ylamino)benzamide
156
N-(3-(2-methoxyethoxy)phenyl)-4-(2-
MS (m/e): 391.3 (M + 1)
methyl-1H-indol-5-yloxy)pyrimidin-2-
amine
157
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 416.4 (M + 1)
(morpholinomethyl)phenyl)pyrimidin-2-
amine
158
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(3-
MS (m/e): 476.5 (M + 1)
thiomorpholinopropoxy)phenyl)pyrimidin-
2-amine
159
N-(3-(2-
MS (m/e): 452.4 (M + 1)
(dimethylamino)ethylsulfonyl)phenyl)-4-
(2-methyl-1H-indol-5-yloxy)pyrimidin-2-
amine
160
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 494.4 (M + 1)
morpholinoethylsulfonyl)phenyl)pyrimidin-
2-amine
161
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 478.4 (M + 1)
(pyrrolidin-1-yl)
ethylsulfonyl)phenyl)pyrimidin-2-amine
162
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 462.4 (M + 1)
thiomorpholinoethoxy)phenyl)pyrimidin-
2-amine
163
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 430.3 (M + 1)
(pyrrolidin-1-
yl)ethoxy)phenyl)pyrimidin-2-amine
164
4-(2-methyl-1H-indol-5-yloxy)-N-(3-((4-
MS (m/e): 493.5 (M + 1)
(methylsulfonyl)piperazin-1-
yl)methyl)phenyl)pyrimidin-2-amine
165
2-(4-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 459.5 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)piperazin-1-yl)ethanol
166
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 431.3 (M + 1)
((tetrahydro-2H-pyran-4-
yl)methoxy)phenyl)pyrimidin-2-amine
167
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 409.4 (M + 1)
(methylsulfonylmethyl)phenyl)pyrimidin-
2-amine
168
tert-butyl 4-(2-(3-(4-(2-methyl-1H-indol-
MS (m/e): 545.4 (M + 1)
5-yloxy)pyrimidin-2-
ylamino)phenoxy)ethyl)piperazine-1-
carboxylate
169
N,N-dimethyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 416.5 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino))phenyl)propanamide
170
(E)-N-methyl-3-(3-(4-(2-methyl-1H-
MS (m/e): 400.2 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino)phenyl)acrylamide
171
4-(2-methyl-1H-indol-5-yloxy)-N-(3-
MS (m/e): 416.18 (M + 1)
(tetrahydro-2H-pyran-4-
yloxy)phenyl)pyrimidin-2-
amine
172
N-(3-(2-aminoethoxy)phenyl)-4-(2-
MS (m/e): 376.3 (M + 1)
methyl-1H-indol-5-yloxy)pyrimidin-2-
amine
173
N-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 424.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)methanesulfonamide
174
N-(2-hydroxyethyl)-3-(4-(2-methyl-1H-
MS (m/e): 404.1 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino)benzamide
175
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 444.5 (M)
(piperazin-1-yl)ethoxy)phenyl)pyrimidin-
2-amine
176
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 431.2 (M + 1)
yloxy)pylrimidin-2-ylamino)-N-(2-
(methylamino)-2-oxoethyl)benzamide
177
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 473.0 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2-
morpholinoethyl)benzamide
178
3-(4-(2-methyl-1H-indol-5-
MS (m/e): 471.4 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2-
(piperidin-1-yl)ethyl)benzamide
179
N-methyl-3-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 402.2 (M + 1)
yloxy)pyrimidin-2-
ylamino))phenyl)propanamide
180
N-(2-methoxyethyl)-3-(4-(2-methyl-1H-
MS (m/e): 418.1 (M + 1)
indol-5-yloxy)pyrimidin-2-
ylamino)benzamide
181
N-(4-(4-(2-methyl-1H-indol-5-
MS (m/e): 410.2 (M + 1)
yloxy)pyrimidin-2-
ylamino)phenyl)methanesulfonamide
182
2-(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 487.1 (M + 1)
yloxy)pyrimidin-2-ylamino)phenyl)-N-(2-
morpholinoethyl)acetamide
183
4-(2-methyl-1H-indol-5-yloxy)-N-(3-(2-
MS (m/e): 439.2 (M + 1)
(methylsulfonyl)ethoxy)phenyl)pyrimidin-
2-amine
184
N-methyl(3-(4-(2-methyl-1H-indol-5-
MS (m/e): 424.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)phenyl)methanesulfonamide
185
N-(6-methoxypyridin-3-yl)-4-(2-methyl-
MS (m/e): 348.2 (M + 1)
1H-indol-5-yloxy)pyrimidin-2-
Amine
186
methyl 2-(4-(4-(4-fluoro-2-methyl-1H-
MS (m/e): 406.2 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)acetate
187
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 364.2 (M + 1)
N2-(2-methoxyphenyl)pyrimidine-2,4-
diamine
188
N2-(3-bromophenyl)-N4-(4-fluoro-2-
MS (m/e): 412.3 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
189
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 412.3 (M + 1)
N2-(3-(methylsulfonyl)
phenyl)pyrimidine-2,4-diamine
190
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 359.3 (M + 1)
ylamino):pyrimidin-2-
ylamino)benzonitrile
191
N2-(2-chloro-4-fluorophenyl)-N4-(4-
MS (m/e): 386.2 (M + 1)
fluoro-2-methyl-1H-indol-5-
yl)pyrimidine-2,4-diamine
192
N-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 427.3 (M + 1)
ylamino)pyrimidin-2-
ylamino)phenyl)methanesulfonamide
193
N2-(3,4-difluorophenyl)-N4-(4-fluoro-2-
MS (m/e): 370.2 (M + 1)
methyl-1H-indol-5-yl)pyrimidine-2,4-
diamine
194
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 463.4 (M + 1)
N2-(3-(2-
morpholinoethoxy)pbenyl)pyrimidine-
2,4-diamine
195
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 540.3 (M + 1)
N2-(3-(2-(4-(methylsulfonyl)piperazin-1-
yl)ethoxy)phenyl)pyrimidine-2,4-diamine
196
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 462.3 (M)
N2-(2-(2-
morpholinoethoxy)phenyl)pyrimidine-
2,4-diamine
197
N2-(3-(3-
MS (m/e): 435.4 (M + 1)
(dimethylamino)propoxy)phenyl)-N4-(4-
fluoro-2-methyl-1H-indol-5-
yl)pyrimidine-2,4-diamine
198
N-cyclopropyl-2-(3-(4-(4-fluoro-2-
MS (m/e): 431.4 (M + 1)
methyl-1H-indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)acetamide
199
N-(2-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 471.4 (M + 1)
5-ylamino)pyrimidin-2-yl amino)
phenoxy)ethyl)methanesulfonamide
200
2-(2-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 394.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)phenoxy)ethanol
201
N2-(3-(2-
MS (m/e): 421.4 (M + 1)
(dimethylamino)ethoxy)phenyl)-N4-(4-
fluoro-2-methyl-1H-indol-5-
yl)pyrimidine-2,4-diamine
202
(1-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 461.5 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperidin-4-yl)methanol
203
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 391.3 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-
methylbenzamide
204
trifluoro-N-(3-(4-(4-fluoro-2-methyl-1H-
MS (m/e): 481.3 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)methanesulfonamide
205
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 446.22 (M + 1)
N2-(3-(piperidin-4-
ylmethoxy)phenyl)pyrimidine-2,4-
diamine
206
(E)-3-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 473.5 (M + 1)
5-ylamino)pyrimidin-2-ylamino)phenyl)-
1-morpholinoprop-2-en-1-one
207
trifluoro-N-(4-(4-(4-fluoro-2-methyl-1H-
MS (m/e): 481.3 (M + 1)
indol-5-ylamino)pyrimidin-2-
ylamino)phenyl)methanesulfonamide
208
N-(5-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 392.4 (M + 1)
ylamino)pyrimidin-2-ylamino)pyridin-2-
yl)acetamide
209
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 483.5 (M + 1)
N2-(3-(morpholinosulfonyl)
phenyl)pyrimidine-2,4-
Diamine
210
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 427.1 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-
methylbenzenesulfonamide
211
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 408.4 (M + 1)
N2-(3-(2-
methoxyethoxy)phenyl)pyrimidine-2,4-
diamine
212
4-(4-fluoro-2-methyl-1H-indol-5-yl)-N-
MS (m/e): 525.5 (M + 1)
(3-(3-(thiomorpholino-1′,1′-
dioxide)propoxy)phenyl)pyrimidin-2-
amine
213
N-(2-(dimethylamino)ethyl)-3-(4-(4-
MS (m/e): 448.5 (M + 1)
fluoro-2-methyl-1H-indol-5-
ylamino)pyrimidin-2-
ylamino)benzamide
214
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 407.5 (M + 1)
N2-(3-(2-
(methylamino)ethoxy)phenyl)pyrimidine
2,4-
diamine
215
(E)-3-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 473.1 (M + 1)
5-ylamino)pyrimidin-2-ylamino)phenyl)-
1-morpholinoprop-2-en-1-one
216
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 493.5 (M + 1)
N2-(3-(3-
thiomorpholinopropoxy)phenyl)pyrimidine-
2,4-diamine
217
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 511.4 (M + 1)
N2-(3-(2-morpholino
ethylsulfonyl)phenyl)pyrimidine-2,4-
diamine
218
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 479.4 (M + 1)
N2-(3-(2-thiomorpholino
ethoxy)phenyl)pyrimidine-2,4-
diamine
219
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 447.4 (M + 1)
N2-(3-(2-(pyrrolidin-1-
yl)ethoxy)phenyl)pyrimidine-2,4-
diamine
220
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 510.4 (M + 1)
N2-(3-((4-(methylsulfonyl)piperazin-1-
yl)methyl)phenyl)pyrimidine-2,4-
diamine
221
2-(4-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 474.7 (M − 1)
ylamino)pyrimidin-2-
ylamino)benzyl)piperazin-1-
yl)ethanol
222
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 428.4 (M + 1)
ylamino)pyrimidin-2-ylamino)
phenylmethanesulfonate
223
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 426.4 (M + 1)
N2-(3-(methylsulfonylmethyl)
phenyl)pyrimidine-2,4-
diamine
224
tert-butyl 4-(2-(3-(4-(2-methyl-1H-indol-
MS (m/e): 544.4 (M + 1)
5-ylamino)pyrimidin-2-yl
amino)phenoxy)ethyl)piperazine-1-
carboxylate
225
tert-butyl 4-(2-(3-(4-(4-fluoro-2-methyl-
MS (m/e): 562.3 (M + 1)
1H-indol-5-ylamino)pyrimidin-2-
ylamino)phenoxy)ethyl)piperazine-1-
carboxylate
226
3-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 433.4 (M + 1)
ylamino)pyrimidin-2-ylamino))phenyl)-
N,N-dimethylpropanamide
227
(E)-3-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 417.2 (M + 1)
5-ylamino)pyrimidin-2-ylamino)phenyl)-
N-methylacrylamide
228
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 448.4 (M + 1)
N2-(3-((tetrahydro-2H-pyran-4-
yl)methoxy)phenyl)pyrimidine-2,4-
diamine
229
N2-(3-(2-aminoethoxy)phenyl)-N4-(4-
MS (m/e): 393.2 (M + 1)
fluoro-2-methyl-1H-indol-5-
yl)pyrimidine-2,4-diamine
230
N-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 441.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)methanesulfanamide
231
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 421.2 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
hydroxyethyl)benzamide
232
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 490.1 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
morpholinoethyl)benzamide
233
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 488.4 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
(piperidin-1-
yl)ethyl)benzamide
234
3-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 419.2 (M + 1)
ylamino)pyrimidin-2-ylamino)phenyl)-N-
methylpropanamide
235
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 435.2 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
methoxyethyl)benzamide
236
N-(4-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 427.2 (M + 1)
ylamino)pyrimidin-2-yl
amino)phenyl)methanesulfonamide
237
2-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 504.1 (M + 1)
ylamino)pyrimidin-2-ylamino)phenyl)-N-
(2-
morpholinoethyl)acetamide
238
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 448.2 (M + 1)
ylamino)pyrimidin-2-ylamino)-N-(2-
(methylamino)-2-
oxoethyl)benzamide
239
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 434.4 (M + 1)
N2-(3-(tetrahydro-2H-pyran-4-
yloxy)phenyl)pyrimidine-2,4-
diamine
240
1-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 441.4 (M + 1)
ylamino)pyrimidin-2-
ylamino)benzyl)sulphonyl-
methylamine
241
N4-(4-fluoro-2-methyl-1H-indol-5-yl)-
MS (m/e): 365.4 (M + 1)
N2-(6-methoxypyridin-3-yl)pyrimidine-
2,4-diamine
242
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)
MS (m/e): 464.4 (M + 1)
N-(3-(2-morpholinoethoxy)
phenyl)pyrimidin-2-amine
243
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 478.4 (M + 1)
N-(3-(3-morpholino
propoxy)phenyl)pyrimidin-2-amine
244
2-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 395.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)pbenoxy)ethanol
245
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 526.7 (M + 1)
N-(3-(3-(thiomorpholino-1′,1′-dioxide)
propoxy)phenyl)pyrimidin-2-amine
246
(R)-4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 420.5 (M + 1)
yloxy)-N-(3-(pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
247
(S)-4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 420.5 (M + 1)
yloxy)-N-(3-(pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
248
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 512.4 (M + 1)
N-(3-(1-(methylsulfonyl)piperidin-4-
yloxy)phenyl)pyrimidin-2-amine
249
(R)-4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 498.4 (M + 1)
yloxy)-N-(3-(1-
(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
250
N-(2-(dimethylamino)ethyl)-3-(4-(4-
MS (m/e): 448.5 (M + 1)
fluoro-2-methyl-1H-indol-5-
yloxy)pyrimidin-2-
ylamino)benzamide
251
(1-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 462.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)piperidin-4-
yl)methanol
252
2-(1-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 476.5 (M + 1)
yloxy)pyrimidin-2-
ylamino)benzyl)piperidin-4-
yl)ethanol
253
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 408.4 (M + 1)
N-(3-(2-(methylamino)ethoxy)
phenyl)pyrimidin-2-amine
254
(E)-3-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 474.5 (M + 1)
5-yloxy)pyrimidin-2-ylamino)phenyl)-1-
morpholinoprop-2-en-1-one
255
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 434.5 (M + 1)
N-(3-(morpholino
methyl)phenyl)pyrimidin-2-amine
256
(S)-4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 498.4 (M + 1)
yloxy)-N-(3-(1-
(methylsulfonyl)pyrrolidin-3-
yloxy)phenyl)pyrimidin-2-amine
257
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 392.4 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-
methylbenzamide
258
N-(2-(3-(4-(4-fluoro-2-methyl-1H-indol-
MS (m/e): 472.4 (M +0 1)
5-yloxy)pyrimidin-2-ylamino)phenoxy)
ethyl)methanesulfonamide
259
trifluoro-N-(3-(4-(4-fluoro-2-methyl-1H-
MS (m/e): 482.3 (M + 1)
indol-5-yloxy)pyrimidin-2-yl amino)
phenyl)methanesulfonamide
260
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 494.5 (M + 1)
N-(3-(3-thiomorpholinopropoxy)
phenyl)pyrimidin-2-amine
261
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 496.4 (M + 1)
N-(3-(2-(pyrrolidin-1-yl)ethylsulfonyl)
phenyl)pyrimidin-2-amine
262
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)
MS (m/e): 512.4 (M + 1)
N-(3-(2-morpholinoethylsulfonyl)
phenyl)pyrimidin-2-amine
263
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)
MS (m/e): 480.4 (M + 1)
N-(3-(2-thiomorpholinoethoxy)
phenyl)pyrimidin-2-amine
264
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 448.4 (M + 1)
N-(3-(2-(pyrrolidin-1-
yl)ethoxy)phenyl)pyrimidin-2-amine
265
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 511.4 (M + 1)
N-(3-((4-(methylsulfonyl)piperazin-1-
yl)methyl)phenyl)pyrimidin-2-amine
266
2-(4-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 477.5 (M + 1)
yloxy)pyrimidin-2-ylamino)benzyl)
piperazin-1-yl)ethanol
267
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-N-
MS (m/e): 449.4 (M + 1)
(3-((tetrahydro-2H-pyran-4-yl)methoxy)
phenyl) pyrimidin-2-amine
268
trifluoro-N-(4-(4-(4-fluoro-2-methyl-1H-
MS (m/e): 482.3 (M + 1)
indol-5-yloxy) pyrimidin-2-ylamino)
phenyl)methanesulfonamide
269
tert-butyl 4-(2-(3-(4-(4-fluoro-2-methyl-
MS (m/e): 563.4 (M + 1)
1H-indol-5-yloxy)pyrimidin-2-
ylamino)phenoxy)ethyl)piperazine-1-
carboxylate
270
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 435.4 (M + 1)
N-(3-(tetrahydro-2H-pyran-4-
yloxy)phenyl)pyrimidin-2-amine
271
N-(3-(2-aminoethoxy)phenyl)-4-(4-
MS (m/e): 394.4 (M + 1)
fluoro-2-methyl-1H-indol-5-
yloxy)pyrimidin-2-amine
272
N-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 442.4 (M + 1)
yloxy)pyrimidin-2-yl
amino)benzyl)methanesulfonamide
273
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 422.1 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2
hydroxyethyl)benzamide
274
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 449.5 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2-
(methylamino)-2-
oxoethyl)benzamide
275
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 491.1 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2-
morpholinoethyl)benzamide
276
N-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 428.1 (M + 1)
yloxy)pyrimidin-2-yl amino)
phenyl)methanesulfonamide
277
3-(4-(4-fluoro-2-methyt-1H-indol-5-
MS (m/e): 489.1 (M + 1)
yloxy)pylrimidin-2-ylamino)-N-(2-
(piperidin-1-
yl)ethyl)benzamide
278
3-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 420.2 (M + 1)
yloxy)pyrimidin-2-ylamino)phenyl)-N-
methylpropanamide
279
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 436.1 (M + 1)
yloxy)pyrimidin-2-ylamino)-N-(2-
methoxyethyl)benzamide
280
N-(4-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 428.1 (M + 1)
yloxy)pyrimidin-2-yl amino)
phenyl)methanesulfonamide
281
2-(3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 505.1 (M + 1)
yloxy)pyrimidin-2-ylamino)phenyl)-N-(2-
morpholinoethyl)acetamide
282
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)-
MS (m/e): 457.2 (M + 1)
N-(3-(2-(methylsulfonyl)
ethoxy)phenyl)pyrimidin-2-amine
283
4-(4-fluoro-2-methyl-1H-indol-5-yloxy)
MS (m/e): 366.4 (M + 1)
N-(6-methoxypyridin-3-yl)pyrimidin-2-
amine
Example 284
Synthesis of 3-(4-(2-methyl-1H-indol-5-ylamino)pyrimidin-2-yl amino)phenol (Compound 284)
A solution of N2-(3-methoxylphenyl)-N4-(2-methyl-1H-indol-5-yl)pyrimidine-2,4-diamine (0.1 mmol) in 5 ml CH 2 Cl 2 was placed in an ice bath. To this was added BBr 3 (0.5 mmol). The reaction mixture was stirred overnight at room temperature, then poured into ice water, and extracted with ethyl acetate. The organic layer was washed sequentially with water and brine, dried over anhydrous Na 2 SO 4 , and concentrated. The residue was purified by column chromatography to provide the desired product in a yield of 83%.
1 H NMR (DMSO-d 6 , 400 MHz): δ 10.501 (s, 1H), 9.115 (s, 1H), 8.956 (s, 1H), 8.868 (s, 1H), 7.908 (d, J=6 Hz, 1H), 7.716 (s, 1H), 7.271 (d, J=8 Hz, 1H), 7.210 (d, J=8.4 Hz, 1H), 7.114 (d, J=8 Hz, 1H), 6.968 (t, J=8 Hz, 1H), 6.322 (dd, J=8, 1.6 Hz, 1H), 6.097 (m, 2H), 2.377 (s, 3H); MS (m/e): 331.4 (M+1).
Examples 285-295
Syntheses of Compounds 285-295
Compounds, 285-295 were each synthesized in a manner similar to that described Example 284.
compound
Name
1 NMR (CD 3 OD, 400 MHz)/MS
285
4-(5-(4-(2-methyl-1H-indol-5-
7.863 (d, J = 6.0 Hz, 1H), 7.286 (d, J = 8.8 Hz, 1H),
ylamino)pyrimidin-2-ylamino)-1H-
6.830 (br, 2H), 6.125-6.080 (m, 4H), 5.558-5.527
pyrazol-3-yl)phenol
(m, 2H), 2.415 (s, 3H); MS (m/e): 411.8 (M + 1).
286
2-(4-(2-methyl-1H-indol-5-
7.791 (d, J = 6.0 Hz, 2H), 7.584 (s, 1H), 7.047 (d,
ylamino)pyrimidin-2-ylamino)phenol
J = 8.8 Hz, 1H), 7.063 (d, J = 7.6 Hz, 1H), 6.974 (t,
J = 7.6 Hz, 1H), 6.882 (d, J = 8.0 Hz, 1H), 6.794 (t, J = 8.0 Hz, 1H), 6.164 (d, J = 6.0 Hz, 1H), 6.124 (s, 1H), 2.027 (s, 3H); MS (m/e): 332.2 (M + 1).
287
4-(4-(2-methyl-1H-indol-5-
10.573 (s, 1H), 9.162 (s, 1H), 9.007 (s, 1H), 8.985 (s,
ylamino)pyrimidin-2-ylamino)phenol
1H), 7.952 (d, J = 5.6 Hz, 1H), 7.766 (s, 1H), 7.301 (d,
J = 8 Hz, 1H), 7.262 (d, J = 8 Hz, 1H), 7.123 (d, J = 8 Hz, 1H), 7.011 (m, 1H), 6.332 (dd, J = 8, 1.6 Hz, 1H), 6.103 (m, 2H), 2.391 (s, 3H); MS (m/e): 331.4 (M + 1)
289
4-(4-(2-methyl-1H-indol-5-
8.133 (d, J = 6.0 Hz, 1H), 7.324(d, J = 8.4 Hz, 1H),
yloxy)pyrimidin-2-ylamino)phenol
7.225-7.183 (m, 3H), 6.819 (dd, J= 8.8 Hz, J= 2.4
Hz, 1H), 6.533 (s, 1H), 6.530 (s, 1H), 6.213 (d, J = 5.6 Hz, 1H), 6.172 (s, 1H), 2.428 (s, 3H); MS (m/e): 374.3 (M + 1).
290
3-(4-(2-methyl-1H-indol-5-
8.179 (d, J = 6.0 Hz, 1H), 7.333 (d, J = 8.8 Hz, 1H),
yloxy)pyrimidin-2-ylamino)phenol
7.193 (s, 1H), 7.095 (s, 1H), 6.953 (d, J = 7.2 Hz,
1H), 6902 (t, J=8.0 Hz, 1H), 6.831 (d, J = 8.8 Hz, 1H), 6.387 (d, J = 7.6 Hz, 1H), 6.244 (d, J = 6.0 Hz, 1H), 6.171 (s, 1H), 3.332 (s, 3H) , 2.454 (s, 3H); MS (m/e): 333.2 (M + 1).
291
2-(4-(4-fluioro-2-methyl-1H-indol-5-
11.249 (s, 1H), 8.943 (d, J = 4.8 Hz, 1H), 7.920 (d,
ylamino)pyrimidin-2-ylamino)phenol
J = 5.6 Hz, 1H), 7.867 (m, J = 6.4 Hz, 2H), 7.128 (d,
J = 8.0 Hz, 1H), 7.078 (t, J = 8.4-6.8 Hz, 1H), 6.797 (s, 2H), 6.589 (s, 1H), 6.217 (s, 1H), 6.075 (s, 1H), 4.061 (m, J = 7.2-6.8 Hz, 1H) 2.406 (s, 3H); MS: 350.2 (M + 1).
292
4-(4-(4-fluoro-2-methyl-1H-indol-5-
11.212 (s, 1H), 8.845 (s, 1H), 8.689 (d,
ylamino)pyrimidin-2-ylamino)phenol
J = 10.0 Hz, 1H), 7.868 (d, J = 5.6 Hz, 2H), 7.427 (d,
J = 8.4 Hz, 2H), 7.107(t, J = 8.4-6.4 Hz, 1H), 6.509 (d, J = 8.0 Hz, 2H), 6.208 (s, 1H), 5.940 (m, J = 3.6-1.6 Hz, 1H), 4.060 (m, J = 7.2-6.8 Hz, 1H), 2.408 (s, 3H); MS (m/e): 350.2 (M + 1).
293
3-(4-(4-fluoro-2-methyl-1H-indol-5-
11.217 (s, 1H), 9.069 (s, 1H), 8.836 (s, 1H),
ylamino)pyrimidin-2-ylamino)phenol
8.715 (s, 1H), 7.922 (d, J = 6.0 Hz, 1H), 7.224 (d,
J = 8.4 Hz, 2H), 7.128 (T, J = 6.4-2.4 Hz, 2H), 6.839 (t, J = 8.4-6.4 Hz, 1H), 6.268 (d, J = 1.6 Hz, 2H), 6.249 (s, 1H), 6.207 (s, 1H) , 4.043 (m, J = 7.2-6.8 Hz, 1H), 2.400 (s, 3H); MS (m/e): 350.2 (M + 1).
294
3-(4-(2-methylbenzo[d]oxazol-6-
9.500 (s, 1H), 9.175 (s, 1H), 9.054 (s, 1H), 8.164
ylamino)pyrimidin-2-ylamino) phenol
(s, 1H), 8.003 (d, J = 6.0 Hz, 1H), 7.569 (m, 2H),
7.230 (m, 2H), 6.996 (dd, 1H), 6.338 (d, J = 8.0 Hz, 1H), 7.239 (d, J = 6.0 Hz, 1H), 2.607 (s, 3H). MS (m/e): 334.2 (M + 1).
295
3-(4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 351.4 (M + 1)
yloxy)pyrimidin-2-
ylamino)phenol
Example 296
Synthesis of N-(2-methoxypyrimidin-4-yl)-N-(2-methyl-1H-indol-5-yl)pyrimidine-2,4-diamine (Compound 296)
The solution of 2-chloropyrimidin-4-amine (1 mmol) and sodium methoxide (1.5 mmol) in 10 ml methanol was refluxed for 2 h, after removing of solvent, the residue was dissolved in CH 2 Cl 2 and washed with water, dried over anhydrous NaSO4, concentrated in vacuo to give 2-methoxypyrimidin-4-amine.
To a solution of 2-methoxypyrimidin-4-amine (0.1 mmol) and N-(2-chloropyrimidin-4-yl)-2-methyl-1H-indol-5-amine (0.1 mmol) in 3 ml dioxide, CsCO 3 (0.2 mmol), Pd(OAc) 2 (10 mmol %) and Xantphos (10 mmol %) were added. The mixture was stirred under microwave irradiation at 200° C. for 40 mins. After cooling the solution was filtered and the filtrate was concentrated in vacuo, the residue was purified by column chromatography(C-18) to give N-(2-methoxypyrimidin-4-yl)-N-(2-methyl-1H-indol-5-yl)pyrimidine-2,4-diamine (yield 48%).
1 H NMR (DMSO-d6, 400 MHz): 10.839 (s, 1H), 9.718 (s, 1H), 9.281 (s, 1H), 8.162 (d, J=6.0 Hz, 1H), 8.032 (m, 2H), 7.693 (s, 1H), 7.251 (d, J=8.8 Hz, 1H), 7.099 (d, J=7.2 Hz, 1H), 6.300 (d, J=6.0 Hz, 1H), 6.107 (s, 1H), 3.863 (s, 3H), 2.383 (s, 3H); MS (m/e): 348.2 (M+1)
Examples 297-299
Syntheses of Compounds 297-299
Compounds 297-299 were each synthesized in a manner similar to that described in Example 296.
compound
Name
1 H NMR (DMSO-d 6 , 400 MHz)/MS
297
N-(2-methoxypyridin-4-yl)-N-(2-methyl-
10.837 (s, 1H), 9.421 (s, 1H), 9.144 (s, 1H),
1H-indol-5-yl)pyrimidine-2,4-diamine
7.978 (d, J = 6.0 Hz, 1H), 7.838 (d, J = 6.0 Hz, 1H),
7.606 (s, 1H), 7.333-7.303 (m, 2H), 7.249 (d, J = 8.4 Hz, 1H), 7.084 (d, J = 8.0 Hz, 1H), 6.205 (d, J = 5.6 Hz, 1H), 6.088 (s, 1H), 3.775 (s, 3H), 2.382 (s, 3H); MS (m/e): 347.2 (M + 1)
298
N-(2-methoxypyridin-4-yl)-N-(2-methyl-
11.258 (s, 1 H), 10.400 (br, 1H), 9.036 (s, 1H),
1H-indol-5-yl)pyrimidine-2,4-diamine
8.829 (s, 1H), 8.509 (s, 1H), 8.048 (d, J = 8.4 Hz,
1H), 7.911 (d, J = 5.6 Hz, 1H), 7.007-7.122 (m, 2H), 6.743 (dd, J = 8.4 Hz, 1.6 Hz, 1H), 6.194 (s, 1H), 6.012 (br, 1H), 3.166 (s, 3H), 2.397 (s, 3H); MS (m/e): 428.1 (M + 1)
299
N-(5-(4-(2-methyl-1H-indol-5-
MS (m/e): 411.4 (M + 1)
yloxy)pyrimidin-2-ylamino)pyridin-2-
yl)methanesulfonamide
Example 300
Synthesis of N-(2-(4-fluorophenoxy)pyrimidin-4-yl)-2-methyl-1H-indol-5-amine (Compound 300)
N-(2-chloropyrimidin-4-yl)-2-methyl-1H-indol-5-amine (0.1 mmol) and p-fluorophenol (0.1 mmol) were dissolved in 0.5 ml DMF. To this was added K 2 CO 3 (0.2 mmol). After stirred at 60° C. for 5 h, the reaction mixture was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried by anhydrous Na 2 SO 4 , and concentrated. The resulting oil residue was purified by column chromatography to provide compound 300 in a yield of 76%.
1 H NMR (DMSO-d6, 400 MHz): δ 10.802 (s, 1H), 9.491 (s, 1H), 7.990 (d, J=5.4 Hz 1H), 7.495 (s, 1H), 7.295 (m, J=8.4-3.6 Hz, 4H), 7.236 (d, J=5.4 Hz 1H), 7.133 (d, J=5.6 Hz, 1H), 6.486 (d, J=5.6 Hz, 1H), 5.902 (s, 1H), 2.402 (s, 3H); MS (m/e): 335.1 (M+1).
Example 301-303
Syntheses of Compounds 301-303
Compounds 301-303 were prepared in a similar manner to that described in Example 300.
Compound
Name
1 H NMR (CD 3 OD, 400 MHz)/MS
301
2-methyl-N-(2-(4-
11.190 (s, 1H), 9.046 (s, 1H), 7.959
phenoxyphenoxy)pyrimidin-4-yl)-1H-
(s, 1H), 7.931 (d, J = 6.0 Hz, 1H), 7.681 (d,
indol-5-amine
J = 7.2 Hz, 2H), 7.361 (t, J = 8.0-7.6 Hz, 2H),
7.114 (m, J = 8.4-7.2 Hz, 3H), 6.903 (d, J = 8.0 Hz, 2H), 6.755 (d, J = 7.2 Hz, 2H), 6.179 (s, 1H), 6.024 (s, 1H), 2.338 (s, 3H); MS (m/e): 409.2 (M + 1)
302
N2-cyclopropyl-N4-(2-methyl-1H-
7.739 (d, J = 6.4 Hz, 1H), 7.593 (s, 1H),
indol-5-yl)pyrimidine-2,4-diamine
7.252 (d, J = 7.6 Hz, 1H), 7.119 (d, J = 8.0
Hz, 1H), 6.009 (s, 1H), 6.016 (d, J = 6.0 Hz, 1H), 2.425 (s, 3H), 0.784 (m, J = 5.2- 2.4, 2H), 0.626 (m, J = 2.0-0.8 Hz, 3H), 0.547 (m, J = 2.0-1.2 Hz, 3H). MS (m/e): 280.2 (M + 1)
303
N2-cyclohexyl-N4-(2-methyl-1H-indol-
MS (m/e): 322.3 (M + 1)
5-yl)pyrimidine-2,4-diamine
Example 304
Synthesis of 5-(2-(3-methoxyphenoxy)pyrimidin-4-yloxy)-2-methyl-1H-indole (Compound 304)
To a solution of 2,4-dichloropyrimidine (1 mmol) and 5-hydroxy-2-methylindole (1 mmol) in 5 ml EtOH was added Et 3 N (1 mmol). The reaction mixture was refluxed for 5 h. After removal of the solvent in vacuo and addition of H 2 O, the mixture was extracted with EtOAc. The organic layers were combined, washed with a saturated NaCl aqueous solution, dried over anhydrous Na 2 SO 4 , and concentrated in vacuo. The resulting oil residue was purified by column chromatography to give 5-(2-chloropyrimidin-4-yloxy)-2-methyl-1H-indole in a yield of 75%.
5-(2-Chloropyrimidin-4-yloxy)-2-methyl-1H-indole (0.1 mmol) and m-methoxyphenol (0.1 mmol) were dissolved in 0.5 ml DMF. K 2 CO 3 (0.2 mmol) was then added. After the reaction mixture was stirred at 60° C. for 5 h, it was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The crude product was purified by column chromatography to provide compound 304 in a yield of 76%.
1 H NMR (CD 3 OD, 400 MHz): δ 8.303 (d, J=5.6 Hz, 1H), 8.084 (s, 1H), 7.305-7.262 (m, 3H), 6.908 (dd, J=8.8 Hz, J=2.4 Hz, 1H), 6.816-6.764 (m, 3H), 6.463 (d, J=5.6 Hz, 1H), 6.226 (s, 1H), 3.780 (s, 3H), 2.465 (s, 3H); MS (m/e): 346.5 (M−1).
Example 305
Synthesis of 3-(4-(2-methyl-1H-indol-5-ylamino)pyrimidin-2-ylamino)benzonitrile (Compound 305)
To a solution of 2,4-dichloropyrimidine (1 mmol) and 5-Aminobenzimidazole (1 mmol) in 5 ml EtOH, was added Et 3 N (1 mmol). The reaction mixture was refluxed for 5 hours. After removal of the solvent in vacuo and addition of H 2 O, the mixture was extracted with EtOAc. The organic layers were combined, washed with a saturated NaCl aqueous solution, dried over anhydrous Na 2 SO 4 , and concentrated in vacuo. The residue was purified by column chromatography to give N-(2-chloropyrimidin-4-yl)-1H-benzo[d]imidazol-5-amine in a yield of 80%.
N-(2-chloropyrimidin-4-yl)-1H-benzo[d]imidazol-5-amine (0.1 mmol), 3-aminobenzonitrile (0.1 mmol), and p-TsOH monohydrate (0.2 mmol) were dissolved in 0.5 ml DMF. After the reaction mixture was stirred at 60° C. for 5 h, it was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The resulted oil was purified by column chromatography to provide compound 305 in a yield of 76%.
1 H NMR (CD 3 OD, 400 MHz): δ 8.178 (s, 1H), 7.942 (d, J=6.4 Hz, 2H), 7.825 (br, 1H), 7.633-7.603 (m, 2H), 7.469 (dd, J=8.8 Hz, 5 Hz, 1H), 7.212 (t, J=8.4 Hz, 1H), 7.075 (d, J=8.0 Hz, 1H), 6.254 (d, J=6.0 Hz, 1H), 3.345 (s, 1H); MS: 327.2 (M+1).
Example 306
Synthesis of N2-(3-methoxyphenyl)-N4-(2-methylbenzo[d]oxazol-6-yl)pyrimidine-2,4-diamine (Compound 306)
To a solution of 2,4-dichloropyrimidine (1 mmol) and 2-methyl-1,3-benzoxazol-5-amine (1 mmol) in 5 ml EtOH was added Et 3 N (1 mmol). The reaction mixture was refluxed for 5 h. After removal of the solvent in vacuo and addition of H 2 O, the mixture was extracted with EtOAc. The organic layers were combined, washed with a saturated NaCl aqueous solution, dried over anhydrous Na 2 SO 4 , and concentrated in vacuo. The residue was purified by column chromatography to give N-(2-chloro pyrimidin-4-yl)-2-methylbenzo[d]oxazol-6-amine in a yield of 73%.
N-(2-chloropyrimidin-4-yl)-2-methylbenzo[d]oxazol-6-amine (0.1 mmol), 3-methoxyaniline (0.1 mmol), and p-TsOH monohydrate (0.2 mmol) were dissolved in 0.5 ml DMF. After the reaction mixture was stirred at 60° C. for 5 h, it was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The resulting oil residue was purified by column chromatography to provide compound 306 in a yield of 82%.
1 H NMR (DMSO-d6, 400 MHz): δ 9.431 (s, 1H), 9.158 (s, 1H), 8.136 (s, 1H), 8.022 (d, J=5.6 Hz, 1H), 7.566 (d, J=8.8 Hz, 1H), 7.517 (d, J=8.8 Hz, 1H), 7.418 (s, 1H), 7.367 (d, J=8.0 Hz 1H), 7.126 (t, J=8.4 Hz, 1H), 6.490 (m, 1H), 6.224 (d, J=5.2 Hz, 1H), 3.674 (s, 3H), 2.609 (s, 3H); MS (m/e): 348.3 (M+1).
Example 307
Synthesis of N2-(3-ethynylphenyl)-N4-(2-methylbenzo[d]oxazol-6-yl)pyrimidine-2,4-diamine (Compound 307)
Compound 307 was synthesized in a similar manner to that described in Example 306.
1 H NMR (DMSO-d6, 400 MHz): δ 9.566 (d, J=5.2 Hz, 1H), 9.309 (s, 1H), 8.099 (s, 1H), 8.038 (d, J=6.0 Hz, 1H), 7.917 (s, 1H), 7.805 (d, J=8.4 Hz, 1H), 7.574 (m, 2H), 7.231 (m, 1H), 6.996 (d, J=7.6 Hz, 1H), 7.278 (d, J=5.6 Hz, 1H), 4.059 (s, 1H), 2.608 (s, 3H); MS (m/e): 342.2 (M+1).
Example 308
Synthesis of N2-(3-ethynylphenyl)-N4-(1H-indazol-6-yl)pyrimidine-2,4-diamine (Compound 308)
To a solution of 2,4-dichloropyrimidine (1 mmol) and 5-aminoindazole (1 mmol) dissolved in 5 ml EtOH was added Et 3 N (1 mmol). The reaction mixture was refluxed for 5 h. After removal of the solvent in vacuo and addition of H 2 O, the mixture was extracted with EtOAc. The organic layers were combined, washed with a saturated NaCl aqueous solution, dried over anhydrous Na 2 SO 4 , and concentrated in vacuo. The resulted oil was purified by column chromatography to give N-(2-chloropyrimidin-4-yl)-1H-indazol-5-amine in a yield of 80%.
N-(2-chloropyrimidin-4-yl)-1H-indazol-5-amine (0.1 mmol), 3-ethnylaniline (0.1 mmol), and p-TsOH (0.2 mmol, monohydrate) were dissolved in 0.5 ml DMF. After the reaction mixture was stirred at 60° C. for 5 h, it was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The residue was purified by column chromatography to provide compound 308 in a yield of 74%.
1 H NMR (DMSO-d 6 , 400 MHz): δ 12.966 (brs, 1H), 9.344 (brs, 1H), 9.234 (brs, 1H), 8.145 (s, 1H), 8.005 (m, 2H), 7.893 (s, 1H), 7.795 (d, 1H), 7.527 (d, J=8.8 Hz, 1H), 7.471 (d, J=8.8 Hz, 1H), 7.212 (t, 1H), 7.021 (d, 1H), 6.626 (d, 1H), 4.037 (s, 1H); MS (m/e): 327.2 (M+1).
Example 309
Synthesis of N2-(3-methoxylphenyl)-N4-(2-methyl-1H-indol-5-yl)pyrimidine-2,4-diamine (Compound 309)
2,4-Dichloro-5-fluoropyrimidine (1 mmol) and 5-amino-2-methylindole (1.5 mmol) were dissolved in 3 ml CH 3 OH and 9 ml H 2 O. After the reaction mixture was stirred at room temperature for 1 h, it was diluted with H 2 O, acidified with 2N HCl, and sonicated. The reaction mixture was then filtered, washed with H 2 O and dried to give N-(2-chloro-5-fluoropyrimidin-4-yl)-2-methyl-1H-indol-5-amine in a yield of 78%.
N-(2-chloro-5-fluoropyrimidin-4-yl)-2-methyl-1H-indol-5-amine (0.1 mmol), m-methoxyaniline (0.1 mmol), p-TsOH monohydrate (0.2 mmol) were dissolved in 0.5 ml DMF. After the reaction mixture was stirred at 60° C. for 5 h, it was diluted with water and extracted with ethyl acetate. The organic layer was washed with water and brine sequentially, dried over anhydrous Na 2 SO 4 , and concentrated. The residue was purified by column chromatography to provide compound 309 in a yield of 60%.
1 H NMR (CD 3 OD, 400 MHz, δ ppm): 7.854 (d, J=4.0 Hz, 1H), 7.703 (d, J=1.6, 1H), 7.248 (s, 2H), 7.177 (br, 2H), 7.054 (t, J=4.2 Hz, 2H), 6.942 (s, 2H), 3.506 (s, 3H), 2.235 (s, 3H); MS (m/e): 364.2 (M+1).
Example 310
Synthesis of 2-(3-methoxyphenylamino)-4-(2-methyl-1H-indol-5-ylamino)pyrimidine-5-carbonitrile (Compound 310)
2-Methyl-2-thiopseudourea (5 mmol) and ethyl ethoxymethylenecyanoacetate (5 mmol) were dissolved in 20 ml EtOH. To this was added K 2 CO 3 (10 mmol). After the mixture was refluxed for 48 h, it was cooled to room temperature and filtered. The solvent was concentrated in vacuo and purified by column chromatography to give 4-hydroxy-2-(methylthio) pyrimidine-5-carbonitrile in a yield of 65%.
4-Hydroxy-2-(methylthio) pyrimidine-5-carbonitrile (3 mmol) and m-anisidine (3 mmol) in pentan-1-ol was refluxed for 40 h under nitrogen. The reaction mixture was concentrated in vacuo. The residue was washed with water and dried to afford 4-hydroxy-2-(3-methoxyphenylamino)pyrimidine-5-carbonitrile.
To a solution of 4-hydroxy-2-(3-methoxyphenylamino)pyrimidine-5-carbonitrile in POCl 3 was added DMF 0.5 ml. The solution was refluxed for 3 h. The reaction mixture was cooled to room temperature and poured into ice-water. The solution was adjusted to pH=8-9 by aqueous sodium carbonate solution and extracted with dichloromethane. The combined organic layers were washed with brine, dried over anhydrous Na 2 SO 4 , concentrated in vacuo to afford 4-chloro-2-(3-methoxyphenylamino)pyrimidine-5-carbonitrile.
4-Chloro-2-(3-methoxyphenylamino)pyrimidine-5-carbonitrile was converted to compound 310 in a similar manner to that described in Example 1.
1 H NMR (DMSO-d6, 400 MHz): δ 10.925 (s, 1H), 9.710 (d, J=11.2 Hz, 1H), 0.349 (d, J=10.4 Hz, 1H), 8.441 (s, 1H), 7.474 (s, 1H), 7.252 (s, 1H), 7.223 (d, J=6.8 Hz, 1H), 7.187 (s, 1H), 7.062 (m, J=1H), 6.923 (d, J=2.0 Hz, 1H), 6.485 (t, 1H); 6.098 (s, 1H), 3.453 (s, 3H), 2.387 (s, 3H); MS (m/e): 371.2 (M+1).
Example 311-317
Syntheses of Compounds 311-317
Compounds 311-317 were prepared in a similar manner to that described in Example 310.
compound
Name/Structure
1 H NMR(DMSO-d 6 ,400 Hz)/MS
311
4-(2-methyl-1H-indol-5-y1amino)-2-(3-(3-
11.184 (s, 1H), 10.745 (s, 1H), 9.492
morpholinopropoxy)phenylamino)pyrimidine-
(s, 1H), 8.396 (s, 1H), 7.322 (s, 1H),
5-carbonitrile
7.292 (d, J = 7.2, 1H), 7.147 (m, 1H),
6.919 (m, 1H), 6.815 (d, J = 8.8, 1H), 6.416 (d, J = 7.2, 1H), 6.261 (t, J = 4.8, 1H), 6.129 (s, 1H), 3.447 (m, 2H), 3.547 (m, 4H), 2.398 (s, 3H), 2.337 (m, 6H), 1.747 (m, 2H). MS (m/e): 484.2 (M + 1)
312
4-(2-methyl-1H-indol-5-yloxy)-2-(3-(3-
MS (m/e): 485.3 (M + 1)
morpholinopropoxy)phenylamino)pyrimidine-
5-carbonitrile
313
4-(2-methyl-1H-indol-5-ylamino)-2-(3-(2-
MS (m/e): 470.5 (M + 1)
morpholinoethoxy)phenylamino)pyrimidine-
5-carbonitrile
314
4-(4-fluoro-2-methyl-1H-indol-5-
MS (m/e): 427.2 (M + 1)
ylamino)-2-(3-
(trifluorcmethyl)phenylamino)-
pyrimidine-5-carbonitrile
315
2-(3,4-dimethoxyphenylamino)-4-(2-
MS (m/e): 401.4 (M + 1)
methyl-1H-indol-5-ylamino)pyrimidines
carbonitrile
316
4-(4-fluoro-2-methyl-1H-indol-s-
MS (m/e): 488.5 (M + 1)
ylamino)-2-(3-(2-
morpholinoethoxy)phenylamino)
pyrimidine-5-carbonitrile
317
2-(5-cyano-2-(3,4-
MS (m/e): 391.1 (M + 1)
dimethoxyphenylamino) pyrimidin-4-
ylamino)benzamide
Example 318
KDR, Kinase Activity Assay Using Z'-Lyte Kinase Assay Kit
Inhibition of kinase activity of a recombinant KDR catalytic domain (Invitrogen, Carlsbad, Calif., U.S.A., Cat. PV3660) was determined using Z'-LYTE™ Tyr1 Peptide assay kit (Invitrogen, Cat. PV3190) in a black 384-well plate (Thermo labsystems, Cambridge, U.K., Cat. 7805). The assay was performed according to the procedures recommended by the manufacturer.
Briefly, a test compound (10 mM stock in DMSO) was diluted to 1:4 with distilled water containing 8% DMSO. The solution was placed in a test well and three control wells (C1, C2, and C3) at 2.5 μl/well. Coumarin-fluorescein double-labeled peptide substrate was mixed with the KDR catalytic domain (“kinase”). 5 μl of the kinase/peptide mixture was added to each of the test, C1, and C2 wells, but not C3 (Final concentration: 0.3 μg/ml of Kinase, 2 μM of peptide). 5 μl of Phosphor-Tyr1 peptide was added to the C3 well. 2.5 μl of 40 μM ATP was added to the test well and C2 well and 2.5 μl of 1.33× kinase buffer (1× buffer: 50 mM HEPES, pH7.5, 0.01% Brij-35, 5 mM MgCl 2 , 5 mM MnCl 2 , and 1 mM EGTA) was added to the C1 and C3 wells. The plate was briefly spun at 1000 rpm to settle all solution down to the bottom of the wells and then sealed and shaken at 250 rpm and 25° C. for 1 hour.
A development reagent was diluted to 1:128 according to the recommendation of the manufacturer. 5 μl of the diluted development reagent was added to each well. The plate was spun at 1000 rpm to settle all solution down to the wells, and then sealed and shaken at 250 rpm and 25° C. for 1 hour.
5 μl of a stop reagent was added to each well. The plate was spun at 1000 rpm to settle all solution down to the wells, and then sealed at 250 rpm and 25° C. for 2 minutes. Emission of the solution at each well was measured by a Victor™3 micro-plate reader at Excitation 400 nm/Emission 445 nm and 520 nm. The emission ratio and phosphorylation (“Phos.”) percentage were calculated by the following equations:
Emission Ratio = Coumarin Emission ( 445 nm ) Fluorescein Emission ( 520 nm ) % Phosphorylation = 1 - ( Emission Ratio × F 100 % ) - C 100 % ( C 0 % - C 100 % ) + [ Emission Ratio × ( F 100 % - F 0 % ) ]
where:
C 100% =Average Coumarin emission signal of the 100% Phos. Control C 0% =Average Coumarin emission signal of the 0% Phos. Control F 100% =Average Fluorescein emission signal of the 100% Phos. Control F 0% =Average Fluorescein emission signal of the 0% Phos. Control
The inhibition ratio was calculated as follows:
Inhibition %=(Phos. in C2 well−Phos. in test well)/(Phos. in C2 well)×100%
The result showed that all of the tested compounds inhibited the activity of KDR. The IC 50 values ranged from 0.001 to 10 μM.
Other Embodiments
All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. For example, compounds structurally analogous to the compounds of this invention can be made and used to practice this invention. Thus, other embodiments are also within the claims. | A compound of the following formula:
wherein R 1 , R 2 , R 3 , R4, R5, T, U, V, X, Y, Z, G, and Z are defined herein. It also discloses a method of treating an angiogenesis-related disorder, e.g., cancer or age-related macular degeneration, with such a compound. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a semiconductor device, and more particularly a vertical bipolar transistor that is formed using silicon-on-insulator (SOI) integrated bipolar transistor and complementary metal oxide semiconductor (hereinafter BiCMOS) technology.
BACKGROUND OF THE INVENTION
[0002] The semiconductor industry has been seeking more cost effective solutions for manufacturing BiCMOS devices for mass applications of radio frequency (RF)/analog and wireless/fiber-based telecommunications for decades. Si/SiGe BiCMOS technology is widely used and has been quite successful. However, as complementary metal oxide semiconductor (CMOS) adopts thin silicon-on-insulator (SOI) substrates for lower power and higher speed (due to device scaling), the thick subcollector of conventional bipolar junction transistors (BJTs) becomes incompatible with the integration of high-performance SOI CMOS devices.
[0003] In order to facilitate integration with SOI CMOS, lateral SOI BJTs have been proposed and studied. See, for example, S. Parke, et al. “A versatile, SOI CMOS technology with complementary lateral BJT's”, IEDM, 1992, Technical Digest, 13-16 Dec. 1992, page(s) 453-456; V. M. C. Chen, “A low thermal budget, fully self-aligned lateral BJT on thin film SOI substrate for lower power BiCMOS applications”, VLSI Technology, 1995. Digest of Technical Papers. 1995 Symposium on VLSI Technology, 6-8 Jun. 1995, page(s) 133-134; T. Shino, et al. “A 31 GHz fmax lateral BJT on SOI using self-aligned external base formation technology”, Electron Devices Meeting, 1998. IEDM '98 Technical Digest, International, 6-9 Dec. 1998, page(s) 953-956; T. Yamada, et al. “A novel high-performance lateral BJT on SOI with metal-backed single-silicon external base for low-power/low-cost RF applications”, Bipolar/BiCMOS Circuits and Technology Meeting, 1999. Proceedings of the 1999, 1999, page(s) 129-132; and T. Shino, et al. “Analysis on High-Frequency Characteristics of SOI Lateral BJTs with Self-Aligned External Base for 2-GHz RF Applications”, IEEE, TED, vol. 49, No. 3, pp. 414, 2002.
[0004] Even though lateral SOI BJT devices are easier to integrate with SOI CMOS, the performance of such devices is quite limited. This is because the base width in the lateral SOI BJTs is determined by lithography. Hence, it cannot be scaled down (less than 30 nm) readily without more advanced and more expensive lithography technologies such as e-beam lithography.
[0005] Another type of SOI BJT, which is a vertical SOI SiGe bipolar device, has also been proposed and demonstrated to offer higher base-collector breakdown voltage, higher early voltage and better BVCEO-fT tradeoff. This type of SOI BJT is described, for example, in J. Cai, et al., “Vertical SiGe-Base Bipolar Transistors on CMOS-Compatible SOI Substrate”, 2003 IEEE Bipolar/BiCMOS Circuits and Technology Meeting. This SOI BJT device uses a fully depleted SOI layer as the collector at zero substrate bias. The application of a substrate bias to this SOI BJT device allows for significant improvement in overall device performance by reducing collector space-charge region transit time and collector resistance through the formation of an accumulation layer.
[0006] A problem with the SOI BJT device described above is that the buried oxide (BOX) layer in high performance CMOS SOI substrates is typically 100-200 nm thick. As a result, the substrate bias needed for significant performance improvement is unacceptably large (greater than about 20 V). In order for these devices to be practical for SOI BiCMOS applications, the substrate bias must be held at or below the voltage applied to the CMOS, typically less than 3 V.
[0007] In view of the above, there is a need for providing a SOI BJT structure that overcomes the drawbacks mentioned in the prior art SOI BJTs.
SUMMARY OF THE INVENTION
[0008] The present invention provides a vertical SOI BJT which uses a SOI layer with a back gate-induced majority carrier accumulation layer as a subcollector located on regions of a second buried insulating region having a second thickness using a standard SOI starting wafer with a first buried insulating region having a first thickness and the method thereof. In accordance with the present invention, the first thickness of the first buried insulating region is greater than the second thickness of the second buried insulating region. The reduced thickness of the second buried insulating region underneath the bipolar devices allows for a significantly reduced substrate bias that is CMOS compatible, while maintaining the advantages of the thick first buried insulating region underneath the CMOS.
[0009] The accumulation layer can then be formed to reduce collector resistance and transit time by applying a back-bias that will not compromise the quality and reliability of the CMOS.
[0010] A method of forming a bipolar transistor including a localized thin buried insulating region (second buried insulating region) is provided. In broad terms, the method of the present invention includes the steps of:
[0011] providing a silicon-on-insulator (SOI) substrate comprising a first semiconductor layer containing a first conductivity type dopant located over a first buried insulating layer, wherein a portion of the first buried insulating layer beneath said first semiconductor layer is removed providing an undercut region;
[0012] forming a second buried insulating layer on exposed surfaces of said first semiconductor layer, wherein said second buried insulating layer is thinner than said first buried insulating layer;
[0013] filling the undercut region and the removed portion of the first semiconductor layer with a conductive back electrode material;
[0014] forming a base comprising a second semiconductor layer containing a second conductivity type dopant that is different than the first conductivity type dopant on said substrate;
[0015] forming an emitter comprising a third semiconductor layer including said first conductivity type dopant over a portion of said base; and
[0016] biasing the conductive back electrode material to form an accumulation layer at an interface between the first semiconductor layer and the second buried insulating layer.
[0017] The first semiconductor layer includes an intrinsic collector and an extrinsic collector. The base may include a single crystal portion atop semiconductor material, and a polycrystalline portion atop insulating material.
[0018] In accordance with the present invention, a vertical NPN or PNP SOI BJT can be formed. The NPN transistor is formed when the first and third semiconductor layers contain an n-type dopant, while the second semiconductor layer comprises a p-type dopant. A PNP transistor is formed when the first and third semiconductor layers contain a p-type dopant and the second semiconductor layer contains an n-type dopant.
[0019] Specifically, a trench is first etched through the first semiconductor layer of an SOI substrate exposing the first buried insulating layer which normally has a thickness from about 100 to about 500 nm. A portion of the first buried insulating layer is then removed using an isotropic etch process that undercuts the first semiconductor layer. A thin insulating layer (less than about 15 nm) is then grown to form the second buried insulating layer. The trench and area where the first buried insulating layer was removed is filled in with a conductive material such as in-situ doped polysilicon. The conductive-fill can then be used to apply a substrate bias. These processing steps provide a structure that includes a conductive back electrode that contains a second buried insulating region of a second thickness located on a surface thereof and a first buried insulating region of a first thickness that is greater than the second thickness that is located abutting the region containing the conductive back electrode and the overlayer first insulating layer. In accordance with the present invention, a bipolar device can be formed atop this structure such that it is located above the second buried insulating layer.
[0020] With such a reduced buried insulating layer thickness underneath the bipolar device, a significantly reduced substrate bias (less than 3 V) compatible with the CMOS is able to create a strong enough vertical electric field to form an accumulation layer which forms the subcollector of the inventive device, while maintaining the advantages of a thick first buried insulating layer underneath the CMOS.
[0021] There are no known alternative solutions to this problem. One possible alternative is to use a patterning process to form regions of thin and thick buried insulating regions on the SOI wafer during a SIMOX (separation by implantation of oxygen) process. However, by using an oxygen implant, it is difficult to make a buried insulating region having a thickness of less than 10 nm. Moreover, it is difficult to control the thickness of the buried insulating region formed by conventional SIMOX processes. Also, this method purposed above would require costly additional lithography and implant steps to produce the SOI wafers.
[0022] In addition to the method described above, the present invention also contemplates the bipolar transistor that is formed utilizing the above method. Specifically, and in broad terms, the bipolar transistor of the present invention comprises:
[0023] a conductive back electrode for receiving a bias voltage;
[0024] a second buried insulating layer located over said conductive back electrode having a second thickness;
[0025] a first buried insulating layer located adjacent to said second buried insulating layer and said conductive back electrode, said first buried insulating layer having a first thickness that is greater than the second thickness;
[0026] a first semiconductor layer located predominately over said second buried insulating layer, said first semiconductor layer including a first conductivity type dopant, wherein said conductive back electrode is biased to form an accumulation layer in said first semiconductor layer at an interface between said first semiconductor layer and said second buried insulating layer;
[0027] a base located atop at least said first semiconductor layer, said base comprising a second semiconductor layer having a second conductivity type dopant that differs from the first conductivity type dopant; and
[0028] an emitter comprising a third semiconductor layer of the first conductivity type dopant located over a portion of said base.
[0029] In addition to SOI BJT's the present invention, in particularly the substrate including different regions of buried insulating thickness could be used as a substrate for forming a back-gated complementary metal oxide semiconductor (CMOS) device. The back-gated CMOS device could be formed alone on the substrate or it could be formed with a bipolar transistor, including the SOI HBT described above, in BiCMOS applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIGS. 1A-1B are pictorial representations (through different views) illustrating a single-finger emitter device of the present invention along two directions that are perpendicular to each other.
[0031] FIGS. 2A-2E illustrate the process flow for making the substrate that is employed in the present invention which includes a second buried insulating region that is thin and an adjoining first buried insulating region that has a thickness that is greater than the second buried insulating region. The second buried insulating region is located atop a conductive back electrode.
[0032] FIGS. 3A-3B show cross sections of an SOI wafer that underwent the process illustrated in FIGS. 2A-2E . In the drawings, the first buried insulating layer was undercut by 0.3 microns. An 8 nm thick thermal oxide, e.g., the second buried insulating layer, was then grown followed by LPCVD polysilicon fill to form the conductive back electrode.
[0033] FIG. 4 is a cross sectional view illustrating an expanded view of the structure shown in FIG. 2E .
[0034] FIGS. 5A and 5B are pictorial representations (through different views) illustrating a back-gated CMOS device of the present invention along two directions that are perpendicular to each other.
DETAILED DESCRIPTION OF THE INVENTION
[0035] The present invention, which provides a vertical SOI BJT which uses a SOI layer with a back gate-induced accumulation layer as the subcollector located on regions of a second buried insulating region having a second thickness using a standard SOI starting wafer with a first buried insulating region having a first thickness and the method thereof, will now be described in greater detail by referring to the drawings that accompany the present application. The drawings are provided for illustrative purposes and thus they are not drawn to scale. Moreover, in the drawings like and/or corresponding elements are referred to by like reference numerals.
[0036] The present invention provides a bipolar transistor structure that includes a conductive back electrode for receiving a bias voltage, a second buried insulating layer located over the conductive back electrode, and a first semiconductor layer, which comprises an SOI layer of a SOI substrate, located over the second buried insulating layer. The first semiconductor layer includes a collector region containing a first conductive type dopant. The collector region includes an intrinsic collector and an extrinsic collector. The extrinsic collector and the intrinsic collector, which are of the first conductivity type, have different dopant concentration; the extrinsic collector having a higher dopant concentration that the intrinsic collector.
[0037] In accordance with the present invention, a base comprising a second semiconductor layer containing a second conductivity type dopant is located atop the first semiconductor layer. The inventive bipolar transistor also includes an emitter comprising a third semiconductor layer containing the first conductivity type dopant located over a portion of the base, e.g., the second semiconductor layer. During operation, the conductive back electrode is biased to form an accumulation layer in the SOI layer at an interface between the SOI layer and the second buried insulating layer. The configuration of the inventive bipolar transistor structure will become more apparent by referring to FIGS. 1A-1B .
[0038] One possible device layout of the inventive bipolar transistor is shown in FIGS. 1A-1B wherein a single-finger emitter device is shown. By “finger”, it is meant that the emitter has at least one portion that extends outward from a common emitter region. Although the drawings show a one-finger emitter device, the present invention is not limited to only that device layout. Instead, the present invention contemplates device layouts that include a number of emitter-fingers. Multi-finger configurations are preferred over the singe-finger device layout since they typically reduce the emitter resistance for achieving high ƒ max , i.e., the maximum oscillation frequency at which the unilateral power gain becomes unity.
[0039] The cross sectional views of the single-finger emitter device layout is shown in FIGS. 1A and 1B . FIG. 1A is the cross sectional view along an axis B-B′, while FIG. 1C is the cross sectional view along an axis C-C′; the two axis are perpendicular to each other. Specifically, the cross sectional views shown in FIG. 1A and FIG. 1B depict a vertical bipolar transistor 10 of the present invention. The vertical bipolar transistor 10 includes a Si-containing substrate layer 14 , a first buried insulating layer 16 having a first thickness, a second buried insulating layer 22 having a second thickness that is less than the first thickness of the first buried insulating layer 16 . As shown, the first buried insulating layer 16 is located on an upper surface of the Si-containing substrate 14 and the second buried insulating layer 22 is located around the conductive back electrode 24 . The second buried insulating layer 22 thus includes an upper portion 22 u located atop the conductive back electrode 24 and a lower portion 22 l located atop the Si-containing substrate 14 . The upper portion 22 u of the second buried insulating layer 22 is the region in which the accumulation layer will form thereon.
[0040] The vertical bipolar transistor 10 shown in FIGS. 1A-1B further includes trench isolation regions 28 that are located, as shown in FIG. 1A , atop the first buried insulating layer 16 , as well as atop the conductive back electrode 24 , as shown in FIG. 1B . Hence, the trench isolation regions 28 surround the active device region of the structure. The structure also includes a first semiconductor layer 18 (hereinafter referred to as the SOI layer) which is located on the upper portion 22 u of the second buried insulating layer 22 as well as a portion of the first buried insulating layer 16 . The first semiconductor layer 18 is the original SOI layer of the initial substrate employed in the present invention.
[0041] In accordance with the present invention, the first semiconductor layer 18 is the collector region of the inventive structure that is doped with a first conductivity type dopant, either an n- or p-type dopant. The collector region includes an extrinsic collector 41 and an extrinsic collector 43 that has a greater dopant density, i.e., concentration, as compared to intrinsic collector 41 . As shown, the intrinsic collector 41 is located between two extrinsic collectors 43 .
[0042] A base (or base region) 100 is located atop the SOI layer 18 and the trench isolation region 28 . The base 100 comprises a second semiconductor layer of a second conductivity type dopant that differs in terms of its conductivity from the first conductivity type dopant. The base 100 comprises a polycrystalline portion 100 b and a single crystalline portion 100 a . As shown, the polycrystalline portion 100 b is located predominately atop isolation regions, while the single crystal portion 100 a is located atop the SOI layer 18 .
[0043] Atop of the base 100 is an emitter 52 which is comprised of a third semiconductor layer. The third semiconductor layer forming emitter 52 may be comprised of the same or different material as the base 100 or the SOI layer 18 . The emitter 52 is heavily doped with the first conductivity type dopant. First insulator 30 and second insulator 36 are located in the structure as well. The first insulator 30 is located atop the structure including the SOI layer 18 and it has an opening therein in which the intrinsic portion 100 a of the base 100 is in contact with the SOI layer 18 . The second insulator 36 is located atop portions of the base 100 and it also has an opening therein that allows the emitter 52 to be in contact with the intrinsic portion 100 a of the base 100 .
[0044] Although not shown, the exposed portions of the emitter 52 , the SOI layer 18 , the polycrystalline region 100 b and conductive back electrode 24 may include a metal silicide. The metal silicide located atop the exposed surfaces of the conductive back electrode 24 is the region in which biasing of the substrate can take place. During biasing, a portion of the SOI layer 18 that is located atop the upper portion 22 u of the second buried insulating region 22 is converted into an accumulation layer 62 . The accumulation layer 62 is a majority carrier layer that serves as the subcollector of the inventive bipolar transistor. This is unlike prior art bipolar transistor in which the subcollector is comprised of an impurity-doped region.
[0045] The process flow for making a substrate that includes the buried insulating regions of different thicknesses is illustrated in FIGS. 2A-2E . It is noted that the process shown and described in making the substrate shown is similar to the process disclosed in co-pending and co-assigned U.S. patent application Ser. No. 10/787,002, filed Feb. 25, 2004, the entire content of which is incorporated herein by reference. In the following description of the first and second buried insulating layers (or regions) 16 and 22 , respectively, are referred to as buried oxide (BOX) regions. Although BOX regions are depicted and described as oxides, the present invention works equally well when the regions 16 and 22 are other insulating materials, i.e., nitrides or oxynitrides.
[0046] FIG. 2A shows the cross-section of a typical SOI substrate 12 used for a high-performance CMOS application that can be employed in the present invention. The initial SOI substrate 12 comprises a Si-containing substrate layer 14 , a first buried insulating layer 16 of a first thickness (herein after thick BOX) 16 , and a top Si-containing layer 18 (which is, in accordance with the nomenclature of the present invention, the first semiconductor layer or the SOI layer 18 ). The term “Si-containing” is used herein to denote any semiconductor material that includes silicon therein.
[0047] Illustrative examples of such Si-containing materials include but are not limited to: Si, SiGe, SiGeC, SiC, Si/Si, Si/SiGe, preformed SOI wafers, silicon germanium-on-insulators (SGOI) and other like semiconductor materials.
[0048] The SOI layer 18 of the initial SOI substrate 12 is typically a doped layer, which may contain an n- or p-type dopant. Doping can be introduced into the SOI layer 18 prior to, or after formation of the SOI substrate 12 . The doped SOI layer 18 comprises the collector region of the inventive bipolar transistor 10 . The dopant concentration within the SOI layer 18 is typically from about 1E17 to about 1E19 atoms/cm 3 .
[0049] The Si-containing layer 18 of the SOI substrate 12 may have a variable thickness, which is dependent on the technique that is used in forming the SOI substrate 12 . Typically, however, the Si-containing layer 18 of the SOI substrate 12 has a thickness from about 10 to about 1000 nm, with a thickness from about 50 to about 500 nm being more typical. The thickness of the thick BOX 16 may also vary depending upon the technique used in fabricating the SOI substrate 12 . Typically, however, the thick BOX 16 of the present invention has a thickness from about 100 to about 1000 nm, with a BOX thickness from about 120 to about 200 nm being more typical. The thickness of the Si-containing substrate layer 14 of the SOI substrate 12 is inconsequential to the present invention.
[0050] The initial SOI substrate 12 can be formed using a layer transfer process such as, a bonding process. Alternatively, a technique referred to as separation by implanted oxygen (SIMOX) wherein ions, typically oxygen, are implanted into a bulk Si-containing substrate and then the substrate containing the implanted ions is annealed under conditions that are capable of forming a buried insulating layer, i.e., thick BOX 16 , can be employed.
[0051] Next, and as shown in FIG. 2B , at least one trench 26 that extends to the upper surface of the Si-containing substrate layer 14 is formed by lithography and etching. The lithography step includes applying a photoresist to the surface of the SOI substrate 12 , exposing the photoresist and developing the exposed photoresist using a conventional resist developer. The etching step used in forming the trench 26 includes any standard Si directional reactive ion etch process. Other dry etching processes such as plasma etching, ion beam etching and laser ablation, are also contemplated herein. The etch can be stopped on the top of the thick BOX 16 (not shown), or on the Si-containing substrate 14 underneath the thick BOX 16 , as shown in FIG. 2B . As shown, portions of the SOI layer 18 and the thick BOX 16 that are protected by the patterned photoresist are not removed during etching. After etching, the patterned photoresist is removed utilizing a conventional resist stripping process.
[0052] An isotropic oxide etch selective to silicon (such as a timed hydrofluoric acid based etch or similar etch chemistry) is then used to remove portions of the thick BOX 16 underneath the SOI layer 18 where the vertical bipolar device will be fabricated (See FIG. 2C ). The isotropic etch forms an undercut 20 beneath the SOI layer 18 that will be subsequently filled with a conductive back electrode material. The SOI layer 18 is supported by portions of the thick BOX 16 that are not removed by this etch. Before this etching step, all pad layers should be removed from atop the SOI layer otherwise bending of the SOI layer occurs.
[0053] A thermal process such as a wet and/or dry oxidation, nitridation or oxynitridation, is then used to grow the second buried insulating layer 22 , i.e., thin BOX, on the exposed surfaces of the SOI layer 18 , see FIG. 2D . Note that the second buried insulating layer (hereinafter thin BOX) 22 forms on the exposed horizontal and vertical surfaces of the SOI layer 18 as well as the exposed surface of the Si-containing substrate layer 14 . The thin BOX 22 formed on the SOI layer 18 is given the reference numeral 22 u , while the BOX formed on the Si-containing substrate layer 12 is given the reference numeral 22 l . In accordance with the present invention, the thin BOX 22 has a second thickness that is less than the first thickness of the first buried insulating layer, i.e., thick BOX 16 . Typically, the thin BOX 22 has a thickness from about 1 to about 15 nm. Deposited oxides such as a low-temperature oxide (LTO) or a high-density oxide (HTO) can also be employed. When deposited oxides are used, the oxide would also be present on the sidewalls of the opened structure as well. Note that the oxide also grows, although to a lesser extent, on oxide surfaces as well. The growth of oxide on an oxide surface is not, however, differentiated in the drawings of the present application.
[0054] At this point of the present invention, a conductive back gate electrode material (which becomes the conductive back electrode 24 ) such as, for example, doped polysilicon, a silicide or a conductive metal is deposited to fill in the area previously occupied by the removed thick BOX 16 . The deposition is performed using a conventional deposition process such a chemical vapor deposition, plasma-assisted chemical vapor deposition, chemical solution deposition, evaporation and the like. In one embodiment, doped polysilicon is used as the conductive back electrode material and it is deposited at a temperature from about 400° to about 700° C. using a low-pressure chemical vapor deposition (LPCVD) process. Doping of the polysilicon layer may occur in-situ or after deposition using an ion implantation process. The structure can then be planarized, if needed, by chemical mechanical polishing or by a dry etch of the polysilicon selective to oxide. The resultant structure that is formed after performing the above steps is shown, for example, in FIG. 2E .
[0055] FIG. 3A and FIG. 3B show an SEM cross section of an SOI wafer that underwent the process described above. The BOX was undercut by 0.3 microns. An 8 nm thick thermal oxide was then grown followed by LPCVD polysilicon fill.
[0056] FIG. 4 shows an expanded cross sectional view of the structure depicted in FIG. 2E . Region 102 denotes the active device area in which a bipolar transistor can be formed. The active area 102 includes an upper thin BOX 22 u located atop the conductive back electrode 24 . The conductive electrode 24 , in turn, is located on the lower thin BOX 22 l , which is located atop the Si-containing substrate layer 14 .
[0057] After providing the structure shown in FIG. 2E (or FIG. 4 ), a bipolar device such as shown in FIG. 1B is formed atop the structure utilizing conventional BiCMOS processing techniques that are well known to those skilled in the art. Specifically, the following process can be used in forming the bipolar transistor atop the structure shown in FIG. 2E (or FIG. 4 ).
[0058] First, trench isolation regions 28 are formed into the structure shown in FIG. 2E (or FIG. 4 ) utilizing conventional processes well known to those skilled in the art. For example, the trench isolation regions 28 can be formed by trench definition and etching, optionally lining the trench with a liner material and then filling the trench with a trench dielectric material such as, for example, tetraethylorthosilicate (TEOS) or a high-density oxide. The trench dielectric material can be densified after the filling of the trench and, if needed, a planarization process, such as chemical mechanical polishing, can be employed.
[0059] Next, the SOI layer 18 can be further doped at this point of the present invention with a first conductivity type dopant (n- or p-type) using various masked implantation schemes to provide an extrinsic collector and/or intrinsic collector within the SOI layer 18 . A first insulator 30 , such as an oxide, nitride, oxynitride or multilayers thereof, is then formed on the surface of the structure by a thermal process or by deposition, such as chemical vapor deposition. The thickness of the first insulator 30 can vary depending on the technique used in forming the same. Typically, the first insulator 30 has a thickness from about 10 to about 100 nm.
[0060] After forming the first insulator 30 on the surface of the structure shown in FIG. 2E (or FIG. 4 ), the first insulator 30 is patterned to provide an opening that exposes a surface of the SOI layer 18 . The at least one opening in the first insulator 30 is formed by lithography and etching.
[0061] Next, the base 100 is formed by utilizing a low-temperature epitaxial growth process that is typically performed at a temperature from about 450° C. to about 800° C. In accordance with the present invention, the base 100 is comprised of a second semiconductor layer that can include, for example, Si, SiGe or combinations thereof. The low-temperature epitaxial process forms a base 100 that comprises an intrinsic portion 100 a that is typically monocrystalline, and an extrinsic portion 100 b that is typically polycrystalline. The area in which the material of base 100 changes from monocrystalline to polycrystalline is referred to as a facet region.
[0062] The base 100 can be doped during the epitaxial growth process or it can be doped after utilizing ion implantation. An annealing step can be used to activate the dopants within the base layer. The base 100 is doped with a second conductivity type dopant that differs in conductivity type from that of the SOI layer 18 , which is comprised of a first semiconductor material.
[0063] The base 100 has a variable thickness in which the extrinsic portion 100 b is thickener than the intrinsic portion 100 a . On average, the base 100 typically has a thickness from about 10 to about 150 nm.
[0064] A second insulator 36 that may comprise the same or different insulator as the first insulator 30 is then formed on top of the base 100 . The second insulator 36 is formed by a conventional deposition process such as chemical vapor deposition. The thickness of the second insulator 36 may vary depending on the process used in forming the same. Typically, the second insulator 36 has a thickness from about 50 to about 150 nm.
[0065] The second insulator 36 is then patterned by lithography and etching to provide at least one opening that exposes the surface of the underlying intrinsic portion 100 a of the base 100 .
[0066] Next, the emitter 52 comprising a third semiconductor layer, such as Si, SiGe or a combination thereof, is formed on the second insulator 36 as well as the exposed surface of the intrinsic portion 100 a of the base 100 . In accordance with the present invention, the emitter 52 includes the same conductivity type dopant as the SOI layer 18 . The doping of the emitter 52 may occur in-situ or post deposition utilizing an ion implantation process. The emitter 52 formed typically has a thickness from about 50 to about 200 nm.
[0067] The emitter 52 and portions of the second insulating layer 36 are then patterned by lithography and etched providing the structure shown in FIGS. 1B and 1C . After patterning, the exposed surfaces containing Si, i.e., extrinsic base portion 100 b , conductive back electrode 24 and emitter 52 , are then subjected to a conventional silicidation process in which a silicide metal such as Ti, Ni, Co, W, Re or Pt (singularly or alloys thereof) is first deposited and then annealed to cause interaction of the metal and Si and subsequent formation of a silicide on each region including metal and Si. Alloys of the above mentioned metals are also contemplated herein. Any remaining metal, not silicided, is typically removed after the silicide process using a conventional wet etching process. It is noted that the silicides formed in the extrinsic portion 100 b of the 100 are self-aligned to the base emitter 52 . The silicidation process is not shown in the drawings the present invention.
[0068] At this point of the present invention, an optional barrier material such as a nitride can be formed atop the structure. The optional barrier material is not shown in the drawings of the present invention.
[0069] An interconnect dielectric such as, for example, boron phosphorus doped silicate glass, an oxide, an organic polymer or an inorganic polymer is then deposited using a conventional deposited process such as chemical vapor deposition, plasma-assisted chemical vapor deposition, evaporation, spin-on coating, chemical solution deposition and the like. The interconnect dielectric has a thickness after deposition that is on the order of about 500 to about 1000 nm. After deposition of the interconnect dielectric, the interconnect dielectric is planarized by chemical mechanical polishing or other like planarization process so as to have a thickness after planarization from about 300 to about 600 nm and thereafter a contact opening that extends to the surface of each silicide is formed by lithography and etching. Each of the contact openings is then filled with a metal contact such as W, Cu, Al, Pt, Au, Rh, Ru and alloys thereof. The formation of the interconnect structure is not shown in the drawings.
[0070] The structure can now be biased by applying an external voltage to the conductive back electrode 24 through the contacts produced above. The biasing causes an accumulation layer 62 to be formed in a portion of the base SOI layer 18 that is located above the thin BOX 22 u . The amount of voltage applied in forming the accumulation layer 62 is typically 5 V or less. The accumulation layer 62 serves as the subcollector of the inventive structure.
[0071] The method described above can be used to form a plurality of vertical bipolar transistors on the active area of the SOI substrate. The methods described above can also be used in conjunction with a conventional CMOS process flow which is capable of forming CMOS devices such as field effect transistors, in areas adjacent to the areas containing the vertical bipolar transistors of the present invention, to form BiCMOS for RF or mixed-signal applications. In the prior art, the CMOS devices are typically formed prior to the bipolar devices with CMOS areas usually protected during fabrication of the bipolar transistors. The drawback of this method is that the MOS device performance often becomes degraded to the excessive thermal budget that CMOS devices experience during the fabrication of the dipolar devices, such as dopant activation anneal after implants. An advantage of this invention over prior art processes is that the inventive method utilizes the typical CMOS process to form a bipolar device hence the CMOS and bipolar devices can be fabricated interactively and share the same activation anneal.
[0072] It is noted that the processing steps described above in forming the substrate shown in FIGS. 2A-2E and FIG. 4 can be used in conjunction with conventional back-gate processes to form a back-gated CMOS device. The CMOS device can be provided separately from the SOI BJT device depicted in FIG. 1A and FIG. 1B , or it can be formed together with the SOI BJT device or any other bipolar transistor in a BiCMOS application.
[0073] Specifically, FIG. 5A and FIG. 5B shows a back-gated CMOS device that can be formed on the substrate shown in FIG. 2A or FIG. 4 . The back-gated device 300 includes Si-containing substrate layer 14 , a first buried insulating layer 16 having a first thickness located atop a portion of the Si-containing substrate 14 . Other portions of the Si-containing substrate include the lower portion 22 l of the second buried insulating layer 22 having a second thickness that is less than the first thickness. A back-gate electrode 24 is located atop the lower portion 22 l of the second buried insulating layer 22 . An upper portion 22 u of the second buried insulating layer 22 is located atop the conductive back electrode 24 and portions of first buried insulating layer 16 . SOI layer 18 including source/drain diffusion regions 310 and extension regions 320 is located atop the upper portion 22 u of the second buried insulating layer. Trench isolation regions 28 which extend to the first buried insulating layer 16 are located abutting the SOI layer 18 . The front-gated device also includes, a gate dielectric 300 located atop a portion of the SOI layer 18 and a gate conductor 350 located atop the gate dielectric 350 . An optional, but preferred, reoxidation liner 340 is present on at least the sidewalls of the gate conductor 350 . Insulating spacers 330 are located in the structure as well. Gate dielectric 300 and gate conductor 350 are components of a field effect transistor.
[0074] The back-gated device 300 is fabricated by first utilizing the methodology used in forming the substrate shown in FIGS. 2E and 4 , and then by utilizing conventional CMOS processes steps that are well known in the art. The gate dielectric 300 , the gate conductor 350 and the insulating spacers 330 are composed of conventional materials well known to those skilled in the art. For example, the gate dielectric 300 can be an oxide, nitride, oxynitride, a dielectric material having a dielectric constant greater than 4.0, preferably greater than 7.0, or a stack thereof; the gate conductor 350 can be composed of polySi, polySiGe, a metal, a metal silicide, a metal nitride or any combination, including multilayers thereof; and the insulating spacers 330 are composed of an oxide, nitride, oxynitride or combinations, including multilayers thereof.
[0075] While the present invention has been particularly shown and described with respect to preferred embodiments, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present invention. It is therefore intended that the present invention not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims. | The present invention provides a “subcollector-less” silicon-on-insulator (SOI) bipolar junction transistor (BJT) that has no impurity-doped subcollector. Instead, the inventive vertical SOI BJT uses a back gate-induced, majority carrier accumulation layer as the subcollector when it operates. The SOI substrate is biased such that the accumulation layer is formed at the bottom of the first semiconductor layer. The advantage of such a device is its CMOS-like process. Therefore, the integration scheme can be simplified and the manufacturing cost can be significantly reduced. The present invention also provides a method of fabricating BJTs on selected areas of a very thin BOX using a conventional SOI starting wafer with a thick BOX. The reduced BOX thickness underneath the bipolar devices allows for a significantly reduced substrate bias compatible with the CMOS to be applied while maintaining the advantages of a thick BOX underneath the CMOS. A back-gated CMOS device is also provided. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a 35 USC 371 application of PCT/DE 03/01679 filed on May 23, 2003.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to an improved fuel injection valve for internal combustion engines.
2. Description of the Prior Art
A fuel injection valve of the type with which this invention is concerned is described, for example, in the patent application DE 100 31 265 A1 and has a valve body that contains a bore delimited its end oriented toward the combustion chamber by a valve seat that has at least one injection opening leading from it, which feeds into the combustion chamber of the engine in the installed position of the fuel injection valve. The bore contains a piston-shaped valve needle in a longitudinally sliding fashion, which has a valve sealing surface at its combustion chamber end, i.e. the end oriented toward the valve seat, and this valve sealing surface of the valve needle cooperates with the valve seat. In the closed position of the valve needle, i.e. when the valve needle is resting with its valve sealing surface against the valve seat, the injection openings are closed, whereas when the valve needle is lifted away from the valve seat, fuel flows between the valve sealing surface and the valve seat, through the injection openings, and from there, is injected into the combustion chamber of the engine.
The longitudinal movement of the valve needle in the bore is the result of the ratio between two forces: on the one hand, a hydraulic force that is generated by the pressure in the fuel-filled pressure chamber formed between the wall of the bore and the valve needle so that a hydraulic force is exerted on the valve needle. On the other hand, a suitable device that acts on the end of the valve needle oriented away from the combustion chamber exerts a closing force on the valve needle. The hydraulic force on the valve needle depends on the effective area that is acted on by the fuel, which yields a force component in the longitudinal direction. The opening pressure of the fuel injection valve, i.e. the fuel pressure in the pressure chamber at which the hydraulic force on the valve needle is sufficient to move it in the longitudinal direction away from the valve seat counter to an opposing closing force therefore depends, among other things, on the contact line between the valve needle and the valve seat, i.e. the so-called hydraulically effective seat diameter, because this affects the partial area of the valve sealing surface that is subjected to the fuel pressure. Wear between the valve sealing surface and the valve seat over the life of the fuel injection valve causes a change in this area, thus altering the hydraulically effective seat diameter. This also changes the opening pressure, which results in a changed opening dynamic of the valve needle. This also changes the injection time and injection quantity of fuel, which can lead to problems in modern, high-speed internal combustion engines, particularly with regard to fuel consumption and emissions.
SUMMARY AND ADVANTAGES OF THE INVENTION
The fuel injection valve according to the invention, has the advantage over the prior art that without changing the geometry of the valve needle, a constant opening pressure can be maintained over the entire service life of the fuel injection valve. To this end, the valve seat has two conical partial surfaces, the second conical partial surface downstream of the first conical partial surface. The second conical partial surface is raised in relation to the first conical partial surface so that in the closed position, the valve needle comes into contact with the second conical partial surface and the edge at the transition between the first conical partial surface and the second conical partial surface defines the hydraulically effective seat diameter.
Advantageous modifications of the subject of the invention are disclosed.
In a first advantageous embodiment of the subject of the invention, the second conical partial surface has the same cone angle as the first conical partial surface. As a result, the two conical partial surfaces can be produced with the same tool, which eliminates the need to readjust the milling or grinding tool during manufacture.
In another advantageous embodiment, the second conical partial surface is raised in relation to the first conical partial surface, preferably by 2 mm to 20 mm. Providing a step of this kind assures a constant opening pressure without changing the stability ratios in the valve body in the region of the valve seat.
In another advantageous embodiment, a third conical partial surface is embodied on the valve seat downstream of the second conical partial surface and is recessed in relation to the second conical partial surface. As a result, the valve seat surface against which the valve needle can rest is also delimited by a step on the downstream side. This results in precisely defined hydraulic ratios at the contact area between the valve needle and the valve seat.
The embodiments of the valve seat according to the invention are particularly advantageous if the valve needle has a sealing edge that is embodied between two conical sealing surfaces and rests against the second conical partial surface when the valve needle is in the closed position. This assures the constant opening pressure, even over very long periods of operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the invention will become apparent from the detailed description contained herein below, taken in conjunction with the drawings, in which:
FIG. 1 shows a longitudinal section through a fuel injection valve,
FIG. 2 shows an enlargement of the detail labeled II from FIG. 1 , in the region of the valve seat,
FIG. 3 shows an enlargement of the detail labeled III from FIG. 2 , and
FIG. 4 shows the same detail as FIG. 2 , but in this instance, the fuel injection valve is embodied as a so-called blind hole nozzle in the region of the valve seat.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a longitudinal section through a fuel injection valve according to the invention. A valve body 1 has a bore 3 in which a piston-shaped valve needle 5 is guided in a longitudinally sliding fashion. The valve needle 5 is guided here in a sealed fashion with a guide section 15 oriented away from the combustion chamber in a guide section 23 of the bore 3 . Starting from the guide section 15 , the valve needle 5 tapers toward the combustion chamber, forming a pressure shoulder 13 and, at its combustion chamber end, transitions into an essentially conical valve sealing surface 7 . Between the valve needle 5 and the wall of the bore 3 , a pressure chamber 19 is formed, which widens out radially at the level of the pressure shoulder 13 . This radial expansion of the pressure chamber 19 is fed by a supply bore 25 that extends in the valve body 1 and can supply highly pressurized fuel to the pressure chamber 19 . At its end oriented toward the combustion chamber, the bore 3 is delimited by a valve seat 9 that has at least one injection opening 11 extending from it, which feeds into the combustion chamber of an engine in the installed position of the fuel injection valve.
FIG. 2 shows an enlargement of the detail labeled II from FIG. 1 . The valve sealing surface 7 of the valve needle 5 is divided into a first conical sealing surface 107 and a second conical sealing surface 207 , with a sealing edge 17 formed at the transition between them due to the differing cone angles of the two conical sealing surfaces 107 , 207 . The valve seat 9 is essentially conically embodied and has three conical partial surfaces: the first conical partial surface 109 is adjoined by the second conical partial surface 209 , which is in turn adjoined by the third conical partial surface 309 . The second conical partial surface 209 is raised in relation to the first conical partial surface 109 and is positioned in relation to the valve needle 5 so that in the closed position of the valve needle 5 , when the needle is resting against the valve seat 9 , the sealing edge 17 rests against the second conical partial surface 209 .
FIG. 3 shows an enlargement of the detail labeled III from FIG. 2 , i.e. an even larger depiction of the crucial part of the valve seat 9 . Between the first conical partial surface 109 and the second conical partial surface 209 , a first annular step 21 is formed, which delimits the hydraulically effective seat diameter. This plays a decisive role for the opening behavior of the fuel injection valve; the longitudinal movement of the valve needle 5 in the bore 3 is determined by the ratio of two forces: on the one hand, a closing force that a suitable device, not shown in the drawing, exerts on the end of the valve needle oriented away from the combustion chamber. On the other hand, the valve needle 5 is subjected to a hydraulic opening force that is oriented counter to the closing force and is exerted on the valve needle 5 by the fuel pressure in the pressure chamber 19 . The areas of the valve needle 5 , which, when subjected to pressure, produce a resulting force component in the longitudinal direction, are primarily the pressure shoulder 13 and parts of the valve sealing surface 7 . If the closing force is constant, then it defines the opening pressure, i.e. the fuel pressure in the fuel chamber 19 at which the valve needle 5 begins its opening stroke motion.
With ideally fixed ratios, i.e. if neither the valve needle 5 nor the valve seat 9 were to be deformed, then the sealing edge 17 of the valve needle 5 would define the hydraulically effective seat diameter. The total area of the valve seat surface 7 upstream of the sealing edge 17 , i.e. the first conical sealing surface 107 in this exemplary embodiment, would be acted on by the fuel pressure, thus determining the hydraulic opening pressure. But because the valve needle 5 hammers into the valve needle 9 , over time, a flat contact develops between the valve sealing surface 7 and the valve seat 9 , thus also changing the hydraulically effective seat diameter in a way that reduces the area subjected to pressure, which causes the opening pressure to increase. But the design of the raised second conical partial surface 209 on the valve seat 9 limits the increase of this hydraulic seat diameter to the first annular step 21 so that the opening pressure remains unchanged even over extended operation of the fuel injection valve. The second annular step 22 embodied between the second conical partial surface 209 and the third conical partial surface 309 delimits the area against which the valve needle 5 rests at the end oriented toward the injection openings so that precisely defined hydraulic ratios prevail at the valve seat. Adhesive forces possibly occurring between the valve needle and valve seat thus remain constant.
FIG. 4 shows the same detail as FIG. 2 of a different fuel injection valve, which has a slightly altered seat geometry. As in the exemplary embodiment shown in FIG. 2 and FIG. 3 , the third conical partial surface 309 is recessed in relation to the second conical partial surface 209 , thus forming a second annular step 22 . The third conical partial surface 309 transitions into a blind hole 30 from which the injection openings 11 lead. The valve needle 5 has a slightly altered valve sealing surface 7 ; it does once again have a first conical sealing surface 107 and a second conical sealing surface 207 , but an annular groove 27 is provided between these two conical sealing surfaces 107 , 207 . The sealing edge 17 that comes into contact with the second conical partial surface 209 in the closed position of the valve needle 5 is formed at the transition between the annular groove 27 and the first conical sealing surface 107 . The recessed third conical partial surface 309 achieves two things: on the one hand, it geometrically limits the effective seat area to the second conical partial surface 209 , which makes it possible to precisely define and calculate the hydraulic ratios in the gap between the valve seat 9 and the valve sealing surface 7 , particularly at the very beginning of the opening stroke motion. On the other hand, the recessed third conical partial surface 309 reduces the throttling action for the fuel flowing into the blind hole 30 that would otherwise be intensely throttled at the transition between the third conical partial surface 309 and the blind hole 30 , which would reduce the injection pressure at the injection openings 11 .
The height d of the annular step 21 , as shown in FIG. 3 , is preferably from 2 mm to 20 mm, which assures that on the one hand, the hydraulically effective seat diameter is precisely determined and on the other hand, the stability ratios in the region of the valve seat 9 of the valve body 1 remain unchanged. The width a of the second conical partial surface, as shown in FIG. 2 , is preferably 0.2 mm to 0.5 mm.
There is considerable design latitude in the embodiment of the cone angles of the conical partial surfaces 109 , 209 , 309 of the valve seat 9 . On the one hand, it is possible for all of the conical partial surfaces 109 , 209 , 309 to have an identical cone angle. However, it is also possible for them to have slightly different cone angles in order to optimize the influx properties of the fuel in the gap between the valve seat 9 and the valve sealing surface 7 , particularly in order to optimally embody the inlet conditions of the fuel into the blind hole 30 , as is the case in a fuel injection valve of the type shown in FIG. 4 .
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A fuel injection valve with a valve body that contains a bore delimited at its end oriented toward the combustion chamber by a valve seat and whose end region oriented toward the combustion chamber has at least one injection opening. A piston-shaped valve needle is contained in the bore in a longitudinally sliding fashion and has an essentially conical valve sealing surface by means of which the valve needle cooperates with the valve seat in order to control the at least one injection opening. The valve seat has a first conical partial surface and a second conical partial surface wherein the second conical partial surface is disposed downstream of the first conical partial surface and is raised in relation to it. | 5 |
This application claims the benefit of U.S. Provisinal Application No. 60/103,409, filed Oct. 17, 1998.
FIELD OF THE INVENTION
The present invention relates to the art of catalytic alkylation. More specifically, the invention relates to a method for adding fresh or inventoried liquid alkylation catalyst, to an alkylation unit.
BACKGROUND OF THE INVENTION
Alkylation is a reaction in which an alkyl group is added to an organic molecule. For example, an isoparaffin can be reacted with an olefin to provide an isoparaffin of higher molecular weight. In petroleum refining, the process reacts a C 2 to C 5 olefin with isobutane in the presence of an acidic catalyst to produce an upgraded product stream referred to as alkylate. This alkylate is a valuable blending component in the manufacture of gasoline due not only to its high octane rating but because it is free of aromatic components.
Industrial alkylation processes have historically used concentrated hydrofluoric or sulfuric acid catalysts under relatively low temperature conditions. Acid strength is preferably maintained at 88 to 94 weight percent by the continuous addition of fresh acid and the continuous withdrawal of spent acid. As used herein, the term “concentrated hydrofluoric acid” refers to an essentially anhydrous liquid containing at least about 85 weight percent HF.
Hydrofluoric and sulfuric acid alkylation processes share inherent drawbacks including environmental and safety concerns, acid consumption, and sludge disposal. For a general discussion of sulfuric acid alkylation, see the series of three articles by L. F. Albright et al., “Alkylation of Isobutane with C 4 Olefins”, 27 Ind. Eng. Chem. Res ., 381-397, (1988). For a survey of hydrofluoric acid catalyzed alkylation, see 1 Handbook of petroleum Refining Processes 23-28 (R. A. Meyers, ed., 1986).
Hydrogen fluoride, or hydrofluoric acid (HF) is highly toxic and corrosive. However, it is used as a catalyst in isomerization, condensation, polymerization and hydrolysis reactions. The petroleum industry uses anhydrous hydrogen fluoride primarily as a liquid catalyst for alkylation of olefinic hydrocarbons to produce alkylate for increasing the octane number of gasoline. Years of experience in its manufacture and use have shown that HF can be handled safely, provided the hazards are recognized and precautions taken. Though many safety precautions are taken to prevent leaks, massive or catastrophic leaks are feared primarily because the anhydrous acid will fume on escape creating a vapor cloud that can be spread for some distance. Previous workers in this field approached this problem from the standpoint of containing or neutralizing the HF cloud after its release.
U.S. Pat. Nos. 4,938,935 and 4,985,220 to Audeh and Greco, as well as U.S. Pat. No. 4,938,936 to Yan teach various methods for containing and/or neutralizing HF acid clouds following accidental releases.
In addition to these efforts directed at making the HF acid circulating in a plant safer by reducing its cloud forming tendencies, there is concern about making every part of the process safer. One significant hazard, which has previously been overlooked by others, is adding fresh HF acid to the plant. A similar problem is re-inventory, that is, the return of the HF acid inventory to the plant after a plant shutdown to permit repair or inspection of equipment.
Now this is done by rotating equipment, typically pumps with seals. Such equipment can and does leak or fail. Standard practice is to use tandem seals which should prevent a catastrophic leak, however failures do happen and leaks can occur.
Usually the fresh acid, added to replenish acid consumed or lost during processing, is relatively pure acid. Fresh acid does not contain sulfolane or other agents which are present in the HF acid circulating in acid inventory of the plant, so it represents a potential threat to the environment even when sulfolane or the like is present in the acid inventory.
Some efforts have been made to reduce the amount of rotating pumps used in HF alkylation units, which are reviewed briefly hereafter.
TRANSFER OF HF ACID WITHIN AN ALKYLATION PLANT
U.S. Pat. No. 5,334,788, Baucom et al, taught fluorine gas reactions in an eductor.
U.S. Pat. No. 5,322,673, a Division of U.S. Pat. No. 5,220,094 taught use of an alkylation recontactor with an internal mixer. FIG. 2 showed an eductor moving acid inventory and mixing it with hydrocarbon.
U.S. Pat. No. 5,304,522, Jalkian et al, taught use of an eductor to process a slurry of solid sorbent with an alkylate rich stream and a sulfolane-enriched stream, which had previously been stripped of most HF acid in an HF stripper. The sulfolane was added as a vapor suppressant, but the process is still basically an HF alkylation unit with an acid inventory less likely to form a large vapor cloud if accidentally released.
U.S. Pat. No. 5,185,487, Love et al, taught use of an eductor to mix organic fluoride-containing alkylate with HF acid to release the HF and make more alkylate.
U.S. Pat. No. 4,349,931, Mikulicz, taught use of eduction to move an HF containing stream from a reactor to a stripping column. The hydrocarbon stream used as a “pumping means, comprises about 92 mole % isobutane, 2 mole % propane and 6 mole % n-butane.”
U.S. Pat. No. 4,199,409, Skraba, taught use of an eductor to recycle an HF rich acid soluble oil (ASO) from the bottoms to various intermediate levels of an HF acid rerun column. The motive fluid was isobutane vapor.
U.S. Pat. No. 4,046,516 Burton et al, taught use of an eductor to transfer catalyst from one reaction zone in the HF alkylation unit to another.
U.S. Pat. No. 4,014,953, Brown taught use of an eductor in the base of the acid regenerator associated with an HF alkylation unit. Isoparaffin was the drive fluid, and stripping fluid, for a liquid ASO stream containing HF.
U.S. Pat. No. 3,910,771, Chapman, taught use of something similar to an eductor in a vessel designed to convert alkyl fluorides in HF alkylate into alkylate.
U.S. Pat. No. 2,894,999, Lawson, taught use of an eductor in an HF alkylation plant, using relatively hot, high pressure vapor from the deisobutanzier to educt vapor from, and provide evaporative cooling of, an HF alkylation reactor.
These patents were directed to “internal” eductors, that is, eductors moving an HF containing liquid from one place in the relatively high pressure HF alkylation plant to another place within the plant. The relatively modest pressure differentials, and the fact that the liquid streams being educted were under relatively high pressure made eductors safe and easy to use.
FRESH ACID TRANSFER
Despite the widespread use of eductors for internal liquid transfer in HF units, they have never been used, so far as is known, to add either fresh or inventoried HF acid back into the unit. Acid eggs have probably been used. One approach, reviewed below, avoided mechanical equipment, but called for a sophisticated device with a significant number of extra valves and pressure gages, all potential “weak spots” in an HF alkylation plant.
U.S. Pat. No. 4,982,036, Hachmuth et al, taught use of compressed gas to transfer acid catalyst from a transport vehicle to the alkylation process. The approach is similar to use of an “acid egg”, wherein acid is added to a vessel, following which the vessel is pressurized with a gas to provide the “head” needed to transfer the acid to the desired location. While a useful approach, it involves some capital expense for vessels and creates volumes of inert gas—the drive fluid used to energize the “acid egg”—which must eventually be processed.
Thus while many improvements have been made in the HF alkylation process, such as the above mentioned attempts to reduce the use of mechanical pumps in the process, there were still some problems.
One problem area was getting fresh acid into the plant to periodically make up for acid losses. Now mechanical pumps are used to do this and these can leak or fail. Use of a pump with shut off valves at a remote tank leaves a significant amount of concentrated HF acid in the pump and the transfer line to the plant. While concentrated HF acid is not especially corrosive, there are concerns about having any inventory of this material around to leak out if a flange gasket leaks or valve stem packing fails. To overcome this problem, refiners provide flush lines to permit displacement of HF acid into the plant. This safely removes the acid in the pump and transfer line, but introduces additional valves and lines.
The problems are exacerbated because fresh acid is typically added only once a week or once a month, as determined by the needs of the plant for fresh acid addition to maintain acid strength. Pumps which are used continuously are more reliable than those which run for only a few hours once a week or once a month. The seals are especially troublesome, and such pumps typically use dual seals, and flush the seals with isobutane so that the pumps “see” as little HF as possible, but even with these precautions, seals fail. The use of isobutane flush liquid at least makes it relatively easy to spot a failed seal in that isobutane vaporizes and the cooling due to “autorefrigeration” causes condensation/frost buildup on the pump.
Another problem with conventional approaches to acid replenishmnent is that the plant is frequently “shocked” by the addition of large amounts of fresh acid. The sudden increase in acid concentration in the mixer settler causes an alkylate production spike which causes a minor unit upset until the fresh acid is diluted and the alkylate production returns to normal. While this could theoretically be avoided by adding the makeup acid at a lower rate, or at more frequent intervals, in practice plant operators want to add acid quickly and be done with it. Additional upset occurs because 2,000 to 5,000 gallons of fresh, liquid HF acid is added to the plant. This liquid volume physically displaces hydrocarbon rich liquid from the settler, leading to a sudden apparent increase in alkylate production.
More frequent addition, e.g., daily or hourly addition is not advisable for safety reasons. It is best not to operate acid addition pumps any more often than is necessary so turning pumps repeatedly on and off is not recommended. Slower addition is not an option in many plants as the pumps are sized relatively large to handle multiple jobs. An additional concern is that centrifugal pumps rely on fluid flow for cooling of the pump. The pump, and or the driver, can be damaged if the pump is started with the discharge line fully closed or even partially open without adequate fluid flow.
Use of an “acid egg” to transfer fresh acid is theoretically possible, but requires significant capital expense to provide the “egg” to hold the acid and a relatively complicated and expensive manifold system to provide pressurizing gas. Great care must be taken to isolate the “egg” from the fresh HF acid storage tank, lest the storage tank be overpressured causing tank failure or large discharge of vapor through the tank's relief valve or rupture disk. Relatively high pressures would be required, typically around 300 psig, to move relatively large amounts of fresh HF acid through a system of transfer lines into an HF alkylation unit operating at relatively high pressures, typically 200-300 psig. Additional precautions would need to be taken to prevent, or deal with, possible discharge of large amounts of pressuring gas into the HF alkylation unit.
Thus while the “acid egg” approach would permit acid addition without a mechanical pump, the cost of multiple valves and an extra high pressure rated vessel costs, by my estimate, about two to four times the cost of a mechanical pump. I was also concerned about all the additional possible acid leak points, maintenance of such a system and possibly lower reliability.
A related but less severe problem is restarting after a shutdown. During a complete shutdown, to permit an inspection or work on the unit, the entire acid inventory of the plant is removed and sent to a secure HF acid inventory storage drum. During startup, the procedure is reversed. This involves transfer of the acid inventory from the HF acid inventory storage drum back into the HF alkylation unit. Such a transfer usually occurs only after a unit shutdown when there is less concern about upsetting the unit.
The difficulty of restoring the acid inventory is similar to that of adding fresh HF acid to the operating plant. The plant during startup runs at essentially the same pressure in the reactor section as during normal operation and the pressure in the acid inventory tank is essentially the same as the pressure in the fresh HF acid storage tank.
The amount of HF acid in inventory may be similar to or much larger than the amount of fresh HF acid added to replenish losses, but inventory replacement is infrequent while acid replenishment occurs frequently.
Some plants use the same vessel for acid inventory and HF addition, some use separate vessels. Most HF units use one relatively large, dedicated, infrequently used pump to restore acid inventory after a shutdown and a separate, dedicated, smaller and more frequently used pump to add fresh acid.
A high capacity pump is used to restore inventory because rapid addition of acid inventory, after a plant shutdown, minimizes downtime. The plant is not going to be “upset” by rapid restoration of acid after a shutdown, so operators do not need to be slow in restoring acid inventory. Slow addition of fresh, or makeup, acid, is desired to minimize plant upsets dues to changes in catalytic production of alkylate or physical displacement of alkylate, so a smaller pump is used for fresh acid addition than is used to restore plant inventory after a shutdown.
I wanted to eliminate as much rotating mechanical equipment as possible from the HF alkylation unit, to reduce possible harm to the environment and to eliminate the cost of maintaining this mechanical equipment. I also wanted to reduce the amount of HF acid that was in relatively exposed and vulnerable process lines, which can be broken if equipment is dropped on them, or vehicles driven into them.
I also wanted to reduce or eliminate the unit upsets which now occur when a large slug of fresh HF acid is added to the unit to make up acid consumed in the process. I wanted to be able to reinventory the plant, after a shutdown.
I found that eductors, and special operating procedures, could be used to eliminate much mechanical equipment in an HF alkylation unit and eliminate unit upsets when fresh acid is added.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the present invention provides a HF alkylation process comprising mixing liquid HF acid, a fresh isobutane feed stream, a recycle isobutane stream and a fresh olefin feed stream to form a liquid mixture; alkylating said olefins in said mixture with isobutane in an HF alkylation reactor operating at HF alkylation conditions including a pressure sufficiently high to maintain said isobutane in the liquid phase in at least a portion of said reactor, to form a liquid mixture comprising isoparafinnic alkylate produced in the course of said alkylation reaction, alkyl fluorides, and HF contaminated with a minor amount of acid soluble oil (ASO) produced during said alkylation reaction; separating said mixture into an alkylate product rich phase, a recycle HF acid phase, and an isobutane recycle phase; regenerating, at least periodically, a portion of said liquid HF acid in an acid regenerator to remove ASO therefrom and produce an ASO stream containing a minor portion of acid or alkyl fluorides and a regenerated HF acid stream which is recycled to said alkylation reactor; consuming, at least a portion of said liquid HF acid by at least one of mechanical loss, formation of alkyl fluorides which remain in a liquid alkylate product phase, or losses associated with a regeneration step; storing fresh HF acid in an HF acid storage vessel at liquid HF storage conditions sufficient to maintain said acid in a liquid phase and at a superatmospheric pressure which is below the pressure of said alkylation reactor; educting, at least periodically, liquid HF acid from said storage vessel to said HF alkylation process by educting liquid HF acid from said storage vessel using an eductor and as a motive fluid a liquid phase hydrocarbon feed or product stream associated with said alkylation process.
In another embodiment, the present invention provides a method of periodically adding fresh or makeup HF acid to an HF alkylation process operating at a pressure above 200 psig from a liquid HF acid storage tank operating at a pressure below 200 psig and wherein said pressure differential between said process and said storage tank is sufficient to preclude use of a recycle isobutane stream produced in said alkylation process to educt liquid HF from said storage tank into said alkylation process comprising temporarily increasing the pressure in said liquid HF storage tank above said normal storage tank operating pressure; diverting a portion of a recycle isobutane stream from said plant to use as a motive fluid in an eductor fluidly connected with said liquid HF storage tank; said alkylation reaction; discharging from said eductor a stream comprising isobutane motive fluid and educted liquid HF acid into a portion of said HF alkylation process.
In yet another embodiment the present invention provides a method of restoring an inventory of HF acid to an HF alkylation process after a shutdown of the HF alkylation plant to permit using said inventory of HF acid to alkylate a fresh olefin stream with a stream comprising recycle isobutane produced in one or more fractionators to produce alkylate comprising: restoring isobutane recycle by adding isobutane and a startup alkylate stream to said alkylation unit and fractionating same in said one or more fractionators to produce an isobutane recycle stream and a startup alkylate stream with a reduced isobutane content to establish temperatures and operating conditions in said one or more fractionators and startup pressures in said process; educting a stored HF inventory from an HF inventory storage tank operating at HF storage conditions including a pressure less than said startup pressure in said process into said HF alkylation plant using a recycle isobutane stream produced by said one or more fractionators to produce an HF alkylation plant with isobutane recycle established and an inventory of HF acid in the plant.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified schematic diagram illustrating the major processing steps of one embodiment of the present invention, using dual eductors and separate storage drums for fresh and inventory acid.
FIG. 2 is a simplified process flow of an embodiment using a single eductor and single storage drum for both fresh and inventory acid.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The HF alkylation process is conventional, well known and widely used. Detailed discussion thereof, beyond that of the prior art patents previously reviewed, which are incorporated by reference, is not necessary.
FIG. 1 is a simplified, schematic flow diagram of a conventional HF alkylation unit, with many pumps, instrumentation and like equipment omitted for the sake of clarity. Light olefins in line 7 are mixed with an isobutane rich stream in line 9 and charged via line 24 to alkylation reactor 25 . A liquid, HF rich acid phase is charged to the reactor via line 29 .
An emulsion of HF acid, alkylate, and unreacted reactants is discharged from the reactor via line 26 and charged to settler 27 . A liquid hydrocarbon phase containing the alkylate and light hydrocarbons is removed from an upper portion of the settler via line 28 for further processing in means not shown. Such processing recovers a high octane alkylate product fraction, which is a gasoline blending stock, and a recycle isobutane fraction which is returned to the process via line 8 .
An acid phase is withdrawn from the settler via line 29 and recycled to the reactor via catalyst circulating pump 30 and line 29 .
Acid is lost or consumed during the alkylation process and/or during the acid regeneration process (not shown) wherein acid soluble oil (ASO) is removed from the recirculating HF acid to maintain the purity thereof. To maintain an appropriate acid inventory and acid strength, at least periodically, and typically once every week or every other week, fresh HF acid is added to the unit from HF acid storage drum 10 . Acid is stored in this vessel under a fuel gas blanketing system 60 , with any gas vented via pressure controller 65 and line 66 to an acid flare. Drum 67 also includes a level indicating system 67 , which shows the level of HF acid in the drum. It is not possible to use a conventional sight glass to determine the acid level because the HF acid would attack the glass.
In the process of the present invention, fresh HF acid is withdrawn from drum 67 via line 11 , block valve 12 and check valve 13 and charged to eductor 40 . The driving fluid for the eductor is preferably recycle isobutane which passes via lines 8 and 4 through flow indicator/controller 70 and shut off valve 41 to eductor 40 . Relatively high pressure isobutane educts HF acid from the storage drum 10 into the acid settler via lines 44 and 26 .
In the embodiment shown, it is also possible to re-inventory the plant after a shutdown. The acid inventory tank 20 , which is much larger than drum 10 , contains not fresh HF acid, but rather the slightly diluted HF acid inventory of the plant, diluted with acid soluble oil (ASO) and minor amounts of dissolved and/or entrained isobutane and alkylate, and a very small amount of water. The contents of this vessel is the suction fluid to eductor 50 . Thus the acid inventory is educted back into the plant by passing via line 21 and valve 22 into eductor 50 , which will usually be much larger than eductor 40 . The motive fluid is preferably recycle isobutane, charged via lines 8 and 4 and valve 51 into eductor 50 , with the educted fluid being discharged via lines 54 and 44 into line 26 to enter the settler 27 .
FIG. 2 shows a highly simplified process flow of the process. Acid (both fresh and, when needed, acid inventory) is stored in tank 110 and transferred via eductor 140 into settler 127 or other process vessel within the plant. Acid from tankage flows via line 202 to meet recycle isobutane in line 201 , with the eductor effluent transferred via line 203 to vessel 127 .
The operating conditions are changed somewhat depending on whether weekly fresh acid addition to maintain acid strength is practiced, flow condition 1 , or if the plant is being rapidly re-inventoried after a shutdown, flow condition 2 .
Fluid flows and fluid pressures during flow condition 1 can be summarized as follows: pressure at the base of vessel 110 will typically be 83 psig, with flowthrough line 202 being 25 gpm. Flowthrough line 201 will be 228 gpm and the pressure will be 315-319 psig. Pressure downstream of eductor 140 in line 203 will be 213 psig, with a flow of 253 gpm.
During flow condition 2 vessel 110 will have a bottom pressure of about 125 psig and flowthrough line 202 will be 150 gpm. Flowthrough line 201 will be 600 gpm and pressure just upstream of the eductor 140 will be 310 psig. Flowthrough line 203 will be 750 gpm, and pressure will be 230 psig.
The design shown permits the same lines to be used to supply motive fluid, cooled recycle isobutane in this instance, to both the fresh acid eductor and the acid inventory eductor.
The use of two eductors, or different sizes/capacities, and with each closely associated with the appropriate storage tank, makes it harder for an operator to inadvertently upset the unit by adding acid too quickly.
One benefit of using a modestly sized eductor to add fresh acid is the avoidance of minor plant upsets which will occur whenever a large volume of fresh acid is transferred into the mixer settler. A large amount of fresh acid increases acid purity/or physically displaced alkylate to produce an alkylate production spike. This caused a minor unit upset until the fresh acid was mixed in with the inventory and alkylate production returned to normal. Adding the fresh acid slowly significantly reduces this problem.
THE EDUCTION STEP
The eduction step involves an eductor, a motive fluid and a moved fluid (either fresh HF or the acid inventory of the plant. The theory, metallurgy, motive fluid and fluid moved, are reviewed at greater length below.
The design and use of eductors is well known. These are widely used in refineries in vacuum services and internally in HF alkylation units. The eductor uses a venturi principle. A high pressure motive fluid passes at relatively high velocity through the throat or narrow portion of a venturi to create a vacuum which draws a second fluid, called suction fluid, into the stream. The two fluids mix and are discharged from the eductor. The design of the venturi can be conventional and forms no part of the present invention.
The liquid/liquid eductor may be of any suitable configuration, and liquid/liquid eductors fabricated from nickel/copper alloys such as Monel brand alloys are preferred. For a discussion of liquid/liquid eductors, see generally R. H. Perry et al., 6 Chemical Engineers' Handbook 15 (5th ed., 1973). Eductors are generally taught in U.S. Pat. Nos. 4,815,942 to Alperin et al, 4,898,517 to Eriksen, and 4,960,364 to Tell, which patents are incorporated herein by reference.
In some applications the high strength HF acid can safely be handled by carbon steel. The composition or metallurgy of the eductor, per se, can be conventional and forms no part of the present invention. I prefer to use HASTELLOY“C” which provides both corrosion resistance to HF acid in all concentrations and has excellent surface hardness to withstand the highly erosive eductor environment.
For fresh HF acid addition, or to return the acid inventory to the plant after a shutdown, a motive fluid is essential. The motive fluid is preferably one which is compatible with the HF alkylation process, such as alkylate or isobutane. I prefer to use either recycle isobutane.
At first thought, it might seem obvious and easy to use isobutane, especially in view of its extensive use as a motive fluid for internal recycle within an HF alkylation plant. Isobutane is a well behaved liquid within the high pressure confines of the HF alkylation unit, which typically operates well above the vapor pressure of isobutane. On closer examination, refiners will learn isobutane is not suitable. Isobutane is a terrible motive fluid for moving a relatively low pressure material (HF acid in a storage tank) to a relative high pressure service (the high pressure environment within the HF alkylation plant).
When isobutane, or other high vapor pressure liquid material, is used, the liquid wants to assert its vapor pressure and will “vapor lock” the venturi. This vapor lock problem is not a problem within a conventional HF alkylation unit which operates at pressures of 200-300 psig, sufficiently high to keep isobutane in a liquid form.
Thus it is not possible to use isobutane as a motive fluid for HF acid when the HF acid is stored under conventional HF acid storage conditions and the HF has to be transferred into a plant operating at several 100 psi pressure. This is because the HF acid, for safety, is stored under relatively low pressure, usually 50 psig or less. Such pressures are enough to maintain the HF acid primarily in the liquid phase, but not sufficient to prevent vaporization of isobutane in the venturi where a small fraction of the liquid isobutane will vaporize, causing the venturi to “lose suction” and not be able to draw any HF acid into the venturi.
I devised a way, and specialized operating procedure, to permit use of isobutane, which was both safe and did not unduly increase production of HF contaminated tank vent gas. Modestly increasing pressure in the acid storage drum over the pressure level normally used for acid storage, preferably while temporarily resetting the vent pressure control system, was the key. Thus for a typical acid storage vessel operating at a pressure ranging from super-atmospheric to 50 psig, and typically from 20-40 psig, the pressure might be increased 10-50 psi, and/or the eductor located at an elevation sufficiently below that of the storage tank so that isobutane motive fluid will remain essentially liquid rather than vaporize.
Permanently, or temporarily, resetting the vent pressure control on the acid storage drum to some arbitrary pressure above the desired operating pressure of the tank, but well below the design pressure limit of the vessel, minimizes venting off the acid storage drum to the acid flare. This maximizes the amount of HF acid which is added to the plant and minimizes acid discharge to, and the impact on, the relief gas scrubbing system.
CONTROL OF ISORECYCLE
Use of relatively large amounts of isobutane as the motive fluid can present problems and opportunities. It is possible to use the existing isobutane recycle pumps, to supply isobutane as motive fluid for the eductor and recycle isobutane to the reactor. This eliminates the need to buy an additional pump (for isobutane motive fluid). The isobutane recycle pumps associated with an HF alkylation unit usually have some excess capacity, and in any event the pressure drop associated with getting isobutane through the eductor and into the acid settler (the preferred place to add fresh acid) is usually less than the pressure drop associated with getting isobutane through the reactor and into the settler.
I prefer to monitor, directly or indirectly, the amount of isobutane recycle to the reactor and reduce this in an amount roughly equivalent to the amount of isobutane motive fluid. This minimizes plant upsets which can, and do, occur when a large amount of fresh acid is suddenly added to the acid settler, and the minor upset due to reducing the iso:olefin ratio in the reactor. To accomplish this, flow indicator controllers on both the normal isobutane recycle line and on the motive fluid line may be used. A less accurate, and less effective, measure of control may be achieved by using an isobutane recycle pump of known characteristics and calculating the pressure drops associated with each isobutane line (recycle to the reactor and motive fluid). Measuring and/or controlling one fluid flow can be used to measure/control the other.
A additional benefit to using an alkylation plant hydrocarbon stream, preferably isobutane, as the motive fluid is that flushing of the eductor and lines is easy. After the desired amount of acid is added, flow of, e.g., isobutane through the eductor will purge the line of HF. It is beneficial, for safety and for corrosion, to reduce the amount of HF acid which is in lines. This can theoretically be achieved to some extent even when using reciprocating or centrifugal pumps, but increases the cost and complexity of the system. The only way to thoroughly purge a mechanical pump is to run the pump with a significant amount of the purge fluid flowing through the pump, and this would require fairly large isobutane flow lines.
General Guidelines for Plant Operators
Revise the operating procedures to operate the fuel gas regulator to the acid storage drum at 80 PSIG. This is necessary to make sure the eductor picks up suction on the isobutane flush in the lines at start up.
Revise the operating procedures to reset the vent pressure control on the acid storage drum to 135 PSIG. This will minimize venting off the acid storage drum to the acid flare which will retain additional HF Acid in the drum, and limit the impact on the relief gas scrubbing system.
EXAMPLE
The HF alkylation fresh acid eductor was commissioned and utilized to pump fresh acid from the HF acid storage drum to the mixer settler using isobutane as the motive fluid.
At 10:00 A.M. the eductor was lined out following the original operating guidelines. The isorecycle rate was lowered by 5,000 BPD to allow for operation of the eductor. The original operating procedures were to operate the eductor with a suction pressure of 50 PSIG. At this pressure, the eductor was not able to take suction. This was due to the suction line being filled with isobutane flush, and not HF acid. The decision was made by the unit foreman to raise the suction pressure to the eductor in order to force it to take suction. When the suction pressure was raised to 58 PSIG, the eductor audibly took suction, and began pumping HF Acid. The pressure on the acid storage drum was raised to 70 PSIG during the duration of the educting.
At 10:30 A.M. the eductor began pumping the HF acid. The original level in the vessel was noted at 2.3 feet.
At 1:30 P.M. the eductor was isolated from the HF acid storage drum. The level in the vessel was noted at 0.8 feet. Over a period of 3.0 hours 1.5 feet of HF Acid were pumped from the acid storage drum to the unit. This is an average rate of approximately 16 GPM. All of the acid lines were then flushed clean, isorecycle rate was increased by 5,000 BPD back to normal rates, and the eductor was isolated to complete the acid addition procedure.
In general a positive response was received on the system from the operation personnel. The following comments and suggestions were made:
1. In reviewing the performance of the educting system it was noted that it was difficult to balance the isorecycle flows in the unit, since no direct flow measurement is available on the isobutane used as the motive force to the eductor. It is recommended that a DCS mounted flow meter be installed on the motive isorecycle to the eductor to aid in prevention of upsets when lining the eductor out, and also to help in making sure that adequate motive fluid flow is going through the eductor to obtain proper performance.
2. It was also noted that the Acid Relief neutralizer system took a fairly good hit during the educting operation. The effects of this can be minimized by raising the set pressure on the pressure controller on the acid storage drum. This will limit the amount of venting from the storage drum. The pressure controller can be set to a maximum of 135 PSIG. The acid storage drum pressure will then be controlled with a pressure regulator on the incoming fuel gas. This pressure is to be set at 80 PSIG. These changes can be made with revisions to the operating procedures, and no equipment modifications.
3. It was also noted that an unexpected benefit of the eductor occurred. Previously, HF acid addition resulted in a large volume of fresh acid being transferred into the mixer settler. This fresh acid raised acid purity and resulted in an alkylate production spike, which caused a minor unit upset, until the fresh acid was diluted and the alkylate production returned to normal. The new eductor added the fresh acid slow enough that it did not cause the alkylate spike to occur.
4. It was noted that the unit provided an average flow of 16 GPM was drawn from the eductor. The eductor was designed to provide a flow rate of 25 GPM. Because of lack of information on the motive flow rate, and lack of a PI tag on the acid storage drum level to infer flow rate from the eductor, the flow rate the eductor was pumping at can not be accurately determined and no conclusions can be made as to the eductor's performance. The eductor rate will be checked against design after the addition of the motive fluid flow meter is completed.
Typical charge rates for some streams in an HF alkylation unit are shown in Table I.
DRY FEED
DESCRIPTION
ISOBUT.
TO
DRY SATUR.
ALKY
IC
Component
FEED
REACTOR
FEED
PRODUCT
RECYCLE
BP SD
156
5.244
6.656
7,996
67,522
GP GR. 60° F.
0.562
0.557
0.573
0.697
0.561
(mw)
LB/HR TOTAL
1,295
66,969
55,576
31,176
554,891
COMPONENTS,
MPH
C 2 & LIGHTER
3.2
C 3 =
375.5
C 3
0.3
262.0
22.3
1453.2
iC 4
21.1
262.5
502.5
0.8
7709.5
C 4 =
342.5
nC 4
0.7
85.1
415.9
52.3
513.2
C5's
0.2
10.4
16.5
36.6
25.2
C 6 +
691.8
52.0
ALKYLATE
HF
235.4
H2O
TOTAL
22.3
1325.3
957.5
751.5
3753.1
For such a plant, when makeup HF acid addition is practiced, the flow rate of makeup HF acid is 25 gpm, the amount of isobutane recycle is 228 gpm, producing 253 gpm of HF/isobutane.
When restoring acid inventory, the recycle isobutane flow is much larger, 600 gpm, and the recycle isobutane pump discharge pressure is increased from 325 to 345 psig. This larger volume and increased pressure of isobutane are sufficient to educt 150 gpm of HF from the storage tank into the plant.
Changes and modifications in the specifically described embodiments can be carried out without departing from the scope of the invention which is intended to be limited only by the scope of the appended claims. | A slipstream of high pressure, cooled isobutane recycle from within an alkylation process unit is used to withdraw hydrofluoric acid from a storage vessel by means of an eductor and discharges the same into a reactor section of the unit. The eductor is preferably constructed of HASTELLOY “C” which provides both corrosion resistance to HF acid and has excellent surface hardness to withstand the highly erosive eductor application. This eductor eliminates potential release of HF acid due to failure of conventional rotating equipment seals or sealing systems, is low cost, has no moving parts, and is fireproof (will not lose containment during a fire). | 8 |
BACKGROUND OF THE INVENTION
This invention relates to photoflash lamps and, more particularly, to flashlamps of the type containing a primer bridge ignited by a high voltage pulse. The invention further relates to a method of making photoflash units using such lamps.
High voltage flashlamps may be divided historically into three catagories: (1) those having a spark gap within the lamp such that electrical breakdown of a gaseous dielectric (e.g., the combustion-supporting oxygen atmosphere) is an integral part of the lamp ignition mechanism; (2) those having a conductive primer bridge that electrically completes the circuit between the lead-in wires; such primers are rendered conductive by additives such as acetylene black, lead dioxide, or other electrical conduction-promoting agents; and (3) lamps having an essentially nonconducting primer bridge that connects the inner ends of the lead-in wires and which becomes conductive, upon application of a high voltage pulse, by means of breakdown of the dielectric binder separating conductive particles therein.
The earliest high voltage flashlamps were of the spark gap type construction wherein an electrical spark would pass through the gaseous atmosphere within the lamp. The spark would jump between two electrodes, at least one of which was coated with a primer composition. Such lamps tend to exhibit poor sensitivity and reliability when flashed from low power sources such as the miniaturized piezoelectric devices that are suited for incorporating into pocket-sized cameras. Most of the electrical input energy in such lamps is lost to the gas atmosphere by the spark. Also, the electrical characteristics vary considerably from one lamp to another because of shreds of metallic combustible in the spark gap and consequent variations in effective gap length.
The use of spaced lead-in wires interconnected by a quantity of electrically conductive primer gives rise to highly predictable behavior and a well-defined electrical path through the lamp. Here again, however, relatively high-powered flash sources must be used in order to attain reliable lamp flashing.
Present state of the art flashlamps of the high voltage type make use of a bridge of initially nonconducting primer to interconnect the inner ends of the lead-in wires. Considerably higher sensitivity is attainable by this method, apparently because the breakdown and discharge follow a discrete path through the primer composition and thereby promote greater localized heating. With respect to specific construction, such flashlamps typically comprise a tubular glass envelope constricted and tipped off at one end and closed at the other end by a press seal. A pair of lead-in wires pass through the glass press and terminate in an ignition structure including a glass bead, one or more sleeves or a glass reservoir of some type. A mass of primer material contained on the bead, sleeve or reservoir bridges across and contacts the ends of the lead-in wires. Also disposed within the lamp envelope is a quantity of filamentary metallic combustible, such as zirconium or hafnium, and a combustion-supporting gas, such as oxygen, at an initial fill pressure of several atmospheres. The outer surface of the lamp envelope is generally covered with a protective reinforcing coating such as cellulose acetate.
Lamp functioning is initiated by application of a high voltage pulse (e.g., several hundred to several thousand volts, as, for example, from a piezoelectric crystal) across the lamp lead-in wires. The mass of primer within the lamp then breaks down electrically and ignites; its deflagration, in turn, ignites the shredded combustible which burns actinically.
The primers used in such flashlamp are designed to be highly sensitive toward high-voltage breakdown. Electrical energies as low as a few microjoules are sufficient to promote ignition of such primers and flashing of the lamp. This high sensitivity is needed in order to provide lamps that will function reliably from the compact and inexpensive piezoelectric sources that are practical for incorporation into modern, miniature cameras. The mechanical energy delivered to the piezoelectric crystal and thereby the electrical output energy therefrom is limited both by the size of the device and by the necessity to minimize camera vibration and motion during use.
The high degree of electrical sensitivity needed in high-voltage flashlamps gives rise to distinct problems of inadvertent flashing during their manufacture, lacquer coating, and subsequent handling. Any static charges on equipment or personnel can cause these lamps to flash. Some such lamp flashes even occur when the lamps are lying stationary in an isolated spot. Apparently, even air movements can generate sufficient electrostatic energy to promote flashing of those lamps that are by nature the most sensitive and susceptible. This problem is greatly compounded by the fact that flashlamps flash sympathetically, i.e., the radiant energy from one lamp that flashes is sufficiently intense to ignite the shredded combustible in adjacent lamps. During lamp manufacture on modern high-speed equipment, it is necessary, or at least high expedient, at certain stages of processing to accumulate the lamps in containers, having from about 30 to more than 2,000 lamps in a container. The problem that is encountered is that should one lamp be inadvertently ignited, all lamps in that container will sympathetically flash and be lost.
It is common practice in photoflash lamp manufacturing to dip the lacquered lamps into a bath which leaves a film of antistatic agent on their surfaces. This does much to prevent buildup of an electrostatic charge on a lamp itself by rubbing or handling. It does not, however, give a significant protection for the lamp against contact with external charges.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of this invention to provide an improved high-voltage type photoflash lamp with means for aiding in the prevention of inadvertent flashing due to electrostatic discharges during manufacture, processing and handling.
A further object is to provide an improved method for making a photoflash unit.
These and other objects, advantages and features are attained in accordance with the principles of this invention by providing means outside of the lamp envelope which electrically interconnects the external portions of the lamp lead-in wires to effect a short circuit thereacross. In this manner the lamp is conveniently disabled prior to use or assembly so as to provide protection against inadverent flashing due to electrostatic discharges. In making a photoflash unit including such a lamp, the external electrical connection is cut to enable the lamp just prior to assembling the lamp into the unit.
BRIEF DESCRIPTION OF THE DRAWING
This invention will be more fully described hereinafter in conjunction with the accompanying drawing, which is an elevational view of a photoflash lamp having an external lead interconnection in accordance with the invention.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring to the drawing, the high-voltage type flashlamp illustrated therein comprises an hermetically sealed light-transmitting envelope 2 of glass tubing having a press 4 defining one end thereof and an exhaust tip 6 defining the other end thereof. Supported by the press 4 is an ignition means comprising a pair of lead-in wires 8 and 10 extending through and sealed into the press, an insulating sleeve 12 extending within the envelope about lead-in wires 8, and a mass of primer material 14 bridging the ends of the lead-in wires within the envelope. The insulating sleeve 12 may be formed of glass or ceramic and is preferably sealed into the envelope press 4 at one end so that only the inward end of the sleeve is open. Lead-in wire 10 passes through press 4 and is formed so that it rests and terminates at or near the open end of the sleeve 12. The mass of primer material 14, which may be dip-applied, is disposed to substantially cover the open end of the sleeve 12 and bridge the ends of the lead-in wires.
Typically, the lamp envelope 2 has an internal diameter of less than one-half inch and an internal volume of less than 1 cc. A quantity of filamentary combustible fill material 16, such as shredded zirconium or hafnium foil, is disposed within the lamp envelope. The envelope 2 is also provided with a filling of combustion-supporting gas, such as oxygen, at a pressure of several atmospheres. Typically, the exterior surface of the glass envelope 2 is also provided with a protective lacquer coating, such as cellulose acetate (not shown).
It has been found that a significant improvement in the resistance of high-voltage type flashlamps toward inadvertent ignition due to contact with external charges can be attained by manufacturing such lamps in a way that provides an electrical connection between the external ends of the lead-in wires. This may be done, for example, by fabricating the lead-in wires from a single hairpin and leaving the bight 11 to electrically interconnect lead-in wires 8 and 10. This bight, or loop, 11 effects a short circuit across the wires and apparently provides its protective function by preventing voltage differentials across the two wires, which in turn prevents firing of the primer bridge by electrical discharges through it from one lead-in wire to the other. In effect, the loop 11 disables the lamp.
If such lamps are to be flashed individually, the protective loop could remain in place until the lamp is, for example, pulled out of the package; a cut partially through each lead-in wire would then permit breakoff and enabling of that lamp. If such lamps are to be mounted in multilamp units such as flash cubes or flash arrays, then the cutting of the loop would be the last lamp operation to take place before actual lamp insertion into the device.
For example, a preferred method of making a photoflash unit according to the invention comprises the following steps. First, in the manufacturing of the lamp, the hairpin 8, 11, 10 is shaped, and insulating sleeve 12 is inserted over the top portion of lead-wire 8. The lead-in wires and one end of sleeve 12 are then sealed into one end of a length of glass envelope tubing at the press 4, with the hairpin bight 11 extending outwardly therefrom. A quantity of primer material is dip-applied so as to provide the mass 14 bridging the free ends of the lead-in wires within the envelope tubing. The envelope tubing is then filled with a quantity of filamentary combustible material 16, such as shredded zirconium, and a combustion supporting gas, such as oxygen. The open end of the tubing is then constricted and tipped off to provide an hermetically sealed envelope. A protective lacquer coating is then applied to the exterior of the glass envelope, such as by dipping an drying. All through this process the lamp leads are interconnected by loop 11, which maintains the lamp in a disabled state for providing electrostatic protection. Just prior to assembly to the lamp mounting means of the photoflash unit (such as a base or printed circuit board), the electrical interconnection (loop 11) is cut to enable the lamp so that it can be fired.
Operation of such enabled high voltage type flashlamps is initiated when a high voltage pulse from, e.g., a piezoelectric crystal, is applied across the two lead-in wires 8 and 10. Electrical breakdown of the primer causes its deflagration which, in turn, ignites the shredded metallic combustible 16.
The advantage of this invention is that it provides significant electrostatic protection for high-voltage type flashlamps in a way that is inexpensive and which lends itself readily to automated lamp manufacturing processes. Such protection improves the safety of handling such flashlamps and also greatly reduces the loss of produce due to inadvertent ignition caused by stray electrostatic charges.
An obvious alternative method would involve attachment of foil, clips, or a wire shorting member across the lead-in wires of high-voltage flashlamps. The use of such secondary shorting means would be more expensive, less failsafe, and would introduce difficulties in automated application. A second obvious alternative would involve twisting or otherwise mechanically interlocking the external ends of the lead-in wires. This, too, would give less positive electrical connection of the lead-in wires. Also, the operation of untwisting or disconnecting the wires automatically, prior to assembly into a flash device would be formidable.
The idea believed to be new is the electrical interconnection of the exterior lead-in wires of high-voltage type flashlamps so as to render such lamps resistant toward contact with externally charged objects. This is most conveniently done by forming the lead-in wires from a single loop and retaining that loop, external to the lamp, as the electrical interconnection between the lead-in wires.
A test which illustrates the concepts disclosed herein was carried out using lamps of the design shown. The lamps were fabricated from 0.259: O.D. type 7052 glass. Lamp internal volume was 0.35 cm 3 ; pressure was 1220 cm. Hg absolute; zirconium shred weight was 14.5 mg.; and shred 16 dimensions were 4 inch length and 0.00093: × 0.0012 inch cross-section. The lead-in wires were 0.014: diameter Rodar; and the insulating sleeve 12 was type 7052 glass 0.160 inches long, having an O.D. of 0.060 inch and an I.D. of 0.030 inches. Approximately 3 mgs. of primer was used; the primer comprised 99.4% by weight zirconium powder and 0.6% by weight cellulose nitrate. In the test, the lamps were placed tip-down into brass cups of 3/8 inch I.D. and about 5/8 inches deep, mounted on a motor-driven turntable. The turntable and brass cups were electrically grounded. The lamp leads passed under a contactor having a DC potential of 6,300 volts. Each group comprised 150 lamps.
______________________________________ No. Flashed % Flashed______________________________________Test (interconnected leads) 32 21.3Control (individual leads) 91 60.7______________________________________
This test shows a threefold reduction in lamp flashing in this somewhat severe test when the lead-in wires were connected externally in the form of a loop, or bight.
Although the invention has been described with respect to a specific embodiment, it will be appreciated that modifications and changes may be made by those skilled in the art without departing from the true spirit and scope of the invention. | A high-voltage type photoflash lamp having an ignition structure comprising a mass of primer material bridging a pair of lead-in wires which comprise the two legs of a generally hairpin-shaped wire. The bight of the hairpin-shaped wire is disposed outside the lamp envelope and provides electrostatic protection by short circuiting the lamp prior to use. Also disclosed is a method of making a photoflash unit containing such a lamp wherein the bight is cut (to enable the lamp) prior to assembling it into the unit. | 5 |
This application is a continuation application of copending international application PCT/US97/09501 filed Jun. 4, 1997, which claims priority to converted provisional application No. 60/056,917, (formerly U.S. Ser. No. 08/657,947), filed Jun. 4, 1996, now abandoned. The patent applications are incorporated by reference herein.
BACKGROUND OF THE INVENTION
A drug delivery system should deliver drug at a rate dictated by the needs of a medical procedure over the period of the procedure, that is, the goal of any drug delivery system is to provide a therapeutic amount of drug to the proper site in the body to promptly achieve, and then maintain, the desired drug concentration. This objective emphasizes the need for spatial placement and temporal delivery of a drug or treatment. Spatial placement is the targeting of a drug to a specific organ, tissue, or bodily system such as the blood stream; while temporal delivery refers to controlling the rate of drug delivery to the target.
Targeted drug delivery systems include colloidal drug delivery systems and resealed or modified cells, for example, resealed or modified erythrocytes or leukocytes. Colloidal drug delivery systems include nanoparticles, microcapsules, nanocapsules, macromolecular complexes, polymeric beads, microspheres, liposomes, and lipid vesicles.
Liposomes are formed from phospholipids that are dispersed in an aqueous medium and spontaneously form multilamellar concentric bilayer vesicles (also termed multilamellar vesicles (MLVs)). MLVs generally have diameters of from 4 mm to 25 nm. Sonication or solvent dilution of MLVs results in the formation of small unilamellar vesicles (SUVs) with diameters in the range of 300 to 500 Å.
Liposomes resemble cellular membranes, and water- or lipid-soluble substances can be entrapped in the aqueous spaces or within the bilayer, respectively. An important determinant in entrapping compounds is the physicochemical properties of the compound itself. Polar compounds are trapped in the aqueous spaces and are released through permeation or when the bilayer is broken; nonpolar compounds bind to the lipid bilayer of the vesicle, and tend to remain there unless the bilayer is disrupted by temperature or exposure to lipoproteins.
Liposomes may interact with cells via a number of different mechanisms, for example: endocytosis by phagocytic cells of the reticuloendothelial system such as macrophages and neutrophils; adsorption to the cell surface, either by nonspecific weak hydrophobic or electrostatic forces, or by specific interactions with cell-surface components; fusion with the plasma cell membrane by insertion of the lipid bilayer of the liposome into the plasma membrane, with simultaneous release of liposomal contents into the cytoplasm; or by transfer of liposomal lipids to cellular or subcellular membranes, or vice versa, without any association of the liposome contents. It often is difficult to determine which mechanism is operative and more than one may operate at the same time.
Intravenously injected liposomes may persist in tissues for hours or days, depending on their composition, and half-lives in the blood range from minutes to several hours. Larger liposomes are taken up rapidly by phagocytic cells of the reticuloendothelial system and exit only in places where large openings or pores exist in the capillary endothelium, such as the sinusoids of the liver or spleen. Thus, these organs are the predominant site of uptake. On the other hand, smaller liposomes show a broader tissue distribution but still are sequestered highly in the liver and spleen. In general, this in vivo behavior limits the potential targeting of liposomes to only those organs and tissues accessible to their large size. These include the blood, liver, spleen, bone marrow and lymphoid organs.
Attempts to overcome the limitation on targeting of liposomes have centered around two approaches. One is the use of antibodies, bound to the liposome surface, to direct the antibody and the liposome contents to specific antigenic receptors located on a particular cell-type surface. Further, carbohydrate determinants (glycoprotein or glycolipid cell-surface components that play a role in cell-cell recognition, interaction and adhesion) may also be used as recognition sites since they have potential in directing liposomes to particular cell types.
Further lipid vesicles, such as nonphospholipid paucilamellar lipid vesicles (PLV's), are made from materials such as polyoxyethylene fatty esters, polyoxyethylene fatty acid ethers, diethanolamines, long-chain acyl amino acid amides, long-chain acyl amides, polyoxyethylene sorbitan mono and tristearates and oleates, polyoxyethylene glyceryl monostearates and monooleates, and glyceryl monostearates and monooleates, (U.S. Pat. Nos. 4,911,928, 4,917,951, and 5,000,960).
Resealed erythrocytes are another form of targeted drug delivery. When erythrocytes are suspended in a hypotonic medium, they swell to about one and a half times their normal size, and the membrane weakens, resulting in the formation of small pores. The pores allow equilibration of the intracellular and extracellular solutions. If the ionic strength of the medium then is adjusted to isotonicity, the pores will close and cause the membrane of the erythrocyte to return to normal or “reseal”. Using this technique with a drug present in the extracellular solution, it is possible to entrap a substantial amount of the drug inside the resealed erythrocyte and to use this system for targeted delivery via intravenous injection.
Studies on the behavior of normal and modified reinfused erythrocytes indicate that, in general, normal aging erythrocytes, slightly damaged erythrocytes and those coated lightly with antibodies are sequestered in the spleen after intravenous reinfusion; but heavily damaged or modified erythrocytes are removed from the circulation by the liver. This suggests that resealed erythrocytes can be targeted selectively to either the liver or spleen, which can be viewed as a disadvantage in that other organs and tissues are inaccessible. Thus, the application of this system to targeted delivery has been limited mainly to treatment of lysosomal storage diseases and metal toxicity, where the site of drug action is in the reticuloendothelial system.
Labeling of red blood cells with chromium-51 and white blood cells with indium-111, as well as labeling of liposomes with contrast media and therapeutic agents is known. U.S. Pat. No. 5,466,438 relates to liposoluble complexes of paramagnetic ions and compounds bearing long acyl chains useful as magnetic resonance imaging contrast agents. U.S. Pat. No. 5,000,960 relates to coupling a molecule having a free sulfhydryl group to a lipid vesicle having a free sulfhydryl group incorporated as one of the structural molecules of the lipid phase thereby forming a covalent disulfide bond linkage. U.S. Pat. No. 4,931,276 relates to methods for introducing desired agents into red blood cells, and U.S. Pat. No. 4,478,824 relates to methods and apparatus for causing reversible intracellular hypertonicity in red blood cells of mammals in order to introduce desired materials into the cells, or achieve therapeutically desirable changes in the characteristics of intracellular hemoglobin. Further, poor accumulation of liposomal cadmium-texaphyrin in tumor tissue was cited as a possible explanation for low efficiency of photodynaric therapy in König et al., ( Lasers in Surgery and Medicine 13:522, 1993; in: Photodynamic Therapy and Biomedical Lasers, P. Spinelli, M. Dal Fante and R. Marchesini, eds., Elsevier Science Publishers, 1992, 802).
Photodynamic therapy (PDT) is a treatment technique that uses a photosensitizing dye that produces cytotoxic materials, such as singlet oxygen (O 2 ( 1 D g )) from benign precursors (e.g. ((O 2 ( 3 S g —)), when irradiated in the presence of oxygen. Other reactive species such as superoxide, hydroperoxyl, or hydroxyl radicals may be involved. At the doses used, neither the light nor the drug has any independent activity against the disease target.
The effectiveness of PDT is predicated on three main factors: i) The photosensitive dyes used in PDT preferably have the ability to localize at the treatment site as opposed to surrounding tissue. ii) The high reactivity and short lifetime of activated oxygen means that it has a very short range and is unlikely to escape from the cell in which it is produced; cytotoxicity is therefore restricted to the precise region of photoactivated drug. iii) Developments in light delivery, such as lasers, light emitting diodes, and fiber optics, allow a beam of intense light to be delivered accurately to many parts of the body.
In recent years, considerable effort has been devoted to the synthesis and study of new photosensitizers (a review is found in Brown, S. B. and Truscott, T. G., 1993, Chemistry in Britain, 955-958). The development of more effective photochemotherapeutic agents requires the synthesis of compounds which absorb in the spectral region where living tissues are relatively transparent (i.e., 700-1000 nm), have high triplet quantum yields, are minimally toxic, and have physiologically acceptable water/lipid partition coefficients. Texaphyrins have proven to be effective sensitizers for generating singlet oxygen and for photodynamic therapy (U.S. Pat. Nos. 5,272,142; 5,292,414; 5,439,570; and 5,451,576, incorporated by reference herein).
Magnetic resonance imaging has become an important diagnostic tool in medicine, especially for tumor imaging. Imaging of tissue is dependent upon a difference in the relaxation rates of nuclear spins of water protons from various tissues in a magnetic field. The relaxation rate can be enhanced by use of a contrast agent, thereby improving a resulting image. The gadolinium cation is a superior contrast agent due to its seven unpaired f-electrons and high magnetic moment. However, gadolinium cation is too toxic to be used directly for imaging at concentrations required for effective enhancement. Texaphyrins bind the gadolinium ion in a stable manner and have proved to be nontoxic and effective contrast agents for imaging (U.S. Pat. Nos. 5,252,720, 5,451,576, and 5,256,399, incorporated by reference herein). Further development of texaphyrin-based magnetic resonance imaging protocols would be of significant value for the improvement of medical diagnostic imaging.
Macular degeneration due to damage or breakdown of the macula, underlying tissue, or adjacent tissue is the leading cause of decreased visual acuity and impairment of reading and fine “close-up” vision. Age-related macular degeneration (ARMD) is the major cause of severe visual loss in the elderly. The most common form of macular degeneration is called “dry” or involutional macular degeneration and results from the thinning of vascular and other structural or nutritional tissues underlying the retina in the macular region. A more severe form is termed “wet” or exudative macular degeneration. In this form, blood vessels in the choroidal layer (a layer underneath the retina and providing nourishment to the retina) break through a thin protective layer between the two tissues. These blood vessels may grow abnormally directly beneath the retina in a rapid uncontrolled fashion; resulting in oozing, bleeding, or eyentually scar tissue formation in the macula which leads to severe loss of central vision. This process is termed choroidal neovascularization.
Neovascularization results in visual loss in other eye diseases including neovascular glaucoma, ocular histoplasmosis syndrome, myopia, diabetes, pterygium, and infectious and inflammatory diseases. In histoplasmosis syndrome, a series of events occur in the choroidal layer of the inside lining of the back of the eye resulting in localized inflammation of the choroid and consequent scarring with loss of function of the involved retina and production of a blind spot (scotoma). In some cases, the choroid layer is provoked to produce new blood vessels that are much more fragile than normal blood vessels. They have a tendency to bleed with additional scarring, and loss of function of the overlying retina. Diabetic retinopathy involves retinal rather than choroidal blood vessels resulting in hemorrhages, vascular irregularities, and whitish exudates. Retinal neovascularization may occur in the most severe forms.
Current diagnosis of ocular disorders often includes use of a fluorescein or indocyanine green angiogram. In this procedure, the dye is injected into the blood stream through a vein in the arm. Special filters are placed in the light path, and in front of the film, to permit only the fluorescent dye to be seen as it passes through the vessels in the retina Pictures of the vascular anatomy are taken of the retina and macula as the dye passes through the blood vessels of the back of the eye. Vascular occlusions or leakage of dye indicates abnormal vasculature. Optical coherence tomography is another technique that uses noncontact imaging and provides high-depth resolution in cross-sectional tomographs of the retina.
Current treatment of neovascularization relies on ablation of blood vessels using laser photocoagulation. However, such treatment requires thermal destruction of the tissue, and is accompanied by full-thickness retinal damage, as well as damage to medium and large choroidal vessels. Further, the patient is left with an atrophic scar and visual scotoma. Moreover, recurrences are common, and the prognosis for the patient's condition is poor.
Developing strategies, such as PDT, have sought more selective closure of the blood vessels to preserve the overlying neurosensory retina PDT of conditions in the eye characterized by neovascularization has been attempted using the conventional porphyrin derivatives such as hematoporphyrin derivative and PHOTOFRIN® porfimer sodium. Problems have been encountered in this context due to interference from eye pigments. In addition, phthalocyanine and benzoporphyrin derivatives have been used in photodynamic treatment. PCT publication WO 95 24930 and Miller et al., ( Archives of Ophthalmology, June, 1995) relate to treatment of eye conditions characterized by unwanted neovasculature comprising administering a green porphyrin to the neovasculature and irradiating the neovasculature with light having a wavelength of 550-695 nm. U.S. Pat. No. 5,166,197 relates to phthalocyanine derivatives reportedly useful for macular degeneration. Asrani and Zeimer ( British Journal of Ophthalmology, 1995, 79:766-770) relate to photoocclusion of ocular vessels using a phthalocyanine encapsulated in heat-sensitive liposomes. Levy ( Semin. Oncol. 1994, 21/6, suppl. 15 (4-10)) relates to photodynamic therapy and macular degeneration with porfimer sodium (PHOTOFRIN®, requiring light of 630 nm and causing cutaneous photosensitivity that may last for up to 6 weeks), and benzoporphyrin derivative (BPD verteporfin, causing cutaneous photosensitivity of a few days). Lin et al. relate to the photodynamic occlusion of choroidal vessels using benzoporphyrin derivative BPD-MA. Further, BPD and tin purpurin (SnET2) are insoluble in aqueous solutions and require hydrophobic vehicles for administration.
Texaphyrins are aromatic pentadentate macrocyclic expanded porphyrins” useful as MRI contrast agents, as radiosensitizers and in photodynamic therapy. Texaphyrin is considered as being an aromatic benzannulene containing both 18- and 22-electron delocalization pathways. Texaphyrin molecules absorb strongly in the tissue-transparent 700-900 nm range, and they exhibit inherent selective uptake or biolocalization in certain tissues, particularly regions such as, for example, liver, atheroma or tumor tissue. Paramagnetic texaphyrins have exhibited significant tumor selectivity as detected by magnetic resonance imaging. Texaphyrins and water-soluble texaphyrins, method of preparation and various uses have been described in U.S. Pat. Nos. 4,935,498; 5,162,509; 5,252,720; 5,256,399; 5,272,142; 5,292,414; 5,369,101; 5,432,171; 5,439,570; 5,451,576; 5,457,183; 5,475,104 5,504,205; 5,525,325; 5,559,207; 5,565,552; 5,567,687; 5,569,759; 5,580,543; 5,583,220; 5,587,371; 5,587,463; 5,591,422; 5,594,136; 5,595,726; 5,599,923; 5,599,928; 5,601,802; 5,607,924; and 5,622,946; PCT publications WO 90/10633, 94/29316, 95/10307, 95/21845, and 96/09315; allowed U.S. patent application Ser. Nos. 08/484,551 and 08/624,311; and pending U.S. patent application Ser. Nos. 08/458,347; 08/657,947; 08/591,318; 08/700,277; and 08/763,451; each patent, publication, and application is incorporated herein by reference.
Problems with prior art drug and PDT delivery systems include lack of specificity, toxicity, expense, and technical difficulties, among others. Problems with prior art magnetic resonance imaging contrast agents include insufficient differential biolocalization, insufficient signal, toxicity, and slow clearance, among others. Because of these problems, known procedures are not completely satisfactory, and the present inventors have searched for improvements.
SUMMARY OF THE INVENTION
The present invention relates generally to the fields of targeted drug delivery, medical imaging, diagnosis, and treatment. More particularly, it concerns compositions having a texaphyrin-hpophilic molecule conjugate loaded into a biological vesicle; and methods for imaging, diagnosis and treatment using this loaded vesicle.
Accordingly, the present invention provides compositions comprising a texaphyrin-lipophilic molecule-vesicle complex. Such compositions include cells of the vascular system, such as red blood cells or white blood cells, and micellar vesicles such as liposomes or nonphospholipid vesicles, loaded with a texaphyrin conjugated to a lipophiliz molecule. When the texaphyrin portion of the complex is photosensitive and when the complex is irradiated, the complex ruptures, depositing its contents. The invention therefore includes methods for delivering diagnostic or therapeutic agents via loaded texaphyrin-lipophilic molecule-vesicle complexes.
“Loading” means labeling of membranes of a vesicle, embedding into a vesicular membrane, or incorporation into the interior of a vesicle. In particular, loading would include attachment to or within cells circulating within the vascular system or to or within liposomes or other lipid vesicles.
A texaphyrin-lipophilic molecule-biological vesicle complex is an embodiment of the present invention. By “biological vesicle” is meant a membranous structure having a lipid bilayer, or a micelle. By “lipid bilayer” is meant a bimolecular sheet of phospholipids and/or glycolipids. A biological vesicle may be a cell, such as a red cell or white cell, or membranous fragment thereof; a liposomal membrane; a nonphospholipid vesicle, or a colloidal drug delivery system. In one embodiment of the present invention, the biological vesicle is a resealed red blood cell.
As used herein, a “lipophilic molecule” is a molecule having a lipid-water distribution coefficient that is optimal for localization to lipid-rich tissues or materials compared to localization in surrounding nonlipid-rich tissues or materials. “Lipid-rich” means having a greater amount of triglyceride, cholesterol, fatty acids or the like. Lipophilic molecules that may be conjugated to a texaphyrin include cholesterol; steroids including progestagens such as progesterone, glucocorticoids such as cortisol, mineralocorticoids such as aldosterone, androgens such as testosterone and androstenedione, and estrogens such as estrone and estradiol; phospholipids such as phosphatidyl choline, phosphatidyl serine, phosphatidyl ethanolamine, phosphatidyl inositol, or cardiolipin; sphingolipids such as sphingomyelin; glycolipids such as cerebroside, or ganglioside; molecules having isoprenoid side chains such as vitamin K 2 , coenzyme Q 10 , chlorophyll, or carotenoids; low density lipoprotein (LDL); or the like. Preferred lipophilic molecules are steroids, more preferably estradiol, or cholesterol, for example.
A method for photodynamic therapy is also an aspect of the present invention. The method comprises administering a photosensitive texaphyrin-lipophilic molecule-vesicle complex to a subject, and irradiating the complex. Preferably, the vesicle portion of the complex is a red blood cell, and in one embodiment, the subject is a donor of the red blood cell.
When loaded with a photosensitive texaphyrin-lipophilic molecule conjugate, a loaded vesicle has utility as a diagnostic or therapeutic agent since the cell or liposome can be disrupted using an appropriate light source, thereby depositing a diagnostic or therapeutic agent in vivo. Therefore, a method for delivery of an agent to a targeted biological site is a further embodiment of the present invention. The method comprises i) loading a vesicle with a photosensitive texaphyrin-lipophilic molecule conjugate and the agent to form a complex; ii) allowing the complex to locate at the targeted biological site; and iii) irradiating the complex. The complex is lysed by irradiating, thereby delivering the agent to the targeted biological site. The agent may be a diagnostic agent, photodynamic therapy agent, a chemotherapeutic agent, a radiation sensitizing agent, or naturally occurring cellular contents of a cell. A preferred vesicle portion of a complex to be loaded is a red blood cell, a preferred lipophilic molecule portion of a complex is estradiol or cholesterol, and the photosensitive texaphyrin-lipophilic molecule conjugate may have a diamagnetic metal cation bound by the texaphyrin. A preferred diamagnetic metal cation is Lu(III), La(III), In(III), Y(III), Zn(II) or Cd(II); a most preferred diamagnetic metal cation is Lu(III). Availability of red blood cells loaded with a photosensitive texaphyrin-lipophilic molecule conjugate provides a method for delivering a therapeutic PDT agent to a desired site with a high concentration of oxygen. By presenting a PDT agent this way, it is expected that the patient will experience less toxicity.
The method of photolysis of loaded blood cells or liposomes involves at least two sources of specificity. A first source of specificity is the natural localization of loaded cells or liposomes into the blood, liver, spleen, bone marrow, or lymphoid organs. A second source of specificity is the positioning of the laser light. Such positioning of laser light, either by manual or mechanical means, would be particularly advantageous when the photolysis is to be effected at a particular biological locus, such as, for instance, a deepseated tumor site. Here, the fact that the-texaphyrins absorb light at wavelengths where bodily tissues are relatively transparent (700-900 nm) is particularly advantageous. This procedure allows for the effective implementation of light-based strategies at loci deep within the body with relatively little deleterious light-based photosensitization of other tissues where the texaphyrin conjugates are not localized or where the light is not focused.
Further, the present invention provides for the possibility of using the patient's own blood for loading with a diagnostic or a therapeutic agent and a texaphyrin-lipophilic molecule conjugate. In so doing, a uniquely “customized” therapy with reduced toxicity, increased circulation, and maximum therapeutic effect is provided.
Vesicles loaded with a photosensitive texaphyrin-lipophilic molecule conjugate and a chemotherapeutic drug have utility in conventional chemotherapy. In such a case, by directing laser light at a tumor and lysing the vesicle, a chemotherapeutic agent is released only in proximity to the cancer. In addition, a localized photodynamic therapeutic effect of irradiating the texaphyrin will occur.
Another embodiment of the present invention is a method of imaging. The method comprises the steps of administering a detectable texaphyrin-lipophilic molecule-vesicle complex to a subject, and imaging the complex.
When the detectable texaphyrin is fluorescent, imaging is by observing fluorescence of the texaphyrin. When the detectable texaphyrin is complexed with a paramagnetic metal cation, imaging is by magnetic resonance imaging. Further imaging methods include x-ray imaging, Raman scattering, magnetometry (bioluminescence), or gamma scanning when the texaphyrin is complexed with a gamma emitting isotope. For fluorescent imaging, texaphyrins may be activated by 400-500 nm light (the Soret band) or 700-900 nm light, preferably 700-800 nm, (the Q band) and, therefore, provide considerable versatility for use in humans.
The term “fluorescent”, as used herein, means that upon photoirradiation by light associated with the absorption profile of texaphyrin, light is emitted at a longer wavelength by the irradiated texaphyrin. All texaphyrins are fluorescent, albeit, to varying degrees, and texaphyrins complexed with Y(III), Lu(III), Gd(III), Dy(III), Eu(III), or Mn(III) are particularly preferred as fluorescent texaphyrins, for example.
In addition to fluorescent detection, texaphyrins may be imaged by x-radiation, by Raman scattering, or by magnetometry; further, texaphyrins complexed with a paramagnetic metal cation may be used for magnetic resonance imaging. Preferred paramagnetic metal cations for complexing with a texaphyrin include Mn(III), Mn(III), Fe(III), or trivalent lanthanide metals other than La(III), Lu(III), and Pm(III). More preferably, the paramagnetic metal is Mn(II), Mn(M), Dy(III), or Gd(III); most preferably, Gd(III). Any of various types of magnetic resonance imaging can be employed in the practice of the invention, including, for example, nuclear magnetic resonance (NMR), NMR spectroscopy, and electronic spin resonance (ESR). The preferred imaging technique is NMR.
Gamma particle detection may be used to image a texaphyrin complexed to a gamma-emitting metal. 51 Chromium, 68 gallium, 99 technetium, or 111 indium are preferred metals for complexing to texaphyrins for gamma particle scanning. Monochromatic X-ray photon sources may be used for imaging also.
The present invention is useful in imaging a patient generally, and/or in specifically diagnosing the presence of diseased tissue in a patient. The imaging process of the present invention may be carried out by administering a detectable texaphyrin-lipophilic molecule-vesicle complex of the invention to a patient, and then scanning the patient to obtain visible images of an internal region of a patient and/or of any diseased tissue in that region. The complexes of the present invention are particularly useful in providing images of the blood pool, liver, reticuloendothelial system, spleen, bone marrow, lymph nodes, and muscle; they are especially effective blood pool agents, and are highly effective at enhancing the liver and highly useful for improving the detection of hepatic metastases. Red blood cells loaded with a texaphyrin-lipophilic molecule conjugate, when injected intravenously, have been demonstrated to serve as a contrast agent for MRI Vesicles loaded with a paramagnetic texaphyrin-lipophilic molecule conjugate have utility as a blood pool contrast agent, facilitating the enhancement of normal tissues, magnetic resonance angiography, and marking areas of damaged endothelium by their egress through fenestrations or damaged portions of the blood vascular system. The patient may be any type of animal, but preferably is a mammal, and most preferably is a human.
Texaphyrin-lipophilic molecule conjugates and texaphyrin-lipophilic molecule-vesicle complexes are also provided for use in ocular diagnosis and therapy, in particular, therapy involving photodynamic therapy of conditions of the eye characterized by abnormal vasculature. Accordingly, an aspect of the present invention is directed to a method for carrying out angiography of the eye, i.e., observing, vasculature of an eye of a subjecl The method comprises the steps of administering a detectable texaphyrin-lipophilic molecule or texaphyrin-lipophilic molecule-vesicle complex to the subject; and observing the vasculature of the eye. Observing may be by fluorescence or other imaging methods as herein described.
In a further aspect of the invention, a method for treating an ocular condition of a subject characterized by abnormal vasculature is provided. The method comprises the steps of administering a photosensitive texaphyrin-lipophilic molecule conjugate or a photosensitive texaphyrin-lipophilic molecule-vesicle complex to the subject; and photoirradiating the vasculature. The method may further comprise the step of observing the ocular condition of the subject by imaging the texaphyrin as stated herein.
A method for photodynamic therapy of macular degeneration of a subject, comprising the steps of administering a photosensitive texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex to the subject; and photoirradiating the macula is another aspect of the invention.
A method for observing and treating an ocular condition of a subject characterized by abnormal vasculature using a single agent is also an aspect of the invention. The method comprises the steps of administering a photosensitive fluorescent texaphyrin-lipophilic molecule or a photosensitive fluorescent texaphyrin-lipophilic molecule-vesicle complex to the subject; observing the ocular condition of the subject by fluorescence of the texaphyrin; and photoirradiating the vasculature.
For angiography, texaphyrins may be activated by 400-500 nm light (the Soret band) or 700-800 nm light (the Q band) and, therefore, provide considerable versatility for use in humans. For phototherapy, texaphyrins may be irradiated at 400-500 nm and at longer wavelengths of light where ocular tissues are relatively transparent, especially where light can penetrate blood and vascular tissue, i.e., 700-800 nm, especially at about 732 nm. Texaphyrins are particularly effective as visualizing agents in angiography of ocular blood vessels due to their localization in areas of abnormal permeability or damage as described in U.S. Ser. No. 08/763,451, incorporated by reference herein.
Texaphyrin-lipophilic molecules or texaphyrin-lipophilic molecule-vesicle complexes can be administered in a bolus injection allowing for a sufficiently large amount of drug to be present in the blood and for fast-turnaround between dosing and treatment. Further, texaphyrins are cleared quickly from the body; no toxicity to the eye has been observed in the use of texaphyrins in angiography.
A method of inducing formation of antibodies having binding specificity for a texaphyrin in a subject is also an aspect of the present invention. This method comprises administering a photosensitive texaphyrin-lipophilic molecule-vesicle complex to a subject, and irradiating the complex. Irradiating with light disrupts the vesicle, causing the contents to be deposited in the subject, thereby exposing the subject to the texaphyrin and inducing antibody production to texaphyrin. In this case, the texaphyrin may be considered a hapten; if the vesicle is a foreign cell, then the vesicle may be considered an adjuvant in addition to being the carrier that delivers the texaphyrin. By “foreign” is meant that the loaded vesicle is from a different species of animal than the animal into which the loaded cell is administered. For example, the cell for loading may be a goat cell, and the subject administered the loaded cell may be a rabbit.
In addition, a further immunogen may be loaded into the vesicle for inducing antibodies having binding specificity for that immunogen. Antibodies having binding specificity for the cellular contents of the disrupted cell may also be formed.
A further aspect of the invention is an antibody having binding specificity for a texaphyrin molecule. Such antibodies are useful for purification of a texaphyrin, for screening assays for the presence of a texaphyrin, or for the presence of texaphyrin degradation products from metabolic processes.
A method of making a texaphyrin-lipophilic molecule-cell complex is an aspect of the present invention. The method comprises i) obtaining a texaphyrin-lipophilic molecule conjugate, and ii) incubating a cell with the texaphyrin-lipophilic molecule conjugate in a hypotonic saline solution for a time and under conditions wherein a texaphyrin-lipophilic molecule-cell complex is formed An optional step is to include a drug or therapeutic agent when incubating in the hypotonic solution. A preferred cell is an erythrocyte. Advantages of using resealed or modified autologous erythrocytes as drug carriers include the fact that they are biodegradable, fully biocompatible, and nonimmunogenic; they exhibit flexibility in circulation time depending on their physicochemical properties; the entrapped drug is shielded from immunologic detection; and chemical modification of a drug is not required.
A method of making a texaphyrin-lipophilic molecule-liposome complex is an aspect of the present invention. The method comprises the step of incubating a texaphyrin-lipophilic molecule conjugate with a lipid or incorporating a texaphyrin-lipophilic molecule into a preformed liposome or micelle for a time and under conditions wherein a texaphyrin-lipophilic molecule-liposome complex is formed. An optional step is to include a drug or therapeutic agent during the incubation or incorporation.
In summary, a vesicle loaded with a texaphyrin-lipophilic molecule conjugate is useful in medical imaging, diagnosis, and therapy.
Following long-standing patent law convention, the terms “a” and “an” mean “one or more” when used in this application, including the claims.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Loading of a biological vesicle, such as a red blood cell (RBC), white blood cell (WBC), or a liposome with a texaphyrin-lipophilic molecule conjugate has previously not been shown. In the present invention, RBC's were successfully loaded with GdT2BET-estradiol conjugate (GTE 1 A ). However, attempted loading with GdT2BET alone was not successful, thereby indicating that a lipophilic molecule “handle” is an important aspect of the texaphyrin conjugate for loading success. Although the examples that follow demonstrate loading of red blood cells, the invention is not limited thereto; it is contemplated that other cells may be loaded as well, such as stem cells, bone marrow cells, platelets, granulocytes, lymphocytes including T and B cells, monocytes, neutrophils, eosinophils, plasma cells, macrophage, dendritic cells, or a cell of mesenchymal, ectodermal, or endodermal origin. Macrophages loaded with a texaphyrin-lipophilic molecule conjugate are expected to have utility in the treatment of atheroma since macrophages complex with cholesterol to form foam cells, a component of early atheroma
Loaded vesicles will naturally biolocalize into the blood, liver, spleen, bone marrow or lymphoid organs. Due to the size of a vesicle, such as a red blood cell or a liposome, compared to the size of a texaphyrin-lipophilic molecule conjugate, it is expected that the vesicle will dominate in tenns of biolocalization, and any localizing effect of a site-directing lipophilic molecule or the inherent biolocalization of texaphyrins will be secondary. For example, a texaphyrin-estradiol conjugate loaded into a vesicle may have some specificity for an estradiol receptor if the estradiol is superficial to the vesicle. Similarly, a vesicle loaded with a texaphyrin-cholesterol conjugate may have localization to the liver in addition to the natural localization of the vesicle to the liver.
Human LDL is a physiologic serum protein metabolized by cells via uptake by high affinity receptors. In particular, neovascularization has been shown to have increased numbers of LDL receptors; and by increasing the partitioning of the texaphyrn into the lipoprotein phase of the blood, LDL is expected to more efficiently deliver texaphyrin to target tissue. A texaphyrin-LDL conjugate is selective for neovascularization since leakage of the conjugate is expected to occur only in neovasculature due to the large size of the conjugate. LDL can be isolated and purified according to the procedure of Hauel et al., ( J. Clin. Invest., 34:1345, 1995).
In the loading of red blood cells of the present invention, red blood cells are separated from plasma and washed in normal saline. They are then treated with hypertonic saline which leaves them crenated with their internal salt concentration being higher than normal. The crenated cell pellet is resuspended in hypotonic saline containing a texaphyrin-lipophilic molecule conjugate. Because of the concentration difference between the cell interior and the hypotonic solution, water and the conjugate are driven into the cells. The cells are then washed several times in normal saline. This procedure results in a red blood cell with extensive labeling with the texaphyrin-lipophilic molecule conjugate. Further methods for loading cells are known to those of skill in this art in light of the present disclosure and may be utilized in the preparation of complexes of the present invention, for example, inducing an osmotic difference by use of sucrose solutions, treating with calcium chloride or calcium phosphate, or the like.
White cells are obtained from blood by, for example, centrifugation through Ficoll Hypaque media. This separates the white blood cells from plasma components and red blood cells. Other techniques for obtaining specific types of cells are known to one of skill in the art in light of the present disclosure.
Liposomes may be prepared by any number of techniques that include freeze-thaw, sonication, chelate dialysis, homogenization, solvent infusion, microemulsification, spontaneous formation, solvent vaporization, reverse phase, French pressure cell technique, or controlled detergent dialysis, for example. Such preparation methods are known to one of skill in the art in light of the present disclosure. Preparation may be carried out in a solution, such as a phosphate buffer solution, containing a texaphyrin-lipophilic molecule conjugate so that the conjugate is incorporated into the liposome membrane. Alternatively, the conjugate may be added to already formed liposomes. Liposomes employed in the present invention may be of any one of a variety of sizes, preferably less than about 100 nm in outside diameter, more preferably less than about 50 nm.
Micelles may be prepared by suspension of a texaphyrin-lipophilic molecule and lipid compound(s) in an organic solvent, evaporation of the solvent, resuspension in an aqueous medium, sonication and then centrifugation. Alternatively, the texaphyrin-lipophilic molecule may be added to preformed micelles, which micelles are made by methods known by one of skill in the art in light of the present disclosure.
Techniques and lipids for preparing liposomes and micelles are discussed in U.S. Pat. No. 5,466,438, and references cited therein. The disclosures of each of the foregoing references are incorporated herein by reference.
A texaphyrin-lipophilic molecule conjugate as used herein is an aromatic pentadentate expanded porphyrin analog with appended functional groups, at least one of which is a lipophilic molecule. Pendant groups may enhance solubility or biolocalization or may provide coupling sites for site-directing molecules.
Examples of texaphyrin-lipophilic molecule conjugates are those having structure I or structure II:
M is H, or a divalent or trivalent metal cation. A preferred divalent metal cation is Ca(II), Mn(II), Co(II), Ni(II), Zn(II), Cd(II), Hg(II), Fe(II), Sm(III), or UO 2 (II). A preferred trivalent metal cation is Mn(III), Co(III), Ni(III), Fe(III), Ho(III), Ce(III), Y(III), In(III), Pr(III), Nd(III), Sm(III), Eu(III), Gd(III), Tb((III), Dy(III), Er(III), Tm(III), Yb(III), Lu(III), La(III), or U(III). Most preferred trivalent metal cations are Lu(III) and Gd(III).
R 1 -R 4 , R 7 and R 8 are independently hydrogen, halide, hydroxyl, alkyl, alkenyl, alkynyl, aryl, haloalkyl, nitro, formyl, acyl, hydroxyalkyl, alkoxy, hydroxyalkoxy, hydroxyalkenyl, hydroxyalkynyl, saccharide, carboxy, carboxyalkyl, carboxyamide, carboxyamidealkyl, amino, aminoalkyl, a lipophilic molecule, or a couple that is coupled to a lipophilic molecule.
R 6 and R 9 are independently selected from the groups of R 1 -R 4 , R 7 and R 8 , with the proviso that the halide is other than iodide and the haloalkyl is other than iodoalkyl.
R 5 and R 10 -R 12 are independently hydrogen, alkyl, alkenyl, alkynyl, aryl, hydroxyalkyl, alkoxy, hydroxyalkoxy, hydroxyalkenyl, hydroxyalkynyl, carboxyalkyl, carboxyamide, carboxyamidealkyl, amino, aminoalkyl, or a couple that is coupled to a saccharide, or to a lipophilic molecule. The term “n” is an integer value less than or equal to 5.
R 13 is alkyl, alkenyl, oxyalkyl, or hydroxyalkyl having up to about 3 carbon atoms and having rotational flexibility around a first-bound carbon atom. Rotational flexibility allows the rest of the group to be positioned outside the plane of the texaphyrin. Thus, for example, a preferred alkenyl is CH 2 —CH═CH 2 . The pyrrole nitrogen substituent is most preferably a methyl group. A texaphyrin having a methyl group attached to a ring nitrogen is described in U.S. Pat. No. 5,457,183, incorporated by reference herein.
In this texaphyrin-lipophilic molecule conjugate, at least one of R 1 -R 12 is a lipophilic molecule or a couple that is coupled to a lipophilic molecule. In a more preferred embodiment, at least one of R 1 , R 2 , R 3 , R 4 , R 7 and R 9 is a lipophilic molecule, and more preferably is estradiol or cholesterol, or a couple that is coupled to estradiol or cholesterol. In a presently preferred embodiment, the texaphyrin-lipophilic molecule conjugate is the conjugate depicted herein as 1 A or 1 B .
Texaphyrins of the present conjugates may be metal-free or may be in a complex with a metal. Divalent and trivalent metal complexes of texaphyrins are by convention shown with a formal charge of n + , where n=1 or 2, respectively. The value “n” will typically be an integer less than or equal to 5; however, one skilled in the art in light of the present disclosure would realize that the value of n would be altered due to any charges present on substituents R 1 -R 12 .
It is understood by those skilled in the art that texaphyrin-metal complexes have one or more additional ligands providing charge neutralization and/or coordinative saturation to the metal ion. Such ligands include chloride, nitrate, acetate, cholate, and hydroxide, among others.
Photosensitive texaphyrins are used for PDT. A photosensitive texaphyrin may be a free-base texaphyrin or may be metallated with a diamagnetic metal. The term “photosensitive,” as used herein, means that upon photoirradiation by light associated with the absorption profile of texaphyrin, texaphyrin effects the generation of oxygen products that are cytotoxic. Cytotoxic oxygen products may be singlet oxygen, hydroxyl radicals, superoxide, hydroperoxyl radicals, or the like. A photosensitive texaphyrin may be a texaphyrin metal complex, and in this embodiment, the metal M is a diamagnetic metal cation and the diamagnetic metal cation preferably is Lu(III), La(III), In(III), Y(III), Zn(II) or Cd(II). A more preferred diamagnetic metal cation is Lu(III).
Representative examples of alkanes useful as alkyl group substituents of the present invention include methane, ethane, straight-chain, branched or cyclic isomers of propane, butane, pentane, hexane, heptane, octane, nonane and decane, with methane, ethane and propane being preferred. Alkyl groups having up to about thirty, or up to about fifty carbon atoms are contemplated in the present invention. Representative examples of substituted alkyls include alkyls substituted by two or more functional groups as described herein.
Representative examples of alkenes useful as alkenyl group substituents include ethene, straight-chain, branched or cyclic isomers of propene, butene, pentene, hexene, heptene, octene, nonejne and decene, with ethene and propene being preferred. Alkenyl groups having up to about thirty or fifty carbon atoms, and up to about five double bonds, or more preferably, up to about three double bonds are contemplated in the present invention.
Representative examples of alkynes useful as alkynyl group substituents include ethyne, straight-chain, branched or cyclic isomers of propyne, butyne, pentyne, hexyne, heptyne, octyne, nonyne and decyne, with ethyne and propyne being preferred. Alkynyl groups having up to about thirty, or up to about fifty carbon atoms, and having up to about five or up to about three triple bonds are contemplated in the present invention.
The aryl may be a compound whose molecules have the ring structure characteristic of benzene, naphthalene, phenanthrene, anthracene, and the like, i.e., either the 6-carbon ring of benzene or the condensed 6-carbon rings of the other aromatic derivatives. For example, an aryl group may be phenyl or naphthyl, and the term as used herein includes both unsubstituted aryls and aryls substituted with one or more nitro, carboxy, sulfonic acid, hydroxy, oxyalkyl or halide substituents. In this case, the substituent on the phenyl or naphthyl may be added in a synthetic step after the condensation step which forms the macrocycle.
Among the halide substituents, chloride, bromide, fluoride and-iodide are contemplated in the practice of this invention with the exception of iodide for R 6 and R 9 . R 6 and R 9 may have chloride, bromide or fluoride substituents. Representative examples of haloalkyls used in this invention include halides of methane, ethane, propane, butane, pentane, hexane, heptane, octane, nonane and decane, with halides, preferably chlorides or bromides, of methane, ethane and propane being preferred.
“Hydroxyalkyl” means alcohols of alkyl groups. Preferred are hydroxyalkyl groups having one to twenty, more preferably one to ten, hydroxyls. “Hydroxyalkyl” is meant to include glycols and polyglycols; diols of alkyls, with diols of C 1-10 alkyls being preferred, and diols of C 1-3 alkyls being more preferred; and polyethylene glycol, polypropylene glycol and polybutylene glycol as well as polyalkylene glycols containing combinations of ethylene, propylene and butylene.
Representative examples of oxyalkyls include the alkyl groups as herein described having ether linkages. “Oxyalkyl” is meant to include polyethers with one or more functional groups. The number of repeating oxyalkyls within a substituent may be up to 200, preferably is from 1-20, and more preferably, is 1-10, and most preferably is 1-5. A preferred oxyalkyl is O(CH 2 CH 2 O) x CH 3 where x=1-100, preferably 1-10, and more preferably, 1-5.
“Oxyhydroxyalkyl” means alkyl groups having ether or ester linkages, hydroxyl groups, substituted hydroxyl groups, carboxyl groups, substituted carboxyl groups or the like.
Representative examples of thioalkyls include thiols of ethane, thiols of straigth-chain, branched or cyclic isomers of propane, butane, pentane, hexane, heptane, octane, nonane and decane, with thiols of ethane (ethanethiol, C 2 H 5 SH) or propane (propanethiol, C 3 H 7 SH) being preferred. Sulfate-substituted alkyls include alkyls as described above substituted by one or more sulfate groups, a representative example of which is diethyl sulfate ((C 2 H 5 ) 2 SO 4 ).
Representative examples of phosphates include phosphate or polyphosphate groups. Representative examples of phosphate-substituted alkyls include alkyls as described above substituted by one or more phosphate or polyphosphate groups. Representative examples of phosphonate-substituted alkyls include alkyls as described above substituted by one or more phosphonate groups.
Representative examples of caboxy groups include carboxylic acids of the alkyls described above as well as aryl carboxylic acids such as benzoic acid. Representative examples of carboxyamides include primary carboxyamides (CONH 2 ), secondary (CONHR′) and tertiary (CONR′R″) carboxyamides where each of R′ and R″ is a functional group as described herein.
Representative examples of useful amines include a primary, secondary or tertiary amine of an alkyl as described hereinabove.
“Carboxyamidealkyl” means alkyl groups with secondary or tertiary amide linkages or the like. “Carboxyalkyl” means alkyl groups having hydroxyl groups, carboxyl or amide substituted ethers, ester linkages, tertiary amide linkages removed from the ether or the like.
The term “saccharide” includes oxidized, reduced or substituted saccharide; hexoses such as D-glucose, D-mannose or D-galactose; pentoses such as D-ribose or D-arabinose; ketoses such as D-ribulose or D-fructose; disaccharides such as sucrose, lactose, or maltose; derivatives such as acetals, amines, and phosphorylated sugrs; oligosaccharides, as well as open chain forms of various sugars, and the like. Examples of amine-derivatized sugars are galactosamine, glucosamine, sialic acid and D-glucarine derivatives such as 1-amino-1-deoxysorbitol.
A couple may be described as a linker, i.e., the covalent product formed by reaction of a reactive group designed to attach covalently another molecule at a distance from the texaphyrin macrocycle. Exemplary linkers or couples are amides, amine, disulfide, thioether, ether, polyether, ester, or phosphate covalent bonds. PCT publication WO 94/29316 is incorporated by reference herein for providing syntheses of texaphyrin-conjugates having these types of linkages or couples.
In most preferred embodiments, conjugates and appended groups are covalently bonded to the texaphyrin via a carboncarbon, carbon-nitr 6 gen, carbon-sulfur, or a carbon-oxygen bond, more preferably a carbon-oxygen or a carbon-nitrogen bond.
In the practice of the present invention, preferred functionalizations for texaphyrin I or II are: when R 6 and R 9 are other than hydrogen, then R 5 and R 10 are hydrogen or methyl; and when R 5 and R 10 are other than hydrogen, then R 6 and R 9 are hydrogen, hydroxyl, or halide other than iodide. Other preferred functionalizations are where R 6 and R 9 are hydrogen, then R 5 , R 10 , R 11 , and R 12 are independently hydrogen, phenyl, lower alkyl or lower hydroxyalkyl. The lower alkyl is preferably methyl or ethyl, more preferably methyl. The lower hydroxyalkyl is preferably of 1 to 6 carbons and 1 to 4 hydroxy groups, more preferably 3-hydroxypropyl. The phenyl may be substituted or unsubstituted.
In a presently preferred texaphyrin I or II, R 1 is CH 2 CH 3 or (CH 2 ) 2 CH 2 OH; R 2 and R 3 are CH 2 CH 3 ; R 4 is CH 3 ; R 5 , R 6 , and R 9 -R 12 are H; R 8 is a lipophilic molecule or a couple that is coupled to a lipophilic molecule; and R 7 is H, OH, OCH 3 or O(CH 2 CH 2 O) x CH 3 where x is 1-10 and preferably 1-5, more preferably 3. Preferably, R 8 is estradiol or cholesterol, or a couple that is coupled to estradiol or cholesterol.
A couple that is coupled to a lipophilic molecule may be further described as O(CH 2 CH 2 O) m — where m is 1-10 and preferably 1-5, or as O(CH 2 ) n CO— where n is 1-10 and preferably 1-3.
Presently preferred texaphyrin-lipophilic molecule conjugates, T2BET-estradiol conjugates, are provided as 1 A and 1 B .
“T2” refers to two hydroxyl groups on the tripyrrane portion of texaphyrin, “BET” refers to the ethoxy R groups on the benzene portion of the molecule, and estradiol is the lipophilic molecule of this conjugate. The synthesis of this conjugate is provided in Example 1.
In other presently preferred texaphyrin compounds I or II, R 1 -R 12 are as in Tables A and B for texaphyrins A1-A108, and M is as defined hereinabove. While the cited texaphyrins are presently prefenrrd for use in the present invention, the invention is not limited thereto.
TABLE A
Representative Substituents for Texaphyrin Macrocycles A1-A108 of the Present Invention.
Substituents for R 1 -R 6 are provided in TABLE A and for R 7 -R 12 in TABLE B.
TXP
R 1
R 2
R 3
R 4
R 5
R 6
A1
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
CH 3
H
H
A2
″
″
″
″
″
″
A3
″
″
″
″
″
″
A4
″
″
″
″
″
″
A5
″
″
″
″
″
″
A6
″
″
″
″
″
″
A7
″
″
″
″
″
″
A8
″
″
″
″
″
″
A9
″
″
″
″
″
″
A10
″
″
″
″
″
″
A11
″
″
″
″
″
″
A12
″
COOH
COOH
″
″
″
A13
CH 2 (CH 2 ) 2 OH
COOCH 2 CH 3
COOCH 2 CH 3
CH 3
H
H
A14
CH 2 CH 2 CON(CH 2 CH 2 OH) 2
CH 2 CH 3
CH 2 CH 3
″
″
″
A15
CH 2 CH 2 ON(CH 3 )CH 2 —
″
″
″
″
″
(CHOH) 4 CH 2 OH
A16
CH 2 CH 3
″
″
″
″
″
A17
CH 2 (CH 2 ) 2 OH
″
″
″
″
″
A18
″
″
″
″
″
″
A19
″
″
″
″
″
″
A20
CH 2 CH 3
CH 3
CH 2 CH 2 COOH
″
″
″
A21
″
″
CH 2 CH 2 CO-
″
″
″
lipophilic molecule
A22
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
″
″
″
A23
″
″
″
″
″
″
A24
″
″
″
″
″
″
A25
″
″
″
″
″
″
A26
″
″
″
″
″
″
A27
″
COOH
COOH
″
″
″
A28
″
COOCH 2 CH 3
COOCH 2 CH 3
″
″
″
A29
CH 2 CH 2 CO-lipophilic
CH 2 CH 3
CH 2 CH 3
CH 3
H
H
molecule
A30
CH 2 CH 2 O-lipophilic molecule
″
″
″
″
″
A31
CH 2 (CH 2 ) 2 OH
″
CH 2 CH 2 CO-
″
″
″
lipophilic molecule
A32
″
″
CH 2 CH 2 CO-
″
″
″
lipophilic molecule
A33
CH 2 CH 3
CH 3
CH 2 CH 2 COOH
″
″
″
A34
″
″
CH 2 CH 2 CO-
″
″
″
lipophilic molecule
A35
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
″
″
″
A36
″
″
″
″
″
″
A37
″
″
″
″
″
″
A38
″
″
″
″
″
″
A39
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
CH 3
H
COOH
A40
″
″
″
″
″
COOH
A41
″
″
″
″
″
CONHCH—
(CH 2 OH) 2
A42
″
″
″
″
″
CONHCH—
(CH 2 OH) 2
A43
″
″
″
″
″
H
A44
″
″
″
″
″
OCH 3
A45
″
″
″
″
″
″
A46
″
″
″
″
″
″
A47
″
″
″
″
″
″
A48
″
″
″
″
″
″
A49
″
″
″
″
″
″
A50
″
″
″
″
″
CH 3
A51
″
″
″
″
″
″
A52
″
″
″
″
″
″
A53
″
″
″
″
″
″
A54
″
″
″
″
CH 3
H
A55
″
″
″
″
″
″
A56
″
″
″
″
″
″
A57
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
CH 3
CH 3
H
A58
″
″
″
″
″
″
A59
″
″
″
″
″
″
A60
″
″
″
″
″
″
A61
″
″
″
″
″
″
A62
″
″
″
″
″
″
A63
″
″
″
″
″
OH
A64
″
″
″
″
″
F
A65
″
″
″
″
CH 2 (CH 2 ) 6 OH
H
A66
″
″
″
″
H
Br
A67
″
″
″
″
″
NO 2
A68
″
″
″
″
″
COOH
A69
″
″
″
″
″
CH 3
A70
″
″
″
″
C 6 H 5
H
A71
″
COOH
COOH
″
CH 2 CH 3
″
A72
″
COOCH 2 CH 3
COOCH 2 CH 3
″
CH 3
″
A73
CH 2 CH 2 CON(CH 2 CH 2 OH) 2
CH 2 CH 3
CH 2 CH 3
″
″
″
A74
CH 2 CH 2 ON(CH 3 )CH 2
″
″
″
″
″
(CHOH) 4 CH 2 OH
A75
CH 2 CH 3
″
″
″
CH 2 (CH 2 ) 6 OH
″
A76
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
CH 3
CH 3 or CH 2 CH 3
H
A77
″
″
″
″
″
″
A78
″
″
″
″
″
″
A79
″
″
″
″
″
″
A80
″
″
″
″
″
″
A81
″
″
″
″
″
″
A82
″
″
″
″
″
″
A83
″
″
″
″
″
″
A84
″
″
″
″
″
″
A85
″
″
″
″
H
″
A86
″
″
″
″
″
″
A87
″
″
″
″
CH 3 or CH 2 CH 3
″
A88
″
″
″
″
″
″
A89
″
″
″
″
″
″
A90
″
″
″
″
″
″
A91
″
″
″
″
″
″
A92
″
″
″
″
″
″
A93
″
COOH
COOH
″
″
″
A94
″
COOCH 2 CH 3
COOCH 2 CH 3
″
″
″
A95
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 2 CO-
″
″
″
lipiphilic molecule
A96
CH 2 CH 3
CH 3
CH 2 CH 2 COOH
″
″
″
A97
″
″
CH 2 CH 2 CO-
″
″
″
lipiphilic molecule
A98
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
CH 2 CH 3
″
″
″
A99
CH 2 CH 3
″
″
″
″
″
A100
″
″
″
″
″
″
A101
″
″
″
″
″
″
A102
″
″
″
″
″
″
A103
″
″
″
″
″
″
A104
″
″
″
″
″
″
A105
CH 2 (CH 2 ) 2 OH
″
″
″
″
″
A016
″
″
″
″
″
″
A107
″
″
″
″
″
″
A108
″
″
″
″
″
″
TABLE B
Representative Substituents for Texaphyrin Macrocycles A1-A108 of the Present Invention.
Substituents for R 1 -R 6 are provided in TABLE A and for R 7 -R 12 in TABLE B.
TXP
R 7
R 8
R 9
R 10
R 11
R 12
A1
O(CH 2 ) 3 OH
O(CH 2 ) 3 OH
H
H
H
H
A2
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
A3
O(CH 2 ) n CON-linker-lipophilic
″
″
″
″
″
molecule, n = 1-10
A4
O(CH 2 ) n CON-linker-lipophilic
H
″
″
″
″
molecule, n = 1-10
A5
OCH 2 CO-lipophilic molecule
″
″
″
″
″
A6
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
″
A7
OCH 2 CON-linker-lipophilic
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
molecule
A8
OCH 2 CO-lipophilic molecule
″
″
″
″
″
A9
O(CH 2 CH 2 O) 100 CH 3
″
″
″
″
″
A10
OCH 2 CON(CH 2 CH 2 OH) 2
H
″
″
″
″
A11
CH 2 CON(CH 3 )CH 2-
″
″
″
″
″
(CHOH) 4 CH 2 OH
A12
CH 2 CON(CH 3 )CH 2-
″
″
″
″
″
(CHOH) 4 CH 2 OH
A13
CH 2 CON(CH 3 )CH 2-
H
H
H
H
H
(CHOH) 4 CH 2 OH
A14
CH 2 CON(CH 3 )CH 2-
″
″
″
″
″
(CHOH) 4 CH 2 OH
A15
OCH 3
OCH 3
″
″
″
″
A16
OCH 2 CO 2 -lipophilic molecule
H
″
″
″
″
A17
O(CH 2 ) n COOH, n = 1-10
″
″
″
″
″
A18
(CH 2 ) n -CON-linker-lipophilic
″
″
″
″
″
molecule, n = 1-10
A19
YCOCH 2 -linker-lipophilic
″
″
″
″
″
molecule, Y = NH,O
A20
O(CH 2 ) 2 CH 2 OH
O(CH 2 ) 2 CH 2 OH
″
″
″
″
A21
″
″
″
″
″
″
A22
OCH 2 COOH
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
A23
O(CH 2 ) n CO-lipophilic
H
″
″
″
″
molecule, n = 1-10
A24
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) n -lipophilic
″
″
″
″
molecule, n = 1-10, in
particular, n = 3 or 5
A25
OCH 3
OCH 2 CO-lipophilic
″
″
″
″
molecule
A26
″
CH 2 CO-lipophilic molecule
″
″
″
″
A27
″
″
″
″
″
″
A28
OCH 3
CH 2 CO-lipophilic molecule
H
H
H
H
A29
″
OCH 3
″
″
″
″
A30
″
″
″
″
″
″
A31
H
O(CH 2 ) n COOH, n = 1-10
″
″
″
″
A32
″
(CH 2 ) n -CON-linker-
″
″
″
″
lipophilic molecule, n = 1-10
A33
OCH 3
O(CH 2 CH 2 O) 3 —CH 3
″
″
″
″
A34
″
″
″
″
″
″
A35
H
O(CH 2 ) n CO-lipophilic
″
″
″
″
molecule, n = 1-10
A36
OCH 3
O(CH 2 ) n CO-lipophilic
″
″
″
″
molecule, n = 1-10
A37
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 ) n CO-lipophilic
″
″
″
″
molecule, n = 1-10
A38
″
O(CH 2 CH 2 O) n -lipophilic
″
″
″
″
molecule, n = 1-10
A39
O(CH 2 ) 3 OH
O(CH 2 ) 3 OH
O(CH 2 ) 3 OH
H
H
H
A40
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O( 3 CH 3
COOH
″
″
″
A41
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 3 CH 3
(CH 2 ) 3 OH
″
″
″
A42
″
″
O(CH 2 CH 2 O) 3 CH 3
″
″
″
A43
″
O(CH 2 ) 3 COOH
″
″
″
″
A44
H
OCH 2 COOH
OCH 3
″
″
″
A45
″
OCH 2 COOH
″
″
″
″
A46
″
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
A47
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
″
A48
″
OCH 2 CO-lipophilic
″
″
″
″
molecule
A49
″
OCH 2 COOH
″
″
″
″
A50
″
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O)CH 3
″
″
″
A51
″
OCH 2 COOH
″
″
″
″
A52
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 100 CH 3
OCH 3
″
″
″
A53
H
OCH 2 CO-lipophilic
″
″
″
″
molecule
A54
O(CH 2 ) 3 OH
O(CH 2 ) 3 OH
H
CH 3
″
″
A55
H
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
A56
O(CH 2 CH 2 O) 3 CH 3
″
″
″
″
″
A57
H
OCH 2 CO-lipophilic
H
CH 3
″
″
molecule
A58
″
OCH 2 CO-lipophilic
″
″
″
″
molecule
A59
″
OCH 2 CON
″
″
″
″
(CH 2 CH 2 OH) 2
A60
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 100 CH 3
″
″
″
″
A61
″
OCH 2 CO-lipophilic
″
″
″
″
molecule
A62
H
CH 2 CON(CH 3 )CH 2
″
″
″
″
(CHOH) 4 CH 2 OH
A63
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 3 CH 3
OH
″
″
″
A64
″
″
F
″
″
″
A65
″
″
H
CH 2 (CH 2 ) 6 OH
″
″
A66
″
″
Br
H
″
″
A67
″
″
NO 2
″
″
″
A68
″
″
COOH
″
″
″
A69
″
″
CH 3
″
″
″
A70
″
″
H
C 6 H 5
″
″
A71
″
″
″
CH 2 CH 3
″
″
A72
″
″
″
CH 3
″
″
A73
″
″
″
″
″
″
A74
OCH 3
OCH 3
″
″
″
″
A75
H
OCH 2 CO-lipophilic
″
CH 2 (CH 2 ) 6 OH
″
″
molecule
A76
O(CH 2 ) 3 OH
O(CH 2 ) 3 OH
H
CH 3 or
CH 3 or
CH 3 or
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A77
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 3 CH 3
″
CH 3 or
CH 3 or
CH 3 or
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A78
O(CH 2 ) 3 OH
O(CH 2 CH 2 O) 3 CH 3
″
CH 3 or
CH 3 or
CH 3 or
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A79
H
O(CH 2 ) n CO-lipophilic
″
CH 3 or
CH 3 or
CH 3 or
molecule, n = 1,2,3
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A80
H
O(CH 2 ) n CO-lipophilic
″
CH 3 or
CH 3 or
CH 3 or
molecule, n = 1,2,3
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A81
H
O(CH 2 ) 3 OH
″
CH 3 or
CH 3 or
CH 3 or
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A82
O(CH 2 ) 3 OH
O(CH 2 ) n CO-lipophilic
″
CH 3 or
CH 3 or
CH 3 or
molecule, n = 1,2,3,
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A83
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 ) n CO-lipophilic
″
CH 3 or
CH 3 or
CH 3 or
molecule, n = 1-10
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A84
″
O(CH 2 ) n CO-lipophilic
″
CH 3 or
CH 3 or
CH 3 or
molecule, n = 1,2,3
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A85
″
O(CH 2 CH 2 O) 3 CH 3
″
CH 3 or
CH 3 or
CH 3 or
CH 2 CH 3
CH 2 CH 3
CH 2 CH 3
A86
″
″
″
CH 3 or
CH 2 (CH 2 ) 2 OH
CH 2 (CH 2 ) 2 OH
CH 2 CH 3
A87
″
″
″
CH 3 or
″
″
CH 2 CH 3
A88
″
O(CH 2 CH 2 O) 3 CH 3
″
CH 3 or
″
″
CH 2 CH 3
A89
O(CH 2 CH 2 O) 3 CH 2 —CH 2 -
O(CH 2 CH 2 O) 120 CH 3
H
H
H
H
lipophilic molecule
A90
H
lipophilic molecule
″
″
″
″
A91
OCH 2 CO-lipophilic molecule
OCH 2 CO-lipophilic
″
″
″
″
molecule
A92
CH 2 CO-lipophilic molecule
CH 2 CO-lipophilic molecule
″
″
″
″
A93
″
″
″
″
″
″
A94
″
″
″
″
″
″
A95
H
YCOCH 2 -linker-lipophilic
″
″
″
″
molecule Y = NH,O
A96
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 CH 2 O) 5 -lipophilic
″
″
″
″
molecule
A97
″
O(CH 2 CH 2 O) 5 -lipophilic
″
″
″
″
molecule
A98
H
O(CH 2 ) 3 CO-lipophilic
″
″
″
″
molecule
A99
″
O(CH 2 ) 3 CO-lipophilic
″
″
″
″
molecule
A100
OCH 3
O(CH 2 ) 3 CO-lipophilic
″
″
″
″
molecule
A101
O(CH 2 CH 2 O) 3 CH 3
O(CH 2 ) 3 CO-lipophilic
″
″
″
″
molecule
A102
″
O(CH 2 CH 2 O) 5 -estradiol
″
″
″
″
A103
″
O(CH 2 CH 2 O) n -estradiol,
″
″
″
″
n = 1-10
A104
″
O(CH 2 CH 2 O) n -cholesterol,
″
″
″
″
n = 1-10
A105
″
O(CH 2 CH 2 O) n -cholesterol,
″
″
″
″
n = 1-10
A106
OCH 3
O(CH 2 CH 2 O) n -estradiol,
″
″
″
″
n = 1-10
A107
H
O(CH 2 CH 2 O) n -estradiol,
″
″
″
″
n = 1-10
A108
O(CH 2 CH 2 O) x CH 3 , x = 1-10
O(CH 2 CH 2 O) n -estradiol,
″
″
″
″
n = 1-10
One skilled in the art of organic synthesis in light of the present disclosure and the disclosures in the patents, applications and publications incorporated by reference herein could extend and refine the referenced basic synthetic chemistry to produce texaphyrins having various substituents. For example, polyether-linked polyhydroxylated groups, saccharide substitutions in which the saccharide is appended via an acetal-like glycosidic linkage, an oligosaccharide or a polysaccharide may be similarly linked to a texaphyrin. A doubly carboxylated texaphyrin in which the carboxyl groups are linked to the texaphyrin core via aryl ethers or functionalized alkyl substituents could be converted to various esterified products wherein the ester linkages serve to append further hydroxyl-containing substituents. Polyhydroxylated texaphyrin derivatives may be synthesized via the use of secondary amide linkages. Saccharide moieties may be appended via amide bonds. Polyhydroxylated texaphyrin derivatives containing branched polyhydroxyl(polyol) subunits may be appended to the texaphyrin core via aryl ethers or ester linkages.
Treatment of carboxylated texaphyrins with thionyl chloride or p-nitrophenol acetate would generate activated acyl species suitable for attachment to monoclonal antibodies or other biomolecules of interest. Standard in situ coupling methods (e.g., 1,1′-carbonyldiimidazole) could be used to effect the conjugation.
Substituents at the R 6 and R 9 positions on the B (benzene ring) portion of the macrocycle are incorporated into the macrocycle by their attachment to ortho-phenylenediamine in the 3 and 6 positions of the molecule. Substituents at the R 5 and R 10 positions on the T (tripyrrane) portion of the macrocycle are incorporated by appropriate functionalization of carboxyl groups in the 5 positions of the tripyrrane at a synthetic step prior to condensation with a substituted ortho-phenylenediamine. A lipophilic molecule may be added after the condensation step to form the texaphyrin macrocycle.
Lipophilic molecules having an amine functionality are modified post-synthetically with an activated carboxylic ester derivative of a texaphyrin. In the presence of a Lewis acid such as FeBr 3 , a bromide-derivatized texaphyrin will react with an hydroxyl group of a lipophilic molecule to form an ether linkage between the texaphyrin linker and the lipophilic molecule. A couple that is coupled to a lipophilic molecule may be further described as O(CH 2 CH 2 O) m — where m is 1-10 and preferably 1-5, or as O(CH 2 ) n CO— where n is 1-10 and preferably 1-3.
Texaphyrin-lipophilic molecule conjugates may be made by methods as described herein and as known and described in the art, such as in U.S. patents, in pending applications, previously incorporated by reference herein. Texaphyrins have a number of properties that lend themselves for use in imaging and photodynamic treatment protocols, for example: texaphyrins have inherent biolocalization, localizing to tumors, atheroma, or the liver; they have absorption in the physiologically important range of 700-900 nm; they provide stable chelation for an otherwise toxic metallic cation; and are sufficiently nontoxic for in vivo use.
An aspect of the present invention is use of texaphyrin-lipophilic molecules or texaphyrin-lipophilic molecule-vesicle complexes in ocular diagnosis and therapy; especially diagnostic angiograms, and photodynamic therapy of conditions of the eye characterized by abnormal vasculature. “Abnormal vasculature”, as used herein, means undesirable vasculature; neovasculature; irregular, occluded, weeping, or inflamed ocular vessels or ocular tissues; inflammatory ocular membranes; abnormal conditions having to do with channeling of fluids in the ocular area, especially blood vessels; and includes conditions such as macular degeneration, glaucoma, disc or retinal neovascularization in diabetic retinopathy, pannus which is abnormal superficial vascularization of the cornea or conjunctiva, pterygium which is thickening of the bulbar conjunctiva on the cornea, conditions having retinal or choroidal neovasculature, ocular histoplasmosis syndrome, myopia, ocular inflammatory diseases, central serous retinopathy, subretinal neovascular membrane, or neovasculature induced by neoplasm, such as melanoma or retinal blastoma, for example.
“Observing the vasculature”, as used herein, means carrying out an imaging procedure and collecting information from an angiogram where fluorescent texaphyrins are used, from an x-ray, or from magnetic resonance image, for example, to interpret the condition of the eye. The condition of the eye may be normal, or may include vascular leakage or occlusions, for example. As used herein, “eye” or “ocular” includes the eye, underlying and adjacent tissue, and related tissues near and around the eye that have an influence on the functioning of the eye.
The parameters used for effective angiography and effective treatment in PDT methods of the invention are interrelated. Therefore, the dose is adjusted with respect to other parameters, for example, fluence, irradiance, duration of the light used in photodynamic therapy, and the time interval between administration of the dose and the therapeutic irradiation. Such parameters should be adjusted to produce significant damage to abnormal vascular tissue without significant damage to the surrounding tissue or, on the other hand, to enable the observation of blood vessels in the eye without significant damage to the surrounding tissue. Typically, the dose of texaphyrin of the texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex used is within the range of from about 0.1 to about 50 μmol/kg/treatment, and preferably from about 0.10-20 μmol/kg/treatment. Further, as the texaphyrin dose is reduced, the fluence required to treat neovascular tissue may change.
After the photosensitizing texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex has been administered, the tissue being treated in the eye is irradiated at the wavelength of maximum absorbance of the texaphyrin, usually either about 400-500 nm or about 700-800 nm. The light source may be a laser, a light-emitting diode, or filtered light from, for example, a xenon lamp; the light may have a wavelength range of about 400-900 nm, preferably about 400-500 nm or 700-800 nm, more preferably about 730-770 nm; and the light may be administered topically, endoscopically, or interstitially (via, e.g., a fiber optic probe). Preferably, the light is administered using a slit-lamp delivery system. A wavelength in this range is especially preferred since blood and retinal pigment epithelium are relatively transparent at longer wavelengths and, therefore, treatment results in less tissue damage and better light penetration. The fluence and irradiance during the irradiating treatment can vary depending on type of tissue, depth of target tissue, and the amount of overlying fluid or blood.
The optimum length of time following texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex administration until light treatment can vary depending on the mode of administration, the form of administration, and the type of target tissue. For example, a time interval of minutes to about 5 h should be appropriate for vascular tissue. The time of light irradiation after administration may be important as one way of maximizing the selectivity of the treatment, thus minimizing damage to structures other than the target tissues. For a human, it is believed that the texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex begins to reach the retinal and choroidal vasculature within seconds following administration, and persists for a period of minutes to hours, depending on the dose given. Treatment within the first five minutes following administration should generally be activated with focused light. At later time points, both focused or general illumination may be used.
In addition, texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex can be used to observe the condition of blood vessels as a single agent, or in concert with other dyes such as fluorescein or indocyanine green to follow the progress of destruction of abnormal vascular tissue. In such angiographic systems, a sufficient amount of texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex is administered to produce an observable fluorescent emission when excited by light, preferably light having a wavelength in the range of about 430-480 nm. Images are recorded by illuminating the eye with light in the excitation wavelength range and detecting the amount of fluorescent light emitted at the emission wavelength of about 730-760 nm. A preferred device, which both emits and receives light in the 430-760 nm range, is the TOPCON™ 50VT camera in the Ophthalmic Imaging System (Ophthalmic Imaging System Inc., 221 Lathrop Way, Suite 1, Sacramento Calif.).
A camera is used to collect the emitted fluorescent light, digitize the data, and store it for later depiction on a video screen, as a hard paper copy, or in connection with some other imaging system. While a film recording device may be used when additional dyes such as fluorescein are being used in combination with the texaphyrin-lipophilic molecule conjugate or texaphyrin-lipophilic molecule-vesicle complex, a CCD camera (charge-coupled device) is preferable as being able to capture emissions at higher wavelengths. As a result, one can obtain more sophisticated information regarding the pattern and extent of vascular structures in different ocular tissue layers, giving the ability to detect the “leakiness” that is characteristic of new or inflamed blood vessels. Further, it is preferable to use a camera that is capable of providing the excitation light, appropriately filtered to deliver only light of the desired excitation wavelength range, and then to capture the emitted, fluorescent light with a receiving device, appropriately filtered to receive only light in the desired emission wavelength range.
For the above-described uses, texaphyrin-lipophilic molecule-cell or -liposome complexes are provided as pharmaceutical preparations. A pharmaceutical preparation of such a complex may be administered alone or in combination with pharmaceutically acceptable carriers, in either single or multiple doses. Suitable pharmaceutical carriers include inert solid diluents or fillers, sterile aqueous solution and various organic solvents. The pharmaceutical compositions formed by combining a complex of the present invention and the pharmaceutically acceptable carriers are then easily administered in a variety of dosage forms such as injectable solutions.
For parenteral administration, suspensions of the liposomal complex in sesame or peanut oil, aqueous propylene glycol, or in sterile aqueous solution may be employed. Such aqueous solutions should be suitably buffered if necessary and the liquid diluent first rendered isotonic with sufficient saline or glucose. These particular aqueous solutions are especially suitable for intravenous, intramuscular, subcutaneous and intraperitoneal administration. In this connection, sterile aqueous media which can be employed will be known to those of skill in the art in light of the present disclosure. Intravenous administration of loaded red or white blood cell complexes of the present invention is contemplated as the most preferred method of administration.
Sterile technique is used for removal of cells from a patient, loading with a sterile texaphyrin-lipophilic molecule conjugate and replacement of loaded cells into the same patient. A pharmaceutically acceptable carrier may be used, which carrier can be a solvent or dispersion medium containing, for example, water, ethanol, polyol (for example, glycerol, propylene glycol, and liquid polyethylene glycol, and the like), suitable mixtures thereof, and vegetable oils. The proper fluidity can be maintained, for example, by the use of a coating, such as lecithin, and by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars such as mannitol or dextrose or sodium chloride. A more preferable isotonic agent is a mannitol solution of about 2-8% concentration, and, most preferably, of about 5% concentration.
Sterile conjugate solutions are prepared by incorporating the active compounds in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filtered sterilization. Generally, dispersions are prepared by incorporating the various sterilized active ingredients into a sterile vehicle which contains the basic dispersion medium and the required other ingredients from those enumerated above. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum-drying and freeze-drying techniques which yield a powder of the active ingredient plus any additional desired ingredient from a previously sterile-filtered solution thereof.
As used herein, “pharmaceutically acceptable carrier” includes any and all solvents, dispersion media, coatings, antibacterial and antifungal agents, isotonic and absorption delaying agents and the like. The use of such media and agents for pharmaceutically active substances is well known in the art. Except insofar as any conventional media or agent is incompatible with the active ingredient, its use in the therapeutic compositions is contemplated. Supplementary active ingredients can also be incorporated into the compositions.
For fluorescent detection methods of the present invention, a sufficient amount of texaphyrin is administered to produce an observable fluorescent emission when excited by light, preferably light having a wavelength in the range of about 430-480 nm. Images are recorded by illuminating with light in the excitation wavelength range and detecting the amount of fluorescent light emitted at the emission wavelength of preferably about 730-760 nm. Such dose can be determined without undue experimentation by methods known in the art or as described herein.
The complexes to be used in the photodynamic methods of the present invention are administered in a pharmaceutically effective amount. By “pharmaceutically effective” is meant that dose which will, upon exposure to light, cause disruption of the loaded vesticle. The specific dose will vary depending on the particular complex chosen, the dosing regimen to be followed, photoirradiation exposure, and timing of administration. Such dose can be determined without undue experimentation by methods known in the art or as described herein.
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 inventors 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
Synthesis of a Texaphyrin-Lipophilic Molecule Conjugate
The present example provides the synthesis of a texaphyrin-lipophilic molecule conjugate where the lipophilic molecule is estradiol. The synthetic route is provided by Schematic A.
Penta(ethyleneglycol) diiodide (2). Penta(ethyleneglycol) ditosylate 1 (25 g, Aldrich Chemical, Milwaukee, Wis.), sodium iodide (17.15 g, 2.5 eq.), and acetone (ca. 500 mL) were combined and heated at reflux for 4 hours; Upon cooling, solids were removed by filtration and washed with acetone. Acetone was removed from the combined filtrate and washed by rotary evaporation. The resulting solid was dissolved in CHCl 3 (250 ml), and washed with water (250 mL), a 5% aqueous solution of Na 2 S 2 O 3 (2×250 mL) and water (250 mL). Solvent was removed by rotary evaporation and the resulting solid dried in vacuo to give diiodide 2 (19.164 g, 91.3%).
3-(2-(Ethoxy-2-(ethoxy-2-(ethoxy-(2-iodoethoxy))))ethoxy)17β-hydroxy- 3- oxy-1,3,5(10)-estratriene (4). The diiodide 2 (12.50 g), β-estradiol 3 (2.500 g, Aldrich Chemical, Milwaukee, Wis.), potassium carbonate (1.500 g) and anhydrous acetonitrile (250 mL) were combined in a flask. The reaction mixture was heated at reflux for 9 hours, whereupon it was allowed to cool in ambient temperature, and solvent removed by rotary evaporation. The residue was dissolved in CHCl 3 (125 mL), washed with water, and solvent removed by rotary evaporation. The crude product was purified by silica gel chromatography using 0.5 to 1.0% MeOH in CHCl 3 as eluent. Fractions containing only product were combined, solvent was removed by rotary evaporation, and the residue dried in vacua to give iodide 4 (2.010 g, 36.4%).
Dinitrobenzene sodium salt (5), method one. The dinitrobenzene sodium salt 5 was prepared by reacting 4,5-dinitrocatechol (5 g, 0.025 mol) and triethylene glycol monomethyl ether monotosylate (11.9 g, 0.037 mol, 1.5 eq.) with K 2 CO 3 (5.18 g, 0.037 mol, 1.5 eq.) in methanol, with heating to reflux under nitrogen atmosphere overnight. The reaction was allowed to cool to RT, and the solvent was removed under reduced pressure. The residue was then resuspended into 250 mL of 1M NaOH, after which chloroform was added. The lower chloroform layer plus precipitate were drained off and the orange solid precipitate was collected by filtration and vacuum dried under high vacuum overnight to give the light orange solid product 5, in 81% yield.
Dinitrobenzene Sodium Salt (5), method two. An alternate method of synthesis of the dinitrobenzene sodium salt is as follows. In a dry 250 mL round bottom flash, 4,5-dinitrocatechol (10 g, 0.050 mol) and K 2 CO 3 (10.37 g, 0.075 mol) were combined in absolute methanol (120 mL) under nitrogen atmosphere. To the orange mixture, triethylene glycol monomethyl ether tosylate (23.85 g, 0.075 mol) was added and the resulting suspension was heated to reflux. The reaction was deemed complete by TLC analysis by the disappearance of the starting catechol and appearance of the bright yellow monoalkylated intermediate. Therefore, after 16 h the red suspension was cooled to 0° C. The resulting suspension was filtered, washed thoroughly with cold isopropyl alcohol (50 mL) and hexanes (50 mL). The monoalkylated potassium salt was then suspended in 10% aqueous NaOH (100 mL), vigorously stirred for 15-20 min at room temperature, filtered, and then rinsed thoroughly with cold isopropyl alcohol (70 mL) and hexanes (50 mnL). (This step aids the removal of excess K 2 CO 3 and potassium tosylate). The bright orange salt was dried in vacuo and afforded 15 g (˜81%). 1 H NMR (d 6 acetone): selected peaks, δ3.40 (OMe), 6.30 (ArH), 7.42 (ArH); EI MS (M+Na + ) 369; EI HRMS (M+Na + ) 369.0910 (calcd. for C 13 H 18 N 2 O 9 Na 369.0910).
3-(2-(Ethoxy-2-(ethoxy-2-(ethoxy-(2-(1-oxy-2-(2-(ethoxy-2-(ethoxy-(2-methoxy)))ethoxy)4,5-dinitrobenzene)ethoxy))))ethoxy)-17βhydroxy-3-oxy-1,3,5(10)-esratriene (6). The iodide 4 (500 mg) and the sodium salt of 1-hydroxy-2-(2-(ethoxy-2-(ethoxy-(2-methoxy)))ethoxy)-4,5-dinitrobenzene 5 (336 mg, 1.1 eq.) and acetonitrile (5 mL) were combined in a flask and the reaction mixture was heated at reflux overnight. Potassium carbonate (126 mg, 1.1 eq.) was added, and heating continued for ca. four hours. The reaction mixture was transferred to a separatory funnel with CHCl 3 (ca 25 mL), washed with water (2×15 mL), solvent removed on a rotary evaporator, and the residue dried overnight in vacuo. The crude product was purified by silica gel chromatography using 2% MeOH in CHCl 3 as eluent. Fractions containing only product were combined, solvent was removed by rotary evaporation, and the residue dried in vacuo to give 6 as a yellowish solid (549 mg, 80.5%). FAB: MH + 821.
Using known chemistry for the synthesis of texaphyrins (see the texaphyrin patents previously incorporated by reference herein) the dinitro compound 6 was reduced to the diamine 7 using an atmospheric pressure hydrogenation with 10% Pd on charcoal and 2 eq. of conc. HCl. The reduction was usually complete in 1-2 h. Afterwards, the catalyst was filtered off using a pad of Celite, the diamine solution was diluted with methanol, 1 equivalent of diformyl tripyrrane 8 was added, and the reaction was heated to reflux under nitrogen. The reaction started immediately after the addition of diformyl tripyrrane and was usually complete in 1-3 hr. Proton and carbon NMR of the resulting non-aromatic macrocycle 9 was consistent with structure. The nonaromatic macrocycle 9 was oxidatively metallated using 1.5 equiv.s of either lutetium acetate or gadolinium acetate and 10 equiv.s of triethylamine under air atmosphere to give the lutetium estradiol complex 10 (in 38% yield with a relative purity of 89%) or the gadolinium estradiol complex 11 (in 47% yield with a relative purity of 91%), respectively.
The synthesis of a texaphyrin-cholesterol conjugate is carried out in a similar manner using cholesterol instead of estradiol.
Example 2
Loading Red Blood Cells with a Texaphyrin-Lipophilic Molecule Conjugate
The present example provides for the loading of red blood cells with a texaphyrin-estradiol conjugate. Red blood cells (RBC's) were successfully loaded with gadolinium texaphyrin-estradiol conjugate 11 (“GTE”) following an osmotic challenge to the red blood cells. Subsequently, UV/Vis spectra revealed that most of the conjugate was contained within the cell wall of the red blood cells.
For the studies below, the following general procedure was used: Whole blood from rabbit was collected in the presence of heparin and centrifuged. The serum layer was removed, and the RBC's were resuspended in saline (138 mM NaCl), and washed three times. After the third wash, the pelleted RPC's were resuspended in hypertonic saline (268 mM NaCl). The cells were mixed gently, held approximately 3 min at room temperature, and centrifuged. The pelleted RBC's were resuspended in three volumes of hypotonic saline (110 mM NaCl) containing GTE to give Gd texaphyrin-estradiol-red blood cell complex.
I. In a first study, 300 mL of pelleted RBC's were resuspended in 1.0 mL of 110 mM NaCl with 0.2 or 0.4 mmoles of GTE. The cells were mixed gently and sonicated. After three washes, the pellet of GTE-RBC complex (300 mL) was resuspended with saline to a total volume of 2.0 mL. To determine the GTE content, 750 mL of this 2.0 mL solution were removed, 250 mL of fresh saline was added, and the optical density was read on a spectrophotometer. A control cuvette contained an equivalent mass and volume of RBC's treated similarly but without GTE. The O.D. of the 2.0 mL solution was 0.9859, which indicated a yield of 120 mg total GTE complex (T2BET2, 732 nm, a 15.35 mg/mL solution has an O.D. of 0.3291).
II. In a second study, two different amounts of a stock solution of 2 mM GTE in 5% mannitol were used; 1.6 mL with 4.0 mL packed RBC's, and 6.6 mL with 5.5 mL packed RBC's. To prepare the respective complexes, the RBC's were washed as described previously, the respective volumes of RBC's were resuspended with hypertonic saline to a total volume of 50 mL and centrifuged. The supernatant was removed and solutions of hypotonic saline with GTE were added so as to keep the volume at 40 mL. The suspensions were treated as described above and the final washed RBC's were suspended in a volume of 15 mL with normal saline and transferred to 100×17 mm tubes to be analyzed by MRI (see, Example 3) (for the 1.6 mL reaction, 11 mL of saline; for the 6.6 mL reaction, 9.5 mL of saline; the control was 5.0 mL packed RBC's and 10 mL of saline).
III. In a further study, RBC's were loaded with GTE to be used as an injectable into rabbits. Packed RBC's (5.0 mL, washed as described) were treated with hypertonic saline and 40 mL total volume of hypotonic saline with 6.0 mL GTE. After sonication, the cells were washed 3 times and resuspended with 2.5 mL of normal saline. The resulting complex was used for injection into rabbits (see, Example 4).
Example 3
In Vitro Imaging with GdT2BET-Estradiol-Red Blood Cell Complex
The present example provides in vitro magnetic resonance imaging (MRI) results with GTE-RBC complex.
Packed or resuspended red blood cell complexes were imaged using a GE 0.5T Signa magnetic resonance imager (GE Medical Systems, Milwaukee, Wis.) and the following parameters: pulse sequences, spin echo 350/15; acquisition parameters, 20FOV, 256×256; slice thickness/space, 5 mm/12.5 mm; and nex; 2.
Table 2 provides MRI values using GTE-RBC complex (from Example 2, II). CuSO 4 is an imaging standard that allows the intensity (whiteness) of the signal to be gauged.
TABLE 2
MRI Values of GdT2BET-Estradiol-Red Blood Cell Complexes
RBC
RBC with
RBC with
Saline
CuSO 4
Sample
Control
3.2 mmol GTE
13.2 mmol GTE
control
Standard
Packed
818
1386
1405
311
1181
GTE-RBC
793
1354
1514
309
1166
Complexes
Average
805.5
1370
1459.5
310
1173.5
Resuspended
530
876
2095
298
1144
GTE-RBC
496
800
2084
280
1103
Complexes
487
793
2105
270
1095
Average
504.333333
823
2094.666667
282.67
1114
Approximately 8.3 μmol GTE was incorporated in 5 ml of packed red cells using this method.
Example 4
In Vivo Imaging with GdT2BET-Estradiol-Red Blood Cell Complex
The present example demonstrates magnetic resonance imaging of an animal using GTE-RBC complexes. MRI scans revealed contrast enhancement of tissues and enhanced angiograms for up to 30 min after injection.
A New Zealand white rabbit (2.72 kg) having a V2 carcinoma tumor implanted in each thigh. was injected with 7 mL of GTE-RBC complex and a normal New Zealand white rabbit (3 kg) was also injected with the same amount of the complex as a control. The rabbit having the tumors died after 2.5 mL of the complex was injected. The rabbit appeared to be already very sick from the cancer. The normal rabbit was scanned precontrast, immediately post-injection, and 30 min after injection. The rabbit was positioned supine inside a knee coil and entered the magnetic field feet first. The rabbit was anesthetized and maintained with ketamine/Rompun cocktail during MRI. The scan parameters were as in Example 3 with the acquisition parameter being 256×160 for this animal study and the MR angiogram scanning technique was 2D TOF for the aorta.
The normal rabbit had good liver and angiogram enhancement for at least 30 min after injection of the GTE-RBC complex.
Example 5
Photodynamic Therapy Using Photosensitive Texaphyrin-Lipophilic Molecule-Loaded-Vesicles
The present example provides for the light-dependent lysis of loaded vesicles, such as red blood cells or liposomes, and the consequent deposition of the contents at the irradiated site. When irradiated with light of an appropriate wavelength, vesicles loaded with a photosensitive texaphyrin will lyse.
The effect of PDT with photosensitive texaphyrin-loaded vesicles is multifaceted in that specificity is provided by the biolocalization of the vesicle, a PDT effect is seen in the vicinity of the deposited texaphyrin due to singlet oxygen product toxicity, and if a therapeutic agent is incorporated into the vesicle in addition to the texaphyrin, the therapeutic agent is deposited at a target site. A chemotherapeutic drug may be delivered to a target site in this manner, for example.
A preferred photosensitive texaphyrin is a lutetium texaphyrin, for example, compound 1 B as described herein. In the present light-dependent lysis, the light may have a wavelength range of about 650-900 nm, preferably 700-800 nm, and most preferably 730-770 nm.
Example 6
Liposomes Comprising a Texaphyrin-Lipophilic Molecule Conjugate
The present example provides for the incorporation of a texaphyrin-lipophilic molecule conjugate into liposomes and liposomal-like particles.
A texaphyrin-lipophilic molecule conjugate may be incorporated into small unilamellar liposomes as follows, for example. Egg phosphatidylcholine conjugated with ethylene glycol and cholesterol (8:2 molar ratio) are suspended in chloroform and a 33% molar concentration of texaphyrin-lipophilic molecule conjugate is added to the solution. The chloroform is evaporated under vacuum and the dried material is resuspended in phosphate buffered saline (PBS). The mixture is transferred to a cryovial, quick frozen in liquid nitrogen, and thawed five times. The material is then extruded through an extruder device (Lipex Biomembranes, Vancouver, B.C., Canada) 10 times using a 400 nm diameter pore size polycarbonate filter to produce 400 nm liposomes. A portion of the 400 nm liposomes is extruded through 100 nm diameter filters 10 times to produce 100 nm liposomes. A portion of the 100 nm liposomes is then extruded 10 times through 15 nm filters, producing liposomes of 30 nm size.
Liposomes prepared as described above may also be subjected to a Microfluidizer (Microfluidics, Newton, Mass.). Specifically, liposomes may be passed 10 times through the microfluidizer at a pressure of 16,000 psi and a flow rate of 450 mL/min. The resulting liposomes are expected to have a mean average size of 30-40 nm, which may be verified by Quasi Elastic Light Scattering.
A texaphyrin-lipophilic molecule conjugate incorporated in this way into liposomes may be physically inside the liposome, incorporated into the lipid bilayer of the liposome, or incorporated in such a way that part of the conjugate is outside of the liposome. A liposome incorporating a texaphyrin-lipophilic molecule can be stabilized using ethylene glycol to slow its uptake by phagocytic white blood cells.
Example 7
Induction of Antibody Formation Using Texaphyrin-Lipophilic Molecule-Loaded-Red Blood Cells or -Liposomes
In addition to conventional methods known to those of skill in the art of immunology for making antibodies having a particular binding specificity, antibodies having binding specificity for a texaphyrin molecule may be induced in a host that has been administered a texaphyrin-lipophilic molecule loaded-red blood cell or -liposome. Further, if the loaded cell also contains an immunogen, antibodies may be generated having binding specificity for that immunogen.
Using a photosensitive texaphyrin, light will lyse such a loaded red blood cell or liposome causing release of its contents within a host. Consequent exposure of the host to an immunogen contained therein would induce antibody formation to the immunogen. Candidate immunogens may include, but are not limited to, surface HIV proteins, such as gp 120, for example. This method would be particularly effective using a loaded cell from an animal different than the animal injected, for example, using loaded goat red blood cells for injection into a rabbit. The goat cells may act as adjuvant in this case.
All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the composition, methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. More specifically, it will be apparent that certain agents which are both chemically and physiologically related may be substituted for the agents described herein while the same or similar results would be achieved, All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims. | Compositions having a texaphyrin-lipophilic molecule conjugate loaded into a biological vesicle and methods for imaging, diagnosis and treatment using the loaded vesicle are provided. For example, liposomes or red blood cells loaded with a paramagnetic texaphyrin-lipophilic molecule conjugate have utility as a blood pool contrast agent, facilitating the enhancement of normal tissues, magnetic resonance angiography, and marking areas of damaged endothelium by their egress through fenestrations or damaged portions of the blood vascular system. Liposomes or cells loaded with a photosensitive texaphyrin-lipophilic molecule conjugate can be photolysed, allowing for a photodynamic therapy effect at the site of lysis. Availability of red blood cells loaded with a photosensitive texaphyrin-lipophilic molecule conjugate provides a method for delivering a photodynamic therapeutic agent to a desired site with a high concentration of oxygen. By presenting the agent in this way, it is expected that a patient will experience less toxicity. | 0 |
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a compressor housing modification for the compressor portion of a turbocharger. The particular embodiment disclosed in this application relates to a compressor housing portion of a turbocharger such as is used on large diesel engines. However, the invention disclosed in this application can be applied to compressor housings used on other types of internal combustion engines. For purposes of illustration, the invention is described in this application in terms of a preexisting compressor housing manufactured with an integrally-formed throat. As described herein, the integrally-formed throat is removed and replaced with a separate throat insert which can be replaced and which can have different throat sizes for a given sized compressor housing.
A turbocharger increases the power available to an integral combustion engine by making use of the dynamic energy present in the rapidly moving exhaust gases which are removed from the compression chamber of the engine during each cycle. The exhaust gases are directed through a turbine and against a turbine wheel. The turbine wheel has blades which convert the energy in the exhaust gases into rotary motion of the wheel and the shaft on which the wheel rotates. On the other end of the same shaft is a compressor wheel mounted for rotation in a compressor housing. The rotation of the compressor wheel takes intake air being conveyed to the air intake manifold of the engine and compresses it. The energy added to the air during the compression process is released when the air is mixed with fuel and ignited, thereby increasing the available power output of the engine.
The shaft on which the turbine wheel and compressor wheel are mounted rotates at extremely high speeds. Accordingly, the shaft and wheels must be very delicately balanced and aligned relative to the turbine housing and compressor housing, respectively. Fof this reason, the shaft is very carefully mounted on bearings which not only control the rotation of the shaft but also the axial movement of the shaft between the compressor housing and the turbine housing. To achieve maximum efficiency, the shape of the turbine wheel and the compressor wheel must very closely correspond to the adjacent surfaces of the turbine housing and compressor housing, respectively. This is a particularly critical factor with regard to the compressor housing and the compressor wheel. In order to achieve a smooth, efficient and relatively quiet transfer of energy from the rapidly rotating compressor wheel to the air being fed to the engine, the cross-section of the compressor wheel and the corrresponding cross-sectional surface of the compressor housing must be substantially the same. The compressor wheel is spaced-apart only so far as is necessary to prevent actual contact between the compressor wheel and the compressor housing. The portion of the compressor housing which corresponds to the cross-sectional shape of the compressor wheel is called the throat. The throat is an annular orifice which reduces in diameter as its surface moves away from the compressor wheel. In cross-section, its shape generally resembles that of a trumpet bell.
Occasionally, the bearings on which the compressor wheel shaft is mounted become loose and permit the compressor wheel to move into actual contact with the throat of the compressor housing. The rapid rotation of the compressor wheel quickly destroys the uniform shape of the throat. In some cases, the damage is relatively minor. In such instances, prior art repair of the compressor housing involves remachining the surface of the throat to restore the throat to its desired shape. However, if the damage to the throat involves deep scars or gashes, remachining is not possible because the remaining thickness of the throat would be below minimum specifications. Therefore, prior art methods of repairing compressor housings involve first a determination of the extent of damage to the compressor housing throat. If the damage is relatively minor, the throat surface is remachined as described above. If the damage is substantial, the compressor housing is scrapped even though the remainder of the compressor housing is completely satisfactory for continued use. Even when compressor housings can be remanufactured by remachining the throat, repaired compressor housings must be stocked in a wide variety of compressor housing types and throat diameters.
The necessity to maintain a large inventory of different sizes increases substantially the expense of repairing or overhauling engines since very often the repairs must be made on a emergency basis and there is no time to order correctly sized compressor housings from a centrally located parts depot. There has long existed a need for a way in which to use compressor housings which have damaged throats but are otherwise in godd condition and, also, a way to reduce substantially the number of compressor housings required to be carried in inventory in repair and overhaul facilities. The invention described in this application achieves both objectives in a novel manner.
SUMMARY OF THE INVENTION
Therefore, it is an object of the invention to provide a compressor housing having a replaceable inlet throat which can be removed if damaged or if a change in inlet throat size is desired, and replaced with another inlet throat. It is another object of the invention to provide a compressor housing without an integrally-formed throat which can be inventoried in relatively small numbers and, when installed, be mated with a replaceable inlet throat of any one of a wide variety of required sizes.
It is another object of the present invention to provide a method of manufacturing a compressor housing which permits a separately formed inlet throat to be mated to and removed from the compressor housing as required, and replaced.
These and other objects of the present invention are achieved in the preferred embodiment disclosed below by providing a compressor housing having a centrally-disposed through bore in fluid communication with a fluid conduit, and a separately formed inlet throat for being positioned in the bore and secured to the fluid conduit of the compressor housing for providing a compressor housing having a replaceable inlet throat which can be removed if damaged, or if a change in inlet throat size is desired, and replaced. According to a preferred embodiment of the invention, the circumference of the bore is undersized relative to the circumference of the inlet throat, with the degree of undersizing being predetermined to permit the fluid conduit to be heated to expand the circumference of the bore to permit insertion of the inlet throat in the bore to form an interference fit between the inlet throat and the fluid conduit when the fluid conduit has cooled.
According to the method described in this application, a compressor housing is manufactured by first forming a ring-shaped fluid conduit having a centrally disposed bore in fluid communication therewith and an outlet therein; forming a separate inlet throat adapted to be positioned within the bore and secured to the fluid conduit in fluid communication therewith; and positioning the inlet throat in the bore and securing the inlet throat in the fluid conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects of the invention have been set forth above. Other objects and advantages of the invention will appear as the description of the invention proceeds when taken in conjunction with the following drawings, in which:
FIG. 1 is an exploded view of a turbocharger of the type wherein a compressor housing according to the present invention is used;
FIG. 2 is a perspective view of a prior art compressor housing having an integrally-formed throat;
FIG. 3 is a cross-sectional view of the prior art compressor housing shown in FIG. 2;
FIG. 4 is a perspective view of a compressor housing, from the opposite side shown in FIG. 2, wherein the integrally-formed throat has been cut from the compressor housing and removed;
FIG. 5 is a cross-sectional view taken substantially along lines 5--5 in FIG. 4 showing the structure of the compressor housing after removal of the integrally-formed throat;
FIG. 6 shows the cross-section of the compressor housing shown in FIG. 5, after the step of machining away the walls of the air inlets somewhat to form an annular, integrally-formed seat;
FIG. 7 is a perspective view of a compressor housing and a replaceable throat insert, showing the manner of insertion of the insert in the housing;
FIG. 8 is a cross-section taken along lines 8--8 of FIG. 7 of the replaceable throat insert according to the invention; and
FIG. 9 is a cross-sectional view of a compressor housing according to the present invention showing the replaceable throat insert in position within the housing.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, a turbocharger in which a compressor housing according to the present invention is used is illustrated in FIG. 1 and generally designated by reference numeral 10. The turbocharger is shown in an exploded view for clarity and ease of description. Exhaust gases from an engine (not shown) enter the turbine through an inlet 14 and impinge upon a concentrically mounted turbine wheel 13. The exhaust gases exit turbine 11 axially through an outlet 14. Turbine wheel 13 is mounted on one end of a shaft 15. Oil seals 16, a heat shield 17 and an insulation ring 18 are mounted on shaft 15 adjacent turbine wheel 13. Shaft 15 is then mounted concentrically within a bearing housing 19. Shaft 15 rotates within a turbocharger bearing 20 and a turbocharger bearing insert 21 An o-ring 22 and an oil seal plate 23 are likewise mounted on shaft 15. An oil seal sleeve 24 and an oil control ring 25 are mounted on shaft 15 on the side of the oil seal plate 23 remote from turbine wheel 13. Then, a compressor wheel 27 is mounted in shaft 15 and secured thereto by a rotor nut 28. Compressor wheel 27 is mounted within a concentric bore 29 in a compressor housing 30.
The turbine housing 11 and compressor housing 30 are secured together by means of a V-band clamp 32 formed of two substantially semi-circular clamp members 32A and 32B which are secured together on opposite sides by means of a suitably sized bolt 33 cooperating with washers 34 and 35, and a nut 36. V-band clamp 32 engages an integrally-formed, annular flange 12A on turbine housing 12 and an integrally-formed, annular flange 30A on compressor housing 30, thereby holding the entire turbocharger 10 together.
A throat insert 45 is positioned within the compressor housing 30, as will be described in detail below. Air at atmospheric pressure enters bore 29 and is boosted to a predetermined high pressure by the rotation of compressor wheel 27. The pressurized air exits the compressor housing 30 centrifugally through an outlet 31 which is normally connected to the air intake manifold of the diesel engine (not shown).
As described earlier, movement of shaft 15 in the axial direction towards either turbine housing 11 or compressor housing 30 is prevented by adjustment within the bearing housing 19. As wear occurs, movement of shaft 15 in the axial direction can cause compressor wheel 27 to contact adjacent surfaces of compressor housing 30.
Referring now to FIGS. 2 and 3, inlet throat 40 according to the prior art is integrally formed with, and defines a concentric, decreasing radius extending along the axial length of compressor housing 30. One portion of the inner surface of inlet throat 40 defines a curved wall portion 40A, and the other end terminates in an annular, straight cylindrical wall portion 40B to which a suitably sized air inlet conduit (not shown) is attached. Air enters inlet 29, is compressed by the rotation of compressor wheel 27 and is conveyed into an encircling fluid conduit 42 and centrifugally accelerated out of compressor housing 30 through compressor outlet 31.
The compressor wheel 27 rotates in closely spaced-apart relation to the surface portion 40A of inlet throat 40. As described above, if compressor wheel 27 contacts inlet portion 40A, substantial damage is done to the surface. Therefore, referring now to FIG. 4, in the invention according to this application, the integrally-formed inlet throat 40 is cut by a lathe or some other suitable means from within inlet 29 and discarded. The portion of compressor housing 30 defining the sidewalls of inlet 29 are used to position the compressor housing concentrically on the lathe for removal of inlet throat 40 since inlet throat 40 and air inlet 29 are concentric with each other.
After removal of inlet throat 40, compressor housing 30, in cross-section, appears as is shown in FIG. 5. As is apparent, air inlet 29 now comprises a cylindrical through bore from one axial end of compressor housing 30 to the other.
Referring now to FIG. 6, the inner sidewalls of compressor housing 30 defining air inlet 29 are machined away to form an annular integrally-formed seat 44 within air inlet 29.
Referring now to FIG. 7, a separate, replaceable inlet throat 45 is provided. Inlet throat 45 has an enlarged, annular base 46 with a small, outwardly protruding annular lip 47 thereon. The remaining length of inlet throat insert 45 comprises a mounting collar 48 having outer sidewalls of reduced diameter. A through bore is defined by the inner, cylindrical sidewalls of inlet throat insert 45. As can best be seen by reference to FIG. 8, the inner walls of inlet throat insert 45 defining the through bore comprise a curved wall portion 49A and a straight wall portion 49B. The throat insert 45 can be machined or otherwise suitably formed of aluminum or another suitable metal.
Referring now to FIG. 9, inlet throat insert 46 is positioned within the bore defined by the inner walls 49 of inlet throat insert 45. The lip 47 mates with the integrally-formed seat 44 to provide proper placement and alignment of inlet throat insert 45 within inlet 29.
While it is possible to use a number of different securing methods, it is believed preferable to secure inlet throat insert 45 within inlet 29 by means of an interference fit. This fit can be achieved in a number of different ways. However, by whatever precise method achieved, the circumference of the mounting portion of the bore 29 defined by the inner walls of compressor housing 30 is slightly undersized relative to the outer circumference of base 46 of insert 45. Insertion and proper mounting are achieved by relative heating and/or cooling of the respective parts to permit assembly. For example, compressor housing 30 can be heated to expand slightly the circumference of bore 29. Inlet throat insert 45 is inserted within bore 29 and, when the compressor housing 30 cools, the circumference of bore 29 decreases forming an interference fit by which the inlet throat insert 45 is securely mounted. The interference fit can also be achieved by cooling inlet throat insert 45 relative to compressor housing 30, or, by heating compressor housing 30 and simultaneously cooling inlet throat insert 45 to permit insertion of inlet throat insert 45 within bore 29.
By using this mounting method, inlet throat insert 45 can be removed by repeating the process of heating and/or cooling described above. In addition to the substantial economies achieved by permitting reuse of the undamaged portions of the compressor housing 30, further savings can be achieved because of the need to inventory only a relatively few of the compressor housings. Rather, the much less expensive inlet throat inserts 45 can be manufactured in a wide variety of sizes. The only dimensions that need be uniform from size to size is the dimension of the base 46 and lip 47, to permit insertion of differently sized inlet throat inserts 45 within the same sized compressor housing bore 29.
A compressor housing having a replaceable inlet throat is described above. Also described is a method of manufacturing a compressor housing having a replaceable inlet throat insert and a method of remanufacturing a compressor housing having an integrally-formed inlet throat to accommodate a replaceable inlet throat insert. Various details of the invention may be changed without departing from its scope. Furthermore, the foregoing description of the preferred embodiment according to the present invention is provided for the purpose of illustration only and not for the purpose of limitation--the invention being defined by the claims. | A compressor housing (30) is disclosed of the type characterized by having a centrally-disposed, concentric, flow restricting inlet throat in fluid communication with an encircling fluid conduit having a tangentially disposed outlet. Compressor housing (30) includes a separately formed inlet throat insert (45) for being positioned in a bore (29) in compressor housing (30). Insert (45) can be removed if damaged, or if a change in inlet throat size is desired. | 8 |
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to the LED technical field and more particularly to a heat conductive technology for an LED lamp core and the interior of an LED chip.
[0003] 2. Description of Related Arts
[0004] The heat dissipating problem is a key technical problem serving as a bottleneck for the wide spreading of the LED illumination. Since an LED chip requires to dissipate heat, it is hard for an LED illuminating lamp to perform like an incandescent lamp, fluorescent lamp, and etc. with the light bulb being as a standardized component as well as be convenient to assemble, so that the cost is even higher.
[0005] An analysis from a single viewpoint of heat transmission theory suggests that the heat dissipating process of LEDs is not complicated. However, the heat transmission theory, mature heat transmission technology, and other basic knowledge related to heat transmission are not fully acknowledged by the people skilled in the art of LEDs, so that the current LED heat dissipating technology and products are complicated.
[0006] A heat transferring process from an LED node to an air convection heat exchanging surface (radiator) is a heat conduction process. Because an area of an LED chip is relatively small whilst a heat flux density is significantly high, the heat conduction process actually plays a very important role in the whole LED heat dissipating procedure. An effective and simple solution for reducing a heat resistance of the heat conduction process is to employ a high heat conductive material such as copper and aluminum. However, copper and aluminum are both metal conductors. An LED illuminating device, as an electric appliance, should meet the requirement of safe use of the electricity, so that a predetermined insulating effect should be ensured between the LED node and the radiator (metallic exploded components). A typical insulation requirement is to withstand at least a kilovoltage. Insulation and heat conduction are somewhat incompatible. In a current product, an LED wafer is provided on a ceramic insulation substrate so that high voltage withstanding capability and not low thermal conductivity are made use of so as to solve the problem. The ceramic such as Al 2 O 3 ceramic material has a thermal conductivity up to 20W/m·K, but is still 10 times smaller than aluminum and about twenty times smaller than copper. And the heat flux density on the LED wafer is high as 10 6 W/m 2 . When a 0.2 mm Al 2 O 3 insulation substrate is employed, a temperature difference of heat conduction on the insulation substrate amounts to 10° C.
SUMMARY OF THE PRESENT INVENTION
[0007] The object of the present invention is focused on in the heat conduction process in the LED heat dissipating process, to solve the heat dissipating problem in the standardization of the lamp core as well as the contradiction between the heat conduction and insulation within the LED chip, so as to provide a technical solution of a simple structure and low cost.
[0008] Additional advantages and features of the invention will become apparent from the description which follows, and may be realized by means of the instrumentalities and combinations particular point out in the appended claims.
[0009] According to the present invention, the foregoing and other objects and advantages are attained by a LED lamp core mainly consisting of wafers, a heat diffusion plate, and a heat conductive core. The heat produced by the wafers is transferred to the heat conductive core via the heat diffusion plate, and then is transferred from the heat conductive core to the radiator. The present invention has the following characteristics. The heat conductive core is made of aluminum or copper. The heat transferring contact surface (i.e. the heat is transferred outward from the heat conductive core)between the heat conductive core and the radiator employs a taper structure, or screwed-cylinder structure, or taper screwed-cylinder structure. The wafers are soldered and attached on the heat diffusion plate. The area of the heat diffusion plate is five times larger than the area of the wafer/wafers. The thickness of the heat diffusion plate is not less than 0.5 mm. And the heat diffusion plate uses copper, or aluminum, or copper-aluminum composite material. A high voltage insulation layer, the thickness of which is larger than 0.1 mm, is provided between the heat diffusion plate and the heat conductive core.
[0010] The heat conductive core may employ a taper structure. The radiator is correspondingly provided with mating a taper hole, so that when a relatively small pushing and squeezing force is applied, a contact pressing force which is amplified several times is produced between the taper surface of the heat conductive core and the conical hole surface of the radiator and thus the thermal contact resistance is reduced.
[0011] Since the surface area of the screwed-cylinder surface is amplified, the heat transferring contact area is amplified and the thermal contact resistance between the heat conductive core and the radiator is reduced. For example, when a normal 60° triangular screw is introduced, the surface area will be two times of the cylinder surface. The LED lamp core is installed into the radiators (lamp fittings) with a rotation manner, so that no additional tools are required and thus the operation is very convenient.
[0012] The advantages of taper screwed-cylinder structure include that of the taper structure and the screwed-cylinder structure: the heat transferring contact area is amplified, the contact pressing force is amplified and the installation is convenient.
[0013] The heat conductive core of the present invention solves the heat transferring problem between the LED lamp core and the radiators, and the assembling of the LED lamp core is convenient, so that the primary issue for the realization of the LED lamp core standardization is solved.
[0014] The important function of the heat diffusion plate is firstly made definite: heat diffusion function, in the prevent invention, and the name is defined as heat diffusion plate. Due to the small area of the LED wafer such as a wafer of a size of 1×1 mm, even the power is only 1.2 W, the heat flux density amounts to 10 6 W/m 2 , this is very high and thus solving the thermal contact resistance between the wafers and the heat diffusion plate becomes a primary issue, and the electrical insulation therebetween is a secondary issue. When employing a soldering technology, the wafers are soldered and attached on the heat diffusion plate through the soldering process, the heat conduction temperature difference between the wafers and the heat diffusion plate can be effectively reduced. As a heat diffusion plate serving to diffuse heat, not only a material of high conductivity is required, the area and the thickness also should be large enough, so the heat diffusion plate is preferred to use copper and aluminum. And the area of the heat diffusion plate should be five times larger than the area of the wafer/wafers on the heat diffusion plate, and the thickness thereof should be not less than 0.5 mm. In a practical design, the area of the heat diffusion plate should be at least ten times larger than the area of the wafers. If the size of the wafer is 1×1 mm and the power is 1W, the thickness of the heat diffusion plate should be above 1.0 mm. The object and effect for this are to effectively diffuse heat in the heat diffusion plate and reduce the heat flux density between the heat diffusion plate and the heat conductive core. In order to meet the requirement of the insulation for the safe use of electricity, a high voltage insulation layer is provided between the heat diffusion plate and the heat conductive core to solve this problem.
[0015] In the present invention, the high voltage insulation layer is defined as an insulation layer which can withstand above 500V volts D.C.
[0016] The thickness of the high voltage insulation layer provided between the heat diffusion plate and the heat conductive core is larger than 0.1 mm. When a Al 2 O 3 ceramic insulation layer with a thickness of 0.1 mm is introduced, it can withstand one kilovotage volts D.C. This makes the insulation layer provided between the heat diffusion plate and the heat conductive core take responsibility of most or all of the insulation requirement for the safe use of electricity, so that the insulation requirement between the wafers and the heat diffusion plate is reduced or even the insulation therebetween is not considered at all, so as to reduce the heat transferring temperature difference therebetween.
[0017] If tin soldering is used between the wafers and the heat diffusion plate with a thickness of tin therebetween is 20 μm and the heat flux density is 10 6 W/m 2 , the heat transferring temperature difference between the two interfaces is calculated and the result is Δt=0.32° C. Through the heat diffusion plate, if the heat flux density is reduced eight times to be 1.25×10 5 W/m 2 , the high voltage insulation layer between the heat diffusion plate and the heat conductive core employs a Al 2 O 3 ceramic with a thickness of 0.2 mm and a heat conductivity of 20W/m·K, the heat transferring temperature difference at the high voltage insulation layer is calculated and the result is Δt=1.25° C. In other words, the sum of the heat transferring temperature difference between the two interfaces is within 2° C.
[0018] If a Al 2 O 3 ceramic insulation plate with a thickness of 0.2 mm is provided between the wafer and the heat diffusion plate (heat sink) according to a structure of a product of the state of the art, the heat transferring temperature difference of the two sides of the ceramic plate is calculated and the result is Δt=10° C. which is five times larger than the above value.
[0019] It can be seen that the heat transferring temperature difference in the LED lamp core is significantly reduced with the present invention. In the following detailed description of the preferred embodiments, the advantages of the LED lamp core of the present invention such as convenient for water-proof, mass production, and standardization will be described in details.
[0020] For the LED chip component consisting of wafers and a heat diffusion plate, a detailed structure and manufacturing method is provided from the perspective of reducing heat conduction resistance, bringing down the costs, and facilitating the manufacturing process.
[0021] Firstly, the heat diffusion plate uses aluminum, or copper, or copper-aluminum composite material. The soldering contact area between the wafer and the heat diffusion plate is larger than one third of the area of the wafer. The heat diffusion plate is provided with a high voltage insulation layer, or a low voltage insulation layer.
[0022] Secondly, the pn junction electrode of the wafer is a V type electrode. A flip chip structure is used. The heat diffusion plate uses aluminum, or copper, or copper-aluminum composite material. The wafer is provided with heat conduction solder pad. The soldering contact area between the wafer and the heat diffusion plate is larger than one third of the area of the wafer. The outside of the n-electrode, and the p-electrode or part of the p-electrode of the wafer is covered by a layer of ceramic insulation membrane generated through vapor deposition. The heat conduction solder pad is provided at the outside of the ceramic insulation membrane.
[0023] Thirdly, a wafer locating plate of insulation material is introduced into the LED chip. The wafer locating plate is soldered or adhered and attached on the heat diffusion plate. The wafer is embedded into the wafer locating and embedding opening of the wafer locating plate while the wafer is soldered and attached on the heat diffusion plate.
[0024] Fourth, a manufacturing and packaging method of the LED chip characterized in that: a wafer locating board which is provided with a plurality of wafer locating and embedding openings and at least two retaining holes are introduced. The heat diffusion board is provided with corresponding solder pads and locating holes. The wafers are firstly embedded and fixed on the wafer locating board and are retained in position by the retaining holes, and then together with wafer locating plate are attached to the heat diffusion board and heated to finish the soldering procedure between the wafer and the heat diffusion plate. Alternatively, the wafer locating plate is attached and fixed on the heat diffusion board first, and then the wafers are embedded into the wafer locating and embedding openings, and then heating to finish the soldering procedure between the wafer and the heat diffusion plate.
[0025] Still further objects and advantages will become apparent from a consideration of the ensuing description and drawings.
[0026] These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a sectional view illustrating the features of an LED lamp core of the present invention equipped with a radiator having a heat conductive core of a taper structure, wherein the coupling relation between the lamp core and the radiator is illustrated.
[0028] FIG. 2 is a sectional view illustrating the features of an LED lamp core of the present invention with a heat conductive core of a screwed-cylinder structure.
[0029] FIG. 3 is a sectional view illustrating the features of an LED lamp core of the present invention with a heat conductive core of a taper screwed-cylinder structure, wherein a lamp housing is also equipped, wherein the features of the structure of the leading wire and measurement for achieving waterproof effect are also illustrated.
[0030] FIG. 4 is a sectional view illustrating the features of an LED lamp core of the present invention, wherein the electrical connection employing a structure of resilient contact terminals or contact spots between the lamp core and the lamp fitting (radiator) is illustrated.
[0031] FIGS. 5 and 6 are schematic views illustrating the wafer distribution of the LED lamp core, wherein the wafers or wafer group are arranged to be radially dispersed and are dispersed as even as possible.
[0032] FIG. 7 is a sectional view illustrating the features of an LED lamp core of a high power of the present invention, wherein a middle hollow structure is provided for installation of fins.
[0033] FIGS. 8 and 9 are sectional views illustrating the features of two kinds of LED chip of the present invention, wherein the pn junction is an L type electrode which is particularly suitable for the wafer with carborundum substrate.
[0034] FIG. 10 is a sectional view illustrating the features of an LED chip of the present invention, wherein the pn junction is a V type electrode, wherein the chip has a flip chip structure in which the heat conduction solder pad is integrally formed with the p solder pad so that the chip is particularly suitable for wafers with sapphire substrates.
[0035] FIG. 11 is a schematic view of the features of the wafer of the chip in FIG. 10 illustrating the p-electrode, the n-electrode and solder pads thereof, the ceramic insulation membrane, and the heat conduction solder pad, wherein the n solder pad is illustrated at four corners.
[0036] FIG. 12 is a schematic view of the ceramic insulation membrane and heat conduction solder pad in FIG. 11 .
[0037] FIG. 13 is a sectional view illustrating features of an LED chip of the present invention.
[0038] FIG. 14 a schematic views of the wafer of the chip in FIG. 13 , wherein the p-electrode, the n-electrode and solder pads thereof, the ceramic insulation membrane, the heat conduction solder pad are illustrated.
[0039] FIG. 15 a schematic view of the ceramic insulation membrane and heat conduction solder pad in FIG. 14 .
[0040] FIGS. 16 and 17 are schematic views illustrating the features when a wafer locating board of the present invention is used to ensure the mating soldering between the wafer and the heat diffusion board, wherein FIG. 17 is a sectional view illustrating the features in FIG. 16 .
[0041] FIG. 18 is a schematic view illustrating the features when a wafer locating board of the present invention is used to ensure the mating soldering between the wafer and the heat diffusion board.
[0042] FIGS. 19 and 20 are schematic views respectively illustrating two kinds of LED chip of the present invention with wafer locating plate, wherein the pn junction electrode is an L type electrode and the LED chips are suitable for the wafer with carborundum substrate.
[0043] FIGS. 21 , 22 and 23 are schematic views respectively illustrating three kinds of LED chip of the present invention with wafer locating plate, wherein the pn junction electrode is an L type electrode and the LED chips have flip chip structures.
[0044] FIG. 24 is a schematic view illustrating features of the chip in FIG. 23 .
[0045] Wherein in the Figs:
[0046] 1 wafer; 2 heat diffusion plate; 3 radiator;
[0047] 4 high voltage insulation layer; 5 screw; 6 heat conductive core;
[0048] 7 fin; 8 low voltage insulation layer; 9 leading wire;
[0049] 10 sealing glue; 11 PCB board; 12 lamp housing; 13 contact spot;
[0050] 14 resilient contact terminal; 15 substrate; 16 heat conduction solder pad
[0051] 17 n solder pad; 18 n leading wire; 19 electrode leading wire insulation layer;
[0052] 20 p-electrode; 21 ceramic insulation membrane; 22 n-electrode;
[0053] 23 p solder pad; 24 p leading wire; 25 wafer locating board;
[0054] 26 retaining hole; 27 heat diffusion board; 28 wafer locating plate;
[0055] 29 conduction wire; 30 soldering flux.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0056] Referring to FIG. 1 , a heat conductive core 6 employs a taper structure. The taper column surface (i.e. the exterior heat transferring surface of the heat conductive core) is firmly contacted with central conical hole of a radiator 3 . Heat is transferred from the heat conductive core 6 to the radiator 3 via the contact surfaces, so that the gap between the contact surfaces should be as small as possible. In the taper column and conical hole, a relatively small pushing and squeezing force will result in an above ten times amplified contact pressing force. In FIG. 1 , a screw 5 is used to apply pulling force so that the heat conductive core 6 is firmly retained in the central conical hole of the radiator 3 . In order to further reduce the thermal contact resistance between the heat conductive core and the radiator, a heat conduction paste such as silicone grease should be coated on the cylinder surface.
[0057] As illustrated in FIG. 1 , a single heat diffusion plate 2 , a plurality of wafers are provided (soldered) on the heat diffusion plate 2 . The heat diffusion plate 2 is attached to an end surface of the heat conductive core 6 via a high voltage insulation layer 4 . The end surface is called heat absorption surface. Another end opposite to this end, which is provided with screw 5 , is called rear end of the heat conductive core. The surface of the heat diffusion plate which is closely attached to the heat absorption surface of the heat conductive core is called surface B of the heat diffusion plate while another surface which is provided with wafers is called surface A of the heat diffusion plate.
[0058] An anodization process, in which aluminum oxide membrane is grown on the aluminum metal surface of the heat conductive core or the heat diffusion plate to serve as the high voltage insulation layer, the problem of the thermal contact resistance between the high voltage insulation layer and the heat diffusion plate as well as the heat conductive core is solved. The anodization process is of low costs and high efficiency, thus is suitable for mass production.
[0059] In the LED lamp core of FIG. 2 , the heat conductive core 6 uses a screwed-cylinder structure. A single heat diffusion plate structure is also incorporated. But the wafers 1 are centralizedly provided at the center of the heat diffusion plate 2 , and the surface A of the heat diffusion plate 2 is provided with a low voltage insulation layer 8 , and the wafers 1 are provided (soldered) on the low voltage insulation layer 8 . The insulation layer enables a circuit, and solder pads and electrode leading wires corresponding to the wafers to be provided on the surface A of the heat diffusion plate as well as other auxiliary components (such as Electro-Static Discharge protect component) together with the wafers are provided on the heat diffusion plate. This structure is of high integrality and is convenient for downstream production.
[0060] Since the heat flux density of the wafers is relatively high, reducing the heat conduction resistance of the low voltage insulation layer becomes significantly important.
[0061] The insulating intensity is not so important for it just need to reach the maxim voltage without need to meet the requirement of safe use of electricity. A peak voltage of 220V commercial power is 380V. In other words, the insulating intensity of the low voltage insulation layer 8 can be enough if the maxim intensity reaches 450V, it is defined as low voltage insulation and so called low voltage insulation layer.
[0062] A ceramic membrane prepared through vapor deposition such as diamond, SiC, AlN, BN, BeO, Al2O3, and etc. is advantageous for good insulation and heat conductivity. Especially, Diamond, SiC, AlN, BN and BeO, which are high heat conductive ceramic, not only are suitable to be used as the low voltage insulation layer on the surface A of the heat diffusion plate, but also more suitable to be used as ceramic insulation membrane on the wafers which will be described in detail in the following disclosure. The vapor deposition process includes physical vapor deposition (PVD) and chemical vapor deposition (CVD) which are both suitable for manufacturing the low voltage insulation layer of the present invention.
[0063] Aluminum anodization process also can be used to prepare the low voltage insulation layer on the surface A of the heat diffusion plate. Although the heat conductivity of the resulting aluminum oxide membrane is not high as the ceramic membrane prepared by vapor deposition, the costs are relatively low and a thicker membrane is easy to obtain, and the insulating intensity can reach above 100V. When in a design, the thickness of the aluminum oxide membrane of the low voltage insulation layer is smaller than 50 μm so that the heat conduction resistance is controlled.
[0064] Although copper is more expensive than aluminum, few materials of heat diffusion plate need to be used. And more importantly, because the heat flux density of the wafers is very high, so a high heat conductivity material is more important. So copper is preferred for the heat diffusion plate. If an aluminum oxide insulation layer with anodization is required to be formed on the surface of a copper heat diffusion plate, a copper-aluminum composite material can be used. Accordingly, an aluminum layer can be coated on the surface of a copper plate. The thickness of the aluminum layer on the surface A of the heat diffusion plate should be small enough as long as it reaches the required aluminum thickness which is enough for anodization.
[0065] FIG. 3 illustrates an LED lamp core of the present invention, wherein the heat conductive core 6 employs a screwed-cylinder structure, a lamp housing 12 is also equipped. A leading wire 9 penetrates the heat conductive core 6 and is guided out from the rear side of the heat conductive core. As shown in FIG. 3 , sealing glue 10 is provided on rear side of the heat conductive core at the out guiding position of the leading wire 9 , so that a reliable water-proof of the out guiding position of the leading wire 9 is achieved. The water-proof of the front side of the lamp core may be achieved via the lamp housing 12 as well as potting with sealing glue.
[0066] As shown in FIG. 3 , each wafer is equipped with a heat diffusion plate to form a structure of multiple LED chips. In addition, the high voltage insulation layers 4 are not only proved on the heat absorption surface of the heat conductive core 6 , but also are provided on the surface B of the heat diffusion plate 2 , so that a single LED chip will have a high voltage insulation characteristic. A PCB board 11 is also illustrated in FIG. 3 , the LED chips are embedded into the PCB board 11 . The auxiliary circuit of the LED chip can be provided on the PCB board 11 and the leading wire 9 can also be soldered with the circuit on the PCB board 11 .
[0067] In FIG. 3 , the electrical connection between the lamp core and an external power source can employ the leading wires, but connecting wire terminals, contact spots, or contact discs also be used. The connecting wire terminals, contact spots (contact discs) are provided at the rear side of the heat conductive core. Connecting wires (leading wire 9 ) penetrate the heat conductive core. In other words, the connecting wires are hided within the heat conductive core. The LED lamp core illustrated in FIG. 4 uses the structure of contact spots. The contact spots 13 on the lamp core contact with the resilient contact terminal 14 fixed on the radiator 3 , the structure is similar to the structure of a current light bulb.
[0068] In order to reduce the heat conduction resistance, the arrangement of LED wafers on the heat diffusion plate, or the LED chip consisting of wafers and heat diffusion plates on the heat conductive core should be dispersedly configured as dispersive as possible. The power of a single wafer should be as small as possible but the numbers of the wafers should be as many as possible. FIG. 5 illustrates a dispersive configuration of six wafers on a heat diffusion plate. FIG. 6 illustrates four chips are dispersedly provided on the heat conductive core 6 , each chip is a chip group consisting of three wafers. In the design of the LED lamp core, the numbers of the wafers or the wafer group should be as many as possible and should be not less than three, but a too large number may result in high manufacturing costs. The power of a single wafer should be as small as possible, the maxim power should be not more than 4W. But a too small power of the single wafer also means that the numbers of the wafers should be increased and thus may result in high costs. The wafers or wafer groups (chips) in FIG. 5 and FIG. 6 are all radially dispersed. This kind of dispersive configuration is desirable.
[0069] In the LED lamp core illustrated in FIG. 7 , the heat conductive core has a middle hollow structure and is provided with fin 7 . Such a configuration is designed for an LED lamp core of a high power. Because the higher the power of the LED lamp core, the more the number of the wafers or the chips. In addition, the wafers and the chips should be radially and dispersedly provided, so that the outer diameter of the heat conductive core is extremely large. The central portion is a hollow structure that can be used for installing fins.
[0070] In the LED lamp core illustrated in FIGS. 3 , 4 , and 7 , the high voltage insulation layer 4 is provided on the surface B of the heat diffusion plate 2 . If the high voltage insulation layer is formed from oxidation of aluminum anode, a copper-aluminum composite material is preferred for the heat diffusion plate 2 . According to the present invention, the soldering contact area between the wafer and the heat diffusion plate should not be less than one third of the area of the wafer. In addition, the area of the heat diffusion plate should be more than five times (preferably not less than ten times) larger than the area of the wafer while the thickness thereof is not less than 0.5 mm.
[0071] In the LED chip illustrated in FIG. 8 , the pn junction electrode employs an L contact (Laterial-Contact) which is called L type electrode for short. LED wafer with carbonrundum substrate is suitable for employing this kind of electrode because SiC can form an conductor through doping. The carbonrundum substrate can be used as an n-electrode. The outer surface of the substrate 15 is provided with a heat conduction solder pad 16 , i.e. n-solder pad. A low voltage insulation layer 8 , which can be formed through vapor deposition or aluminum anodization, is provided on the surface B of the heat diffusion plate 2 illustrated in FIG. 8 . Corresponding heat conduction solder pads (i.e. n leading wire solder pad) and n leading wires are provided on the surface of the low voltage insulation layer 8 , the LED wafer is soldered and attached on the low voltage insulation layer 8 . The LED chip illustrated in FIG. 9 is similar with the LED chip illustrated in FIG. 8 , the main difference is that the heat conduction solder pad 16 on the substrate 15 is directly soldered with the metal on the heat diffusion plate 2 and the surface B of the heat diffusion plate 2 is provided with a high voltage insulation layer 4 .
[0072] In the LED chip illustrated in FIG. 10 , the pn junction electrode employs a V contact (Vertical-Contact) which is called V type electrode for short. And a flip chip structure is used. The LED wafer with sapphire substrate is suitable for this kind of structure. As shown in the Fig, the heat conduction solder pad 16 on the substrate 15 is directly soldered with the metal on the heat diffusion plate 2 . The heat conduction solder pad 16 , which serves as the p solder pad, is communicated with the p-electrode 20 . A ceramic insulation membrane 21 prepared through vapor deposition is provided between the heat conduction solder pad 16 and the p-electrode 20 . The heat diffusion plate 2 severs as a p leading wire. The p pins of the chip can be directly soldered with the heat diffusion plate 2 . The surface B of the heat diffusion plate 2 is provided with a high voltage insulation layer 4 . The surface A of the heat diffusion plate 2 is provided with a n leading wire 18 , a electrode leading wire insulation layer 19 is provided therebetween. The n leading wire 18 is provided with solder pads which can be directly soldered with the n solder pads 17 on the wafers 1 . The soldering contact area between the wafer 1 and the heat diffusion plate 2 comprises the area of the heat conduction solder pad 16 and the area of the n solder pad. If the area of the heat conduction solder pad 16 is large enough, the issue of the heat conduction resistance of the electrode leading wire insulation layer 19 is not so important. As illustrated in FIGS. 11 and 12 , the n-electrode 22 and part of the p-electrode 20 are covered by the ceramic insulation membrane 21 . The heat conduction solder pad 16 is provided at the outer side of the ceramic insulation membrane 21 . The objective of using such a structure of the ceramic insulation membrane 21 is to increase the area of the heat conduction solder pad (i.e. the soldering contact area between the wafer and the heat diffusion plate) to be as large as possible.
[0073] The LED chip illustrated in FIG. 13 is similar to the LED chip illustrated in FIG. 10 with a V type electrode, and a flip chip structure. The difference is that all of the n-electrode 22 and the p-electrode 20 (except the solder pads) are covered by the ceramic insulation membrane 21 , and the heat conduction solder pad 16 is spaced apart from the p solder pad 23 and is spaced apart from the two electrodes, as shown in FIGS. 14 and 15 . The surface A of the heat diffusion plate 2 is further provided with p leading wire 24 which is separated by the electrode leading wire insulation layer 19 .
[0074] An LED wafer of 1×1 mm is a wafer of large size. Such a small area is provided with electrode solder pads and the heat conduction solder pad, as shown in FIGS. 11 and 14 , the size of the electrode solder pad is generally as small as having a diameter of 0.1 mm. In addition, inexistence of a shortcircuit soldering should be guaranteed, so that a mating accuracy between the wafer and the heat diffusion plate is really high. An eutectic welding with a few seconds of heating is a typical solution. If the wafers are positioned and mated one by one before heating and soldering, the requirement of the equipments is high and also is expensive, the efficiency is also low. The low efficiency and high costs of the package of the LED chip of a high power are also issues of the current LED industry.
[0075] The present provides a wafer locating plate to solve the above mentioned problem, as shown in FIGS. 16 and 17 , a plurality of wafer locating and embedding openings are provided in a wafer locating board 25 . A wafer 1 is embedded in the wafer locating and embedding opening. The wafer locating board 25 is further provided with retaining holes 26 . Six retaining holes 26 are illustrated in the drawings. At least two retaining holes 26 should be provided when in a practical design. A punching process, which has a high accuracy, a simple equipment, and high efficiency, is used for forming the retaining holes 26 and the wafer locating and embedding openings. The heat diffusion board 27 is provided with corresponding retaining holes and solder pads with respect to the wafers based on the positions of the retaining holes. The position of the wafer is determined by the wafer locating and embedding opening in the wafer locating board 25 . The mating between the wafer locating board 25 and the heat diffusion board 27 is determined by the retaining holes 26 , so that the mating accuracy between the solder pad on each wafer and corresponding solder pad on the heat diffusion board is ensured. The whole piece is then heated and soldered so as to complete the soldering of a plurality of wafers ( 55 wafers in the drawings) at a time. This process not only has a high efficiency, but also is advantageous for its simple equipments. During heating and soldering, a pressing is required so that the wafer is pressed to be attached on the heat diffusion plate and thus the quality of the soldering is ensured. Since the wafer is embedded into the wafer locating and embedding opening, so that it is easy to guarantee that the wafer will not move during pressing. This step can be carried out with the following two manners. (1), the wafers 1 are firstly embedded and fixed on the wafer locating board 25 , then together with wafer locating board 25 are attached to the heat diffusion board 27 and then heated to finish the soldering procedure between the wafer and the heat diffusion plate. (2), the wafer locating board 25 is retained in position by the retaining holes and then is attached and fixed on the heat diffusion board 27 , and then the wafers 1 are embedded and fixed on the wafer locating board 25 , and then heating to finish the soldering procedure between the wafer and the heat diffusion plate. After the soldering procedure, the wafer locating board 25 can be removed, but also can be remained. Referring to FIGS. 19 and 20 , the wafer locating board cut and remained in the LED chip is called wafer locating plate. In this respect, the wafer locating plate should be made of insulation material such as polyester membrane plate which can endure a relatively high temperature.
[0076] As illustrated in FIG. 18 , the above mentioned process is used to manufacturing the LED chip (as shown in FIG. 5 ) with a structure of a single heat diffusion plate and multiple wafers. A wafer locating board and a heat diffusion board are respectively provided with many wafer locating plates and heat diffusion plates which are connected together and arranged in lines. When the mating soldering and the potting with sealing glue are finished, the connecting portions are cut so that the LED chips are formed one by one.
[0077] FIG. 19 illustrates an LED chip with a wafer locating plate. The wafer locating plate 28 is provided with electrode leading wires and solder pads (or circuit). The wafer in FIG. 19 uses an L type electrode. The heat conduction solder pad 16 is the n solder pad. The n leading wire 18 penetrates the wafer locating plate 28 and gets out from the top thereof. The wafer locating plate 28 is provided with p leading wire 24 . The p solder pad 23 on the wafer and the solder pad on the p leading wire 24 are connected by conduction wire 29 .
[0078] In the LED chip illustrated in FIG. 20 , the electrode solder pad (p solder pad 23 ) on the wafer is adjacent to an edge of the wafer (preferably provided at a corner thereof). The solder pad of the electrode leading wire (p leading wire 24 ) on the wafer locating plate 28 is closely adjacent to the corresponding solder pad (p solder pad) on the wafer. The two electrode solder pads are directly soldered and communicated by soldering fluxes 30 (such as tin).
[0079] In the LED chip with a wafer locating plate illustrated in FIG. 21 , a V type electrode and a flip chip structure are employed. The surface A of the heat diffusion plate 2 is provided with a low voltage insulation layer 8 while the surface B thereof is provided with a high voltage insulation layer 4 . The low voltage insulation layer 8 is provided with an electrode leading wire (n leading wire 18 , p leading wire is not illustrated in the drawings), and heat conduction solder pad (p leading wire solder pad). The LED chip illustrated in FIG. 22 , which is similar with the LED chip illustrated in FIG. 21 , also uses a V type electrode and a flip chip structure. The obvious difference is that n solder pad 17 is provided on the side wall of the wafer, the solder pad of the n leading wire 18 on the wafer locating plate 28 is closely adjacent to the corresponding solder pad (n solder pad 17 ) on the side wall of the wafer. The two electrode solder pads are directly soldered and communicated by soldering fluxes 30 .
[0080] In the LED chip illustrated in FIGS. 23 and 24 , the four corners of the wafer are cut off to form a one-quarter segment of a circle respectively. The n solder pad 17 and p solder pad 23 are provided in the side walls of the four unfilled corners and are arranged with diagonal distribution, the solder pad of the leading wire on the wafer locating plate 28 is closely adjacent to the solder pad on the side wall of the wafer. The two electrode solder pads are directly soldered and communicated by soldering fluxes 30 . The ceramic insulation membrane 21 covers an integral surface of the wafer. The heat conduction solder pad 16 is apart from the two electrodes. The heat diffusion plate 2 is a pure metal board plate. The heat conduction solder pad 16 on the wafer is directly soldered with the metal on the heat diffusion plate 2 . Such a structure is beneficial for increasing the area of the heat conduction solder pad (soldering contact area) as well as reducing the requirement of mating accuracy.
[0081] As illustrated in FIGS. 11 , 14 and 24 , the electrode solder pads are all provided at the corners, also can be provided adjacent to the edge of the wafer. But installing at the corners is more beneficial for making use of the wafer area to obtain more illuminating areas. The n and p solder pads illustrated in FIGS. 14 and 24 are all provided at the corners with diagonal distribution configuration.
[0082] In order to enhance the light extracting rate, a light reflective membrane should be provided on the outer surface of the wafer locating plate for reflecting out the light reflected to the surface of wafer locating plate.
[0083] One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
[0084] It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims. | An LED lamp core, an LED chip, and a method for manufacturing the LED chip are provided. A heat conductive core ( 6 ) using the structure of taper column or taper threaded column can be conveniently installed, and solves the heat conductive problem from the standardization of the LED lamp core. A heat diffusion plate ( 2 ) is made of copper or aluminum, and the area and the thickness thereof should be large enough, so as to achieve the effect of heat diffusion. A wafer ( 1 ) is welded on the heat diffusion plate ( 2 ), reducing the temperature difference between the wafer ( 1 ) and the heat diffusion plate ( 2 ) is primary and the insulation between the same is secondary. A high voltage insulation layer ( 4 ), which is required for safety, is provided between the heat diffusion plate ( 2 ) and the heat conductive core ( 6 ), and the heat flux density between the heat diffusion plate ( 2 ) and the heat conductive core ( 6 ) has already been reduced by the heat diffusion plate ( 2 ). The technique using a wafer locating plate solves the problem of aligning weld, costly equipment and low production efficiency. | 5 |
REFERENCE TO RELATED APPLICATIONS
The present application is a Continuation-in-Part of U.S. patent application Ser. No. 08/322,613 filed Oct. 12, 1994, for an AMBULATORY, ULTRASONIC TRANSIT TIME, REAL-TIME, CERVICAL EFFACEMENT AND DILATATION MONITOR WITH DISPOSABLE PROBES issued Aug. 8, 1995, as U.S. Pat. No. 5,438,996. This predecessor application and patent is to the selfsame inventors W. Scott Kemper and Michael P. Guberek who are included among the co-inventors of the present application.
The present application is a companion to U.S. patent application Ser. No. 08/512,333 for a DEVICE FOR HOLDING MEDICAL INSTRUMENTATION SENSORS AT AND UPON THE CERVIX OS OF A HUMAN FEMALE, PARTICULARLY FOR HOLDING THE ULTRASONIC TRANSDUCERS OF AN ULTRASONIC TRANSIT TIME, REAL-TIME, CERVICAL EFFACEMENT AND DILATATION MONITOR filed on an even date herewith. The related application is to inventors including the selfsame Michael Harrison, W. Scott Kemper and Michael P. Guberek who are included among the co-inventors of the present application.
The contents of the predecessor and of the companion patent applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally concerns systems and methods for automatically administering tocolytic, labor-preventing, drugs in order to prevent the premature onset of labor and to prolong gestation so that the mortality, and complications, of premature childbirth may be, insofar as is possible, avoided.
The present invention particularly concerns the automated administration of tocolytic drugs in response to detection of the commencement of earliest stages of labor by use of a real-time, transit-time, ultrasonic monitor--including an ambulatory version of such monitor--of the dilatation and/or effacement of the cervix os of a pregnant human female.
2. Description of the Prior Art
The avoidance of spontaneous abortion and premature labor, and the prolongation of gestation, in human females is desirable for many very important reasons. Gestation is desirably prolonged for variously increasing minimum periods in order to (i) make more probable a viable live birth, (ii) reduce the incidence of health complications attending a prematurely born child, and (iii) reduce the time period during which a premature infant, even if healthy, must, because of its size and viability, receive extraordinary care. All the factors of (i) live birth, (ii) a healthy child, and (iii) a child that can timely leave the hospital in the custody of its parent(s), obviously have an impact on the happiness and well-being of the parents and relatives. There is also and impact on society from premature births, including a very great societal economic impact in caring for children who are delivered greatly prematurely.
Fortunately, there is a class of drugs call tocolytic, or labor-preventing, drugs that are effective to postpone labor. Typical tocolytic drugs included Ritodrine and Terbutaline, which are beta-sympathomimetic. However, these drugs must generally, in order to be effective, be administered before the full onset of labor, and are of uncertain efficacy or safety if administered after full blown labor has begun.
Although tocolytic drugs are sometimes continuously administered at low levels to a pregnant woman, normally by infusion, during the duration of a high risk period of her pregnancy, normally between about twenty-eight and thirty-four weeks gestation (28-34 weeks), the drugs have undesirable side effects upon renal function, respiratory function, heart rate and general body musculature tone. Dosages must remain low, typically now more than 0.1 cc per hour of 1 mg/cc solution Terbutaline. The effectiveness of these low dosages in avoiding the onset of labor is inconsistent, and poorly quantified.
Perhaps the best data exists concerning the postponement of labor resulting from the special case of a surgical operation upon the fetus. If nothing preventative is done an operation upon the fetus will invariably induce labor. Typically Indomethacin--a non-steroidal drug serving to decrease prostaglandin synthesis and to decrease any prostaglandin cascade leading to labor--is administered orally or rectally both pre- and post-operation. Indomethacin is not suitable for administration longer than several days because it induces renal failure in the fetus. Intravenous magnesium--which serves as a direct acting muscle relaxant--is also administered post operatively, typically for a week or so until the respiratory depression induced in the mother is no longer tolerable. Finally, a tocolytic drug, typically Terbutaline, is typically started some days after the operation, often at the time that magnesium is discontinued. All the best and most advanced pharmacological regimens that can be given, circa 1995, will typically hold off labor in about 90% of the pregnancies for a week or two after an operation on the fetus, but seldom longer than that. The body seems to build up an immunity to the function of the drugs.
The response of a pregnant woman whose fetus is at strong risk of premature delivery by virtue of having been operated on to tocolytic drugs may, or may not, be analogous to the response of a woman who, for essentially unknown reasons, is biologically disposed to premature labor. However, since the tocolytic drugs are expected to function the same in the bodies of both such women, it is useful to assess just what, and what cannot, be done to postpone labor in the more consistent, and predictable, cases of women who have incurred an operation on their unborn child. These later case shown that it is difficult, if not impossible, to control the onset of labor over a long, multi-week and multi-month, period simply by the use of drugs.
It will further be understood that a continuous maintenance of a pregnant woman and her fetus on labor-preventing drugs for so long as is the multi-month period during which labor and childbirth would presently desirably be postponed is presently, circa 1995, would be hazardous, with likely adverse health consequences to the mother and the fetus. Finally, tocolytic drugs are of only modest, and apparently decreasing, effectiveness when used continuously.
Accordingly, it would be most desirable to use tocolytic drugs only if and when required, namely when the woman's body is about to enter true labor. When it is considered that some of the patients on which these drugs may be used as a precaution might not have, in actual fact, suffered premature labor if no drugs at all had been used, the desirability of not administering tocolytic drugs unless they actually become required is accentuated.
The best way of postponing premature labor is to very timely detect the early onset of labor, and to very timely administer a tocolytic drug, normally all within a period of one hour or, preferably, even less. The detection of labor is commonly by (i) the woman's reporting, and the physician's observation of, uterine contractions, in combination with (i) cervical dilatation or effacement. Uterine contractions alone are quite common, and an unreliable single indicator of the onset of actual labor. If nothing is done to suppress labor once it is detected as giving rise to both (i) uterine contractions and (ii) cervical dilatation/effacement, it invariably proceeds.
If, however and by example, an injection of 0.5 cc of 1 mg/cc Terbutaline solution is administered to a pregnant female of 28-34 weeks pregnancy in the first stages of labor, the success rate in avoiding such an escalation of the labor as almost invariably leads to delivery (alternatively, spontaneous abortion), and prolonging pregnancy, is modestly good, and is very roughly estimated to be about 60% successful for pregnancies not otherwise complicated such as by systemic pathological conditions, or trauma to the mother.
There is scant data, and most of that empirical, regarding the relative efficacy of timeliness in the administration of tocolytic drugs. This lack of data exists because (i) pregnant women are seldom in a hospital or other environment where the very earliest onset of true labor can be recognized, (ii) an attending physician may be reticent to diligently proceed at all hours of the day and night, and simply in response to reported "labor pains", to make all such detailed observations over a period of hours as may permit that the onset of true labor can be recognized at the earliest possible moment, and (iii) manual digital methods for detecting the onset of labor effectively demand that labor should be somewhat advanced even before it can be unambiguously recognized with certainty. However, it is known that chemical changes in the woman's body, most notably the prostaglandin cascade, escalate with labor. It is also known that once labor has progressed to a certain point it is essentially irreversible. It seems logical that early intervention is desirable.
As will be further discussed, the cyclical dilatation and effacement of the cervix os of a gravid female appears, circa 1995, to be a useful and non-invasive way of detecting the very earliest onset of labor in mammals, including humans. The cervix os undergoes a cyclical dimensional variation, as well as an overall increase in size, for the duration of human labor, which is typically some hours, culminating in delivery. This dimensional variation may, with appropriate instrumentation and continuous monitoring, be observed to have started at a very particular and precise point in time. There is no known phenomena, either physical or neurological or biochemical, that marks the beginning of human labor any more precisely, any better, or, importantly, any earlier. Accordingly, observation and continuing observation of the cervix os is a very powerful and well established technique, known even to the ancients, for monitoring the onset, and the progress, of labor.
The record short human gestations which have resulted in viable live births are, circa 1995, twenty-six (26) weeks. These exceptionally rare survivals are the subjects of papers in medical journals. The normal period considered the practical minimum for gestation if a live birth is likely realizable in a major medical center is twenty-eight (28) weeks. If the birth transpires in a facility without specialized facilities for the care of premature infants, or in areas of the second or third world where childbirth becomes progressively more hazardous for both the mother and child, the period during which the child is desirably maintained in utero increases all the way to normal full term. Human gestation is desirably extended to thirty-four (34) weeks in order to assure near-normal probability of a viable live birth even under the best, first-world, circumstances. Although the probability of successful delivery, and the good health of the newborn continues to improve (sometimes for reasons more reflective of the overall good health and prenatal care of the mother as opposed simply to the benefit of being longer in the womb) all the way up to the normal full human gestation period of thirty-six to forty (36-40) weeks, active medical intervention is normally not used to postpone labor beyond thirty-four (34) weeks.
Accordingly, human gestation is, if possible and other medical conditions of the pregnant woman not counter-indicating, preferably prolonged as long as about thirty-four (34) weeks, which is considered the lower limit for live birth in advanced modern facilities without appreciably greater complications than are incurred by babies carried to the full normal term of thirty-six to forty (36-40) weeks. If gestation can be prolonged from the practical minimum of twenty-eight (28) weeks at which viable live births routinely transpire in advanced hospitals for only four (4) weeks longer, i.e., to thirty-two (32) weeks, then a cost savings in excess of $100,000 to $300,000 U.S. can typically be realized circa 1995--even over the costs of continuous hospitalization and monitoring of the mother during the critical period. It should be understood that there are some areas of the United States, and most of the world, where neither the quality nor the quantity of resource exists to keep a highly premature infant alive. Although direct financial outlays may be less in these areas, the human cost is very great. People inevitably wishing to have children, and there being no viable way to even certainly detect, let alone prevent the pregnancies of, females at risk for premature delivery, it is thus of consummate interest to prolong, if possible, pregnancies until (usually) near full term.
Cause and constant supervision of high-risk pregnancies has historically involved the use of what were, at the times introduced, new and advanced technologies. This lengthy background has led, culminating in the present and related inventions, to the continuous recording and monitoring of cervical dilatation during labor by means of ultrasonic cervimetry. To support this continuous monitoring, probes must be maintained continuously in position.
The ancients knew that the dilatation of the cervix, discernable with and by the fingers during manual digital assessment, attended the onset of labor in the human female.
2.1 The General History of Cervimeters Including Ultrasonic Cervimeters, and of the Measurements Obtainable With Such Cervimeters
Current medical knowledge of cervical behavior descends largely from a huge base of historical data obtained by repeated digital palpation or `digital cervimetry` during labor. Both vaginal and rectal examination have been used. The latter method was introduced by Kroenig to prevent ascending uterine infection. Reference Kroeig, A. Der Ersatz der inneren Untersuchung Kriessender durch die Unteersuchung per Rectum; CENTRALBL GYNAKOL 1894; 18:235-243. Semmelweiss' classic work involving the relationship between vaginal examination and puerperal infection is well appreciated. Reference Semmelweiss, I., in Von Gorky, Y., ed., Semmelweisss gesammte Werke, Jena. 1905, VEB Gustav Fisher Verlag.
Although digital examination offers valuable clinical information on the progress of labor, its intermittent character does not allow an assessment of the dynamics of cervical dilatation. For that reason many attempts have been made to construct devices, cervimeters, for objective and continuous measurement of cervical dilatation based on (electro) mechanical, electronic and ultrasonic principles. A historical overview of some of nineteen various instruments published since the early fifties is presented in the article Assessment of cervical dilatation during labor; a review, by T. vand Dessel, et al. appearing in EUR. JNL. OBS. GYN. & REP. BIO. 41 (1991) 165-171.
Instrument-based cervimetry, or cervical dilatation measurement, has in particular been performed by mechanical, magnetic and/or ultrasonic means. A history of instrument-based cervimetry is presented by Moss, P. L., et al. as Continuous cervical dilatation monitoring by ultrasonic methods during labor, appearing in AM. J. OBSTET. GYNECOL. 132:16, 1978. The following text is derived from that article.
Moss, et al. point out that Friedman was the author in 1936 of a report discussing mechanical cervimetry. See Friedman, E. A.: Cervimetry, an objective method for study of cervical dilatation in labor, AM. J. OBSTET. GYNECOL. 71:1189, 1956. This paper was followed by another paper co-authored with Von Micsky in 1963. See Friedman, E. A., and Von Micsky, L. I.: Electronic cervimeter, A research instrument for the study of cervical dilatation in labor, AM. J. OBSTET. GYNECOL. 87: 789.
Siener cooperated with West from 1962 to 1972, and with Krementsoy in 1968, in the use the same method. See Siener, H.: An apparatus for recording the opening of the cervix during labor, ZENTALBL GYNAEWKOL 78:2069, 1956; Siener, H.: A new electromechanical apparatus for measuring labor activities by the execution of combination measurements, ARCH. GYNAEKOL. 196: 365, 1961; Siener, H.: First stage of labor recorded by cervical tonometry, AM. J. OBSTET. GYNECOL. 86:303, 1963; Siener, H. and West, I.: Internal isometry and graphic registration of cervix dilatation as a basis for calculation of labor effectiveness and soft tissue resistance, GEBURTSHILFE FRAUENHEILKD 32: 123. 1972; and Krementsoy, U.: Improved technique for measurement of cervical dilatation, BIOMED. ENG. (N.Y.) 2:350 1968.
The magnetic cervimeter was first proposed by Smith in 1954. See Smith, C. N.: Measurement of the forces and strains of labor and the action of certain oxytocic drugs, International Congress of Obstetrics and Gynecology, Geneva, 1954, S. A. George, P. 1030. However there were many drawbacks and it was only in 1971 that Rice, and also Kriewall, tried to solve these problems. Reference Rice, D. A.: Mechanism and measurement of cervical dilatation. Doctoral thesis, Purdue University, Lafayette, Ind., 1974. Reference also Kriewall, T. J.: Measurement and analysis of cervical dilatation in human parturition, Doctoral theses, University of Michigan, Ann Arbor, Mich., 1974.
Ultrasonic cervimetry was introduced in the period from 1974 to 1976 by Neuman, Wolfson, and Zador. Reference Neuman, M. R. Wolfson, R. N. and Zador, I,: Ultrasonic transit time methods for monitoring the progress of obstetrical labor, TRANSACTIONS OF PROFESSIONAL GROUP ON ULTRASONICS--IEEE, Vol. 33, 1975; Zador, J.: Ultrasonic determination of cervical dilatation during labor, Master's thesis, Case Western Reserve University, Cleveland, Ohio, 1974; Zador, I, Neuman, M. R. and Wolfson, R. N.: Continuous monitoring of cervical dilatation during labour by ultrasonic transit-time measurement, MED. BIOL. ENG. 14-229, 1976; and Wallenburg, H. C. S., and Wladimiroff, J. W.: Ultrasonic measurement of cervical dilatation during labor, AM. J. OBSTET. GYNECOL. 126:288, 1978.
A comparison of the advantages and inconveniences of each prior art method is shown in the first four columns of the Table of FIG. 1.
2.2 Ultrasonic Cervimetry
A typical advanced method of ultrasonic cervimetry, and the analysis of the measurements obtained thereby, was expounded by Moss, P. L., et al. in the aforementioned paper Continuous cervical dilatation monitoring by ultrasonic methods during labor, appearing in AM. J. OBSTET. GYNECOL. 132:16, 1978.
The major goal of Moss, et al., as stated in their own words, was to evaluate ultrasonic cervimetry and to look at the characteristics of the recordings with respect to conventional variables of fetal monitoring. In particular, Moss, et al. looked at the relationship between dynamic changes in cervical dilatation and intrauterine pressure. They looked at both the amplitudes of the changes and the phase relationships between the two signals.
The installation of the transducers consisted of fixing two piezoelectric crystals, each of dimension 1 mm by 5 mm, to the external os of the uterine cervix. The installation took place at 3 cm or more of dilatation. The crystals were fixed in places dramatically opposed to each other and were so held in position by spring-loaded clips.
The ultrasonic cervimeter in use generated an ultrasound wave each second, and the total time elapsed from the emission of that signal by one crystal to the reception by the other was compiled and converted into a distance. The ultrasound wave velocity was considered to be constant at 1.48 mm per microsecond. Since time, and not intensity, of the signal was the important parameter, the crystals had to rotate more than 60 degrees from one another before an error in the measurements was introduced. Migration was not possible since the clips teeth, when closed, pierced the cervix through and through.
The dilatation value along with the fetal heart rates, the fetal electrocardiograms, and the uterine contractions were recorded on an eight channel recorder.
Clinical accuracy was 0.6 cm. When the ultrasound recording of cervical dilatation is compared to the intrauterine pressure curve, it is characterized by a baseline and wave-shape curve of dilatation (DWP). The maximal amplitude component is called cervical maximal plasticity. The onset of the DWP is related to cervical resistivity, and the end of DWP reflects the relaxation time of cervical dilatation. The data show that as dilatation enters the active phase of labor, the plasticity, the resistivity, and the duration of relaxation of the cervix increase. These observations are related to the structural changes of the cervix during labor. (AM. J. OBSTET, GYNECOL. 132.16 1978).
It was noted by Moss, et al. (op. cit.) that cervical dilatation and fetal descent can be monitored simultaneously by ultrasound.
2.3 Problems With Previous Cervimeters--Mechanical and Electromechanical Cervimeters
The analysis of this section 2.3, and of the following sections 2.4 and 2.5, is a substantial extract and paraphrase of the aforementioned article Assessment of cervical dilatation during labor: a review, by T. van Dessel, J. H. M. Frijns, F. Th. J. G. Th. Kok, and H. C. S. Wallenburg appearing in EUROPEAN JOURNAL OF OBSTETRICS & GYNECOLOGY AND REPRODUCTIVE BIOLOGY, 41 (1991) 165-171.
Two main prototypes of mechanical cervimeters have been described, the calipers-type and the string-type.
In the basic calipers-type cervimeter, X-cross calipers equipped with a centimeter rule at the distal end are used to measure the distance between opposing cervical rims. The Krementsov cervimeter, called an `orificiometer` 18!, has a ring at each proximal caliper end in which the fingers of the examiner can be placed. See Krememtsov, Y. G., Improved technique for measurement of cervical dilatation, BIOMED. ENGIN. 1968:2:350. It enables the examiner to verify his findings by vaginal examination. The Tervila cervimeter consists of two pairs of Kelly clamps, attached separately to the cervical edges, and connected in a hinge-like way. See Tervila, L., Measurement of cervical dilatation in labour, AM. J. OBSTET. GYNECOL. 1953;51:374-376. The Friedman cervimeter is equipped with bulldog clips for attachment to the cervical rims. See Freidman, E. A., Cervimetry: an Objective method for the study of cervical dilatation in labor, AM. J. OBSTET. GYNECOL. 1956;71:1189-1193. Measurement is continuous, but readings are obtained at 2 to 10 minute intervals and plotted manually against time.
Disadvantages of these simple mechanical cervimeters are the discontinuity of readings, the lack of recording facilities and the quite heavy mechanical construction that interferes with dilatation during measurement.
In later years, low-weight calipers with cervical attachment clips were combined with potentiometers to convert the movements of the caliper arms into an electrical signal that could be recorded on a polygraph. Electromechanical cervimeters of this basic type were described by Vossius, G. in Eine Methode zur quantitativen Messung der Erweiterung und des Tiefertretens des Muttermundes Wahrend der Geburt. Z GESAMTE EXP MED 1961;134:506-512, by Svoboda, M. in CSL. GYNAEKOL 1958;23:621-623, cited by Warm R., Ueber die Messung der Muttermundseroffnung unter der Geburt. Z ARZTL FORTBILD 1967;61:661-666, by Richardson, J. Aa, Sutherland, I. A., Allen D. W., and Dore F., in The development of an instrument for monitoring dilatation of the cervix during labour; BIOMED. ENGIN. 1976;11:311-313, and by Richardson J. A., Sutherland I. A.; Measurement of cervical dilatation during labour; Physical science techniques in obstetrics and gynecology, Tunbridge Wells: Pitman Medical, Kent, United Kingdom, 1977. In the paper The electromechanical Friedman cervimeter by Friedman, E. A., and Von Micsky, L. I., an electronic cervimeter is taught as a research instrument for the study of cervical dilatation in labor. Reference AM. J. OBSTET. GYNECOL. 1963;87:789-792. The Freidman electronic cervimeter is attached to the cervix by a retractable row of needles. At a preset dilatation the needle attachments to the cervix are automatically released. In another instrument developed and expounded by Langreder, W. in Geburtshilfliche Messungen, BIBL. GYNAECOL 1965;20(S), movements are recorded by means of a photoelectric cell. The cervimeters described by Warm, R. in Ueber die Messung der Muttermundseroffnung unter der Geburt. appearing in Z. ARTZL FORTBILD 1967;61:661-666, and by Kazda S. Brotanek V. in Part played by cervix in uterine activity at the onset of labour appearing in CSL. GYNAEKOL 1962;27:333-337, have a similar design. A pair of calipers is connected to an invisible hinge in a heavy extravaginal part containing an internal potentiometer. Kazda and Brotanek report successful recordings in 90 patients without presenting data.
Siener has reported several cervimeters. The original Siener cervimeter was reported by Siener H., Ein neues elektromechanisches Wehenmessgerat zur Durchfuhrung von Kombinationsmessungen, ARCH. GYNAKOL 1961;196;365-372, by Siener H., First stage of labor recorded by cervical tonometry; AM. J. OBSTET. GYNECOL. 1963;86:303-309, by Siener H. and Wust L. Innere Wehenmessung and graphische Registrierung der Muttermunds-Eroffnung als Grundlagen zur Berechnung der Weheneffektivitat und des Weichteil-widerstandes; GEBURTSH FRAUENHEILK 1972;32:125-130. It was also reported by Embrey M. P. and Siener, H. Cervical tocodynamometry; J. OBSTET. GYNAECOL. BRIT. COMMONW. 1965;72:225-228, and in Siener H., Cervical dynamometry, a new method in obstetrical research; AM. J. OBSTET. GYNECOL. 1964;89:579-582. The Siener cervimeter offers the opportunity for both measurement of cervical dilatation and measurement of cervical dilatation forces, after fixation of the calipers. Later Siener used the concept of the electromechanical calipers cervimeter to construct even more sophisticated devices: the cervical dynamometer and the `erweiterte Zervixwehenmesser` (`expanded cervix-contraction meter`). Reference Siener H., Die erweiterte Zervixwehenmessung; GEBURTSH FRAUENHEILK 1959;19:140-145. The cervical dynamometer allowed measurement of the pressure of the fetal head on the cervix after fixation of the intravaginal arms of the cervimeter. The `expanded cervix-contraction meter` combined a calipers cervimeter with a metal construction for measurement of fetal descent.
The string-type cervimeter consists of strings or cords, attached to the cervix. Changes in dilatation cause changes in length of the strings which are transmitted to a kymograph by a mechanical pulley-guided system. Reference Siener H., Studien uber das Verhalten des Muttermundes wahrend der Eroffnungsperiode; ARCH. GYNAEKOL 1957;118:556-576. Alternatively, the changes could be electrically communicated by a linear differential transformer. Reference Smyth C. N., Measurement of the forces and strains of labour and the action of certain oxytocic drugs. Comptes Rendus du Congres International de Gynecologie et d'obstetrique, Geneva, 1954;1030-1039.
Some instruments are described for assessment of cervical properties other than dilatation. Glass and coworkers has used the medical engineering principle of indentation to design an electromechanical device for measurement of the relative softness of the cervix. Reference Glass B. L., Munger R. E., Johnson W. L.; Instrument to measure tissue softness of the uterine cervix in pregnancy; MED. RES. ENGIN. 1968;7:34-35. An instrument to measure the amount of pressure of the fetal head on the cervix has been reported by Noack and Blaschkowski. Reference Noack H. and Blaschkowski E., Zur Frage der graphischen Registrierung von Kontraktionen des Muttermundes unter der Geburt; Z. GYNAKOL 1958; 80:1609-1616.
Mechanical cervimeters are cumbersome in clinical practice and they cannot be used for continuous measurement of dilatation. Most electromechanical devices offer the possibility of continuous registration but have the disadvantage of a mechanical intravaginal part, which may interfere with cervical dilatation.
2.4 Problems With Previous Cervimeters--Electromagnetic Cervimeters
Electromagnetic cervimeters were described by Wolf in a his congress report: Wolf W., Kongressbericht. ARCH. GYNAKOLOGIE 1951;180:177-180; and later by Rice, D. A. in Mechanism and measurement of cervical dilatation; Doctoral dissertation. 1974, Purdue University, Lafayette, Ind. U.S.A.. With these cervimeters cervical dilatation is measured using two small induction coils, attached to opposing cervical rims. An electrical current, sent through one of the coils, establishes a magnetic field that is detected in the opposite coil and then recorded. Kriewall has used a permanent magnet dipole as a magnetic field source and two Hall-effect magnetic-field transducers as detectors. Reference Kriewall, T. J., Measurement and analysis of cervical dilatation in human parturition; Doctoral thesis, 1974, University of Michigan, Ann Arbor, Mich., U.S.A. The signals derived with this technique are processed to determine the distance between the transducers.
Electromagnetic cervimeters with clinical applicability have not been described.
2.5 Problems With Previous Cervimeters--Ultrasound Cervimeters
Abdominal routes have been used to visualize cervical dilatation by means of ultrasound during pregnancy. Reference Sarti D. A., et al. Ultrasonic visualization of a dilated cervix during pregnancy; RADIOL. 1979;130:417-420; Varma T. R., Patel R. H., and Pillai U. Ultrasonic assessment of cervix in normal pregnancy; ACTA. OBSTET. GYNECOL. SAND. 1986;65:229-233; Parulekar S. G. and Kiwi R., Dynamic incompetent cervix uteri; J. ULTRASOUND MED. 1988;7:481-485.
Vaginal routes have been used to visualize cervical dilatation by means of ultrasound during pregnancy. Reference Balde M. D., Stolz W., Unteregger B., and Bastert G.; L'echographie transvaginale, un rapport dans le diagnotic de la beance du col uterin; J. GYNECOL. OBSTET. BIOL. REPROD. (Paris) 1988;17:629-633.
Transperineal routes have been used to visualize cervical dilatation by means of ultrasound during pregnancy. Reference Lewin B., L'echotomographie perineale. Une nouvelle methode de mesure objective du col; J. GYNECOL. OBSTET. REPROD. 1976;5:289-295; and Jeanty P., Perineal scanning; AM. J. PERINATOL. 1=86;3:289-295.
Reports in the literature dealing with systematic visual assessment of cervical dilatation during labor could not be found by T. van Dessel, et al. (op. cit.), nor by Applicants.
A different approach uses two ultrasound transducers attached to opposing rims of the cervix. An ultrasonic signal generated by one transducer is received by the opposing one. Since the ultrasound velocity is known, the transmission time allows computation of the distance between the transducers.
The first ultrasound cervimeter was described by Zador et al. in 1974. Reference Zador, I, Neuman, M. R., and Wolfson, R. N.; Continuous monitoring of cervical dilatation during labour by ultrasonic transmit-time measurement; MED. BIOL. ENGIN. 1976;14:299-305; also Zador, I., Wolfson R. N., and Neuman, M. R., Ultrasonic measurement of cervical dilatation during labor; ANN. CONF. ENGIN. MED. BIOL. 1974;16:187. These authors used spring-loaded clips to attach the transducers to the cervix. A total of 24 readings of women in labor were reported, but no specific data were given. Apparently, practical problems were encountered, because further clinical studies with this device could not be found.
A similar cervimeter has been presented by Kok, et al. in 1976 in preliminary reports. Reference Kok, F. T., Wallenburg, H. C., and Wladimiroff, J. W., Ultrasonic measurement of cervical dilatation during labor; AM. J. OBSTET. GYNECOL. 1976;126:288-290; also Eijskoot, F., Storm, J., Kok, F. T., Wallenburg, H., and Wladimiroff, J.; An ultrasonic device for continuous measurement of cervical dilatation during labor; ULTRASONICS 1977;55:183-185. The problems with the fixation of the transducers to the cervix were eliminated by using special spiral-shaped transducers. The data was analyzed off-line by a computer, and accuracy and precision in vitro and in vivo were shown to be good in a well-documented study of 62 women in labor. Reference Kok, F. T., JGT; Ultrasonic cervimetry (summary in English); PhD-Thesis, Erasmus University, School of Medicine and Health Sciences, Rotterdam, 1977.
Cervical dilatation appeared to follow a wave pattern reflecting the intrauterine pressure curve. Maximal cervical dilatation coincided with the maximal intensity of each contraction. Generally, the derived curve of cervical dilatation showed the sigmoid shape postulated by Friedman (op. cit.) and by Krementsov Y. G. in Improved technique for measurement of cervical dilatation; BIOMED. ENGIN. 1968;2:350. A decelerative phrase was never detected. Using a similar device Moss and coworkers have investigated 13 women in labor. Reference Moss P. L., Lauron P., Roux J. F., Neuman M. R., and Dmytrus K. C.; Continuous cervical dilatation monitoring by ultrasonic methods during labor; AM. J. OBSTET. GYNECOL. 1978;132:16-19. T. Van Dessel, et al. (op. cit.) observed--contrary to the findings reported by Kok, Zador I, Neuman M. R., Wolfson R. N. in Continuous monitoring of cervical dilatation during labour by ultrasonic transmit-time measurement. MED. BIOL. ENGIN. 1976;14:299-305--that the peaks of uterine contraction and cervical dilatation were out of phase.
Ultrasound visualization of the cervix may be helpful in monitoring the patient at risk for premature delivery, but does not allow continuous registration of dilatation during labor. However, ultrasonic cervimetry does offer continuous and reliable recording with little discomfort to the patient, but clinical data has been limited. T. van Dessel, et al., (op. cit.) felt in 1991 that " u!ltrasound cervimetry may be a useful research tool for the study of the cervical response to the uterine contractions during labor. For clinical obstetric purposes, however, digital assessment of cervical dilatation seems sufficient."
2.6 Problems With Previous Ultrasonic Cervimeters--Position-holding of Placed Probes
In the predecessor patent application it is taught that ultrasonic transducers to which various barbs of the order of corkscrews to fish hooks are affixed may be reliably semi-permanently affixed to the cervix os, which is devoid of nerve endings. The fact that the placement of these vicious-looking devices may benefit the patient without inducing pain or harm--much in the manner of the similarly-appearing corkscrew probe of a cardiac pacemaker--does little to assuage the sensitivities of the female in whose birth canal these devices are to be affixed.
Especially since the ultrasonic probes are generally to be maintained in position for intervals ranging from days to weeks, and for total observational periods ranging to several months, while the carrier female is conscious, and because the carrier female must be able to recognize a probe should it come loose and become resident in, or become ejected from the vaginal canal, the patient should be shown the probe and its affixation means, and its function and operation should be both explained to the patient and understood by the patient.
The present invention will be seen to be directed to a more psychologically-user-friendly placement and holding device for cervical instrumentation, including a device for holding pair of ultrasonic transducer probes as may be used with a cervical dilatation and effacement monitor.
2.7 The Desirability of Continuous Accurate Convenient Cervical Dilation/effacement Monitoring, With Automated Alarms
The inventors of the present invention are of a contrary opinion to the opinion of T. van Dessel, et al., (op. cit.) in the aforementioned paper that "digital assessment of cervical dilatation . . . is! sufficient" and that, by implication, ultrasound cervimetry has no role in the clinical environment.
In the first place, the only realistic alternative to ultrasonic cervimetry is, and has proven to be, no cervimetry at all, and exclusive reliance the time-honored approach of digital assessment of cervical dilatation. This procedure, which should be, and regularly is, performed every hour after the onset of labor, is (i) manifestly inadequate to detect the onset of labor itself, (ii) laborious, (iii) without automatic contemporaneous generation of a permanent record, and (iv) of no greater quality in results obtained than the skill and attentiveness of the practitioner.
Despite the lack of clinical, or patient portable, instrumentation for the detection of the onset of labor (should such event be sharply definable, and it is), the detection of this event is very important in those rare cases where premature labor must be avoided. The inventors of the present invention are involved in the verification of instrument with one of the major centers for the management of problem pregnancies and premature births in the United States if not also the world circa 1994. Prolongation of gestation beyond a certain, threshold, number of weeks is currently very, even crucially, important to the survival of the fetus at birth. This minimum gestation period for live birth has greatly decreased in recent years, but cannot be expected to decrease to shorter than the period within which spontaneous abortions, or premature labor, occur in the human female. Accordingly, the only way that some fetuses will ultimately be viable is if tenure in the womb is prolonged.
Powerful drugs exist to arrest labor. However, these drugs cannot be continuously, or even regularly administered, during the projected terminal phase (at whatsoever period gestation) of a particular problem pregnancy. Accordingly, it is of crucial importance to detect the onset of labor (should such event be detectable, and it is) at the earliest possible moment in order that it may be stopped, if desired or required, by the administration of drugs or otherwise.
Next, once labor has begun, and even in normal pregnancies and deliveries, the inventors of the present invention do not take such a cavalier attitude as do their peers to the present lack of hard, recorded, and/or instantaneous quantitative data about what has gone on, and is going on, from moment to moment during labor. The dilatation/effacement of the cervix is a very good indicator of the progress, and or of problems, with labor.
2.7.1 Timing of Therapeutic Regimens Based in Cervical Dilation/Effacement Monitoring, and Problems with the Timely Administration of Same
The first, and potentially greatest, advantage to the continuous monitoring of cervical dilatation/effacement during labor, if not also in the period before, is that it can promote superior timing in the administration of medical therapies to support the suppression of labor or during labor. Cervical dilatation/effacement monitoring promotes the timely and optimally timed therapeutic administrations in consideration of (i) the earliest possibly recognition of changing conditions, including problem conditions, during labor, (ii) a definitive record of exactly how long certain conditions have persisted, and (iii) the possibility of machine aids, ranging from alarms to the comparison of profiles to mathematical modeling.
In short, the fact that most births occur normally even should the midwife or obstetrician be ignorant of cervical dilatation, and the complementary fact that some births encounter problems, are both facts of nature, and not of man. However, the fact that intervention in the birth process, primarily by Caesarian section, is occasionally ancient and generally successful does not invariably mean that it has been optimally timed for the health of the fetus and/or the mother.
Timing in the administration of therapeutic regimens during labor has always been recognized to be an issue. For example, the administration of pain-killing drugs to the mother is permissible during the early stages of labor whereas the administration of the same drugs becomes impermissible in later stages of labor. For example, a Caesarian delivery is not normally attempted until some lapse of reasonable progress towards a normal, vaginal, delivery. The questions that should be asked by a clinical practitioner in considering the efficacy of a monitor device in accordance with the present invention are these: Is there any evidence that the timing of some (or any) interventions is more critical than the timing of other interventions, or more critical than is generally recognized, or, God forbid, more critical that is generally possible under current methods for the measurement of the progress of labor? If so, what interventions would so benefit? Finally, is the monitoring of cervical dilatation and/or effacement (the thinning of the cervical rim, which thinning is of course proportional to the expansion of the cervix) an appropriate, or useful, measure of the progress, and/or the onset of problems, during labor? The present specification does not contain proof that the answers to the first and the third questions are yes, nor need it do so. However, data from animal trials at the Fetal Treatment Center of the University of California, San Francisco, during 1994-1995 suggests that this "yes" answer.
Also discerned in the animal trials, which confirms the experience of most obstetricians, is the very great utility of timeliness in the administration of tocolytic drugs to prevent premature labor. Labor induces physicochemical changes in the woman's body. The pharmacology of tocolytic drugs is believed to counteract, or oppose, these changes, thereby stopping the progression of labor (with sufficient dosage). However, and as every mother knows, labor is progressive. Once the woman's body is fully involved it is simply not possible to reverse the course of labor with drugs, and to attempt to do so might be dangerous.
Because the course of labor in each woman is different, it is hard to make complete generalizations about the efficacy of timeliness in the administration of tocolytic drugs. Generally, however, the clinical experience of the two clinician inventors of the present application at the Fetal Treatment Center of the University of California, San Francisco, leads to the following statement. First, if it is absolutely certain that childbirth is desired to be postponed (which it usually is if the attending physician is even thinking about the possibility), then it cannot be said that any administration of tocolytic drugs after the onset of true labor is unambiguously detected is "too soon". Indeed, the tocolytic drugs would desirably be given instantaneously after the onset of labor is confirmed.
At this earliest time a baseline dosage of a tocolytic drug will be sufficient to arrest labor in such a percentage of women (other pathological conditions not prevailing) as is currently un-quantified, but that is very, very roughly estimated to be about 60%. After injection of an initial bolus, the dosage is normally continued at a lower rate, depending upon the woman's condition and other indices of the progress of labor. This is the most optimal regimen presently known. Increasing the dosage is unavailing, and likely dangerous. Even with the best drugs and regimens presently known, arresting labor at this point is troublesome, and the those drugs and dosages commonly believed appropriate and sufficient by a skilled specialist attending physician/obstetrician will not suffice to successfully arrest labor in, very roughly, about 40% of the time. Finally, after a woman has been in full labor for only a few hours, it is generally unavailing either to commence, or to continue, any drug regimen at all to try and arrest labor. Any drugs sufficient to do so after a certain point would likely be dangerous to the mother and/or fetus.
In certain "high-risk" pregnancies the expectant mothers are hospitalized during a certain, critical, portion of the pregnancy typically from twenty-four (24), or less, to thirty-two, or more, weeks. The forced inactivity of the mother contributes to the avoidance of premature labor. However, even some percentage of these expectant mothers will, often for unexplained reasons, experience the onset of labor. The hospital environment then becomes very useful for the relatively immediate obtaining of medical advice, and care including the early infusion of a tocolytic drug. These prolonged hospital stays of a generally otherwise healthy patient, or at least a patient sufficiently healthy so as not to otherwise warrant hospitalization, is extremely expensive in the U.S. circa 1995. It is hard to tell when such an extreme preventive measure is warranted, and when it may, in subsequent pregnancies of a high-risk woman, again become warranted. One time-honored technique is, quite unfortunately, to let a woman accumulate such a series of spontaneous abortions and non-viable premature deliveries as ultimately appear to require hospitalization if any viable live birth is to be realized.
There in an additional, prevalent but somewhat unpredictable, problem occurring with premature delivery/spontaneous abortion of pregnant women suffering trauma, including the trauma of being operated on themselves for conditions that may or may not concern their pregnancy, or having their fetus operated on in the womb. These women are much more likely than normal to experience spontaneous abortions and non-viable premature deliveries. However, the timing of these occurrences is unpredictable. Hospitalization of every woman experiencing a fall or other untoward event during pregnancy could would be exceedingly expensive, and disruptive.
The previous discussion "boils down" to the facts that childbirth has never been without risk for either the child or the mother, and that some premature infants are stillborn or handicapped, sometimes exceedingly severely so. It has been so since the human race began. However, it may not be cost effective to "procreate by the percentages" in a modern industrialized society. If people are to have fewer children, as population trends both domestically and worldwide seem to necessitate, than more becomes invested not just in each living child but in each opportunity to have a living, healthy child. With the continuing deferral of the age of childbearing first by American women of the "baby boomer" generation, and now by their career-minded daughters, many American women are undertaking to have children at chronological ages where their probability of reproductive success is diminished simultaneously that the remaining years during which birth can be given are waning. Some cost-effective means of improving the likelihood of realizing satisfactory full-term pregnancies for these women would be highly desirable.
The present invention does not directly concern the medical diagnosis of problems during delivery, which is part of the evolving medical art of obstetrics. The present invention does concern, however, new machines and methods for both the comprehensive measurement and display of, and the generation of alarms and infusion of tocolytic drugs responsively to, the measurement of cervical dilatation/effacement during labor. The present invention will be seen to concern a new approach to attempting to maintain a fetus in the womb for such a minimal gestation period as is highly beneficial to the fetus, highly salubrious to the mental health and well being of the parent(s), and high cost effective to society.
2.7.2 The Communication of the History of a Birth Based in Cervical Dilation/Effacement Monitoring
The oral record and the written does not suffice for the communication of the stages, and circumstances, of complicated labor. The hard-copy, graphical, record of a continuous monitoring of cervical dilatation/effacement during labor can promote a number of ends. It permits the ready visualization of the progress of the labor. It permits all temporal junctures at which therapies were administered to be identified, and the results of these therapies (insofar as affecting cervical dilatation/effacement) recognized. It permits the ready communication of a history of the labor to (i) students, (ii) history, (iii) medical review boards and courts, and (iv) other physicians, including those who may attend other labors of the same female some years hence.
2.7.3 Previous Monitoring of At-Risk Pregnancies
A previous attempt to monitor pregnancies at risk of early delivery relied on strain gauges held in contact with the abdomen to detect premature uterine activity. A monitoring device so operating has been made and sold by Tocos, Incorporated of Orange County, California and also by HealthDyne. The device is typically used to sample uterine activity only some few hours a day while the woman patient is hooked up to a monitor. The monitor transmits the sensed uterine activity and movement via modem to a regional office for assessment by a nurse. If excessive activity is detected then the woman will be directed to contact her physician.
The utility of this system in registering the onset of true labor, even during such periods as the system is connected and operating, has been questioned in the ob-gyn literature. The system suffers from sensing and reporting normal uterine contractions which may not be true precursors, or the best indicators, of the actual onset of labor. A physician will, as previously explained, also assess cervical dilatation/effacement, as well as uterine contractions, in determining whether labor is occurring.
2.7.4 Diligence in Childbirth Monitoring Based in the Monitoring of Cervical Dilation/Effacement
Childbirth in humans is a lengthy process which can commence totally asynchronously with the other duties and schedule of an attending obstetrician or midwife. The attentiveness of personnel attending to the labor can sometimes languish over the long periods involved. It is equally as undesirable that these personnel should be overly zealous. It is (i) difficult, (ii) unreasonable on the basis of medical results obtained, (iii) and more disturbing than beneficial to the patient, that a physician or attending midwife should be making excessively frequent manual digital assessment of the dilatation of the cervix during labor.
Accordingly, manual assessment of cervical dilatation during labor that is either too infrequent, or too frequent, is avoided. However, there is a fair amount going on in the cervical dilatation on a time scale that is short, and thus insufficiently captured, relative to even the most frequent manual digital assessment. Namely, this dilatation is cyclic on a time scale of typically from one (1) to two (2) minutes, as will be shown in this specification. Moreover, there is no desire to delay the recognition of changes, especially such changes as may be significant, simply because they do not coincide with the periodic, and likely infrequent, schedule of manual digital assessment.
In most labors and deliveries, including those that have problems, observational vagaries as may result in (i) imprecision and/or (ii) untimeliness in detection/measurement of the dilatation/effacement of the cervix the are of no consequence. The challenge is with those few difficult, often premature, labors and deliveries in which the timeliness and quality of information may be, or become, critical. In episodes of labor of this sort the physician faces a dilemma. His continuing observational interventions may precipitate the very events that he/she seeks to avoid. Conversely, optimal intervention may be compromised if the physician is not in possession of the most timely and accurate information.
Accordingly, a system that would continuously, accurately and reliably monitor cervical dilatation/effacement during labor without substantial discomfort, inconvenience, disturbance or hazard to the patient would be very desirable. It would be even better if such a system were usable outside a hospital, or clinical, environment. Finally, it would be very useful if such a system could be proactive, or at least timely reactive, to prevent premature labor/spontaneous abortion. The present invention concerns such a system.
SUMMARY OF THE INVENTION
The present invention contemplates infusing of tocolytic (labor-preventing) drugs in response to the onset of premature labor or spontaneous abortion as is detected by ultrasonic monitoring of the dilatation and/or effacement of the cervix os.
The purpose of the invention is to avoid spontaneous abortion (death of the fetus), and/or to postpone labor until the fetus is more likely to be born alive, less likely to suffer the deleterious health effects of premature birth, and less likely to require the extensive postnatal care that is, circa 1995, occasionally extremely expensive (ranging to $1M+ U.S. circa 1995) for infants born viable but prior to thirty-two (32) weeks gestation.
In one embodiment of the present invention, the onset of labor of a pregnant human female is continuously automatically monitored, potentially for periods of several months, by ultrasonic measurement of the dilatation and/or effacement of the cervix os. The preferred measurement is of both the (i) absolute dilatation and/or effacement (i.e., an absolute dimension), and also the (ii) cyclical variations in dilatation and/or effacement (i.e., relative changes in a dimension) of the cervix os. The measurement is preferably performed with and by a real-time transit-time ultrasonic monitor, and more preferably by a computerized ambulatory monitor. The monitor is coupled to ultrasonic transducer probes that are preferably emplaced, and held, in the vaginal canal in preferred positions about, and across, the cervix os.
Upon detection of certain conditions in the dilatation or, equivalently, the effacement of the cervix os such as are indicative of the early onset of labor (equivalently, spontaneous abortion), time is of the essence if the onset of full blown labor and ultimate birth/abortion is to be avoided. Two transducer probes of an ultrasonic monitor are affixed at, and about, the cervix os in a first placement opposed across the cervical opening if dilatation is to be measured, and in a second placement upon the wall of the cervix os if effacement is to be measured. The initial physical placement of the transducer probes upon the cervix os of a particular woman determines the absolute, baseline, dimensional measurements. Baseline cervical dilatation and effacement are each typically less than one (1) centimeter, and may even be nearly zero if the two probes are nearly touching.
The conditions that are preferably detected by the ultrasonic cervical monitor may be any one or ones of (i) absolute cervical dilatation, with an alarm threshold limit of typically greater than a preset increment of one to two (1-2) centimeters over the baseline measurement, (ii) absolute cervical effacement, with an alarm threshold limit of preferably one to two (1-2) centimeters over the baseline measurement, and/or (iii) greater than a present, normally 10%, cyclic dimensional variation in either dilatation or effacement within an alarm threshold preset limit of a fixed number, preferably less than five (5), cycles per hour.
Preferably both (i) the absolute dimensions of cervical dilatation or effacement, and also (ii) cyclical variations in such dilatation or effacement, are detected. The preferred monitor is self-normalizing to the baseline measurements. The threshold value(s) associated with each condition is (are) preferably variably preset, normally in a simple programming operation performed by the woman's obstetrician. The monitor is also possessed of manufacturer's default presets, and it will assess any programmed preset for being reasonable, and within a manufacturer's allowable dimensional range (as reflects the anatomy of a human female).
In response to detection that any one or ones of variously predetermined cervical conditions--and preferably both of the preferred two monitored conditions of (i) absolute dilatation/effacement and (ii) detected cyclical variations in measured dilatation/effacement--have exceeded an associated preset threshold(s), the preferred system of the invention preferably first produces an alarm, preferably an audible alarm. The preferred audible alarm is reasonably dignified, and is of the order of the only-modestly-obtrusive volume and tone of a common telecommunications pager. The female patient has normally been instructed in advance to respond to the alarm by doing what she can to cease such behaviors as may be inducing the commencement of labor, by becoming inactive and preferably assuming a supine position, and/or by immediately contacting her obstetrician/gynecologist by telephone (preferably by cellular telephone carried by the patient in geographic areas so served).
Nonetheless to the patient female's best efforts, and/or professional medical advice timely forthcoming in real time, labor may often continue. In this eventuality--or occasionally if so predetermined by programmed entry, immediately upon occurrence of the alarm condition (regardless of whether or not an alarm is sounded)--the preferred system of the invention will cause an infusion of a predetermined dosage of a tocolytic (labor-preventing) drug. The administration of the drug is preferably subcutaneously by an ambulatory infusion pump electrically triggered and controlled by the cervimeter monitor. The infusion pump may be powered by compressed gas, normally nitrogen, or by electricity, normally in the form of batteries. If electrical, the pump may use a motorized pump, including motors of the solenoid type and pumps of the peristaltic type. The preferred infusion pump has the extensive programmable controllability and alarms as to its performance (integrated with the alarms of the monitor) as are typical, for example, of the existing MiniMed® 404-SP ambulatory miniaturized battery-powered infusion pump of MiniMed Technologies (MiniMed® is a registered trademark of MiniMed Technologies).
The monitoring, and potential infusion, preferably transpires between 28 and 34 weeks of pregnancy. The preferred (and also the default) three threshold condition(s) preset in the monitor, and also alarmed by the monitor if exceeded (in combination), are: (i) more than one (1) centimeter of cervical effacement above baseline, or (ii) more than one (1) centimeter of cervical dilatation above baseline, coupled with (iii) more than five (5) cycles of greater than ten percent (10%) in effacement or in dilatation in the course of any one (1) hour period. For example, six (6) cycles of twenty percent (20%) variation in dilatation without accompanying increase in dilatation of more than one (1) centimeter will not suffice to cause an alarm. The physiological interpretation of such an occurrence would be that the woman is experiencing uterine (and cervical) contractions, but is not (yet) entering labor. Conversely, the same cyclical contractions, and corresponding cyclical variations in dilatation/effacement, further accompanied by a one (1) centimeter expansion of the dilatation of the cervix os would be indicative of early labor, and would be alarmed by the monitor.
The woman wearing the ambulatory monitor and infusion pump is given the ability to turn off the alarm. She is also accorded a variably preset short period of time, normally five minutes, in which to reject, or suspend action on, those indications of cervical condition that are commonly displayed on the monitor, and/or the interpretation of the onset of labor that has just been made by the monitor from these indications. If the woman does not suspend action, the monitor will trigger the infusion pump to automatically subcutaneously inject a tocolytic drug. This injection is neither so large nor sensation-inducing so as would physically disrupt and affect the woman regardless of her present posture and/or activity such as, for example, driving a car. There is, however, a feeling, and a possible psychological impact, to the injection. The woman is accordingly permitted to suspend, or to permanently override, the impending injection while she momentarily prepares herself, and/or contacts her physician-obstetrician by telephone. If the woman and/or the physician decide, a pushbutton activation of the monitor can cause the tocolytic drug to be summarily injected.
The presently preferred tocolytic drugs are Terbutaline and Ritodrine, and more preferably Terbutaline. The preferred profusion pump preferably contains 0.5 cc of a 1 mg/cc sterile solution of Terbutaline. The Terbutaline is preferably infused subcutaneously almost immediately that the compound threshold conditions indicating onset of labor are sensed, preferably as a bolus in the amount of 0.25 mg of (0.25 cc of the 1 mg/cc solution). Infusion thereafter desirably continues at the rate of 0.2 mg per hour (0.1 cc of the 1 mg/cc solution) until, if medical aid is not earlier obtained, the supply of the drug is exhausted after approximately another 7.5 hours, or else the patient is directed to disconnect the infusion line or pump.
The system is fail safe in design, and will not harm the patient even if all the Terbutaline is instantaneously injected. All normal failure modes--especially as are attendant upon loss of battery or pressurized gas power, or physical disconnection of any of the ultrasonic transducers, monitor and infusion pump, or infusion catheter--will cause that no drug will be infused.
The system of the present invention is also useful in more routine, full term, pregnancies and labor. The monitor and its probes in combination with the controlled infusion pump may be fitted, for example, to a woman entering a hospital at full term of pregnancy in the first stages of labor. The monitor may be flexibly programmed to, for example, continuously or periodically or occasionally infuse a tocolytic drug in order to "even out" the progress of labor, and/or to postpone labor some hours in order that the actual childbirth may transpire at a time most safe for the mother and her newborn child (normally in the morning), and convenient to the attending hospital staff and physician.
In these manners of using the monitoring and infusion system of the present invention, the onset of labor/spontaneous abortion can be (i) early detected, (ii) early alarmed and (iii) early beneficially altered even before it is possible to receive the diagnosis or treatment of a physician or other health care provider.
These and other aspects and attributes of the present invention will become increasingly clear upon reference to the following drawings and accompanying specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 contains a table comparing the advantages and inconveniences of prior art methods of cervimetry with the method, and cervical monitor instrument, of the system of the present invention.
FIG. 2 is a diagrammatic perspective view showing a preferred embodiment of a preferred system in accordance with the present invention including both an ambulatory cervical effacement/dilatation monitor having disposable probes, and an ambulatory infusion pump, in operational use for monitoring, and for infusing upon the occurrence of certain conditions, an ambulatory pregnant human female.
FIG. 3a is a detail diagram of first positions of affixation of the disposable probes of the ambulatory cervical effacement/dilatation monitor to the cervix uteri of the ambulatory pregnant human female previously seen in FIG. 2, the first affixation positions being so as to monitor cervical dilatation.
FIG. 3b is diagram, at an enlarged scale from FIG. 3b, of a second positions of affixation of the disposable probes to the cervix uteri of the pregnant human female previously seen in FIG. 2, the second affixation positions being so as to monitor cervical effacement.
FIG. 4, consisting of FIG. 4a through FIG. 4c, show various preferred embodiments of the head of a disposable probes, two of which probes which are used with the preferred embodiment of the ambulatory cervical effacement/dilatation monitor previously seen in FIGS. 2 and 3.
FIG. 5a is a graph showing a calibration of the ambulatory cervical effacement/dilatation monitor used in the system in accordance with the present invention.
FIG. 5b is a graph showing the typically varying dilatation of the cervix uteri of a human female, or any higher primate, during labor.
FIG. 6 is a schematic block diagram of a substantially analog first portion of the preferred embodiment of the ambulatory cervical effacement/dilatation monitor previously seen in FIG. 2.
FIG. 7a is a schematic block diagram of a substantially digital second portion of the preferred embodiment of the ambulatory cervical effacement/dilatation monitor used in the system of the present invention, the analog portion of which ambulatory cervical effacement/dilatation monitor was previously seen in FIG. 6.
FIG. 7b is a schematic block diagram of a preferred embodiment of an ambulatory infusion pump used in the system of the present invention.
FIG. 7c is a schematic block diagram of the stepper motor control of the preferred embodiment of the ambulatory infusion pump used in the system of the present invention previously seen in FIG. 7b.
FIG. 8 is a flow chart of the function of the preferred embodiment of the ambulatory cervical effacement/dilatation monitor used in the system of the present invention previously seen in perspective view in FIG. 2, and in schematic block diagram in FIGS. 6 and 7.
FIG. 9 is a schematic block diagram of a preferred embodiment of the complete system of the present invention for infusing of tocolytic drugs in response to the onset of premature labor detected by ultrasonic monitoring of the dilatation and/or effacement of the cervix os, the block diagram being coupled with a diagrammatic representation of a placement of ultrasonic transducers at and about the cervix os.
FIGS. 10a through 10c are graphs showing the timing of certain control signals, and the resulting administration of tocolytic drugs by the infusion pump under control of the software program running in the ultrasonic monitor of the cervix os in the system of the present invention previously seen in FIG. 9, the programmed administration being in response to the dilatation and/or effacement of the cervix os sensed and interpreted by the monitor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention includes both a (i) monitor of cervical dilatation or, alternatively, effacement, in combination with (ii) an infusion pump. The monitoring is directed to detecting and measuring the dilatation--meaning the opening--or, equivalently, the effacement--meaning the thickness of the rim--of the cervix uteri, of the cervix os of a human female particularly so as to detect the onset of labor.
It should be noted that as the cervix expands during labor, increasing the dilatation distance, the rim of the cervix stretches and becomes thinner, decreasing the effacement distance, or thickness of the rim. One phenomena is related to the other. Both phenomena show the same cyclical variation during labor, and each may be correlated to the other.
The probes of an ultrasonic acoustic cervimeter that is a part of the system of the present invention are preferrably affixed across the major chord, or diameter, of the cervix uteri from a one side to the other, or at least across a minor chord for such a maximum distance of separation on the face of the cervix as is possible. In such positions the probes measure dilatation.
However, the probes may be affixed, if required or desired, along but a single radii of the cervix with a one probe located more centrally, on an interior wall of the cervix (which is in the overall shape of a torus) and with the remaining probe located nearby on the exterior wall of the cervix. In such a position the probes measure effacement.
The cervical monitor of the system of the present invention may be implemented in many different forms--ranging from a straightforward ultrasonic acoustic distance measuring device, or sonic cervimeter, to a full-blown computerized cervical dilatation/effacement alarming monitor with a memory and a time-based display of a running history of dilatation/effacement measurements. One preferred embodiment is as a battery-powered monitor with a memory and a graphical display, plus combined audible and visual alarm indications, that is completely self-contained and portable, and that is intended for continuous use on, partially within, and by, an ambulatory female patient.
This embodiment typically takes one hundred (100) measurements a second, forming a running average of the cumulative measurements taken over a period of five (5) seconds and displaying the averaged measurements for the previous one hundred and twenty-eight (128) five-second intervals (for a total of 102/3 minutes). The cumulative measurements for a longer period are stored to the capacity of memory, typically the averaged measurements for at least the previous six hundred and forty (640) five-second intervals for a total of over sixty (60) minutes). The ambulatory monitor typically so functions on two (2) 9 v.d.c. dry cell batteries, typically for a period of more than eight weeks.
A table comparing the major advantages and inconveniences of prior art methods of cervimetry with the method, and the cervimeter, of the system of the present invention is shown in FIG. 1. It may immediately be observed that the ultrasonic cervimetry method, nonetheless to being performed by an instrument that is uniquely compact and suitable for ambulatory use, to record a history of cervical dilatation/effacement that is described as "total" as opposed to "limited". By this it is meant that previous monitors, especially including ultrasound monitors, recorded a history of cervical dilatation/effacement only when the patient was "hooked up" to the previous monitors, usually in a hospital after the onset of labor. Data regarding any such long or short term transient events during pregnancy as did not lead to the full onset of labor was unrecorded and unavailable. Indeed, very little is known at the present time about exactly what (other than the lapse of time, or intentionally-administered medications) will most likely induce the onset of labor in a particular human female, and what precursors to this event and/or flags to the likely causative agent(s) (such as exercise, or diet, or temperature) might be observed. The preferred cervical monitor is, of course, dedicated to providing a full and complete record of cervical dilatation/effacement over a period potentially as long as many months. During this period of time there is little or nothing regarding the dilatation (or, equivalently, the effacement) of the cervix that will not be recorded, and archived into a history store that is retrievable to and analyzable by, a health care professional. Accordingly, the recorded history is described as "total".
Because the preferred cervical monitor is intended to be in continuous use twenty-four hours a day during all periods--which periods may be protracted and many months in duration--when the dilatation (or, equivalently, the effacement) of the cervix of the female patient wearing the monitor is of medical interest, it is possible for the monitor to make a visual or audible alarm, as well as to control the administration of tocolytic drugs, when certain conditions are detected. Certain basic conditions regarding the cervical dilatation/effacement curing the onset of, and during the progress of, labor are well understood, and the monitor looks for, and alarms, the occurrence of these conditions.
It may well be, and is expected, however, that certain high-risk pregnancies will exhibit detectable, possibly unique, phenomena prior to events such as spontaneous abortion. If particular warning signs to the continuation of the pregnancy of a particular human female, or class of human females, can be recognized from the study of historical data on such female, or on such class of females, then it is contemplated that it will be desirable to warn such a female or females of the incipient occurrences of such signs in her/their later pregnancies. As will be seen, the preferred ambulatory cervical monitor is a programmable device. If necessary or desired, it can be preset to alarm, and to variously alarm, conditional upon almost any condition(s) of the cervix transpiring over almost any time interval(s) that the monitor is capable of detecting. Although setting up the preferred ambulatory cervical monitor to alarm upon arbitrarily determined criteria (one, or many) involves (by present understanding of cervical dilatation/effacement indications in high-risk pregnancies) highly skilled labor and attendant expense, it should be understood that the monitor is intended to be used, among other applications, on pregnant females that have never successfully carried so long so as to give live birth, let alone to term. Moreover, it should be understood that if cautions performed by the female and/or her medical advisors in response to monitor alarms and/or recorded records can prevent, or can even slightly delay by a matter of months or even scant weeks, highly premature births, then the very considerable expense of administering to premature newborns can be ameliorated, or even substantially saved.
This simple concept deserves further exposition. People do not like to, and effectively cannot, be told that they cannot have children because they are at risk of giving birth prematurely, and at great expense. People, especially those who desire but do not yet have children, do not like to think that such medical care, no matter how expensive, as might permit their prematurely born child to survive is being withheld on economic grounds. An ounce of prevention is worth a pound of cure--although it is perhaps not so "showy" in terms of hospital obstetrics facility, practice, and practitioners. A successful obstetrician in the current U.S. health care environment (circa 1995) is one who judiciously avoids problems, not just one who is skilled in overcoming problems. The monitor and the entire system of the present invention are directed to aiding an obstetrician, a general health care practitioner, and a woman patient herself, in avoiding the expense, risk, and potentially traumatic consequences of premature birth.
A diagrammatic perspective view of a preferred embodiment of the system of the present invention is shown in FIG. 2. An ambulatory cervical effacement/dilatation monitor 1 having disposable probes 13 is in use for monitoring a pregnant human female 2 (shown partially in cut-away view and partially in phantom line) is shown in FIG. 2. The female 2 is ambulatory. Wires 12 connect a portable control unit 11 to the probes 13, The wires 12 descend (in the standing female) from the cervix os 21 whereat the probes 13 are affixed through the vaginal canal (not shown) to the exterior of the body of the female 2. They then proceed past normal boundaries and apertures of both underclothing and clothing to the site of the control unit 11, which may be worn virtually anywhere on the body in a position covered or uncovered by clothing as is desired. The wires 12 are normally quite small and flexible, and are appropriately sheathed in soft and flexible plastic. The preferred surrounding plastic is preferably (i) surgical grade, (ii) antibacterial, (iii) and readily cleansed. The entire interconnection system of the wires 12 is designed with due consideration to (i) comfort for long term wear, and (ii) avoidance of establishing any path by which germs might abnormally be conducted to the region of surface of the cervix 21. Both the wires and the preferred ultrasonic transducers are coated with a biologically inert material, preferably respectively Teflon® polymeric material Teflon is a registered trademark of E. I. DuPont de Nemours) and EPO-TEK™ coating (EPO-TEK is a trademark of Epoxy Technology, Inc.).
The ambulatory cervical effacement/dilatation monitor 1 having disposable probes is connected to an ambulatory infusion pump 3. The infusion pump contains a reservoir containing a tocolytic drug (not shown). The infusion pump and its reservoir are flow connected by a catheter 31 to a needle (not shown in FIG. 1, shown in FIG. 7b) held under a cuff 32 for the purpose of making a subcutaneous injection of the tocolytic drug under automated control of the monitor 1.
A detail diagram of the affixation of the disposable probes 13 of the preferred ambulatory cervical effacement/dilatation monitor 1 to the cervix os 21 of the pregnant human female 2 (previously seen in FIG. 1) is shown in FIG. 3. The particular affixation of the probes 13 that is illustrated is where each of the two probes is on the rim of the cervix 21 at roughly 180° separation. In this position the probes 13 are positioned to measure, by the delay in an ultrasound pulse traveling between them, the cervical dilatation, or distance across the cervix. Note that in the FIG. 3 it appears as if the central opening of the cervix os is void and filled with air, which would be unsuitable to transmit ultrasound. In actual fact the complete path in a substantially straight line between probes 13 is completely filled with tissues, mucous and fluids. An ultrasonic path can be reliably established and maintained between the probes 13 under all normal and abnormal conditions. Indeed, neither ultrasonic signal attenuation nor change in attenuation (signal level) presents any significant problem(s) or challenge(s)--at least when the preferred probes are used (as will be discussed in conjunction with FIG. 4)--and there is little difficulty that (i) and ultrasonic pulse emitted at a one of the probes 13 will be duly received and the other one of the probes 13, and that (ii) this pulse will travel a true path, meaning straight between the two probes 13.
A diagram, at an enlarged scale from FIG. 3b, of the affixation of the disposable probes to the cervix uteri of the pregnant human female in positions to monitor effacement is shown in FIG. 3b. The probes 13 are mounted along a same wall region, and normally on opposite sides of the wall, of the cervix os 21. When the cervix os 21 dilates (enlarges) then the distance between the probes 13 as such are attached in FIG. 3a will increase. However, during the same dilatation (enlargement) the distance between the probes 13 as such are attached in FIG. 3b will decrease. The increase is related (although not linearly) to the decrease, and vice versa. The status of the cervix os may be monitored, and interpreted, from data concerning either dilatation or effacement (or both). The normally measured, observed, monitored and interpreted quantity is dilatation, and the ensuing discussion of the function of the cervical monitor will be based on dilatation. However, a practitioner of the medical arts will understand that these and other physiological measurements are interrelated, and that the monitoring, alarming and infusing functions of the present invention are not dependent upon the particular placement of the probes 13, nor the particular path and distance that is monitored.
Various preferred embodiments of the head of a disposable probes, two of probes which are used with the preferred embodiment of the preferred ambulatory cervical effacement/dilatation monitor previously seen in FIGS. 2 and 3, are shown in FIG. 4, consisting of FIG. 4a through FIG. 4c. The body of the embodiments of FIGS. 4a and 4b is substantially cylindrical whereas the embodiment of FIGS. 4c is substantially spherical. The transducer of each of these two body configurations is in the substantial shapes of a three-dimensional, non-planar, bodies. This is somewhat unusual because an ultrasonic transducer is normally housed in a substantially planar parallelepiped body, typically a disk. Such need not be the case, however. The ultrasound, which is electrically produced in a crystal, will radiate from the surface of the surrounding housing, whatsoever its shape.
Each of the preferred transducer bodies shown in FIGS. 4a-4c is characterized in that ultrasound emissions from the transducer occur along a multiplicity of axis in multiple different directions. The reason that the transducers are so omnidirectional is that, when secured to the wall of the cervix uteri of human female such as by their barbed fishhook or corkscrew coil (to be discussed), the transducers are substantially insensitive to their initial placement(s) and alignment(s), and also to any directional changes occurring before or during labor. The preferred transducers serve to maintain good acoustic coupling under all conditions.
It is, or course, necessary to maintain the transducers 13 in their predetermined, fixed, locations upon the cervix os 21 so that ultrasonic transit time measurements may be performed. There are insubstantial nerve endings on the cervix os, which is also physically very robust and resilient to permanent damage. Ultrasonic probes have heretofore been attached by corkscrews, and that embodiment of a probe 13 in accordance with the present invention that is shown in FIG. 4b continues this tradition. Corkscrews are a good, and proven, means of attachment of probes to muscle, as witness cardiac pacemakers. However, there are differences between cardiac probes and ultrasonic transducers. In the former case an electrical signal is being coupled to the muscle, and reliable continuous electrical and physical contact must be maintained therewith. In the present ultrasonic probes, understand that no electrical, nor acoustical, energy is being attempted to be coupled into the muscle (of the cervix os) through, or by, the probe attachment. There is, or course, no electrical coupling to the muscle. The acoustic coupling is, by and large, to the surrounding mucous and fluids, and the probe is not configured for coupling acoustic energy into the cervix os (if it was then should lie tight against the cervix os). The probes' attachments are simply to hold the probes in position so that they may follow the movement of the muscle, and so that the varying distance between them may be monitored.
So considering the function of the attachment of a probe 13, the barbs of the embodiments of FIGS. 4a and 4c, of like barbs in the substantial shapes of fishhooks, are preferred for some patients. Namely, the barbed probes are generally easier, and faster, to attach in patients who are sensitive to discomfort. A corkscrew probe should be unscrewed in order to remove, but a barbed probe of the design of FIGS. 4a and 4c will usually exit cleanly if simply pulled strongly. In those generally rare affixation, and locations, where a fishhook barb (not shown) better serves retention, and positioning of the probe, then the barb may be removed exactly as a fishhook is removed from the flesh of the body. Namely, the barb is worked forward to exit the surface, and is cut off as exposed. The barb-less probe is then withdrawn.
Alternatively, the entire positioning and holding of the probes may transpire by use of a flexible elastomeric annulus-shaped membrane as is taught in the companion patent application filed on the same date. The annular membrane has a shape-retentive memory and exerts a force so as to assume and to maintain a predetermined closed-loop geometric shape, normally a circle. The annular membrane fits circumferentially about the cervix os of a human female so as to hold and retain various medical instrumentation probes, an more particularly the two opposed wire-connected ultrasonic transducers of the real-time transit-time ultrasonic monitor of cervical dilatation and effacement. The annular membranae may optionally extend as a tube downwards in the vaginal canal, in the manner of a female diaphragm, as to shield the wires from the walls of the vagina. The membrane expands and contracts with such cyclical variation in the dilatation and effacement of the cervix os as occurs from the earliest onset of labor until imminent childbirth. This membrane and its held transducer probes of an ultrasonic cervimeter may be situated in place about the cervix os for prolonged periods ranging to several months, or may be placed only at the onset of full labor, for monitoring purposes.
A graph showing a calibration of the preferred ambulatory cervical effacement/dilatation monitor is shown in FIG. 5a. The calibration is performed in the controller 11 by producing in manually controllable steps successive delays such as would be indicative, if received from probes 13, of an increasing amount of separation between the probes 13. The "manually controllable steps" simply involve the stepwise rotation of a multiple position switch which, in its successive positions, couples an increasing amount of delay into the simulated probe input to the controller 11 (the schematic diagram of which controller 11 will be shown in FIGS. 6 and 7). The lowest level of the trace in the graph of FIG. 5a is indicative of a probe separation of 10 mm; the highest level of the trace is indicative of a probe separation of 60 mm. If the number of steps are carefully counted, if may be observed that the preferred resolution of the cervimeter monitor 1 is at least as small as 5 mm.
FIG. 5b is a graph showing the typical varying dilatation of the cervix uteri of a human female, or other higher primate such as a rhesus monkey, during labor. The total period shown is about thirty (30) minutes in which period twenty (20) relatively even cycles have transpired for an average cycle time of one and one-half (11/2) minutes per cycle.
A schematic block diagram of a substantially analog first portion 11 of the preferred ambulatory cervical effacement/dilatation monitor 1 is shown in FIG. 6. The first portion 11 is, in of itself, a complete sonomicrometer. Sonomicrometers are known in the art, and the circuit of the block diagram of FIG. 6 is simply a particular version of a sonomicrometer that is, quite obviously, adapted to the measurement task at hand in terms of (i) acoustic signal power, (ii) acoustic signal reception sensitivity, and, most importantly, (iii) the duration (not the frequency) of an acoustic signal pulse that will be appropriate to measure the distances involved in cervical dilatation, and (iv) a repetition rate of the acoustic signal pulse that will be appropriate to measure all changes in the distances involved in cervical dilatation. Notably, the frequency of the acoustic signal is an innate property of the probes, or transducers 13, which "ring" when electrically excited at their resonant frequency(ies). The probes, or transducers, 13 may suitably operate over a broad range of ultrasonic frequencies, and preferably ring at a natural resonant frequency of about 5 Mhz.
A CLOCK portion of the CLOCK AND TIMING 111 produces a fundamental 1.58 MHz frequency. This frequency is chosen because an ultrasonic acoustic pulse will travel approximately 1 millimeter in tissue--and very nearly the same in mucous or other water-based fluids--in the period of one cycle of 1.58 MHz, or 0.63 microseconds. The 1.58 Mhz signal is provided as signal CLOCK 111.
A TIMING portion of the CLOCK AND TIMING 112 produces pulses of (i) 50 microsecond duration (of 1.58 MHz signal) (ii) at a pulse repetition rate of 100 Hz. The duty cycle of the collective pulses is correspondingly ((5×10 -5 )×1×10 2 ) per second, or a low 0.5% which serves to save power. These 50 microsecond pulses at the 100 Hz. rate are applied to the set, or S, input of the PULSE GENERATOR 116 and the PINGER 114. The PINGER 116 serves as an amplifier. The 50 microsecond pulse duration is sufficient, when driven by the PINGER 114, so as to cause the driven one of the probes, or transducers, 13 to ring, producing an acoustic pulse (which gradually decays in amplitude) for an effective duration, as is such pulse is detectable at the other one of the transducers 13 and by the RECEIVER 118, of about 1 msec. (One hundred such acoustic pulses each second give an acoustic duty cycle of approximately 10%.) The duration of this acoustic pulse is, or course, not particularly important save that each pulse shall have completely died away before a next later pulse is generated. In accordance with the principles of transit time sonomicrometry, it is the delay incurred by this pulse in reaching the receiving one of the probes, or transducers, 13 that is important. Each and every pulse will incur a delay of about 0.63 microseconds per millimeter traversed.
The signal developed in the RECEIVER 118 in response to each received acoustic pulse is shaped in an automatic gain control, AGC, circuit 120 and is then subject to detection in LEVEL DETECT circuit 122. The signal AGC VOLTAGE 113 is a function of the amount of signal gain being applied in, and by, the AGC circuit 120, and will be highest when the received signal acoustic is lowest, or non-existent (as between acoustic pulses, or before an acoustic pulse has arrived). A use of such signal AGC VOLTAGE 113 will be later shown in FIG. 7. The signal output of LEVEL DETECT circuit 122 will assume a logic High condition within a few tens of nanoseconds that the acoustic pulse is received by the RECEIVER 118. The signal will, as applied to the reset, or R, input of the PULSE GENerator circuit 114, serve to reset this circuit. (It will be understood that electrical delays are small in relation to acoustic delays in a sonomicrometer.) The signal PULSE 115 arising from the PULSE GENerator circuit 114 accordingly starts with each transmission of an acoustic pulse, and ends with the reception of the same pulse. Its duration is thus indicative of the acoustic delay in the communication of the ultrasonic pulse between the two transducers 13.
FIG. 7 is a schematic block diagram of a substantially digital second, data logging and alarming, portion of the preferred embodiment of the preferred ambulatory cervical effacement/dilatation monitor 1. This data logging and alarming portion receives all three signals 111, 113, and 115 developed in the analog, sonomicrometer, portion previously seen in FIG. 6. The signal CLOCK, which is at a frequency of 1.58 Mhz, serves to increment a COUNTER 124 that is enabled for counting for the duration of signal PULSE 115. The number of counts accrued during the duration of each signal PULSE 115 is the thus the distance in millimeters that the ultrasonic acoustic signal traversed between probes 13 (shown in FIG. 6). Permitting the COUNTER 124 to read directly in millimeters avoids the necessity of a later conversion. Once the count is terminated by the logic Low condition of signal PULSE 115, the COUNTER 124 will put the accrued count onto a digital communications bus that is called DIMENSION BUS 117 because it carries the cervical dimension. The COUNTER 124 will also reset itself to zero for the next counting interval (which, in accordance with CLOCK AND TIMING 112 shown in FIG. 6, will occur in 10 milliseconds).
The current count, which is the cervical dilatation (or effacement) in millimeters, is received into a LATCH 126 and a COMPARE circuit 128. The COMPARE circuit 128 also receives a digital quantity from the PHYSIO LIMIT SET register 130. This quantity represents the greatest reasonable, real-world, change that would be expected in cervical dilatation over the time interval between successive counts, or 10 milliseconds. This quantity is equivalent to a change in cervical diameter of about 1 millimeter per second. The previous cervical measurement that was stored in LATCH 126 is compared with the current cervical measurement received via DIMENSION BUS 117, and with the maximum expected change received from PHYSIO LIMIT SET register 130 in order to make the single determination that the presently-received cervical dimension either is, or is not, reasonable. An unreasonable reading might be received, for example, due to ultrasonic noise. If the cervical dimension, as is upon the DIMENSION BUS 117, is reasonable then the input from the COMPARE circuit 128 to the AND gate 132 is a logic High, satisfying one of the two inputs to AND gate 132.
The other, remaining, input to the AND gate 132 is derived from differential amplifier 134. The signal 119 from this differential amplifier 134 will be a logic High, satisfying the remaining one of the inputs to AND gate 132, at such times as the signal AGC VOLTAGE 113 is greater than a preset signal level supplied from the reference voltage level, or LEVEL SET 136. The signal AGC VOLTAGE 113 will so be greater than the preset signal level supplied from reference voltage level SET 136 when, and upon such times, as the RECEIVER 118 (shown in FIG. 6) is not receiving an ultrasonic pulse. According to being in an interval between the reception of ultrasound, the COUNTER 124 is not incrementing, and the cervical dimension that is upon the DIMENSION BUS 117 driven from the COUNTER 124 is (momentarily) stable, and invariant. Satisfaction of the AND gate 132 will produce a logic High gating signal to the DISPLAY 138, and will cause the DISPLAY 138 to capture the cervical dimension quantity that is upon the DIMENSION BUS 117 and to display it as a vertical bar in a next successive position proceeding towards the right across a visual display area.
The display 138, if not substantially the entire data logger shown in FIG. 7, may optionally, and even preferably, based upon a microprocessor. A practitioner of the digital logic design arts will have no difficulty in accomplishing the counting and comparison functions already discussed in FIG. 7, as well as certain other functions to be discussed, in the logic and the registers of a microprogrammed microprocessor. A microprocessor may, for example, scale the cervical dimension received on DIMENSION BUS 117 in order to appropriately size, and place, a graphical display on the DISPLAY 138. Indeed, almost as soon as the practitioner of the digital logic design arts starts to think about the flexibility, and power, of a microprocessor as applied to the data logging and alarming task of FIG. 7, it is possible to realize that, other than the necessity of comparing analog signal levels in the differential amplifier 134 (and also in differential amplifier 140, yet to be discussed) and displaying data in the DISPLAY 138, veritably everything could be done in a microprocessor. In such a case FIG. 7 could be equally validly considered as a functional, as opposed to a hardware, block diagram.
The preferred implementation of the present invention is, as is shown in FIG. 7, to (i) use a microprocessor (not shown) as part of DISPLAY 138, but (ii) not to place have all such functionality as might conceivably be accomplished by the microprocessor so accomplished. This is for two reasons not immediately apparent on the face of FIG. 7. First, it is contemplated that, with an appropriate data storage memory and sequential memory addressing (not shown) that a power-consuming microprocessor and a visual display might be turned off for periods of time and from time to time, saving energy when no one cares to view historical cervical dilatation (effacement) data in the DISPLAY 138. Second, and although various alarms the development of which is yet to be discussed are shown to be communicated directly to the DISPLAY 138, and presumably to any microprocessor (not shown) lodged therein, if is very simple to understand that, by use of discrete circuits no more complex than a latch, it would be possible to register, and to sound and/or display (in the form of a light, or LED), one or more alarms without the involvement of any microprocessor, or microcoded program. Although outside the scope of the present disclosure, the data logging and alarming circuitry of FIG. 7 can thus readily be made to have (i) a reduced-power, fall back, operational mode, and/or (ii) substantially fail-safe operation.
An alarming monitor of cervical dilatation/effacement does not incur the reliability requirements of, for example, a cardiac pacemaker. If the instrument fails the patient neither aborts, nor gives birth, nor suffers any adverse effects whatsoever. However, it is anticipated that, in some pregnancies, successful live birth may be dependent upon the adequacy and continuity of the cervical monitoring, and the timely administration of all such interventions (primarily tocolytic drugs) as are indicated to be prudent and necessary as a result of such monitoring. Accordingly, the cervical dilatation (or effacement) monitor is desirably, and is, constructed as a quality instrument, with due regard by design for its potentially crucial function.
Continuing in FIG. 7, a battery (not shown), nominally of a 9 v.d.c. type which typically suffices to last at least two (2) weeks and more commonly two (2) months in continuous use, produces a battery voltage BATT VOLTS 121. This battery voltage is compared in differential amplifier 140 to the voltage output of a constant voltage circuit LEVEL SET 142. Until, an unless, the battery voltage falls below a predetermined level, normally eight (8) v.d.c., the signal ALARM 123 will be maintained a logic High level, and the DISPLAY 138 will not produce an alarm. At any such times as the battery voltage were to fall below the predetermined level the signal ALARM 123 will go to a Logic Low level, and the DISPLAY 138 will produce a visual and/or audible alarm in plenty of time to replace the battery (not shown) before power reserves are exhausted.
A comparison of the cervical dilatation (effacement) measurement as is present on the DIMENSION BUS 117 is made in, and by, COMPARE circuit 144 to a predetermined dimension that is stored in the DIMN ALARM SET register 146. The DIMN ALARM SET register 146 is intended to contain a maximum dimension in the case of evaluating cervical dilatation, or, conversely, a minimum dimension in the case of evaluating cervical effacement, which, when the cervical dimension is respectively greater than or less than the stored dimension, is indicative that labor has begun (or at least of an extreme cervical condition). The result of the comparison is communicated to OR gate 148 as a logic High signal in the event that the threshold is exceeded. The predetermined dimension that is stored in the DIMN ALARM SET register 146 is preferably adjustably so predetermined, and stored. A microprocessor (not shown, typically closely associated with DISPLAY 138) may facilitate this storage, normally of a value that is determined by the attending physician or obstetrician.
In a similar manner, another comparison of the cervical dilatation (effacement) measurement made in, and by, COMPARE circuit 152 to a predetermined dimension that is stored in the DIMN RATE ALARM SET register 152. Notably, the cervical dimension is not even transferred to the COMPARE circuit 152 until the COMPARE circuit 144 is satisfied, meaning that a threshold cervical dilatation/effacement measurement has been exceeded. The DIMN RATE ALARM SET register 152 is intended to contain a minimum rate of the change of dimension cervical dilatation, or effacement. This quantity is involved once labor has begun (which was presumptively determined by satisfaction of COMPARE Circuit 144). If the predetermined rate of change is not exceeded then this may be indicative of problems with the progress of labor. The result of the comparison is also communicated to OR gate 148 as a logic High signal in the event that the predetermined rate of change is not exceeded. The predetermined rate of change that is stored in the DIMN RATE ALARM SET register 152 is preferably adjustably so predetermined, and stored. A microprocessor (not shown, typically closely associated with DISPLAY 138) again facilitates this storage, normally again of a value that is determined by the attending physician or obstetrician.
Satisfaction of the OR gate 148 produces a logic High signal ALARM 125, which signals received into DISPLAY 125 is used to produce a visual and/or audio alarm. The signal ALARM 125 is also routed TO INFUSION CONTROLLER, where it is used to control the infusion of the tocolytic drug by the infusion pump.
A schematic block diagram of a preferred embodiment of an ambulatory infusion pump 3 (previously seen in FIG. 2) used in the system of the present invention is shown in FIG. 7b. The signal ALARM 125 received from the OR gate 140 of the monitor 1 (shown in FIG. 7a) is delayed in a RESETTABLE PROGRAMMABLE TIME DELAY. The default value of the delay is five minutes, which may be set higher or lower by action of PROGRAM SWITCH 302. The delayed signal ALARM is routed to STEPPER MOTOR CONTROL 303, the details of which are further diagrammed in FIG. 7c. The STEPPER MOTOR CONTROL 303 acts to control the STEPPER MOTOR 304 to inject first a bolus, and then a continuing smaller infusion, of a tocolytic drug stored in reservoir 305 through the catheter 31 (also shown in FIG. 2) and the needle 33 into the woman patient 2 (shown in FIG. 2). An OVER-PRESSURE SENSOR detects any failure of flow, and feeds back to the STEPPER MOTOR CONTROL 303. Likewise, and UNDER RATE/OVER RATE INFUSION MONITOR 307 directly monitors the output control signal of the STEPPER MOTOR CONTROL 303 as is transmitted to the STEPPER MOTOR 304, and sounds an alarm (different from the alarm of monitor 1) if, and when, and untoward infusion condition is detected.
A schematic block diagram of the preferred STEPPER MOTOR CONTROL 303 of the preferred embodiment of the ambulatory infusion pump 3 (previously seen in FIG. 1) used in the system of the present invention is shown in FIG. 7c. A "BOLUS" INJECTION PULSE GENERATOR 3031 operating under control of a PROGRAM 3032 produces a first, relatively larger and relatively shorter, drive pulse the effect of which will be shown in FIG. 10c. A "SLOW" RATE INJECTION PULSE GENERATOR 3033 operating under control of a PROGRAM 3034 produces a second, relatively smaller and relatively longer, drive pulse the effect of which will be shown in FIG. 10c. The two drive pulses are combined in OR gate 3035 and amplified in STEPPER MOTOR DRIVER AMPLIFIER 3036. The amplified pulses are then routed to, and used to drive, the STEPPER MOTOR 304 (shown in FIG. 7b) to inject the tocolytic drug.
A flow chart of the function of the preferred embodiment of the ambulatory cervical effacement/dilatation monitor used in the system of the present invention previously seen in perspective view in FIG. 2, and in schematic block diagram in FIGS. 6 and 7, is shown in FIG. 8. The flow chart is, as well as being functional, suitable to serve as the flow chart of a sequential controller, particularly (but not necessarily) including a microprogrammed microprocessor. It will be recognized by a practitioner of the digital circuit design arts that the relative simplicity of the functional control block diagrammed in FIG. 8 may be accomplished by, and in, many alternative circuit implementations including, but not limited to, a microprogrammed microprocessor circuit.
The function of the ambulatory cervical effacement/dilatation monitor 1 commences with BEGIN block 800 upon application of power, and proceeds to commencing ultrasound transmission with ENABLE PINGER block 802. An ultrasound, or "ping", transmission count N is incremented in block 804, and inquiry is made as to whether this count has exceeded 100 in block 806. As will be developed in the further explanation of FIG. 8, it is a highly abnormal condition, indicating that at least 101 ultrasound pulses have been transmitted with no intervening receptions, if N is greater than 100. In such an eventuality, transducer or transducer interconnect hardware failure is indicated, and a TRANSDUCER ALARM is sounded in block 808 and the monitor 1 brought to a STOP in block 810.
Normally block 806 is satisfied, and the inquiry as to whether the Automatic Gain Control (AGC) voltage is greater than a threshold--AGC VOLT>THRESHOLD--is made in block 812. If not, no ultrasonic pulse has as yet been received, and the transmission process is re-enabled commencing with block 802.
If a received pulse is detected in block 812, then a reasonability check on the detected delay is performed in block 814. It is therein inquired as to whether the detected change is within the physiological limits of the human subject, IS CHANGE <=PHYSIO LIMIT? In the event that it is not, process error has occurred and the transmission process is again re-enabled commencing with block 802.
If, however, all status and reasonableness checks of blocks 806, 812 and 814 are satisfied, flock 816 is entered to assess whether the change in measurements dictates a rate alarm. If the measurement change does not exceed the predetermined alarm threshold, then DELTA MEAS<RATE ALARM? is answered yes and block 820 is entered. Should, however, the measurement change exceed the predetermined alarm threshold, then an ALARM is indicated in block 818.
Similarly, block 820 is entered to assess whether the absolute magnitude of the measurement dictates an alarm. If the measurement change does not exceed a predetermined alarm threshold dimension, then MEAS<DIMN ALARM? is answered yes and block 822 is entered. Should, however, the measured dimension exceed the predetermined alarm threshold dimension, then an ALARM is indicated in block 824.
Whether a dimension, or a dimensional change, has occasioned the respective ALARM of block 824, of or block 818, or not, the block 822 DISPLAY MEAS is always entered and the measurement displayed. The count number of the ultrasound transmission is thereafter reset to zero--SET N=0--in block 824, and the entire loop process re-entered at block 802.
A schematic block diagram of a preferred embodiment of the complete system of the present invention for infusing of tocolytic drugs in response to the onset of premature labor detected by ultrasonic monitoring of the dilatation and/or effacement of the cervix os is shown in FIG. 9. FIG. 9 also shows a diagrammatic representation of a placement of ultrasonic transducers 13 at and about the cervix os 21. The signals from transducers 13 are received at the CERVICAL SONOMICROMETER--MONITOR 1 (which is but a lengthened, and more descriptive, name for the monitor 1 previously seen in FIG. 2). The CERVICAL SONOMICROMETER--MONITOR 1 ultimately conceptually produces signals representative of cervical DIMENSION, a cervical DIMENSION ALARM and a cervical RATE ALARM (which conceptual signals combined are the same as the real, physical, signal ALARM 125 that is shown in FIGS. 7a and 7b). The reason the DIMENSION and the DIMENSION RATE conceptual signals are separated, and distinct, in FIG. 9 is to better illustrate that the system, and the CERVICAL SONOMICROMETER--MONITOR 1 is firmly in possession of both quantities. In response to control from the CERVICAL SONOMICROMETER--MONITOR 1, the CONTROL UNIT 3 (partial) and the INFUSION PUMP 3 (partial)--which were combined as infusion pump 3 in FIG. 2--serve to further time, and control, the ejection of a tocolytic drug from the reservoir 305 (also shown in FIG. 7b) through the catheter 31 into the Patient 2 (shown in FIG. 2). Insofar as the injection of the tocolytic drug ultimately effects the ultrasonically monitored dilatation/effacement, and the cyclical variations on dilatation/effacement, of the cervix os 21, the system of the present invention diagrammed in FIG. 9 is closed loop.
Graphs showing the timing of certain control signals, and the resulting administration of tocolytic drugs by the infusion pump under control of the software program running in the ultrasonic monitor of the cervix os in the system of the present invention previously seen in FIG. 9, are shown in FIGS. 10a through 10c. The signal ALARM 125, previously seen in FIGS. 7a and 7b, that represents the detected onset of labor by the monitor 1 (shown in FIG. 9) is graphed in FIG. 10a. After the variably programmed time delay of RESETTABLE PROGRAMMABLE TIME DELAY 301 shown in FIG. 7b, the signal SAFETY TIME DELAY also goes to a logic High, or true, condition. This is the signal used to control the STEPPER MOTOR CONTROL, and the infusion, that are block diagrammed in FIGS. 7b and 7c. The resulting drug injection rate is, under the programmed control of the STEPPER MOTOR CONTROL 303 as was previously shown in FIGS. 7b and 7c, preferably as shown in FIG. 10c. An initial BOLUS is injected, followed by the steady slower injection rate labeled MAINTENANCE. The overall programmed injection, and administration, of the tocolytic drug is in response to the dilatation and/or effacement of the cervix os as was sensed, monitored and interpreted by the monitor 1.
In accordance with the preceding explanation, many variations and alterations of the preferred embodiment of the present invention will suggest themselves to a practitioner of the electronic medical equipment design arts. For example, many more separate, and detailed, alarms could be made contingent upon conditions which may be quite intricate, and convolute. For example, the display, and history display, could be of alternative intervals and epochs. For example, the infusion of tocolytic drugs could be periodic, and at a low level, as well as episodic based on cervical monitoring. For example, the infusion of tocolytic drugs could be under control of a modem connection to a physician's office, or in response to other, additional, sensed stimuli or conditions other than just cervical dilatation.
In accordance with these and other possible variations and adaptations of the present invention, the scope of the invention should be determined in accordance with the following claims, only, and not solely in accordance with that embodiment within which the invention has been taught. | The onset of spontaneous abortion or premature labor of a pregnant human female is continuously monitored, potentially for periods of several months and longer, by a real-time transit-time ultrasonic monitor of the dilatation and/or effacement of the cervix os, preferably by a computerized ambulatory monitor. The preferred computerized monitor sounds an alarm upon the detection of variably present conditions, normally the compound conditions of five or more 10% cyclical variations in the dilatation or effacement of the cervix os within a period of one hour, coupled with a greater than 1 centimeter increase over baseline of either dilatation or effacement, which compound conditions normally indicate the early onset of labor. The monitor connects to an infusion pump, likewise preferably ambulatory, for directing and controlling the infusion of one or more tocolytic, labor-preventing, drugs if labor continues. In this manner patient activity and patient chemistry can be early detected, early alarmed and early beneficially altered even before it is possible to receive the diagnosis or treatment of a physician of other health care provider. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a servo motor monitoring unit for monitoring a servo motor controller which drives a load, such as a machine tool, and more particularly to a servo motor monitoring unit with a fault detection and cause determination function.
2. Description of the Prior Art
In the prior art, there is known a troubleshooting unit for use with a motor controller (see Japanese Patent Disclosure Publication No. 291682 of 1989) which comprises a plurality of status observers for selectively monitoring control signals, e.g. voltage, current, speed and other signals, and estimating the disturbance torque of a motor in different modes. A fault location is guesstimated from the estimated values. Since such unit employs a plurality of status observers, the constants of the motor must be exactly known. In general, however, the motor constants are easily affected by individual differences and temperature, leading to errors. In addition, what is essential in controlling a servo motor is whether the actual position is tracking the position commands. For this purpose, it is necessary to continuously compare the position command and a position detection feedback signal incoming from a position detector, to provide an alarm such as "excessive error," "excessive deviation," or the like if the difference therebetween is larger than a predetermined threshold value, and to alert the operator to any fault. The above unit, however, does not monitor the position itself, which is an essential factor in monitoring a servo motor.
On the other hand, there is also known prior art for monitoring position. As shown in FIG. 6, a servo motor monitoring unit 601 comprises a counting section 601a for receiving a position command signal P R and a position detection feedback signal P F and operating on a difference therebetween, and a range determining section 601b for determining fault if the difference obtained by the counting section 601a is greater than a predetermined threshold value, and outputting a fault alarm such as "excessive error." Referring to FIG. 6, numeral 602 indicates a servo motor, 603 a position detector for detecting the position of the servo motor 602, 604 a position command generator for outputting the position command signal, and 605 a servo controller for controlling the driving of the servo motor 602 in accordance with the position command signal P R and the position detection feedback signal P F .
The operation of the unit configured as described above will now be described.
The servo controller 605 compares the position command signal P R output by the position command generator 604 and the position detector 603 and controls the drive current of the servo motor 602. The position detector 603 outputs the position detection feedback signal P F in accordance with the operation of the servo motor 602. In the servo motor control system as described above, the position detection feedback signal P F cannot track the position command signal P R when: (1) the load is too heavy to generate acceleration; (2) the polarity of the position detection feedback signal P F from the position detector 603 is reversed; and (3) electrical connections to the servo motor 602 are improper. In any of such cases ((1) to (3)), the servo motor monitoring unit 601 causes the counting section 601a to operate on the difference between the position command signal P R and the position detection feedback signal P F , and causes the range determining section 601B to compare that difference with a predetermined threshold value, determine that a fault has occurred if the difference is larger than the threshold value, and output a fault alarm.
FIG. 7 is a flowchart illustrating the sequence of said operation. First, the difference D between the position command signal P R and the position detection feedback signal P F is found (step 701). Then, whether the difference D is within the range of the predetermined threshold value is determined (step 702). The fault alarm "excessive error" is output if the difference D is outside the threshold value range (step 703). On the other hand, if the difference D is within that range, the operation returns to step 701 and repeats processing.
The servo motor monitoring unit known in the art may be able to determine the occurrence of a fault in accordance with the difference D between the position command signal P R and the position detection feedback signal P F , but cannot determine the cause thereof, i.e. it cannot determine whether the difference D has increased due to insufficient torque because the machine (load) is too heavy or has collided with an obstacle, or due to opposite servo because of incorrect connection to the servo motor, or because the feedback of the equipment has been connected reversely. Hence, when the fault alarm "excessive error" is output, the cause of the fault must be investigated, taking much time.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to overcome the disadvantages in the prior art by providing a servo motor monitoring unit which allows the servo motor controller to be easily restored in a short time when the difference D between the position command signal P R and the position detection feedback signal P F is determined to be excessive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a servo motor monitoring unit according to one embodiment of the present invention;
FIG. 2 is a flowchart of the operation for the servo motor monitoring unit of one embodiment of the present invention, and FIG. 2(a) is a flowchart illustrating operations in an alternative embodiment;
FIG. 3 is a timing chart of a servo control system during normal operation;
FIG. 4 is a timing chart of a servo control system when the torque is insufficient;
FIG. 5 is a timing chart of the servo control system when servo is opposite;
FIG. 6 illustrates a servo motor monitoring unit of the prior art.
FIG. 7 is a flowchart of the operation of the servo motor monitoring unit of the prior art; and
FIG. 8 is a timing chart illustrating the servo control system when the controlled machine has collided with an object.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of a servo motor monitoring unit according to the present invention will now be described in detail with reference to the drawings.
FIG. 1 illustrates the configuration of a servo system to which the servo motor monitoring unit 101 of the present invention has been applied. The servo motor monitoring unit 101 comprises a counting section 101a for receiving a position command signal P R and a position detection feedback signal P F and determining the difference D therebetween, a range determining section 101b for determining fault if the difference D obtained by the counting section 101a is greater than a predetermined threshold value, and a determining section 101c for determining the cause of fault occurrence in accordance with a sign of the position detection feedback signal P F (i.e., the sign of the acceleration of this signal) and that of a current feedback value P 0 . In FIG. 1, numeral 102 indicates a servo motor; 103, a position detector for detecting the position of the servo motor 102; 104, a position command generator for outputting position command signals, and 105, a servo controller for controlling the power delivered to the servo motor 102 in accordance with the position command signal P R and the position detection feedback signal P F .
The operation of the servo motor monitoring unit according to the present embodiment configured as described above will now be described in greater detail.
Referring to FIG. 1, the servo controller 105 compares the position command signal P R output by the position command generator 104 and the position detection feedback signal P F output by the position detector 103 to control the current used in driving the servo motor 102. As the servo motor 102 runs, the position detector 103 outputs the position detection feedback signal P F accordingly. In the meantime, the servo motor monitoring unit 101 causes the counting section 101a to determine the difference between the position command signal P R and the position detection feedback signal P F , causes the range determining section 101B to compare that difference with a predetermined threshold value, and determines the occurrence of fault if the difference is larger than the threshold value. Further, the determining section 101c compares the sign b of the acceleration of the position detection feedback signal P F and that of the current feedback value P 0 , and determines the cause of the excessive position error as "insufficient torque" if the signs match, or "opposite servo" if the signs do not match.
FIG. 2 is a flowchart illustrating the sequence of the above operation. First, the difference D between the position command signal P R and the position detection feedback signal P F is found (step 201). Then, whether the difference D is within a given range of a predetermined threshold value (determination value) or not is determined (step 202), and the sign b of the acceleration of the position detection feedback signal P F is compared with the current feedback sign (sign of the current feedback value P 0 ) if the difference D is outside the threshold value range (step 203). If the above signs do not match, an "opposite servo" fault alarm is output (step 204), or if they match, an "insufficient torque" fault alarm is output (step 205). On the other hand, if the difference D is Within the threshold value range, the operation returns to step 201 and repeats processing.
The basis for determining "insufficient torque" and "opposite servo" in the sign determining section 101C will now be described with reference to graphs shown in FIGS. 3, 4 and 5.
FIG. 3 illustrates the waveforms of the output signals (position command signal P R , position detection feedback signal P F and current feedback value P 0 ) provided by the corresponding portions of the servo control system when operating without fault, and also shows the acceleration of the position feedback signal. Note that the above embodiment assumes that a positive current flows when the servo motor accelerates in the forward direction. The top graph in FIG. 3 gives the relationship between the position command signal P R and position detection feedback signal P F , the next graph indicates the difference therebetween, and the bottom graph indicates the change in the current feedback value P 0 .
FIG. 4 provides an example of "insufficient torque," wherein acceleration is initiated at t 0 , but due to a current limitation at t 1 , the position detection feedback signal P F cannot track the position command signal P R normally, and the difference D therebetween exceeds the threshold value at t A , resulting in a fault alarm. Since the sign of the position detection feedback signal (i.e., the sign of the acceleration of this signal) matches that of the current feedback value P 0 in this case, the cause of the fault can be determined as "insufficient torque".
FIG. 5 indicates an example of "opposite servo," wherein the position command signal P R has been output at t 0 , but the motor runs abnormally in a direction opposite to the command of the position command signal P R due to positive feedback caused by opposite servo, and the difference D exceeds the threshold value, resulting in a fault alarm. Since the sign of the position detection feedback signal (i.e., the sign of the acceleration of this signal) does not match that of the current feedback value P 0 in this case, the cause of the fault can be determined as "opposite servo". In the above embodiment, it has been assumed that positive current feedback (i.e. the current feedback value P 0 is positive) flows when the motor is accelerated in the forward direction. When the opposite assumption is made, it will be appreciated that the cause of the fault will be determined as "opposite servo" if the position detection feedback signal sign a matches the current feedback value P 0 sign, and as "insufficient torque" if they do not match.
In the present embodiment, inability to accelerate the servo motor due to a heavy machine load is not differentiated from collision of the machine with an obstacle and both are determined as "insufficient torque."
Since the acceleration of the position detection feedback signal suddenly drops toward zero at the time of collision, it is also possible to distinguish "machine collision" from other "insufficient torque" situations if the acceleration value falls below a certain threshold value. A flowchart showing the operation of this alternative is shown in FIG. 2(a), and a timing chart is depicted in FIG. 8. In this example, the possibility of collision is checked by calculating the acceleration value within the difference detection routine (see step 202(a)), and branching at step 202(b) if the acceleration falls below a given threshold. In this instance, machine collision is discriminated and a "machine collision" fault alarm is raised. The flowchart of FIG. 2(a) is otherwise the same as that of FIG. 2. That, is, if the acceleration has not dropped, comparison of the acceleration sign with that of the current feedback is carried out at step 203. In this alternative embodiment, determining section 101c performs the additional function of acceleration value threshold comparison.
It will be apparent that the invention, as described above, achieves a servo motor monitoring unit including fault determining means for determining a fault in servo motor operating status and the cause of the fault in accordance with a position command signal, a position detection feedback signal and the feedback value of motor current supplied to said servo motor. The monitoring unit therefore allows the servo motor controller to be easily restored within a short period when the difference D between the position command signal P R and position detection feedback signal P F becomes excessive. In other words, the servo motor monitoring unit provides quick troubleshooting at occurrence of any fault, ensuring improved maintenance performance. | The invention relates to a monitor system for a servo controller used in connection with servo motors utilized in multivarious machines, such as machine tools. In addition to detecting a servo system fault when the difference between the commanded position and the actual position exceeds a predetermined value, the system monitors several servo system parameters to distinguish between different causes of servo faults. Identifying the source of the fault leads to improved maintenance and decreased system down time when a fault occurs. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to an illumination system for an electron beam lithography apparatus used for the manufacture of semiconductor integrated circuits.
BACKGROUND OF THE INVENTION
[0002] Electron beam exposure tools have been used for lithography in semiconductor processing for more than two decades. The first e-beam exposure tools were based on the flying spot concept of a highly focused beam, raster scanned over the object plane. The electron beam is modulated as it scans so that the beam itself generates the lithographic pattern. These tools have been widely used for high precision tasks, such as lithographic mask making, but the raster scan mode is found to be too slow to enable the high throughput required in semiconductor wafer processing. The electron source in this equipment is similar to that used in electron microscopes, i.e., a high brightness source focused to a small spot beam.
[0003] More recently, a new electron beam exposure tool was developed based on the SCALPEL (SCattering with Angular Limitation Projection Electron-beam Lithography) technique. In this tool, a wide area electron beam is projected through a lithographic mask onto the object plane. Since relatively large areas of a semiconductor wafer (e.g., 1 mm 2 ) can be exposed at a time, throughput is acceptable. The high resolution of this tool makes it attractive for ultra fine line lithography, i.e., sub-micron. The requirements for the electron beam source in SCALPEL exposure tools differ significantly from those of a conventional focused beam exposure tool, or a conventional TEM or SEM. While high resolution imaging is still a primary goal, this must be achieved at relatively high (10-100 μA) gun currents in order to realize economic wafer throughput.
[0004] The axial brightness required is relatively low, e.g., 10 2 to 10 4 Acm −2 sr −1 , as compared with a value of 10 6 to 10 9 Acm −2 sr −1 for a typical focused beam source. However, the beam flux over the larger area must be highly uniform to obtain the required lithographic dose latitude and CD control.
[0005] A formidable hurdle in the development of SCALPEL tools was the development of an electron source that provides uniform electron flux over a relatively large area, has relatively low brightness, and high emittance, defined as D*α micron*milliradian, where D is beam diameter, and α is divergence angle. Conventional, state-of-the-art electron beam sources generate beams having an emittance in the 0.1-400 micron*milliradian range, while SCALPEL-like tools require emittance in the 1000 to 5000 micron*milliradian range.
[0006] Further, conventional SCALPEL illumination system designs have been either Gaussian gun-based or grid-controlled gun-based. A common drawback of both types is that beam emittance depends on actual Wehnelt bias, which couples beam current control with inevitable emittance changes. From a system viewpoint, independent control of the beam current and beam emittance is much more beneficial.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a charged particle illumination system component for an electron beam exposure tool and an electron beam exposure tool that provides independent emittance control by placing a lens array, which acts as an “emittance controller”, in the illumination system component. In one embodiment, a conductive mesh grid under negative bias is placed in the SCALPEL lithography tool kept at ground potential, forming a multitude of microlenses resembling an optical “fly's eye” lens. The mesh grid splits an incoming solid electron beam into a multitude of subbeams, such that the outgoing beam emittance is different from the incoming beam emittance, while beam total current remains unchanged. The mesh grid enables beam emittance control without affecting beam current. In another embodiment, the illumination system component is an electron gun. In yet another embodiment, the illumination system component is a liner tube, connectable to a conventional electron gun.
[0008] The optical effect of the mesh grid may be described in geometrical terms: each opening in the mesh acts as a microlens, or lenslet, creating its own virtual source, or cross-over, having diameter d, on one side of the mesh grid. Each individual subbeam takes up geometrical space close to L, where L equals the mesh pitch. The beam emittance ratio after the mesh grid to the one created by the electron gun, equals
r =( L/d ) 2 .
[0009] In another embodiment of the present invention, the mesh grid includes multiple (for example, two, three, or more) meshes. In an odd numbered configuration (greater than one), the outward two meshes may have a curved shape; such a lens would enable beam emittance control and also reduce spherical aberration.
[0010] In another embodiment of the present invention, the lens array is a continuous lens made of foil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a schematic diagram of one conventional Wehnelt electron gun with a tantalum disk emitter.
[0012] [0012]FIG. 2 is a schematic diagram of an electron gun modified in accordance with the invention.
[0013] FIGS. 2 ( a ) and 2 ( b ) illustrate variations of the present invention.
[0014] [0014]FIG. 2( c ) illustrates the effect of the mesh grid on the electron beam.
[0015] [0015]FIG. 3 is a schematic representation of the electron emission profile from the conventional Wehnelt electron gun.
[0016] [0016]FIG. 4 illustrates the effect of the mesh grid in one embodiment of the present invention.
[0017] [0017]FIG. 4( a ) is a schematic diagram of a mesh grid of the invention showing the relevant dimensions.
[0018] [0018]FIG. 5 is a more general representation of the optics of the present invention.
[0019] [0019]FIG. 6 illustrates the potential across the mesh grid.
[0020] FIGS. 6 ( a ) and 6 ( b ) illustrate the potential across alternative mesh grid arrangements.
[0021] [0021]FIG. 7 illustrates the equipotential fields around a mesh grid, calculated by the SOURCE computer simulation model with a bias voltage of −40 kV.
[0022] [0022]FIG. 8 illustrates the multi lens effect in the mesh grid, calculated using the CPO3d computer simulation model with a bias voltage of −40 kV.
[0023] [0023]FIG. 9 is a schematic diagram illustrating the principles of the SCALPEL exposure system.
DETAILED DESCRIPTION
[0024] Referring to FIG. 1, a conventional Wehnelt electron gun assembly is shown with base 11 , cathode support arms 12 , cathode filament 13 , a Wehnelt electrode including Wehnelt horizontal support arms 15 and conventional Wehnelt aperture 16 . The base 11 may be ceramic, the support members 12 may be tantalum, steel, or molybdenum. The filament 13 may be tungsten wire, the material forming the Wehnelt aperture 16 may be steel or tantalum, and the electron emitter 14 is, e.g., a tantalum disk. The effective area of the electron emitter is typically in the range of 0.1-5.0 mm 2 . The electron emitter 14 is preferably a disk with a diameter in the range of 0.05-3.0 mm. The anode is shown schematically at 17 , including anode aperture 17 a , the electron beam at 18 , and a drift space at 19 . For simplicity the beam control apparatus, which is conventional and well known in the art, is not shown. It will be appreciated by those skilled in the art that the dimensions in the figures are not necessarily to scale. An important feature of the electron source of SCALPEL exposure tools is relatively low electron beam brightness, as mentioned earlier. For most effective exposures, it is preferred that beam brightness be limited to a value less than 10 5 Acm −2 sr −1 . This is in contrast with conventional scanning electron beam exposure tools which are typically optimized for maximum brightness. See e.g., U.S. Pat. No. 4,588,928 issued May 13, 1986 to Liu et al.
[0025] The present invention is shown in FIG. 2. A mesh grid 23 is disposed in the path of the electron emission 25 in the drift space 19 . According to FIG. 2, the mesh grid 23 is placed in the electrostatic field-free drift space 19 , insulated from the drift tube, or liner 20 , and it is biased to a specified potential Um. The potential difference between the mesh grid 23 and the liner 20 creates microlenses out of each opening in the mesh grid 23 . The electron beam 18 is split into individual subbeams (beamlets), and each beamlet is focused moving through its respective mesh cell, or microlens. The mesh grid 23 is separated from the liner 20 by an insulator 24 . The mesh grid 23 and the insulator 24 may both be part of a mesh holder.
[0026] One characteristic of the drift space 19 is that there is substantially no or no electric field present. The substantial absence of the electric field results in no acceleration or deceleration of electrons, hence the electrons are permitted to “drift”, possibly in the presence of a magnetic field. This in contrast to the vacuum gap 19 a , which has a strong electric field.
[0027] FIGS. 2 ( a ) and 2 ( b ) illustrate variations on FIG. 2. In particular, FIGS. 2 ( a ) and 2 ( b ) both show the mesh grid 23 within a liner 20 attached to an electron gun assembly 1 . In FIG. 2( a ), the liner 20 is attached to the electron gun assembly 1 via a liner flange 21 and an electron gun flange 16 . In FIG. 2( b ), the liner 20 is attached to the electron gun assembly 1 at weld 22 . The liner 20 and electron gun assembly 1 could be attached by other techniques known to one of ordinary skill in the art, as long as the attachment is vacuum tight. Alternatively, the mesh grid 23 could be placed below the boundary between the liner flange 21 and the electron gun flange 16 or below the weld 22 , within the electron gun assembly 1 , as long as the mesh grid 23 remains within the drift space 19 .
[0028] One advantage of the embodiments illustrates in FIGS. 2 ( a ) and 2 ( b ) is that they permit the use of conventional non-optimal electron guns. A conventional electron gun produces a beam which is too narrow and too non-uniform. The arrangements in FIGS. 2 ( a ) and 2 ( b ) permit increased performance utilizing a conventional electron gun, since the mesh grid 23 contained within the liner 20 improves the beam emittance by making it wider and more uniform, which is more suitable for SCALPEL applications. The effect of the mesh grid 23 is more clearly illustrated in FIG. 2( c ).
[0029] The electron emission pattern from the Wehnelt gun of FIG. 1, is shown in FIG. 3. The relatively non-uniform, bell curve shaped output from the Wehnelt is evident. FIG. 4 illustrates the electron beam emittance through the mesh grid 23 . The emittance on the left side of the mesh grid 23 is low, whereas after passing through the mesh grid 23 , the emittance of the electron beam is much higher.
[0030] The screen element that forms the mesh grid 23 can have a variety of configurations. The simplest is a conventional woven screen with square apertures. However, the screen may have triangular shaped apertures, hexagonal close packed apertures, or even circular apertures. It can be woven or non-woven. Techniques for forming suitable screens from a continuous layer may occur to those skilled in the art. For example, multiple openings in a continuous metal sheet or foil can be produced by technique such as laser drilling. Fine meshes can also be formed by electroforming techniques. The mesh grid 23 should be electrically conducting but the material of the mesh is otherwise relatively inconsequential. Tantalum, tungsten, molybdenum, titanium, or even steel are suitable materials, as are some alloys as would be known to one skilled in the art. The mesh grid 23 preferably has a transparency in the range of 40-90%, with transparency defined as the two dimensional void space divided by the overall mesh grid area.
[0031] With reference to FIG. 4( a ), the mesh grid has bars “b” of approximately 50 μm, and square cells with “C” approximately 200 μm. This mesh grid has a transparency of approximately 65%. Examples of mesh grid structures that were found suitable are represented by the examples in the following table.
TABLE I Cell dimension “C”, μm Bar width “b”, μm Grid #1 200 50 Grid #2 88 37 Grid #3 54 31
[0032] The cell dimension “C” is the width of the opening in a mesh with a square opening. For a rectangular mesh grid the dimension “C” is approximately the square root of the area of the opening. It is preferred that the openings be approximately symmetrical, i.e., square or round.
[0033] The thickness t of the mesh grid is relatively immaterial except that the aspect ratio of the openings, C/t, is preferably greater than 1. A desirable relationship between the mesh grid parameters is given by:
C:t>−1.5
[0034] In yet another embodiment, the lens array may include more than one mesh. In one embodiment, the lens array includes three meshes. The outer two meshes may be prepared having curved shape; such a lens would provide beam emittance control and decrease spherical aberration.
[0035] In addition the outer two meshes may also be replaced with foils, such as an SiN foil, with a thickness of approximately 0.1 μm. Such a film would permit substantially no physical interaction (inelastic collisions), and therefore a transparency approaching 100%.
[0036] Due to the large current being passed through the lens array (either mesh or continuous), the transparency is important. If a percentage of the beam impacts the structure of the mesh or continuous film, the high current is likely to melt the mesh or continuous film.
[0037] [0037]FIG. 5 is more general representation of the optics of the present invention. 81 is the cathode of a standard high brightness electron gun, either a W hairpin, or a LaB 6 crystal or a BaO gun as used in for example a CRT. 82 is the gun lens formed by the Wehnelt electrode and the extraction field. 83 is the gun cross-over with diameter dg. 84 is the electron beam emerging from the gun, with half aperture angle α g as they appear looking back from where the beam has been accelerated to 100 kV. The emittance of the gun is now
E = π 2 4 d g 2 α g 2
[0038] After the beam has spread out to a diameter which is considerably larger than the diameter of the lenslets 85 , the lens array 80 is positioned. Each lenslet 85 creates an image 86 of the gun cross-over with size d i . Each subbeam 87 now has a half opening angle α.
[0039] The emittance increase created by the lens array 80 can be derived. Liouvilles theorem states that the particle density in six dimensional phase space cannot be changed using conservative forces such as present in lenses. This implies that the emittance within each subbeam that goes through one lenslet is conserved and thus:
N · π 2 4 d i 2 α i 2 = π 2 4 d g 2 α g 2
[0040] where N is the number of subbeams.
[0041] The emittance of the beam appears to be
N · π 2 4 L 2 α R 2
[0042] where L is the pitch of the lenslets 85 and thus
V · π 2 4 L 2
[0043] is the total area of the lens array 80 . The new emittance of the beam is termed the effective emittance. The emittance increase is E eff /E gun =L 2 /d i 2 .
[0044] It is not necessary to create a real cross-over with the lenslet array. The calculation of the emittance increase then proceeds differently, but the principle still works.
[0045] For a large emittance increase, it is beneficial to use a large pitch of the mesh grid 23 . However, the newly formed beam should include a reasonably large number of subbeams so that the subbeams will overlap at essential positions in the system such as the mask. Example 1 illustrates typical values.
EXAMPLE 1
[0046] A LaB 6 gun of 0.2 mm diameter is used. The cross-over after the gun lens could be 60 μm, thus the emittance increase is a factor of eight using Grid #1 in Table 1.
[0047] The lens array 80 may be the mesh grid 23 at potential V 1 , between liner 20 at potential V 0 as shown in FIG. 6, or include two grids 23 and 23 ′ at the potentials illustrated in FIG. 6( a ) or three grids 23 , 23 ′, 23 ″ at the potentials illustrated in FIG. 6( b ), or any other configuration which contains a grid mesh with an electrostatic field perpendicular to the gridplane.
[0048] The focal distance of the lenslets 85 in FIG. 5 is typically in the order of 4×Vacc/Efield, where Vacc is the acceleration potential of the electron beam and Efield the strength of the electrostatic field. In Example 1, the distance between the gun cross-over and the lens array could be typically 100 mm, calling for a focal length of about 50 mm to create demagnified images. Thus, at 100 kV acceleration, the field should be 10 kV/mm.
[0049] In an alternative embodiment, if a specific configuration requires a strong field, the mesh grid 23 could be incorporated in the acceleration unit of the gun, between the cathode and the anode. This would have the additional advantage that the beam has not yet been accelerated to the full 100 kV at that point.
[0050] In an alternative embodiment, the mesh grid 23 could also be incorporated in the electron gun in the Wehnelt-aperture 16 of FIG. 2. The mesh pitch must again be much smaller than the cathode diameter. This would lead to lenslet sizes in the order of μm's.
[0051] The present invention has been confirmed by computer simulation with both Charged Particle Optics (CPO, Bowring Consultant, Ltd., and Manchester University) and SOURCE (by MEBS, Ltd.) models. In the SOURCE model, the mesh grid 23 is approximated by a series of circular slits. In both the CPO and SOURCE programs, a lens including two grounded cylinders with a biased mesh in the gap between those cylinders is simulated. FIG. 7 shows a detail of the SOURCE model, with fields. The lensfields are clearly visible in the openings in the mesh.
[0052] Further, the modeling has been done with a three-dimensional simulation program CPO3d. FIG. 8 illustrates the potential distribution in the plane of the mesh. Again, the multi-lens effect in the mesh grid can be clearly seen.
[0053] As indicated above the electron gun of the invention is most advantageously utilized as the electron source in a SCALPEL electron beam lithography machine. Fabrication of semiconductor devices on semiconductor wafers in current industry practice contemplates the exposure of polymer resist materials with fine line patterns of actinic radiation, in this case, electron beam radiation. This is achieved in conventional practice by directing the actinic radiation through a lithographic mask and onto a resist coated substrate. The mask may be positioned close to the substrate and the image of the mask projected onto the substrate for projection printing.
[0054] SCALPEL lithography tools are characterized by high contrast patterns at very small linewidths, i.e., 0.1 μm or less. They produce high resolution images with wide process latitude, coupled with the high throughput of optical projection systems. The high throughput is made possible by using a flood beam of electrons to expose a relatively large area of the wafer. Electron beam optics, comprising standard magnetic field beam steering and focusing, are used to image the flood beam onto the lithographic mask, and thereafter, onto the substrate, i.e., the resist coated wafer. The lithographic mask is composed of regions of high electron scattering and regions of low electron scattering, which regions define the features desired in the mask pattern. Details of suitable mask structures can be found in U.S. Pat. Nos. 5,079,112 issued Jan. 7, 1992, and 5,258,246 issued Nov. 2, 1993, both to Berger et al.
[0055] An important feature of the SCALPEL tool is the back focal plane filter that is placed between the lithographic mask and the substrate. The back focal plane filter functions by blocking the highly scattered electrons while passing the weakly scattered electrons, thus forming the image pattern on the substrate. The blocking filter thus absorbs the unwanted radiation in the image. This is in contrast to conventional lithography tools in which the unwanted radiation in the image is absorbed by the mask itself, contributing to heating and distortion of the mask, and to reduced mask lifetime.
[0056] The principles on which SCALPEL lithography systems operate are illustrated in FIG. 9. Lithographic mask 52 is illuminated with a uniform flood beam 51 of 100 keV electrons produced by the electron gun of FIG. 2. The membrane mask 52 comprises regions 53 of high scattering material and regions 54 of low scattering material. The weakly scattered portions of the beam, i.e., rays 51 a , are focused by magnetic lens 55 through the aperture 57 of the back focal plane blocking filter 56 . The back focal plane filter 56 may be a silicon wafer or other material suitable for blocking electrons. The highly scattered portions of the electron beam, represented here by rays 51 b and 51 c , are blocked by the back focal plane filter 56 . The electron beam image that passes the back focal plane blocking filter 56 is focused onto a resist coated substrate located at the optical plan represented by 59 . Regions 60 replicate the features 54 of the lithographic mask 52 , i.e., the regions to be exposed, and regions 61 replicate the features 53 of the lithographic mask, i.e., the regions that are not to be exposed. These regions are interchangeable, as is well known in the art, to produce either negative or positive resist patterns.
[0057] A vital feature of the SCALPEL tool is the positioning of a blocking filter at or near the back focal plane of the electron beam image. Further details of SCALPEL systems can be found in U.S. Pat. Nos. 5,079,112 issued Jan. 7, 1992, and 5,258,246 issued Nov. 2, 1993, both to Berger et al. These patents are incorporated herein by reference for such details that may be found useful for the practice of the invention.
[0058] It should be understood that the figures included with his description are schematic and not necessarily to scale. Device configurations, etc., are not intended to convey any limitation on the device structures described here.
[0059] For the purpose of definition here, and in the appended claims, the term Wehnelt emitter is intended to define a solid metal body with an approximately flat emitting surface, said flat emitting surface being symmetrical, i.e., having the shape of a circle or regular polygon. Also for the purpose of definition, the term substrate is used herein to define the object plane of the electron beam exposure system whether or not there is a semiconductor workpiece present on the substrate. The term electron optics plane may be used to describe an x-y plane in space in the electron gun and the surface onto which the electron beam image is focused, i.e., the object plane where the semiconductor wafer is situated.
[0060] As set forth above, in the present invention, an electron optical lens array is inserted into the illumination optics of the SCALPEL tool. The position of this lens array, or fly's eye lens, is such that each lenslet creates a beam cross-over with a smaller diameter d than the distance between the lenslets L, which increases the effective emittance of the beam by a factor (L/d) 2 . The electron optical lens array is a mesh grid with an electrostatic field perpendicular to the grid. One advantage over conventional systems is that the present invention allows the use of a standard high brightness electron gun. Another advantage is that the effective emittance can be varied without stopping a large part of the electron current on beam shaping apertures which is now the only way to change the emittance. Yet another advantage is that a homogeneous illumination of the mask may be obtained.
[0061] Various additional modifications of this invention will occur to those skilled in the art. All deviations from the specific teachings of this specification that basically rely on the principles and their equivalents through which the art has been advanced are properly considered within the scope of the invention as described and claimed. | A method and apparatus for controlling beam emittance by placing a lens array in a drift space of an illumination system component. The illumination system component may be an electron gun or a liner tube or drift tube, attachable to an electron gun. The lens array may be one or more mesh grids or a combination of grids and continuous foils. The lens array forms a multitude of microlenses resembling an optical “fly's eye” lens. The lens array splits an incoming solid electron beam into a multitude of subbeams, such that the outgoing beam emittance is different from the incoming beam emittance, while beam total current remains unchanged. The method and apparatus permit independent control of beam current and beam emittance, which is beneficial in a SCALPEL illumination system. | 7 |
FIELD OF THE INVENTION
This invention relates to an apparatus for displaying products such as eyeglasses or jewels. More precisely, the present invention is directed towards a holding device comprising a vise that may hold a product in any desired orientation in order to display it in a very attractive manner.
DESCRIPTION OF THE PRIOR ART
There exist many types of holders for displaying products such as, for example, eyeglasses. Reference to eyeglasses holders is suitable here for comparison purposes, because the present invention is well adapted to hold an eyeglass.
The existing eyeglasses holders are designed to hold side-by-side eyeglasses on a plurality of rails or on a plurality of notches. Such devices are designed to hold eyeglasses in only one plane and are not well adapted for shop window display. In other words, these holders are not well adapted to set the products in a fashionable way, like in an unconventional orientation. These holders also interfere with the aesthetic aspect of the eyeglass since their presence is predominant. Examples of such holders are disclosed in U.S. Pat. Nos. 4,558,788 and 4,890,745.
To set a shop window display, the products must be disposed in an environment and in a way that will attract the consumer's attention. This usually requires to show the products individually and with different angles. The present invention is very suitable to achieve this requirement. It also permits to hold the eyeglass with minimum disturbance of its aesthetic aspect.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a holder for displaying one or more products in a very attractive manner and in any desired orientation.
More specifically, this invention provides an display apparatus comprising:
(a) a holding means;
(b) at least one main stem having two opposite ends, one of the opposite ends being a free end;
(c) a first attachment means to the at least main stem to the holding means; and
(d) a tip element comprising:
a tip member fixed to the free end of the at least one main stem by a second attachment means,
another stem projecting from the tip member, the other stem having a free end and a second end attached to said tip member by a third attachment means, and
a means to attach a product to be displayed fixed to the free end of the other stem by a fourth attachment means.
In accordance with a preferred embodiment, the main stem is L-shaped, adjacent the end opposite to the free end of the main stem, and has a circular cross-section.
The first attachment means preferably comprises a hole made in the holding means, in which the end opposite to the free end of the main stem is pivotally engaged.
The second attachment means preferably comprises a hole made in the tip member, in which the free end of the main stem is pivotally engaged.
According to another preferred embodiment, the other stem is L-shaped and said third attachment means comprises a hole, made in the tip member, in which the second end of the other stem is pivotally engaged.
The means used to attach a product is preferably a vise pivotally attached to the free end of the other stem by the fourth attachment means. The fourth attachment means comprises a hole made in the means to attach a product, in which the free end of the other stem is pivotally engaged. The vise comprises two jaws between which the product is held. The vise preferably comprises two screws to move the jaws toward and away from each other. Each of the two screws has a large, finger-operable head.
According to a further preferred embodiment, the display apparatus further comprises at least one sliding element movable along and rotatable about the main stem between the opposite ends thereof, the sliding element comprising:
a sliding member slidably mounted onto the main stem, the sliding member being lockable in any desired position along the main stem,
an additional L-shaped stem projecting from the sliding member, the additional L-shaped stem having a first arm fixed to said sliding member by a fifth attachment means and a second arm projecting from the sliding member. The additional L-shaped stem also has a second arm projecting from the sliding member, the fifth attachment means preferably comprising a hole made in the sliding member, in which the first arm is pivotally engaged; and
another means to attach a product to be displayed fixed to the second arm by a sixth attachment means.
The sliding member is preferably constructed as a slidable vise and is lockable by a screw having a large, finger-operable head. The other means used to attach a product to the second arm is preferably another vise pivotally attached to the second arm by the sixth attachment means. The sixth attachment means preferably comprises a hole made in the other vise, in which the second arm is pivotally engaged. The other vise comprises two jaws between which an additional product is held. Preferably, the other vise comprises two screws to move the jaws toward and away from each other the jaws. Each of the two screws has a large, finger-operated head.
According to still a preferred embodiment, the first, second, third and fourth attachment means comprise at least one friction screw located in a threaded hole perpendicular to and intersecting one of the stems. Each of the screws has a friction tip, preferably made of brass, in contact with one of the stems and generating an adjustable friction force.
The fifth and the sixth attachment means may also comprise at least one friction screw located in a threaded hole perpendicular to and intersecting the additional L-shaped stem. Each of the friction screws has a friction tip in contact with the additional L-shaped stem and generating an adjustable friction force.
The holding means may comprise a base, having preferably a rectangular shape, made of, or filled up with, a heavy material. Preferably, the means to attach a product to be displayed is made of a material that is not susceptible to scratch the product, such as plastic.
A non restrictive description of a preferred embodiment of the invention will now be given with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a display apparatus according to the invention.
FIG. 2 is a side elevational view of the apparatus shown in FIG. 1, but fixed to an edge of a table.
FIG. 3 is a front elevational view of the tip member of the apparatus of FIG. 1.
FIG. 4 is a side elevational cross section view of the tip member shown in FIG. 3.
FIG. 5 is a front elevational in partial cross section view of the sliding member of the apparatus of FIG. 1.
FIG. 6 is a side elevational cross section view of a sliding member shown in FIG. 5.
FIG. 7 is a side elevational view in partial cross section of the attaching vise of the tip member of the apparatus of FIG. 1.
FIG. 8 is a bottom plan view in partial cross section of the vise shown in FIG. 7.
FIG. 9 is a side elevational in partial cross section view of the base of the apparatus of FIG. 1.
FIG. 10 is a bottom elevational view of the base shown in FIG. 9.
DESCRIPTION OF PREFERRED EMBODIMENT
The apparatus according to the invention as shown in FIG. 1 comprises holding means consisting of a box-shaped base 10 to which is fixed a main stem 12 that is made up of a hard steel and has a circular cross section. The base 10 is used when the apparatus is to be placed on a surface such as a table. The purpose of the base 10 is to support the main stem 12 and the other components of the apparatus. More than one main stems can be supported by the base 10. The base 10 is made of, or filled up with a heavy material such as brass, to provide more stability to eccentric loads. The brass is advantageous because it can be easily machined. The box-shaped base 10 may also have a rectangular shape but any other shape can be convenient.
It is also possible to have a base having a pin underneath the base 10 that can be inserted in a hole located in a board to prevent the holder from toppling. The base 10 can then be lighter and stand very eccentric loads, like when two or more main stems are used.
The holding means may consist of a stirrup piece 80 as shown in FIG. 2, that is screwable onto an horizontal or vertical supporting member such as a counter, a ceiling tile, a slot wall or an edge of other objects.
The holding means may further consist of a suction cup (not shown) that is attachable on a flat and smooth surface such as, for example, a window.
The holding means may also further consist of a pad (not shown) that can be glued to fix the apparatus to a surface.
The main stem 12 is pivotally engaged to the base 10 by means of a hole 14 in which a L-shaped portion 16 of the main stem 12 is entered. A screw 90 (FIG. 9) is used to apply a friction on the main stem 12 so that the main stem 12 cannot turn too easily or be easily removed from the base 10. The desired friction is set by the user by screwing or unscrewing the screw 90 which is located in a threaded hole perpendicular to and intersecting the hole in which the main stem 12 is inserted to be held by the base 10. The friction generated by the contact of the screw on the surface of the main stem 12 is such that the swivel cannot turn under the weight of the main stem 12 or the weight of what it supports while giving the user the possibility to rotate the main stem 12 without having to use a tool or having to unscrew the screw 90. A brass tip 92 is used as a friction tip to generate friction without damaging the surface of the main stem 12 since the brass is softer than the steel.
A fired paint may be applied on the surface of the main stem 12. The L-shaped portion is angled at about 90°. The diameter of the hole 14 is slightly higher than the diameter of the main stem 12 so the L-shaped portion 16 can easily rotate in the hole 14.
According to the invention, as shown in FIG. 1, the apparatus also comprises a tip element 18 fixed to the free end of the main stem 12. The tip element 18 comprises a tip member 20 which is pivotally attach to the free end of the main stem 12. A screw 22 (FIG. 4) is used to apply a friction on the main stem 12 so that the tip member 20 cannot turn too easily or be easily removed from the main stem 12. The desired friction is set by the user by screwing or unscrewing the screw 22 (FIG. 3) which is located in a threaded hole perpendicular to and intersecting the hole in which the main stem 12 is inserted. The friction generated by the contact of the screw on the surface of the main stem 12 is such that the swivels cannot turn under the weight of what they are supporting while also giving the user the possibility to rotate the stems without having to use a tool or having to unscrew the screws. A brass tip 24 may be used as a friction tip to generate friction without damaging the surface of the main stem 12.
The apparatus also comprises another stem 26 fixed to the tip member 20. Means to attach a product such as an eyeglass or a jewel are fixed to the free end of the other stem 26. These means are a vise 28 comprising two jaws 30 and 31 that can be adjusted to squeeze a part of the product such as the temple end of the eyeglass 34. The two jaws 30 and 31 are brought closer to each other by means of two screws 36 so the vise can generate the proper amount of friction to hold the product. The vise 28 is preferably made of a plastic material that is not susceptible to scratch the product held.
The jaw 30 has two holes 32 in which the screws 36 are inserted and the jaw 31 has two threaded holes in which the end of the screws 36 are inserted. The screws 36 mesh with the threaded brass inserts 41. The inserts 41 are used to prevent the wear of the jaw 31 that is likely to happen if the threaded hole was done directly in it since the jaw 31 is preferably made of plastic. When the screws 36 are unscrewed, the two jaws 30 and 31 are moved away from each other by means of helicoidal springs 38 concentric to each screw 36. The springs 38 help keeping the two jaws away from each other when substituting a product for another. Two recesses 37 concentric to the springs 38 allow the springs 38 to not interfere when the two jaws 30 and 31 are very close to each other. Each screw 36 has a large, finger-operated head 40 so that it be turned without need of a tool such as a screwdriver or a hexagonal key.
As shown in FIGS. 1 and 4, the other stem 26 is preferably L-shaped and has an end pivotally fix to the tip member 20 by means of a hole 42 in which the L-shaped end of the other stem 26 is inserted. A screw 44, with a brass tip 46, is used to apply a friction that holds the other stem 26 in any desired position and prevents it from turning by itself under its weight or the weight of the product. The vise 28 (FIGS. 7 and 8) is pivotally fixed to the other stem 26 by insertion of the free end of the other stem 26 into a hole 48. A screw 50, with a brass tip 52, is used to apply a friction that holds the vise 28 in the desired position and prevents it from turning by itself under its weight or the weight of the product. The screw 50 is located in a threaded hole perpendicular to and intersecting the hole in which the other stem 26 is inserted.
The apparatus may further comprise one or more sliding elements 60 to hold other products Each sliding element 60 is mounted onto the main stem 12 and is movable along and rotatable about it between its base 10 and the tip member 20. It comprises a sliding member 64, such as a vise, mounted onto the main stem 12. An L-shaped stem 65 having one arm inserted in a hole in the sliding member 64. The L-shaped stem 65 is pivotally mounted in the hole. The sliding member 60 also comprises a means to attach a product such as the vise 66 which is identical to the vise 28. The sliding member 64 is preferably operated by a screw 70 have a large, finger-operated head that meshes with a threaded brass insert 71. The screw 70 brings together the two parts of the sliding member 64 that are separated by the slot 74.
When displaying an eyeglass, the eyeglass is preferably displayed in an open position To achieve this, the screws attaching the temples to the eyeglass frame are tightened. The earpiece of one of the temples is then inserted between the jaws 30 and 31, which are then tightened to hold the eyeglass.
The invention, as shown in FIG. 1, allows the product to be displayed in a plurality of orientations. More specifically, the product on the tip element can be oriented in about 4 degrees of freedom represented by arrows on FIG. 1: the main stem 12 can rotate in one plane, the tip member can rotate about the main stem 12, the other stem 26 can rotate in one plane and the vise 28 can rotate about the free end of the other stem 26 The product held with the sliding element has 5 degrees of freedom: the main stem 12 can rotate in one plane, the sliding member 64 can rotate about and slide along the main stem 12, the other stem 65 can rotate in one plane and the vise 66 can rotate about the free end of the other stem 65. | A display apparatus for displaying products such as eyeglasses or jewels, comprising a heavy base, a main stem having one end pivotally fixed to the base and another free end, and a tip element fixed to the free end of the main stem. The tip element includes another pivotable stem and a vise to attach the product to be displayed. Screws are used to apply friction to the surfaces of the stems to keep them in any desired orientation while allowing the stems to be turned without a tool. A brass tip helps reducing the wear on the stem surfaces in contact with the screws. The display apparatus may further comprise a sliding element including another pivotable stem and another vise to attach another product. The display apparatus is particularly well adapted for displaying eyeglasses in an optical shop window. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to electronic devices used to charge and communicate with mobile electronic devices.
[0003] 2. Description of the Related Art
[0004] In modern society we are becoming ever more mobile. It is very common to have notebook computers in small and light form factors to greatly aid in communications and computing in varying locations. One common aspect of notebook computers is that they are battery powered. As a result, they all have some sort of algorithm to conserve the battery power. Typically this includes entering low-power or standby states after determined periods of inactivity. During these standby or low-power states one of the common things that is done is to turn off power to all of the peripheral devices and peripheral ports.
[0005] Also common in the modern mobile society are small electronic mobile devices such as cell phones, music players and PDAs (Personal Data Assistants). All of these are very small, battery powered personal devices. In many cases they connect to a larger computer, such as a notebook computer or a desktop computer, to receive files and to otherwise interface with the larger computer system. Because they are smaller devices and battery powered, they have a limited lifetime on their battery charge. To this end they need to be charged on a reasonably frequent basis.
[0006] One of the common ways that has been developed for these types of devices to be recharged is to plug them into the computer using their data connection and then use the power provided on that data connection to recharge the devices. For example, say the device connects by a USB or 1394 interface. A constant DC voltage is provided on each of those interfaces and this DC voltage can be readily used to recharge the batteries in the mobile device. In this manner the user does not have to carry around AC adapters for each of the particular devices and does not have to rely on disposable batteries. They can just use their standard data connection cable for recharging capabilities. This recharging of these small mobile devices is not an appreciable draw or drain on the notebook computer battery, for example, as that is a very high capacity battery as compared to the particular small devices.
[0007] Given that this capability of charging the small mobile devices from the larger mobile device such as the notebook computer is common and becoming ubiquitous, it is desirable to be able to make this process as efficient as possible to simplify user operations.
BRIEF SUMMARY OF THE INVENTION
[0008] A system according to the present invention enables battery powered devices such as notebook computers to efficiently charge smaller mobile devices such as music players, cell phones and PDAs using the power signals provided over their data connections. This is done efficiently by ensuring that the power to the small mobile device is not interrupted, particularly not interrupted should the notebook computer otherwise go into a standby or low-power state. This addresses a problem which has been determined in existing devices where, when the notebook computer goes to sleep or powers down, all the peripheral device ports are turned off and power is disconnected from them. Thus this power disconnection removes the power connection being used simply to charge the small mobile devices.
[0009] In systems according to the present invention, the presence of the small mobile device is known and any power-down capabilities of the notebook computer are limited, at least for the period where the small mobile device is being recharged. This detection can be done at any of the levels of software present in the notebook computer. For example, an application can detect the presence of the device and then tell the operating system not to go into a low power state. The detection can be done by the operating system itself and thus detect that it should not itself go into the low-power state. It can be done at a lower firmware level so that even should the operating system try to put the computer into a power-down state, the firmware or BIOS will override such capabilities.
[0010] This charging and not powering down can be further optimized by determining the particular device and its charging characteristic or charging requirements or by having the device provide feedback as to its charge state. As soon as it is determined that the device is fully charged, then the notebook computer can be returned to full power-down conditions as in normal operations.
[0011] Thus by not allowing the computer to power-down at least the power provided through the peripheral data ports, the small mobile devices can be rapidly charged.
A BRIEF DESCRIPTION OF THE FIGURES
[0012] FIG. 1 is a drawing illustrating various small mobile devices connected to a notebook computer.
[0013] FIG. 2 is a block diagram of an exemplary notebook computer including the details relating to the power connections for the peripheral device ports.
[0014] FIG. 3 is a block diagram illustrating the various software layers present in an exemplary notebook computer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring now to FIG. 1 , an exemplary notebook computer 100 is connected to a music player 102 and a PDA 104 . The music player 102 is connected to the notebook computer 100 using a link 106 such as USB or 1394. Similarly, the PDA 104 is connected to the notebook computer 100 using a data link 108 , again a USB link in common practice or a 1394 or other link as desired. The data links 106 and 108 are the conventional data links used between the devices 102 and 104 and the notebook computer 100 to transfer data. For example, the data link 106 is normally used to transfer music files between the notebook computer 100 and the music player 102 . The data link 108 is used to provide the communications between the notebook computer 100 and the PDA 104 . By using the power lines present on the data links, it is thus possible to charge the various mobile devices, such as the music player 102 or the PDA 104 .
[0016] Referring now to FIG. 2 , a simplified block diagram of the exemplary notebook computer 100 is shown. A power supply 200 is used to power the notebook computer 100 and any devices connected to the notebook computer 100 as desired. Most of the power supply connections are not shown for simplicity. A processor or CPU 202 forms the core processing element of the notebook computer 100 . The processor 202 is connected to a bridge chip 204 which connects the processor 202 to memory (not shown) and to various peripheral buses as desired. One of the peripheral buses provided by the bridge 204 can be a bus such as a PCI bus 206 . In the illustrated example a USB host controller 208 is connected to the PCI bus 206 , as is a 1394 host controller 210 . The USB host controller 208 is connected to a USB connector 212 . It can be seen that the two data lines 214 in the USB connection are provided directly from the USB host controller 208 to the USB connector 212 . One of the other connections on the USB connector 212 is connected to ground. Similarly the 1394 host controller 210 provides four data lines 216 to a 1394 connector 218 . A fifth line on the illustrated 1394 connector 218 is connected to ground. The final line on each of the USB connector 212 and the 1394 connector 218 is a power line.
[0017] To assist and manage the power-down of the notebook computer 100 a power management unit 220 is connected to the processor 202 , to the bridge 204 and to the power supply 200 . The power management unit 220 has various requirements and capabilities to detect system operation and to also timely control the power down of the various systems in the notebook computer 100 . This includes control of clock systems (not shown) and various transistors used to control switchable power lines. For example, power management unit 220 is connected to the gate of a transistor 222 . The drain of the transistor 222 is connected to the power supply 200 while the source of the transistor 222 is connected to the power pin of the 1394 connector 218 .
[0018] In a similar manner the USB host controller 208 is connected to the gate of a transistor 224 , whose drain is connected to the power supply 200 and whose source is connected to the power pin of the USB connector 212 . Thus the power management unit 220 is responsible for controlling the transistor 222 to provide power to the 1394 connector 218 , while the USB host controller 208 includes internal registers to control the transistor 224 which provides power to the USB connector 212 . There is also a link between the power management unit 220 and the bridge 204 to allow the processor 202 to interoperate and communicate with the power management unit 220 .
[0019] Therefore if power-down of the notebook computer 100 is desired, the power management unit 220 disables or turns off the transistor 222 while the USB host controller 208 is instructed by the processor 202 to turn off or disable the transistor 224 . The power management unit 220 in many cases also controls power to the USB host controller 208 and the 1394 host controller 210 such that they are powered-off, as well as having their clock signals stopped.
[0020] Referring now to FIG. 3 a simple diagram of the software present in the exemplary notebook computer 100 is shown. The lowest level of software is the BIOS or basis input/output system 300 . This is the lowest level of software and is often contained in an EPROM and is otherwise known as firmware. The BIOS 300 provides the lowest level of interconnect between the physical devices, i.e., the peripheral devices, and the higher level software in the notebook computer 100 . Interacting with the BIOS 300 are the drivers 302 . These drivers act as an interface between the low-level functionality of the BIOS 300 and the high-level operations of the operating system 304 . Present above the operating system 304 are the individual applications 306 .
[0021] As noted above, it has been determined that one of the problems with a system as shown in FIG. 1 is that should the notebook computer 100 go into a power-down or sleep mode, power on the exemplary 1394 and USB connectors 212 and 218 is disabled. Thus any charging of the connected music player 102 or PDA 104 is halted while the laptop or notebook computer 100 is in the low power state.
[0022] In systems according to the present invention, one of the software modules, such as the BIOS 300 , the operating system 304 , the drivers 302 or the applications 306 , determines the existence and connection of an external device such as the music player 102 or the PDA 104 . In one embodiment the appropriate recognizing software can then instruct the operating system 304 not to disable the power to the connected mobile device. This can be done in several manners. For example, if it is an application program, such as iTunes from Apple Computer, Inc., the application can detect an attached iPod from Apple Computer, Inc., and inform the operating system at a high level not to perform any power management functions. This state can remain in effect even if the application is terminated.
[0023] While this approach is quite satisfactory at performing the desired function of recharging the mobile device, there are further optimized embodiments. For example, the operating system 304 can also detect the presence of the connected mobile device. The operating system 304 can then on its own not enter the power-down state. Alternatively, the operating system 304 can enter a power-down state for all components except for the particular port to which the mobile device is connected. In a further embodiment, the data connections to that particular connected port can be powered down, just so long as the power connection, i.e., the DC connection from the appropriate transistor 222 or 224 , is still being provided to charge the device. This could also additionally be done at the driver level or BIOS level if desired.
[0024] In the most simplistic embodiments, the port or the computer is not powered down until it is detected that the device has been removed. This may be inefficient in certain cases, such as the mobile device being fully charged and yet the notebook computer 100 will still not be allowed to go into a lower-power state, but it is still an improved manner of charging the mobile device. This embodiment can be optimized by determining the particular type of peripheral or mobile device attached to the notebook computer 100 and determining its power charging characteristics. For example, in certain instances the mobile device is relative simplistic and its recharging time is known. Therefore the controlling function, such as the application software, can inform the operating system not to go into the low-power state for a time greater than the known recharging time of the mobile device.
[0025] In a more sophisticated example, the mobile device can report its charging status and therefore the relevant software can periodically query the mobile device and determine its charge state. When the device is fully charged, then the application or other software can instruct the operating system that full power-down can occur.
[0026] Another enhancement is a determination whether the charging device such as the notebook computer 100 is operating on AC power or is itself operating on DC power. Should the operation be on AC power, then a relatively simplistic operation can be used such as not entering any power-down state. If, however, it is operating in a DC power condition off its own internal battery, then more sophisticated algorithms, such as feedback of actual charge status or defined time as discussed above, can be utilized if desired. Further, the notebook computer 100 can actually go into a lower-power state periodically while still having power to the attached mobile device being provided. The notebook computer 100 can then wake-up periodically to query the attached mobile device to determine if it has been fully charged. If it has not been fully charged, the cycle can repeat as the notebook computer 100 goes into another power-down state until the next time to wake-up and check charging status. When the mobile device finally indicates a fully charged state, even the power to the mobile device can be disabled and the notebook computer 100 can stop the periodic wake up.
[0027] While a notebook computer 100 has been used as an example host device to provide the charging capabilities, it is understood that desktop computers and numerous other types of electronic devices which also enter power-down states and which can be used to recharge smaller mobile devices can perform in a similar manner. For example, if a television set were to have the appropriate 1394 port, it could be used to charge a 1394 connected device, such as a music player. The television set could determine that it is being used as a charging source for the music device and not turn off that port. While 1394 and USB connections have been used as examples, it is understood that any connection providing power, such as PS/2 keyboard and mouse connections, may be utilized. Further, it is understood that the operations can be performed in parallel for multiple connected devices.
[0028] The preceding description was presented to enable any person skilled in the art to make and use the invention as claimed and is provided in the context of the particular examples discussed above, variations of which will be readily apparent to those skilled in the art. Accordingly, the claims appended hereto are not intended to be limited by the disclosed embodiments, but are to be accorded their widest scope consistent with the principles and features disclosed herein. | A system which enables battery powered devices such as notebook computers to efficiently charge smaller mobile devices such as music players, cell phones and PDAs using the power signals provided over their data connections is made more efficient by ensuring that the power to the small mobile device is not interrupted should the notebook computer otherwise go into a standby or low-power state. The presence of the small mobile device is known and any power-down capabilities of the notebook computer are limited, at least for the period where the small mobile device is being recharged. This detection can be done at any of the levels of software present in the notebook computer. This charging and not powering down can be further optimized by determining the particular device and its charging requirements or by having the device provide feedback as to its charge state. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of U.S. Provisional Patent Application No. 61/167,457 entitled “RAINSCREEN ATTACHMENT SYSTEM,” filed Apr. 7, 2009, the contents of which are hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under grant number SBAHQ-05-I-0061 awarded by the U.S. Small Business Administration. The government has certain rights in the invention.
[0003] FIELD OF THE INVENTION
[0004] A novel method of attaching building façade panels to the exterior of buildings to create a drained/back-ventilated rainscreen. More particularly, the invention consists of a series of brackets and panel configurations that allow the panels to be attached easily, allow airflow behind the panels, allow for the thermal expansion and contraction of the panels, allow for guttering of water, and reduce the labor and material requirements when compared to existing systems.
BACKGROUND OF THE INVENTION
[0005] Current aluminum composite material (ACM) panel attachment methods are labor intensive and require a large amount of aluminum extrusions. This makes the overall system costly when compared to other building siding materials. Also, most current systems are designed to be water-tight by means of rubber seals and/or caulking. A water-tight system is difficult to achieve in practice and does not allow for the removal of moisture trapped in the interior of the panels.
[0006] ACM panels are typically spaced between ⅜ and ¾ inches apart for aesthetics and to allow for the thermal expansion of the panels. Existing ACM systems use caulking, aluminum extrusions, or additional pieces of ACM (referred to as reveal strips) to fill in the joint gap between the panels.
SUMMARY OF THE INVENTION
[0007] The invention is a method and apparatus for attaching panels, e.g., aluminum composite material (ACM) panels, to the exterior of buildings to create a drained/back-ventilated rainscreen. The system is based on the Drained/Back Ventilated (D/B-V) Rainscreen principle. The system will allow air to flow freely behind the panels, thereby providing a means of removing moisture from the interior of the panels. The system will allow some water penetration, but will control this water using a guttering network. The system consists of a series of interlocking brackets and panel configurations that allow the panels to be attached easily, allow airflow behind the panels, allow for the thermal expansion and contraction of the panels, allow for guttering of water, and reduce the labor and material requirements when compared to existing systems.
[0008] By creating a novel panel configuration that allows the panels to overlap, the Improved Rainscreen Attachment System (IRAS) eliminates the need to fill the gap between panels with additional components. In the system of the invention, the reveal strip is integrated into the right side of a left panel. The reveal strip is formed from the ACM and therefore requires no additional painting or means of fastening. Standard hat furring channel, a very common building material, is located behind the joint gap and serves as an inexpensive means of guttering in the vertical direction any water that penetrates the vertical joint as well as water that has been channeled there by the horizontal joint guttering system.
[0009] In the improved rainscreen attachment system of the invention, guttering in the horizontal direction is achieved by a channel that is formed out of panel material and is an integral part of the panel. Again, because the channel is integrated into the panel, the channel requires no additional painting or means of fastening. The horizontal joint prevents rainwater from getting behind the panels yet allows for air to flow freely in behind the panels. This air flow provides a means of removing moisture from the inside of the panels.
[0010] The joints also allow the bottom of each panel to float up or down or from side to side to compensate for the thermal expansion and contraction of the panels. Without this feature the panel edges would be fixed and the panels would tend to bow (referred to as “pillowing”) as the panels thermally expand. In the current system, only the top of each panel is fixed, while the other three sides are allowed to float. If deemed necessary, the top of each panel could also be designed to have some limited amount of float. This would be accomplished by simply slotting the mounting holes in the top brackets and using shouldered bolts to attach the brackets to the external sheathing.
[0011] Upper brackets provide a rigid framework for the gutter section of the ACM. The upper brackets also serve as the means of attaching the panel to the wall and create a gap, e.g., 1 inch, between the panel and the wall to allow for adequate airflow between the wall and the panel.
[0012] Bottom brackets are provided of varying lengths depending on whether a long or short joint gap is desired. The bottom bracket allows the bottom of the panel to hook onto the top of the previously placed panel. The bottom bracket may be only 3 inches wide, a continuous extrusion nearly equal in length to the width of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an elevation view of the panel system of the invention;
[0014] FIG. 2 is a top view of the panel system of FIG. 1 taken along lines 2 - 2 of FIG. 1 ;
[0015] FIG. 3 is a rear elevation view of one of the panels of the panel system of FIG. 1 ;
[0016] FIG. 4 is a side view of one of the panels of the panel system of FIG. 1 , taken along lines 4 - 4 of FIG. 3 ;
[0017] FIG. 5 is a side view of the panel of FIG. 4 shown assembled with other panels;
[0018] FIG. 6 is an enlarged view of a top of one panel and a bottom of a second panel of the panel system of FIG. 1 and showing the interlocking configuration of the first and second panels in partial phantom lines;
[0019] FIG. 7 is an enlarged perspective view of a bottom clip of the panel system of FIG. 1 ;
[0020] FIG. 8 is an enlarged perspective view of a top clip of the panel system of FIG. 1 ;
[0021] FIG. 9 is a perspective view of an alternate embodiment of the panel system;
[0022] FIG. 10 is a top view of the panel system of FIG. 9 ; and
[0023] FIG. 11 is a rear perspective view of a panel interior of the panel system of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] A wall mounted panel system designated generally 10 comprises a plurality of panels 12 . A plurality of panels 12 , for example first panel 14 , second panel 16 , third panel 18 , fourth panel 20 . Hat channels 21 are affixed to a wall surface 23 behind panels 12 . Hat channels 21 are located behind a joint gap formed by adjacent panels and functions as a vertical gutter for any water that may migrate behind the panels. First panel 14 includes a main vertical member 22 having a top edge 24 , right edge 26 , left edge 28 , and bottom edge 30 . Panels 12 are preferably constructed of a composite aluminum skin bonded to a polyethylene core. The aluminum skin material may be machined from one side to facilitate bending of the material, e.g., to create edges 24 , 26 , 28 , and 30 .
[0025] Top member 32 ( FIGS. 4 , 5 ) has an inside surface and an outside surface. Top member 32 and main vertical member 22 have an inside surface that defines a first recess 34 ( FIGS. 4-6 ) and a second recess 36 (not shown) where members 22 and 32 join, i.e., wherein the metallic skin and a portion of the core material is removed to create a recess for receiving a protrusion of an upper bracket. Top member 32 extends rearwardly from top edge 24 of main vertical member 22 . Top member 32 has an upper vertical flange member 38 that protrudes upwardly therefrom. Upper vertical flange member 38 has a right end 40 that extends a distance to the right of right edge 26 of main vertical member 22 .
[0026] An uppermost horizontal member 42 ( FIGS. 1 , 3 , 4 , 6 ) extends forwardly from a top edge of upper vertical flange member 38 . Uppermost horizontal member 42 preferably has a width equal to a width of main vertical member 22 . Top member 32 , vertical flange member 38 , and uppermost horizontal member 42 form a channel or horizontal gutter that directs water horizontally.
[0027] Bottom member 44 has an outside surface and an inside surface. Bottom member 44 defines a first recess 46 and a second recess 48 machined on the inside surface, i.e., wherein the metallic skin and a portion of the core material is removed to create a recess for receiving a protrusion of a bottom bracket.
[0028] Right member 50 ( FIGS. 1 , 3 ) extends rearwardly away from right edge 26 of main vertical member 22 . Right member 50 has a right vertical flange member 52 that protrudes therefrom to a distance equal to the distance of upper vertical flange member 38 extends to the right of right edge 26 of main vertical member 22 . An upper end of right vertical flange member 38 is inserted behind the right end 40 of upper vertical flange member 38 , thereby creating a shingle-like overlap to deter an influx of water behind panel system 10 .
[0029] Right border flange member 54 is affixed to an outer edge of the right vertical flange member 52 . Right border flange member 54 extends in a rearward direction from the right vertical flange member 52 .
[0030] Left member 56 extends rearwardly from left edge 28 of main vertical member 22 . A first upper bracket 58 has a forward upwardly extending member 60 and a rearward upwardly extending member 62 separated by upper horizontal member 64 . Rearward upwardly extending member 62 defines a first mounting orifice 66 . Forward upwardly extending member 60 , rearward upwardly extending member 62 , and an upper surface of upper horizontal member 64 define an upwardly facing channel 68 . First upper bracket 58 further defines a lower downwardly extending member 70 and a lower horizontal member 72 wherein a lower surface of upper horizontal member 64 engages an upper surface of uppermost horizontal member 42 . Lower horizontal member 72 engages a lower surface of top member 32 (see, e.g., FIG. 6 ).
[0031] First brace member 74 ( FIG. 3 ) has a first end 76 , a second end 78 , base 80 ( FIGS. 4 , 5 ), and a top surface 82 . Base 80 is in contact with a rear surface of main vertical member 22 . The top surface 82 of first end 78 is affixed to the lower vertical downwardly extending member 70 of first upper bracket 58 .
[0032] A second upper bracket 84 has a forward upwardly extending member 86 and a rearward upwardly extending member 88 separated by an upper horizontal member (not shown). Rearward upwardly extending member 88 defines second mounting orifice 92 . Forward upwardly extending member 86 , rearward upwardly extending member 88 , and an upper surface of the upper horizontal member define an upwardly facing channel similar to upwardly facing channel 68 of first upper bracket 58 . Second upper bracket 84 further defines a lower downwardly extending member 96 and a lower horizontal member similar to lower horizontal member 72 of first upper bracket 58 . A lower surface of the upper horizontal member engages an upper surface of uppermost horizontal member 42 . The lower horizontal member engages a lower surface of top member 32 .
[0033] Second brace member 100 has a first end 102 , a second end 104 , a base, and a top surface 108 . The base is in contact with a rear surface of main vertical member 22 . Top surface 108 of second end 104 is affixed to lower downwardly extending member 96 of second upper bracket 84 . First brace member 74 and second brace member 100 are preferably affixed to an inside of main vertical member 22 with a structural silicon or other adhesive. Brace members 74 and 100 function as stiffeners that distribute load to wall 23 rather than through panel 12 , thereby allowing panel system 10 to meet high wind load standards.
[0034] Referring now primarily to FIGS. 4 and 6 , first lower bracket 110 has a base surface 112 affixed to a rear surface of main vertical member 22 . First lower bracket 110 further defines an upper horizontal member 114 and upper upwardly extending vertical member 116 that extends from a rearward edge of upward horizontal member 114 . First lower bracket 110 additionally defines a downwardly extending vertical member 118 that defines a receiving space 120 between downwardly extending vertical member 118 and base surface 112 . First lower bracket 110 further defines lower horizontal surface 122 for engaging an inside surface of bottom member 44 .
[0035] Second end 78 of first brace member 74 contacts an upper surface of bottom member 44 .
[0036] Second lower bracket 124 has a base surface affixed to the rear surface of main vertical member 22 . Second lower bracket 124 further defines upper horizontal member and upwardly extending vertical member 130 that extends from a rearward edge of upper horizontal member 128 . Second lower bracket 124 additionally defines downwardly extending vertical member that defines receiving space between the downwardly extending vertical member and base surface 126 . Second lower bracket 124 further defines lower horizontal surface 136 for engaging inside surface of bottom member 44 .
[0037] Second end 104 of second brace member 100 contacts an upper surface of bottom member 44 .
[0038] Although first panel 12 was discussed above, it should be understood that second panel 14 , third panel 16 , and fourth panel 18 share similar components that will share the numerical designations of counterpart components from panel 12 .
[0039] Wall mounted panel system 10 additionally includes second panel 16 that may be installed above first panel 14 ( FIG. 1 ) by locating downwardly extending vertical member 118 of first lower bracket 110 of second panel 16 into upwardly facing channel 68 of first upper bracket 58 of first panel 14 . Additionally, downwardly extending vertical member 132 of second lower bracket 124 of second panel 16 is located in upwardly facing channel 94 of second upper bracket 84 of first panel 14 . The interface between upper brackets 58 , 84 of first panel 14 and lower brackets 110 , 124 of second panel 16 allow for relative movements between panels 14 and 16 . Each of panels 12 , 14 , 16 , and 18 are affixed to a wall surface at first mounting orifice 66 and second mounting orifice 92 , thereby permitting three directions of expansion and contraction.
[0040] Wherein space 138 between first panel 14 and second panel 16 is occupied by upper vertical flange member 38 of second panel 16 .
[0041] Additionally, third panel 18 may be installed adjacent to first panel 14 . Wherein space 140 between first panel 14 and third panel 18 is occupied by right vertical flange member 52 . The integrated upper flange member 38 and right vertical flange member 52 provide coverage between panels 12 , i.e., form integral reveal strips, thereby ensuring consistency in color and a relation in components of panel system 10 .
[0042] Referring now to FIGS. 9-12 , shown is an alternate embodiment 200 of the panel system of the invention, which shares some components of the previously discussed system 10 . System 200 utilizes panels 202 having a main vertical member 222 . Panels 202 have a top member 232 having an inside surface and an outside surface. Top member 232 extends rearwardly from top edge 224 of main vertical member 222 . Top member 232 has an upper vertical flange member 238 that protrudes upwardly therefrom. Bottom member 244 , right member 250 and left member 256 extend rearwardly from main vertical member 222 (see FIG. 11 ).
[0043] Panels 202 are affixed to a wall surface 23 in the same manner as wall system 10 , discussed above. Embodiment 200 , however, utilizes a modified hat channel 221 that provides an integral reveal strip 223 , thereby eliminating a need for panels 202 to have integral flange members between side by side adjacent panels. In this embodiment of the invention, upper vertical flange members 238 ( FIG. 11 ) occupy the space in between above and below adjacent panels 202 .
[0044] Three brace members 282 are shown affixed to a rear surface of main vertical member 222 . However, greater than three or less than three brace members 282 may be utilized as conditions warrant.
[0045] The panel system of the invention is advantageous in that the system presents clean lines for an improved aesthetic appearance. The wall attachment methodology and interlocking brackets that allow relative movement between panels ensures that three-directional movement is facilitated to accommodate thermal expansion and other forces. The shingled jointery created by overlapping surfaces functions to minimize water penetration and to eliminate the necessity for gaskets and sealants between adjacent panels. The panel system of the invention eliminates a requirement for affixing a framework to a wall surface to receive panels, since each panel is affixed to the wall surface via upper brackets. As can be seen in FIG. 6 , the interlocking panels of the invention facilitate air flow behind the panels to effect the drying of water that has migrated behind the panels.
[0046] Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the claims. | A wall mounted panel system wherein panels are permitted three directions of expansion and contraction since each of panel is affixed to the wall at a single point. For example, the system includes a first and second panel adjacent to one another. An upper bracket and a lower bracket are affixed to the back of each panel, wherein the upper brackets are affixed to the wall and wherein the lower bracket of the first panel is movably engaged with the upper bracket of the second panel. The panels do not communicate with any sealing members, thereby allowing for air to flow freely behind the panels for providing a means of removing moisture from behind the panels. A brace member in communication with the interior surface of each panel has an upper end affixed to the upper bracket and a lower end affixed to the lower bracket. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional Patent Application No. 61/600,135, VARIABLE SPEED COLLABORATIVE WEB BROWSING SYSTEM, filed Feb. 17, 2012 which is hereby incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to computerized social networks and e-commerce. More particularly, the present invention relates to facilitating ad-hoc screen sharing and co-browsing between users of a social network.
DESCRIPTION OF THE DRAWINGS
[0003] For a more complete understanding of the present invention and further advantages thereof, references are now made to the following Detailed Description, taken in conjunction with the drawings, in which:
[0004] FIG. 1 is a generalized block diagram illustrating implementing a shop-with-a-friend (“s.w.a.f”) system in conjunction with a social network.
[0005] FIGS. 2 a and 2 b are generalized block diagrams illustrating architecture of a s.w.a.f mechanism, in one possible embodiment.
[0006] FIGS. 3 a - 3 e are generalized block diagrams illustrating database architecture in an implementation of a s.w.a.f system, according to one possible embodiment of the present invention.
[0007] FIG. 4 is a generalized block diagram illustrating an ability of a user to preview activities of other users, via a s.w.a.f mechanism, in one possible embodiment of the present invention
[0008] FIGS. 5 a & 5 b are generalized flow diagrams illustrating dynamic pricing in a system incorporating s.w.a.f technology, in once possible embodiment of the present invention.
[0009] FIG. 6 is a generalized block diagram illustrating a s.w.a.f enabled system wherein a social-network “invite friends” control facilitates a one-click co-shopping experience between two users, in one possible embodiment of the present invention.
[0010] FIG. 7 is a generalized block diagram illustrating a s.w.a.f system augmenting a website, in one possible embodiment of the present invention.
[0011] FIG. 8 is a generalized block diagram illustrating an ability to display suggestions to a user of connecting to other users who are shopping for similar items, via a s.w.a.f mechanism, in one possible embodiment of the present invention.
[0012] FIG. 9 is a generalized block diagram illustrating a Facebook® application, operating in conjunction with a s.w.a.f system, in one embodiment of the present invention.
DETAILED DESCRIPTION
[0013] FIG. 1 is a generalized block diagram illustrating implementing a shop-with-a-friend (“s.w.a.f”) system in conjunction with a social network.
[0014] The s.w.a.f mechanism is comprised of a “s.w.a.f. engine” 100 , the s.w.a.f engine residing on servers accessible to a client via a web-browsing mechanism; and, a “s.w.a.f client engine” 111 , residing on a device accessible to the user and communicating with the s.w.a.f server engine 100 over a network (e.g. the Internet.)
[0015] In the present example, users “Person 1 ” 104 b , “Person 2 ” 104 c , “Person 3 ” 104 c may be using a system which utilizes the s.w.a.f server engine 100 . For example, users 104 a - 104 c may be on one or more websites tied into the s.w.a.f engine 100 . The s.w.a.f engine 100 may utilize a data-store 101 , e.g. a database, containing, among other data, data pertaining to the users 104 a - 104 c.
[0016] The client s.w.a.f engine 111 may receive information from the s.w.a.f engine 100 , via communication channels 110 a - 110 c . In this example, for illustrative purposes only, the communications channels 110 a - 110 c may correspond directly with the users 104 a - 104 c , respectively (e.g. communications channel 110 a may carry information pertaining to “Person 1 ” 104 a .)
[0017] A user 116 may be connected to the s.w.a.f server 100 via a s.w.a.f client component 114 , communicating with the s.w.a.f client engine 111 . The s.w.a.f client engine 111 may receive information pertaining to all users connected to the swaf server 100 : “Person 1 ” 104 b , “Person 2 ” 104 c and “Person 3 ” 104 c.
[0018] The information received by the swaf client engine 111 may be further filtered to include only users who are “friends” (the definition of a “friend” defined by a social network) of the User 116 on the social network 106 , accessible by the swaf client engine 111 .
[0019] The information received via the swaf engine 111 , via channels 110 a - 110 c , corresponding to the users 104 a - 104 c , may be further filtered by the swaf client engine 111 to present the user 116 with information pertaining only to his/her friends, as defined in the social network 106 .
[0020] In one possible embodiment, the User 116 may only see (i.e. have access to, be able to interact with, etc.) “Person 1 ” 104 a and “Person 3 ” 104 c , because these people have profiles in the social network 106 (as “Friend 1 ” 108 a and “Friend 3 ” 108 b ) and because these people are friends of the User 116 in the social network 106 .
[0021] In another related possible embodiment, the users “Person 1 ” 104 a and “Person 3 ” 104 c may be able to see and/or interact with the User 116 , via the swaf mechanism, by virtue of being friends on the social network 106 .
[0022] In other possible embodiments, various other rules may be implemented, and options presented to users, allowing, disallowing and limiting electronic interactions via the swaf mechanism, based on social network relationships and other factors.
[0023] FIGS. 2 a and 2 b are generalized block diagrams illustrating architecture of a s.w.a.f mechanism, in one possible embodiment. A website 200 may communicate with a social network 250 (e.g. Facebook®) Each user commences interaction with the website 200 by visiting the website's 200 URL (i.e. web address, e.g. www.amazon.com)
[0024] The website 200 may allow the user to log into the social network 250 by using the user's social network 250 credentials. Once the user has logged into their social network 250 profile, the website 200 may gain access to the user's social graph, including the user's list of friends, etc.
[0025] The website 200 may be rendered on the user's electronic device via a web-browsing application (e.g. Internet Explorer®, Chrome®, Safari®, etc.) In rendering the contents of the website 200 , the user electronic device's web-browsing application may create a document 202 containing user-sided-representation of the website 200 . The document 202 may contain DOM elements (Document Object Model) accessible programmatically and visible to the user. For example: dialog boxes, input fields, buttons, etc.
[0026] The document 202 may contain (or have access to) a s.w.a.f document engine 230 . The s.w.a.f document engine 230 may be a library of Javascript and/or JQuery code which facilitates communication between the document 202 and its elements, and a s.w.a.f server engine 240 , which in turn, facilitates communications with remote users and their documents.
[0027] The s.w.a.f server engine 240 may be written in a server-side coding language (e.g. PHP, Ruby on Rails, C++, Java, etc.) and communicate with the s.w.a.f document engine 230 . The communication between the s.w.a.f document engine 230 and the s.w.a.f server engine 240 may be facilitated using AJAX (Asynchronous JavaScript and XML), or any other protocol.
[0028] The s.w.a.f server engine 240 may communicate with a data store 242 , the data store 242 storing records on users' live usage of the s.w.a.f system, including, but limited to, a period heart-beat from each user's s.w.a.f engine and instructions sent from one user to another.
[0029] Referring now to FIG. 2 b , the document 202 , displayed in the user's web-browser, may contain elements 255 (e.g. a button, an input field, a selection field, a drop-down box or any other object displayed on a website). The s.w.a.f document engine 230 may contain modules for facilitating synchronized communication between documents used be two or more remote users.
[0030] One module may be a function for processing outgoing messages 232 . The function for processing outgoing messaging 232 may communicate with elements 255 in the document 202 , specifically querying their state and responding to events generated by the elements 255 . The function for processing outgoing messages 232 may then transmit messages reflecting changes in the elements 255 , onto the s.w.a.f server engine 240 .
[0031] For example, the element 255 may represent a button invoking a “purchase” function in the document 202 , while the document 202 represents a page in the Amazon.com® website depicting a certain item. In this example, in response to a user's clicking the “purchase” button associated with the element 255 , the function for processing outgoing messages 232 may create an electronic message depicting the clicking action, and transmit it, via AJAX, onto the s.w.a.f server engine “nexus” system 240 .
[0032] Another module within the s.w.a.f document engine 230 may be a function for processing incoming messages 234 . The function for processing incoming messages 234 may receive and process from the s.w.a.f server engine 240 , messages affecting elements in documents in other users' web browsers, and invoke corresponding action on elements 255 on the present document 202 .
[0033] For example, the s.w.a.f server engine 240 may contain an electronic instruction to invoke a “purchase” button within a document in the user's browser, the electronic instruction generated by a remote user clicking a corresponding “purchase” button on their web browser. The function for processing incoming messages 234 may receive the message from the s.w.a.f server engine 240 , and may then send a “click” instruction to the corresponding element 255 (i.e. “purchase” button in this example) on the user's local browser.
[0034] FIGS. 3 a - 3 e are generalized block diagrams illustrating database architecture in an implementation of a s.w.a.f system, according to one possible embodiment of the present invention. Due to the fact that users' browsers are not able to communicate with each other directly, a database 310 may be utilized to broker communication between various web browsers.
[0035] User 1 and User 2 may utilize webbrowsers that include s.w.a.f modules 300 and 302 , respectively. The s.w.a.f modules 300 and 302 may communicate with a s.w.a.f server 308 , which in turn, may store information in a data store 310 . The s.w.a.f modules 300 and 302 may be embedded in a hosted website 306 , which in turn communicates with a social network 304 .
[0036] For example, the website 306 may be www.zebedo.com, www.amazon.com, http://apps.facebook.com/shopzebedo, etc. and may allow a user access to a social network 304 , such as Facebook®. The system depicted in this illustration allows multiple users accessing the same website 306 to synchronize their viewing and using the website 306 from different browsers.
[0037] The data store 310 may contain records containing s.w.a.f-related information on the users User 1 and User 2 , form the s.w.a.f modules 300 and 302 associated with those users. In a presently-preferred embodiment, the data store 310 may contain a row of data in one table per user.
[0038] The data store 310 is illustrated here containing two rows of information: a top-row containing data-elements 312 a - 312 d , associated with User 1 's s.w.a.f module 300 ; and, a bottom-row containing data-elements 314 a - 314 d , associated with User 2 's s.w.a.f module 302 .
[0039] In this example, the “bizID” column contains value “ABC” 312 a corresponding to user 1 's s.w.a.f module 300 , and value “ABC” 314 a corresponding to user 2 's s.w.a.f module 302 . In cases where one single s.w.a.f instance is handling two or more websties/businesses, it may be advantageous to identify each s.w.a.f database 310 record with a unique business ID to insure users on different websites are not able to shop together, while on different websites.
[0040] In this example, the “uID” column contains value “12345” 312 b corresponding to user 1 's s.w.a.f module 300 , and value “ 6789 ” 314 b corresponding to user 2 's s.w.a.f module 302 . Similarly, the “uName” column contains value “User 1 ” 312 c corresponding to user 1 's s.w.a.f module 300 , and value “User 2 ” 314 c corresponding to user 2 's s.w.a.f module 302 .
[0041] Values in the database 310 may be updated via a “heartbeat” periodic message, e.g. of initial frequency of 3 Hz, transmitted by the s.w.a.f modules 300 and 302 , populating corresponding database rows, including last-checkin-timestamps 312 d and 314 d . All database communications may generally be originated by the s.w.a.f modules 300 and 302 , transmitting messages to the s.w.a.f server engine 308 , which writes information into the database 310 , reads information and transmits relevant information back to the s.w.a.f modules 300 and 302 .
[0042] Heartbeat (or synch) frequency may be set to vary depending on state of connectivity. For example, “idle” frequency, i.e. when user is not connected via a s.w.a.f session to any other user, may be set to 3 Hz. When sending a connection request and awaiting a reply, the heartbeat frequency may be increased to 1 Hz. When connected to a remote user via a live s.w.a.f joint-shopping session, the synch frequency may be increased to 0.2 Hz (to allow for smoother, more real-time synchronized action between users, for example, when one user clicks on a button, the corresponding button on the other user's screen should experience a click almost at the same time.) When a s.w.a.f live shopping session is terminated or discontinued, synch frequency may decreased to consume less system resources.
[0043] In one preferred embodiment of the present invention, “stale” records (e.g. records older than 2 minutes) may be cleared up by the s.w.a.f server engine 308 when the latter is called by any of the s.w.a.f modules 300 and 302 . In other potential embodiments, the database 310 may be “self-cleaning”, i.e. delete own stale records; or a service/process within, or outside of the s.w.a.f server engine 308 , may clean stale database records.
[0044] Referring now to FIG. 3 b , the s.w.a.f modules 300 of User 1 may query the “User 2 row” ( 314 a - 314 d ) of the database 310 , via the s.w.a.f server engine 308 , and display to User 1 information 316 pertaining to User 2 (e.g. User 2 's name and any other pertinent information.) Similarly, the s.w.a.f modules 302 of User 2 may query the “User 1 row” ( 312 a - 312 d ) of the database 310 , via the s.w.a.f server engine 308 , and display to User 2 information 318 pertaining to User 1 . This functionality may allow a user to see what other users are “present” at a given store in real time, and engage in a live interactive session with them.
[0045] Referring now to FIG. 3 c , User 1 may choose to initiate a live s.w.a.f session with User 2 . User 1 's s.w.a.f module 300 may transmit a message to the s.w.a.f server engine 308 , which in turn may place a request for connection 320 a and 320 b , in “User 2 's row” in the database 310 . In one possible embodiment, the message may be comprised of the requesting-user's-uID “12345” 320 a , and an instruction representation request to connect “connectRqst” 320 b.
[0046] As the s.w.a.f modules 302 of User 2 performs periodic heartbeat-read/writes into the database 310 , via the s.w.a.f module 308 , the s.w.a.f modules 302 may read the request-to-connect instruction 320 b (as well as all other associated connection request information from User 2 's row/record in the database 310 ) and may display the information 322 to User 2 (e.g. “User 1 wishes to shop with you, would you like to accept?”). User 2 may then accept or reject the invitation.
[0047] Referring now to FIG. 3 d , in a case where User 2 has accepted the request from User 2 , User 2 's s.w.a.f modules 302 may populate User 1 's row ( 312 a - 332 a ) in the database 310 with information confirming acceptance of the connection, etc. User 1 's s.w.a.f module 300 may then read that information, causing it to display 326 to User 1 connection information. Likewise, User 2 may see similar connection information 324 .
[0048] Once s.w.a.f connection has been established between User 1 and User 2 , referring now to FIG. 3 e , actions performed by one user may be automatically performed by the s.w.a.f mechanism for the other user. For example, a web browser used by User 1 and displaying web content, may contain an element 350 (e.g. a button in this illustration, but generally an input field, a drop-down box, a YouTube® video control element, etc.)
[0049] An element's click event (e.g. button 350 being clicked) may trigger the s.w.a.f module 300 to process the click-event and transmit a message to the s.w.a.f server engine 308 , causing the latter to write into the database 310 record of User 2 , an instruction to generate a click of the corresponding element/button within User 2 's web browser. The instruction may include information such as “1 |clicked”, where the “1” represents the element clicked, and the “clicked” represents the action. In related embodiment, and elements name/Id or any other information delimiting an element on a document, may be used.
[0050] The instruction may be received by the s.w.a.f module 302 of User 2 , when the latter queries the s.w.a.f server engine 308 for new pending messages. In addition to receiving the instruction, the s.w.a.f module 302 may process the instruction and execute a command within its web-browser document—in this case, generating an instruction to “click” button 352 .
[0051] The resulting effect is that User 2 , while passive (i.e. not clicking the button 352 ) may observe that the button 352 is clicked automatically. In addition, the clicking of the buttons 350 and 352 may initiate a similar action for both users on their corresponding web browsers. For example, if both users are at an Amazon.com® virtual store, clicking the button 350 may initiate a purchase-flow for User 1 . However, as User 1 and User 2 are connected via the s.w.a.f mechanism, button 352 may be automatically-clicked for User 2 , also initiating a purchase-flow for User 2 within User 2 's web browser.
[0052] FIG. 4 is a generalized block diagram illustrating an ability of a user to preview activities of other users, via a s.w.a.f mechanism, in one possible embodiment of the present invention. A user who is not-yet connected to any other user in a s.w.a.f session, may be privy to at least information regarding other users—e.g. friends—who are at a website that is part of a s.w.a.f system.
[0053] User 1 400 , User 2 402 a , User 3 402 b and User 4 402 c , may be on one or more website's that is part of a s.w.a.f system. These users may be at different geographic locations, accessing the website (or websites) from various different types of electronic devices and different web browsing applications. Further, these users may be viewing different things on the websites(s). For example, one user may be reading reviews on cameras, whereas another may be choosing a specific shoe in the right size.
[0054] A system that is s.w.a.f-enabled is “aware” of the activities of each user via a s.w.a.f client engine that is active within a document displayed in the browser of each user, and which communicates with a s.w.a.f server engine. For example, Users 402 a - 402 c may access a website via browsers 404 a - 404 c , respectively. The browsers 404 a - 404 c , may display web content that includes s.w.a.f client engines 406 a - 406 c , respectively, which may in turn, communicate with the s.w.a.f server engine 410 .
[0055] Similarly, User 1 400 may browse a s.w.a.f enabled website whose content includes the s.w.a.f client engine 412 , also connected to the s.w.a.f server engine 410 . Accordingly, one or more of the s.w.a.f client engines may present their corresponding users with information pertaining to other users' current browsing activities.
[0056] For example, in the illustration of FIG. 4 , User 2 402 a and User 3 402 b are engaged in a joint-shopping session, and User 4 402 c is shopping for an iPhone. Accordingly, User 1 400 may be notified of Users 2 , 3 , 4 's activities, for example “User 2 is shopping together with User 1 ” 414 or “User 3 is looking at an iPhone” 418 . Further, User 1 400 may be prompted to connect to any of the other users. In one presently-preferred embodiment, the connection may be facilitated with a single click on notifications 414 or 418 , connecting to a live s.w.a.f session with Users 2 and 3 or User 4 , respectively.
[0057] In various possible embodiments of the present invention, various privacy considerations may be implemented to control and limit users' view into other users activities. For example, but not limited to: allowing view only into activities of Facebook friends and/or allowing a user to specify a global setting on whether their shopping activities may be viewed, and/or allowing a business to specify rules, and/or allowing users to select specific friends/stores/items which may be visible to others, etc.
[0058] FIGS. 5 a & 5 b are generalized flow diagrams illustrating dynamic pricing in a system incorporating s.w.a.f technology, in once possible embodiment of the present invention. Merchants may offer groups of buyers discount pricing, especially in situations where a friend-brings-a-friend and all can make a decision at one time. Friends may also influence friends to buy a certain brand. For example, if four friends are co-shopping trying to collectively decide on running shoes, debating between Nike® and other brands, Nike® may decide to offer an instantaneous discount to all four friends if all commit to buying together.
[0059] At step 500 , a user may enter a s.w.a.f-enabled website, for example Amazon.com®. In the prior art, at step 502 , price for each item(s) may be calculated and presented to the user at step 504 . For example, “Panasonic 40 in LED TV $500”.
[0060] At step 506 , a second user, User 2 , may enter the same store. At step 508 , it may be determined whether User 2 is connected via s.w.a.f to User 1 (e.g. User 2 has clicked on User 1 's picture and requested a shop-together experience, and User 1 accepted.) If at step 508 it is determined User 1 and User 2 are not connected via a s.w.a.f session, User 2 would be displayed the same pricing as User 1 (i.e. “Panasonic 40 in LED TV $500”).
[0061] If at step 508 it is determined User 1 and User 2 are connected via a s.w.a.f session, at step 512 , special “discounted group pricing” may be computed for both user, and at steps 514 a and 514 b , Users 1 and 2 , respectively, may be presented with the discounted price (e.g. “Panasonic 40 in LED TV $450, 10% discount”) In various possible embodiments of the present invention, various business rules may apply, such as allowing discount only if both users commit to a purchase; usage of variable pricing/discounts etc. In addition, other users at the virtual store, not shopping together via s.w.a.f, may see other, e.g. standard, pricing.
[0062] Conversely, discount levels may be automatically adjusted downwards when less users are shopping together via s.w.a.f. If at step 520 it is determined that Users 1 and 2 are disconnected, e.g. at step 518 a User 2 leaves the store/website; or at step 518 b User 1 and User 2 become disconnected/choose to terminate shopping together, at step 522 the discount pricing may be rescinded for one or both users. As result, at steps 524 a and 524 b , Users 1 and 2 , respectively, may automatically see pricing revert to original pricing, i.e. “Panasonic 40 in LED TV $500”.
[0063] In a related-possible embodiment of the present invention, users may be presented with “teaser pricing” should they invite their friends to shop together. For example, referring now to FIG. 5 b , at step 506 User 2 may enter the same virtual store as their friend, User 1 . At step 508 , it may be determined whether User 1 and User 2 are connected via a s.w.a.f mechanism, i.e. are co-shopping.
[0064] If at step 508 it is determined the two users are not already shopping together, at step 550 it may be determined whether User 1 and User 2 are friends (e.g. as defined by a social network such as Facebook®, wherein friendship is discerned from the users’ social graphs.)
[0065] If it is determined at step 550 that User 1 and User 2 are friends, at step 552 proposed group-discounting may be calculated and presented to the user at steps 554 a and 554 b . For example, at step 554 a , User 1 may see a pop-up notification to the effect of “Your friend, User 2 , is available to shop together. Invite her and you will each receive a 10% discount on purchases.” In a further embodiment, User 1 may click on the pop-up to automatically invite User 2 to shop together via the s.w.a.f mechanism.
[0066] FIG. 6 is a generalized block diagram illustrating a s.w.a.f enabled system wherein a social-network “invite friends” control facilitates a one-click co-shopping experience between two users, in one possible embodiment of the present invention. Social network feature common controls, such as Facebook®'s “send” and “share” buttons, which allow a user to see a list of their friends, select one or more friends from the list, and send them a message through the social network. In the prior art, a friend receiving a message may click a hyperlink embedded in the invite-message and be taken to a different location (commonly the application/web-address from which the user had sent the invite.)
[0067] User 1 612 a may access a s.w.a.f-enabled website 600 (e.g. www.amazon.com or a Facebook®-application such as http://apps.facebook.com/shopzebedo) User 1 's web-browsing application, used to access the website 600 , may contain a document 602 a (a document generally refers to the content of a webpage rendered inside a user's browser, based on web content from a website.)
[0068] The document 602 a may contain user-accessible elements and controls such as the Facebook® “send” button 604 . Upon clicking the “send” button 604 , User 1 612 a may be presented with a list of one-or-more social-network 608 friends. User 1 612 a may select a friend, e.g. User 2 , and send User 2 612 b an invite via the social-network.
[0069] In the prior art, an invite message 610 from a friend may be displayed on a wall associated with User 1 and/or User 2 in the social-network 608 ; or in a newsfeed of User 1 and/or User 2 ; or as a chat-message to User 2 , etc. User 2 612 b may select the invite message 610 displayed, and automatically be displayed the website 600 via his/her web browser, in the prior art.
[0070] In a s.w.a.f-enabled system, upon launching the website 600 , User 2 612 b may be automatically connected to a s.w.a.f system, illustrated herein as comprising components 606 a , 606 b and 620 . The s.w.a.f server engine 620 may broker a s.w.a.f connection between User 1 612 a and User 2 612 b , via s.w.a.f document engines 606 a and 606 b , respectively.
[0071] In one preferred embodiment of the present invention, the invite message 610 may content a unique token, e.g. “123”, which may uniquely represents User 1 's invite of User 2 to website 600 . The s.w.a.f document engine 606 b of User 2 612 b may transmit the content of the token, e.g. “123”, to the s.w.a.f document engine 606 a of User 1 612 a . In response, the s.w.a.f document engine 606 a of User 1 612 a may automatically initiate a connection with the s.w.a.f document engine 606 b of User 1 612 b ; and, the s.w.a.f document engine 606 b of User 2 may automatically reply accepting the s.w.a.f joint-shopping invite.
[0072] In effect, User 1 may use Facebook®'s “share” or “send” or any other social plug-in to invite User 2 (via posting on own wall, User 2 's wall, in a chat, newsfeed, etc) User 2 may then click on the invite and be presented with the web portal of the website from which User 1 had sent the invite. User 1 and User 2 would then be automatically connected to each other via a s.w.a.f joint-shopping session.
[0073] FIG. 7 is a generalized block diagram illustrating a s.w.a.f system augmenting a website, in one possible embodiment of the present invention. A non-s.w.a.f website can be enhanced with s.w.a.f-enabling components, allowing the website to facilitate co-browsing/shopping among users.
[0074] A webstie 700 , representing a non-s.w.a.f website, typically includes a main web-accessible file, e.g. “index.php” 710 , accessible to users User 1 and User 2 using web browsers 704 and 706 , respectively (e.g. when a user navigates to website's 700 URL, e.g. www.amazon.com , a main page such as index.php is typically accessed first.)
[0075] In common implementation in the prior art, the website 700 main page “index.php” 710 may contain two types of code: code for server-sided execution 712 , and code for client-sided execution 722 . The server-sided code is typically in the form of PHP, C++, Ruby on Rails, Jave, etc. The client-sided code is typically Javascript.
[0076] In the prior art, although User 1 and User 2 are both accessing the website 700 , they are unaware of one another, and have no means of interacting. For example, if website 700 is Amazon.com®, User 1 may be accessing Amazon.com® from an iPhone to purchase a camera, whereas User 2 may be accessing Amazon.com® from an Android-based device to browse for books; however, all the while, User 1 and User 2 are unware of each other's presence and are unable to shop together.
[0077] In one preferred embodiment of the present invention, the website 700 may be augmented with s.w.a.f technology, allowing User 1 and User 2 to co-browse/shop. Further, the s.w.a.f technology does not require either User 1 or User 2 to install plug-ins or any other “screen sharing” technology on their respective client devices.
[0078] Four main s.w.a.f components may be added to the website 700 to enable User 1 and User 2 to co-browse/shop: a server-and-client s.w.a.f web-page components, 720 and 722 respectively, to index.php 710 ; and, a server-sided component 724 to the website; and a database 726 .
[0079] The server-side s.w.a.f web-page components 720 , and the client-side s.w.a.f web-page components 722 , may be part of index.php 710 , with the server-side s.w.a.f web-page components 720 embedded in the portion of the code of index.php 710 handling server-sided code 712 ; and, the client-side s.w.a.f web-page components 722 embedded in the portion of index.php 710 handling client-sided code 714 .
[0080] The server-side s.w.a.f web-page components 720 may perform functions such as reading users' social graphs from a social-network, etc. The client-side s.w.a.f web-page components 722 may utilize Javascript or JQuery to perform at least the following functions: trigger off of elements in on the page index.php 710 , communicate a state-change of the elements to remote users, receive communications from remote users and change the state of local elements in index.php 710 .
[0081] The communication between the client-side s.w.a.f web-page components 722 and the s.w.a.f server 724 , may utilize technology such as AJAX. The s.w.a.f server 724 may communicate with the s.w.a.f database 726 . In various possible embodiments, the s.w.a.f server 724 and/or the s.w.a.f database 726 may be either internal to the website 700 , jointly or severally, and/or external (e.g. hosted elsewhere on the Internet).
[0082] FIG. 8 is a generalized block diagram illustrating an ability to display suggestions to a user of connecting to other users who are shopping for similar items, via a s.w.a.f mechanism, in one possible embodiment of the present invention. A user browsing a website for one type of content, e.g. shopping for a type of items, may be privy to other information indicating other users, e.g. his/her friends, shopping for a similar type of item; and may be offered a one-click s.w.a.f. connection to them to shop jointly.
[0083] User 8 400 , User 2 802 a and User 3 802 b , may be on one or more website's that is part of a s.w.a.f system. These users may be at different geographic locations, accessing the website (or websites) from various different types of electronic devices and different web browsing applications. Further, these users may be viewing different things on the websites(s). For example, one user may be shopping for a new cell phone, whereas another may be choosing a specific shoe in the right size.
[0084] A system that is s.w.a.f-enabled is “aware” of the activities of each user via a s.w.a.f client engine that is active within a document displayed in the browser of each user, and which communicates with a s.w.a.f server engine. For example, Users 802 a - 802 b may access a website via browsers 808 a - 808 b , respectively. The browsers 808 a - 808 b , may display web content that includes s.w.a.f client engines 806 a - 806 b , respectively, which may in turn, communicate with the s.w.a.f server engine 810 .
[0085] Similarly, User 1 800 may browse a s.w.a.f enabled website whose content includes the s.w.a.f client engine 812 , also connected to the s.w.a.f server engine 810 . Accordingly, one or more of the s.w.a.f client engines may present their corresponding users with information pertaining to other users' current browsing activities.
[0086] For example, in the illustration of FIG. 8 , User 1 800 is shopping for an iPhone. Coincidentally, in the example, User 3 802 b is also shopping for an iPhone. Accordingly, User 1 800 may be notified of User 3 's activities, for example “User 32 is also shopping for iPhone, would you like to shop together?” 818 . In one presently-preferred embodiment, the connection may be facilitated with a single click on notification 818 , connecting to a live s.w.a.f session with Users 3 . Similarly, User 3 may also be notified of User 1 's shopping for a similar type of item, and may be offered a one-click-connect.
[0087] In one embodiment, the logic of presenting a user with notification of other users shopping for similar things, may take place in the user browser's own s.w.a.f client engine. The s.w.a.f client engine is aware of what its own user is shopping for; and receives information on other users’ activities, and determines when to prompt its own local user of other users shopping for something similar.
[0088] In another possible embodiment, a s.w.a.f server engine may monitor the activities of users connected thru it; and may execute logic to send messages to users who are engaged in similar activities, offering them to join in a co-shopping experience.
[0089] In another possible embodiment, a s.w.a.f client engine may actively send solicitation to other s.w.a.f client engines, querying them for their users' activities and displaying information and invitation to connect to users who are engaged in a similar activity.
[0090] In various possible embodiments of the present invention, various privacy considerations may be implemented to control and limit users' view into other users activities. For example, but not limited to: allowing view only into activities of Facebook friends and/or allowing a user to specify a global setting on whether their shopping activities may be viewed, and/or allowing a business to specify rules, and/or allowing users to select specific friends/stores/items which may be visible to others, etc.
[0091] FIG. 9 is a generalized block diagram illustrating a Facebook® application, operating in conjunction with a s.w.a.f system, in one embodiment of the present invention. A web-browsing application/browser 900 may display a URL 902 (uniform resource locator) such as “http://apps.facebook.com/shopzebedo”, which, in the example, is an application displaying an application canvass page 950 within the Facebook® framework. The application canvass page 950 may be a web-application external to Facebook®, presented in a frame within Facebook®, and connected to Facebook's social graph.
[0092] In order to operate in conjunction with a s.w.a.f system, the user's browser 900 does not need to include any addition software such as plug-ins, ActiveX controls, Adobe Flash® player etc.
[0093] A list of friends 904 a - 904 f may be presented to a user. The friends 904 a - 904 f may be Facebook® users who are friends of the current user, selected by various algorithms and sorted in various orders. For example, from left-to-right, friends 904 a - 904 c may be ordered in order of their birthdays—from soonest to latest; or, alternatively, in order of their closeness to the user, etc. The friends 904 a - 904 c may also represent users who are actively online, i.e. actively logged into Facebook®.
[0094] A list of users 904 d - 904 f may be comprised of users who are actively connected to the s.w.a.f system (typically users using the website http://apps.facebook.com/shopzebedo, although other websites may be connected with the same s.w.a.f system.) The users 904 d - 904 f may be available for immediate joint-shopping s.w.a.f session, given both their presence online and their existent connection to the underlying s.w.a.f system.
[0095] The user may be prompted with a visual queue 906 to connect to any of the friends 904 a - 904 f . In the preferred embodiment, the visual queue 906 may be a popup that appears automatically when the user slides their cursor over one of the friends 904 a - 904 f.
[0096] In the presently preferred embodiment, the user would “single click” on the visual queue 906 , associated with a friend 904 a - 904 f , and be automatically connected to that friend via a live s.w.a.f session. In the case of friends 904 d - 904 f , a direct s.w.a.f message may be sent from a s.w.a.f client engine component in the user's browser 900 to corresponding s.w.a.f client engine component displayed in the friends' 904 a - 904 f browser, prompting the friend to accept or reject a live s.w.a.f session.
[0097] In the case of friends 904 a - 904 c , given that they are not actively connected to the s.w.a.f system, as per FIG. 6 , these friends may be presented with a Facebook® message (e.g. on their wall, newsfeet, chat, etc.) asking them to navigate to the URL 902 . Once these friends navigate to that URL (and optionally accept additional terms/register), they may be automatically connected to the s.w.a.f system; and, may be automatically joined into a joint live s.w.a.f session with the user. Selecting a Facebook® social plugin, such as “share” 924 , may allow the user to select a friend or friends, who may or may not be displayed as friends 904 a - 904 f , and for the selected friend(s) to be automatically connected to the present user via a live s.w.a.f session, once the selected friend(s) has/have navigated to the URL 902 .
[0098] A product 918 may be displayed for viewing and for purchase. The user may browse through available products using one or more graphical controls; and, when in a live s.w.a.f session with one or more remote users, selecting a particular item 918 may cause that item to be selected for all connected users.
[0099] Similarly, the user's clicking on any other control in the browser 900 may cause that control to be clicked in browsers of all remote users connected to the user via a live s.w.a.f session. Similarly, the remote users' clicks on any controls in their browsers may cause a similar click to take place in the contents of the browser 900 . For example, one user's clicking of the “check out” 920 button, beginning a checkout process (possibly with a merchant in a separate browser from 900 ) may cause the same “check out” 920 button to be automatically selected in a remote user's web browser, commencing the same purchase flow. Similarly, selecting a media-playing button, such as “play movie” (or “pause”, “fast forward”, etc.) 926 , may cause a movie (e.g. off of Youtube®) to be played in the browser 900 —and also within the browser of a fiend in a live s.w.a.f session.
[0100] It will be understood that the inventive system has been described with reference to particular embodiments, however additions, deletions and changes could be made to these embodiments without departing from the scope of the inventive system. Although the order filling apparatus and method have been described include various components, it is well understood that these components and the described configuration can be modified and rearranged in various other configurations. | The present invention is directed towards computerized social networks and e-commerce including facilitating ad-hoc screen sharing and co-browsing between users of a social network. The collaborative web browsing method comprising providing a server computer having a Shopping With A Friend (SWAF) server engine coupled to a database, a SWAF client engine coupled to the SWAF server engine and a plurality of client computers each having a web browser program that runs the SWAF client engine. The web browser program does not include a collaboration plug-in. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This Application claims the benefit of U.S. Provisional Application No. 61/065,383, filed 11 Feb. 2008, the disclosure of which earlier Application is incorporated by reference herein and made a part hereof, including but not limited to those portions which specifically appear in this Application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to sediment barriers. This invention relates to an apparatus and method for controlling water flow, soil erosion and/or sediment flow at, for example, a construction site.
[0004] 2. Discussion of Related Art
[0005] Environmental concerns and federal regulations, such as the Clean Water Act and the accompanying National Pollution Discharge Elimination System (NPDES) Program, require construction sites, including road work projects, to control water flow to stop sediment loss and control soil erosion in and around a construction site.
[0006] The typical method currently used for controlling water flow to stop sediment loss and soil erosion is to secure one or more hay bales and/or a silt fence section in and around the construction area. While these barriers are generally effective, both can be easily compromised.
[0007] Hay bales, being a natural product, have a tendency to degrade and break down quickly and can become laden with weeds and other contaminates which can cause substantial environmental damage at the construction site. When a hay bale becomes wet, the hay material becomes heavy and bulky, making installation and removal difficult. Because hay bales are an agricultural product, hay bales are susceptible to climatic periods, and may be in short supply and difficult to obtain at a job site at certain times of the year.
[0008] Silt fencing can be effectively used at job sites when it is used for its primary purpose of preventing sediment loss. Silt fencing is designed to form a pool of water, which allows sediment to drop out. However, silt fencing is not designed to stand up against relatively high water flows. Silt fencing is susceptible to wind or other forms of weather damage. Generally, a silt fence is stapled to a stake which stuck into the ground and thus high winds or high water flow can rip the fabric from the staple or separate the staple from the stake. Once a silt fence is thus damaged, it is no longer able to protect against sediment loss.
[0009] Thus, there is a need for an improved barrier that controls water flow, sediment flow and/or prevents soil erosion in and around construction sites. Desirably, the barrier should be able to maintain integrity over time, by resisting wind, water and other forms weather related damage. There is a need for a barrier that allows construction workers to easily move the barrier to various locations, and not be heavy and bulky to handle, thereby preventing lifting related accidents and saving on freight charges. The barrier should be reusable at various construction sites. Thus, the apparatus should minimize or eliminate the chance of transporting weeds and other contaminants, because of concerns about introducing contaminants at each successive construction site.
SUMMARY OF THE INVENTION
[0010] A general object of this invention is to provide an improved barrier to reduce or eliminate soil erosion.
[0011] A more specific object of this invention is to overcome one or more of the problems previously described.
[0012] This invention relates to an apparatus for controlling water flow, soil erosion and/or sediment flow, such as along a ground surface or other surface. The apparatus includes a dam portion with a water-permeable, sediment impermeable cover enclosing a chamber, and a filler material disposed within the chamber. A rigid supporting structure is attached to the dam portion. A tail portion extends from a bottom edge of the dam portion. The supporting structure secures to the surface to hold the dam portion in an upright position, and the tail portion is disposed at an angle from the dam portion in a direction toward the flow of water.
[0013] This invention further provides an apparatus for controlling water flow, soil erosion and/or sediment flow along a surface, including a dam portion with a water-permeable, sediment impermeable cover enclosing a chamber, and a filler material disposed within the chamber. Each of two sleeves can be attached to one of opposing edges of the dam portion. A stake can be disposed through each of the sleeves and a tail portion can extend from a bottom edge of the dam portion. A support structure can be secured to the surface to hold the dam portion in an upright position, and the tail portion can be disposed at an angle from the dam portion, such as in a direction toward the flow of water.
[0014] This invention further provides a method for controlling water flow, soil erosion and/or sediment flow across a surface. The method includes providing a sediment barrier including a water-permeable, sediment impermeable cover enclosing a chamber, and disposing a filler material within the chamber. A sleeve can be attached to each of opposing edges of the dam portion, and a stake can be disposed through each of the sleeves. A tail portion can extend from a bottom edge of the dam portion. The sediment barrier can be positioned at an angle, such as perpendicular to a direction of the water flow. The sediment barrier can be secured in place by embedding an end of each of the stakes into the surface and/or extending the tail portion from the sediment barrier along the surface in a direction against the water flow.
[0015] In some embodiments, the sediment barrier of this invention has a geotextile cover over a polypropylene core material as a dam portion. The dam portion can be at least partially permeable to water, and impermeable to soil and other sediment, thereby allowing water to filter out undesired soil and other sediment. This invention can be used to pool and filter water, such as a function of the material selected as the cover and the density of the polypropylene core. A geotextile tail portion can extend from the dam portion along a section of the ground in which the barrier is placed. The tail portion can extend upstream against a direction of a flow of water. The tail portion increases the effectiveness of this invention by preventing soil and other sediment from seeping under the dam portion and undermining the purpose of the sediment barrier.
[0016] The sediment barrier of this invention can have a pair of supporting structures, such as wooden stakes, to provide vertical support and to anchor the sediment barrier in a position. The supporting structures pass through sleeves which are attached to the dam portion.
[0017] The sediment barrier of this invention controls water flow, sediment flow and/or prevents soil erosion in and around construction sites. The apparatus of this invention is able to maintain integrity over time, resisting wind, water and other forms weather related damage. The apparatus of this invention can be lightweight, allowing construction workers to easily move the apparatus to various locations. The apparatus of this invention is reusable at various construction sites and is resistant to weeds and other contaminants, lessening the possibility of introducing contaminants at successive construction sites.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other characteristics and features of this invention will be better understood from the following detailed description taken in conjunction with the drawings, wherein:
[0019] FIG. 1 is a perspective view of a sediment barrier, according to one embodiment of this invention;
[0020] FIG. 2 is a front view of the sediment barrier as shown in FIG. 1 ;
[0021] FIG. 3 is a partial sectional view of the sediment barrier shown in FIG. 1 , taken along line 3 - 3 in FIG. 2 ;
[0022] FIG. 4 is a top view of two sediment barriers connected in a staggered formation, according to one embodiment of this invention; and
[0023] FIG. 5 is a top view of three sediment barriers connected in a staggered formation, according to another embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIGS. 1-3 illustrate a sediment barrier 10 , according to one embodiment of this invention. The sediment barrier 10 includes or comprises a body or a dam portion 12 and a retainer or a tail portion 14 . In some embodiments of this invention, dam portion 12 includes or comprises a front cover 16 and a back cover 18 . The front cover 16 and/or the back cover 18 can be constructed from one or more higher-flow mono-filament geotextile fabrics, such as known to those skilled in the art of geotextile fabrics, which are generally light-weight, durable and resistant to growth of weeds and/or other contaminants. As used in this specification and in the claims, the term “geotextiles” refers to permeable fabrics which, when used in association with soil, have an ability to separate, filter, reinforce, protect and/or drain. The front cover 16 and/or the back cover 18 can be formed from rectangular shaped sheets, such as shown in FIG. 2 , or from any other suitable shape. The front cover 16 and/or the back cover 18 each is joined at its edges to form at least one pocket 20 , or interior volume, therebetween, and in some embodiments a plurality of pockets 20 , such as shown in FIG. 3 .
[0025] The front cover 16 and/or back cover 18 each can be joined along its end and side edges with a seam 22 . The seam 22 can be any suitably durable conventional stitching for fabric. Alternative methods of forming the seam 22 include, but are not limited to, adhesive sealing, heat sealing and/or riveting. In other embodiments, the front cover 16 and/or the back cover 18 each is formed from a single, folded sheet of geotextile fabric which forms or defines the interior volume or pockets 20 . In other embodiments, a separating seam 23 can be utilized to form more than one pocket 20 . The separating seam 23 can be of any suitably durable conventional stitching for fabric.
[0026] As shown in FIG. 3 , a core formed of a filler material 24 is positioned within the pocket 20 . The filler material 24 can be permeable to allow water to pass and to prevent soil and other sediment from passing through the filler material 24 . The filler material 24 can be constructed of a three-dimensional polypropylene, but may also be constructed of any other suitable material which can filter, for example sediment and soil from water. In some embodiments of this invention, the filler material 24 is constructed of a polypropylene material having a density from about 0.5 pounds per cubic foot to about 15.0 pounds per cubic foot. As shown in FIGS. 1-3 , according to certain embodiments of this invention, the front cover 16 , the back cover 18 and/or the filler material 24 can form an elliptical or a multi-elliptical shaped dam portion 12 . The dam portion 12 can be formed as any other suitable three-dimensional shape, depending on the need or the intended use.
[0027] In some embodiments of this invention, the dam portion 12 comprises two sleeves 26 , each disposed at one of the opposing side edges. Preferably, but not necessarily the sleeves 26 are constructed of the same material as both the front cover 16 and the back cover 18 . The sleeves 26 can be joined to the dam portion 12 using a sleeve seam 28 . Preferably, the sleeve seam 28 is a conventional stitching or other suitable fastener for fabric. Alternative methods for attaching a sleeve at the sleeve seam 28 includes, but is not limited to, adhesive sealing, heat sealing and/or riveting. In other embodiments, the sleeve 26 can be formed of a unitary piece of fabric or sheet material with the front cover 16 and/or the back cover 18 .
[0028] The dam portion 12 can be vertically supported with one support structure 30 , or a plurality of supporting structures 30 . The support structure 30 can be positioned within the sleeve 26 . A portion 31 of the support structure 30 can extend beyond the end of the sleeve 26 . As shown in FIGS. 1-3 , the portion 31 extending beyond the sleeves 26 can be embedded in the ground and/or attached to another structure to secure the sediment barrier 10 in the desired position or location. The support structure 30 can be a stake and/or any other suitable support structure, and can be constructed of any suitable material, such as a metal or a plastic.
[0029] Extending at an angle from a bottom, a bottom portion and/or a bottom edge of the dam portion 12 is the tail portion 14 , which can also be referred to as a retainer, a flap or an apron. The tail portion 14 can prevent sediment from passing below, by and/or underneath the dam portion 12 , which could undermine the purpose of the sediment barrier 10 . The tail portion 14 can be constructed of the same material or a different material as the front cover 16 and the back cover 18 . In other embodiments, the tail portion 14 can be constructed of an impermeable material, for example to filter water solely by the dam portion 12 . In certain embodiments, the tail portion 14 is fixedly connected to and/or integrated with the dam portion 12 .
[0030] Methods of forming the fixed connection include, but are not limited to, sewing with a thread, adhesive sealing, heat sealing and/or riveting. In other embodiments, the tail portion 14 can be detachably connected to the dam portion 12 . Methods of forming the detachable connection include, but are not limited to, buttons, hook and loop fasteners, such as Velcro™ fasteners, and/or zippers. In other embodiments, the tail portion 14 and at least one of the front cover 16 and the back cover 18 is constructed from or integrally formed as a single piece or an integrated piece of fabric.
[0031] As shown in FIGS. 1-3 , the tail portion 14 is secured or fixed in position with at least one securing pin 32 inserted into or attachable to the ground. Any number of securing pins can be used, such as two or three pins, for each tail portion 14 . Securing pins 32 are preferably but not necessarily made of metal or plastic. As shown in FIG. 4 , the tail portion 14 can include riveted holes 47 or another suitable structure through which the securing pin 32 can pass. In other embodiments, the securing pins 32 can pierce or puncture through the tail portion 14 . In alternative embodiments, the securing pins 32 are replaced by soil, sand, gravel, bricks and/or any other suitably heavy object. Often, as the sediment barrier 10 is used, sediment will build up on the tail portion 14 and thus further secure or fix the tail portion 14 in position.
[0032] In accordance with some embodiments of this invention, the sediment barrier 10 can be used alone or in combination with one or more additional sediment barriers 10 , for example to protect a site.
[0033] FIG. 4 shows two sediment barriers 40 assembled according to one embodiment of this invention. FIG. 4 shows a top view of a pair of sediment barriers 40 connected in a staggered formation. Any other staggered configuration is possible. The tail portions 42 of the sediment barrier 40 can include or form one or more slits 34 . Each of the slits 34 is disposed along a side edge 44 of the tail portion 42 . The slits 34 allow the support structure 46 from an adjacent sediment barrier 40 to easily pass through the tail portion 42 , thereby allowing for the staggered relative placement as shown in FIG. 4 , or otherwise, to create an overlapping sediment barrier structure. In other embodiments, the sleeves 26 of adjacent sediment barriers 10 can be configured to accommodate a single shared supporting structure between the sleeves 26 .
[0034] Various and alternative configurations are available for the slits 34 according to this invention. For example, each slit 34 can be a simple cut in the fabric of the tail portion 14 , optionally reinforced by threads, such as a button hole, or the slit 34 can be a shaped cut, such as a rectangle shown in FIG. 4 , or other shapes depending on a need, such as depending on the size and shape of the support structure extending therethrough. FIG. 5 illustrates yet another embodiment of this invention, showing the slits 34 as notches 50 cut out from the edges 52 of the tail portions 54 .
[0035] To utilize the sediment barriers 40 in FIG. 4 , for example, to protect a water drainage grate 49 from receiving undesirable amounts of sediment, the dam portion 41 can be placed at a general angle, such as generally perpendicular to a water flow direction, shown by arrow 48 , with the tail portions 42 placed upon the ground and extending in a direction against the direction of the water flow and/or the sediment flow 48 . Water can pass through the sediment barrier 40 and into the grate 49 while preventing soil and/or other sediment from passing through and instead to build materials upon the tail portions 42 of each sediment barrier 40 .
[0036] Thus, this invention also relates to a method of controlling water flow, soil erosion and/or sediment flow across a surface. The sediment barriers 40 can be desirably aligned, such as generally perpendicular to an expected direction of the water flow and secured in place by embedding an end of each of the stakes 30 into the surface. The tail portions can extend from the sediment barrier 40 along the surface, such as the ground, in a direction against the water flow and/or the sediment, such as shown in FIG. 4 .
[0037] An end of a stake of a second sediment barrier 40 can be inserted through the slit 34 in the tail portion of the first sediment barrier 40 , and the second sediment barrier 40 can be secured in place by embedding an end of each of the second stakes into the surface. Construction of an overall barrier structure can be continued by similarly inserting an end of one stake of a third sediment barrier through the slit in the tail portion of the second sediment barrier. In this manner, the sediment barriers of this invention provide the ability to construct an overall barrier structure having the necessary and suitable size and shape for any given site.
[0038] Details of the discussed embodiments are given for purposes of illustration and are not to be construed as limiting the scope of this invention. Although only a few exemplary embodiments of this invention are described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention. Further, it is recognized that many embodiments may not achieve all of the advantages of some embodiments, yet the absence of a particular advantage shall not be construed to necessarily mean that such an embodiment is outside the scope of this invention. | An apparatus and method for controlling water flow, soil erosion, and/or sediment flow in and around a construction site. The apparatus includes a three-dimensional, water-permeable polypropylene filled geotextile pocket that is secured to the ground with a supporting structure. The apparatus includes a tail portion that is placed flat against the ground, facing upstream against the direction of water flow. The tail portion can be secured with pins that provide protection against movement of the tail portion and reduce an amount of sediment passing under the apparatus. | 4 |
CLAIM OF PRIORITY
This application is Continuation of U.S. patent application Ser. No. 13/569,834 filed on Aug. 8, 2012 and claiming priority of U.S. Pat. No. 8,448,401 filed as application Ser. No. 13/029,336 on Feb. 17, 2011 which claims priority to U.S. Ser. No. 61/305,255 filed Feb. 17, 2010, the contents of all of which are fully incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to the installation of building siding, and more particularly to insulation board and processes related to installing the insulation.
BACKGROUND OF THE INVENTION
Houses in America often have their exterior walls clad with siding to protect the predominately wooden construction from the elements. Vinyl siding has become particularly popular over the last several decades as it is inexpensive, relatively easy to clean and relatively durable. However, in recent years, fiber cement siding has begun to replace vinyl siding. Fiber cement is a product made of sand, cement and cellulose. As a siding material, fiber cement has advantages over both wood and vinyl in that it is rot resistant, termite resistant and non-combustible. Because of these properties fiber cement siding has become widely used in bush fire regions of Australia, and is now becoming a material of choice for new construction in the United States also. Fiber cement siding can also be painted and can be made to look like wood. Its one significant disadvantage is that the fiber cement planks used in the siding are relatively heavy and need to be placed one at a time. Any method of making their alignment easier is, therefore, of great practical utility.
On the other hand vinyl and other types of building siding remain common and insulation at the times of high energy costs has become an important consideration. Therefore, there is a need of insulation practical to use with vinyl and other types of building sidings as well as fiber cement siding.
The system and method of this invention provide both increased thermal insulation and significantly simple installation of the insulation. Furthermore the invention provides an alignment of the fiber cement planks when fiber cement siding is used. The simplified insulation does not compromise the thermal insulation but makes the system more affordable and time saving.
DESCRIPTION OF THE RELATED ART
The relevant patent literature involving siding alignment and insulation products and processes include:
U.S. Patent Publication Number 2009/0019814 is directed to a panelized cladding system including a plurality of battens securable to a building structure, each batten having a structure engaging surface and an integrally formed finish ready panel supporting surface. Fiber cement cladding panels are secured to or through the battens such that the finish ready panel supporting surface of each batten forms an external recessed surface of an expressed joint formed thereon.
U.S. Pat. No. 6,418,610 relates to a method for using a support backer board system and siding. The support backer board system comprises at least a first layer. The first layer is made from a material selected from the group consisting of alkenyl aromatic polymers, polyolefins, polyethylene terephthalate, polyesters, and combinations thereof. The board system is thermoformed into a desired shape with the desired shape being generally contoured to the selected siding. The siding is attached to the board system so as to provide support thereto. In one process, the siding may be vinyl.
U.S. Pat. No. 8,091,313 discloses an apparatus and method for a drainage system of an exterior wall of a building comprising insulation having a rear face for contact with the exterior wall of the building and a drainage plane positioned on the rear face for removal of water from the exterior wall.
CA 2,742,046 discloses an insulation system for securing cladding to the exterior surface of a building. An insulated panel has a front face and a rear face. Joining elements are defined in horizontal edges of the panel for connecting adjacent panels to each other. A horizontal attachment member, such as a nailing hem, is mounted to the rear face of the panel for attaching the insulated panel to the exterior surface. Receiving members are present on the front face of the panel, and can be located in receiving channels. The receiving member is generally made from a material that is better at retaining fasteners, such as nails, than the material of the insulated panel itself.
U.S. Pat. No. 7,762,040 discloses a method for installing siding panels to a building including providing a foam backing board having alignment ribs on a front surface and a drainage grid on a back surface and then establishing a reference line at a lower end of the building for aligning a lower edge of a first backing board an tacking thereon. The system includes tabs and slots along vertical edges of the foam backing board to align and secure adjacent backing boards to each other. A siding panel is butted against one of the lower alignment ribs and secured thereto. Another siding panel is butted against and secured to the adjacent alignment rib to form a shadow line between the adjacent siding panels on the building.
U.S. 20100251648, 2011021073, 20110271622, and US20110271624 disclose foam backing panels for use with lap siding and configured for mounting on a building. The foam backing panels comprise a rear face configured to contact the building, a front face configured for attachment to the lap siding, alignment means for aligning the lap siding relative to the building, means for providing a shadow line, opposing vertical side edges, a top face extending between a top edge of the front face and rear face and a bottom face extending between a bottom edge of the front face and rear face.
The existing art does not provide sufficient protection against moisture drainage of building structures, sufficient aeration between the building surface and the insulation, nor a method or means to easily align drainage panels or attach the insulation boards.
Various implements are known in the art, but fail to address all of the problems solved by the invention described herein. One embodiment of this invention is illustrated in the accompanying drawings and will be described in more detail herein below.
SUMMARY OF THE INVENTION
The present invention relates to an apparatus that forms an insulating barrier behind building siding. The siding may be of any material, vinyl siding, wood siding, fiber cement siding or any other siding material.
In U.S. patent application Ser. No. 13/029,336 and corresponding provisional application 61/305,255, the contents of both of which are incorporated herein by reference, the inventor provided an easy to install shaped insulation board with a separate two sided water drainage panel. The inventor has now developed the product further, and provides here an insulation board that in it self may act as two sided water drainage panel and simultaneously allows aeration between the board and the building surface.
According to one preferred embodiment the siding is fiber cement siding and the insulation also acts as an installation guide that aids in attaching fiber cement planks or boards that form the siding.
In a preferred embodiment, a rectangular insulating board made of a suitable thermal insulating material has a substantially flat, rectangular back surface including multiple drainage areas for water draining.
The substantially flat back surface of the insulation board has a plurality of molded drainage areas. The drainage areas consist of vertically positioned drainage grooves and ridges and the drainage areas are separated from each other by inner stud ridges that are designed to coincide with the building studs for attachment of the board. The inner stud ridges may also be designed to be higher than the drainage ridges, whereby the system leaves an aeration space between the drainage areas and building surface when the board is attached on the building studs.
The front surface has preferably one or more stud marking areas. The stud marking areas may contain vertically running stud marking grooves that may also act as water drainage channels but also enable easy lining of the boards plus guide attachment to the studs. The stud marking areas may contain other markings for attachment to the studs as well, such a nail spots, letters, numbers, or color codes.
The front surface may be shaped to form a number of flat-faced, protruding horizontal ridges. The protruding ridges are preferably aligned substantially parallel to an edge of the rectangle. A cross-section, taken orthogonal to the alignment of the protruding ridges, has a saw-tooth shape. The front side of the board also includes means to guide attachment to the building studs.
The protruding horizontal ridges are shaped and sized so that the following may be done. A standard-size, fiber cement plank, or board, may be placed face-down on a long face of a protruding ridge of the shaped insulating board. The fiber cement board may be positioned to have its long edge abutting the short face of an adjacent protruding ridge. A second fiber cement board of a similar size may then be placed face-down on a long face of the adjacent protruding ridge. When the second fiber cement board is positioned to have its long edge abut the short face of the next adjacent ridge, the second board may then overlap the first fiber cement board. The overlap is such that the underside face of the overlap of the second board lies flat on the upper face of the first board. The invention of this disclosure also comprises shaped flashing elements that are sandwiched between the insulation board and the fiber cement boards to provide water protection in areas where two insulation boards are abutting either horizontally or vertically. The shaped insulating board is aligned on the wall to a required orientation. The required orientation is preferably the orientation in which the protruding ridges are aligned in the same direction as the desired orientation of the length of the fiber cement board when it is attached.
An aspect of the instant invention in addition to provide a guidance system for installation of the cement boards is to provide an insulation board that allows efficient water drainage and aeration. Furthermore, the instant invention not only provides guidance for installing the cement boards, but provides guidance to easily align the drainage channels and to attach the insulating boards on the building studs.
Once the shaped insulating board is attached to the wall, it may then serve as a guide for positioning the fiber cement board. The fiber cement board may be positioned by abutting its long side against a short edge of one of the protruding ridges, with the fiber cement board's face against the long face of an adjacent protruding ridge. The fiber cement board is then correctly aligned and may be slid along the ridge edge until it is in place for attaching to the wall. The attachment may, for instance, be by means of a fastener such as, but not limited to, nails, screws, bolts or some combination thereof.
Therefore, the present invention succeeds in conferring the following, and others not mentioned, desirable and useful benefits and objectives.
It is an object of the present invention to provide a shaped insulating board for attachment on building studs, having a vertical cross section, a horizontal cross section, a front surface and a substantially flat back surface, wherein the back surface is forming a molded drainage panel, said drainage panel comprising a multitude of drainage areas, each drainage area being formed by vertical drainage ridges and drainage grooves, and each drainage area being separated from each other by an inner stud ridge, said vertical ridges and grooves running from an upper end of the back surface to a lower end of the back surface, and said stud ridges located from each other at distance such that a multiplication of the distance equals to the distance between building studs, whereby each building stud coincides with one stud ridge, and the front surface comprising markings for attachments on building studs, said markings coinciding with stud ridges on the back surface.
It is another object of the present invention to provide fiber cement siding system comprising:
a multitude of fiber cement boards; a shaped insulating board, having a vertical cross section, a horizontal cross section, a shaped front surface and a substantially flat back surface,
the front surface being formed of horizontally aligned ridges having a short face and a long face, the short face of one ridge being joined in an angle to the long face of an adjacent ridge, whereby the vertical cross section has a substantially saw tooth like edge toward the front surface and a flat edge toward the back surface, the front surface further comprising a plurality of stud marking areas, each stud marking area consisting of vertically oriented stud marking grooves running across the horizontally aligned ridges from an upper end of the front surface to a lower end of the front surface, said vertically oriented grooves being separated from each other by an outer stud ridge, and the stud marking areas being separated from each other by clearance ridges, said clearance ridges having a width equaling to a distance between building studs, the back surface having a molded drainage panel, said drainage panel comprising a multitude of drainage areas, each drainage area being formed by vertical drainage ridges and drainage grooves, and each drainage area being separated from each other by an inner stud ridge, said vertical ridges and grooves running from an upper end of the back surface to a lower end of the back surface, and said inner stud ridge coinciding with the outer stud ridge, whereby the horizontal cross section of the insulating board has non grooved stud ridge areas in between of grooved drainage areas, and said non grooved stud ridge areas locate from each other at distance equaling to the distance between building studs; and a multitude of flashing elements, said flashing elements consisting of a first rectangle having a short edge substantially equal in length to the width of the short face of the protruding ridge of the front surface of the shaped insulating board, a second rectangle having a long edge longer than the long face of the protruding ridge of the shaped insulating board, and a short edge having a length substantially equal to a long edge of the first rectangle, and wherein the long edge of the first rectangle forms a substantially contiguous join with the short edge of the second rectangle in an angle matching the angle of the joint of the short and the long face of adjacent protruding ridges of the front side of the shaped insulating board.
It is an object of the present invention to provide a thermal insulation including an efficient drainage system.
It is another object of the present invention to provide thermal insulation with drainage panels that allows proper aeration between the insulation and the building surface.
It is a further object of the present invention to provide a system to align the drainage channels of abutting insulation boards.
Another object of the present invention is to easily enable attachment of the insulation board onto the building studs.
It is an object of the present invention to provide additional thermal insulation to houses.
It is an object of the present invention to prevent water damage to building structures.
It is another object of the present invention to provide a tool for rapid positioning of fiber cement boards.
Yet another object of the present invention is to provide quicker, and therefore less expensive, installation of fiber cement siding.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 2 shows a vertical cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 3A shows a horizontal cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention.
FIG. 3B is an enlarged detail of the grooves and ridges on the cross section shown in FIG. 3A .
FIG. 4 A. shows an isometric view of the substantially flat back surface of one embodiment of the shaped insulating board of the present invention having a series of drainage areas separated by stud ridges. The vertical cross section in this embodiment is saw tooth like.
FIG. 4 B shows an isometric view of the substantially flat back surface of another embodiment of the shaped insulating board of the present invention having a series of drainage areas separated by stud ridges. The vertical cross section in this embodiment is not saw tooth like.
FIG. 5 shows an isometric view of a shaped flashing element of the present invention.
FIG. 6 shows an isometric view of shaped flashing elements placed to cover a horizontal gap between two adjacent shaped insulating boards.
FIG. 7 shows an isometric view of shaped flashing elements sandwiched between fiber cement boards and shaped insulating board and covering a vertical gap between two adjacent shaped insulating boards.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
Reference will now be made in detail to embodiments of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
FIG. 1 shows an isometric view of a preferred embodiment of a shaped insulating board of the present invention. FIG. 1 shows the shaped insulating board 100 , the front surface 155 , the upper end of the front surface 156 , the lower end of the front surface 157 , the back surface 200 , the upper end of the back surface 202 , the lower end of the back surface 204 , protruding ridges of the front surface 150 , vertical stud marking areas 190 , the front surface, stud marking grooves 192 , clearance ridge 196 between the stud marking areas, outer stud ridge 195 separating the stud marking grooves 192 , and markings for attachment 198 on the outer stud ridges.
FIG. 2 shows a vertical cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention. The figure shows the shaped insulating board 100 , the front surface 155 , the back surface 200 , and the saw-tooth shaped vertical cross section 160 . The long face of protruding ridges 185 and the short face of the protruding ridges are also shown.
FIG. 3 A shows a horizontal cross-sectional view of a preferred embodiment of a shaped insulating board of the present invention. The figure shows the building studs 125 , the building surface 105 , the horizontal cross section 170 , the back surface 200 , the front surface 155 , the stud marking grooves 192 , the outer stud ridge 195 , the clearance ridges 196 between the stud marking areas, the drainage areas 300 , the inner stud ridges 305 , the drainage grooves 310 , and the drainage ridges 320 .
FIG. 3B shows an enlarged detail of the horizontal cross-section of the shaped insulating board of FIG. 3A . The figure shows the back surface 200 , the front surface 155 , the stud marking grooves 192 , the inner stud ridge 195 , the clearance ridge 196 , drainage groove 310 , drainage ridge 320 and inner stud ridge 305 .
FIG. 4 A shows an isometric view of the back surface with stud markings according to one embodiment. The figure shows the back surface 200 , the vertical saw tooth like cross section 160 , the horizontal cross section 170 , the drainage areas 300 , the drainage grooves 310 , the drainage ridges 320 and the inner stud ridges 305 .
FIG. 4 B shows an isometric view of the back surface with stud markings of another embodiment where the front side does not have the protruding ridges and accordingly the vertical cross section is not saw tooth like. The figure shows the back surface 200 , the vertical cross section 160 , the horizontal cross section 170 , the drainage areas 300 , the drainage grooves 310 , the drainage ridges 320 , an optional diagonal groove 303 , and the inner stud ridges 305 .
FIG. 5 shows an isometric view of a shaped flashing element of the present invention. The figure show the flashing element 420 , the first rectangle 440 , the second rectangle 450 , the long edge of the second rectangle 455 , the short end of the second rectangle 460 , the short end of the first rectangle 442 , and the long end of the first rectangle 445 .
FIG. 6 shows the shaped flashing elements placed to cover a horizontal gap between two adjacent shaped insulating boards. The figure shows the horizontal gap 500 between the boards, the flashing element 420 , the first rectangle 440 , the second rectangle 450 , the short end of the first rectangle 442 , the long end of the first rectangle 445 , the long end of the second rectangle 455 , the short end of the second rectangle 460 , the protruding ridges of the front surface 150 , the long face of protruding ridges 185 , and the short face of protruding ridges 180 .
FIG. 7 shows the flashing elements sandwiched between fiber cement boards 110 and shaped insulating board 100 and covering a vertical gap 550 between two adjacent shaped insulating board. The figure shows the vertical gap 550 , fiber cement boards 110 , flashing element 420 , the first rectangle 440 , the second rectangle 450 , the long end of the first rectangle 445 , the short end of the first rectangle 442 , the long end of the second rectangle 455 , the short end of the second rectangle 460 , the protruding ridges of the front surface 150 , the long face of protruding ridges 185 , and the short face of protruding ridges 180 .
Now referring to FIGS. 1 and 2 , the shaped insulating board 100 has a rectangular, substantially flat back surface 200 . In one preferred embodiment the vertical cross section 160 is saw tooth-like and on the front surface 155 , the shaped insulating board 100 is shaped to have a series of substantially identical, flat-faced protruding ridges 150 . The size and shape of these protruding ridges 150 is largely defined by the dimensions of the standard fiber cement boards 110 typically used for exterior wall siding, for instance, on domestic houses. Further, the front surface 155 of the shaped insulating board 100 has vertical stud marking areas 190 . A stud marking area 190 consists preferably of two vertically running stud marking grooves 192 separated by an outer stud ridge 195 . Alternatively, only one stud marking groove 192 may be used. It is also possible to have more than two stud marking grooves. A skilled artisan would understand that it is in the spirit of this invention to have an insulating board where the front surface does not have the protruding ridges 150 but only the stud marking areas (shown in FIG. 4B ). Such a board would be practical to use for example with vinyl- or wood sidings. The width of the outer stud ridges 195 when measured from the middle of one stud marking groove 192 to middle of the second stud marking groove 192 , is determined by the width of the building studs 125 and is between 1 and 4 inches, preferably between 1 and 2 inches, and most preferably 1.5″ (3.81 cm), but the width may also be larger or smaller. The stud marking areas 190 are separated by clearance ridges 196 . The width of the clearance ridge 196 is determined by the distance between building studs 125 . The standard distance between building studs is 16 or 24 inches (40.64 or 60.96 cm) from stud center to stud center. Accordingly, in the preferred embodiment the width is such that a multiplication of the width would equal with the distance between building studs. In a most preferred embodiment the with of the clearance ridges 196 is 2, 4, 8, 16, or 24 inches, whereby there is always one stud ridge 195 coinciding with each building stud 125 and therefore guide installation of the shaped insulating board 100 . One skilled in the art would appreciate that it is within the scope of this invention to vary the width of the clearance ridges long as there is one stud ridge 195 coinciding with each building stud 125 . According to a preferred embodiment the width of the clearance ridges is 16 inches for buildings where the distance between studs is 16 inches, and 24 inches where the distance between the studs is 24 inches. The stud marking areas 190 of the instant invention also helps aligning horizontally abutting insulation boards so that drainage areas and drainage grooves on the back side of the boards are aligned. Furthermore the stud marking areas 190 enable to position the insulation boards 100 so that they are easy to attach with nails or other means to the studs 125 . According to one preferred embodiment, the outer stud ridges 195 have markings for the attachment 198 . In the embodiments where the width of the clearance area is smaller than the distance between the studs, the markings for attachment 198 are so designed that they locate only on those stud ridges that are to be attached to the studs. The markings may be, but are not limited to spots, lines, crosses, colored areas or other codes. According to one embodiment the front of the board may have letters or numbers and certain numbers or letters serve as markings for attachment 198 . Certain codes may guide attachment to studs that are 16 inches apart from each other, while other codes may guide attachment to studs 24 inches apart from each other. According to one embodiment the codes may be letters which may be part of advertisement or other information.
Now referring to FIGS. 4 A and B, the back surface 200 of the shaped insulating board has several drainage areas 300 , each drainage area comprising several vertical drainage grooves 310 separated by drainage ridges 320 . The drainage areas 300 are separated from each other by inner stud ridges 305 . FIG. 4 A shows an embodiment where the front surface has the protruding ridges whereby the vertical cross section 160 is saw tooth like. FIG. 4 B shows another embodiment where the front surface does not have the protruding ridges and the vertical cross section 160 accordingly does not have the saw tooth like character. FIG. 4B also shows a diagonal groove 303 . According to one embodiment the inner stud ridge 305 may contain one or more diagonal grooves 303 connecting the drainage areas.
Referring now to FIGS. 3A and 3B , the inner stud ridges 305 preferably coincide in location with the outer stud ridges 195 , thereby the inner stud ridge and the corresponding outer stud ridge form a non grooved stud area 302 and the non grooved stud areas coincide with the location of the building studs 125 . When the shaped insulating boards are attached to the building they can be easily attached along the non grooved stud areas 302 to the studs 125 for example with nails, screws or other similar means. As is shown in FIG. 3B , which shows the stud area 302 in details, it can be seen that the inner stud ridge 305 is preferably higher than the drainage ridges 320 . This feature would allow an air space between the building surface 105 and the installed shaped insulating board 100 , because the lower height of drainage ridges 320 would not allow them to touch the building surface 105 when the higher inner stud ridges 305 is aligned along and attached to the building studs 125 . According to a preferred embodiment the height a drainage ridge 320 when measured from the bottom of adjacent drainage groove 310 to the top of the inner drainage ridge 320 is between 1/16 and ¼ inches, more preferably about ⅛ inches and most preferably ⅛ inches (3.18 mm). An inner stud ridge 305 may be 1/16 to ¼ inches higher than the drainage ridge, but preferably is 1/16 inches higher than the drainage ridge 320 . Accordingly, preferably when the height of an inner drainage ridge 320 is measured from the bottom of a drainage grove 310 to the top of the inner drainage ridge 320 , it would be 3/16 inches (4.76 mm) high, and the air space between the building surface 105 and the shaped insulating board 100 would be approximately 1/16 inches (1.18 mm). It is understood by a skilled artisan that the measures may be changed without departing the spirit of the invention.
According to one embodiment the board may contain one or more diagonally positioned grooves 303 across the inner stud ridge. Such diagonal grooves may connect the drainage grooves that locale on both sides of the inner stud ridge. Such an embodiment would provide improved water drainage.
The cross section of the stud marking grooves 192 and the drainage grooves 310 is preferably V-shaped, but it can also be U-shaped, or partially square shaped.
The shaped insulating board 100 may be made from any suitable thermal insulation that is also sufficiently rigid to support standard-sized fiber cement boards 110 during installation.
Suitable materials are insulation such as, but not limited to, polyolefin, polyethylene terephithalate, polyester, alkenyl aromatic polymer, polystyrenic resin and polystyrene, or some combination thereof. Preferably the insulation board is made of polystyrene foam. The board may be up to 2″ (5.08 cm) thick. The size of the boards may vary. According to one preferred embodiment the board is about 4×4 feet (121×121 cm), but any other feasible size is within the scope of the invention.
The shaped insulating board 100 with the optional flat faced protruding ridges, stud markings and drainage areas is preferably shaped by using molding techniques but may be shaped by any method suitable to the material used including hot wire forming techniques such as, but not limited to preformed wire manufacture.
Now referring to FIGS. 5 , 6 and 7 , the instant invention comprises a shaped flashing element 420 to waterproof the horizontal 500 and vertical 550 gaps that are between adjacent shaped insulating boards 100 . According to a preferred embodiment the shaped flashing element 420 is made of coated aluminum, but instead of aluminum other malleable materials such as copper, bronze, tin, or steel may also be used. The flashing element may also be made of plastic or polyethene. Preferably the flashing element is made of aluminum coated with an anticorrosion coating from both sides to avoid corrosion caused by the fiber cement. The shaped flashing element 420 may, for instance, be made by a process such as, but not limited to, molding, machining, bending or some combination thereof.
FIG. 5 illustrates the flashing element according to a preferred embodiment. The flashing element 420 has a first rectangle 440 and a second rectangle 450 . The first rectangle 440 has a short edge 442 substantially equal in length to the width of the short face 180 of the protruding ridge 150 . The second rectangle 450 has a long edge 455 . The long edge 455 may be substantially equal in length to the width of the long face 185 of the protruding ridge 150 of the shaped insulating board 100 , but according to a preferred embodiment the long edge 455 is longer than the width of the long face 185 . According to a most preferred embodiment the long edge 455 is substantially equal in length to the width of the cement board 110 . The short edge of the second rectangle 460 has a length substantially equal to the long edge of first rectangle 440 . The long edge of the first rectangle 442 forms a substantially contiguous join with the short edge of the second rectangle 450 in an angle that matches the angle between adjacent protruding ridges 150 of the shaped insulating board 100 .
FIG. 6 shows an isometric view of shaped flashing elements 420 placed to cover a horizontal gap 500 between two adjacent shaped insulating boards 100 . FIG. 7 shows an isometric view of shaped flashing elements 420 placed to cover a vertical gap 550 between adjacent shaped insulation boards 100 . As shown in FIGS. 6 and 7 , the next step after attaching the shaped insulation board 100 on the building surface is a sandwich flashing elements between the insulation board 100 and the fiber cement boards 110 to cover horizontal 500 or vertical 550 gaps between two adjacent insulation boards 100 . Once the fiber cement boards 110 are secured, the shaped flashing element 420 is held in place without any fastening elements. An advantage in this is to save material and on the other hand to save the flashing elements from any holes that would be created by nails or pins or other fastening means.
In a preferred embodiment, the shaped flashing element 420 may have a width in a range of 0.5 to 12 inches (1.27 cm to 30.48 cm) and a thickness in a range of less than 0.5 inches (1.28 cm). More preferably, the shaped flashing element 420 may have a width in a range of 1 to 3 inches (2.54 to 7.62 cm) and a thickness in a range of less than 0.125 inches (3.18 mm). According to a preferred embodiment the long edge of the second rectangle 455 is preferably between 5 and 8 inches (12.70 to 20.32 cm), but the length primarily depends on the width of the fiber cement planks.
According to one embodiment of this invention, a water proof sheet may be attached on the building surface 105 before attaching the shaped insulating boards 100 . Such water proof sheet may be made of any suitable waterproof or water-resistant for creating a vapor barrier such as, but not limited to, aluminum foil, paper-backed aluminum, polyethylene plastic sheet, a metalized film, or some combination thereof.
Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention. | A shaped insulating board is disclosed for enabling lining of fiber cement boards and simultaneously enabling attachment of the insulating board on the building studs. Furthermore, the shaped insulating board provides a water drainage panel that allows water to drain downward on both sides of the board. The shaped insulating board also provides aeration between the board and the building surface. | 4 |
REFERENCE TO RELATED APPLICATION
[0001] The present application claims the priority to U.S. Provisional Application Ser. No. 62/162,139, filed May 15, 2015, which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to recombinant baculoviruses.
BACKGROUND OF THE INVENTION
[0003] Baculovirus infects insects and is non-pathogenic to humans, but can transduce a broad range of mammalian and avian cells. Thanks to the biosatety, large cloning capacity, low cytotoxicity and non-replication nature in the transduced cells as well as the ease of manipulation and production, baculovirus has gained explosive popularity as a gene delivery vector for a wide variety of applications such as antiviral therapy, cancer therapy, regenerative medicine and vaccine.
[0004] U.S. Pat. No. 7,527,967 discloses a recombinant baculovirus that displays a fusion heterologous polypeptide on the surface of the baculovirus for use in generating an antibod or an immune resposne against a heterologous protein or virus in a subject in ineed thereof. The fusion heterologous polypeptides therein is made by fusing a heterologus antigen with the carboxyl terminal amino acids from 227 to 529 of baculovirus GP64 protein ( FIG. 2C ). The construct therein contains a substantial portion of the extracellular domain of GP64 including B12D5 binding site. When it is used in immunization, the extracellular domain of GP64 may elicit an immune resposne and produce unintended antibodies such as useless anti-GP64 B12D5 antibody (Zhou et al. Virology 2006; 352(2); 427-437). GP64 B12D5 antibody is a neutralization antibody against baculovirus itself instead of a foreign antigen of interest. In addition, baculovirus is slightly immunogenic to porcine.
[0005] Taiwanese Patent No. 1368656 discloses a method of using the signal peptide, transmembrane domain and the cytoplasmic transduction domain from GP64 to present an antigen. The construct therein contains only the transmembrane domain and cytoplasmic trunsduction domain without the extracellular domain of GP64 ( FIG. 2D ). It has less expression of foreign antigen and is sensitive to inactivation reagents (Premanand et al. PLoS ONE 2013; 8(2): e55536).
[0006] Therefore, a heretofore unaddressed need exists in the art to address the aforementioned deficiencies and inadequacies, especially in connection with a baculovirus vector that is insensitive to inactivation reagent and has improved immunogenicity.
SUMMARY OF THE INVENTION
[0007] In one aspect, the invention relates to a vector comprising a transgene encoding a fusion protein, the fusion protein comprising: (a) a signal peptide located at the N-terminus of the fusion protein; (h) a heterologous antigen; and (c) a C-terminal region of baculovirus envelope GP64 protein, having at least 100 amino acid residues in length and lacking a B12D5 binding epitope located within the central basic region of the GP64 protein; wherein the heterologous antigen is located between the signal peptide and the C-terminal region of the GP64 protein.
[0008] In one embodiment of the invention, the vector of the invention is a recombinant baculovirus.
[0009] In another aspect, the invention relates to a recombinant baculovirus displaying on its envelop a fusion protein, the fusion protein comprising: (i) a heterologous antigen; and (ii) a C-terminal region of baculovirus envelope GP64 protein, having at least 100 amino acid residues in length and lacking a B12D5 binding epitope located within the central basic region of the GP64 protein.
[0010] In one embodiment of the invention, the genome of the recombinant baculovirus comprises a transgene encoding a fusion protein comprising: (a) a signal peptide; (b) the heterologous antigen; and (c) the C-terminal region of the baculovirus envelope GP64 protein wherein the antigen is located between the signal peptide and the C-terminal region of the GP64 protein.
[0011] In another embodiment of the invention, the transgene is operably linked to a promoter.
[0012] In another embodiment of the invention, the promoter is polyhedrin.
[0013] In another embodiment of the invention, the C-terminal region of the GP64 protein has from 186 to 220 amino acids in length.
[0014] In another embodiment of the invention, the C-terminal region of the GP64 protein lacks the amino acid sequence of SEQ ID NO: 2, 3, or 4.
[0015] In another embodiment of the invention, the C-terminal region of the GP64 protein comprises the amino acids from 293 to 512 of SEQ ID NO: 1.
[0016] In another embodiment of the invention, the C-terminal region of the GP64 protein comprises amino acids from 327 to 512 of SEQ ID NO: 1.
[0017] In another embodiment of the invention, the C-terminal region of the GP64 protein has an N-terminus between amino acid residues 292 and 328 of SEQ ID NO: 1.
[0018] In another embodiment of the invention, the signal peptide comprises an amino acid sequence selected from the group consisting of SEQ ID NOs: 5, 6, 7, 8, 9, 10, 11, and 12.
[0019] Further in another aspect, the invention relates to an insect cell or a cell transduced with the vector or the recombinant baculovirus of the invention.
[0020] In another embodiment of the invention, the antigen is at least one selected from the group consisting of a pathogen protein, a cancer cell protein, and an immune checkpoint protein.
[0021] The pathogen may be at least one selected from the group consisting of human papillomavirus, porcine reproductive and respiratory syndrome virus, human immunodeficiency virus-1. Dengue virus, hepatitis C virus, hepatitis B virus, porcine circovirus 2, classical swine lever virus, foot-and-mouth disease virus. Newcastle disease virus, transmissible gastroenteritis virus, porcine epidemic diarrhea virus, influenza virus, pseudorabies virus, parvovirus, swine vesicular disease virus, poxvirus, rotavirus, Mycoplasma pneumonia, herpes virus, infectious bronchitis, infectious bursal disease virus. The cancer may be at least One selected from the group consisting of non-small cell lung cancer, breast carcinoma, melanoma, lymphomas, colon carcinoma, hepatocellular carcinoma, and any combination thereof. The immune cheek point may be at least one selected from the group consisting of PD-1, PD-L1, PD-L2, and CTLA-4.
[0022] In another embodiment of the invention, the antigen is at least one selected from the group consisting of classical swine fever virus envelope glycoprotein E2, porcine epidemic diarrhea virus S1 protein, programmed cell death protein 1, and a tumor-associated antigen.
[0023] Yet in another aspect, the invention relates to a method for eliciting an antigen-specific immunogenic response in a subject in need thereof, comprising administering to the subject in need thereof a therapeutically effective amount of the vector or the recombinant baculovirus of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1A is a schematic drawing illustrating a baculovirus vector platform design according to one embodiment of the invention.
[0025] FIG. 1B is a schematic drawing illustrating a foreign antigen or foreign genes not only can be anchored onto the virus envelope but also expressed in the membrane fraction of insect cells by a gBac surface display platform. The rectangle represents a virus.
[0026] FIG. 2A is a schematic drawing showing a full-length GP64 protein. GP64 minimum (GP64 327-482 ), GP64 transmembrane domain (TM) (GP64 483-505 ); cytoplasmic transduction domain (CTD) (GP64 506-512 ).
[0027] FIG. 2B is a schematic drawing showing a baculovirus vector according to one embodiment of the invention. SP: signal peptide; TM: transmembrane domain, CTD: cytoplasmic transduction domain.
[0028] FIG. 2C is a schematic drawing showing a baculovirus vector design disclosed in U.S. Pat. No. 7,527,967.
[0029] FIG. 2D is a schematic drawing showing a baculovirus vector design disclosed in Taiwan Patent No. 1368656.
[0030] FIG. 3 is a graph showing an immune response induced by baculovirus vectors in mice post vaccination (left panel) and neutralization serum (SN) titer measurement of E2-gBac subunit vaccine (right panel) in mice. Each ELISA value shown is an average value from 5 mice. The difference between the gBac and Bac groups is statistically significant. P≦0.05. The strain of baculovirus used was AcNPV. The term “SN” stands for neutralization serum. The term “E2-gBac” stands for “baculovirus vector CSFV E2-gBac” according to the vector design of FIG. 2B . The term “E2-gBac (inactivated)” means the baculovirus was inactivated before it was used for immunization. The term “E2-Bac” stands for “baculovirus vector CSFV E2-Bac” according to the vector design of FIG. 2D .
[0031] FIG. 4 is a graph showing an immune response induced by baculovirus vectors in pigs post vaccination. Each ELISA value shown is an average value from 3 pigs. The difference between the gBac and gp64 groups is statistically significant. P≦0.05. The term “E2-gp64” stands for “baculovirus vector CSFV E2-gp64” according to the vector design of FIG. 2C .
[0032] FIG. 5 is a graph showing antibody titers against porcine epidemic diarrhea virus (PEDV) in 3 specific pathogen-free (SPF) pigs post vaccination with the baculovirus vector PEDV S1-gBac. The 3 SPF pigs were labeled as number 73, 74 and 75, respectively. The tem “IFA” stands for immunofluorescent antibody. The results indicated that the serum from the vaccinated pigs could be recognized by PED virus.
[0033] FIGS. 6A-B are photographs of western blot showing that the antigens E2 of CSFV E2-gBac ( FIG. 6A ) and S1 of PEDV S1-gBac ( FIG. 6B ) from the Sf9 cell samples were detected.
[0034] FIGS. 6C-D are photographs of western blot showing that the antigens of hPD-1-gBac in the samples were recognized and detected by anti-gp64 mAb (left panel) and human PD-1 antibody (right panel), respectively.
DETAILED DESCRIPTION OF THE INVENTION
[0035] 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. Various embodiments of the invention are now described in detail. Referring to the drawings, like numbers indicate like components throughout the views. As used in the description herein and throughout the claims that follow, the meaning of “a”, “an”, and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. Moreover, titles or subtitles may be used in the specification for the convenience of a reader, which shall have no influence on the scope of the present invention. Additionally, some terms used in this specification are more specifically defined below.
DEFINITIONS
[0036] The terms used in this specification generally have their ordinary meanings in the art, within the context of the invention, and in the specific context where each term is used. Certain terms that are used to describe the invention are discussed below, or elsewhere in the specification, to provide additional guidance to the practitioner regarding the description of the invention. For convenience, certain terms may be highlighted, for example using italics and/or quotation marks. The use of highlighting has no influence on the scope and meaning of a term the scope and meaning of a term is the same, in the same context, whether or not it is highlighted. It will be appreciated that same thing can be said in more than one way. Consequently, alternative language and synonyms may be used for any one or more of the terms discussed herein, nor is any special significance to be placed upon whether or not a term is elaborated or discussed herein. Synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and in no way limits the scope and meaning of the invention or of any exemplified term. Likewise, the invention is not limited to various embodiments given in this specification.
[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In the case of conflict, the present document, including definitions will control.
[0038] A vector is a vehicle used to transfer genetic material to a target cell. A viral vector is a virus modified to deliver foreign genetic material into a cell.
[0039] The term “gene transduction”, “transduce”, or “transduction” is a process by which a foreign DNA is introduced into another cell via a viral vector.
[0040] A signal sequence or signal peptide (sometimes referred to as signal sequence, targeting signal, localization signal, localization sequence, transit peptide, leader sequence or leader peptide) is a short (5-30 amino acids long) peptide present at the N-terminus of the majority of newly synthesized proteins that are destined towards the secretory pathway. These proteins include those that reside either inside certain organelles (the endoplasmic reticulum, golgi or endosomes), secreted from the cell, or inserted, into most cellular membranes.
[0041] The term “B12D5” refers to a monoclonal antibody against gp64. B12D5 has a binding epitope of KKRPPTWRHNV (SEQ ID NO: 3) at 277-287 of gp64, or HRVKKRPPTW (SEQ ID NO: 2) located within the central region of gp64 from residues 271 to 292 (SEQ ID NO: 4). See Zhou et al. (2006) Supra; Wu et al (2012) “A pH-Sensitive Heparin-Binding Sequence from Baculovirus gp64 Protein Is Important for Binding to Mammalian Cells but Not to Sf9 Insect Cells” Journal of Virology. Vol. 86 (1) 484-491.
[0042] Programmed cell death protein 1, also known as PD-1 and CD279 (cluster of differentiation 279), is a protein that in humans is encoded by the PDCD1 gene. PD-1 is a cell surface receptor that belongs to the immunoglobulin superfamily and is expressed on T cells and pro-B cells. PD-1 binds two ligands. PD-L1 and PD-L2. PD-1, functioning as an immune checkpoint, plays an important role in down regulating the immune system by preventing the activation of T-cells, which in turn reduces autoimmunity and promotes self-tolerance. The inhibitory effect of PD-1 is accomplished through a dual mechanism of promoting apoptosis (programmed cell death) in antigen specific T-cells in lymph nodes while simultaneously reducing apoptosis in regulatory T cells (suppressor T cells). A new class of drugs that block PD-1, the PD-1 inhibitors, activate the immune system to attack tumors and are therefore used with varying success to treat some types of cancer.
[0043] An antigen may be a pathogenic protein, polypeptide or peptide that is responsible for a disease caused by the pathogen, or is capable of inducing an immunological response in a host infected by the pathogen, or tumor-associated antigen (TAA) which is a polypeptide specifically expressed in tumor cells. The antigen may be selected from a pathogen or cancer cells including, but not limited to, Human Papillomavirus (HPV), Porcine reproductive and respiratory syndrome virus (PRRSV), Human immunodeficiency virus-1(HIV-1), Dengue virus, Hepatitis C virus (HCV), Hepatitis B virus (HBV), Porcine Circovirus 2 (PCV2), Classical Swine Fever Virus (CSFV), Foot-and-mouth disease virus (FMDV), Newcastle disease virus (NDV), Transmissible gastroenteritis virus (TGEV). Porcine epidemic diarrhea virus (PEDV). Influenza virus, Pseudorabies virus, Parvovirus, Pseudorabies virus, Swine vesicular disease virus (SVDV), Poxvirus, Rotavirus, Mycoplasma pneumonia, Herpes virus, infectious bronchitis, or infectious bursal disease virus, non-small cell lung cancer, breast carcinoma, melanoma, lymphomas, colon carcinoma, hepatocellular carcinoma and any combination thereof. For example, HPV E7 protein (E7), HCV core protein (HCV core), HBV X protein (HBx) were selected as antigens for vaccine development. The antigen may be a fusion antigen from a fusion of two or more antigens selected from one or more pathogenic proteins. For example, a fusion antigen of PRRSV ORF6 and ORF5 fragments, or a fusion of antigens from PRRSV and PCV2 pathogens.
[0044] Alternatively, an antigen may be an inhibitory immune checkpoint protein such as PD-1, PD-L1, PD-L2, and CTLA-4, etc.
[0045] The terms “immune checkpoint protein” and “Immune checkpoint” are interchangeable. Immune checkpoints affect immune system functioning. Immune checkpoints can be stimulatory or inhibitory. Tumors can use these checkpoints to protect themselves from immune system attacks. Checkpoint therapy can block inhibitory checkpoints, restoring immune system function. One ligand-receptor interaction under investigation is the interaction between the transmembrane programmed cell death 1 protein (PDCD1, PD-1; also known as CD279) and its ligand, PD-1 ligand 1 (PD-L1, CD274). PD-L1 on the cell surface binds to PD1 on an immune cell surface, which inhibits immune cell activity. Among PD-L1 functions is a key regulatory role on T cell activities. It appears that (cancer-mediated) upregulation of PD-L1 on the cell surface may inhibit T cells that might otherwise attack. Antibodies that bind to either PD-1 or PD-L1 and therefore block the interaction may allow the T-cells to attack the tumor. Ipilimumab is the first checkpoint antibody approved by the FDA. It blocks inhibitory immune checkpoint CTLA-4.
[0046] The term “treating” or “treatment” refers to administration of an effective amount of the fusion protein to a subject in need thereof, who has cancer or infection, or a symptom or predisposition toward such a disease, with the purpose of cure, alleviate, relieve, remedy, ameliorate, or prevent the disease, the symptoms of it, or the predisposition towards it. Such a subject can be identified by a health care professional based on results from any suitable diagnostic method.
[0047] The term “an effective amount” refers to the amount of an active compound that is required to confer a therapeutic effect on the treated subject. Effective doses will vary, as recognized by those skilled in the art, depending on rout of administration, excipient usage, and the possibility of co-usage with other therapeutic treatment.
EXAMPLES
[0048] Without intent to limit the scope of the invention, exemplary instruments, apparatus, methods and their related results according to the embodiments of the present invention are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the invention. Moreover, certain theories are proposed and disclosed herein; however, in no way they, whether they are right or wrong, should limit the scope of the invention so long as the invention is practiced according to the invention without regard for any particular theory or scheme of action.
Example 1
Construction of Vectors and Generation of Recombinant Baculoviruses, Virus-Like Particles, and Proteins
[0049] FIG. 1A shows a gBac platform. A foreign gene (e.g., optimized classical swine fever virus (CSFV) E2 or porcine epidemic diarrhea virus (PEDV) spike genes) may be obtained by PCR synthesis and then cloned into a gBac vector through restriction enzyme sites (e.g., SacI/NotI) using IN-FUSION® cloning kit (Clontech). The gBac vector is derived from baculovirus transfer vector pBACPAK™ (GENBANK™ accession No. U02446). Using the gBac surface display platform of FIG. 1A , a foreign antigen or foreign genes can be anchored onto the virus envelope and also expressed in the membrane fraction of insect cells ( FIG. 1B ).
[0050] FIG. 2A shows a full-length GP64. The baculovirus GP64 envelope fusion protein (GP64 EFP) is the major envelope fusion glycoprotein in some, though not all, baculoviruses. It is found on the surface of both infected cells and budded virions as a homotrimer. Baculovirus enters its host cells by endocytosis followed by a low-pH-induced fusion of the viral envelope with the endosomal membrane, allowing viral entrance into the cell cytoplasm. This membrane fusion, and also the efficient budding of virions from the infected cell, is dependent on GP64.
[0051] FIGS. 2B-D show comparisons of three vectors, gBac (or Reber-gBac), antigen-gp64 (or abbreviated as “gp64” disclosed in U.S. Pat. No. 7,527,967), and Antigen-Bac (or abbreviated as “Bac” disclosed in TW 1368656). The gBac vector was constructed using the signal peptide (SP) and a C-terminal region of GP64 from amino acids 327 to 513. The gp64 vector was constructed using the SP and a C-terminal region of GP64 from amino acids 227 to 513. The Bac vector comprises the insect signal peptide (SP), the TM (transmembrane domain) and CTD (cytoplasmic transduction domain) of GP64 and does not comprise the GP64 extracellular domain amino acids. The symbol triangle before the “SP” represents the polyhedrin promoter, which is located-1 site of the insert gene's start codon.
[0052] A DNA fragment encoding the SP was generated and amplified by PCR with forward and reverse pirmers 5′-GAGCTCATGGTAAGC-3′ (SEQE ID NO: 19) and 5′-AGGCACIAATGCG-3′ (SEQ ID NO: 20), respectively. The C-terminal portion of the gp64 gene (encoding GP64 from aa 327 to aa 513) was generated and amplified by PCR using the forward and reverse pirmers 5′-GCGTGTCTGCTCA-3′ (SEQ ID NO: 21) and 5′-TIAATATTGTCTA-3′ (SEQ ID NO: 22), respectively. The C-terminal portion of the gp64 gene (encoding GP64 from as 227 to as 513 was generated and amplified by PCR using the forward and reverse pirmers 5′-ATCAACAAGCTAA-3′ (SEQ ID NO: 23) and 5′-TTAATATTGTCTA-3′ (SEQ ID NO: 24), respectively. The above foreign genes were resepctively cloned into the pBACPAK8™ transfer vector.
[0053] Using the gBac platform of 2B (or FIG. 1A ), we generated two baculovirus vectors: the baculovirus vector CSFV E2-gBac and the baculovirus vector PEDV S1-gBac ( FIG. 2B design). The former transduces a gene encoding classical swine fever virus (CSFV) envelope glycoprotein E2, and the latter transduces a gene encoding porcine epidemic diarrhea virus S1 Protein.
[0054] For a parallel comparison, we have also used the vectors of FIGS. 2C and 2D and generated two separate baculovirus vectors: the baculovirus vector CSFV E2-gp64 ( FIG. 2C design), and the baculovirus vector CSFV E2-Bac ( FIG. 2D design) for transducing a foreign gene encoding the antigen CSFV E2.
[0055] The fusion genes in the gBac, gp64, and Bac vectors ( FIGS. 2B-D designs, respectively) were sequenced to confirm their identities. Recombinant baculovirus viruses containing the recombinant GP64 gene without the transfer vector backbone were generated by homologous recombination. Methods for this construction and recombination are well known in the art. These recombinant viruses were used to prepare antigens. The modified GP64 gene was inserted into a baculovirus transfer vector under the polyhedron promoter by PCR to form the gBac vector. Because the gBac vector has two homologous recombination sites, the original polyhedron locus of wild-type baculovirus is replaced by gBac sequence when co-transfection with gBac plasmid and wild-type baculovirus.
Example 2
Protein Expression and Purification of Antigens
[0056] Sf9 cells were used for propagaton and infection of recombiant baculovirus. Baculovirus was propagated in Spodoptera frugiperda Sf-9 cell lines and grown at 26° C. in a serum-free medium. The recombinant baculoviruses were produced by infecting Sf-9 cells at an MOI of 5-10 and harvested 3 days after infection. To produce baculovirus on a large scale, the cells may be cultured and infected in bioreactors. The baculovirus fraction were isolated from the culture supernatant of the infected cell. The baculovirus particles were collected by Tangential Flow Filtration (TFF) using a suitable protein cut-off membrane and 0.45 μm sterile membrane.
[0057] To test the production of the antigens, the partially purified baculoviruses or infected cell lysates were subjected to 8-10% sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) and transferred to nitrocellulose membranes. The foreign antigens were detected by mouse anti-gp64 mAb (available from commercial sources and used at 1:5,000 dilution) as the primary antibody. The secondary antibodies were goat anti-rabbit or goat anti-mouse mAb conjugated with alkaline phosphatase (1:5,000 dilution). The protein hands were visualized by ECL PLUS™ Western Blotting Detection Reagents (GE Healthcare). In the baculovirus surface display system, the forein antigens can be firstly expressed on insect cell membrane, then the budding baculovirus take some of cell membrane to form its envelope. As the result, baculovirus display antigens can be harvested from infected cell lysate (mambrane fraction) and virus surface.
Example 3
Expression of the Antigens by Recombinant Viruses
[0058] Before immunization with gBac vaccines, to confirm whether the fusion protein CSFV E2-gBac or PEDV S1-gBac were successfully displayed on the baculovirus envelope, recombinant baculoviruses were collected by centrifugation and TFF. The recombinant baculoviruses were re-suspended in PBS at different concentrations of p.f.u/μl. Incorporation of recombinant proteins into the baculovirus particles were analyzed by Western blotting using anti-gp64 mAb (eBioscience). The fusion protein CSFV E2-gBac was detected at a molecular weight of about 80 kDa and the fusion protein PEDV S1-gBac was detected at a molecular weight of 130 kDa.
Example 4
Vaccine Preparation and Immunization
[0059] The recombinant baculoviruses displaying antigens were mixed with water-in-oil-in-water (w/o/w) adjuvant (MONTANIDE ISA 206 VG, SEPPIC.) for vaccine preparation. Female BALB/c mice of 4-week old, purchased from National Experimental Animal Center, Taiwan, R.O.C., were divided into four groups with 5 mice per group. Mice were immunized subcutaneously twice on day 0 and day-14 ( FIG. 3 ) with 200 μl of a solution containing with 10 7 p.f.u. recombinant baculovirus. The virus of E2-gBac, E2-gp64, and E2-Bac, ( FIGS. 2B-D ), containing CSFV envelope glycoprotein E2, were inactivated and formulated as vaccines. As negative controls, mice were injected with wild type baculovirus (10 7 p.f.u.) or PBS. The blood samples were collected from the caudal vein at week 6. Binary ethylenimine. (BEI) was used to inactivate baculoviruses. It was prepared by dissolving the 0.1 M 2-bromoethylamine hydrobromide (BEA) in 0.2 N NaOH at 37° C. for 1 h. To inactivate the baculovirus, the viral medium was added 4 mM BEI and virus incubated for 16 h at 37° C. After inactivation, sodium thiosulfate (Na 2 S 2 O 3 ) was added to the medium at a final concentration of 10 times the final BEI concentration to stop the inactivation.
Example 5
Immunogenicity of Antigens Produced by Recombinant Viruses
[0060] After immunization, the sera of mice were analyzed for the presence of anti-CSFV E2 antibody using the IDEXX CSFV Ab Test Kit (IDEXX) to detect classical swine fever virus (CSFV) antibodies. The degree of CSFV E2-specific antibodies in the serum was calculated as positive when the blocking percentage was above 40% ( FIG. 3 ). The results indicate that the baculovirus vector displayed the fusion protein CSFV E2-Bac. FIG. 3 show that the baculovirus vector CSFV E2-gBac, whether the baculovirus was inactivated or not, induced a much higher anti-CSFV E2 antibody titer than the baculovirus vector CSFV E2-Bac in mice.
[0061] We have also compared the effects of the three baculovirus vectors in inducing immunogenic responses in pigs. Three SPF (specific pathogen free) pigs were immunized twice (6-week-old and 9-week-old) via intramuscular route with 10 8 pfu of recombinant baculovirus vectors E2-gBac, E2-gp64, E2-Bac, and PBS, respectively. After immunization, the sera of piglets were analyzed for the presence of CSFV E2 antibody using IDEXX CSFV Ab Test Kit (IDEXX). The degree of CSFV E2 specific neutralization antibody in the serum was calculated as positive and efficient when the blocking percentage was above 43%.
[0062] As shown in FIG. 4 , pigs immunized with E2-gBac were able to survive the CSFV challenge. It indicates that competent neutralization antibody had been induced in the pigs (SN titer≧16, IDEXX blocking ratio≧43%). This proves that the gBac platform is a vaccine platform. FIG. 4 shows that the baculovirus vector CSFV E2-gBac induced a much higher anti-CSFV E2 antibody titer than the baculovirus vectors CSFV E2-Bac and CSFV E2-gp64 in pigs. The results indicate that the gBac surface display platform of the invention can induce a stronger immunity than the priro art baculovirus vectors.
[0063] We have also gerenated baculovirus vector for transducing porcine epidemic diarrhea virus S1 protein (PEDV S1) into cells for vaccination applications. We tested its effects in inducing an immunogenic response. Briefly, three 9-week-old SPF pigs (labeled as number 73, 74 and 75, respectively) were each immunized twice via an intramuscular route with 10 8 pfu of recombinant baculovirus vector PEDV S1-gBac or PBS. After immunization, the sera of pigs (from 1 to 4 weeks post vaccination) were analyzed for the presence of anti-PEDV antibodies using an ELISA assay of PED virus. FIG. 5 shows that the baculovirus vector PEDV S1-gBac induced antibody titers against porcine epidemic diarrhea virus in all 3 pigs.
[0064] FIGS. 6A-B are photographs of Western blots showing that the antigens E2 of CSFV E2-gBac ( FIG. 6A ) and S1 of PEDV S1-gBac ( FIG. 6B ) from the Sf9 cell samples were detected. The cell lysates and collected virus were loaded by different cell number and virus titer. We have also constructed the baculovirus vector human programmed cell death protein 1 (hPD-1gBac)-gBac (hPD-1gBac). To test the production of the antigen, the recombinant baculoviruses or infected cell lysates were subjected to 8-10% sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE) and transferred to nitrocellulose membranes. The foreign antigens were detected by a mouse anti-gp64 mAb ( FIG. 6C ) and anti-PDCD-1 antibody ( FIG. 6D ) (Santa Cruz Biotechnology, Santa Cruz, Calif.) as the primary antibodies. The protein bands were visualized by ECL PLUS™ Western Blotting Detection Reagents (GE Healthcare). FIG. 6D shows that the baculovirus displayed human PD-1 antigen on the envelope, and the displayed PD-1 antigen could be recognized by commercial anti-PDCD-1 antibody (Santa Cruz Biotechnology, Santa Cruz, Calif.).
[0065] In summary, the vector of the invention is insensitive to inactivation reagents ( FIG. 3 ) and exhibits higher immunogenicity ( FIG. 4 ). Table 1 shows peptide sequences and SEQ ID NOs.
[0000]
TABLE 1
Protein
a.a.
or peptide
Amino acid sequence* (SEQ ID NO:)
length
Full length
MVSAIVLYVLLAAAAHSAFA AEHCNAQMKTGPYKIKNLDITPPKETLQKD
512
GP64
VEITIVETDYNENVIIGYKGYYQAYAYNGGSLDPNTRVEETMKTLNVGKE
DLLMWSIRQQCEVGEELIDRWGSDSDDCFRDNEGRGQWVKGKELVKRQNN
NHFAHHTCNKSWRCGISTSKMYSRLECQDDTDECQVYILDAEGNPINVTV
DTVLHRDGVSMILKQKSTFTTRQIKAACLLIKDDKNNPESVTREHCLIDN
DIYDLSKNTWNCKFNRCIKRKVEHRVKKRPPTWRHNVRAKYTEGDTATKG
DLMHIQEELMYENDLLKMNIELMHAH INKLNNMLHDLIVSVAKVDERLIG
NLMNNSVSSTFLSDDTFLLMPCTNPPAHTSNCYNNSIYKEGRWVANTDSS
QCIDFSNYKELAIDDDVEFWIPTIGNTTYHDSWKDASGWSFIAQQKSNLI
TTMENTKFGGVGTSLSDITSMAEGELAAKLTS
FMFGHVVNFIILIVILFL
YCMI
RNRNRQY
(SEQ ID NO: 1)
B12D5 binding
HRVKKRPPTW
epitope
(SEQ ID NO: 2, 292-301 of GP64).
B12D5 binding
KKRPPTWRHNV
epitope
(277-287 of gp64; SEQ ID NO: 3)
Gp64 central
KVEHRVKKRPPTWRHNVRAKYT
basic region
(271-292 of gp64; SEQ ID NO: 4)
GP64 signal
MVSAIVLYVLLAAAAHSAFA
20
peptide (SP)
(GP64 1-20 ; SEQ ID NO: 5)
SP1
MRVLVLLACLAAASA
Bombyx mori
(SEQ ID NO: 7)
SP2
MKSVLILAGLVAVALSSAVPKP
Bombyx mori
(SEQ ID NO: 8)
Bombyxin A-4
MKILLAIALMLSTVMWVST
(SEQ ID NO: 9)
Vitellogenin
MKLFVLAAIIAAVSS
(SEQ ID NO: 10)
Chitinase
MRAIFATLAVLASCAALVQS
precursor
(SEQ ID NO: 11)
Adipokintic
MYKLTVFLMFIAF VIIAGAQSMASLTRQDLA
hormone
(SEQ ID NO: 12)
CSFV E2
MLRGQVVQGIIWLLLVTGAQGRLSCKEDHRYAISSTNEIGPLGAEGLTTT
363
(Classical swine
WKEYNHGLQLDDGTVRAICIAGSFKVTALNVVSRRYLASLHKRALPTSVT
fever virus
FELLFDGTSPAIEEMGDDFGFGLCPFDTTPVVKGKYNTTLLNGSAFYLVC
(CSFV)
PIGWTGVIECTAVSPTTLRTEVVKTFKREKPFPHRVDCVTTIVEKEDLFY
envelope
CKLGGNWTCVKGNPVTYTGGQVRQCRWCGFDFKEPDGLPHYPIGCILTNE
glycoprotein
TGYRVVDSPDCNRDGVVISTEGEHECLIGNTTVKVHALDGRLAPMPCRPK
E2) CSFV 96 TD
EIVSSAGPVRKTSCTFNYTKTLRNKYYEPRDSYFQQYMLKGEYQYWFDLD
VTDHHTDYFAEF
(SEQ ID NO: 13)
PEDV S1
CSANTNFRRFFSKFNVQAPAVVVLGGYLPIGENQGVNSTWYCAGQHPTAS
708
(Procine
GVHGIFVSHIRGGHGFEIGISQEPFDPSGYQLYLHKATNGNTNATARLRI
Epidemic
CQFPSIKTLGPTANNDVTTGRNCLFNKAIPAHMSEHSVVGITWDNDRVTV
Diarrhea Virus
FSDKIYYFYFKNDWSRVATKCYNSGGCAMQYVYEPTYYMLNVTSAGEDGI
S1 Protein)
SYQPCTANCIGYAANVFATEPNGHIPEGFSFNNWFLLSNDSTLVHGKVVS
PEDV
NQPLLVNCLLAIPKIYGLGQFFSFNQTIDGVCNGAAVQRAPEALRFNIND
USA/Iowa/1898
TSVILAEGSIVLHTALGTNFSFVCSNSSNPHLATFAIPLGATQVPYYCFF
April 2013
KVDTYNSTVYKFLAVLPPTVREIVITKYGDVYVNGFGYLHLGLLDAVTIN
FTGHGTDDDVSGFWTIASTNFVDALIEVQGTAIQRILYCDDPVSQLKCSQ
VAFDLDDGFYPISSRNLLSHEQPISFVTLPSFNDHSFVNITVSASFGGHS
GANLIASDTTINGFSSFCVDTRQFTISLFYNVTNSYGYVSKSQDSNCPFT
LQSVNDYLSFSKFCVSTSLLASACTIDLFGYPEFGSGVKFTSLYFQFTKG
ELITGTPKPLEGVTDVSFMTLDVCTKYTIYGFKGEGIITLTNSSFLAGVY
YTSDSGQLLAFKNVTSGAVYSVTPCSFSEQAAYVDDDIVGVISSLSSSTF
NSTRELPG
(SEQ ID NO: 14)
Human PD-1
QIPQAPWPVVVAWLQLGWRPGWFLDSPDRPWNPPTFFPALLVVTEGDNAT
170
(Programmed
FTCSFSNTSESFVLNWYRMSPSNQTDKLAAFPEDRSQPGQDCRFRVTQLP
cell death
NGRDFHMSVVRARRNDSGTYLCGAISLAPKAQIKESLAELRVTERRAEVP
protein 1)
TAHPSPSPRPAGQFQTDIY
(SEQ ID NO: 15)
E2-gBac protein
MVSAIVLYVLLAAAAHSAFA MLRGQVVQGIIWLLLVTGAQGRLSCKEDHR
569
(SP-E2-GP64
YAISSTNEIGPLGAEGLTTTWKEYNHGLQLDDGTVRAICIAGSFKVTALN
mini-TM/CTD)
VVSRRYLASLHKRALPTSVTFELLFDGTSPAIEEMGDDFGFGLCPFDTTP
VVKGKYNTTLLNGSAFYLVCPIGWTGVIECTAVSPTTLRTEVVKTFKREK
PFPHRVDCVTTIVEKEDLFYCKLGGNWTCVKGNPVTTGGQVRQCRWCGFD
FDEPDGLPHYPIGKCILTNETGYRVVDSPDCNRDGVVISTEGEHECLIGN
TTVKVHALDGRLAPMPCRPKEIVSSAGPVRKTSCTFNYTKTLRNKYYEPR
DSYFQQYMLKGEYQYWFDLDVTDHHTDYFAEF INKLNNMLHDLIVSVAKV
DERLIGNLMNNSVSSTFLSDDTFLLMPCTNPPAHTSNYCYNNSIYKEGRW
VANTDSSQCIDFSNYKELAIDDDVEFWIPTIGNTTYHDSWKDASGWSFIA
QQKSNLITTMENTKFGGVGTSLSDITSMAEGELAAKLTS
FMGHVVNFVII
IVILFLYCMI
RNRNRQY
(SEQ ID NO: 16)
S1-gBac protein
MVSAIVLYVLLAAAAHSAFA CSANTNFRRFFSKFNVQAPAVVVLGGYLPI
914
(SP-S1-GP64
GENQGVNSTWYCAGQHPTASGVHGIFVSHIRGGHGFEIGISQEPFDPSGY
mini-TM/CTD)
QLYLHKATNGNTNATARLRICQFPSIKTLGPTANNDVTTGRNCLFNKAIP
AHMSEHSVVGITWDNDRVTVFSDKIYYFYFKNDWSRVATKVYNSGGCAMQ
YVYEPTYYMLNVTSAGEDGISYQPCTANCIGYAANVFATEPNGHIPEGFS
FNNWFLLSNDSTLVHGKVVSNQPLLVNCLLAIPKIYGLGQFFSFNQTIDG
VCNGAAVQRAPEALRFNINDTSVILAEGSIVLHTALGTNFSFVCSNSSNP
HLATFAIPLGATQVPYYCFFKVDTYNSTVYKFLAVLPPTVREIVITKYGD
VYVNGFGYLHLGLLDAVTINFTGHGTDDDVSGFWTIASTNFVDALIEVQG
TAIQRILYCDDPVSQLKCSQVAFDLDDGFYPISSRNLLSHEQPISFVTLP
SFNDHSFVNITVSASFGGHSGANLIASDTTINGFSSFCVDTRQFTISLFY
NVTNSYGYVSKSQDSNCPFTLQSVNDYLSFSKFCVSTSLLASACTIDLFG
YPEFGSGVKFTSLYFQFTKGELITGTPKPLEGVTDVSFMTLDVCTKYTIY
GFKGEGHTLTNSSFLAGYVYYTSDSGQLLAFKNVTSGAVYSVTPCSFSEQ
AAYVDDDIVGVISSLSSSTFNSTRELPG INKLNNMLHDLIVSVAKVDERL
IGNLMNNSVSSTFLSDDTFLLMPCTNPPAHTSNCYNNSIYKEGRWVANTD
SSQCIDFSNYEKLAIDDDVEFWIPTIGNTTYHDSWKDASGWSFIAQQKSN
LITTMENTKFGGVGTSLSDITSMAEGELAAKLTS
FMFGHVVNFVIILIVI
LFLYCMI
RNRNRQY
(SEQ ID NO: 17)
hPD1-gBac
MVSAIVLYVLLAAAAHSAFA QIPQAPWPVVWAVLQLGWRPGWFLDSPDRP
376
protein
WNPPTFFPALLVVTEGDNATFTCSFSNTSESFVLNWYRMSPSNQTDKLAA
(SP-hPD1-GP64
FPEDRSQPGQDCRFRVTQLPNGRDFHMSVVRARRNDSGTYLCGAISLAPK
mini-TM/CTD)
AQIKESLRAELRVTERRAEVPTAHPSPSPRPAGQFQTDIY INKLNNMLHD
LIVSVAKVDERLIGNLMNNSVSSTFLSDDTFLLMPCTNPPAHTSNCYNNS
IYKEGRWVANTDSSQCIDFSNYKELAIDDDVEFWIPTIGNTTYHDSWKDA
SGWSFIAQQKSNLITTMENTKFGGVGTLSLSDITSMAEGELAAKLTS
FMF
GHVVNFNIILIVILFLYCMI
RNRNRQY
(SEQ ID NO: 18)
*Full length GP64: The GP64 Signal peptide (SP) (GP64 1-20 ) is underlined and in italics.
The GP64 minimum (GP64 327-482 ) is underlined without italics. The GP64 transmembrane
domain (TM) (GP64 483-505 ) is in bold only. The GP64 cytoplasmic transduction domain
(CTD) (GP64 506-512 ) is in italics only.
E2-gBac protein (SP-E2-GP64 mini-TM/CTD): The GP64 Signal peptide (SP) (GP64 1-20 ) is
underlined and in italics. The GP64 minimum (GP64 327-482 ) is underlined without italics.
The GP64 transmembrane domain (TM) (GP64 483-505 ) is in bold only. The GP64 cytoplasmic
transduction domain (CTD) (GP64 506-512 ) is in italics only.
S1-gBac protein (SP-S1-GP64 mini-TM/CTD): The GP64 Signal peptide (SP) (GP64 1-20 ) is
underlined and in italics. The GP64 minimum (GP64 327-482 ) is underlined without italics.
The GP64 transmembrane domain (TM) (GP64 483-505 ) is in bold only. The GP64 cytoplasmic
transduction domain (CTD) (GP64 506-512 ) is in italics only.
hPD1-gBac protein (SP-hPD1-GP64 mini-TM/CTD): The GP64 Signal peptide (SP) (GP64 1-20 ) is
underlined and in italics. The GP64 minimum (GP64 327-482 ) is underlined without italics.
The GP64 transmembrane domain (TM) (GP64 483-505 ) is in bold only. The GP64 cytoplasmic
transduction domain (CTD) (GP64 506-512 ) is in italics only.
[0066] While embodiments of the present invention have been illustrated and described, various modifications and improvements can be made by persons skilled in the art. It is intended that the present invention is not limited to the particular forms as illustrated, and that all the modifications not departing from the spirit and scope of the present invention are within the scope as defined in the appended claims.
[0067] The embodiments and examples were chosen and described in order to explain the principles of the invention and their practical application so as to enable others skilled in the art to utilize the invention and various embodiments and with various modifications as are suited to the particular use contemplated. Alternative embodiments will become apparent to those skilled in the art to which the present invention pertains without departing from its spirit and scope. Accordingly, the scope of the present invention is defined by the appended claims rather than the foregoing description and the exemplary embodiments described therein.
[0068] Some references, which may include patents, patent applications and various publications, are cited and discussed in the description of this invention. The citation and/or discussion or such references is provided merely to clarify the description of the present invention and is not an admission, that any such reference is “prior art” to the invention described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference. | A recombinant baculovirus displaying on its envelop a fusion protein is disclosed. The fusion protein comprises a heterologous antigen, and a C-terminal region of baculovirus envelope GP64 protein, which has at least 100 amino acid residues in length and lacks a B12D5 binding epitope located within the central basic region of the GP64 protein. The genome of the recombinant baculovirus comprises a transgene encoding a fusion protein that comprises a signal peptide, the heterologous antigen, and the C-terminal region of the baculovirus envelope GP64 protein, in which the antigen is located between the signal peptide and the C-terminal region of the GP64 protein. Methods for eliciting an antigen-specific immunogenic response in a subject in need thereof are also disclosed. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the structure of a PTO portion of a tractor.
[0003] 2. Description of the Related Art
[0004] Conventionally, as one mode of a tractor, there has been known a tractor in which a PTO clutch is mounted in the inside of a rear housing and, at the same time, the PTO clutch adopts a friction multi-disk-type hydraulically operated clutch structure (for example, see patent document 1 (JP-UM-B-7-51393).
[0005] Here, the PTO clutch is communicably connected with a hydraulic pump by way of a clutch changeover valve. The clutch changeover valve is allowed to perform the changeover operation using a manipulation jig and can take a half-clutch state.
[0006] By supplying working oil to the PTO clutch so as to bring the PTO clutch into the connection state in this manner, it is possible to transmit the power to a PTO shaft. In this case, the clutch changeover valve is temporarily brought into the half clutch state by way of the clutch changeover valve using the manipulation jig and, thereafter, the PTO clutch is brought into a complete clutch connection state so as to prevent the power from being rapidly transmitted to the PTO shaft.
[0007] Further, as one mode of a tractor, there has been known a tractor in which while an engine is arranged in a prime mover portion, an inner-and-outer duplicate shaft structure is arranged in the clutch portion, wherein the inner-and-outer duplicate shaft structure is constituted of an inner drive shaft which extends in the longitudinal direction and a cylindrical outer drive shaft which surrounds an outer periphery of the inner drive shaft. The inner drive shaft is interlockingly connected with the above-mentioned engine by way of a PTO clutch, while the outer drive shaft is interlockingly connected with the engine by way of a traveling clutch thus providing the dual clutch structure which includes the PTO clutch and the traveling clutch (for example, see patent document 2 (JP-A-8-80754)).
[0008] Further, a clutch pedal is mechanically and interlockingly connected with the PTO clutch by way of a rod or the like, wherein it is possible to perform the connection and disconnection operation of the PTO clutch by performing the step-in manipulation of the clutch pedal.
[0009] Here, the above-mentioned inner drive shaft is interlockingly connected with the PTO portion by way of a PTO-system power transmission mechanism arranged in the inside of a transmission portion. Further, the above-mentioned outer drive shaft is interlockingly connected with a pair of left and right rear wheels by way of a traveling-system power transmission mechanism arranged in the inside of the transmission portion.
[0010] However, the tractor disclosed in the above-mentioned patent literature 1 has following drawbacks.
[0011] (1) Since the PTO clutch is incorporated in the inside of a rear housing, it is difficult to separately provide a specification which includes the PTO clutch and a specification which has no PTO clutch while using the rear housing in common.
[0012] (2) The structure which temporarily brings the PTO clutch into the half clutch state by way of the clutch changeover valve using the manipulation jig and, thereafter, brings the PTO clutch into the complete clutch connection state is complicated and pushes up a manufacturing cost.
[0013] On the other hand, the tractor disclosed in the above-mentioned patent literature 2 has following drawbacks.
[0014] (1) Since the PTO clutch is arranged in the inside of the clutch portion, it is difficult to mount and dismount the PTO clutch. As a result, it is difficult to separately provide a specification which includes the PTO clutch and a specification which has no PTO clutch while using the clutch housing in common.
[0015] (2) The inner drive shaft which is interlockingly connected with the PTO portion by way of the PTO-system power transmission mechanism and the outer drive shaft which is interlockingly connected with the pair of left and right rear wheels by way of the traveling-system power transmission mechanism are formed into the inner-and-outer duplicate shaft structure and are arranged in the inside of the transmission portion and hence, there arises a drawback that the structure in the inside of the transmission portion becomes complicated and large-sized thus pushing up a manufacturing cost.
[0016] (3) The inner drive shaft is interlockingly connected with the engine by way of the PTO clutch and, at the same time, the outer drive shaft which is interlockingly connected with the engine by way of the traveling clutch thus forming the dual clutch structure which includes the PTO clutch and the traveling clutch and such dual clutch is arranged in the clutch portion and hence, there arises a drawback that the clutch portion becomes complicated and large-sized thus pushing up a manufacturing cost.
SUMMARY OF THE INVENTION
[0017] (1) According to a first aspect of the present invention, in a tractor which detachably mounts a PTO portion on a transmission portion, a PTO clutch mechanism is arranged in the inside of the PTO portion.
[0018] In this manner, since the PTO clutch mechanism is arranged in the inside of the PTO portion which is detachably mounted on the transmission portion, it is possible to easily determine the specification which includes the PTO clutch mechanism or the specification which includes no PTO clutch mechanism depending on whether the PTO clutch mechanism is preliminarily assembled in the PTO portion or not in a stage that the PTO portion is assembled and, at the same time, it is possible to easily complete the assembling by merely mounting the PTO portion on the transmission portion.
[0019] Further, by taking steps opposite to the above-mentioned steps, it is possible to easily perform the maintenance of the PTO clutch mechanism or the like.
[0020] (2) According to a second aspect of the present invention, the PTO clutch mechanism is detachably mounted on the PTO portion.
[0021] In this manner, by detachably mounting the PTO clutch mechanism on the PTO portion, it is possible to provide the specification which includes the PTO clutch mechanism or the specification which includes no PTO clutch mechanism in a state that the PTO portion is used in common.
[0022] Further, the PTO clutch mechanism is detachably mounted on the PTO portion and the PTO portion is detachably mounted on the transmission portion and hence, it is possible to easily perform the assembling operation and the disassembling operation whereby the maintenance operation can be performed easily.
[0023] (3) According to a third aspect of the present invention, a manual manipulating jig is interlockingly connected to the PTO clutch mechanism by way of the interlocking mechanism, and the manual manipulating jig is arranged in the vicinity of a driver's seat.
[0024] In this manner, the manual manipulating jig which is interlockingly connected to the PTO clutch mechanism by way of the interlocking mechanism is arranged in the vicinity of the driver's seat and hence, it is possible to mechanically manipulate the PTO clutch mechanism by way of the interlocking mechanism by manipulating the manual manipulating jig.
[0025] As a result, it is possible to prevent the rapid transmission of power to the PTO shaft in an initial stage and hence, a load applied to a working machine which receives the power from the PTO shaft can be suitably reduced.
[0026] Further, an operator can manipulate a steering manipulation jig with one hand and can manipulate the manual manipulating jig with another hand. Accordingly, at the time of turning a tractor body by manipulating the steering manipulation jig, by manipulating the manual manipulating jig, it is possible to turn the tractor body in a state that the PTO clutch mechanism is disconnected so as to release the transmission of the power to the working machine. On the other hand, after turning the tractor body, by manipulating the manual manipulating jig, it is possible to connect the PTO clutch mechanism with the manual manipulating jig so as to restore the working machine into a state which allows the transmission of the power to the working machine thus allowing the working machine to resume a work.
[0027] Accordingly, it is possible to improve the manipulability of the steering manipulation jig and the manual manipulating jig thus enhancing the working efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 is a side view of a tractor according to the present invention;
[0029] FIG. 2 is an explanatory cross-sectional side view of a clutch portion and a transmission portion;
[0030] FIG. 3 is an explanatory cross-sectional side view of the clutch portion;
[0031] FIG. 4A to FIG. 4C are views showing a advancing/backing changeover mechanism, wherein FIG. 4A is an explanatory cross-sectional back view, FIG. 4B is a plan view showing an appearance of the advancing/backing changeover mechanism, and FIG. 4C is a side view showing the appearance of the advancing/backing changeover mechanism;
[0032] FIG. 5 is an explanatory cross-sectional side view of a PTO transmission portion;
[0033] FIG. 6 is an explanatory cross-sectional back view of a PTO transmission portion;
[0034] FIG. 7 is an explanatory cross-sectional side view of a drive shaft of a second embodiment;
[0035] FIG. 8 is an explanatory cross-sectional side view of a drive shaft of a third embodiment; and
[0036] FIG. 9 is an explanatory cross-sectional side view of a transmission shaft of the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Symbol A shown in FIG. 1 indicates a tractor according to the present invention. The tractor A is configured such that a prime mover portion 2 is mounted on a body frame 1 , a transmission portion 4 is interlockingly connected to the prime mover portion 2 by way of a clutch portion 3 , a driving portion 5 is arranged above the transmission portion 4 , a PTO transmission portion 6 which constitutes a PTO portion having a transmission function is detachably and interlockingly connected to a rear portion of the transmission portion 4 , a pair of left and right front wheels 7 , 7 are interlockingly connected to front axle casings 10 arranged below the body frame 1 and a pair of left and right rear wheels 9 , 9 are interlockingly connected to the transmission portion 4 by way of rear axle casings 8 , 8 .
[0038] Hereinafter, the constitutions of the above-mentioned [prime mover portion 2 ], [clutch portion 3 ], [transmission portion 4 ], [driving portion 5 ] and [PTO transmission portion 6 ] are explained in a specific manner in this order.
[Prime Mover 2 ]
[0039] The prime mover portion 2 is constituted such that, as shown in FIG. 1 , an engine 15 or the like is mounted on the body frame 1 and the engine 15 is covered with a hood 16 which can be opened and closed.
[Clutch Portion 3 ]
[0040] The clutch portion 3 is configured such that, as shown in FIG. 2 and FIG. 3 , a drive shaft 18 which is extended in the longitudinal direction is rotatably supported in the inside of a clutch housing 17 . With respect to the drive shaft 18 , while a front end portion 18 a thereof is pivotally supported on a center portion of a flywheel 19 which is arranged at a front portion in the inside of the clutch housing 17 by way of a front bearing 20 , a rear end portion 18 b thereof is pivotally supported on a support wall body 21 which is formed along a rear-end peripheral portion of the clutch housing 17 by way of a rear bearing 22 .
[0041] Further, a clutch 23 is arranged around a periphery of the front portion of the drive shaft 18 . The flywheel 19 and the drive shaft 18 are connected with each other by way of the clutch 23 in a connectable and disconnectable manner.
[0042] That is, in the clutch 23 , a clutch main body 24 is connected with the flywheel 19 . A cylindrical operating member 26 is slidably mounted on an outer peripheral surface of a cylindrical support member 25 which is arranged at a front outer periphery of the drive shaft 18 and supports a midst portion of the drive shaft 18 in a longitudinal direction. Further, a clutch pedal (not shown in the drawings) which is disposed at the driving portion 5 described later is interlockingly connected with the operating member 26 by way of a clutch operating arm 27 .
[0043] Due to such a constitution, when the clutch pedal is stepped in, a pushing action which is applied to the clutch body 24 by the operating member 26 by way of the clutch operating arm 27 is released and hence, the clutch 23 is disconnected.
[0044] Here, to a rear-end peripheral portion of the clutch housing 17 , a front peripheral portion of a main transmission casing 37 of the transmission portion 4 described later is detachably connected. Further, in the inside of the main transmission casing 37 , a distribution power transmission gear 29 which constitutes a distribution power transmission body is arranged. The distribution power transmission gear 29 is formed such that a rear end portion 18 b of the drive shaft 18 is extended rearwardly and the distribution power transmission gear 29 is integrally formed on the extended portion.
[Transmission Portion 4 ]
[0045] The transmission portion 4 is, as shown in FIG. 2 and FIG. 3 , configured such that, in the inside of a transmission casing 30 which extends in the longitudinal direction and is formed in a cylindrical shape, a traveling-system power transmission mechanism 31 which extends in the longitudinal direction and a PTO-system power transmission mechanism 32 are arranged in parallel to each other.
[0046] Further, in the traveling-system power transmission mechanism 31 , an advancing/backing changeover mechanism 33 which sequentially performs an advancing/backing changeover operation from a front side to a rear side, a main transmission mechanism 34 which performs the main transmission of the power which is changed over by the advancing/backing changeover mechanism 33 , a sub transmission mechanism 35 which performs the sub transmission of the power which is obtained after the main transmission by the main transmission mechanism 34 , and a differential mechanism 36 which transmits the power which is obtained after the sub transmission by the sub transmission mechanism 35 to the left and right rear wheels 9 , 9 in a distributed manner are arranged.
[0047] Further, the above-mentioned advancing/backing changeover mechanism 33 has a start end portion thereof interlockingly connected with the distribution power transmission gear 29 which is integrally formed on the drive shaft 18 .
[0048] Further, while the PTO-system power transmission mechanism 32 has a start end portion thereof interlockingly connected with the distribution power transmission gear 29 which is integrally formed on the above-mentioned drive shaft 18 , the PTO-system power transmission mechanism 32 has a terminal end portion thereof interlockingly connected with the PTO transmission portion 6 described later.
[0049] Due to such a constitution, the power which is transmitted from the engine 15 to the drive shaft 18 is transmitted to the traveling-system power transmission mechanism 31 and the PTO-system power transmission mechanism 32 in a distributed manner by way of the distribution power transmission gear 29 .
[0050] Further, the transmission casing 30 is, as shown in FIG. 2 , formed in a three split-constitution consisting of a main transmission casing 37 which incorporates the advancing/backing changeover mechanism 33 and the main transmission mechanism 34 therein, a sub transmission casing 38 which incorporates the sub transmission mechanism 35 therein, and a differential casing 39 which incorporates the differential mechanism 36 therein. A front-end peripheral portion of the main transmission casing 37 is detachably connected to the rear-end peripheral portion of the above-mentioned clutch housing 17 using connecting bolts (not shown in the drawings), a front-end peripheral portion of the sub transmission casing 38 is detachably connected to a rear-end peripheral portion of the main transmission casing 37 using connecting bolts 41 , and a front-end peripheral portion of the differential casing 39 is detachably connected to a rear-end peripheral portion of the sub transmission casing 38 using connecting bolts 42 .
[0051] Further, the main transmission casing 37 mounts, as shown in FIG. 3 , an inner support wall body 43 on a midst portion thereof. With the use of the inner portion support wall body 43 , the inside of the main transmission casing 37 is split in two thus forming a front chamber 44 and a rear chamber 45 . On the other hand, the above-mentioned advancing/backing changeover mechanism 33 is arranged in the inside of the front chamber 44 , and the main transmission mechanism 34 is arranged in the inside of the rear chamber 45 .
[0052] In the advancing/backing changeover mechanism 33 , as shown in FIG. 3 , between the support wall body 21 which is formed along the rear-end peripheral portion of the above-mentioned clutch housing 17 and the inner support wall body 43 , an advancing/backing changeover input shaft 46 which extends in the longitudinal direction is extended rotatably by way of front and rear bearings 47 , 48 . On the other hand, between an upper portion of the above-mentioned support wall body 21 and an upper portion of the above-mentioned inner support wall body 43 , an advancing/backing changeover output shaft 49 which extends in the longitudinal direction is extended rotatably by way of front and rear bearings 50 , 51 .
[0053] Further, the advancing/backing changeover input shaft 46 is arranged coaxially with the drive shaft 18 and an advancing input gear 52 and a backing input gear 53 are integrally mounted on the above-mentioned advancing/backing changeover input shaft 46 .
[0054] Further, on the advancing/backing changeover output shaft 49 , a distribution input gear 54 which is meshed with the above-mentioned distribution power transmission gear 29 and an advancing/backing changeover body 55 which is capable of changing over the input drive force between the advancing side and the backing side are mounted.
[0055] Further, the advancing/backing changeover body 55 allows an advancing output gear 56 and a backing output gear 57 to be rotatably mounted on the advancing/backing changeover output shaft 49 in a state that the advancing output gear 56 and the backing output gear 57 are arranged close to each other. Further, between both output gears 56 , 57 , a advancing/backing changeover receiving member 58 a is integrally fitted on the advancing/backing changeover output shaft 49 and, at the same time, an advancing/backing changeover slide member 58 b is mounted on an outer peripheral surface of the advancing/backing changeover receiving member 58 a in a state that the advancing/backing changeover slide member 58 b is slidable in the axial direction.
[0056] In this manner, the advancing/backing changeover slide member 58 b can perform the changeover operation to provide an advancing changeover state in which the advancing/backing changeover slide member 58 b is meshed with and connected with the advancing output gear 56 and a backing changeover state in which the advancing/backing changeover slide member 58 b is meshed with and connected with the backing output gear 56 , and a neutral position in which the advancing/backing changeover slide member 58 b is meshed with and connected with neither one of the output gears 56 , 57 .
[0057] Further, as shown in FIG. 3 , FIG. 4A and FIG. 4B , an opening portion 59 is formed in a ceiling portion 37 a of the main transmission casing 37 . The opening portion 59 is closed by a lid body 60 in a state that the opening portion 59 can be opened and closed. On an inner surface of the lid body 60 , a pair of front and rear shaft support members 61 , 62 are mounted in a state that the shaft support members 61 , 62 extend vertically downwardly. A gear support shaft 63 which has an axis thereof directed in the longitudinal direction is extended between both shaft support members 61 , 62 and a counter gear 65 is rotatably supported on the gear support shaft 63 by way of a bearing 64 . Numeral 74 indicates a lid mounting bolt.
[0058] Further, the above-mentioned counter gear 65 is, as shown in FIG. 3 and FIG. 4 , in a state that the lid body 60 is mounted in the opening portion 59 of the main transmission casing 37 in a lid-closed state, meshed with both of the above-mentioned backing input gear 53 and backing output gear 57 simultaneously and hence, the power for backing is transmitted to the backing input gear 53 from the backing output gear 57 by way of the counter gear 65 . On the other hand, in a state that the lid 60 is removed from the opening portion 59 , the connection between the backing output gear 57 and the backing input gear 53 is resolved.
[0059] Here, the advancing output gear 56 is meshed with the advancing input gear 52 .
[0060] Further, as shown in FIG. 4A and FIG. 4C , an opening portion 66 is formed in a right side wall of the main transmission casing 37 and a cap-like case body 67 is detachably mounted in the opening portion 66 . A start end portion of the advancing/backing changeover mechanism 68 is interlockingly connected with an advancing/backing changeover lever (not shown in the drawings) which is provided to the driving portion 5 . On the other hand, a terminal end portion of the advancing/backing changeover mechanism 68 is interlockingly connected with the above-mentioned advancing/backing changeover slide member 58 b and, at the same time, the terminal end portion is supported on the above-mentioned casing body 67 . Numeral 75 indicates casing body mounting bolts.
[0061] That is, at the terminal end portion of the advancing/backing changeover mechanism 68 , a support shaft 69 which has an axis thereof directed in the lateral direction is pivotally supported on an upper portion of a side wall 67 a of the casing body 67 by way of a boss portion 76 . A proximal end portion of a manipulation arm 70 which extends vertically is mounted on a right end portion of the support shaft 69 which projects outwardly from the side wall 67 a , while a proximal end portion of operating arm 71 which extends vertically is mounted on a left end portion of the support shaft 69 which projects inwardly from the side wall 67 a.
[0062] Further, a fork support shaft 72 which extends in the longitudinal direction is extended between lower portions of the front and rear walls 67 b , 67 c of the casing body 67 . A proximal portion 73 a of an advancing/backing changeover fork 73 is slidably fitted on the fork support shaft 72 . A distal end portion of the operating arm 71 is interlockingly connected with the proximal portion 73 a . Further, a distal-end fork portion 73 b of the advancing/backing changeover fork 73 is fitted on an outer peripheral surface of the above-mentioned advancing/backing changeover slide member 58 b.
[0063] In this manner, by manipulating the advancing/backing changeover lever provided to the driving portion 5 , it is possible to allow the advancing/backing changeover slide member 58 b to assume the advancing changeover state or the backing changeover state by way of the advancing/backing changeover mechanism 68 .
[0064] Further, when the advancing/backing changeover slide member 58 b is shifted to the advancing changeover state, the power transmitted to the drive shaft 18 from the engine 15 is transmitted to the advancing/backing changeover input shaft 46 by way of the distribution power transmission gear 29 →the distribution input gear 54 →the advancing/backing changeover output shaft 49 →the advancing output gear 56 →the advancing input gear 52 →the advancing/backing changeover input shaft 46 so as to allow the advancing/backing changeover input shaft 46 to perform the advancing-side rotation, that is, the normal rotation.
[0065] On the other hand, when the advancing/backing changeover slide member 58 b is shifted to the backing changeover state, the power transmitted to the drive shaft 18 from the engine 15 is transmitted to the advancing/backing changeover input shaft 46 by way of the distribution power transmission gear 29 →the distribution input gear 54 →the advancing/backing changeover output shaft 49 →the backing output gear 57 →the counter gear 65 →the backing input gear 53 →the advancing/backing changeover input shaft 46 so as to allow the advancing/backing changeover input shaft 46 to perform the backing-side rotation, that is, the reverse rotation.
[0066] The main transmission mechanism 34 is, as shown in FIG. 2 , arranged in the inside of a rear chamber 45 of the main transmission casing 37 . Between a rear end portion of the advancing/backing changeover input shaft 46 and a shaft support wall forming body 80 which is formed at a front portion in the inside of the sub transmission casing 38 , a main-transmission main shaft 81 which extends in the longitudinal direction is rotatably extended. On the other hand, between the above-mentioned inner support wall body 43 and the above-mentioned shaft support wall forming body 80 , a main-transmission sub shaft 82 which extends in frontward in the longitudinal direction is rotatably extended in parallel with the above-mentioned main-transmission main shaft 81 .
[0067] Further, the main-transmission main shaft 81 has a distal end portion 81 a thereof fitted in and supported by a fit/support recessed portion 83 formed in a center portion of a rear end of the advancing/backing changeover input shaft 46 and a rear portion 81 b thereof supported by the shaft support wall forming body 80 by way of a bearing 84 . That is, the main-transmission main shaft 81 is arranged coaxially with the drive shaft 18 and the advancing/backing changeover input shaft 46 .
[0068] Further, a plurality of main-shaft-side transmission gears are rotatably and concentrically mounted on the main-transmission main shaft 81 thus forming a main-shaft-side transmission gear group 85 . A plurality of transmission bodies are axially slidably fitted on the main-transmission main shaft 81 between respective main-shaft-side gears thus forming a transmission body group 86 . Further, the main-shaft-side transmission gear which is meshed with and connected with any one of the transmission bodies is interlockingly connected with the main-transmission main shaft 81 by way of the transmission body.
[0069] On the other hand, a plurality of sub-shaft-side transmission gears are concentrically mounted on the main-transmission sub shaft 82 thus forming a sub-shaft-side transmission gear group 87 . The respective sub-shaft-side transmission gears are respectively meshed with the opposedly facing main-shaft-side transmission gears, wherein the sub-shaft-side transmission gear 87 a is meshed with the main-shaft-side transmission gear 46 a which is integrally formed with a rear end portion of the advancing/backing changeover input shaft 46 .
[0070] In this manner, the power transmitted to the advancing/backing changeover input shaft 46 is transmitted to the respective main-shaft-side transmission gears by way of the main-shaft-side transmission gear 46 a →the sub-shaft-side transmission gear 87 a →the main-transmission sub shaft 82 →the respective sub-shaft-side transmission gears→the respective main-shaft-side transmission gears which are meshed with the respective sub-shaft-side transmission gears, whereby it is possible to transmit the power to the main-transmission main shaft 81 by way of any one of transmission bodies in a gear-changed state.
[0071] Here, the above-mentioned transmission body group 86 is, as shown in FIG. 2 , interlockingly connected with the main transmission lever 88 mounted on the sub transmission casing 38 by way of a main transmission manipulation mechanism 89 , wherein by manipulating the main transmission lever 88 , the desired transmission body in the inside of the transmission body group 86 is slidably operated by way of the main transmission manipulation mechanism 89 thus performing the main transmission in plural stages.
[0072] The sub transmission mechanism 35 is, as shown in FIG. 2 , arranged in the inside of the sub transmission casing 38 , wherein a sub transmission shaft 91 is interlockingly connected with a rear-end extending portion 81 c of the main-transmission main shaft 81 which is extended to a front portion in the inside of the sub transmission casing 38 by way of a planetary gear mechanism 90 .
[0073] Here, a sun gear 92 which constitutes a portion of the planetary gear mechanism 90 is mounted on the rear-end extending portion 81 c of the main-transmission main shaft 81 . On the other hand, the sub transmission shaft 91 is arranged coaxially with the main-transmission main shaft 81 , has a midst portion thereof supported on a shaft support body 93 disposed in the inside of the sub transmission casing 38 by way of a bearing 94 , and has a rear end portion thereof supported on a shaft support wall 95 formed in the inside of the differential casing 39 described later by way of a bearing 96 .
[0074] Further, between an outer peripheral surface of the sun gear 92 and an outer peripheral surface of the front end portion of the sub transmission shaft 91 , a cylindrical shift gear support body 97 is provided by spline fitting in an axially shiftable manner, a distal end portion of a shift fork 98 is engaged with the shift gear support body 97 , and a sub transmission lever 99 which is mounted on an upper portion of the sub transmission casing 38 is interlockingly connected with a proximal end portion of the shift fork 98 . Due to such a constitution, by manipulating the sub transmission lever 99 , it is possible to perform the sub transmission.
[0075] That is, the above-mentioned constitution allows the sub transmission in which the power is directly transmitted to the sub transmission shaft 91 from the main-transmission main shaft 81 and the sub transmission in which the power is transmitted to the sub transmission shaft 91 from the main-transmission shaft 81 by way of the planetary gear mechanism 90 .
[0076] Further, an opening portion 100 is formed in a bottom portion of the sub transmission casing 38 , a front wheel driving power-take-out portion 101 is mounted by way of the opening portion 100 , and a power-take-out shaft 102 which is mounted on the front wheel driving power-take-out portion 101 and the sub transmission shaft 91 which is provided to the above-mentioned sub transmission mechanism 35 are interlockingly connected with each other by way of a transmission gear group 103 .
[0077] The differential mechanism 36 is, as shown in FIG. 2 , arranged in the inside of the differential casing 39 , a rear end portion of the above-mentioned sub transmission shaft 91 is extended to a front portion in the inside of the differential casing 39 , an output bevel gear 105 is integrally formed with the rear end portion, and the differential mechanism 36 is meshed with and connected with the output bevel gear 105 .
[0078] Further, rear axle power transmission mechanisms (not shown in the drawings) which are respectively disposed in the inside of the respective rear axle casings 8 , 8 are interlockingly connected with the differential mechanism 36 , and rear wheels 9 , 9 are mounted on the respective rear axle power transmission mechanisms by way of the rear axles (not shown in the drawings).
[0079] Further, in the differential casing 39 , an opening portion 106 for maintenance is formed in a ceiling portion thereof, a mounting support frame body 107 is mounted on a peripheral portion of the opening portion 106 , a hydraulic circuit body 108 is mounted on a front portion of the mounting support frame body 107 , and a hydraulic control valve 109 is mounted on the hydraulic circuit body 108 . Further, proximal end portions of a pair of left and right lift arms 111 , 111 are mounted on a rear portion of the mounting support frame body 107 by way of a lift arm support shaft 110 . Lift cylinders 112 , 112 which extend vertically are interposed between midst portions of the respective lift arms 111 , 111 and left and right side portions of the PTO transmission portion 6 described later, and the above-mentioned hydraulic circuit body 108 is connected to the respective lift cylinders 112 , 112 by way of hydraulic pipes (not shown in the drawings).
[Driving Portion 5 ]
[0080] In the driving portion 5 , as shown in FIG. 1 , a steering column 113 is mounted upright at a position behind the prime mover portion 2 and, at the same time, at a position above the clutch portion 3 , a steering wheel 115 is mounted on an upper end portion of the steering column 113 by way of a wheel support shaft 114 , a driver's seat 116 is arranged at a position behind the steering wheel 115 , and the above-mentioned main transmission lever 88 and sub transmission lever 99 are arranged in a concentrated manner at a position disposed on a side of the driver's seat 116 .
[PTO Transmission Portion 6 ]
[0081] In the PTO transmission portion 6 , as shown in FIG. 5 and FIG. 6 , in an opening portion 120 which is formed in a rear end of the differential casing 39 , a PTO case 121 is detachably mounted, and a PTO transmission mechanism 122 and a PTO clutch mechanism 123 are arranged in the inside of the PTO case 121 .
[0082] Hereinafter, the respective constitutions of [the PTO case 121 ], [the PTO transmission mechanism 122 ] and [the PTO clutch mechanism 123 ] are explained in this order in conjunction with FIG. 5 and FIG. 6 .
[PTO Case 121 ]
[0083] The PTO case 121 has, as shown in FIG. 5 and FIG. 6 , the three-split constitution consisting of a front case forming body 124 , an intermediate case forming body 125 and a rear casing forming body 126 , wherein the respective case forming bodies 124 , 125 , 126 are detachably connected with each other, the front case forming body 124 and the intermediate case forming body 125 are arranged in a state that these case forming bodies are housed in the inside of the differential casing 39 , and the rear casing forming body 126 is arranged in a state that the rear casing forming body 126 is bulged rearwardly from the differential casing 39 .
[0084] Further, a flange-like mounting member 127 is integrally formed by molding on a peripheral portion of a front end of the rear casing forming body 126 , and the mounting member 127 is brought into contact with a peripheral portion of a rear end of the differential casing 39 from behind. Further, the mounting member 127 is mounted on the differential casing 39 using mounting bolts 128 which have axes thereof directed in the longitudinal direction.
[0085] In this manner, the PTO case 121 is detachably mounted in the opening portion 120 which is formed in the rear end of the differential casing 39 and hence, in a state that the PTO case 121 is removed from the differential casing 39 , it is possible to easily perform the assembling operation and maintenance operation of the PTO transmission mechanism 122 and the PTO clutch mechanism 123 which are housed in the inside of the PTO case 121 .
[0086] Further, in the PTO case 121 , the front case forming body 124 and the intermediate case forming body 125 are mounted in a state that the front case forming body 124 and the intermediate case forming body 125 are housed in the inside of the differential casing 39 and hence, the transmission casing 30 can be miniaturized (or made compact).
[0087] In the inside of the front case forming body 124 , an input shaft projecting opening portion 131 for receiving an input shaft 130 is formed in a state that the opening portion 131 opens in the longitudinal direction, and a transmission-shaft-front-portion receiving portion 132 is formed at a position above the above-mentioned input shaft projecting opening portion 131 .
[0088] A shaft receiving member 134 which receives a front end portion of the PTO shaft 133 is provided in the inside of the intermediate case forming body 125 , and the shaft receiving member 134 forms a PTO shaft front-portion receiving portion 135 which opens in the longitudinal direction in a midst portion thereof.
[0089] A PTO shaft projecting opening portion 138 is formed in the rear casing forming body 126 in a state that the PTO shaft projecting opening portion 138 is opened in the longitudinal direction, and a transmission-shaft rear-portion receiving portion 139 is formed at a position above the PTO shaft projecting opening portion 138 .
[0090] Further, the input-shaft projecting opening portion 131 which is formed in the front case forming body 124 , the PTO-shaft front-portion receiving portion 135 which is formed in the intermediate case forming body 125 and, the PTO-shaft projecting opening portion 138 which is formed in the rear casing forming body 126 are formed communicably with each other on the same axis which extends in the longitudinal direction.
[0091] Further, the transmission-shaft front-portion receiving portion 132 which is formed in the front case forming body 124 and the transmission-shaft rear-portion receiving portion 139 which is formed in the rear casing forming body 126 are arranged to face each other in an opposed manner in the longitudinal direction.
[0092] Further, on left and right side walls of the rear casing forming body 126 , as shown in FIG. 2 , lift cylinder support shafts 140 , 140 which constitute a lift cylinder mounting portion are formed in a state that these lift cylinder support shafts 140 , 140 project in the outer sideward direction and, a lower end portion of the lift cylinders 112 , 112 are supported by the respective lift cylinder support shafts 140 , 140 .
[PTO Transmission Mechanism 122 ]
[0093] The PTO transmission mechanism 122 is configured as shown in FIG. 5 and FIG. 6 , wherein in the inside of the above-mentioned PTO case 121 , an input shaft 130 , a transmission shaft 141 and the PTO shaft 133 which respectively have axes thereof directed in the longitudinal direction are arranged.
[0094] That is, the input shaft 130 is rotatably supported in the input shaft projecting opening portion 131 formed in the front case forming body 124 of the PTO case 121 by way of bearings 142 , 143 , while the input shaft 130 has a distal end portion 144 thereof projected forwardly and mounts an output gear 145 on a rear end portion thereof.
[0095] Further, between the transmission-shaft front-portion receiving portion 132 which is formed on the front case forming body 124 and the transmission-shaft rear-portion receiving portion 139 which is formed on the rear casing forming body 126 , the transmission shaft 141 is rotatably supported by way of bearings 146 , 147 . A large-diameter input gear 148 , and a second transmission gear 149 and a first transmission gear 150 which are integrally formed with each other are coaxially mounted on the transmission shaft 141 in order from a front side to a rear side, wherein the large-diameter input gear 148 is meshed with the output gear 145 mounted on the above-mentioned input shaft 130 .
[0096] Further, between the PTO-shaft front-portion receiving portion 135 which is formed in the intermediate case forming body 125 and the PTO-shaft projecting opening portion 138 which is formed in the rear casing forming body 126 , the PTO shaft 133 is rotatably supported by way of bearings 151 , 152 .
[0097] Further, a shift gear body 153 is mounted on the intermediate portion of the PTO shaft 133 in spline fitting such that the shift gear body 153 is shifted slidably in the axial direction and, at the same time, a second input gear 154 and a first input gear 155 are rotatably mounted on a front position and a rear position of the shift gear body 153 . While a second side shift gear 156 and a first side shift gear 157 are mounted on the shift gear body 153 , on a rear surface of the second input gear 154 , a second fitting/meshing gear 158 into which the above-mentioned second side shift gear 156 is fitted and with which the second side shift gear 156 is meshed is formed. Further, on a front surface of the first input gear 155 , a first fitting/meshing gear 159 into which the above-mentioned first side shift gear 157 is fitted and with which the first side shift gear 157 is meshed is formed.
[0098] Due to such a constitution, when the first side shift gear 157 is fitted in and meshed with the first fitting/meshing gear 159 of the first input gear 155 by shifting the shift gear body 153 rearwardly, the power which is subjected to the first transmission (low speed step) is transmitted to the PTO shaft 133 by way of the input shaft 130 →the output gear 145 →the large-diameter input gear 148 →the PTO clutch mechanism 123 described later→the second transmission gear 149 and the first transmission gear 150 which are integrally formed→the first input gear 155 →the first fitting/meshing gear 159 →the first side shift gear 157 →the shift gear body 153 →and the PTO shaft 133 .
[0099] Further, when the second side shift gear 156 is fitted in and meshed with the second fitting/meshing gear 158 of the second input gear 154 by shifting the shift gear body 153 frontwardly, the power which is subjected to the second transmission (high-speed step) is transmitted to the PTO shaft 133 by way of the input shaft 130 →the output gear 145 →the large-diameter input gear 148 →the PTO clutch mechanism 123 described later→the second transmission gear 149 and the first transmission gear 150 which are integrally formed→the second input gear 154 →the second fitting/meshing gear 158 →the second side shift gear 156 →the shift gear body 153 →the PTO shaft 133 .
[0100] Further, in the shift gear body 153 , as shown in FIG. 6 , a PTO transmission manipulation mechanism 160 is interlockingly connected.
[0101] That is, in the PTO transmission manipulation mechanism 160 , a transmission manipulation support shaft 163 which has an axis thereof directed in the lateral direction is pivotally supported on a right side wall 161 of the rear casing forming body 126 by way of a boss portion 162 , a proximal end portion of a PTO transmission manipulation arm 164 is mounted on an outer end portion of the transmission manipulation support shaft 163 which is outwardly projected from the right side wall 161 , and a proximal end portion of an operation arm 165 is mounted on an inner end portion of the transmission manipulation support shaft 163 which is inwardly projected from the right side wall 161 .
[0102] Further, a shift fork support shaft 166 which has an axis thereof directed in the longitudinal direction is arranged at a position in the vicinity of the distal end portion of the above-mentioned operation arm 165 , a proximal end portion 168 of a shift fork 167 is slidably mounted on the shift fork support shaft 166 in the lateral direction and, while the distal end portion of the above-mentioned operation arm 165 is connected with the proximal end portion 168 , a proximal end fork portion 170 of the shift fork 167 is engaged with an engaging groove portion 169 which is formed in an outer peripheral surface of the shift gear body 153 .
[0103] Further, a distal end portion of the PTO transmission manipulation arm 164 is interlockingly connected with a PTO transmission lever (not shown in the drawings) which is arranged at a position in the vicinity of the driver's seat 116 by way of an interlockingly connection mechanism (not shown in the drawings). Due to such a constitution, by manipulating the PTO transmission lever, it is possible to perform the shift operation of the shift gear body 153 thus enabling the PTO transmission.
[PTO Clutch Mechanism 123 ]
[0104] A PTO clutch mechanism 123 is, as shown in FIG. 5 and FIG. 6 , detachably interposed between a cylindrical front boss body 171 which is rearwardly extended from the rear end surface of the above-mentioned large-diameter input gear 148 along an outer peripheral surface of the transmission shaft 141 and a cylindrical rear boss body 172 which is frontwardly extended from the front end surface of the above-mentioned second transmission gear 149 along an outer peripheral surface of the transmission shaft 141 . The PTO clutch mechanism can perform the connection or disconnection of the large-diameter input gear 148 and the second transmission gear 149 while synchronizing rotational speeds of the gears 148 , 149 .
[0105] That is, the PTO clutch mechanism 123 is constituted as follows. A ring-shaped support body 173 is fitted on and integrally mounted on the outer peripheral surface of the front side boss body 171 , a slidable support member 174 having a small-width ring shape in the longitudinal direction is mounted on an outer peripheral edge portion of the support body 173 . A front engaging groove 175 which is extended in the longitudinal direction is formed on an outer peripheral surface of the slidable support member 174 , while a ring-shaped slide engaging body 176 is fitted on an outer peripheral surface of the slidable support member 174 . Further, an engaging projecting member 177 which is formed on an inner peripheral surface of the slide engaging body 176 is engaged with the above-mentioned front side engaging groove 175 thus allowing the slide engaging body 176 to be slidable in the longitudinal direction.
[0106] Further, a stepped recessed portion 178 is formed on an outer peripheral surface of the cylindrical rear boss body 172 , a ring-shaped engaging body 179 is fitted on and integrally mounted on an outer peripheral surface of the stepped recessed portion 178 , and a rear engaging groove 180 with which the engaging projecting member 177 of the slide engaging body 176 is engaged is formed on an outer peripheral surface of the ring-shaped engaging body 179 .
[0107] Due to such a constitution, when the slide engaging body 176 is made to slide rearwardly so as to engage the engaging projecting member 177 of the slide engaging body 176 with both of the front side engaging groove 175 and the rear side engaging groove 180 in a state that the engaging projecting member 177 is extended between the front side engaging groove 175 and the rear side engaging groove 180 , it is possible to interlockingly connect the large-diameter input gear 148 and the second transmission gear 149 .
[0108] Accordingly, in such a state, a rotational power of the large-diameter input gear 148 which forms a rotation side is transmitted to the second transmission gear 149 by way of the front side boss body 171 →the front side engaging groove 175 which is formed on the slidable support member 174 of the support body 173 →the engaging projecting member 177 which is formed on the slide engaging body 176 →the rear side engaging groove 180 which is formed on the engaging body 179 →the stepped recessed portion 178 which is formed on the rear boss body 172 →the second transmission gear 149 and hence, the second transmission gear 149 is also integrally rotated.
[0109] Further, outer peripheral portions of a plurality of ring-like movable-side clutch plates 181 are mounted on a rear portion of an inner peripheral surface of the slide engaging body 176 in an axially slidable manner, while a plurality of ring-like fixed-side clutch plates 182 are mounted in a fitting state on an outer peripheral surface of a stepped recessed portion 178 in an axially spaced-apart manner at a given interval, and the movable-side clutch plates 181 are interposed one by one between these neighboring fixed-side clutch plates 182 , 182 .
[0110] In this manner, when the slide engaging body 176 is made to slide rearwardly, the movable-side clutch plate 181 is gradually pushed to the fixed-side clutch plates 182 , 182 and a rotational force of a large-diameter input gear 148 which constitutes a rotation side is gradually transmitted to a second transmission gear 149 which constitutes a stop side. In a state that a rotational speed of the second transmission gear 149 is synchronized with the rotational speed of the large-diameter input gear 148 , an engaging projecting member 177 of the slide engaging body 176 is engaged with a rear engaging groove 180 of an engaging body 179 . As a result, the engagement between the engaging projecting member 177 and the rear engaging groove 180 is smoothly and surely performed thus preventing the generation of uncomfortable sounds.
[0111] Here, the PTO clutch mechanism 123 is detachable mounted on the PTO transmission portion 6 and hence, it is possible to provide the specification (see FIG. 5 ) which includes the PTO clutch mechanism 123 and the specification which does not include the PTO clutch mechanism 123 (see FIG. 9 ) in a state that the PTO transmission portion 6 is used in common.
[0112] Further, the PTO clutch mechanism 123 is detachably mounted on the PTO transmission portion 6 and the PTO transmission portion 6 is detachably mounted on the transmission portion 4 and hence, it is possible to easily perform the assembling operation as well as the disassembling operation thus realizing the easy maintenance operation.
[0113] Further, a PTO clutch manipulation mechanism 185 is, as shown in FIG. 6 , interlockingly connected with the slide engaging body 176 .
[0114] That is, in the PTO clutch manipulation mechanism 185 , a clutch manipulation support shaft 188 which has an axis thereof directed in the lateral direction is pivotally supported on a left side wall 186 of the rear casing forming body 126 by way of a boss portion 187 , a proximal end portion of a PTO clutch manipulation arm 189 is mounted on an outer end portion of the clutch manipulation support shaft 188 which is projected outwardly from the left side wall 186 , and a proximal end portion of a clutch operation arm 190 is mounted on an inner end portion of the clutch manipulation support shaft 188 which is projected inwardly from the left side wall 186 .
[0115] Further, a slide fork support shaft 191 which has an axis thereof directed in the longitudinal direction is arranged at a position in the vicinity of a distal end portion of the above-mentioned clutch operation arm 190 , and a proximal end portion 193 of a slide fork 192 is mounted on the slide fork support shaft 191 in a state that the proximal end portion 193 is slidable in the longitudinal direction. Further, a distal end portion of the clutch operation arm 190 is connected to the proximal end portion 193 , and a distal-end fork portion 195 of the slide fork 192 is engaged with an engaging projecting member 194 which is formed on an outer peripheral surface of the slide engaging body 176 .
[0116] Further, on the proximal end portion 193 of the slide fork 192 , as shown in FIG. 6 , a temporary stopper body 196 is mounted, wherein the temporary stopper body 196 includes a temporary stopper ball 197 which is arranged in a reciprocating manner toward the inside of the proximal end portion 193 and a pusher spring 198 which resiliently biases the temporary stopper ball 197 in the advancing direction.
[0117] Further, in an outer peripheral surface of the slide fork support shaft 191 on which the proximal end portion 193 of the slide fork 192 is fitted, a connection holding engaging groove 199 and a disconnection holding engaging groove 200 with which the pusher spring 198 is engaged are formed.
[0118] Further, a distal end portion of the above-mentioned PTO clutch manipulation arm 189 is interlockingly connected with a PTO clutch lever (not shown in the drawing) which is arranged at a position in the vicinity of a driver's seat 116 by way of an interlockingly connecting mechanism (not shown in the drawing), wherein by manipulating the PTO clutch lever, it is possible to slidably operate the slide engaging body 176 so as to perform the clutch connection/disconnection manipulation.
[0119] In this case, during the clutch connection manipulation, the pushing spring 198 is engaged with the connection holding engaging groove 199 of the slide fork support shaft 191 so as to hold the clutch connection state.
[0120] Further, during the clutch disconnection manipulation, the pushing spring 198 is engaged with the disconnection holding engaging groove 200 of the slide fork support shaft 191 so as to hold the clutch disconnection state.
[0121] Here, the PTO clutch lever is manually manipulated. Due to the manual manipulation of the PTO clutch lever, the movable-side clutch plate 181 and the fixed-side clutch plate 182 are brought into pressure contact with each other and the clutch connection manipulation can be performed while delicately synchronizing the rotational speeds of the large-diameter input gear 148 and the second transmission gear 149 and hence, it is possible to ensure the smooth and reliable connecting manipulation and the prevention of occurrence of uncomfortable sounds or the like.
[0122] Further, the distal end portion 144 of the above-mentioned input shaft 130 is, as shown in FIG. 2 , interlockingly connected with the drive shaft 18 by way of the PTO-system power transmission shaft 210 thus forming the PTO-system power transmission mechanism 32 , wherein the PTO-system power transmission shaft 210 has a front portion to a rear portion thereof arranged in the inside of the transmission casing 30 in a state that an axis thereof is directed in the longitudinal direction.
(PTO-System Power Transmission Shaft 210 )
[0123] The PTO-system power transmission shaft 210 is, as shown in FIG. 2 , configured such that a front end portion thereof is pivotally supported on the support wall body 21 of the clutch housing 17 by way of a bearing 211 , while a rear end portion thereof is interlockingly connected with a distal end portion 144 of the above-mentioned input shaft 130 by way of a connection sleeve 212 .
[0124] Further, an input gear 213 is mounted on a front end portion of the PTO-system power transmission shaft 210 , while the input gear 213 is meshed with the distribution power transmission gear 29 which is integrally formed with the drive shaft 18 .
[0125] Here, the power-take-out gear 214 is mounted on a front portion of the PTO-system power transmission shaft 210 and the power can be taken out to the outside from the power-take-out gear 214 through a power-take-out opening portion 215 which is formed in a left side wall of the main transmission casing 37 .
[0126] Further, a one way clutch 216 is mounted on a rear portion of the PTO-system power transmission shaft 210 .
[0127] In this manner, the power transmitted to the drive shaft 18 from the engine 15 is transmitted to the input shaft 130 by way of the distribution power transmission gear 29 which is integrally formed on the drive shaft 18 →the input gear 213 →the PTO-system power transmission shaft 210 →the input shaft 130 .
[0128] FIG. 7 shows a drive shaft 18 of the second embodiment. This drive shaft 18 has the basic structure which is equal to the basic structure of the drive shaft 18 of the above-mentioned first embodiment. However, the driveshaft 18 of this embodiment differs from the drive shaft 18 of the first embodiment with respect to a point that the drive shaft 18 has the inner-outer duplicate shaft structure which is constituted of an inner drive shaft forming body 230 which extends in the longitudinal direction and a cylindrical outer drive shaft forming body 231 which is rotatably fitted on an outer periphery of the inner drive shaft forming body 230 .
[0129] Further, in the inner drive shaft forming body 230 , a front end portion 232 is interlockingly connected with the flywheel 19 , a PTO distribution power transmission gear 234 is integrally formed on a rear end portion 233 , and the input gear 213 which is integrally formed on the front end portion of the PTO-system power transmission shaft 210 is meshed with the PTO distribution power transmission gear 234 .
[0130] Further, in the outer drive shaft forming body 231 , a front end portion 235 is interlockingly connected with the clutch 23 , a traveling distribution power transmission gear 237 is integrally formed on a rear end portion 236 , and the distribution input gear 54 which is mounted on the advancing/backing changeover output shaft 49 is meshed with the traveling distribution power transmission gear 237 . Numeral 238 indicates a bearing.
[0131] Here, the PTO distribution power transmission gear 234 and the traveling distribution power transmission gear 237 are arranged in a compact manner by arranging these power transmission gears 234 , 237 close to each other coaxially and longitudinally.
[0132] FIG. 8 shows a drive shaft 18 of the third embodiment. This drive shaft 18 has the basic structure which is equal to the basic structure of the drive shaft 18 of the above-mentioned first embodiment. However, the drive shaft 18 of this embodiment differs from the drive shaft 18 of the first embodiment with respect to a point that the drive shaft is split in two, that is, a front-half drive shaft forming body 240 and a rear-half drive shaft forming body 241 and, at the same time, a rear end portion 242 of the front-half drive shaft forming body 240 and front end portion 243 of the rear-half drive shaft forming body 241 are interlockingly connected with each other coaxially by way of a cylindrical connecting body 244 .
[0133] Further, a cylindrical support member 25 which supports a midst portion of the front half drive shaft forming body 240 is allowed to penetrate the support wall body 21 formed along a rear-end peripheral portion of the clutch housing 17 and, at the same time, is extended to the inside of the front chamber 44 of the rear main transmission casing 37 in a cylindrical shape, and a front portion of the rear half drive shaft forming body 241 is rotatably supported on a rear end portion 245 by way of a bearing 246 .
[0134] Further, the distribution power transmission gear 29 is integrally mounted on a midst portion of the rear half drive shaft forming body 241 which is positioned right behind the above-mentioned bearing 246 , while the input gear 213 which is integrally formed on the front portion of the PTO-system power transmission shaft 210 is meshed with the distribution power transmission gear 29 .
[0135] Here, the input gear 213 is arranged in the vicinity of the power-take-out opening portion 215 formed in the left side wall of the main transmission case 37 so as to allow the takeout of the power to the outside from the input gear 213 through the power-take-out opening portion 215 .
[0136] Further, the drive shaft 18 of the second embodiment adopts the specification which is not provided with the advancing/backing changeover mechanism 68 and the opening portion 59 is closed with a closure lid body 247 .
[0137] Accordingly, in the specification which is provided with the advancing/backing changeover mechanism 68 , the drive shaft 18 of the first embodiment or the second embodiment is mounted, while in the specification which is not provided with the advancing/backing changeover mechanism 68 , it is possible to change the specification by mounting the drive shaft 18 of the third embodiment.
[0138] FIG. 9 shows a transmission shaft 141 of the second embodiment. Although the transmission shaft 141 of this embodiment has the basic structure which is equal to the basic structure of the first embodiment, this embodiment differs from the first embodiment with respect to a point that the transmission shaft 141 of this embodiment is not provided with the PTO clutch mechanism 123 .
[0139] That is, in the transmission shaft 141 , a shaft body 248 , the second transmission gear 149 and the first transmission gear 150 are integrally formed and the large-diameter input gear 148 is integrally mounted on a front portion of the shaft body 248 .
[0140] Accordingly, in the specification which includes the PTO clutch mechanism 123 , the transmission shaft 141 of the first embodiment is provided, while in the specification which does not include the PTO clutch mechanism 123 , the transmission shaft 141 is mounted in the second embodiment thus facilitating the change of the specification. | The present invention can easily determine a specification which includes a PTO clutch mechanism or a specification which includes no PTO clutch mechanism. According to the present invention, in a tractor which detachably mounts a PTO portion on a transmission portion, a PTO clutch mechanism is arranged in the inside of the PTO portion. Accordingly, it is possible to easily determine the specification which includes the PTO clutch mechanism or the specification which includes no PTO clutch mechanism depending on whether the PTO clutch mechanism is preliminarily assembled in the PTO portion or not in a stage that the PTO portion is assembled and, at the same time, it is possible to easily complete the assembling by merely mounting the PTO portion on the transmission portion. Further, by taking steps opposite to the above-mentioned steps, it is possible to easily perform the maintenance of the PTO clutch mechanism or the like. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to the architecture of electronic graphics systems for displaying portions of multiple images on a CRT screen.
In general, to display an image on a CRT screen, a focused beam of electrons is moved across the screen in a raster scan type fashion; and the magnitude of the beam at any particular point on the screen determines the intensity of the light that is emitted from the screen at that point. Thus, an image is produced on the screen by modulating the magnitude of the electron beam in accordance with the image as the beam scans across the screen.
Similarly, to produce a color image on a CRT screen, three different beams scan across the screen in very close proximity to each other. However, those three beams are respectively focused on different color-emitting elements on the screen (such as red, green, and blue color-emitting elements); and so the composite color that is emitted at any particular point on the screen is proportional to the magnitude of the three electron beams at that point.
Also, in a digital color system, the intensity and/or color of the light that is to be emitted at any particular point on the CRT screen is encoded into a number of bits that is called the pixel. Suitably, six bits can encode the intensity of light at a particular point on a black and white screen; whereas eighteen bits can encode the color of light that is to be emitted at any particular point on a color screen.
Typically, the total number of points at which light is emitted on a CRT screen (i.e., the total number of light-emitting points in one frame) generally is quite large. For example, a picture on a typical TV screen consists of 480 horizontal lines; and each line consists of 640 pixels. Thus, at six bits per pixel, a black and white picture consists of 1,843,200 bits; and at eighteen bits per pixel, a color picture consists of 5,529,600 bits.
In prior art graphics systems, a frame buffer was provided which stored the pixels for one frame on the screen. Those pixels were stored at consecutive addresses in the sequence at which they were needed to modulate the electron beam as it moved in its raster-scanning pattern across the screen. Thus, the pixels could readily be read from the frame buffer to form a picture on the CRT screen.
However, a problem with such a system is that it takes too long to change the picture that is being displayed via the frame buffer. This is because 1.8 million bits must be written into the frame buffer in order to change a black and white picture; and 5.5 million bits must be written into the frame buffer to change a color picture. This number of bits is so large that many seconds pass between the time that a command is given to change the picture and the time that the picture actually changes. And typically, a graphics system operator cannot proceed with his task until the picture changes.
Also in a graphics system, the picture that is displayed on the screen typically is comprised of various portions of several different images. In that case, it often is desirable to display the various image portions with different degrees of prominence.
For example, it is desirable for each of the image portions to be displayed in its own independent set of colors and/or be displayed with different blink rates. However, this is not possible with the above-described prior art graphics system since there is no indication in a frame buffer of which image a particular pixel is part of.
Accordingly, a primary object of the invention is to provide an improved graphics system for electronically displaying multiple images on a CRT screen.
BRIEF SUMMARY OF THE INVENTION
This object and others are achieved in accordance with the invention by a system for electronically displaying portions of several different images on a CRT screen; which system includes: a memory for storing a complete first image as several pixels in one section of the memory and a complete second image as several other pixels in another section of the memory such that the total number of pixels stored is substantially larger than the number of pixels on the screen; a logic circuit for reading a sequence of the pixels from non-contiguous locations in respective portions of the first and second images and for transferring them, in the sequence at which they are read, to the screen for display with no frame buffer therebetween; the logic circuit for reading including a module for forming non-contiguous addresses for said pixels in the sequence in which they are read with the address of one word of pixels being formed during the time interval that a previously addressed word of pixels is displayed on the screen.
BRIEF DESCRIPTION OF THE DRAWINGS
Various features and advantages of the invention are described in the Detailed Description in accordance with the accompanying drawings wherein:
FIG. 1 illustrates one preferred embodiment of the invention;
FIG. 2 illustrates additional details of a screen control logic unit in FIG. 1;
FIG. 3 illustrates a timing sequence by which the FIG. 1 system operates;
FIG. 4 illustrates the manner in which the FIG. 1 system moves several different images on a screen;
FIG. 5 illustrates a modification to the FIG. 2 screen control logic unit; and
FIG. 6. illustrates still another modification to the FIG. 2 screen control logic unit.
FIG. 7 is a flow chart illustrating the Creat Image Command;
FIG. 8. is a flow chart illustrating the Destroy Image Command;
FIG. 9 is a flow chart illustrating the Locate Viewpoint Command;
FIG. 10 is a flow chart illustrating the Open Viewpoint Command;
FIG. 11 is a flow chart illustrating the Close Viewpoint Command;
FIG. 12 is a flow chart illustrating the Review Priority Command;
FIG. 13 is a flow chart illustrating the Bubble Priority Command;
FIG. 14 is a flow chart illustrating the Move ABS Command;
FIG. 15 is a flow chart illustrating the Line ABS Command;
FIG. 16 is a flow chart illustrating the Load Color Command;
FIG. 17 is a flow chart illustrating the Load Colormap Correlator Command;
FIG. 18 is a flow chart illustrating the Set Blink Command;
FIG. 19 is a flow chart illustrating the Load Overlay Memory Command.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a block diagram of the disclosed visual display system will be described. This system includes a keyboard/printer 10 which is coupled via a bus 11 to a keyboard/printer controller 12. In operation, various commands which will be described in detail later are manually entered via the keyboard; and those commands are sent over bus 11 where they are interpreted by the controller 12.
Controller 12 is coupled via another bus 13 to a memory array 14 and to a screen control logic unit 15. In operation, various images are specified by commands from keyboard 10; and those images are loaded by controller 12 over bus 13 into memory array 14. Also, various control information is specified by commands from keyboard 10; and that information is sent from controller 12 over bus 13 to the screen control logic unit 15.
Memory array 14 is comprised of six memories 14-1 through 14-6. These memories 14-1 through 14-6 are logically arranged as planes that are stacked behind one another. Each of the memory planes 14-1 through 14-6 consists of 64K words of 32 bits per word.
Bus 13 includes 32 data lines and 16 word address lines. Also, bus 13 includes a read/write line and six enable lines which respectively enable the six memories 14-1 through 14-6. Thus, one word of information can be written from bus 13 into any one of the memories at any particular word address.
Some of the images which are stored in memory array 14 are indicated in FIG. 1 as IM a , IM b , . . . IM z . Each of those images consists of a set of pixels which are stored at contiguously addressed memory words. Each pixel consists of six bits of information which define the intensity of a single dot on a viewing screen 16. For any particular pixel, memory 14-1 stores one of the pixel bits; memory 14-2 stores another pixel bit; etc.
To form an image in memory array 14, a CREATE IMAGE command (FIG. 7) is entered via keyboard 10. Along with this command, the width and height (in terms of pixels) of the image that is to be created are also entered. In response thereto, controller 12 allocates an area in memory array 14 for the newly created image.
In performing this allocation task, controller 12 assigns a beginning address in memory array 14 for the image; and it reserves a memory space following that beginning address equal to the specified pixel height times the specified pixel width. Also, controller 12 assigns an identification number to the image and prints that number via the printer 10.
Conversely, to remove an image from memory array 14, a DESTROY IMAGE command (FIG. 8 ) is entered via keyboard 10. The identification number of the image that is to be destroyed is also entered along with this command. In response thereto, controller 12 deallocates the space in memory array 14 that it had previously reserved for the identified image area.
Actual bit patterns for the pixels of an image are entered into memory array 14 via a MOVE ABS command and a LINE ABS command. Along with the MOVE ABS command, the keyboard operator also enters the image ID and the X 1 Y 1 coordinates in pixels of where a line is to start in the image. Similarly, along with the LINE ABS command, the keyboard operator enters the image ID and X 2 Y 2 coordinates in pixels of where a line is to end in the image.
In response thereto, controller 12 sends pixels over bus 13 to memory 14 which define a line in the identified image from X 1 Y 1 to X 2 Y 2 . These pixels are stored in memory 14 such that the pixel corresponding to the top left corner of an image is stored at the beginning address of that image's memory space; and pixels following that address are stored using a left-to-right and top-to-bottom scan across the image. To remove an image from memory 14, a DESTROY IMAGE command is simply entered via keyboard 10 along with the image's ID.
After the images have been created in memory array 14, the screen control logic unit 15 operates to display various portions of those images on a viewing screen 16. To that end, logic unit 15 sends a word address over bus 13 to the memory array 14; and it also activates the read line and six enable lines.
In response, logic unit 15 receives six words from array 14 over a bus 17. Bus 17 includes 32×6 data output lines. One of the received words comes from memory 14-1; another word comes from memory 14-2; etc. These six words make up one word of pixels.
Upon receiving the addressed word of pixels, unit 15 sends them one pixel at a time over a bus 18 to the viewing screen 16. Then, the above sequence repeats over and over again. Additional details of this sequence will be described in conjunction with FIG. 2.
However, before any image can be displayed, a viewport must be located on the viewing screen 16. In FIG. 1, three such viewports are indicated as V 1 , V 2 , and V 7 . These viewports are defined by entering a LOCATE VIEWPORT command via keyboard 10 to logic unit 12.
Along with the LOCATE VIEWPORT command (FIG. 9), four parameters X min , X max , Y min , and Y max are also entered. Screen 16 is divided into a grid of 20 blocks in a horizontal direction and 15 blocks in the vertical direction for a total of 300 blocks. Each block is 32×32 pixels. And the above parameters define the viewport on screen 16 in terms of these blocks.
For example, setting the parameters X min , X max , Y min , and Y max equal to (1, 10, 1, 10) locates a viewport on screen 16 which occupies 10 blocks in each direction and is positioned in the upper le-ft corner of screen 16. Similarly, setting the parameters equal to (15, 20, 1, 10) locates a viewport on screen 16 which is 5×10 blocks in the upper right corner of the screen.
A viewport identification/priority number is also entered via keyboard 10 along with each LOCATE VIEWPORT command. This number can range from 1 to 7; and number 7 has the highest priority. As illustrated in FIG. 1, the viewports can be located such that they overlap. But only the one viewport which has the highest priority number at a particular overlapping block will determine which image is there displayed.
After a viewport has been located, an OPEN VIEWPORT command (FIG. 10) must be entered via keyboard 10 to display a portion of an image through the viewport. Other parameters that are entered along with this command include the identification number of the viewport that is to be opened, the identification number of the image that is to be seen through the opened viewport, and the location in the image where the upper left-hand corner of the opened viewport is to lie. These location parameters are given in pixels relative to the top left-hand corner of the image itself; and they are called TOPX and TOPY..
That portion of an image which is matched with a viewport is called a window. In FIG. 1, the symbol WD 1 indicates an example of a window in image IM a that matches with viewport V 1 . Similarly, the symbol WD 2 indicates a window in image IM b that matches with viewport V 2 ; and the symbol WD 7 indicates a window in image IM z that matches with viewport V 7 .
Consider now, in greater detail, the exact manner by which the screen control logic unit 15 operates to retrieve pixel words from the various images in memory 14. This operation and the circuitry for performing the same is illustrated in FIG. 2. All of the components 30 through 51 which are there illustrated are contained within logic unit 15.
These components include a counter 30 which stores the number of a block in the viewing screen for which pixel data from memory array 14 is sought. Counter 30 counts from 0 to 299. When the count is 0, pixel data for the leftmost block in the upper row of the viewing screen is sought; when the count is 1, pixel data for the next adjacent block in the upper row of the viewing screen is sought; etc.
Counter 30 is coupled via conductors 31 to the address input terminals of a viewport map memory 32. Memory 32 contains 300 words; and each word contains seven bits. Word 0 corresponds to block 0 on screen 16; word 1 corresponds to block 1; etc. Also, the seven bits in each word respectively correspond to the previously described seven viewports on screen 16.
If bit 1 for word 0 in memory 32 is a logical 1,then viewport 1 includes block 0 and viewport 1 is open. Conversely, if bit 1 for word 0 is a logical 0, then viewport 1 either excludes block 0 or viewport 1 is closed.
All of the other bits in memory 32 are interpreted in a similar fashion. For example, if bit 2 of word 50 in memory 32 is a logical 1, then viewport 2 includes block 50 and is open. Or, if bit 7 of word 60 in memory 32 is a logical 0, then viewport 7 either excludes block 60 or the viewport is closed.
Each word that is addressed in memory 32 is sent via conductors 33 to a viewport selector 34. Selector 34 operates on the 7-bit word that it receives to generate a 3-bit binary code on conductors 35; and that code indicates which of the open viewports have the highest priority. For example, suppose counter 30 addresses word 0 in memory 32; and bits 2 and 6 of word 0 are a logical 1. Under those conditions, selector 34 would generate a binary 6 on the conductors 35.
Signals on the conductors 35 are sent to a circuit 36 where they are concatenated with other signals to form a control memory address on conductors 37. If viewport 1 is the highest priority open viewport, then a first control memory address is generated on conductors 37; if viewport 2 is the highest priority open viewport, then another control memory address is generated on the conductors 37, etc.
Addresses on the conductors 37 are sent to the address input terminals of a control memory 38; and in response thereto, control memory 38 generates control words on conductors 39. From there, the control words are loaded into a control register 40 whereupon they are decoded and sent over conductors 41 as control signals CTL1, CTL2, . . . .
Signals CTL1 are sent to a viewport-image correlator 42 which includes three sets of seven registers. The first set of seven registers are identified as image width registers (IWR 1-IWR 7); the second set are identified as current line address registers (CLAR 1-CLAR 7); and the third set are identified as the initial line address registers (ILAR 1-ILAR 7).
Each of these registers is separately written into and read from in response to the control signals CTL1. Suitably, each of the IWR registers holds eight bits; and each of the CLAR and ILAR registers hold sixteen bits.
Register IWR 1 contains the width (in blocks) of the image that is viewed through viewport 1. Thus, if image 5 has a width of 10 blocks and that image is being viewed through viewport 1, then the number 10 is in register IWR 1. Similarly, register IWR 2 contains the width of the image that is viewed through viewport 2, etc.
Register CLAR 1 has a content which changes with each line of pixels on screen 15. But when the very first word of pixels in the upper left corner of viewport 1 is being addressed, the content of CLAR 1 can be expressed mathematically as BA+(TOPY)(IW)(32)+TOPX-X min .
In this expression, BA is the base address in memory 14 of the image that is being displayed in viewport 1. TOPX and TOPY give the position (in blocks) of the top left corner of viewport 1 relative to the top left corner of the image that it is displaying. IW is the width (in blocks) of viewport 1 relative to the image that it is displaying. And X min is the horizontal position (in blocks) of viewport 1 relative to screen 16.
An example of each of these parameters is illustrated in the lower right-hand portion of FIG. 2. There, viewport 1 is displaying a portion of image 1. In this example, the parameter TOPX is 2 blocks; the parameter TOPY is 6 blocks; the parameter IW is 10 blocks; and the parameter X min is 8 blocks. Thus, in this example, the entry in register CLAR 1 is BA+1914 when the upper left word of viewport 1 is being addressed.
Consider now the physical meaning of the above entry in register CLAR 1. BA is the beginning address of image 1; and the next term of (6)(10)(32)+(2)is the offset (in words) from the base address to the word of image 1 that is being displayed in the upper left-hand corner of viewport 1.
That word in the upper left-hand corner of viewport 1 is (6)(10) blocks plus 2 words away from the word at the beginning address in image 1; and each of those blocks contains 32 lines. Therefore, the address of the word in the upper left-hand corner of viewport 1 is BA+(6)(10)(32)+2.
Note, however, that the term X min is subtracted from the address of the word in the upper left-hand corner of viewport 1 to obtain the entry in register CLAR 1. This subtraction occurs because logic unit 15 also includes a counter 43 which counts horizontal blocks 0 through 19 across the viewing screen. And the number in counter 43 is added via an adder circuit 44 to the content of register CLAR 1 to form the address of a word in memory array 14.
To perform this add, conductors 45 transmit the contents of register CLAR 1 to adder 44; and conductors 46 transmit the contents of counter 43 to adder 44. Then, output signals from adder 44 are sent over conductors 47 through a bus transmitter 48 to bus 13. Control signals CTL2 enable transmitter 48 to send signals on bus 13.
In response to the address on bus 13, memory 14 sends the addressed word of pixels on bus 17 to a shifter 49. Shifter 49 receives the pixel word in parallel; and then shifts the word pixel by pixel in a serial fashion over bus 18 to the screen 16. One pixel is shifted out to screen 16 every 40 nanoseconds.
As an example of the above, consider what happens when the block counter 30 addresses the block in the top left corner of viewport 1. That block is (9)(20)+8 or 188. Under such conditions, word 188 is read from memory 32. Suppose next that word 188 indicates that viewport 1 has the highest priority. In response, signals CTL1 from control register 40 will select register CLAR 1.
Then, the count of register CLAR 1 is added to the content of counter 43 (which would be number 8) to yield the address of BA+1922. That address is the location in memory array 14 of the word in image 1 that is at the upper left-hand corner of viewport 1.
To address the next word in the memory array 14, the counters 30 and 43 are both incremented by 1 in response to control signals CTL3 and CTL4 respectively; and the above sequence is repeated. Thus, counter 30 would contain a count of 73; word 73 in memory 32 could indicate that viewport 1 has the highest priority; control signals from register 40 would then read out contents of register CLAR 1; and adder 44 would add the number 9 from counter 43 to the content of register CLAR 1.
The above sequence continues until one complete line has been displayed on screen 16 (i.e., counter 43 contains a count of nineteen). Then, during the horizontal retrace time on screen 16, counter 43 is reset to zero; and the content of each of the CLAR registers is incremented by the content of its corresponding IWR register. For example, register CLAR 1 is incremented by 10. This incrementing is achieved by sending the IWR and CLAR registers through adder 44 in response to the CTL1 control signals.
Another counter 50 is also included in logic unit 15; and it counts the lines from one to thirty-two within the blocks. Counter 50 is coupled via conductors 51 to the control memory address logic 36 where its content is sensed during a retrace. If the count in counter 50 is less than thirty-two, then counter 30 is set back to the value it had at the start of the last line, and counter 50 is incremented by one.
But when counter 50 reaches a count of thirty-two, then the next line on screen 16 passes through a new set of blocks. So in that event during the retrace, counter 30 is incremented by one, and counter 50 is reset to one. All changes to the count in counter 50 occur in response to control signals CTL5.
After the retrace ends, a new forward horizontal scan across screen 16 begins. And during this new forward scan, 20 new words of pixels are read from memory array 14 in accordance with the updated contents of components 30, 42, 43 and 50.
Next, consider the content and operation of the initial line address registers ILAR 1 through ILAR 7. Those registers contain a number which can be expressed mathematically as BA+(TOPY)(IW)(32)+(TOPX)-X min -(Y min )(IW)(32). In this expression, the terms BA, TOPX, TOPY, IW and X min are as defined above; and the term Y min is the vertical position (in blocks) of the top of the viewport relative to screen 16.
At the start of a new frame, the contents of the registers ILAR 1 through ILAR 7 are respectively loaded into the registers CLAR 1 through CLAR 7. Also, the content of the counters 30 and 43 are reset to 0. Then, counters 30 and 43 sequentially count up to address various locations in the memory array 14 as described above.
Each time counter 43 reaches a count of 19 indicating the end of a line has been reached, the registers CLAR 1 through CLAR 7 are incremented by their corresponding IW registers. As a result, the term -(Y min )(IW)(32) in any particular CLAR register will be completely cancelled to zero when the first word of the horizontal line that passes through the top of the viewport which corresponds to that CLAR register is addressed. For example, the term (9)(10)(32) will be completely cancelled out from register CLAR 1 when counter 30 first reaches a count of 180.
Consider now how control bits in viewport map 32 and viewport-image correlator 42 are initially loaded. Those bits are sent by keyboard/printer controller 12 over bus 13 to logic unit 15 in response to the LOCATE VIEWPORT and OPEN VIEWPORT commands. As previously stated, the LOCATE VIEWPORT command (FIG. 9) defines the location of a viewport on screen 16 in terms of the screen's 300 blocks; and the OPEN VIEWPORT command (FIG. 10) correlates a portion of an image in memory 14 with a particular viewport.
Whenever a LOCATE VIEWPORT command is entered via keyboard 10, controller 12 determines which of the bits in viewport map 32 must be set in order to define a viewport as specified by the command parameters X min , X max , Y min , and Y max . Similarly, whenever an OPEN VIEWPORT command is entered via keyboard 10, controller 12 determines what the content of registers IWR and ILAR should be from the parameters X min , Y min , TOPX, TOPY, and IW.
After controller 12 finishes the above calculations, it sends a multiword message M1 over bus 13 to a buffer 50 in the screen control logic unit 15; and this message indicates a new set of bits for one of the columns in viewport map 32 and the corresponding IWR and ILAR registers. From buffer 15, the new set of bits is sent over conductors 51 to viewport map 32 and the IWR and ILAR registers in response to control signals CTL1 and CTL6. This occurs during the horizontal retrace time on screen 16.
Suitably, one portion of this message is a three bit binary code that identifies one of the viewports; another portion is a three hundred bit pattern that defines the bits in map 32 for the identified viewport; and another portion is a twenty-four bit pattern that defines the content of the viewport's IWR and ILAR registers.
Turning now to FIG. 3, the timing by which the above operations are performed will be described. As FIG. 3 illustrates, the above operations are performed in a "pipelined" fashion. Screen control logic 15 forms one stage of the pipeline; bus 13 forms a second stage of the pipeline; memory 14 forms a third stage; and shifter 49 forms the last stage.
Each of the various pipeline stages perform their respective operations on different pixel words. For example, during time interval T0, unit 15 forms the address of the word that is to be displayed in block 0. Then, during time interval Tl, unit 15 forms the address of the word that is to be displayed in block 1, while simultaneously, the previously formed address is sent on bus 13 to memory 14.
During the next time interval T2, unit 15 forms the address of the word of pixels that is to be displayed in block 2; bus 13 sends the address of the word that is to be displayed in block 1 to memory 14; and memory 14 sends the word of pixels that is to be displayed in block 0 to bus 17.
Then during the next time interval T3, unit 15 forms the address of the word of pixels that is to be displayed in block 3; bus 13 sends the address of the word that is to be displayed in block 2 to memory 14; memory 14 sends the word of pixels that is to be displayed in block 1 to bus 17; and shifter 49 serially shifts the pixels that are to be displayed in block 0 onto bus 18 to the screen.
The above sequence continues until time interval T22, at which time one complete line of pixels has been sent to the screen 16. Then a horizontal retrace occurs, and logic unit 15 is free to update the contents of the viewport map 32 and CLAR registers as was described above.
Pixels are serially shifted on bus 18 to screen 16 at a speed that is determined by the speed of the horizontal trace in a forward direction across screen 16. In one embodiment, a complete word of pixels is shifted to screen 16 every 1268 nanoseconds.
Preferably, each of the above-described pipelined stages perform their respective tasks within the time that one word of pixels is shifted to screen 16. This may be achieved, for example, by constructing each of the stages of high-speed Schottky T 2 L components.
Specifically, components 30, 32, 34, 36, 38, 40, 42, 43, 44, 48, 14, 49, 50 and 52 may respectively be 74163, 4801, 74148, 2910, 82S129, 74374, 74374, 74163, 74283, 74244, 4864, 74166, 74163 and 74373. Also, controller 12 may be a 8086 microprocessor that is programmed to send the above-defined messages to control unit 15 in response to the keyboard commands. A flow chart of one such program for all keyboard commands is attached at the end of this Detailed Description as an appendix.
Next, reference should be made to FIGS. 4A, 4B, and 4C in which the operation of a modified embodiment of the system of FIGS. 1-3 will be described. With this embodiment, the images that are displayed in the various viewports on screen 16 can be rearranged just like several sheets of paper in a stack can be rearranged. This occurs in response to a REVIEW VIEWPORT command which is entered via keyboard 10.
For example, FIG. 4A illustrates screen 16 having viewports V1, V2, and V7 defined thereon. Viewport 7 has the highest priority; viewport 2 has the middle priority; viewport 1 has the lowest priority; and each of the viewports display portions of respective images in accordance with their priority.
Next, FIG. 4B shows the viewports V1', V2', and V7, which show the same images as viewports V1, V2, and V7, but the relative priorities of the viewports on screen 16 have been changed. Specifically, viewport V2' has the highest priority, viewport V1' has the middle priority, and viewport V7' has the lowest priority. This occurs in response to the REVIEW VIEWPORT command.
Similarly, in FIG. 4C, screen 16 contains viewports V1", V2", and V7" which show the same images as viewports V1', V2', and V7'; but again the relative priorities of the viewports have again been changed by the REVIEW VIEWPORT command. Specifically, the priority order is first V1", then V7", and then V2".
When the REVIEW VIEWPORT command is entered via keyboard 10, the number of the viewport that is to have the 0 highest priority is also entered. Each of the other viewport priorities are then also changed according to expression: new priority=(old priority+6 - priority of identified viewport) modulo 7. Consider now how this REVIEW VIEWPORT command is implemented. To begin, assume that in order to define the viewports and their respective images and priorities as illustrated in screen 16 of FIG. 4A, the following control signals are stored in unit 15:
(a) Column 1 of map 32 together with registers IWR 1 and ILAR 1 contain a bit pattern which is herein identified as BP#1,
(b) Column 2 of map 32 together with registers IWR 2 ILAR 2 contain a bit pattern which is herein identified as BP#2, and
(c) Column 7 of map 32 together with registers IWR 7 and ILAR 7 contain a bit pattern which is herein identified as BP#7.
FIG. 4A illustrates that bit patterns BP#1, BP#2, and BP#7 are located as described in (a), (b), (c) above. By comparison, FIG. 4B illustrates where those same bit patterns are located in components 32 and 42 in order to rearrange viewports V1, V2, and V7 as viewports V2', V1', and V7'. Specifically, bit pattern BP#2 is moved to column 7 and its associated IWR and ILAR registers; bit pattern BP#1 is moved to column 2 and its associated IWR and ILAR registers; and bit pattern BP#7 is moved to column 1 and its associated IWR and ILAR registers.
In like manner, FIG. 4C illustrates where bit patterns BP#1, BP#2, and BP#7 are located in components 32 and 42 in order to rearrange viewports V1'. V2', and V7' as viewports V1", V2", and V7". Specifically, bit pattern BP#1 is moved to column 7 in memory 32 and its associated registers; bit pattern BP#7 is moved to column 2 of memory 32 and its associated registers; and bit pattern BP#2 is moved to column 1 of memory 32 and its associated registers.
Suitably, this moving occurs in response to controller 12 sending three of the previously defined M1 messages on bus 13 to buffer 50. One such message can be handled by unit 15 during each horizontal retrace of screen 16. So the entire viewport rearranging operation that occurs from FIG. 4A to FIG. 4B, or from FIG. 4B to FIG. 4C, occurs within only three horizontal retrace times. Thus, to achieve this operation, no actual movement of the images in memory 14 occurs at all.
Turning now to FIG. 5, a modification to unit 15 will be described which enables the REVIEW VIEWPORT command to be implemented in an alternative fashion. This modification includes a shifter circuit 60 which is disposed between the viewport map memory 32 and the viewport select logic 34. Conductors 33a transmit the seven signals from memory 32 to input terminals on shifter 60; and conductors 33b transmit those same signals after they have been shifted to the input terminals of the viewport select logic 34.
Shifter 60 has control leads 61; and it operates to shift the signals on the conductors 33a in an end-around fashion by a number of bit positions as specified by a like number on the leads 61. For example, if the signals on the leads 61 indicate the number of one, then the signals on conductors 33a-1 and 33a-7 are respectively transferred to conductors 33b-2 and 33b-1. Suitably, shifter 60 is comprised of several 74350 chips.
Also included in the FIG. 5 circuit is a register 62. It is coupled to buffer 50 to receive the 3-bit number that specifies the number of bit positions by which the viewport signals on the conductors 33a are to be shifted. From register 62, the 3-bit number is sent to the control leads 61 on shifter 60.
By this mechanism, the number of bits that must be sent over bus 13 to logic unit 15 in order to implement the REVIEW VIEWPORT command is substantially reduced. Specifically, all that needs to be sent is the 3-bit number for register 61. A microprogram in control memory 38 then operates to sense that number and swap the contents of the IWR and ILAR registers in accordance with that number. This swapping occurs by passing the contents of those registers through components 45, 44, and 47 in response to the CTL1 control signals.
Referring now to FIG. 6, still another modification to the FIG. 2 embodiment will be described. With this modification, each of the viewports on screen 16 has its own independent color map. In other words, each image that is displayed through its respective viewport has its own independent set of colors.
In addition, with this modification, each viewport on screen 16 can blink at its own independent rate. When an image blinks, it changes from one color to another in a repetitive fashion. Further, the duty cycle with which each viewport blinks is independently controlled.
Also with this modification, a screen overlay pattern is provided on screen 16. This screen overlay pattern may have any shape (such as a cursor) and it can move independent of the viewport boundaries.
Consider now the details of the circuitry that makes up the FIG. 6 modification. It includes a memory array 71 which contains sixteen color maps. In FIG. 6, individual color maps are indicated by reference numerals 71-0 through 71-15.
Each of the color maps has a red color section, a green color section, and a blue color section. In FIG. 6, the red color section of color map 71-0 is labeled "RED 0"; the green color section of color map 71-0 is labeled "GREEN 0"; etc.
Also, each color section of color maps 71-0 through 71-15 contains 64 entries; and each entry contains two pairs of color signals. This is indicated in FIG. 6 for the red color section of color map 71-15 by reference numeral 72. There the 64 entries are labeled "ENTRY 0" through "ENTRY 63"; one pair of color signals is in columns 72a and 72b; and another pair of color signals is in columns 72c and 72d.
Each of the entries 0 through 63 of color section 72 contains two pairs of red colors. For example, one pair of red colors in ENTRY 0 is identified as R15-0A and R15-0B wherein the letter R indicates red, the number 15 indicates the fifteenth color map, and the number 0 indicates entry 0. The other pair of red colors in ENTRY 0 is identified as R15-0C and R15-0D. Suitably, each of those red colors is specified by a six bit number.
Red colors from the red color sections are sent on conductors 73R to a digital-to-analog converter 74R whereupon the corresponding analog signals are sent on conductors 75R to screen 16. Similarly, green colors are sent to screen 16 via conductors 73G, D/A converter 74G, and conductors 75G; while blue colors are sent to screen 16 via conductors 73B, D/A converter 74B, and conductors 75B.
Consider now the manner in which the various colors in array 71 are selectively addressed. Four address bits for the array are sent on conductors 76 by a viewport-color map correlator 77. Correlator 77 also has input terminals which are coupled via conductors 35 to the previously described module 34 to thereby receive the number of the highest priority viewport in a particular block.
Correlator 77 contains seven four-bit registers, one for each viewport. The register for viewport #1 is labeled 77-1; the register for viewport #2 is labeled 77-2; etc. In operation, correlator 77 receives the number of a viewport on conductors 35; and in response thereto, it transfers the content of that viewport's register onto the conductors 76. Those four bits have one of sixteen binary states which select one of the sixteen color maps.
Additional address bits are also received by array 71 from the previously described pixel shifter 49. Recall that shifter 49 receives pixel words on bus 17 from image memory 14; and it shifts the individual pixels in those words one at a time onto conductors 18. Each of the pixels on the conductors 18 has six bits or sixty-four possible states; and they are used by array 71 to select one of the entries from all three sections in the color map which correlator 77 selected.
One other address bit is also received by array 71 on a conductor 78. This address bit is labeled "SO" in FIG. 6 which stands for "screen overlay". Bit "SO" comes from a parallel-serial shifter 79; and shifter 79 has its parallel inputs coupled via conductors 80 to a screen overlay memory 81.
Memory 81 contains one bit for each pixel on screen 16. Thus, in the embodiment where screen 16 is 20×15 blocks with each block being 32×32 pixels, memory 81 is also 20×15 blocks and each block contains 32×32 bits. One word of thirty-two bits in memory 18 is addressed by the combination of the previously described block counter 30 and line counter 50. They are coupled to address input terminals of memory 81 by conductors 31 and 51 respectively.
A bit pattern is stored in memory 81 which defines the position and shape of the overlay on screen 16. In particular, if the bit at one location in memory 81 is a logical "one", then the overlay pattern exists at that same location on screen 16; whereas if the bit is a "zero", then the overlay pattern does not exist at that location. Those "one" bits are arranged in memory 81 in any selectable pattern (such as a cursor that is shaped as an arrow or a star) and are positioned at any location in the memory.
Individual bits on conductor 78 are shifted in synchronization with the pixels on conductors 18 to the memory array 71. Then, if a particular bit on conductor 78 is a "zero", memory 71 selects the pair of colors in columns 72a and 72b of a color map; whereas if a particular bit on conductor 78 is a "one", then array 71 selects the pair of colors in columns 72c and 72d of a color map.
Still another address bit is received by array 71 on a conductor 82. This bit is a blink bit; and it is identified in FIG. 6 as BL. The blink bit is sent to conductor 82 by a blink register 83. Register 83 has respective bits for each of the viewports; and they are identified as bits 83-0 through 83-7.
Individual bits in blink register 83 are addressed by the viewport select signals on the conductors 35. Specifically, blink bit 83-1 is addressed if the viewport select signals identify viewport number one; blink bit 83-2 is addressed if the viewport select signals identify viewport number two; etc.
In array 71, the blink bit on conductor 82 is used to select one color from a pair in a particular entry of a color map. Suitably, the leftmost color of a pair is selected if the blink bit is a "zero"; and the rightmost color of a pair is selected if the blink bit is a "one". This is indicated by the Boolean expressions in color map section 72.
From the above description, it should be evident that each of the images that is displayed through its respective viewport has its own independent set of colors. This is because each viewport selects its own color map via the viewport-color map correlator 77. Thus, a single pixel in memory array 14 will be displayed on screen 16 as any one of several different colors depending upon which viewport that pixel is correlated to.
A set of colors is loaded into memory array 71 by entering a LOAD COLOR MEMORY command (FIG. 16) via keyboard 10. Also, a color map ID and color section ID are entered along with the desired color bit pattern. That data is then sent over bus 13 to buffer 52 whereupon the color bit pattern is written into the identified color map section by means of control signals CTL7 from control register 40. This occurs during a screen retrace time.
Likewise, any desired bit pattern can be loaded into correlator 77 by entering a LOAD COLOR MAP CORRELATOR command (FIG. 17) via keyboard 10 along with a register identification number and the desired bit pattern. That data is then sent over bus 13 to buffer 52; whereupon the desired bit pattern is written into the identified register by means of control signals CTL8 from control register 40.
Further from the above, it should be evident that each of the viewports on screen 16 can blink at its own independent frequency and duty cycle. This is because each viewport has its own blink bit in blink register 83; and the pair of colors in a color map entry are displayed at the same frequency and duty cycle as the viewport's blink bit.
Preferably, a microprocessor 84 is included in the FIG. 6 embodiment to change the state of the individual bits in register 83 at respective frequency and duty cycles. In operation, a SET BLINK command (FIG. 18) is entered via keyboard 10 along with the ID of one particular blink bit in register 83. Also, the desired frequency and duty cycle of that blink bit is entered. By duty cycle is meant the ratio of the time interval that a blink bit is a "one" to a time interval equal to the reciprocal of the frequency.
That data is sent over bus 13 to buffer 52; whereupon it is transferred on conductors 53 to microprocessor 84 in response to control signals CTL9. Microprocessor 84 then sets up an internal timer which interrupts the processor each time the blink bit is to change. Then microprocessor 84 sends control signals CS on a conductor 85 which causes the specified blink bit to change state.
Further from the above description, it should be evident that the FIG. 6 embodiment provides a cursor that moves independent of the viewport boundaries and has an arbitrarily defined shape. This is because in memory 81, the "one" bits can be stored in any pattern and at any position.
Those "one" bits are stored in response to a LOAD OVERLAY MEMORY command (FIG. 19) which is entered via keyboard 10 along with the desired bit pattern. That data is then sent over bus 13 to buffer 52; whereupon the bit pattern is transferred into memory 81 during a screen retrace time by means of control signals CTL10 from control register 40.
Suitably, each of the above described components is constructed of high speed Schottky T 2 L logic. For example, components 71, 74, 77, 79, 81, and 83 can respectively be 1420, HDG0605, 74219A, 74166, 4864, and 74373 chips.
Various preferred embodiments of the invention have now been described in detail. In addition, however, many changes and modifications can be made to these details without departing from the nature and spirit of the invention.
For example, the total number of viewports can be increased or decreased. Similarly, the number of blocks per frame, the number of lines per block, the number of pixels per word, and the number of bits per pixel can all be increased or decreased. Further, additional commands or transducers, such as a "mouse", can be utilized to initially form the images in the image memory 14.
Accordingly, since many such modifications can be readily made to the above described specific embodiments, it is to be understood that this invention is not limited to said details but is defined by the appended claims. | A system for electronically displaying portions of several different images on a CRT screen comprises: a memory for storing a complete first image as several pixels in one section of the memory and a complete second image as several other pixels in another section of the memory such that the total number of stored pixels is substantially larger than the number of pixels on the screen; a logic circuit for reading a sequence of the pixels at non-contiguous locations in the first and second images and for transferring them, in the sequence in which they are read, to the screen for display with no frame buffer therebetween; the logic circuit for reading including a module for forming non-contiguous addresses for the pixels in the sequence in which they are read with the address of one word of pixels being formed during the time interval that a previously addressed word of pixels is being displayed on the screen. | 6 |
[0001] This invention relates to an underwater light, and more particularly to an underwater light which is easy to install and which is easy to replace the bulb.
BACKGROUND OF THE INVENTION
[0002] Underwater light sources have been installed for many years in order to illuminate canals in housing developments. These lights attract fish, provide illumination and generally are attractive.
[0003] There are problems with installing and maintaining prior art underwater lights. As a general rule, when the bulb of a prior art underwater light burns out, it is difficult and expensive to replace the bulb because of the construction of the assembly.
[0004] Underwater light assemblies are known in the prior art, such as in U.S. Pat. Nos. 1,745,901; 3,005,908; 3,946,263; 4,598,346 and 6,315,429 and printed application 2002/0178641. Of more general interest are U.S. Pat. Nos. 4,500,151 and 4,869,683.
SUMMARY OF THE INVENTION
[0005] This invention addresses the need of an underwater lighting system that is easily installed and inexpensively repaired by the consumer. Other systems advertise the need of the installation and the factory replacement of the lamp by trained individuals. The replacement of the lamp in this system is easily done by anyone familiar with the use of a soldering gun. Unlike other systems using a mogul socket or porcelain lamp holder, made by such manufacturers as Philips, to couple the lamp electrically to the wires, none is needed or used in this system. A simple yet very effective method of coupling the wires to the lamp is done by soldering, eliminating one component prone to failure.
[0006] This underwater lighting system can be easily placed in the water, which is typically a canal and be easily retrieved with minimal effort. Current systems use a non-flexible conduit to enclose and protect the wire. This system uses a highly flexible conduit to protect the wire while enabling the simple procedure of deployment and retrieval.
[0007] This invention addresses the need of an underwater system that allows for the placement of the lamp in various depths of water. It is generally known that lamps placed approximately no deeper than 5 feet below the water surface allow both the desired brightness needed while allowing the lamp to be deep enough to insure sailboat keels and boat props from inadvertently damaging the lamp. The combination of new and different components allow for this result. These physical differences are substantial and significant. Previous references have not shown a combination of these components, resulting in an operational advantage to the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an overall schematic view of the underwater lighting system of this invention;
[0009] FIG. 2 is a side view of a high profile model used when water depth is greater than 7 feet; and
[0010] FIG. 3 is a view similar to FIG. 2 , showing the lamp in enlarged cross-section compared to the weight assembly.
DETAILED DESCRIPTION
[0011] Referring to FIGS. 1-3 , the underwater light 10 of this invention comprises a lamp 12 electrically coupled to a transformer 14 by a pair of suitable insulated wires 16 , 17 being part of an insulated three wire assembly 15 received in and protected by a flexible conduit 18 . Currently the preferred lamp 12 is a mercury vapor lamp, although any high intensity lamp may be used. Mercury vapor lamps have been used successfully by numerous builders of underwater lighting systems since the early to mid 1990's. The transformer 14 is controlled by a photoelectric eye (not shown) that automatically turns the light on at night and off at daybreak. The transformer 14 is coupled to an electrical source on shore using a ground fault circuit interrupter to meet electrical code requirements.
[0012] FIG. 2 shows a high profile model used when water depth is greater than 7 feet. The flexible conduit 18 is coupled directly to a PVC nipple 20 of a lamp enclosure 22 . Lamps have been successfully placed in water to depths of 20 feet. This system does not use rebar or a ballasted receptacle to anchor the receptacle to the bottom. Instead, an adjustable weight 24 , separate and unattached from the lamp enclosure, is incorporated. This moveable weight can be made from any material not susceptible to disintegration in water. Currently, the preferred substance is concrete.
[0013] The weight 24 is designed using a small length of 1¼″ O.D. PVC pipe 26 running through the concrete. The PVC pipe 26 is only large enough to allow the flexible conduit 18 to enter and exit. The weight 24 is then run down the length of the flexible conduit 18 to a position pre-determined by water depth. The weight 24 is secured in place by stainless steel clamps 28 along a portion of the flexible conduit 7 which preferably are sufficiently large to prevent weight 24 from moving along the conduit 18 . The moveable weight 24 not only allows for different depths of water levels but also allows flexibility for the lamp to move vertically in the water, thus helping to avoid objects that may hit and break the lamp. Rebar and other methods of weighting by previous systems are not needed. If more weight is needed for conditions where stronger currents are found, additional weights can be slid down the length of the conduit 18 .
[0014] When water depths do not exceed 6 to 7 feet, a shallow water version of this invention may be devised simply by placing a rigid 90° ell attached to the nipple 20 at one end and to the flexible conduit 18 at the other end.
[0015] FIG. 3 shows the lamp 12 and the enclosure 22 of this invention. The lamp 12 includes a glass envelope or bulb 30 housing one or more electrically powered light producing elements 32 and a metal fitting 34 typically providing conventional screw threads 36 thereon and a central button 38 insulated from the metal fitting 34 . The lamp 12 is accordingly of conventional design and would normally screw into a conventional porcelain lamp holder, such as a Philips mogul socket. Instead, in this invention, the metal conductors of a pair of insulated wires 40 , 42 are soldered to the metal threads 36 and button 38 to provide the necessary electrical connection.
[0016] The lamp enclosure 22 comprises an electrically insulating nipple 44 juxtaposed to and preferably abutting the glass envelope 30 and receiving the metal fitting 34 . The nipple 44 is typically made of a polymeric material, such as polyvinyl chloride polymer or other suitable plastic. The space between the lamp 12 and the nipple 44 is filled with a suitable sealant 46 , which is preferably an epoxy sealant such as is available from Minnesota Mining and Manufacturing, Inc. of St. Paul, Minn. under the name SCOTCH-CAST. As shown in FIG. 3 , the sealant 46 covers the button 38 and the ends of the wires 40 , 42 thereby electrically isolating the lamp 12 from any water that might accidentally enter the lamp enclosure 22 . Preferably, the sealant 46 extends to both ends of the nipple 44 . Because most wires used inside the flexible conduit 18 include a ground wire 45 , one end of an insulated wire 47 is embedded in the sealant 46 to provide an anchor for the ground wire 45 .
[0017] The wires 40 , 42 are connected to wires 16 , 17 by water proof wire nuts 50 which are sufficient to keep water away from the metal conductors in the wires 16 , 17 , 40 , 42 . Suitable water proof wire nuts are commercially available from King Innovation of St. Charles, Mo. under the name DRYCONN. In the alternative, conventional wire nuts can be made water proof by injecting a sealant, such as the sealant 46 , into the open end of the wire nuts 50 . Although a water proof wire nut 51 may be used to connect the ground wire 45 to the wire 47 , the wire nut 51 is preferably not waterproof so the ground fault indicator acting on the wire assembly 15 at the transformer 14 will shut off in the event water seeps into the lamp enclosure 22 and the wire 47 inside the sealant 46 has grounded to metal components of the lamp 12 .
[0018] The lamp enclosure also comprises a rubber boot 52 , which is typically a tapered rubber plumber's boot of suitable size, usually 2″×3″, clamped to the nipple 44 by one or more suitable clamps 54 , such as stainless steel or other non-corrodible hose clamps. The end of the boot 52 is closed off by an electrically insulated cap 56 made from polyvinyl chloride or other suitable polymer providing an outlet in which the nipple 22 is threaded. The cap 56 includes an end cap 58 having a nipple 60 glued in the open end thereof to provide a sufficient length so the boot 52 may be easily clamped to the cap 56 by one or more clamps 62 , such as stainless steel or other non-corrodible hose clamps. There is an advantage for the boot 52 to be tapered. The small end of the boot 52 allows the nipple 44 to slide inside. The large end of the boot 52 slides over the nipple 60 comprising part of the end cap 56 and provides sufficient room to tie a knot in the cable assembly 15 . A potting compound 64 , such as the same material as the sealant 46 , covers the bottom of the end cap 58 and seals the enclosure 22 against water entry.
[0019] Manufacture and assembly of the underwater light should now be apparent. In a suitable shop, the conductors of the wires 40 , 42 are soldered to the metal fitting 34 and button 38 . The nipple 44 is placed over the metal fitting 34 , the bulb 12 is inverted and the sealant 46 is poured into the nipple 44 and embedding the end of the wire 47 in the sealant 46 . A bead of caulk 66 is applied between the base of the bulb 12 and the nipple 44 .
[0020] At the installation location, the wires assembly 15 providing the wires 16 , 17 , 45 is run through a suitable length of the conduit 18 , the weight 24 and its pipe 26 are installed on the conduit 18 at a suitable location, and the wire assembly 15 is passed through the nipple 22 and knotted. The wire nuts 50 are attached to the metal conductors of the wires 16 , 17 , 45 , 40 , 42 , 47 . The rubber boot 52 is then attached to the nipple 44 and to the end cap 56 and the underwater light 10 is placed in the water. In the event the water is very shallow, a rigid PVC ell (not shown) is attached to the nipple 22 and the weight 24 is positioned near the opposite end of the ell (not shown) to keep the light 10 near the bottom of the water.
[0021] An important feature of this invention is the ability to easily replace the lamp 12 . When the lamp 12 burns out, the homeowner or repairman fishes the light 10 out of the water simply by pulling on the conduit 18 . The clamps 54 are loosened and removed and the nipple 44 is removed from the boot 52 , exposing the wire nuts 50 . The wires electrically connecting the nipple 44 are disconnected by removing the exposed nuts 50 , 51 . A new lamp/nipple assembly is installed by connecting the wires of the new assembly to the existing wires 16 , 17 , 45 with new wire nuts 50 , 51 . The lamp/nipple assembly is then inserted back into the boot 52 and new clamps 54 are installed and tightened. The light 10 is ready to be placed back in the water. It will accordingly be seen that an important feature of this invention is that the lamp 12 is easy to replace and that, with the exception of the wire nuts 50 , 51 and burned out bulb, every component of the underwater light 10 is reused thereby minimizing overall costs of this invention.
[0022] Although this invention has been disclosed and described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and in the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed. | An underwater light includes a high intensity lamp placed in an enclosure that allows for easy lamp replacement in case of breakage or natural failure. Electrical wires are soldered to a metal fitting on the lamp. The metal fitting is received in a plastic nipple and the space between the fitting and nipple is filled with a sealant, leaving the ends of the wires exposed. The wires are connected by water proof wire nuts and the end of the lamp is enclosed by a rubber boot and an end cap. When the lamp burns out, it is easily replaced by fishing the light out of the water, removing the rubber boot to expose the wire nuts. The wire nuts are removed and the old lamp discarded. A new lamp is installed in reverse order. | 7 |
The present application claims priority based on U.S. Provisional Application No. 60/493,937, entitled “HIGH-THROUGHPUT WIRELESS LAN SYSTEM APPARATUS AND ASSOCIATED METHODS” filed Aug. 8, 2003.
BACKGROUND
To address the problem of ever-increasing bandwidth requirements that are placed on wireless data communications systems, various techniques are being developed to allow multiple devices to communicate with a single base station by sharing a single channel. In one such technique, a base station may transmit or receive separate signals to or from multiple mobile devices at the same time on the same frequency, provided the mobile devices are located in sufficiently different directions from the base station. For transmission from the base station, different signals may be simultaneously transmitted from each of separate spaced-apart antennas so that the combined transmissions are directional, i.e., the signal intended for each mobile device may be relatively strong in the direction of that mobile device and relatively weak in other directions. In a similar manner, the base station may receive the combined signals from multiple independent mobile devices at the same time on the same frequency through each of separate spaced-apart antennas, and separate the combined received signals from the multiple antennas into the separate signals from each mobile device through appropriate signal processing so that the reception is directional.
Under currently developing specifications, such as IEEE 802.11 (IEEE is the acronym for the Institute of Electrical and Electronic Engineers, 3 Park Avenue, 17th floor, New York, N.Y.) each mobile device may transmit a data block of variable length, and then wait for a predetermined timeout period after the data block for an acknowledgment from the base station to signify that the base station received the data block. If the base station transmits and receives on the same frequency, that fact may preclude the base station from transmitting and receiving at the same time, so that the base station waits until all incoming data blocks are complete before sending out any acknowledgments. However, since the data blocks are of variable length, a mobile device sending a short data block may experience an acknowledgment timeout while the base station is still receiving a long data block from another mobile device. The resulting unnecessary retransmission of the short data block may cause inefficiencies in the overall data communications, and under some circumstances may even result in a service interruption.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
FIG. 1 shows a diagram of a communications network, according to an embodiment of the invention.
FIG. 2 shows a timing diagram of a communications sequence involving a base station and multiple mobile devices, according to an embodiment of the invention.
FIG. 3 shows a flow chart of a method of using channel clear detection, according to an embodiment of the invention.
FIG. 4 shows a block diagram of a mobile device, according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.
References to “one embodiment”, “an embodiment”, “example embodiment”, “various embodiments”, etc., indicate that the embodiment(s) of the invention so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may.
In the following description and claims, the terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are either in direct physical or electrical contact, or that two or more elements are not in direct contact with each other but yet still co-operate or interact with each other.
As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.
Unless specifically stated otherwise, as apparent from the following discussions, it is appreciated that throughout the specification discussions utilizing terms such as “processing,” “computing,” “calculating,” or the like, refer to the action and/or processes of a computer or computing system, or similar electronic computing device, that manipulate and/or transform data represented as physical, such as electronic, quantities into other data similarly represented as physical quantities.
In a similar manner, the term “processor” may refer to any device or portion of a device that processes electronic data from registers and/or memory to transform that electronic data into other electronic data that may be stored in registers and/or memory. A “computing platform” may comprise one or more processors.
In the context of this document, the term “wireless” and its derivatives may be used to describe circuits, devices, systems, methods, techniques, communications channels, etc., that may communicate data through the use of modulated electromagnetic radiation through a non-solid medium. The term does not imply that the associated devices do not contain any wires, although in some embodiments they might not.
In keeping with common industry terminology, the terms “base station”, “access point”, and “AP” may be used interchangeably herein to describe an electronic device that may communicate wirelessly and substantially simultaneously with multiple other electronic devices, while the terms “mobile device” and “STA” may be used interchangeably to describe any of those multiple other electronic devices, which may have the capability to be moved and still communicate, though movement is not a requirement. However, the scope of the invention is not limited to devices that are labeled with those terms. Similarly, the terms “spatial division multiple access” and SDMA may be used interchangeably. As used herein, these terms are intended to encompass any communication technique in which different signals may be transmitted by different antennas substantially simultaneously from the same device such that the combined transmitted signals result in different signals intended for different devices being transmitted substantially in different directions on the same frequency, and/or techniques in which different signals may be received substantially simultaneously through multiple antennas on the same frequency from different devices in different directions and the different signals may be separated from each other through suitable processing. The term “same frequency”, as used herein, may include slight variations in the exact frequency due to such things as bandwidth tolerance, Doppler shift adaptations, parameter drift, etc. Two or more transmissions to different devices are considered substantially simultaneous if at least a portion of each transmission to the different devices occurs at the same time, but does not imply that the different transmissions must start and/or end at the same time, although they may. Similarly, two or more receptions from different devices are considered substantially simultaneous if at least a portion of each reception from the different devices occurs at the same time, but does not imply that the different transmissions must start and/or end at the same time, although they may. Variations of the words represented by the term SDMA may sometimes be used by others, such as but not limited to substituting “space” for “spatial”, or “diversity” for “division”. The scope of various embodiments of the invention is intended to encompass such differences in nomenclature.
Various embodiments of the invention may use a sliding timeout period by a STA to accommodate a situation in which transmissions from one or more other STAs may be longer than the transmission from the STA initiating the timeout period. This sliding timeout period may prevent an inadvertent timeout in the STA by waiting until the AP has finished receiving transmissions from the STAs before beginning the timeout period, rather than beginning the timeout period while other STAs may still be transmitting to the AP.
FIG. 1 shows a diagram of a communications network, according to an embodiment of the invention. The illustrated embodiment of an SDMA-based network shows an AP 110 that may communicate with multiple STAs 131 - 134 located in different directions from the AP in the manner described herein. Although AP 110 is shown with four antennas 120 to simultaneously communicate with up to four STAs at a time, other embodiments may have other arrangements (e.g., AP 110 may have two, three, or more than four antennas). Each STA may have one or more antennas to communicate with the AP 110 . In some embodiments the one or more STA antennas may be adapted to operate as omnidirectional antennas, but in other embodiments the one or more STA antennas may be adapted to operate as directional antennas. In some embodiments the STAs may be in fixed locations, but in other embodiments at least some of the STAs may be moved during and/or between communications sequences. In some embodiments the AP 110 may be in a fixed location, but in other embodiments the AP 110 may be mobile.
FIG. 2 shows a timing diagram of a communications sequence involving an AP and two STAs (labeled STA 1 and STA 2 ), according to an embodiment of the invention. Although the illustrated embodiment shows two STAs, other embodiments may comprise other quantities of STAs. In the AP section of FIG. 2 , the line labeled 1 may indicate directional transmissions from the AP to STA 1 , while the line labeled 2 may indicate directional transmissions from the AP to STA 2 . The lines STA 1 and STA 2 may indicate transmissions from STA 1 to the AP and from STA 2 to the AP, respectively. In some embodiments, transmissions from STA 1 and STA 2 are omnidirectional (e.g., substantially in a 360 degree circle around the transmitting STA), although in other embodiments the transmissions from STA 1 and STA 2 may be directional.
Communications between the AP and the STAs may include other communications sequences not shown in FIG. 2 , e.g., communications that occur before and/or after the sequences shown. Such sequences may include, but are not limited to, such things as polls, data, acknowledgements, etc.
In FIG. 2 , it may be assumed that the AP has already established whatever parameters may be needed to directionally transmit different data to multiple STAs substantially simultaneously using SDMA techniques, and to receive different data from multiple STAs substantially simultaneously. Using this capability, the AP may transmit to both STA 1 and STA 2 during polling time period t 1 . In the embodiment shown, the AP transmits a poll (POL 1 ) to STA 1 , requesting a response to the POLL 1 from STA 1 , and the AP transmits a poll (POLL 2 ) to STA 2 , substantially simultaneously with POLL 1 , requesting a response to the POLL 2 from STA 2 . During the polling time period t 1 , any of the poll transmissions may include information other than the poll, e.g, data, administrative information, etc.
During time period t 2 , STA 1 and STA 2 may transmit responses to the AP substantially simultaneously. In the illustrated embodiment, these responses each include data transmitted to the AP in response to the poll from the AP, but other embodiments may produce other types of responses, e.g., administrative information, a request for a particular type of acknowledgment, etc.
During time period t 3 , after all STAs have finished transmitting, the AP may individually acknowledge these responses substantially simultaneously, as shown. ACK 1 is shown as an acknowledgement to the response from STA 1 , while ACK 2 is shown as an acknowledgement to the response from STA 2 . If a given STA does not receive an acknowledgement within a pre-defined timeout period, it may assume the response was not correctly received by the AP and may re-transmit the response when polled again.
The control of timeout periods, whether in the AP or a STA, may be implemented in any feasible manner, e.g., a hardware counter, a software counter, etc.
In the operation shown in FIG. 2 , the response from STA 2 is significantly shorter than the response from STA 1 . If STA 2 begins a timeout period immediately after completing its response, the timeout period may expire before the AP can send an acknowledgement during t 3 , and may even expire while STA 1 is still transmitting, thereby possibly creating a need for a retransmission from STA 2 . To avoid this condition, STA 2 may monitor the channel immediately after completing its response to see if the channel is busy, and not permit a timeout period to be initiated if any STAs are still transmitting.
In some embodiments, after each STA completes its response, it monitors the channel for a clear channel condition (i.e., no STAs are perceived to be transmitting on the channel). In the illustrated example of FIG. 2 , STA 2 may begin monitoring the channel immediately after completion of the DATA 2 response, and detect that another STA is still transmitting on the channel. In the illustrated example, STA 1 is still transmitting, but in the general case STA 2 may not know the identity of the transmitting STA, only that at least one STA is still transmitting.
Once STA 1 stops transmitting, it may also begin monitoring for a clear channel condition immediately after completion of the DATA 1 response. In the illustrated example, no other STAs are transmitting at that time, so the channel may be determined immediately to be clear.
In some embodiments, detection of a clear channel condition may be accomplished by monitoring for the transmission of information (e.g., data, administrative information, etc.) on the channel, but other embodiments may use other techniques (e.g., monitoring for a carrier signal, etc.). Once a clear channel condition is detected, the response time period t 2 may end, and the subsequent acknowledgment time period t 3 may begin. In the illustrated embodiments, an interframe space (IFS) is shown between the various time periods t 1 , t 2 , and t 3 , although the scope of the invention is not limited in this respect. An IFS may provide a short time period to allow for things such as, but not limited to: 1) time to allow for tolerances in the timing of different devices, 2) time to perform processing necessary before beginning the next time period, 3) time to allow a device to switch between transmit and receive modes, 4) etc. In some embodiments, all IFS's have the same duration, but in other embodiments the duration of a particular IFS may depend on where it occurs in the overall sequence. In the example shown, when the response time period ends after completion of the longest response, an IFS time period may be experienced before the STAs begin their acknowledgment timeout periods, although the scope of various embodiments of the invention are not limited in this manner.
In the example of FIG. 2 , timeout period TO 1 is the timeout period for STA 1 , and timeout period TO 2 is the timeout period for STA 2 . Each of these timeout period may be controlled within the respective STA through any feasible means. If the STA does not receive its expected acknowledgment from the AP within the timeout period, the STA may assume that its response was not correctly received by the AP, and may then make arrangements to retransmit the response after another poll from the AP. Alternately, the STA may retransmit the response by gaining access to the channel without requiring a poll, although the scope of the invention is not limited in this regard.
FIG. 3 shows a flow chart of a method of using channel clear detection, according to an embodiment of the invention. As shown in flow chart 300 , at 310 a transmission is completed by a STA. For example, this may correspond to the end of the ‘DATA 2 ’ response in FIG. 2 . At 320 the STA may then monitor the channel for any ongoing transmissions by other STAs. The absence of such ongoing transmission is indicated as a ‘clear channel’ condition in the figures, although the scope of the invention is not limited by the use of this terminology. When other STAs are no longer transmitting, as determined at 330 , an acknowledgment timeout period may begin at 340 . The loop formed at 350 and 360 may determine whether the timeout period expires before an ACK is received. If the ACK is received first at 350 , the timeout period may be ended (e.g., cancelled or aborted) at 380 , and other processing (not shown) begun. If the ACK timeout period expires at 360 before an ACK is received, the process may revert to error processing at 370 . Error processing may include various operations, such as preparing to retransmit the information that was not acknowledged, in response to a future poll. Depending on the frequency with which the channel is monitored, and/or the time the STA takes to recognize that a clear channel is actually clear, it is possible that an ACK may be received before the channel is determined to be clear at 330 , in which case the flow may jump directly to 350 / 380 .
Various embodiments of the invention may be implemented in one or a combination of hardware, firmware, and software. Embodiments of the invention may also be implemented as instructions stored on a machine-readable medium, which may be read and executed by a computing platform to perform the operations described herein, for example those operations described in FIG. 3 and the associated text, and any necessary supporting operations such as, but not limited to, placing data into at least one transmit queue for transmission and reading received data from at least one receive queue. A machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer). For example, a machine-readable medium may include read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; and others.
FIG. 4 shows a block diagram of a mobile device, according to an embodiment of the invention. Computing platform 450 may include one or more processors, and at least one of the one or more processors may be a digital signal processor (DSP), although various embodiments of the invention are not limited in this manner. The combination of demodulator-ADC may convert received radio frequency signals from the antenna into digital signals suitable for processing by the computing platform 450 . Similarly, the combination of DAC-modulator may convert digital signals from the computing platform 450 into radio frequency signals suitable for transmission through the antenna. In the illustrated embodiment, STA 131 has one each of antenna 421 , modulator/demodulator 420 , ADC 430 and DAC 440 , but other embodiments may have multiple antennas and/or may have more than one modulator/demodulator 420 , ADC 430 and/or DAC 440 coupled between each antenna and the computing platform 450 . Other components not shown may be included as needed (either within or external to the illustrated components), such as but not limited to amplifiers, filters, oscillators, etc.
The foregoing description is intended to be illustrative and not limiting. Variations may occur to those of skill in the art. Those variations are intended to be included in the various embodiments of the invention, which are limited only by the spirit and scope of the appended claims. | In a spatial division multiple access system that employs acknowledgements to variable length transmissions within a timeout period, a station that has completed its transmission may delay beginning the timeout period until it determines that other stations on the same channel have completed their transmissions. | 7 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/293,614.
FIELD OF THE INVENTION
[0002] The disclosed device relates to transmissions for motorized vehicles. More particularly it relates to a device which functions as a transmission which is coupled at an input end to a power sources such as an internal combustion or turbine engine and transmits the energy from that power source to drive wheels or prop or other propulsion component of a vehicle varying the amount of torque and speed delivered the engine to fit the immediate requirements of the vehicle. The disclosed device could additionally function as a brake for vehicles when configured differently by attaching the output shaft to a generator or other device doing work, or to a fixed position on the frame of the vehicle, and the input shaft to the drive shaft or other shaft that communicates with the wheels of the vehicle to be slowed.
BACKGROUND OF THE INVENTION
[0003] Engine driven vehicles such as automobiles, buses, tractors, boats, and similar vehicles, conventionally use a transmission to communicate power and torque developed by the engine, to the wheels or drive of the vehicle. Additionally, helicopters and boats are frequently in need of changing the nature of the power transmitted from the engine to the propulsion components powering them varying both the torque and speed to a varying requirement. Early vehicles and current industrial vehicles frequently use a manual transmission which contains a series of different gears which may be interrelated to take input power from the engine and output that power to the wheels with sufficient torque and speed for the vehicle while maintaining the engine at optimum speed to operate.
[0004] Automatic transmissions operate to provide the same communication of variable torque and speed to the rear wheels only they do not require manual manipulation by the user nor a clutch to disengage the transmission during gear changes. Just like that of a manual transmission, the automatic transmission's primary job is to allow the engine to operate in its narrow range of speeds while providing a wide range of output speeds and torque to the drive wheels with which it communicates engine power. Without a transmission, vehicles would therefor be limited to one gear ratio and that ratio would have to be selected to allow the car to travel at the desired top speed. Such an arrangement would provide a vehicle with little acceleration when starting out, and, at high speeds, the engine would be nearing it maximum revolutions.
[0005] The key difference between a manual and an automatic transmission is that the manual transmission locks and unlocks different sets of gears to the output shaft to achieve the various gear ratios, while in an automatic transmission, the same set of gears produces all of the different gear ratios. The planetary gearset in the automatic is the device that makes this possible in an automatic transmission. However, planetary gearsets, bands that lock parts of a gearset, and wet clutches that lock other parts of the gear set are prone to failure and slippage. Further, and incredibly complicated hydraulic control system is required to control the clutches and bands and gear sets of a conventional automatic transmission lending more potential problems to long term reliability in such devices.
[0006] As such, there is a pressing need for a transmission which will automatically vary the amount of torque and speed communicated to the wheels of a vehicle from the engine. Such a transmission should have few moving parts and systems to help insure reliability and ease of maintenance. Such a device should provide the optimum torque and speed to the wheels from the engine while allowing the engine to rotate and operate at its optimum performance speed.
SUMMARY OF THE INVENTION
[0007] The above problems, and others are overcome by the herein disclosed constant velocity transmission which provides maximum torque and speed from the engine to the output shaft and the communicating drive component such as wheels on a vehicle, while maintaining the engine at optimum operational speed. The device herein disclosed and described features a minimum of moving parts and control systems to enhance reliability and performance over conventional automatic transmissions which as noted require a plethora of parts and complicated hydraulic operating and control systems.
[0008] The herein disclosed and described constant velocity transmission takes advantage of the principle of fluid friction to transmit rotational forces providing torque and speed to the output shaft from rotating input shaft communicating with the drive motor. Rotating freely or inside of an appropriate housing, the device develops fluid friction between the major components thereby communicating power from the input shaft, connected to the driving motor to an output shaft which rotates in direct correlation to the motor speed. This fluid friction transfers energy communicated from the rotating motor to the output shaft by way of the fluid friction that develops in the layers of fluid moving in the housing in relation to the input shaft velocity. Initially fluid friction is substantially zero until vanes about the circumference of the inside rotating cone shaped drive cone, laterally translate upon the sloped outer surface of the drive cone and move outward toward the inner ribbed surface of the outer drum. As they move closer to inside surface of the outer drive drum, the vanes increase the fluid friction on the inner ribbed surface thereby exerting more pressure on the outer drum and moving it in the direction of rotation. This fluid friction increases proportionally as the vanes move closer to the driven drum and decreases proportionally as the vanes laterally translate on the drive cone and move away from the driven drum.
[0009] This device will function using any number of different viscosity fluids for fluid friction communication, from conventional transmission oil to water with near equal efficiency since the determining factor is the distance between the translating vanes and the inner surface of the driven drum. In the case of watercraft, the water in which the boat itself moves might be used as the fluid for the device and provide additional benefits from an in exhaustive source and inherent cooling from such a large reservoir.
[0010] This device features a front input shaft communicating power from the drive engine to a drive cone, supported on the input shaft inside of a driven drum which in turn communicates power to an output shaft via the aforementioned fluid friction. The input shaft is appropriately supported by bearings and communicates this support to the drive cone. The driven drum acts as a housing for the components which serve to operate the assembled device and is filled with a working fluid such as hydraulic oil.
[0011] The drive cone which is housed internally in the driven drum has slidable drive vanes along its circumference which laterally translate about the center axis of the drive cone. This lateral translation of the drive vanes on the slope or incline of the drive cone frustro-conical shaped exterior causes the distal edges of the drive vanes to move closer to or further away from the vaned interior surface of the driven drum. As the translating drive vanes move outward closer to the inside vaned surface of the driven drum, the working fluid builds up fluid friction between the different layers of fluid moving at different velocities. This fluid friction rotates the output drum with a force that is in relation to the distance between the drive cone mounted vanes and the stater vanes formed on the surface of the drive strum. The smaller the distance, the greater the fluid friction and the consequential greater applied torque. Conversely, the greater the distance, the less applied torque.
[0012] The operation of the device herein disclosed and described is dependent on a working fluid, in this case, light weight oil such as conventional transmission oil. While some of the fluid remains internal inside the driven drum assembly, in the current best mode a reservoir of additional working fluid is stored in an external reservoir until the input shaft is rotated by an external power source such as a conventional gasoline or diesel engine. The input shaft has splines similar in shape to those of a hydraulic pump rotor and rotate inside a pump housing thereby providing pump operation as the shaft rotates. This pumping action provides the means to pressurize the operating fluid of the device during use.
[0013] The input shaft which communicates rotational power from the attached motor, supported by conventional bearings appropriately positioned in the outer housing supports the driven drum. The input shaft terminates into a bearing at the rear of the driven drum at an end plate which is attached to the output shaft which communicates power from the motor to the wheels or other device being powered. This arrangement thus allows the input shaft to rotate the drive cone located inside the driven drum, independently of the driven drum assembly with the communicating motor driving the input shaft and the driven drum driving the output shaft. Fluid friction transfers rotational energy from the drive cone and translating vanes thereon to the driven drum. The fluid friction intensity is inversely proportional to the distance between the movable drive vanes and the driven drum stator vanes. The smaller this distance, the larger the fluid friction.
[0014] Lateral translation of the vanes along the center axis of the drive cone about the slanted exterior surface is provided by a controllable pressure actuator plate. The pressure actuator plate acts to press upon the rear surface of the vanes and translate them up the ramps on the frustro-conical drive cone. A biasing means such as a spring acts on one end of the pressure actuator to move it rearward while a second controllable biasing means such a hydraulic pressure acts on the other end of the pressure actuator to move it toward the drive cone. By increasing the pressure acting to move the pressure actuator toward the drive cone, the reverse pressure from the rearward biasing means is overcome. Conversely, by decreasing the pressure of the second controllable biasing means, the bias provided by the rearward biasing means overcomes that of the controllable biasing means thereby moving the controllable pressure actuator plate away from the drive cone and allowing the vans to translate to a lower position on the drive cone and further away from the stator vanes of the driven drum. In this fashion, the torque from the input shaft communicated to the output shaft from the driven drum may be easily and accurately controlled to an infinite number of settings rendering the device infinitely variable in its ability to adjust the torque communicated to the output shaft.
[0015] As noted above, the device as herein described and disclosed could not only provide an infinitely variable transmission for a vehicle, but also a means to brake the speed of the vehicle by hooking the device to communicate with the rotating wheels on one end, and a fixed position on the vehicle or to a generator or pump on the output end to brake the vehicle by doing work.
[0016] Accordingly, it is the object of this invention claimed herein to provide a simplified automatic transmission device to transmit power from a power plant at varying amounts of torque and speed to the component being driven by the power plant.
[0017] It is another object of this invention to supply an automatic transmission for a vehicle to transmit power from the engine to the wheels at optimum levels of torque for the moment while concurrently maintaining engine speed at optimum levels.
[0018] It is still another object of this invention to supply a device which can also function as a brake for a vehicle by providing resistance to the rotation supplied from the output shaft to the device.
[0019] Further objectives of this invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0020] The accompanying drawings which are incorporated in and form a part of this specification illustrate embodiments of the disclosed processing system and together with the description, serve to explain the principles of the invention.
[0021] [0021]FIG. 1 is a cut away view of the device showing the components in configured for idle.
[0022] [0022]FIG. 2 is a cut away view of the device showing the components engaged to transmit maximum torque.
[0023] [0023]FIG. 3 is an exploded view of the components of the disclosed device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The device 10 herein disclosed functions using fluid friction to transmit rotational force from an input shaft 12 having a center axis 13 therethrough, communicating with a power source such as an internal combustion engine, a turbine engine, a jet engine, or similar means for power generation, to an output shaft 14 which is connected to the component to be driven or powered by the disclosed device 10 . Generally drive wheels, propellers, flywheels, generators, or any such components which require varied torque from the power source during their operation will benefit from using the disclosed device. As is obvious to those skilled in the art the components which use power from an engine or other source named herein are not all inclusive and use of the device 10 herein disclosed to communicate power to any component with varying torque requirements and speeds is anticipated. The various components of the disclosed device 10 may operate inside of an appropriate optional exterior housing 15 , or may be self housed due to the configuration of the assembled device 10 allowing such. In operation, power communicated from the motor or engine or other means for power generation used in combination herewith is communicated to the input shaft 12 . A drive cone 16 is attached to the input shaft 12 and the drive cone 16 center axis is essentially the center axis 13 of the input shaft. The drive cone 16 which is frustro conical in exterior dimension, has a sloped exterior surface 18 which has a diameter widest at the end closest to the drive input shaft 12 and is narrowest at the opposite end closest to the output shaft 14 in the current best mode although the components could be reversed if translating components were also reversed.
[0025] A plurality of drive vanes 20 are attached to the sloped surface 18 of the drive cone 16 in line with the center axis 13 and substantially equidistantly spaced from each other. The drive vanes 20 are attached to allow them to laterally translate on the sloped surface 18 of the drive cone 16 from a retracted position of FIG. 2 to an extended position as shown in FIG. 1. The drive vanes 20 have an attachment edge 22 configured for cooperative engagement with the sloped surface 18 of the drive cone 16 such that they will laterally translate thereon. The distal edge 24 of the drive vanes 20 , opposite the attachment edge 22 , in the current best mode is angled in relation to the angle of the attachment edge 22 , such that the distal edge 22 is substantially parallel with the center axis 13 of the input shaft.
[0026] Also mounted to the input shaft 12 is a pressure plate 26 which is configured for slideable engagement on the input shaft 12 to translate from rearward position wherein the drive vanes 20 have their distal edge 24 closest to the center axis 13 to a forward position toward the front of the input shaft 12 wherein the pressure plate 26 would press upon the rear edge 28 of the laterally translateable drive vanes 20 thereby moving them to their extended position which places the distal edge 24 of the drive vanes 20 to their position furthest away from the center axis 13 and closest to the interior surface 38 of the driven drum 30 .
[0027] Attached about the output shaft 14 either directly or using spacer 17 is the driven drum 30 which in the current best embodiment is supported for rotational movement about the center axis 13 by an endplate 32 which attaches to the front end of the output shaft 14 and a front plate 34 attached about the input shaft 12 . The center axis 13 extends through the center axis of the driven drum 30 and to the center axis of the output shaft 14 such that all are inline.
[0028] The internal or rear end 36 of the input shaft 12 is in a sealed relationship with the end plate 32 which has a conventional bearing 35 therein to allow rotation of the input shaft 12 in this engagement supported by the end plate 32 however other bearing arrangements could be used and are anticipated. A similar mounting arrangement allows the front plate 34 to be in a sealed engagement with the input shaft 12 and mounted thereon using a conventional bearing 35 or other similar device and a seal to allow the input shaft 12 to spin in its sealed engagement with the front plate 34 . As is obvious to those skilled in the art, many bearing and seal relationships would allow the end plate 32 a sealed rotational engagement on the rear end 36 of the input shaft 12 and the front plate 34 to function with a sealed rotational engagement on the input shaft 12 and such are anticipated.
[0029] As can be seen, the front plate 34 and driven drum 30 and end plate 32 function to form a sealed housing for the drive cone 16 and drive vanes 20 and pressure plate 26 and the other components and working fluid inside the sealed housing so formed.
[0030] Formed on, or attached to, the interior surface 38 of the driven drum 30 are a plurality of stater vanes 40 substantially equidistant from each other in their position on the interior surface 38 of the driven drum 30 . In operation, the power source would communicate rotational power to the input shaft 12 which rotates the attached drive cone 16 . The drive vanes 20 which are laterally translateable in their mount to the drive cone 16 may be slid in their attachment on the exterior of the drive cone 16 to an infinite number of positions between those two points thereby allowing for an infinite number of positions of the distal edges 24 of the drive vanes 20 between their closest position to the interior surface 38 and their closest position to the center axis 13 thereby providing a means for lateral translation of the distal ends 24 of the drive vanes 20 toward and away from the center axis 13 . Of course other such means to laterally translate the distal ends 24 of the drive vanes 20 toward and away from the center axis might be used and are anticipated, such as the drive vanes 20 being retracted into the drive cone 16 and internal hydraulic force inside the drive cone 16 communicating with and moving the attachment ends 24 of the drive vanes 20 away from the center axis, however the current best mode of the device 10 features the lateral translation of the drive vanes 20 in their slideable engagement on the outside of the drive cone 16 .
[0031] Rotation of the input shaft 12 and attached drive cone 16 and drive vanes 20 submersed in the operating fluid of the device 10 , from the power communicated from the power source, develops fluid friction in direct correlation to the motor speed. This fluid friction transfers energy communicated from the rotating motor or similar power source, to the output shaft 14 by way of the fluid friction that develops in the layers of fluid moving in the housing formed by the driven drum 30 and endplate 32 and front plate 34 which is in relation to the input shaft 14 velocity.
[0032] Initially fluid friction is substantially zero until the drive vanes 20 about the drive cone 16 , are laterally translated upon the sloped outer surface 18 of the drive cone 16 by the pressure plate 26 moving from the rearward position toward the forward position. As the pressure plate 26 moves toward the forward position, the drive vanes 20 slide on the sloped surface 18 and their distal edges 24 move outward away from the center axis 13 and toward the inner ribbed surface formed by the stater vanes 40 on the inner surface 38 of the driven drum 30 . As the distal edges 24 move closer to the stater vanes 40 they cause an increase of the fluid friction on stater vanes 40 on the interior surface 38 thereby exerting pressure on the driven drum 30 and moving it in the direction of fluid rotation. The force generated by this fluid friction increases proportionally as the drive vanes 20 move closer to the interior surface 38 of the driven drum 30 and the force so generated decreases proportionally as the drive vanes 20 laterally translate on the drive cone 16 and cause the distal edges 24 to move away from the interior surface 38 of the driven drum 30 and closer to the center axis 13 . The force from the fluid friction thus rotates the driven drum 30 with a force that is in relation to the distance between the distal edges 24 of the drive vanes 20 and the stater vanes 40 formed or mounted on the surface of the driven drum 30 . The smaller the distance, the greater the fluid friction and the consequential greater applied torque force. Conversely, the greater this distance, the less the fluid friction and resulting applied torque. As noted, the device 10 will function using any number of different viscosity fluids for fluid friction communication, from conventional transmission oil to water with near equal efficiency since the determining factor is the distance between distal edges 24 of the translating drive vanes 20 and the stater vanes 40 on the interior surface 38 of the driven drum 40 .
[0033] A means to position or to laterally translate the pressure plate 26 between the rearward position and forward position, in the current best mode is provided by pressurizing the same fluid which is used to transmit power in the device 10 . As depicted, the input shaft 12 has a means to pressurize the fluid in the form of pump 39 attached to the input shaft 12 thereby providing pump operation to pressurize fluid as the input shaft 12 rotates.
[0034] This pressurized fluid is then communicated via conventional tubing 41 and fluid passages 42 in the input shaft 14 to different points of the device internally and returned via the tubing 41 to an external reservoir 44 which communicates the working fluid back to the pump 39 . In a simple embodiment for controlling the lateral translation of the pressure plate 26 , a means to bias the pressure plate between the rearward and forward position is provided by a first biasing means such as a spring 46 acts on one end of the pressure plate 26 to bias it toward the rearward position while the controllable second biasing means provided by the hydraulic pressure ducted to the opposite side of the pressure plate 26 acts on the other end of the pressure plate 26 as a means to bias it toward the forward position. Using a control means such as a valve 43 , by increasing the pressure acting to move the pressure plate 26 to the forward position, the rearward pressure from the first biasing means in the form of the spring 46 is overcome moving the pressure plate 26 forward. Using the control means to decrease the fluid pressure acting on the rear of the pressure plate 26 , the rearward bias provided by the spring 46 overcomes the decreased hydraulic pressure and translates the pressure plate 26 to the rearward position.
[0035] Another means to laterally translate the pressure plate 26 can be provided by using controllable hydraulic pressure imparted to both sides of the pressure plate at varied force levels. The working fluid, in this case, light weight oil is stored in the reservoir 44 and as the input shaft 12 spins the pump 39 operates to draw operating fluid from the reservoir operating intake ports of the pump 12 . Three fluid passages 42 are capable of communicating pressurized working fluid from the pump 39 . A first hydraulic line L 4 is pressurized with low pressure and high fluid volume and supplies pressurized working fluid into formed fluid passages 42 in the input shaft 12 that exit at each of the drive vanes 20 and in cavities and other points throughout the device 10 to provide a continuous supply of cool working fluid throughout the device 10 as would be conventionally done with most mechanical devices needing lubrication and cooling. The fluid from the first hydraulic line L 4 also acts as the working fluid whose viscosity allows the drive vanes 20 , to react by way of the aforementioned fluid friction with the stater vanes 40 attached to the driven drum 30 .
[0036] Two other hydraulic lines, L 2 and L 3 , are pressurized in low volume but with high pressure through a valve assembly, (not specified), that can be either within the pump 39 or external, depending upon application. This valve assembly is interrelated between the on ports and has three positions with Line L 2 on or off, and Line L 3 being on. If turned to Line L 2 on position, the valve opens Line L 3 to the on position allowing the high pressure in Line L 3 to dissipate to the working fluid pressure of L 4 . When reversed, the valve operates in reverse for operation in the other direction. In other words, if L 2 is pressurized and L 3 is vented to the working fluid pressure at the same time. Finally, if L 3 is pressurized, L 2 is vented to the working fluid pressure at the same time.
[0037] Operating as a means to control power imparted from the input shaft 12 to the driven drum 30 when the valve assembly is turned to a position to increase the RPM of the driven drum 30 , it opens L 3 to fluid pressure from the pump 39 , and L 2 simultaneously goes to the vent position, (working fluid low pressure). The high pressure fluid flows along L 3 from the pump 39 into the front outer housing, through the machined opening of the input shaft 12 . Once in the input shaft this fluid pressure flows along the drilled orifice of L 3 , exiting into a chamber 52 formed by the outer circumference of the input shaft 12 and the inside surface 54 of the pressure plate 26 at its attachment about the input shaft 12 . These two mating surfaces are sealed at either end by O-Rings 56 or similar seals and thereby form a first hydraulic cylinder 58 that acts as a means to laterally translated the pressure plate 26 along the outside of the input shaft 12 .
[0038] As the hydraulic pressure in L 3 increases the pressure in the hydraulic cylinder 58 , moves the pressure plate 26 toward the forward position, the outside wall 60 of the pressure plate 26 , slides within a cooperating surface 62 formed in the drive cone 16 . The cooperating surfaces are sealed with seals such as O-Rings 56 and form a second hydraulic cylinder 64 that operates directly opposite the action of the first hydraulic cylinder 58 . Line L 2 , which connects the valve assembly to the second hydraulic cylinder 64 , is vented by the valve action to the working fluid pressure as Line L- 3 is pressurized.
[0039] As the valve assembly is turned to a position to increase the RPM, several things take place at once. Hydraulic pressure of Line L 3 is increased. Hydraulic pressure of Line L 2 is vented to working fluid. The pressure increase in the first hydraulic cylinder 58 , and corresponding pressure decrease in the second hydraulic cylinder 64 , overcomes the bias of the spring 46 , and the pressure plate 26 moves toward the forward position thereby causing the drive vanes 20 to laterally translate on the drive cone 16 and move closer to the stater vanes 40 in the aforementioned fashion. When the drive vanes 20 slide forward along channels machined into the outside diameter of the drive cone 16 in the current best mode, they are held in line by the outer cone segments 48 , that bolt directly to the drive cone 16 and are machined to accept the retaining flange of the movable drive vanes 20 . As the drive vanes 20 slide forward in their machined groves they also move outward up the slope of the drive cone 16 , increasing their relative diameter in the aforementioned operation forming the fluid friction between the drive vanes 20 and stater vanes 40 transferring energy from the rotating drive cone 16 assembly to the driven drum 30 . This energy transfer moves the driven drum 30 in the direction of rotation as that of the drive cone 16 .
[0040] When the valve position is reversed, the drive cone 16 rotates with the drive vanes 20 in the full rearward position and the driven drum 30 slows to a stationary position because no fluid friction takes place between the driven drum 30 and the drive cone 16 because the outer surface of the drive cone is with the drive vanes 20 retracted is distanced too far from the stater vanes 40 to exert enough force on them to move the driven drum 30 .
[0041] Of course those skilled in the art will realize that other means to laterally translate the pressure plate 26 from its rearward position to the forward position and back, could be used such as solenoids, cables, etc. and such is anticipated. However the current best mode works using pressurized working fluid to act upon the pressure plate 26 and a control means such as a valve to control the positioning of the pressure plate 26 by controlling the transmitted fluid pressure thereto. The pressurized fluid either works as two hydraulic cylinders opposing each other, or as one hydraulic cylinder opposing another biasing means such as a spring 46 . As can be seen, using this means to control the position of the pressure plate 26 to an infinite number of positions between its rearward position and forward position, the torque from the input shaft 12 communicated to the output shaft 14 from the driven drum 30 may be easily and accurately controlled to an infinite number of positions of the pressure plate 26 between its forward position and rearward position, thus rendering the device 10 infinitely variable in its ability to adjust the torque communicated to the output shaft 14 .
[0042] Also shown in the drawings are other components of the device 10 in the form of a plurality of drive cone outer vane segments 48 which are attached about the drive cone 16 between the drive vanes 20 and in the current best mode provide reinforcement to the drive vanes 20 . These are fixed vane segments 48 remain in position during the translation of the pressure plate 26 and resulting translation of the drive vanes 20 . The rearward portion 50 of the vane segments 48 is shaped to cooperatively engage with slots formed in the pressure plate 26 and the register with those slots thereby allowing the translation of the pressure plate 26 from the rearward position to the forward position during adjustment of the output of the device 10 to the user requirements.
[0043] As noted above, the device herein disclosed is ideally suited as a transmission for a land vehicle or water vehicle. However, as also noted, the device 10 could also function as a brake for a wheeled vehicle by mechanically communicating the input shaft 12 with the wheels of a vehicle and having the output shaft communicate with a generator, pump, or to a flange attached to the vehicle frame. The output shaft 12 would thus do work with the pump or generator, or when attached to a fixed position such as a fixture on a vehicle frame (not shown), the friction of the fluid inside the driven drum 30 would also provide resistance and thus braking to the vehicle.
[0044] While all of the fundamental characteristics and features of the present invention have been described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instance, some features of the invention will be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should be understood that such substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations are included within the scope of the invention as defined by the following claims. | A constant velocity transmission which provides maximum torque and speed from a power source such as an internal combustion engine to and output shaft of the transmission while maintaining the engine at optimum operational speed. The transmission takes advantage of the principle of fluid friction to transmit rotational forces from drive blades mounted on an input shaft to stater blades positioned on the inside of a drum encompassing one end of the input shaft and the drive blades. The drive blades slidably mounted on a slanted surface of a drive drum on the input shaft and move closer to and away from the stater blades when laterally translated. Fluid driven by the drive blades imparts varied force and torque to the stater blades depending on their distance therefrom thereby transmitting variable speed and torque to the output shaft attached to the drum. | 5 |
FIELD OF THE INVENTION
[0001] This invention relates to a light bulb.
BACKGROUND TO THE INVENTION
[0002] The need to reduce energy consumption is a universal consideration when supplying electrical goods to consumers. Due to their prevalence throughout society, light bulbs account for a large percentage of today's energy usage and thus much effort has been focused on the development of energy efficient lightbulbs. However, current energy efficient bulbs are not a complete solution to the replacement of the traditional filament or incandescent light bulb.
[0003] Fluorescent ‘energy saving’ bulbs are commonly used to replace traditional filament style bulbs, although this is frequently with complaint. Commonly cited problems include a lengthy period after such a bulb is turned on before it reaches its full brightness, and a general dimness of the bulbs compared to their filament based predecessors. Other alternatives include halogen lights and light emitting diodes (LEDs). Whilst these sources of light may easily be as bright as, or surpass the brightness of, traditional filament bulbs, consumers frequently make complaints centred on the colour temperature of the light produced, or the focused nature of the light produced by fittings containing these light sources.
[0004] In addition, many types of halogen or LED bulb cannot be retrofitted into existing lighting fixtures. In this case, any relighting of a space using energy efficient means may require and expensive installation of an entirely new lighting system. Moreover, historically fluorescent ‘energy saving’ and LED light bulbs have been designed in ways that are aesthetically unsatisfactory.
[0005] It is also the case that current lighting technologies offer light bulbs that provide either ambient light or light that is focused on to a single spot or localised area. In some situations, the use of both a focused and ambient light is desired. Currently, such lighting solutions are provided via the use of multiple bulbs, some providing the ambient lighting with others providing a more focused source of light. In this case, energy consumption could be further reduced, and convenience to an end user increased, if both sources of light were provided from a single bulb.
[0006] As such, it is desirable to provide a light bulb that provides both the brightness and warm colour temperature of traditional filament bulbs with the energy efficiency and long bulb life of modern lighting solutions. Any new design should also offer aesthetic advantages over LED and ‘energy saving’ fluorescent bulbs and, preferably, provide a source of both ambient and more focused light. Furthermore, any new light bulb should preferably be backwards compatible with lighting fixtures typically found in both home and commercial settings; for example, including options for use in both screw and bayonet fittings.
SUMMARY OF THE INVENTION
[0007] According to the present invention there is provided a light bulb comprising:
a light source; and a light pipe mounted to the light source; wherein the light pipe is a transparent bar or tube having coloured lines extending along and within it.
[0011] When illuminated by the light source, a light pipe of this construction acts as a means for dissipating light, providing the desirable effect of a traditional filament or incandescent bulb without the high temperatures and low energy efficiency associated with such a light source. It is also the case that the flexibility in design of such a solution offers the ability for the light bulb to come in many different forms, providing a variation in design which allows the light bulb's aesthetics to be tailored to a wide range of end user preferences. Such a light bulb may also include a screw or bayonet fitting, amongst others, allowing it to be retrofitted into existing lighting units providing backwards compatibility with existing lighting installations.
[0012] Furthermore, the length of the light pipe may be used to carry light into an otherwise difficult to illuminate, long, thin bulb with a single point light source. Light from the source may be refracted or reflected within, along and through the light pipe, resulting in the propagation of light along the pipe itself and a diffuse spread of light exiting the light pipe along its entire length.
[0013] Also according to the present invention, there is provided a light bulb, comprising:
a light source; and a light pipe mounted to the light source; wherein the light pipe is a translucent bar or translucent tube.
[0017] The use of a translucent light pipe may be preferred as, in such an embodiment, the light bulb may only create an area of focused light without any associated ambient light. Such an embodiment may be advantageous in situations where a focused area of light is desired distant from any light source, and ambient light between the light source and the focused area of light is undesirable, such as in hybrid solar lighting systems
[0018] It is also preferable that the light bulb provides an area of ambient light and an area of focused light. This can be achieved by the light pipe, which can convey some of the light along it, while allowing some to escape through the sides. Such a lighting system allows a single light bulb to be used in situations where both ambient and focused light are desired by an end user, potentially reducing energy consumption over pre-existing lighting solutions where at least two bulbs would be required. Furthermore, the use of only a single bulb may offer far greater convenience to the end user and a potential reduction in lighting fixture size, due to the reduction in bulb number, allowing a greater degree of aesthetic consideration in the design of said fixtures.
[0019] The light source may be an LED. The use of an LED light source is preferable as LEDs are highly energy efficient sources of light, typically operating at temperatures lower that traditional filament and incandescent bulbs. During operation, LED lights may produce the same light output as a traditional filament or incandescent bulb whilst consuming only 5% of the energy, over a lifespan that is typically seven times longer for the LED. Furthermore, it is possible to power an LED bulb from an existing lighting circuit, enhancing the ability to retrofit light bulbs using LEDs as a light source. In addition, the colour of the LED can be finely tuned, resulting in a light temperature that can be tailored to the application of the bulb or is aesthetically pleasing and acceptable to the consumer.
[0020] The light pipe may be enclosed within a glass bulb. The enclosure of the light pipe within the glass bulb protects it from the accumulation of dust and other debris.
[0021] It may also be preferable for the coloured lines to extend along the inner surface of the tube. The presence of coloured lines along the inner surface of the tube may assist a desired propagation of light along the light pipe, increasing its functionality, for example by channelling or diffracting light in a desired fashion, and providing different aesthetic effects.
[0022] Furthermore, it may be preferable for the shape of the light pipe to magnify coloured lines which extend along the inner surface of the tube when they are viewed from the outside. Such an embodiment may again assist the light pipe in achieving the desired distribution of light from the light source by reflection and refraction.
[0023] In another embodiment, the coloured lines may be enclosed substantially within the bar or tube that forms the light pipe. Again, an embodiment of this form may assist the light pipe in achieving the desired distribution of light from the light source by reflection and refraction.
[0024] In one embodiment, the light pipe may have a substantially annular cross section. In another embodiment, the light pipe may have a substantially rectangular cross section. In an additional embodiment, the light pipe may have a triangular cross section. In one further embodiment, the light pipe may have a substantially circular cross section. Another embodiment of the light bulb includes a light pipe with a cross section that is substantially uniform along a lengthwise axis of the light pipe. Which of these embodiments is preferred may depend on the desired distribution of light from the light source, via the light pipe by reflection and refraction, or the application of the light bulb.
[0025] In another preferred embodiment of the invention, the coloured lines extend substantially parallel to a lengthwise axis of the light pipe. In a further preferred embodiment of the invention the coloured lines may extend helically along the lengthwise axis of the light pipe, the centre of rotation of the helix lying on an axis substantially parallel to the lengthwise axis of the light pipe. Again, which of these embodiments is preferred may depend on the desired distribution of light from the light source, via the light pipe, by reflection and refraction.
[0026] It may also be preferred for the light pipe to be coloured or tinted. Colouring or tinting the light pipe may allow the colour temperature of the light source to be controlled, increasing the range of lighting that can be achieved with the invention and tailoring the light produced by the bulb to its application or for aesthetics.
[0027] Preferably the light pipe may be translucent. The use of a translucent light pipe may be preferable as such a light pipe may allow the amount of light dissipated as ambient light through the sides of the light pipe to be controlled. Such control may be obtained with the variation of the amount of light which may pass through the translucent light pipe. It may be preferable for the degree of translucence to be varied either between individual pipes or along the length of a single pipe.
[0028] It may be preferable to tint or colour a glass bulb that is used in the light bulb. Such a tinting or colouring may be used in conjunction with, or instead of, a tinting or colouring of the light pipe to tailor the colour of the light produced by the light bulb to its application or for aesthetics. In addition, colouring or tinting the glass bulb and/or the light pipe may be used in conjunction with adjusting the colour of the light produced by the light source to achieve a fine layer of control over the light spectrum produced by the light bulb.
[0029] In some embodiments, a light source may be provided only at one end of the light pipe. Alternatively, in some cases it may be preferable to provide a light source at both ends of the light pipe. Such an embodiment may be preferable as it may provide a light with greater power, or enable the retrofitting of the light bulb into additional pre-existing lighting fixtures.
[0030] In a further embodiment, a light source is provided substantially along the centre of the light pipe. This may be preferable as it may provide a more even spread of light from the light bulb if the light pipe has an extended length.
[0031] In another preferred embodiment the coloured lines may include a photo luminescent material. The inclusion of a photo luminescent material in the coloured lines may be preferred as it provides an additional means of manipulating the light output of the light bulb, including the production of light when the bulb is off.
[0032] Furthermore, it may be preferable for the coloured lines to include a photo reflective material. The inclusion of a photo reflective material may be preferred as it provides an additional means of manipulating the light produced by the light source and thus the output of the light bulb. The use of a reflective material in coloured lines extending along the longitudinal axis of the light pipe may be used to reflect additional light along the length of the light pipe, potentially preferable where the light pipe has an extended length.
[0033] The light pipe may be an extruded transparent bar or tube, and the lines may be co-extruded with and into the bar or tube. This technique permits great flexibility in how and where the lines can be embedded within the light pipe, making a wide variety of visual lighting effects possible.
[0034] Preferably, the light pipe may further comprise at least one groove. Such a feature may be preferable as it may allow further customisation of the visual effect obtained by the lightbulb. Preferably said groove may extend along the length of the light pipe. Preferably said groove may be generally parallel with the longitudinal axis of the light pipe.
[0035] According to a further aspect of the invention, there is provided a method for manufacture, comprising:
extruding a light pipe, the light pipe being extruded with a coloured material extending along and within it, and mounting the light pipe to a light source.
[0039] Such a method of extrusion may be preferred as it provides a well characterised method for the production of shapes such as those required in the embodiments of the light pipe and is suitable for both batch and mass production of the light pipe.
DETAILED DESCRIPTION
[0040] The invention will now be described by way of example with reference to the following figures in which:
[0041] FIG. 1 is a schematic view of a light bulb;
[0042] FIG. 2 is a schematic view of a cross section of a light bulb;
[0043] FIG. 3 is a schematic of a process of extruding the light pipe;
[0044] FIG. 4 is a schematic focusing on the inclusion of the coloured lines in the extruded light pipe;
[0045] FIG. 5 is a schematic view of a light bulb with a triangular cross section;
[0046] FIG. 6 is a schematic view of a light bulb with a rectangular cross section;
[0047] FIG. 7 is a schematic view of a light bulb where the coloured lines extend helically within the light pipe;
[0048] FIG. 8 is a schematic view of four different embodiments of a glass bulb that may be added to the light bulb; and
[0049] FIG. 9 is a schematic view of a light bulb with a translucent or frosted light pipe.
[0050] Referring to the drawings in detail, FIG. 1 depicts an embodiment of the light bulb wherein a light pipe 1 with a circular cross section is mounted at its proximal end on a light source (not seen) with a fixing element 2 . The light pipe 1 contains coloured lines 3 that extend substantially along the inner surface of the light pipe, although it will be appreciated by the skilled person that these lines may extend substantially along the outer surface of the light pipe, substantially within the material that forms a main body of the light pipe or any combination of the three. In this embodiment of the light bulb, a glass bulb 4 encloses the light pipe and is attached to the bulb with an outer ring 5 . However, the light bulb may in fact be provided without a bulb. In the present specification the term “light bulb” is used to describe the device, irrespective of whether a glass bulb is in fact included. Both the glass bulb 4 and the light pipe 1 are connected to the light fitting 6 . In this embodiment the light fitting 6 is depicted as a screw fitting, although the use of a bayonet fitting is envisaged as an alternative.
[0051] FIG. 2 is a cross section of the bulb schematically illustrated in FIG. 1 . Here, the affixation of the proximal end of the light pipe 1 to a light source 7 can be seen in more detail. In this embodiment, the light source 7 is an LED bulb, though other solutions such as halogen bulbs are envisaged. It is also envisaged that a light source may be present at both the proximal and distal ends of the light pipe or, alternatively, substantially along the centre line of the light pipe (which may be hollow).
[0052] The light pipe 1 is typically, but not exclusively, a thermosetting plastic and is held in place with respect to the light source 7 by the fixing element 2 . It is envisaged that the plastic forming the main body of the light pipe will be substantially clear, although tinted and coloured materials may also be used. The fixing element 2 is also typically a plastic, although aluminium or alloy alternatives are also envisaged. As depicted in FIG. 2 , the fixing element 2 may grip the light pipe 1 on the outer surface of its proximal end via a series of teeth 8 that interlock with corresponding features on the surface of the light pipe 1 . Alternatively, glue, screws, a screw thread or any other appropriate mechanical means may be used to affix the proximal end of the light pipe 1 to the fixing element 2 and thus the light source 7 .
[0053] For effective operation, in this embodiment, the LED light source 7 is connected to both a heat sink 9 and driver unit 10 . The inclusion of the heat sink 9 allows the light source 7 to be powered by the driver unit 10 without an excessive increase in the temperature of the light bulb and a concomitant decrease in efficiency. In this embodiment, the light pipe 1 , fixing element 2 , light source 7 , heat sink 9 and driver unit 10 are all contained within the glass bulb 4 and light fitting 6 . The light fitting 6 and glass bulb 4 may be held in place, and the other components of the light held within them, using an outer ring 5 . It is envisaged that this outer ring 5 will be typically made from aluminium, though other metals, alloys and plastics are not excluded.
[0054] FIG. 2 also depicts the both the focused 39 and ambient 40 light that may be produced by the light bulb. In use, some of the light produced by the LED light source 7 passes either directly down the light pipe 1 and out of the distal end, or is partially reflected by the internal walls of the light pipe 1 , travelling along the light pipe 1 before exiting at its distal end, forming a focused area (spot) of light 39 . Additionally, some of the light from the LED light source 7 exits the light pipe 1 from various points along its length (in generally random directions), providing a source of diffuse light 40 in combination with the focused light 39 source.
[0055] FIG. 3 is a schematic depiction of the extrusion of the light pipe 1 . To produce the light pipe 1 as depicted in FIGS. 1 and 2 , clear plastic granules are loaded into a first hopper 11 and transported along a first pipe 12 by a first screw drive 13 . The first screw drive 13 is driven by a first motor 14 , transporting the clear plastic granules along the first pipe 12 at a speed controlled by the first speed controller 15 .
[0056] Coloured plastic granules are loaded into a second hopper 16 and transported along a second pipe 17 by a second screw drive 18 . Typically, the material loaded into the second hopper 16 will be plastic alone, although the inclusion of photo-luminescent or photo-reflective materials will be preferable in some embodiments. The second screw drive 18 is driven by a second motor 19 , transporting the coloured plastic granules along the second pipe 17 at a speed controlled by the second speed controller 20 .
[0057] During the transportation of the clear and coloured plastic granules along the first and second pipes 12 , 17 by the first and second screw drives 13 , 18 respectively, the granules are heated until they become a fluid by first and second heating units 21 , 22 . The temperature of both heating units 21 , 22 is controlled independently. A first temperature controlling unit 23 controls the temperature of the first heating unit 21 and a second temperature controller 24 controls the temperature of the second heating unit 22 . The temperature of the heating units 21 , 22 is such that both the clear and coloured plastics are fluid enough for extrusion when they are located at the plastic intersection 25 .
[0058] The plastic intersection extrudes the clear and coloured plastics into the form of an extrudate 26 . An extrudate 26 with approximately the same cross section as the light pipe 1 exits the plastic intersection 25 via the aperture 27 into a water bath 28 . The water bath 28 cools the extrudate 26 such that it becomes entirely solid. The solid extrudate 26 is pulled though the water bath 28 by a track system 29 , before the solid extrudate 26 is cut into sections suitable for use as the light pipe 1 by a cutting tool 30 .
[0059] FIG. 4 is a schematic diagram of the extrusion process inside the plastic intersection. Clear plastic 31 is pushed in an outer central cavity 32 of the plastic intersection 25 by the first screw drive 13 , the clear plastic 31 flowing in an annular shape due to the confinement of an outer mould 33 and first 34 and second 35 central tools. Coloured plastic 36 is pushed into an inner central cavity 37 , located within the first and second central tools 34 , 35 , by the second screw drive 18 . The location of the exit of the coloured plastic 36 from the inner central cavity 37 is controlled by the third central tool 38 . Different embodiments of the third central tool 38 can be used to achieve different distributions of the coloured plastic 26 in the extrudate 26 and thus the final light pipe 1 .
[0060] FIG. 5 is a schematic diagram of an embodiment of a light bulb wherein the light pipe 1 has a triangular cross section.
[0061] FIG. 6 is a schematic diagram of an embodiment of a light bulb wherein the light pipe 1 has a rectangular cross section.
[0062] FIG. 7 is a schematic diagram of an embodiment of a light bulb wherein the light pipe 1 has a circular cross section. In this embodiment, the coloured lines 3 lie within the main body of the light pipe 1 and extend helically along the lengthwise axis of the light pipe 1 .
[0063] The formation of a light pipe with a triangular, rectangular or circular cross section is possible using the extrusion method detailed in FIGS. 3 and 4 . For each extrusion shape, appropriate selections of the outer mould 33 and first 34 second 35 and third 38 central tools must be made to ensure the correct extrudate 26 shape and coloured line 3 location as the extrudate 26 enters the water bath 28 through the aperture 27 . In order to achieve the helical lines of FIG. 7 , the third 38 central tool may be required to rotate with respect to the second 35 tool.
[0064] FIG. 8 is a schematic diagram of four different embodiments of a glass bulb 4 that may be used, but are not essentially used, with the light bulb. Four embodiments of bulb shape that may be used with the light bulb are a teardrop bulb 4 a, a globe bulb 4 b, a tubular bulb 4 c and a chamfer end bulb 4 d, although a person skilled in the art will appreciate these possibilities are not exhaustive. Typically, it will be preferable for the glass bulb 4 to be clear, although the use of coloured, tinted, frosted or mirrored glass remains a possibility.
[0065] FIG. 9 is a schematic diagram of a light bulb wherein the light pipe 1 is translucent or frosted. In this case, the translucent or frosted light pipe 1 allows the passage of light through the pipe and the production of a diffuse light from the light bulb. Such a translucent or frosted light pipe may be formed via the use of a suitable translucent or frosted plastic in the extrusion process, or with the alteration of the light pipe after the extrusion process with paint, abrasion, sputtering or other surface treatments. The light pipe may comprise an etched surface which is not transparent. Finally, a chemical treatments such as etching may be used in the creation of a translucent or frosted light pipe.
[0066] While embodiments of the present invention have been described using the preferred example of an extruded bar or tube to form the light pipe, the skilled person will appreciate that much of the benefit can be achieved using other manufacturing techniques, such as injection moulding. | A light bulb, in particular one which has a light pipe in the form of a bar or tube, mounted to a light source. The light pipe has coloured lines extending along and within it. When illuminated by the light source, the light pipe acts as a means for dissipating light, providing the desirable effect of a traditional filament or incandescent bulb without the high temperatures and low energy efficiency associated with such a light source. Such a light bulb may also include a screw or bayonet fitting, allowing it to be retrofitted into existing lighting units, providing backwards compatibility with existing lighting installations. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of our copending U.S. patent application Ser. No. 07/328,614, filed Mar. 27, 1989, now U.S. Pat. No. 4,936,343.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to gas transfer systems and more particularly, to a carbon dioxide fill manifold and method for using the fill manifold for handling liquid and gaseous carbon dioxide and dispensing the gaseous carbon dioxide to an end-user, such as a carbonated drink-dispensing system. The carbon dioxide fill manifold of this invention is characterized by a fill line valve attached to an atomizer and receiving a fill line for introducing liquid carbon dioxide into the atomizer, at least two liquid cylinder ports provided in the atomizer for receiving corresponding liquid chambers or cylinders and receiving and storing liquid carbon dioxide, at least one gas cylinder port also connected to the atomizer for receiving a corresponding gas cylinder and storing gaseous carbon dioxide generated in the atomizer and a gas service valve connected to the atomizer for receiving a gas service line and supplying gaseous carbon dioxide on demand to an end user. A pressure actuated valve is also provided in the atomizer between the liquid cylinder ports and the gas cylinder port(s) to facilitate automatic dispensing of liquid carbon dioxide from the liquid cylinders through the atomizer, where it vaporizes and expands into gaseous carbon dioxide for storage in the gas cylinder(s) and is ultimately dispensed to an end-user. A pressure relief valve port is also provided in the atomizer for receiving a pressure relief valve to prevent excessive system pressure in the atomizer. The carbon dioxide fill manifold is designed to handle both liquid and gaseous carbon dioxide and to provide a substantially uninterrupted supply of gaseous carbon dioxide to an end-user such as a carbonated drink dispenser, without the necessity of transporting conventional carbon dioxide pressure vessels or cylinders to and from the end-user site.
The carbon dioxide fill manifold of this invention is designed to provide a selected number of liquid bottles, chambers or cylinders and corresponding vapor bottles, chambers or cylinders connected by an atomizer fitted with an internal pressure-regulated check valve, to facilitate an appropriate ratio of gas to liquid in the system. After filling of the liquid cylinder or cylinders is completed according to the method of this invention, the customer or end-user will draw gas from the vapor cylinder(s). When a predetermined volume of gaseous carbon dioxide has been used from these vapor cylinder(s) by the customer to create a predetermined pressure differential in the pressure actuated valve located in the atomizer, the pressure-actuated valve will automatically open to facilitate a flow of additional liquid carbon dioxide into the atomizer. This liquid carbon dioxide rapidly expands into a gas and enters the vapor cylinder(s), in order to refill the vapor cylinder(s). The gas evolution process continues in the atomizer until the preselected pressure differential at the pressure actuated valve has been equalized and the pressure actuated valve then closes. A primary feature of the carbon dioxide fill manifold and method of this invention is the capacity for refilling both the liquid cylinder(s) and the vapor cylinder(s) without disconnecting these vessels from the supply and service lines, respectively. Since the liquid cylinder (s) and vapor cylinder(s) are filled by volume instead of by weight, the need to transport, handle and weigh the various carbon dioxide-containing vessels is eliminated.
A common method of providing an end-user such as a carbonated drink dispensing apparatus with carbon dioxide gas involves the use of high pressure containers, bottles or cylinders which are manufactured in various sizes, typically 20 and 50 pound quantities, wherein the weight designation refers to the weight of the carbon dioxide in the cylinders at full capacity. These cylinders are typically filled by weight instead of volume, since a portion of each cylinder (approximately 32%) must be reserved for expansion of the carbon dioxide into the vapor phase, in order to maintain an appropriate volume of liquid at a desired pressure. The problem of furnishing cylinders of uniform weight and carbon dioxide volume is amplified by the fact that there is no uniform weight or tare among the cylinders themselves. The cylinders are typically filled by placing them on a scale and charging them with liquid carbon dioxide until the desired weight of liquid carbon dioxide is injected therein. Accordingly, the carbon dioxide supplier must periodically interrupt the customer supply, in order to exchange a full vessel for the empty one, using this system. The empty cylinders must then be transported to a warehouse for weighing and refilling and the cycle is repeated. Expansion of a small amount of the carbon dioxide liquid into the gas phase exerts the necessary vapor pressure to maintain a proper gas-liquid balance in these cylinders, to assure proper dispensing of carbon dioxide gas to the end-user. These conventional carbon dioxide supply cylinders are typically equipped with a pressure disc which is designed to rupture if the pressure inside the cylinder rises beyond a specified level. Overfilling, that is, charging liquid carbon dioxide into that portion of the cylinder which is normally reserved for gas expansion purposes, will sometimes cause this disc to burst, an occurrence which is both dangerous and wasteful.
1. Description of the Prior Art
Various types of liquid and gaseous vapor-containing and handling systems are well known to those in the art. A "Fluid Medium Storing and Dispensing System" is detailed in U.S. Pat. No. 2,412,613, dated Dec. 17, 1946, to H. C. Grant, Jr. The patent details one or more receptacles or containers for storing a high-pressure fluid medium such as liquified carbon dioxide. Further included is a fluid medium retaining and releasing apparatus associated with each of the containers, which apparatus is adapted to be operated by the fluid medium from one or more containers in the system. A suitable actuating device which is operable by a relatively small force for initiating simultaneous release of the fluid medium from one or more of the containers, is also provided U.S. Pat. No. 2,492,165, dated Dec. 27, 1949, to D. Mapes, details a "System for Dispensing Fluids". The system includes multiple receptacles containing a fluid under pressure, apparatus provided in each of the receptacles for normally retaining a fluid therein, which apparatus operates to release the fluid from the receptacles, delivery means into which the fluid may be delivered from all the receptacles and a fluid-actuated operating device for operating the retaining apparatus of each receptacle. Apparatus for conducting fluid from the delivery means to the operating apparatus with at least one of the receptacles is also provided. A "Pneumatic Installation" is detailed in U.S. Pat. No. 2,591,641, dated Apr. 1, 1952, to J. Troendle. The installation includes one or more sources of compressed air, one or more devices to be fed with compressed air for pneumatic control purposes, several compressed air reservoirs and conduits connecting the various elements to each other. U.S. Pat. No. 3,760,834, dated Sept. 25, 1973, to David E. Shonerd, et al, details a "Reservoir for Pressurized Fluids". The reservoir includes multiple, straight tubes located in side-by-side relationship and surrounded by a single, elongated tube of substantially less diameter which is helically wound about the straight tubes to define a reservoir for pressurized natural gas. The helically-wound tube serves both as a protective covering and a strengthening structure for the straight tubes. The straight tubes and helically-wound tubes may be interconnected by suitable manifolding and a fill opening is provided for storing pressurized fluid therein. U.S. Pat. No. 1,062,343, dated May 20, 1913, to James H. Mahoney, details an "Apparatus for Dispensing Carbonated Beverages" such as beer, which includes a mechanism for reducing gas pressure while dispensing the liquid, to prevent undue foaming. U.S. Pat. No. 2,363,200, dated Nov. 21, 1944, to P. B. Pew, et al, details an "Apparatus for Dispensing Gas Material". The apparatus includes a system having an arrangement for storing and gasifying relatively large quantities of liquified gas such as liquid oxygen, in order to service large instantaneous demands. An "Apparatus and Method for Filling Gas Storage Cylinders" is detailed in U.S. Pat. No. 2,469,434, dated May 10, 1949, to O. A. Hansen, et al. The patented invention includes a mobile unit which includes a transport truck having a tailgate adapted to provide a temporary station for gas storage containers which are to be evacuated and filled with a gas material such as oxygen, in the gas phase. Suitable equipment is also provided on the truck for first evacuating and then charging the containers at the temporary station from a source such as a container in the liquid phase, which source is also mounted on the truck, together with the necessary apparatus for converting the gas material from the liquid to the gas phase. U.S. Pat. No. 2,479,070, dated Aug. 16, 1949, also to O. A. Hansen, details an "Apparatus for and Method of Dispensing Liquified Gases". The apparatus includes a pair of pressure containers for storing liquified gases, pressure regulating apparatus for maintaining the pressure in the containers above a predetermined value, a liquid line extending externally of the containers, with a heater provided in the liquid line and a pressure sensitive valve connected to the containers for controlling the flow of liquid in the containers. An "Apparatus for Storing and Dispensing Liquified Gases" is detailed in U.S. Pat. No. 3,093,974, dated Jun. 18, 1963, to C. E. Templer, et al. The apparatus includes a storage container for storing and dispensing a liquified gas, a liquid withdrawal pipe opening at a point near the bottom of the container and extending through the top thereof and a liquid feed line connecting the liquid withdrawal pipe to one end of a pressure raising coil located below the level of the bottom of the container. Further included is a vapor feed line connecting the other end of the pressure raising coil with the vapor space of the container through an automatic valve which is arranged to open when the pressure in the container falls below a predetermined value. A jacket surrounding that part of the liquid feed line above the level of the container, is also provided, the jacket having a connection to the liquid withdrawal pipe through a valve arranged to maintain a pressure drop between the liquid feed line and the jacket and the liquid service connection. A "Liquid Cylinder System" is detailed in U.S. Pat. No. 3,392,537, dated Jul. 16, 1968, to R. C. Woerner. The patent is directed to a distribution system for a vaporizable liquid, in which the liquid is stored in individual storage containers and is dispensed under pressure. A pressurizing system is associated with at least one of the storage containers to maintain a desired pressure in the system. U.S. Pat. No. 3,712,073, dated Jan. 23, 1973, to Edwin M. Arenson, details a "Method and Apparatus for Vaporizing and Superheating Cryogenic Fluid Liquid". The apparatus includes a closed vessel for heating medium liquid such that portions thereof are continuously vaporized. The stream of cryogenic fluid to be vaporized and superheated is passed through a heating coil disposed within the vessel and in heat exchange relationship with both the liquid and vapor portions of the heating minimum, so that the cryogenic fluid is vaporized and superheated to a desired level and the vaporized heating medium is continuously condensed and returned to the liquid portion thereof. U.S. Pat. No. 3,990,256, dated Nov. 9, 1976, to Walter G. May, et al, details a "Method of Transporting Gas", which method includes pumping liquified natural gas for a predetermined portion of the desired distance, applying processes in which the refrigeration value of the gas is utilized and the high boiling point components are separated, and subsequently vaporizing the remaining liquid prior to transporting the vapor by pipeline in the gaseous phase. U.S. Pat. No. 4,321,796, dated Mar. 30, 1982, to N. Kohno, details an "Apparatus for Evaporating Ordinary Temperature Liquified Gases". The apparatus includes an ordinary temperature liquified gas storing vessel, an evaporating chamber for evaporating a liquified gas and a liquid level detecting chamber for detecting the liquid level in the evaporating chamber. The detecting chamber is disposed between the storage vessel and the evaporating chamber and the liquid outlet from the storage vessel and detecting chamber are connected by conduit equipped with a liquid pressure reducing valve. The bottom of the detecting chamber and the liquid inlet to the evaporating chamber are connected by a liquid conduit and the respective gas outlets from the detecting chamber and the evaporating chamber are connected to a gas warming chamber. A "Carbonated Beverage Storage and Dispensing System and Method" is detailed in U.S. Pat. No. 4,683,921, dated Aug. 4, 1987, to Timothy A. Neeser. The system employs separate tanks for carbon dioxide and syrup and mixing occurs during dispensing. For each type of syrup there are preferably two syrup supply tanks and each syrup supply tank may be selectively connected to either a syrup filling source or to a sanitizing system for cleaning the tank. The system allows one of the syrup supply tanks to be sanitized or refilled, while the other supplies syrup for dispensing, thus allowing uninterrupted beverage service.
It is an object of this invention to provide a carbon dioxide fill manifold which is designed to provide an end-user with a substantially uninterrupted supply of carbon dioxide gas, while at the same time eliminating the necessity for transporting individual conventional bottles, containers or cylinders for refilling purposes.
Another object of the invention is to provide an on-site carbon dioxide refilling apparatus characterized by a fill manifold for connecting liquid and gaseous carbon dioxide cylinders and a method for automatically transferring the liquid carbon dioxide from the liquid cylinders to the gaseous cylinders where it is vaporized and dispensing the gaseous carbon dioxide to an end user, wherein the quantity of the gas distributed is determined by volume, rather than by weight.
Yet another object of this invention is to provide a new and improved carbon dioxide fill manifold which is designed for on-site use to facilitate connection of multiple liquid chamber bottles and companion vapor chamber bottles using a pressure-actuated atomizer, wherein an end-user or customer is supplied with a substantially uninterrupted source of carbon dioxide gas at a desired pressure.
Another object of the invention is to provide a carbon dioxide fill manifold which includes an atomizer containing a pressure actuated check valve to periodically automatically vaporize a charge of liquid carbon dioxide from a pair of liquid carbon dioxide storage bottles or cylinders connected to the atomizer for storage in a single gaseous carbon dioxide storage bottle also connected to the atomizer and dispensing in the gaseous phase to an end-user.
Still another object of this invention is to provide a carbon dioxide fill manifold which is characterized by a fill line valve and service line valve constructed from high pressure material and connected to a vaporizer or atomizer, connection ports for connecting a selected number of liquid chambers or cylinders and vapor cylinders to the atomizer and a pressure actuated check valve provided in the atomizer between the liquid and gas cylinder connection ports, wherein the total volume of the vapor cylinders represents approximately one-third of the total volume of the liquid chambers and gas cylinders and liquid carbon dioxide is introduced into the fill line to fill the liquid chambers and the liquid carbon dioxide is periodically vaporized into gaseous carbon dioxide in the atomizer responsive to a selected pressure differential across the atomizer, for dispensing to a customer.
Still another object of this invention is to provide a new and improved carbon dioxide fill manifold and method for storing liquid and gaseous carbon dioxide and dispensing carbon dioxide gas to a customer or end-user on a volume, rather than a weight basis and thereby eliminating the necessity of using multiple conventional individual carbon dioxide bottles or cylinders which must be periodically returned to a plant and refilled.
Another object of the invention is to provide a method of storing liquid and gaseous carbon dioxide and dispensing the gaseous carbon dioxide to a customer on demand, which method includes the steps of charging the liquid carbon dioxide into a pair of liquid chambers, allowing the liquid carbon dioxide to flow from the liquid chambers into an atomizer responsive to a selected pressure differential across the atomizer and vaporizing the carbon dioxide for storage in a gaseous chamber.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved carbon dioxide fill manifold which is characterized in a preferred embodiment by a fill line valve connected to a vaporizer or atomizer and fitted with a fill line for receiving a charge of liquid carbon dioxide; a pair of liquid cylinder ports for connecting liquid cylinders to the atomizer for receiving and dispensing the liquid carbon dioxide; a gas cylinder port for connecting a gas cylinder to the atomizer; a pressure actuated valve provided in the atomizer between the liquid cylinder ports and gas cylinder port; and a service line valve fitted with a customer service line, also connected to the atomizer for receiving liquid carbon dioxide vaporized in the atomizer and the gas cylinder responsive to a pressure differential between the liquid cylinders and the gas cylinder. A method for handling and dispensing liquid and gaseous carbon dioxide by the steps of charging liquid carbon dioxide in a pair of liquid carbon dioxide containers, vaporizing the liquid carbon dioxide on demand in an atomizer and a vapor cylinder and subsequently distributing the gaseous carbon dioxide on demand to an end-user, responsive to operation of a pressure actuated check valve provided in the atomizer at a selected pressure differential determined by the difference in pressure between the liquid and gaseous carbon dioxide cylinders.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be better understood by reference to the accompanying drawing, wherein:
FIG. 1 is a sectional view of a preferred embodiment of the atomizer element of the carbon dioxide fill manifold of this invention;
FIG. 2 is a left end view of the atomizer illustrated in FIG. 1;
FIG. 3 is a right end view of the opposite end of the atomizer illustrated in FIG. 1;
FIG. 4 is a perspective, exploded view, partially in section, of the opposite end of the atomizer illustrated in FIGS. 1 and 3.,
FIG. 5 is a side sectional view of a pressure actuated valve provided in the atomizer illustrated in FIG. 1;
FIG. 6 is a perspective view of the carbon dioxide fill manifold rotated 90 degrees from the position illustrated in FIGS. 1 and 2, attached to a gas cylinder; and
FIG. 7 is a perspective view of the carbon dioxide fill manifold coupled to two liquid cylinders and the gas cylinder illustrated in FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 6 and 7 of the drawing, the carbon dioxide fill manifold of this invention is generally illustrated by reference numeral 1. As further illustrated in FIG. 1, the carbon dioxide fill manifold 1 is characterized by a generally cylindrically-shaped atomizer 2, having a plug 13 threaded in one end against an 0-ring 12 for sealing purposes, and a pressure relief valve 24 is threaded in the opposite end. As further illustrated in FIG. 1, the atomizer 2 is further characterized by a housing bore 5, fitted with internal bore threads 6 for receiving the plug threads 15 of the plug 13, which plug 13 is further provided with a hexagonal plug head 14. A smaller valve bore 11 is provided in the atomizer 2 in communication with the housing bore 5 and a pair of liquid cylinder ports 17 are also provided in the atomizer 2 transversely at right angles with respect to each other, in communication with the valve bore 11. A liquid service line port 22 is similarly located in transverse configuration in the atomizer 2 and is also provided in communication with the valve bore 11. As illustrated in FIG. 6, the pressure relief valve 24 is threadably seated in a pressure relief valve port 18, located in the end of the atomizer 2 opposite the plug 13 and the pressure relief valve port 18 also communicates with the valve bore 11. A gas cylinder port 20 is further provided transversely in the housing of the atomizer 2 in spaced relationship with respect to the liquid cylinder ports 17 and liquid service line port 22 and communicates with the housing bore 5, while a gas service line port 21 is oppositely-disposed from the gas cylinder port 20 in the atomizer 2 and also communicates with the housing bore 5. Each of the liquid cylinder ports 17, pressure relief valve port 18, gas cylinder port 20, gas service line port 21 and liquid service line port 22 are provided with internal port threads 19, for connecting various manifold fittings and components, as hereinafter further described. As illustrated in FIGS. 1 and 5, a pressure actuated valve 3 is characterized by a generally cylindrically-shaped valve housing 4, having one end fitted with housing threads 7. The housing threads 7 are seated in corresponding valve bore threads 16, provided in the valve bore 11 of the atomizer 2, in order to threadably seat the pressure actuated valve 3 in the housing bore 5 with the discharge end of the pressure actuated valve 3 projecting into the valve bore 11, as illustrated in FIG. 1. As illustrated in FIG. 6, line fittings 26 are threadably inserted in the respective liquid cylinder ports 17 of the atomizer 2, in order to mount flexible liquid pressure cylinder lines 25 therein, respectively. The liquid pressure cylinder lines 25 are connected to liquid cylinder valves 28, mounted on the two liquid cylinders 27, respectively, as illustrated in FIG. 7. Similarly, a gas cylinder nipple 41 is threadably inserted in the gas cylinder port 20, illustrated in FIG. 1, downstream from the pressure actuated valve 3, for attachment to the corresponding gas cylinder valve fitting 42 of a gas cylinder valve 40, mounted on a single gas cylinder 39, as further illustrated in FIG. 6. In like manner, a liquid service valve fitting 33 is threadably inserted in the liquid service line port 22 of the atomizer 2 upstream from the pressure actuated valve 3 and secures a liquid service valve 32 to the atomizer 2. A flexible liquid service line 31 is attached to the liquid service valve 32 for receiving liquid carbon dioxide and filling the liquid cylinder 27, as hereinafter further described. Similarly, a gas service valve fitting 38 is threadably inserted in the gas service line port 21 of the atomizer 2, for attaching a gas service valve 37 and a gas service line 36 to the atomizer 2 downstream from the pressure actuated valve 3. The gas service line 36 may be attached to customer cylinders or containers (not illustrated) for filling these containers or cylinders with gaseous carbon dioxide, as further hereinafter described. Each of the liquid service valve 32 and the gas service valve 37 are fitted with conventional valve handles 34, for manipulating the liquid service valve 32 and the gas service valve 37 into open and closed positions, respectively. A pressure gauge fitting 44 is mounted in the gas service line 36 downstream from the gas service valve 37, in order to mount a pressure gauge nipple 43 and a pair of pressure gauges 45 and monitor the pressure of the gaseous carbon dioxide entering the customer's containers or cylinders through the gas service line 36, as illustrated in FIGS. 6 and 7.
Referring now to FIGS. 1 and 5 of the drawing, the pressure actuated valve 3 is provided with a longitudinal housing bore 5, having a curved housing seat 8 provided therein, a ball 9 disposed in the housing bore 5 adjacent to the housing seat 8 and a coil spring 10, also positioned in the housing bore 5 and contacting the ball 9, such that the ball 9 normally fits in the housing seat 8 to block the housing bore 5 against the bias in the spring 10. However, upstream pressure exerted against the ball 9 by liquid carbon dioxide will cause the spring 10 to depress at a predetermined liquid carbon dioxide pressure to unseat the ball 9 and allow liquid carbon dioxide to flow through the housing bore 5 in the direction of the arrow illustrated in FIG. 5, as hereinafter further described. As illustrated in FIG. 7, the liquid cylinders 27 and gas cylinder 39 are grouped in a triangle, secured by cylinder bands 47 and transported in an enclosure 48.
Referring again to FIGS. 1, 5, 6 and 7 of the drawing, when it is desired to charge the liquid cylinders 27 with liquid carbon dioxide and ready the carbon dioxide fill manifold 1 for operation, the liquid service line 31 is attached to a source of liquid carbon dioxide such as a truck, tank, container or the like (not illustrated) and the liquid service valve 32 is opened by manipulating the valve handles 34 to the positions illustrated in FIG. 6. The gas cylinder valves 40 are then opened and liquid carbon dioxide is allowed to flow through the valve bore 11 and the pressure actuated valve 3 of the atomizer 2, since the pressure of the incoming liquid carbon dioxide exceeds the pressure in the housing bore 5 and unseats the ball 9 from the housing seat 8. The liquid carbon dioxide begins to vaporize in the housing bore 5 due to the reduced pressure and continues to vaporize as it flows through the cylinder port 20 and into the gas cylinder 39. When the gas cylinder 39 is filled, the liquid service valve 32 is closed by again manipulating the valve handle 34 and the liquid service line 31 may be detached from the source of liquid carbon dioxide. The liquid carbon dioxide continues to flow through the atomizer 2 and into the gas cylinder 39 through the gas cylinder valve 40, where it continues to vaporize into gaseous carbon dioxide. When the gas cylinder 39 reaches a predetermined pressure indicated by the pressure gauges 45 and the pressure differential across the pressure actuated valve 3 is less than a preselected differential, such as, for example, one hundred pounds, the ball 9 seats in the housing seat 8 and encloses the housing bore 5 to prevent additional liquid carbon dioxide from expanding into the gas cylinder 39. When it is desired to dispense gaseous carbon dioxide from the gas cylinder 39 to a customer, a customer carbon dioxide container or cylinder (not illustrated) is connected by appropriate fittings (not illustrated) to the gas service line 36 and the gas service valve 37 is opened by manipulating the valve handle 34 to facilitate a flow of gaseous carbon dioxide from the gas cylinder 39 through the housing bore 5 and the gas service line port 21 of the atomizer 2 and the gas service line 36, into the customer receptacle. When the customer receptacle is filled, the gas service line 37 is closed by again manipulating the valve handle 34 to the opposite position illustrated in FIG. 6. When the pressure of the gaseous carbon dioxide in the gas cylinder 39 drops to a point where the differential pressure between the gaseous carbon dioxide in the housing bore 5 and the liquid carbon dioxide at the valve bore 11 end of the pressure actuated valve 3 is less than one hundred pounds, the liquid carbon dioxide exerts sufficient pressure to again unseat the ball 9 against the bias in the spring 10 and allow additional liquid carbon dioxide to flow through the housing bore 5 of the pressure relief check valve 3 to expand into vapor and replenish the supply of gaseous carbon dioxide in the gas cylinder 39. This procedure continues until the pressure of the liquid carbon dioxide in the liquid cylinders 27 is sufficiently low that a pressure differential of less than one hundred pounds is always maintained at the pressure actuated valve 3 and additional liquid carbon dioxide must then be charged into the liquid cylinders 27 through the liquid service line 31 and liquid service valve 32 from an external source, by following the cylinder charging procedure described above.
Operation of the carbon dioxide fill manifold in several variations of this invention is further illustrated by the following examples:
EXAMPLE I
Test Set-Up:
Three empty cylinders were strapped together with the carbon dioxide fill manifold installed. The two liquid cylinder valves were opened and the fill truck hose of a liquid carbon dioxide supply truck was connected to the liquid service line. The initial pressure of the vapor cylinder was 700 psi and the vapor cylinder valve was closed during the fill operation.
Observations:
______________________________________Accumulated CO2 Weight Flow Pressure At Truck(LBS) (PSI)______________________________________ 6 675 20 650 40 650 80 650100 650120 650140 650145 775Liquid Service Valve Closed______________________________________
As the fill point was reached, the speed of the pump was observed to be noticeably different and at 950 psi the bypass valve in the truck system recirculated the liquid flow back to the truck tank to prevent the possibility of exceeding 950 psi in the liquid service line.
EXAMPLE II
Test Set-Up:
Three empty cylinders were strapped together with the carbon dioxide fill manifold installed and all three cylinder valves were opened. A fill truck hose was connected to the liquid service line and the initial pressure of the empty vapor cylinder designated as the vapor or gas cylinder was unknown.
Observations: The gas in the liquid service line was bled off and pressure was observed to increase from 200 psi and to 500 psi in approximately one minute.
______________________________________Accumulated CO2 Weight Flow Pressure At Truck(LBS) (PSI)______________________________________136 575163 590180 590200 595212 600220 600236 600240 950 (building in 15 sec.)Liquid Service Valve Closed______________________________________
As the fill point was reached, the speed of the pump was observed to be noticeably different. At 950 psi the bypass valve in the truck system recirculated the liquid flow back to the truck tank to prevent the possibility of exceeding 950 psi in the liquid service line.
The entire fill operation lasted 13.5 minutes.
A small leak was observed in one of the fittings, which leak did not materially affect the readings.
EXAMPLE III
Test Set-Up:
Three empty cylinders were strapped together with the carbon dioxide fill manifold installed and all three cylinder valves were opened. The fill truck hose of a liquid carbon dioxide supply truck was connected to the liquid service line and the initial pressure int he vapor cylinder was noted to be 400 psi.
Observations:
Ordinarily, the procedure would call for closing the valve of the vapor cylinder if its initial pressure is less than 600 psi. However, to obtain flow pressure data, this cylinder was left open to the carbon dioxide fill manifold for most of the test.
______________________________________Accumulated CO2 Flow Pressure Vapor CylinderWeight at Truck Pressure(LBS) (PSI) (PSI)______________________________________ 10 600 400 20 600 425 28 625 450 32 650 460 40 650 475 45 650 475 50 650 485 60 650 500 70 650 505 80 650 510 90 650 520100 650 520110 650 520120 650 520130 650 520140 650 520150 675 520160 670 520170 660 525180 660 530Vapor Cylinder Was Closed217 700 575220 850 600Liquid Service Valve ClosedVapor Cylinder Was Opened220 0 540______________________________________
It will be appreciated by those skilled in the art that the material used in the carbon dioxide fill manifold 1 of this invention was chosen to withstand a pressure of up to about 1500 psig for all-season use. For example, the liquid service line 31 were constructed of such material as schedule 80 steel tubing and the atomizer 2 and pressure actuated valve 3, as well as all fittings, were constructed of stainless steel. A positive displacement liquid carbon dioxide pump (not illustrated) may be mounted on a tank truck or other liquid carbon dioxide supply vessel (not illustrated) and used to supply liquid carbon dioxide to the liquid service line 31 at a pressure of about 600-850 psi.
While the pressure actuated valve 3 may be adjusted or chosen to operate at any selected pressure drop between the valve bore 11 and the housing bore 5 of the atomizer 2, a pressure drop of about 100 pounds across the pressure actuated valve 3 is preferred, in order to automatically initiate the flow of liquid carbon dioxide into the atomizer 2 as gaseous carbon dioxide is delivered from the gas cylinder 39 to customer receptacles.
While the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A carbon dioxide fill manifold and method for using which is designed to provide a end-user with an uninterrupted supply of carbon dioxide gas, while at the same time eliminating the necessity of transporting individual, conventional pressurized bottles to be refilled. In a most preferred embodiment the carbon dioxide fill manifold includes a fill line valve connected to an atomizer for receiving a fill line and introducing liquid carbon dioxide into the atomizer, liquid cylinder ports provided in the atomizer for connecting a pair of liquid chambers to the atomizer and receiving and storing the liquid carbon dioxide, a gas cylinder port provided in the atomizer for connecting a vapor container to the atomizer and receiving gaseous carbon dioxide generated in the atomizer and a service line valve also connected to the atomizer for receiving a service lien valve and servicing the end user with gaseous carbon dioxide. A pressure actuated valve is also provided in the atomizer for periodically replenishing the supply of gaseous carbon dioxide from the liquid containers responsive to a selected pressure differential across the pressure actuated valve. A pressure relief valve is seated in the atomizer to guard against excessive liquid carbon dioxide system pressure. | 8 |
FIELD OF THE INVENTION
This invention relates to novel nitrogen-containing bicyclic compounds, pharmaceutical compositions containing these compounds and methods of using these compounds to treat physiological or drug induced psychosis and as antidyskinetic agents.
BACKGROUND OF THE INVENTION
Gray et al. in J. Am. Chem. Soc., 84, 89 (1962) and U.S. Pat. No. 3,127,413 disclose octahydroisoindoles of the formula: ##STR1## The octahydroisoindoles are useful as tranquilizing agents and for potentiating the action of barbiturates.
Processes for preparing trisubstituted perhydro isoindolines of the following formula are described by Achini et al, Helvetica Chimica Acta, 57, 572 (1974): ##STR2##
Otzenberger et al., J. Org. Chem., 39, 319 (1974) disclose a compound of formula: ##STR3## No utility is disclosed.
Rehse et al., Arch. Pharm. (Weinheim), 312, 982 (1979), disclose a compound of formula: ##STR4## The authors disclose this compound is a dopamine agonist.
German Patent DE 3614906 discloses a compound of formula: ##STR5## The patentee discloses this compound is a plant fungicide.
Dunet et al., Bull Soc. Chim. France, 1956, 906, disclose a compound of formula: ##STR6## The authors do not disclose a utility for this compound.
Pogossyan et al., Arm. Khim. Zh., 33, 157 (1980), disclose compounds having the formula: ##STR7## The authors disclose these compounds are reserpine antagonists.
Rashidyan et al., Arm. Khim. Zh., 23, 474 (1970), disclose compounds of formula: ##STR8## The authors do not disclose a utility for these compounds.
Pogossyan et al., Arm. Khim. Zh., 32, 151 (1979), disclose a compound of formula: ##STR9## The authors do not disclose a utility for this compound.
Rashidyan et al., Arm. Khim. Zh., 21, 793 (1968), disclose a compound having the formula: ##STR10## The authors do not disclose a utility for this compound.
Grieco et al., J. Chem. Soc., Chem. Soc., 1987, 185, disclose a compound of formula: ##STR11## The authors do not disclose a utility for this compound.
Larsen et al., J. Am. Chem. Soc., 108, 3512 (1986), disclose a compound having the formula: ##STR12## The authors do not disclose a utility for this compound.
German Patent 3721723 (Hoechst AG) describes substituted 6-oxo-decahydroisoquinolines of the formula: ##STR13## These compounds are useful as antihypertensives and sedatives.
Archer et al., J. Med. Chem., 30, 1204 (1987), disclose a compound having the formula: ##STR14## The authors do not disclose a utility for this compound.
Deslongchamps et al., Can. J. Chem., 53, 3613 (1975), disclose a compound having the formula: ##STR15## The authors do not disclose a utility for this compound.
Jirkovsky et al., Coll. Czech. Chem. Commun., 29, 400 (1964), disclose a compound having the formula: ##STR16## The authors do not disclose a utility for this compound.
Meyers et al., J. Org. Chem., 51, 872 (1986), disclose a compound of formula: ##STR17## The authors do not disclose a utility for this compound.
Bartmann et al., Synth. Commun., 18, 711 (1988), disclose compounds of formula: ##STR18## The authors do not disclose a utility for these compounds.
Compounds of the present invention demonstrate sigma receptor affinity. It is this sigma receptor affinity of the compounds of the present invention which makes them so advantageous over the compounds in the prior art. Traditionally, antipsychotic agents have been potent dopamine receptor antagonists. For example, phenothiazines such as chlorpromazine and most butyrophenones such as haloperidol are potent dopamine receptor antagonists. These dopamine receptor antagonists are associated with a high incidence of side effects, particularly Parkinson-like motor effects or extra-pyramidal side-effects (EPS), and dyskinesias including tardive dyskinesias at high doses. Many of these side effects are not reversible even after the dopamine receptor antagonist agent is discontinued.
The present invention is related to antipsychotic agents which are sigma receptor antagonists, not traditional dopamine receptor blockers known in the art, and therefore the compounds of the present invention have low potential for the typical movement disorder side-effects associated with the traditional dopamine antagonist antipsychotic agents while they maintain the ability to antagonize aggressive behavior and antagonize hallucinogenic-induced behavior.
SUMMARY OF THE INVENTION
Compounds of this invention are novel antagonists of sigma receptors, which may be useful for the treatment of physiological and drug-induced psychosis and dyskinesia.
The compounds of the present invention are nitrogen-containing bicyclic compounds having the formula: ##STR19## or a pharmaceutically acceptable salt, N-oxide, chiral, enantiomeric, diastereomeric or racemic form thereof, wherein:
n=1 or 2;
R 1 is selected from the group including:
C 1 -C 8 alkyl substituted with 1 or more R 4 ,
C 3 -C 8 cycloalkyl, and C 4 -C 10 cycloalkyl-alkyl;
R 2 and R 3 are optional and may be independently selected from the group including:
C 1 -C 8 alkyl substituted with 0-3 R 4 , C 2 -C 8 alkenyl,
C 3 -C 8 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl
C 1 -C 6 perfluoroalkyl, aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, except that R 2 and/or R 3 when aryl may not be at the 2- or 3-position,
a heterocyclic ring system selected from the group including furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl,
--F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , COR 7 , --CN, ═O, forming a carbonyl group, or
R 2 and R 3 may be taken together to form a ring comprising: --CHR 6 --CHR 6 --CHR 6 --,--CHR 6 --CHR 6 --CHR 6 --CHR 6 --, --CHR 6 --CR 6 ═CR 6 --, --CHR 6 --CHR 6 --CHR 6 --CR 6 ═, --CHR 6 --CHR 6 --CR 6 ═CR 6 --, --CHR 6 --CR 6 ═CHR 6 --CHR 6 --, --CR 6 ═CHR 6 --CHR 6 --CR 6 ═, --CR 6 ═CHR 6 --CR 6 ═CR 6 --, and --CHR 6 --CR 6 ═CHR 6 --CR 6 ═;
R 4 may be aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, or
R 4 may be a heterocyclic ring system selected from the group including:
furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl;
R 5 is independently selected at each occeurrence from the group including:
hydrogen, C 1 -C 14 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkanoyl, and aryl;
R 6 is independently selected at each occurrence from the group including:
hydrogen, phenyl, benzyl, phenethyl, phenoxy, benzyloxy, halogen, hydroxy, nitro, cyano, C 1 -C 5 alkyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 7 -C 10 arylalkyl, C 1 -C 4 alkoxy, --NR 7 R 8 , C 2 -C 6 alkoxyalkyl, C 1 -C 4 hydroxyalkyl, methylenedioxy, ethylenedioxy, C 1 -C 4 haloalkyl, C 1 -C 4 haloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, --SO 2 R 7 , --S(═O)R 7 , --SO 2 NR 7 R 8 , --SO 3 H, --CF 3 , --OR 7 , --CHO, --CH 2 OR 7 , --CO 2 R 7 , --C(═O)R 7 , -NHSO 2 R 8 , --OCH 2 CO 2 H, or
a 5- or 6-membered heterocyclic ring containing from 1 to 4 heteroatoms selected from oxygen, nitrogen or sulfur;
R 7 is H, phenyl, benzyl or C 1 -C 6 alkyl;
R 8 is H or C 1 -C 4 alkyl;
or R 7 R 8 can join to form --(CH 2 ) 4 --, --(CH 2 ) 5 --, --(CH 2 CH 2 N(R 9 )CH 2 CH 2 )--, or --(CH 2 CH 2 OCH 2 CH 2 )--;
R 9 is H or CH 3 ; and
the A ring may contain one double bond;
with the following provisos:
(1) when R 2 and R 3 are on the same atom, neither R 2 nor R 3 can be OH;
(2) when n=1 and R 2 is 5-hydroxy and R 3 is 6-alkoxy and the A ring contains no double bond, then R 1 cannot be --CH 2 CH 2 Ph or --CH 2 CH 2 (3-indolyl) or --CH 2 CH 2 (naphthyl);
(3) when n=1 and R 2 is 5-hydroxy or 5-acyloxy and R 3 is alkoxy and the A ring contains no double bond, then R 1 cannot be --(CH 2 )paryl or --(CH 2 )pheteroaryl wherein p=1-3 and the aryl or heteroaryl groups are substituted with 1-3 R 7 ;
(4) when N=1 and R 2 is not present and R 3 is not present and the A ring contains a double bond between carbons 5 and 6, then R 1 cannot be --CH 2 Ph;
(5) when n=1 and R 2 is 5-Cl and R 3 is not present and the A ring contains a double bond between carbons 5 and 6, then R 1 cannot be --CH 2 Ph;
(6) when n=1 and R 2 is 5-OH R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(7) n=1 and R 2 is 5-keto or 5-[1-(1,3-dioxolane)] and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(8) when n=1 and R 2 is not present and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 (2-methylcyclohexyl);
(9) when n=1 and R 2 is 5-Ph and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CH 2 (3,4-dimethoxyphenyl);
(10) when n=1 and R 2 is not present and R 3 is not present and the A ring has a double bond between the 5 and 6 carbons, then R 1 cannot be --CH 2 CH 2 (3-indolyl);
(11) when n=1 and R 2 is 5-NH2 and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CH 2 (3-indolyl) or CHMeCH 2 (3-indolyl);
(12) when n=1 and R 2 is not present and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CHCH 3 CH 2 (4-t-butylphenyl);
(13) when n=2 and R 2 is 3-OH or 5-OH or 5-(═O) and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(14) when n=2 and R 2 is 3-alkyl optionally substituted with cycloalkyl, alkenyl or aryl groups, 3-alkenyl, 3-cycloalkyl, 3-cycloalkenyl, 3-fluorenyl, 3-CHCNPh, 3-CHNO 2 Ph, or 3-CH(CO 2 R 5 ) 2 , and R 3 is 5-(═O) and the A ring has no double bond, then R 1 cannot be --(CH 2 ) q aryl wherein q=1-4;
(15) when n=2 and R 2 is 5-(═O) and R 3 is not present and the A ring contains a double bond between 3 and 4 carbons, then R 1 cannot be CH 2 Ph;
(16) when n=2 and R 2 is not present and R 3 is not present and the A ring contains a double bond between the 2 and 3 carbons, then R 1 cannot be CH 2 Ph;
(17) when n=2 and R 2 is 5-(═CH 2 ) or 5-(═O) and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CH 2 -3-(N--phenylsulfonyl)indoyl; and
(18) when n=2 and R 2 is 6-OMe and R 3 is not present and the A ring contains no double bonds, then R 1 cannot be CH 2 CH 2 Ph.
Also provided by the present invention is a method for treatment of physiological or drug induced psychosis or dyskinesia in a mammal comprising administering to a mammal in need of such treatment an antipsychotic or antidyskinetic effective amount of a compound of formula: ##STR20## or a pharmaceutically acceptable salt, N-oxide, chiral, enantiomeric, diastereomeric or racemic form thereof, wherein:
n=1 or 2;
R 1 is selected from the group including:
C 1 -C 6 alkyl substituted with 1 or more R 4 ,
C 3 -C 8 cycloalkyl, and C 4 -C 10 cycloalkyl-alkyl;
R 2 and R 3 are optional and may be independently selected from the group including:
C 1 -C 8 alkyl substituted with 0-3 R 4 , C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 4 -C 10 cycloalkyl-alkyl C 1 -C 6 perfluoroalkyl,
aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, except that R 2 and/or R 3 when aryl may not be at the 2- or 3-position,
a heterocyclic ring system selected from the group including furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl,
--F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , COR 7 , --CN, ═O, forming a carbonyl group, or
R 2 and R 3 may be taken together to form a ring comprising:
--CHR 6 --CHR 6 --CHR 6 --,--CHR 6 --CHR 6 --CHR 6 --CHR 6 --, --CHR 6 --CR 6 ═CR 6 --, --CHR 6 --CHR 6 --CHR 6 --CR 6 ═, --CHR 6 --CHR 6 --CR 6 ═CR 6 --, --CHR 6 --CR 6 ═CHR 6 --CHR 6 --, --CR 6 ═CHR 6 --CHR 6 --CR 6 ═, --CR 6 ═CHR 6 --CR 6 ═CR 6 --, and --CHR 6 --CR 6 ═CHR 6 --CR 6 ═;
R 4 may be aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, or
R 4 may be a heterocyclic ring system selected from the group including:
furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl;
R 5 is independently selected at each occeurrence from the group including:
hydrogen, C 1 -C 14 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkanoyl, and aryl;
R 6 is independently selected at each occurrence from the group including:
hydrogen, phenyl, benzyl, phenethyl, phenoxy, benzyloxy, halogen, hydroxy, nitro, cyano, C 1 -C 5 alkyl, C 3 -C 10 cycloalkyl, C 3 -C 6 cycloalkylmethyl, C 7 -C 10 arylalkyl, C 1 -C 4 alkoxy, --NR 7 R 8 , C 2 -C 6 alkoxyalkyl, C 1 -C 4 hydroxyalkyl, methylenedioxy, ethylenedioxy, C 1 -C 4 haloalkyl, C 1 -C 4 haloalkoxy, C 1 -C 4 alkoxycarbonyl, C 1 -C 4 alkylcarbonyloxy, C 1 -C 4 alkylcarbonyl, C 1 -C 4 alkylcarbonylamino, --SO 2 R 7 , --S(═O)R 7 , --SO 2 NR 7 R 8 , --SO 3 H, --CF 3 , --OR 7 , --CHO, --CH 2 OR 7 , --CO 2 R 7 , --C(═O)R 7 , --NHSO 2 R 8 , --OCH 2 CO 2 H, or
a 5- or 6-membered heterocyclic ring containing from 1 to 4 heteroatoms selected from oxygen, nitrogen or sulfur;
R 7 is H, phenyl, benzyl or C 1 -C 6 alkyl;
R 8 is H or C 1 -C 4 alkyl;
or R 7 R 8 can join to form --(CH 2 ) 4 --, --(CH 2 ) 5 --, --(CH 2 CH 2 N(R 9 )CH 2 CH 2 )--, or --(CH 2 CH 2 OCH 2 CH 2 )--;
R 9 is H or CH 3 ; and
the A ring may contain one double bond;
with the following provisos:
(1) when R 2 and R 3 are on the same atom, neither R 2 nor R 3 can be OH;
(2) when n=1 and R 2 is 5-hydroxy and R 3 is 6-alkoxy and the A ring contains no double bond, then R 1 cannot be --CH 2 CH 2 Ph or --CH 2 CH 2 (3-indolyl) or --CH 2 CH 2 (naphthyl);
(3) when n=1 and R 2 is 5-hydroxy or 5-acyloxy and R 3 is alkoxy and the A ring contains no double bond, then R 1 cannot be --(CH 2 )paryl or --(CH 2 ) p heteroaryl wherein p=1-3 and the aryl or heteroaryl groups are substituted with 1-3 R 7 ;
(4) when n=2 and R 2 is 3-alkyl optionally substituted with cycloalkyl or aryl groups, 3-alkenyl, 3-cycloalkyl, 3-cycloalkenyl, 3-fluorenyl, 3-CHCNPh, 3-CHNO 2 Ph, or 3-CH(CO 2 R 5 ) 2 , and R 3 is 5-(═O) and the A ring has no double bond, then R 1 cannot be --(CH 2 ) r Aryl
wherein r=1-4.
PREFERRED EMBODIMENTS
Preferred compounds in the present invention are those compounds of formula (I) wherein:
n=1 or 2;
R 1 is C 1 -C 6 alkyl substituted with 1 or more R 4 or C 4 -C 10 cycloalkylalkyl;
R 2 is H, OH or ═O;
R 3 is H, C 1 -C 8 alkyl substituted with 0-3 R 4 or phenyl optionally substituted with 1-3 F, Cl, Br, NO 2 , CN, C 1 -C 8 alkyl, and aryl, provided that phenyl is not in the 2- or 3-position;
R 4 may be aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, or
R 4 may be a heterocyclic ring system selected from the group including:
furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl;
R 5 is independently selected at each occeurrence from the group including:
hydrogen, C 1 -C 14 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkanoyl, and aryl;
R 7 is H, phenyl, benzyl or C 1 -C 6 alkyl; and the A ring may contain one double bond; with the following provisos:
(1) when n=1 and R 2 is not present and R 3 is not present and the A ring contains a double bond between carbons 5 and 6, then R 1 cannot be --CH 2 Ph;
(2) when n=1 and R 2 is 5-OH and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(3) when n=1 and R 2 is 5-keto and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(4) when n=1 and R 2 is not present and R 3 is not present and the A ring has a double bond between the 5 and 6 carbons, then R 1 cannot be --CH 2 CH 2 (3-indolyl);
(5) when n=1 and R 2 is not present and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CHCH 3 CH 2 (4-t-butylphenyl);
(6) when n=2 and R 2 is 3-OH or and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(7) when n=2 and R 2 is not present and R 3 is not present and the A ring contains a double bond between the 2 and 3 carbons, then R 1 cannot be CH 2 Ph.
More preferred in the present invention are compounds of formula (I) wherein:
n=1 or 2;
R 1 is H or C 1 -C 6 alkyl substituted with 1 R 4 wherein 1-3 carbon atoms are between N and R 4 ;
R 2 is H, OH or ═O;
R 3 is H or C 1 -C 8 alkyl;
R 4 may be aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, or
R 4 may be a heterocyclic ring system selected from the group including:
furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl;
R 5 is independently selected at each occeurrence from the group including:
hydrogen, C 1 -C 14 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkanoyl, and aryl;
R 7 is H, phenyl, benzyl or C 1 -C 6 alkyl; and the A ring may contain one double bond; with the following provisos:
(1) when n=1 and R 2 is not present and R 3 is not present and the A ring contains a double bond between carbons 5 and 6, then R 1 cannot be --CH 2 Ph;
(2) when n=1 and R 2 is 5-OH and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(3) when n=1 and R 2 is 5-keto and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(4) when n=1 and R 2 is not present and R 3 is not present and the A ring has a double bond between the 5 and 6 carbons, then R 1 cannot be --CH 2 CH 2 (3-indolyl);
(5) when n=1 and R 2 is not present and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CHCH 3 CH 2 (4-t-butylphenyl);
(6) when n=2 and R 2 is 3-OH or and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(7) when n=2 and R 2 is not present and R 3 is not present and the A ring contains a double bond between the 2 and 3 carbons, then R 1 cannot be CH 2 Ph.
Most preferred in the present invention are compounds of formula (I) wherein:
n=1;
R 1 is C 1 -C 6 alkyl substituted with 1 R 4 wherein 1-3 carbon atoms separate N from R 4 ;
R 2 is H;
R 3 is H or is C 1 -C 8 alkyl;
R 4 may be aryl optionally substituted with 1-3 of the following:
C 1 -C 8 alkyl, C 2 -C 8 alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 perfluoroalkyl, aryl, --F, --Cl, --Br, --I, --NO 2 , --OR 5 , --OC(═O)R 7 , --N(R 7 ) 2 , --SR 5 , --S(O)R 5 , --SO 2 R 5 , --CO 2 R 7 , --CN, or
R 4 may be a heterocyclic ring system selected from the group including:
furyl, thienyl, pyrrolyl, pyridyl, indolyl, quinolyl, isoquinolyl, benzofuryl, benzothienyl, pyrimidyl, pyrazinyl, quinazolyl, phthalazinyl, naphthyridinyl;
R 5 is independently selected at each occeurrence from the group including:
hydrogen C 1 -C 14 alkyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkanoyl, and aryl;
R 7 is H, phenyl, benzyl or C 1 -C 6 alkyl; and the A ring may contain one double bond; with the following provisos:
(1) when n=1 and R 2 is not present and R 3 is not present and the A ring contains a double bond between carbons 5 and 6, then R 1 cannot be --CH 2 Ph;
(2) when n=1 and R 2 is 5-OH and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph; (3) when n=1 and R 2 is 5-keto and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(4) when n=1 and R 2 is not present and R 3 is not present and the A ring has a double bond between the 5 and 6 carbons, then R 1 cannot be --CH 2 CH 2 (3-indolyl);
(5) when n=1 and R 2 is not present and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 CHCH 3 CH 2 (4-t-butylphenyl);
(6) when n=2 and R 2 is 3-OH or and R 3 is not present and the A ring contains no double bond, then R 1 cannot be --CH 2 Ph;
(7) when n=2 and R 2 is not present and R 3 is not present and the A ring contains a double bond between the 2 and 3 carbons, then R 1 cannot be CH 2 Ph.
Specifically preferred compounds of the present invention, named according to Chemical Abstracts approved nomenclature rules, are:
a) cis-2-(4-trifluoromethylbenzyl)-3a,4,7,7a-tetrahydroisoindoline;
b) cis-4-chlorophenethylhexahydroisoindole;
c) trans-2-phenethylhexahydroisoindoline;
d) cis-2-phenethylhexahydroisoindoline.
In the present invention it has been discovered that the compounds above are useful as agents to treat physiological or drug induced psychosis and as antidyskenetic agents. Also provided are pharmaceutical compositions containing compounds of Formula (I)as described above.
The present invention also provides methods for the treatment of drug induced psychosis or dyskinesia by administering to a host suffering from such drug induced psychosis or dyskinesia a pharmaceutically effective amount of a compound of Formula (I) as described above.
The compounds herein described may have asymmetric centers. All chiral, enantiomeric, diastereomeric, and racemic forms are included in the present invention. Thus, the compounds of Formula (I) may be provided in the form of an individual stereoisomer, a non-racemic stereoisomer mixture, or a racemic mixture.
Many geometric isomers of olefins, C═N double bonds, and the like can also be present in the compounds described herein, and all such stable isomers are contemplated in the present invention.
When any variable occurs more than one time in any constituent or in Formula (I), or any other formula herein, its definition on each occurrence is independent of its definition at every other occurrence. Also, combinations of substituents and/or variables are permissible only if such combinations result in stable compounds.
As used herein, "alkyl" is intended to include both branched and straight-chain saturated aliphatic hydrocarbon groups having the specified number of carbon atoms. The number of carbon atoms in a group is specified herein, for example, as C 1 -C 5 to indicate 1-5 carbon atoms. As used herein "alkoxy" represents an alkyl group of indicated number of carbon atoms attached through an oxygen bridge; "cycloalkyl" is intended to include saturated ring groups, such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl and cyclooctyl; and "biycloalkyl" is intended to include saturated bicyclic ring groups such as [3.3.0]bicyclooctane, [4.3.0]bicyclononane, [4.4.0]bicyclodecane (decalin), [2.2.2]bicyclooctane, and so forth. "Alkenyl" is intended to include hydrocarbon chains of either a straight or branched configuration and one or more unsaturated carbon-carbon bonds which may occur in any stable point along the chain, such as ethenyl, propenyl, and the like; and "alkynyl" is intended to include hydrocarbon chains of either a straight or branched configuration and one or more triple carbon-carbon bonds which may occur in any stable point along the chain, such as ethynyl, propynyl and the like. "Cycloalkyl-alkyl" is intended to include cycloalkyl attached to alkyl. "Halo" as used herein refers to fluoro, chloro, bromo, and iodo; and "counterion" is used to represent a small, negatively charged species such as chloride, bromide, hydroxide, acetate, sulfate, and the like.
As used herein, "aryl" or "aromatic residue" is intended to mean phenyl or naphthyl; "carbocyclic" is intended to mean any stable 5- to 7- membered monocyclic or bicyclic or 7- to 14-membered bicyclic or tricyclic carbon ring, any of which may be saturated, partially unsaturated, or aromatic, for example, indanyl or tetrahydronaphthyl (tetralin).
As used herein, the term "heterocycle" is intended to mean a stable 5- to 7- membered monocyclic or bicyclic or 7- to 10-membered bicyclic heterocyclic ring which is either saturated or unsaturated, and which consists of carbon atoms and from 1 to 3 heteroatoms selected from the group consisting of N, O and S and wherein the nitrogen and sulfur heteroatoms may optionally be oxidized, and the nitrogen may optionally be quaternized, and including any bicyclic group in which any of the above-defined heterocyclic rings is fused to a benzene ring. The heterocyclic ring may be attached to its pendant group at any heteroatom or carbon atom which results in a stable structure. The heterocyclic rings described herein may be substituted on carbon or on a nitrogen atom if the resulting compound is stable. Examples of such heterocycles include, but are not limited to, pyridyl, pyrimidinyl, furanyl, thienyl, pyrrolyl, pyrazolyl, imidazolyl, tetrazolyl, benzofuranyl, benzothiophenyl, indolyl, indolenyl, quinolinyl, isoquinolinyl or benzimidazolyl, piperidinyl, 4-piperidonyl, pyrrolidinyl, 2-pyrrolidonyl, pyrrolinyl, tetrahydrofuranyl, tetrahydroquinolinyl, tetrahydroisoquinolinyl, decahydroquinolinyl, pyrazinyl, quinazzoyl, phthalazinyl, naphthyridinyl or octahydroisoquinolinyl.
The term "substituted", as used herein, means that one or more hydrogen on the designated atom is replaced with a selection from the indicated group, provided that the designated atom's normal valency is not exceeded, and that the substitution results in a stable compound.
By "stable compound" or "stable structure" is meant herein a compound that is sufficiently robust to survive to a useful degree of purity from a reaction mixture, and formulation into an efficacious therapeutic agent.
As used herein, "pharmaceutically acceptable salts" refer to derivatives of the disclosed compounds that are modified by making acid or base salts. Examples include, but are not limited to, mineral or organic acid salts of basic residues such as amines; alkali or organic salts of acidic residues such as carboxylic acids.
Pharmaceutically acceptable salts of the compounds of the invention can be prepared by reacting the free acid or base forms of these compounds with a stoichiometric amount of the appropriate base or acid in water or in an organic solvent, or in a mixture of the two; generally, nonaqueous media like ether, ethyl acetate, ethanol, isopropanol, or acetonitrile are preferred. Lists of suitable salts are found in Remington's Pharmaceutical Sciences, 17th ed., Mack Publishing Company, Easton Pa., 1985 p. 1418, the disclosure of which is hereby incorporated by reference.
DETAILED DESCRIPTION OF THE INVENTION
The compounds disclosed in this section are numbered according to Chemical Abstracts rules.
Methods of Preparation
(1) Hydroisoindolines
Diels-Alder reaction of butadiene or substituted butadienes with maleic anhydride or substituted maleic anhydrides is known to give adducts of type 1. Reaction of these adducts with amines R 1 NH 2 and ##STR21## dehydration of the intermediate maleamic acids gives imides of type 2 which on reduction with complexed metal hydrides such as lithium aluminum hydride or sodium bis(methoxyethoxy) aluminum hydride gives the amines 3 of this invention. The double bond can be removed by catalytic hydrogenation in either intermediates 1 or 2 or in the final product 3. The double bond may also be moved to 4.5; 3a,4; or 3a,7a-positions by the action of a catalyst, such as a rhodium salt.
Alternatively, the Diels-Alder reaction may be carried out with maleimides (4) which gives imides 2 directly. When R 1 contains ##STR22## functionalities that are reduced by complexed metal hydrides, the desired products may be obtained by alkylating amines 3 (R 1 ═H) with R 1 X (where X is, for instance, Cl, Br, I, methanesulfonyl, or p-toluenesulfonyl) in the presence of an organic or inorganic base.
When the butadiene component in the Diels-Alder reaction is substituted in the 2-position with a protected hydroxyl group (such as, acetoxy or trimethylsilyloxy groups), compounds of type 5 are obtained which on removal of the protecting by known methods give ketones 6. ##STR23## Reduction as described above gives amino alcohols of type 7 which may be oxidized by well-known methods, such as the Swern oxidation, or with pyridine-SO 3 , to the ketones 8. The latter may alternatively be obtained by converting imides 2 into the corresponding epoxides 9 ##STR24## which on reduction, as described above, give the aminoalcohols 7. The latter may be acylated by standard methods.
A similar series of reactions may be carried out with butadienes carrying a protected hydroxyl group in the 1-position: ##STR25## Ketones 8 may be converted into aminoalcohols 12 by reaction with organometallic reagents, such as R 2 Li or R 2 MgX (where X is Cl, Br, or I). ##STR26## Compounds 12 may be dehydrated by known methods to give the olefinic amines 13 which on catalytic hydrogenation give the saturated amines 14. The same sequence of reactions may be carried out with ketones 11.
Substituents R 2 may be introduced into the 3a position by conversion of imides 2 or their saturated analogs into the anion with a strong base such as lithium diisopropylamide followed by treatment with R 2 X where X═Cl, Br, I, CH 3 SO 3 , p--CH 3 C 6 H 4 SO 3 or other suitable leaving groups. ##STR27##
An alternative approach to the hydroisoindoles of the present invention uses the intramolecular Diels-Alder reaction. For instance, diene amides 15, which may be prepared by standard amide-forming reactions from the known acids and amines, cyclize on heating to give lactams 16 which on ##STR28## reduction give the amines 17 of this invention. This type of reaction is reviewed in Organic Reactions, Vol. 32, Chapter 1. Alternatively, amides of type 18 may be converted via lactams 19 into amines 17. Finally, amines ##STR29## 20 may be cyclized to give amines 17 directly. In the latter reaction it may be of advantage to use a protecting group R 1 such CF 3 CO to facilitate the cyclization. The protecting group is then removed by standard methods to give amines 17 (R 1 ═H) which are subsequently alkylated with R 1 X, as described earlier.
(2) Hydroisoquinolines
A large number of hydroisoquinolines having hydrogen on the nitrogen atom may be prepared via known methods (Comprehensive Heterocyclic Chemistry, Pergamon Press, 1982; Vol. 2; Chemistry of Heterocyclic Compounds, Wiley, Vol 38). These may be converted into the compounds of this invention by known methods of introducing substituents R 1 on nitrogen, such as, reaction with a reagents R 1 X (X═Cl, Br, I, OSO 2 Ar, OSO 2 Me, etc.) in the presence of a base ##STR30## Alternatively, isoquinolines 21 which are known or are available from known ##STR31## methods, may be quaternized by reaction with R 1 X and the quaternary isoquinolinium salts may be reduced by well-known methods with hydrogen in the presence of a catalyst. Tetrahydroisoquinolines 23 are well known and may be prepared by many different methods (cf. the two references given above). These may be treated with R 1 X as described above and the compounds so obtained may be reduced with hydrogen and a catalyst to give compounds of this invention. ##STR32##
Another approach to the hydroisoquinolines of this invention involves the intramolecular Diels-Alder reaction as described in section 1 above. This approach is illustrated below: ##STR33## Certain ketones of types 24 and 25 may be obtained by a Robinson annellation of piperidones (cf. for instance, L. Augustine, J. Org. Chem., 33, ##STR34## 1853 (1958)). Ketones 24 and 25 may be modified further. Thus, reduction with complexed metal hydrides, such as sodium borohydride or lithium aluminum hydride gives alcohols, e.g. 26 which may be converted ##STR35## into compounds 27 by known methods for the removal of hydroxyl groups, for instance, by conversion into the toluenesulfonate followed by reduction. 1,2-Addition of organometallic reagents to ketones 24 or 25 gives substituted alcohols, e.g. 28 in which the hydroxyl groups may also be removed as indicated above to give compounds 29. 1,4,-addition of ##STR36## organocuprates to ketones 24 gives 4a-substituted derivatives 30 (Bartmann et al., Synthetic Communications, 18, 711 (1988)). These may ##STR37## be further modified as described above for ketones 24 and 25.
EXAMPLES
Analytical data were recorded for the compounds described below using the following general procedures. Proton NMR spectra were recorded on a Varian FT-NMR spectrometer (200 MHz or 300 MHz); chemical shifts were recorded in ppm (∂) from an internal tetramethylsilane standard in deuterochloroform or deuterodimethylsulfoxide and coupling constants (J) are reported in Hz. Mass spectra (MS) or high resolution mass spectra (HRMS) were recorded on Finnegan MAT 8230 spectrometer or Hewlett Packard 5988A model spectrometer. Melting points are uncorrected. Boiling points are uncorrected.
Reagents were purchased from commercial sources and, where necessary, purified prior to use according to the general procedures outlined by D. D. Perrin and W. L. F. Armarego, Purification of Laboratory Chemicals, 3rd ed., (New York: Pergamon Press, 1988). Chromatography was performed on silica gel using the solvent systems indicated below. For mixed solvent systems, the volume ratios are given. Parts and percentages are by weight unless otherwise specified. Common abbreviations include: THF (tetrahydrofuran), TBDMS (t-butyl-dimethylsilyl), DMF (dimethylformamide), Hz (hertz) TLC (thin layer chromatography).
The exemplified compounds are named according to the Chemical Abstract reulres of nomenclature.
EXAMPLE 1
cis-2-(4-Fluorophenethyl)-3a,4,7,7a-tetrahydroisoindoline ##STR38##
A solution of 9.3 g of 1,2,3,6-tetrahydrophthalic anhydride in 30 mL of dry THF was treated with 8.08 g of 4-fluorophenethylamine, heated under reflux for 30 mins. and concentrated under vacuum. The residual solid was heated with stirring in a 160°-oil bath for 1 hour and the product was recrystallized from 1-chlorobutane to give 10.32 g. of N-(4-fluorophenethyl)-1,2,3,4-tetrahydrophthlalimide.
To 2.0 g of the above intermediate in 20 mL of dry THF was added with cooling 16 mL of 1 M lithium aluminum hydride in THF and the mixture was heated under reflux for 2 hours. Water (0.64 mL), 15% aqueous sodium hydroxide solution (0.64 mL), and water (1.8 mL) were added sequentially, with cooling. The solids were removed by filtration and washed several times with methylene chloride. The combined filtrates were concentrated and the residue was short-path distilled (150° bath temperature, 0.001 mm) to give 1.63 g of 2-(4-fluorophenethyl-3a,3,7,7a-tetrahydroisoindoline. 1 H-NMR (in CDCl 3 ) δ7.2 (m, 2H); 7.0 (m, 2H); 5.8 (m, 2H); 3.0 (m, 2H); 2.6-2.8 (m, 4H); 2.4 (m, 2H); 2.1-2.3 (m, 4H) and 1.9 (d, 2H). The fumarate had m.p. 125°- 126° after crystallization from 2-propanol.
Anal. Calcd. for C 20 H 24 FNO 4 : C, 66.46; H, 6.69; N, 3.88; Found: C, 66.63; H, 6.63; N, 3.67.
EXAMPLE 2
cis-2-(4-Fluorophenethyl)hexahydroisoindoline ##STR39##
A mixture of 0.44 g of cis-2-(4-fluorophenethyl)-3a,4,7,7a-tetrahydroisoindoline (Ex. 1), 7 mL of ethanol and 0.08 g of prereduced PtO 2 was stirred under hydrogen for 1 hr. 20 mins. The catalyst was removed by filtration, the filtrate was concentrated and the residue was short-path distilled (140° bath, 0.002 mm) to give 0.41 g. of cis-2-(4-fluorophenethyl)hexahydroisoindoline. 1 H NMR (in CDCl 3 ) δ7.2 (d/d, 2H); 7.0 (t, 2H); 2.8 (d/d, 2H); 2.7 (s, 4H), 2.5 (d/d, 2H); 2.2 (m, 2H) and 1.2-1.6 (m, 8H). The fumarate had m.p.130°-131° after crystallization from 2-propanol.
Anal. Calcd. for C 20 H 26 FNO 4 : C, 66.10; H, 7.21; N, 3.85; Found: C, 66.14; H, 7.14; N, 3.80.
EXAMPLE 3
trans-2-Phenethylhexahydroisoindoline ##STR40##
Phenethylamine (11.9 g) was added slowly to a mixture of 15.16 g of trans-hexahydrophthalic anhydride and 50 mL of THF. After the exothermic reaction had subsided, the solvent was removed under vacuum to give 25.2 g of a solid. A mixture of 11.15 g of this solid and 50 mL of acetyl chloride was heated under reflux for 20 mins., the excess reagent was removed under vacuum and the residue was dissolved in 200 mL of methylene chloride. The solution was treated with 10% aqueous sodium carbonate to a basic PH, the layers were separated and the aqueous layer was extracted several times with methylene choride to give 9.21 g of crude product. Crystallization from 15 mL of 2-propanol gave 6.73 g of trans-2-phenethylhexahydrophthalimide.
To a solution of 1.27 g of the imide in 10 mL of dry THF were added 15 mL of 1 M lithium aluminum hydride in THF and the mixture was heated under reflux for 6 hours. Isolation by the procedure given in Example 1 and short-path distillation (140° bath, 0.001 mm) gave 1.12 g. of trans-2-phenethylhexahydroisoindoline. 1 H-NMR (in CDCl 3 ) δ7.2-7.3 (m, 5H); 2.9 (d/d, 2H); 2.8(s, 4H); 2.4 (t, 2H); 1.7-1.9 (m, 4H), 1.5 (m, 2H), 1.2 (m, 2H) and 1.1 (m, 2H). The fumarate had m.p. 170°-171° (dec.) after crystallization from ethanol.
Anal. Calcd. for C 20 H 27 NO 4 : C, 69.54; H, 7.88; N, 4.05; Found: C, 69.44; H, 7.74; N, 3.97.
EXAMPLE 4
cis-2-(4-Pyridylethyl)-3a,4,7,7a-tetrahydroisoindoline ##STR41##
A mixture of 0.64 g of cis-3a,4,7,7a-tetrahydroisoindoline, 0.6 mL of 4-vinylpyridine, 0.4 mL of acetic acid and 10 mL of methanol was heated under reflux for 16 hours. Removal of the solvent and short-path distillation of the residue (160° bath temperature, 0.002 mm) gave 0.74 g. of cis-2-(4-pyridylethyl)-3a,4,7,7a-tetrahydropyridine. 1 H NMR (in CDCl 3 ) δ8.5 (d, 2H); 7.1 (d, 2H); 5.8 (m, 2H); 3.0 (m, 2H); 2.7-2.8(m, 4H); 2.4 (m, 2H); 2.2-2.3 (m, 4H) and 1.9 (d, 2H). The dihydrochloride hemi-hydrate had an indefinite melting point after crystallization from 2-propanol.
Anal. Calcd. for C 15 H 22 Cl 2 N 2 .1/2H 2 O: C, 58.07; H, 7.47; N, 9.03; Found: C, 58.27; H, 7.47; N, 9.15.
EXAMPLE 5
cis-5-Hydroxy-2-phenethylhexahydroisoindoline ##STR42##
A mixture of 10 g of cis-2-phenethyl-3a,4,7,7a-tetrahydroisoindoline (prepared by the method of Example 1), 80 mL of chloroform and 12 g. of m-chloroperoxybenzoic acid was stirred at room temperature for 30 mins. Methylene chloride (200 mL) and 15% aqueous sodium hydroxide (100 mL) were added and the dried organic phase was concentrated to give 10.2 g of crude cis-5,6-epoxy-2-phenethylhexahydroisoindoline as a mixture of two isomers.
To 8.5 g of the above product in 80 mL of dry THF was added at 0°, 80 mL of 1 M lithium aluminum hydride in THF. The mixture was stirred in an ice bath for 1 hour, then refluxed for 6 hours. Isolation as described in Example 1 gave 7.00 g of crude product which on short-path distillation (180° bath temperature, 0.001 mm) gave 6.10 g. of cis-5-hydroxy-2-phenethylhexahydroisoindoline (mixture of two isomers) as an oil. The fumarate had m.p. 118°-126° after crytallization from 2-propanol.
Anal Calcd. for C 20 H 27 NO 5 ; C, 66.46; H, 7.53; N, 3.88; Found: C, 66.37; H, 7.51; N, 3.81.
EXAMPLE 6
cis-2-Phenethylhexahydroisoindolin-5-one ##STR43##
To a solution of 0.68 g of cis-5-hydroxy-2-phenethylhexahydroisoindoline (Example 5) in 6 mL of dry dimethylsulfoxide and 5 mL of triethylamine was added a solution of 1.82 g SO 3 .pyridine in 7 mL of dry DMSO. After stirring at room temperature for 4 hours, 20 mL of 15% sodium hydroxide solution was added with cooling and the solution was extracted with toluene to give 0.63 g of product. Short-path distillation (160° bath temperature, 0.001 mm) gave 0.51 g of cis-2-phenethylhexahydroisoindolin-5-one as an oil. The fumarate had m.p. 130°-134° (dec.) after crystallization from 2-propanol.
Anal. Calcd. for C 20 H 25 NO 5 : C, 66.83; H, 7.01; N, 3.90; Found: C, 66.45; H, 7.13; N, 3.79
EXAMPLE 7
cis-2-Phenethyl-3a,4,5,7a-tetrahydroisoindoline ##STR44##
A mixture of 5.0 g of cis-N-phenethyl-1,2,3,6-tetrahydrophthalimide (prepared by the method of Example 1), 0.5 g of chlorotris(triphenylphosphine)rhodium and 50 mL of p-xylene was heated under reflux for 48 hours. Removal of the solvent and short-path distillation of the residue (150° bath temperature, 0.001 mm) gave 4.72 g of cis-N-phenethyl-1,2,3,4-tetrahydrophthalimide containing 12% of unrearranged starting material.
To a solution of 2.04 g of the above product in 15 mL of dry THF was added, with cooling, 20 mL of 1 M lithium aluminum hydride in THF. The mixture was heated under reflux for 6 hours. Isolation as described in Example 1 and short-path distillation of the residue (150° bath temperature, 0.001 mm) gave 1.39 g of cis-2-phenethyl-3a,4,5,7a-tetrahydroisindoline containing ca. 10% of cis-2-phenethyl-3a,4,7,7a-tetra-hydroisoindoline. 'H NMR (in CDCl 3 ) : δ7.1-7.3 (m, 5H); 5.8 (m, 1H); 5.7 (d, split further, 1H); 3.0-3.1 (m, 2H); 2.8 (m, 2H); 2.7 (m, 2H); 2.4 (m, 1H); 2.1-2.3 (m, 2H); 2.0 (m, 2H); 1.8(m, 1H); 1.7 (m, 1H) and 1.4 (m, 1H). The fumarate had m.p. 145°-148° (dec.) after two crystallizations from ethanol.
Anal. Calcd. for C 20 H 25 NO 4 ; C, 69.94; H, 7.34; N, 4.08; Found: C, 69.62; H, 7.25; N, 3.97.
EXAMPLE 8
5-Methyl-2-phenethyl-3a,4,5,7a-tetrahydroisoindoline ##STR45##
Sorboyl chloride (3.53 g) was added to a mixture of 4.0 g of N-allylphenethylamine, 25 mL of methylene chloride and 25 mL of 15% aqueous sodium hydroxide, keeping the temperatue below 15°. The mixture was stirred in an ice bath for 1 hour, then at room temperature overnight. The aqueous layer was extracted several times with toluene and the combined organic phases were washed successively with 5% hydrochloric acid, water, and 10% sodium carbonate solution. Removal of the solvents gave 6.37 g of N-allyl-N-phenethylsorbamide. This product was heated under reflux in 50 mL of p-xylene for 10 hours. Removal of the solvent gave 6-methyl-3a,4,5,7a-tetrahydroisoindolin-1-one as a mixture of isomers still containing about 10% of the uncyclized starting material.
To a solution of this material in 30 ml of dry THF was added 50 mL of 1 M lithium aluminum hydride in THF and the mixture was heated under reflux for 22 hours. Isolation as described in Example 1 followed by purification by way of the hydrochloride gave 4.50 g of crude product. Short-path distillation (125° bath temperature, 0.001 mm) gave 2.25 g of 5-methyl-2-phenethyl-3a,4,5,7a-tetrahydroisoindoline as a mixture of two isomers. 'H-NMR (in CDCl 3 ) δ7.1-7.3 (m,5H); 5.6-5.7 (m, 2H) and 1.0 (2d,3H), among others. The fumarate had m.p. 141°-146° after crystallization from 2-propanol.
Anal. Calcd. for C 21 H 27 NO 4 : C, 70.56; H, 7.61; N, 3.92; Found: C, 70.33; H, 7.53; N, 3.88
EXAMPLE 9
cis-2-(4-Bromophenethyl)-3a,4,7,7a-tetrahydroisoindoline ##STR46##
A mixture of 0.6 g of cis-3a,4,7,7a-tetrahydroisoindoline, 1.4 g of 4-bromophenethyl bromide, 1.0 g of potassium carbonate and 3 mL of dimethylformamide was stirred and heated in a 90° oil bath for 1 hour. Toluene (20 mL) and water (20 mL) were added and the aqueous layer was extracted with toluene. Addition of 10 mL of 10% hydrochloric acid to the toluene solution resulted in the formation of three layers. The two lower layers were made basic with aqueous sodium hydroxide solution. Extraction with methylene chloride gave 0.89 g of crude product which on short-path distillation gave 0.63 g of cis-2-(4-bromophenethyl)-3a,4,7,7a-tetrahydroisoindoline. 'H NMR (in CDCl 3 ) δ7.4 (d, 2H); 7.0 (d, 2H); 5.8 (m, 2H); 3.0 (m, 2H); 2.6-2.8 (m, 4H); 2.4 (m, 2H); 2.1-2.3 (m, 4H) and 1.9 (d, 2H). The fumarate had m.p. 166°-167° after crystallization from ethanol.
Anal. Calcd. for C 20 H 24 BrNO 4 : C, 56.88; H, 5.73; N, 3.32; Found: C, 56.91; H, 5.64; N, 3.21
EXAMPLE 10
cis-2-(3,4-Dichlorophenethyl)-3a,4,7,7a-tetrahydroisoindoline ##STR47##
To a solution of 1.13 g of 3,4-dichlorophenylacetic acid in 6 mL of THF was added 0.90 g of 1,1'-carbonyldiimidazole. After 30 minutes a solution of 0.61 g of cis-3a,4,7,7a-tetrahydroisoindoline in 2 mL of THF was added and the mixture was stirred at room temperature overnight. Toluene (50 mL) was added, and the solution was washed successively with 5% hydrochloric acid, water, and 10% aqueous sodium carbonate solution, dried, and concentrated to give 1.50 g of cis-2-(3,4-dichlorophenylacetyl)-3a,4,7,7a-tetrahydroisoindole.
To 0.70 g of this intermediate and 3 mL of toluene was added at 0° 2 mL of 3.4 M sodium bis(2-methoxyethoxy)aluminum hydride in toluene and the mixture was stirred in an ice bath for 1 hour and at room temperature for 4 hours. Aqueous sodium hydroxide solution (15%, 5 mL) and water (10 mL) were added with cooling. From the toluene layer there was obtained 0.66 g of crude product which was partitioned into a neutral and basic fraction. The latter was short-path distilled (140° bath temperature, 0.003 mm) to give 0.48 g of cis-2-(3,4-dichlorophenethyl)-3a,4,7,7a-tetrahydroisoindoline. 'H NMR (in CDCl 3 ) : δ7.3 (AB quartet, 2H);7.0 (d/d, 1H); 5.8 (m, 2H); 3.0 (m, 2H); 2.8 (m, 4H), among others. The hydrochloride had m.p. 201°-202° after recrystallization from ethanol.
Anal. Calcd. for C 16 H 20 Cl 3 N : C, 57.76; H, 6.06; N, 4.21; Found: C, 57.86; H, 6.04; N, 4.09.
EXAMPLE 11
2-Phenethyldecahydroisoquinoline ##STR48##
To 5.0 g of decahydroisoquinoline (mixture of cis and trans isomers), 20 mL of methylene chloride and 50 mL of 15% aqueous sodium hydroxide solution was added at 10°-15° a solution of 7 mL of phenylacetyl chloride in 20 mL of methylene chloride. Removal of the solvent from the dried organic layer and crystallizaiton of the residue from hexanes gave 3.12 g of 2-phenylacetyldecahydroisoquinoline.
To a solution of 0.5 g of the above intermediate in 10 mL of dry THF was added, with cooling, 4 mL of 1 M lithium aluminum hydride in THF. The mixture was heated under reflux for 6 hours and the product was isolated as described in Example 1. Short-path distillation (140° bath temperature, 0.001 mm) gave 0.43 g of 2-phenethyldecahydroisoquinoline. The fumarate had m.p. 169°-170° after crystallization from 2-propanol.
Anal. Calcd. for C 21 H 29 NO 4 : C, 70.17; H, 8.13; N, 3.90; Found: C, 69.92; H, 8.00; N, 3.62
EXAMPLE 12
2-Phenethyl-1,2,3,4,5,6,7,8-octahydroisoquinoline ##STR49##
A mixture of 2.05 g of 5,6,7,8-tetrahydroisoquinoline, 4.30 g of 2-bromoethylbenzene, and 5 mL of dimethylformamide was stirred in a 75°-80° oil bath for 4 hours. The solvent was removed under vacuum, the residue was dissolved in 4 mL of acetonitrile and 8 mL of 1-chlorobutane were added. The precipitate was collected after 1 hour to give 3.28 g of 2-phenethyl-5,6,7,8-tetrahydroisoquinolinium bromide.
To a mixture of 2.00 g of the above intermediate and 10 mL of ethanol was added at 0° 0.56 g of sodium borohydride in small portions. Water was added after stirring in an ice bath for 1 hour, and the product was extracted into methylene chloride. Removal of the solvent and short-path distillation of the residue (150°, 0.002 mm) gave 1.28 g of 2-phenethyl-1,2,3,4,5,6,7,8-octahydroisoquinoline. 'H NMR (in CDCl 3 ) δ7.2-7.3 (m, 5H); 2.9 (m, 4H); 2.6 (m, 4H); 2.1 (m, 2H); 1.8 (m, 4H), and 1.6 (m, 4H). The fumarate had m.p. 159°-160° after crystallization from ethanol.
Anal. Calcd. for C 21 H 27 NO 4 : C, 70.56; H, 7.61; N, 3.92; Found: C, 70.50; H, 7.63; N, 3.81.
EXAMPLE 13
cis-2,3a-Dibenzyl-3a,4,7,7a-tetrahydroisoindoline ##STR50##
To 0.99 mL (7.1 mmoles) of diisopropylamine was added under nitrogen 15 mL of dry THF and the mixture was cooled to -78°. To the solution was then added 3.0 mL of n-butyl lithium (2.15 M in hexanes). The mixture was allowed to warm to room temperature and then recooled to -78°. A mixture of 1.42 g (5.9 mmoles) of cis-2-benzyl-3a,4,7,7a tetrahydro-1H-isoindole-1.3(2H)-dione in 5 mL of dry THF was added to the above solution by cannula, and the transfer was completed using 2×2.5 mL THF. Benzyl bromide (0.70 mL, 5.9 mmoles) was added to the stirred solution via syringe. The mixture was stirred at -78° for 0.5 h and then allowed to warm to room temperature and stirred for another 3 h. To the reaction mixture was added 15 mL of water, and the excess THF was removed by evaporation. The product was extracted with methylene chloride and the combined organic extracts were dried and evaporated to give 2.82 g of a brown oil. Chromatography of the oil on silica gel using hexane-ethyl acetate (2:1) to elute recovered 1.48 g of cis-2,3a-dibenzyl-3a,4,7,7a-tetrahydro-1H-isoindole-1.3(2H)-dione as a yellow oil. NMR (CDCl 3 ): δ7.00-7.27 (m, 10 H); 5.81-5.92 (m, 2H); 4.49 (s, 2H); 3.23-3.31 (d, 1H); 2.88-2.94 (m, 1H); 2.68-2.76 (d, 1H); 2.58-2.67 (m, 2H); 2.01-2.19 (m, 2H).
To 0.70 g (18.4 mmoles) of lithium aluminum hydride in 10 mL of THF was added at 0° 1.46 g (4.4 mmoles) of the above intermediate in 10 mL of THF by cannula. The transfer was completed using 2×2.5 mL of THF. The mixture was refluxed for 18 h and then cooled to 0°. The mixture was quenched by the slow addition of 0.7 mL water, followed by 0.7 mL of 15% aqueous sodium hydroxide solution and then 2.1 mL water. The reaction mixture was stirred at 0° for 15 min., and then the precipitated salts were removed by filtration through celite. The filtrate was evaporated to dryness, and the residue was dissolved in methylene chloride. The organic phase was washed with water, dried and evaporated to give 1.14 g of cis-2,3a-dibenzyl-3a,4,7,7a-tetrahydroisoindoline as a clear oil. NMR (CDCl 3 ): δ7.03-7.38 (m, 10 H); 5.67-5.80 (m, 2 H); 3.47-3.67 (q, 2H); 2.74-2.96 (m, 2H); 2.60-2.73 (q, 2H); 2.46-2.55 (t, 2H); 2.06-2.36 (m, 3H); 1.83-2.06 (m, 3H). The fumaric acid salt had m.p. 142°-144° after crystallization from isopropyl alcohol.
Anal Calcd. for C 26 H 29 NO 4 : C, 74.44; H, 6.97; N, 3.34; Found: C, 74.39; H, 6.97; N, 3.29
EXAMPLE 14
cis-2,3a-Dibenzylhexahydroisoindoline ##STR51##
A mixture of 0.46 g (1.3 mmoles) of cis-2,3a-dibenzyl-3a,4,7,7a-tetrahydroisoindoline (Ex. 13), 0.46 g of platinum oxide and 100 mL of methanol were hydrogenated at 50 p.s.i. for 1 h. The catalyst was removed by filtration through celite and the filtrate was evaporated to give 0.41 g of the title compound as a clear oil.
The fumaric acid salt had m.p. 156°-158° after crystallization from isopropyl alcohol. NMR (DMSO-d 6 ): δ7.18-7.38 (m, 10H); 6.57 (s, 2H); 3.75-3.90 (q, 2H); 2.72-3.93 (m, 4H); 2.55-2.63 (d, 1H); 2.43-2.52 (d, 1H); 1.93-2.06 (m, 1H); 1.55-1.60 (m, 1H); 1.21-1.52 (m, 7H).
Anal. Calcd. for C 26 H 31 NO 4 : C, 74.08; H, 7.41; N, 3.32; Found: C, 74.10; H, 7.28; N, 3.21.
Tables I and II contain additional examples prepared by the methods disclosed above.
TABLE I__________________________________________________________________________ ##STR52##Example F = fum. C H N C H NNo. R.sup.1 R.sup.2 H = HCl m.p. calcd found__________________________________________________________________________14a ##STR53## H F 203-205d 66.84 9.04 4.33 67.01 9.06 4.2914b ##STR54## H F 164-165° 68.34 9.46 3.99 68.24 9.44 3.9715 CH.sub.2 Ph H F 160-161° 68.86 7.60 4.23 68.92 7.55 4.1816 CH.sub.2 C.sub.6 H.sub.4 F-4 H F 123-125° 65.31 6.92 4.01 64.96 6.65 3.8317 CH.sub.2 C.sub.6 H.sub.4 CF.sub.3 -4 H F 167-168° 60.14 6.06 3.51 60.15 5.89 3.3218 ##STR55## H F 164-165° 60.51 6.87 4.15 60.38 6.79 4.0419 CH.sub.2 CH.sub.2 Ph H F 155-156° 69.54 7.88 4.05 69.46 7.77 4.0620 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 F-3 H H 230-232d 67.71 8.17 4.95 67.64 8.12 4.8321 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 Cl-4 H F 162-163°d 63.23 6.90 3.69 63.23 7.21 3.5222 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 OMe-4 H F 130-131° 67.18 7.79 3.73 66.81 7.66 3.7023 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 OH-4 H H 180-182° 68.19 8.50 4.97 68.03 8.55 4.8324 CH.sub.2 CH.sub.2 Ph 3a-Me F 157-159°d 70.17 8.13 3.90 69.99 8.11 3.8225 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 F-4 5-OH free base.sup.a,b26 CH.sub.2 CHPh.sub.2 H F 163-165° 74.08 7.41 3.32 74.18 7.31 3.2427 ##STR56## H F 151-152 72.89 7.39 3.54 73.01 7.30 3.4628 CH.sub.2 CH.sub.2 CHPh.sub.2 H F 165-167° 74.45 7.64 3.22 74.56 7.64 3.12__________________________________________________________________________ .sup.a Mixture of isomers .sup.b 'H NMR spectrum (in CDCl.sub.3); δ 7.1(t, split further, 2H) 6.9(t, 2H); 3.8 and 3.6(2m, 1H) and 1.2-3.0(m, 17H)
TABLE II__________________________________________________________________________ ##STR57##Example F = fum. C H N C H NNo. R.sup.1 R.sup.2 H = HCl m.p. calcd. found__________________________________________________________________________29 ##STR58## H F 118-120° 65.51 7.90 4.77 65.51 7.90 4.7730 ##STR59## H F 189-191°d 67.26 8.47 4.36 67.35 8.51 4.2931 ##STR60## H F 151-152°d 69.13 8.41 4.03 69.08 8.62 3.9432 CH.sub.2 Ph H F 142-143° 69.28 7.04 4.25 69.06 6.93 4.1933 CH.sub.2 C.sub.6 H.sub.4 F-4 H F 144-145° 65.69 6.38 4.03 65.76 6.39 3.9634 CH.sub.2 C.sub.6 H.sub.4 F.sub.2 -3,4 H F 142-143° 62.46 5.79 3.83 62.69 5.87 3.7335 CH.sub.2 C.sub.6 H.sub.4 Cl-4 H F 129-130° 62.72 6.09 3.85 62.71 6.02 3.7136 CH.sub.2 C.sub.6 H.sub.3 Cl.sub.2 -3,4 H F 122-126° a37 CH.sub.2 C.sub.6 H.sub.4 CF.sub.3 -3 H F 160-161° 60.45 5.58 3.52 60.26 5.49 3.3938 CH.sub.2 C.sub.6 H.sub.4 CF.sub.3 -4 H F 152-153° 60.45 5.58 3.52 60.54 5.53 3.4539 ##STR61## H F 107-108° 63.94 6.63 4.39 63.99 6.62 4.2540 ##STR62## H H 196-197° 61.04 7.09 5.48 60.88 6.96 5.4341 CH.sub.2 CH.sub.2 Ph H F 126-127° 69.95 7.34 4.08 70.01 7.23 4.0142 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 F-2 H H 171-173° 68.20 7.51 4.97 68.42 7.47 4.8343 CH.sub. 2 CH.sub.2 C.sub.6 H.sub.4 F-3 H H 197-199°d 68.20 7.51 4.97 68.30 7.35 4.8544 CH.sub.2 CH.sub.2 C.sub.6 H.sub.3 F.sub.2 -3,4 H H 192-193° 64.10 6.72 4.67 63.90 6.63 4.5145 CH.sub.2 CH.sub.2 C.sub.6 H.sub.3 F.sub.2 -3,5 H H 224-226°d 64.10 6.72 4.67 64.23 6.76 4.4946 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 Cl-3 H H 188-189° b47 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 Cl-4 H F 154-155° c48 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 CF.sub.3 -4 H F 126-127° 61.31 5.88 3.40 61.58 5.87 3.3649 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 CF.sub.3 -4 H F 137-138° 61.31 5.88 3.40 60.86 5.78 3.2550 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 NO.sub.2 -4 H F 161-162° 61.85 6.23 7.21 61.85 6.22 7.0651 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 OMe-4 H F 138-139° 67.54 7.29 3.75 67.22 7.24 3.6752 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 OH-4 H H 201- 203° 68.68 7.93 5.01 68.81 7.94 4.9153 CH.sub.2 CH.sub.2 Ph 3aMe F 177-178° 70.56 7.61 3.92 70.70 7.62 3.8354 CH.sub.2 CH.sub.2 C.sub.6 H.sub.4 F-4 5-Me H 180°d 69.02 7.84 4.74 68.94 7.89 4.5355 CH.sub.2 CH.sub.2 Ph 5-Ph H 177-181° d56 CH.sub.2 CH.sub.2 Ph 4,7-Ph.sub.2 H 185-187° 80.84 7.27 3.37 80.66 7.33 3.1957 ##STR63## H F 136-138°d 70.96 7.09 3.94 70.89 7.00 3.8558 CH.sub.2 CHPh.sub.2 H F 171-172°d 74.44 6.97 3.34 74.40 6.90 3.2759 ##STR64## H F 146-147° 73.26 6.92 3.56 72.93 6.84 3.4660 ##STR65## H F 132-133° 61.87 6.63 4.01 61.93 6.56 4.0161 ##STR66## H F 129-130° 61.87 6.63 4.01 61.68 6.59 4.0162 ##STR67## H H 201-202° 71.38 7.66 9.25 7.18 7.79 9.0763 (CH.sub.2).sub.2 Ph 4,7-Me.sub.2 ; 5-(CH.sub.2).sub.4 -6 F 208-210°d 73.38 8.29 3.29 72.92 8.40 3.4664 (CH.sub.2).sub.3 Ph H F 141-142° 70.56 7.61 3.92 70.58 7.56 3.8865 CH.sub.2 CH.sub.2 CHPh.sub.2 H F 163-164° 74.80 7.21 3.23 74.90 7.12 3.18__________________________________________________________________________ a .sup.1 H NMR spectrum of the free base (in CDCl.sub.3): δ 7.4(s, 1H); 7.4(d, 1H); 7.2(d, 1H); 5.8(m, 2H); 3.6(s, 2H); 2 2.1-2.3(m, 4H) and 1.9(d, 2H). b .sup.1 H NMR spectrum of the free base (in CDCl.sub.3): δ 7.2(m, 3H); 7.1(d, split further, 1H); 5.8(m, 2H); 3.0(m, 2H); (m, 4H); 2.4(m, 2H); 2.1-2.3(m, 4H) and 1.9(d, 2H). c .sup.1 H NMR spectrum of the free base (in CDCl.sub.3); δ 7.2(d, 2H); 7.1(d, 2H); 5.8(m, 2H); 3.0(m, 2H); 2.6-2.8(m, 4H) 1.9(d, 2H). b Highresolution mass spectrum of free base: calcd. for C.sub.22 H.sub.25 N: 303, 1987; measured: 303, 1988.
Tables III and IV contain examples of additional compounds which may be prepared by the methods disclosed above.
TABLE III__________________________________________________________________________ ##STR68## Ring A DoubleEx. # R.sup.1 R.sup.2 R.sup.3 Bond Position__________________________________________________________________________66 4-CH.sub.3 C.sub.6 H.sub.4 CH.sub.2 CH.sub.2 5-Ph H --67 3- .sub.- t-BuC.sub.6 H.sub.4 CH.sub.2 4-Ph H --68 4-cyclohexylC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H --69 4-H.sub.2 CCHCH.sub.2 C.sub.6 H.sub.4 CH.sub.2 5O 3a-CH.sub.3 5, 670 4- -n-C.sub.4 F.sub.9 C.sub.6 H.sub.4 CH.sub.2 H H 5, 671 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 5O 6-CH.sub.3 5, 672 4-CF.sub.3 C.sub.6 H.sub. 4 CH.sub.2 4-CH.sub.3 7-CH.sub.3 5, 673 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 4, 574 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 3a, 475 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 3a, 7a76 4-C.sub.2 F.sub.5 C.sub.6 H.sub.4 CH.sub.2 H H 5, 677 4-C.sub.2 F.sub.5 C.sub.6 H.sub.4 CH.sub.2 H H 5, 678 3-CH.sub.3 SOC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 5-OH H --79 4-C.sub.2 H.sub.5 SO.sub.2 C.sub.6 H.sub.4 CH.sub.2 6-CH.sub.3 CO 4-cyclopropyl --80 2-C.sub.2 H.sub.5 SC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H 5, 681 4-H.sub.2 NC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 Cl H 5, 682 4-CH.sub.3 NHC.sub.6 H.sub.4 CH.sub.2 H H 5, 683 4-(CH.sub.3).sub.2 NC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H 5, 684 4-NC.sub.6 H.sub.4 CH.sub.2 H H --85 3-HO.sub.2 CC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H --86 4-C.sub.2 H.sub.5 O.sub.2 C.sub.6 H.sub.4 (CH.sub.2).sub.3 H H 5, 687 3-benzofurylethyl H H 5, 688 2-pyrrolylmethyl 4-furyl H --89 4-quinolylpropyl H H 5, 690 2-isoquinolylmethyl 5-(3-indolyl) H --91 2-benzothienylthyl H H 5, 692 2-pyrimidylethyl H H 5, 693 2-pyrazinylpropyl H H 5, 694 2-quinazolylethyl H H 5, 695 2-phthalazinylbutyl H H 5, 696 2-naphthyridinyl H H --97 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 4-(CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.2)-5 --98 4-ClC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 3a-(CH.sub.2 CH.sub.2 CH.sub.2)-4 --99 4-ClC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 5-CH.sub.2 CH(CH.sub.3)CH.sub.2 CH.sub.2 -6 --100 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 4O H 5, 6101 4-CF.sub.3 -3ClC.sub.6 H.sub.3 CH.sub.2 H H 5, 6102 4-Cl-3-CF.sub.3 C.sub.6 H.sub.3 CH.sub.2 CH.sub.2 H H --103 4-ClC.sub.6 H.sub.4 (CH.sub.2).sub.5 H H --104 C.sub. 6 H.sub.5 (CH.sub.2).sub.6 H H 5, 6__________________________________________________________________________
TABLE IV______________________________________ ##STR69## Ring A DoubleEx. # R.sup.1 R.sup.2 R.sup.3 Bond Position______________________________________105 CF.sub.3 C.sub.6 H.sub.4 (CH.sub.2).sub.3 H H --106 4-ClC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H --107 C.sub.6 H.sub.5 (CH.sub.2).sub.3 4a-CH.sub.3 H --108 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 6O H 4a, 5109 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 5, 6110 4-ClC.sub.6 H.sub.4 CH.sub.2 CH.sub.2 H H 6, 7111 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 7, 8112 4-ClC.sub.6 H.sub.4 CH.sub.2 H H 8, 8a113 4-CF.sub.3 C.sub.6 H.sub.4 CH.sub.2 H H 4a, 8a114 cyclohexyl H H --115 cyclooctylmethyl H H --______________________________________
UTILITY SECTION
The compounds of this invention and their pharmaceutically acceptable salts possess psychotropic properties, particularly antipsychotic activity of good duration with potent sigma receptor antagonist activities while lacking the typical movement disorder side-effects of standard dopamine receptor antagonist antipsychotic agents. These compounds may also be useful as antidotes for certain psychotomimetic agents such as phencyclidine (PCP), and as antidyskinetic agents.
In Vitro
Sigma Receptor Binding Assay
Male Hartley guinea pigs (250-300 g, Charles River) were sacrificed by decapitation. Brain membranes were prepared by the method of Tam (Proc. Natl. Acad. Sci. USA 80: 6703-6707, 1983). Whole brains were homogenized (20 seconds) in 10 vol (wt/vol) of ice-cold 0.34 M sucrose with a Brinkmann Polytron (setting 8). The homogenate was centrifuged at 920×g for 10 minutes. The supernatant was centrifuged at 47,000 ×g for 20 minutes. The resulting membrane pellet was resuspended in 10 vol (original wt/vol) of 50 mM Tris HCl (pH 7.4) and incubated at 37° C. for 45 minutes to degrade and dissociate bound endogenous ligands. The membranes were then centrifuged at 47,000×g for 20 minutes and resuspended in 50 mM Tris HCl (50 mL per brain).
0.5 mL aliquots of the membrane preparation were incubated with unlabeled drugs, 1 nM (+)-[ 3 H]SKF 10,047 in 50 mM Tris HCl, pH 7.4, in a final volume of 1 mL. Nonspecific binding was measured in the presence of 10 μM (+)-SKF 10,047. The apparent dissociation constant (Kd) for (+)-[ 3 H]SKF 10,047 is 50 nM. After 45 minutes of incubation at room temperature, samples were filtered rapidly through Whatman GF/C glass filters under negative pressure, and washed 3 times with ice-cold Tris buffer (5 mL).
IC 50 s were calculated from log-logit plots. Apparent K i s were calculated from the equation, K i =IC 50 /[1+(L/Kd)](4), where L is the concentration of radioligand and K d is its dissociation constant. The data are shown in Table V under the heading SIGMA.
Dopamine Receptor Binding
Membranes were prepared from guinea pig striatum by the method described for sigma receptor binding. The membranes were then resuspended in 50 mM Tris HCl (9 mL per brain).
0.5 mL aliquots of the membrane preparation were incubated with unlabeled drugs, and 0.15 nM [ 3 H]spiperone in a final volume of 1 mL containing 50 mM Tris HCl, 120 mM NaCl and 1 mM MgCl 2 (pH 7.7). Nonspecific binding was measured in the presence of 100 nM (+)-butaclamol. After 15 minutes of incubation at 37° C., samples were filtered rapidly through Whatman GF/C glass filters under negative pressure, and washed three times with ice-cold binding buffer (5 mL).
IC 50 s were calculated from log-logit plots. Apparent K i s were calculated from the equation K i =IC 50 [1+(L/K d )](4), where L is the concentration of radioligand and K d is its dissociation constant. The data are shown in Table V under the heading DRB.
The examples of this invention exhibit potent binding affinity for sigma receptors but not for dopamine receptors. Therefore these compounds are not expected to produce the extrapyramidal symptoms that are typical of that produced by haloperidol and other typical antipsychotics that are dopamine receptor antagonists.
In Vivo
Mescaline-Induced Scratching in Mice
This is a modification of the procedure of Fellows and Cook (in Psychotropic Drugs, ed. by S. Garrattini and V. Ghatti, pp. 397-404, Elsevier, Amsterdam,1957) and Deegan and Cook (J. Pharmacol. Exp. Ther. 122: 17A,1958). Male CF1 Mice (Charles River) were injected orally with test compound and placed singly into square (13 cm) Plexiglass observation chambers. Twenty minutes later mice were injected orally with mescaline (25 mg/kg). Beginning 25 minutes after treatment with mescaline (45 minutes after treatment with test compound), scratching episodes were counted during a 5 minute observation period. A scratching episode is defined as a brief (1-2 sec) burst of scratching either the head or the ear with the hind foot. The data are shown in Table V under the heading MUR MESC.
Isolation-Induced Aggression in Mice
This is a modification of the method of Yen et al. (Arch. Int. Pharmacodyn. 123: 179-185, 1959) and Jannsen et al. (J. Pharmacol. Exp. Ther. 129: 471-475, 1960). Male Balb/c mice (Charles River) were used. After 2-4 weeks of isolation in plastic cages (11.5×5.75×6 in) the mice were selected for aggression by placing a normal group-housed mouse in the cage with the isolate for a maximum of 3 minutes. Isolated mice failing to consistently attack an intruder were removed from the colony.
Drug testing was carried out by treating the isolated mice with test drugs or standards. Thirty minutes after dosing with test drugs by the oral route, one isolated mouse was removed from its home cage and placed in the home cage of another isolate. Scoring was a yes or no response for each pair. A maximum of 3 minutes was allowed for an attack and the pair was separated immediately upon an attack. Selection of home cage and intruder mice was randomized for each test. Mice were treated and tested once or twice a week with at least a 2 day washout period between treatments. The data are shown in . . . under the heading MUR MIIA.
TABLE V______________________________________Example MUR MURNo. SIGMA DRB MESC MIIA______________________________________ 1 +++ - +++ 2 +++ - +++ 3 +++ - +++ 4 +++ - 5 + - +++ 6 +++ - +++ 7 +++ - + 8 +++ - +++ 9 +++ -10 +++ - +++11 +++ - ++12 +++ +13 +++ -14 +++ - 14a +++ - 14b +++ - ++15 +++ -16 +++ -17 +++ - +++18 +++ -19 +++ - +++ -20 +++ - ++21 +++ - +++ +22 +++ -23 +++ -24 +++ - +25 + -26 + -27 +++ -28 +++ -29 +++ -30 +++ -31 +++ -32 +++ -33 +++ -34 +++ -35 +++ -36 +++ -37 +++ - +38 +++ - ++ ++39 +++ -40 +++ - +++41 +++ - +++42 +++ -43 +++ -44 +++ -45 +++ -46 +++ -47 +++ - +++48 +++ - +49 +++ - +50 +++ - + +51 +++ -52 +++ -53 +++ -54 +++ - +++55 +++ ++ +++56 +++ -57 +++ -58 + -59 +++ -60 +++ -61 +++ -62 +++ -63 +++ - +++64 +++ -65 +++ - +______________________________________
Dosage Forms
Daily dosage ranges from 1 mg to 2000 mg. Dosage forms (compositions) suitable for administration ordinarily will contain 0.5-95% by weight of the active ingredient based on the total weight of the composition.
The active ingredient can be administered orally in solid dosage forms, such as capsules, tablets, and powders, or in liquid dosage forms, such as elixirs, syrups, and suspensions; it can also be administered parenterally in sterile liquid dosage forms.
Gelatin capsules contain the active ingredient and powdered carriers, such as lactose, sucrose, mannitol, starch, cellulose derivatives, magnesium stearate, stearic acid, and the like. Similar diluents can be used to make compressed tablets. Both tablets and capsules can be manufactured as sustained release products to provide for continuous release of medication over a period of hours. Compressed tablets can be sugar coated or film coated to mask any unpleasant taste and protect the tablet from the atmosphere, or enteric-coated for selective disintegration in the gastrointestinal tract.
Liquid dosage forms for oral administration can contain coloring and flavoring to increase patient acceptance.
In general, water, a suitable oil, saline, aqueous dextrose (glucose), and related sugar solutions and glycols such as propylene glycol or polyethylene glycols are suitable carriers for parenteral solutions. Solutions for parenteral administration preferably contain a water soluble salt of the active ingredient, suitable stabilizing agents, and if necessary, buffer substances. Antioxidizing agents such as sodium bisulfite, sodium sulfite, or ascorbic acid, either alone or combined, are suitable stabilizing agents. Also used are citric acid and its salts and sodium EDTA. In addition, parenteral solutions can contain preservatives, such as benzalkonium chloride, methyl- or propyl-paraben, and chlorobutanol.
Suitable pharmaceutical carriers are described in Remington's Pharmaceutical Sciences, A. Osol, a standard reference text in this field. | There are provided nitrogen-containing bicyclic compounds which are useful in the treatment of physiological or drug induced psychosis or dyskinesia in a mammal. These novel compounds are selective sigma receptor antagonists and have a low potential for movement disorder side effects associated with typical antipsychotic agents. | 2 |
Background of the Invention
[0001] 1. Field of the Invention
[0002] The present invention relates to high-frequency modules and mobile communication apparatuses including high-frequency modules, and more particularly, to a high-frequency module which can be shared by three different communication systems and a mobile communication apparatus including such a high-frequency module.
[0003] 2. Description of the Related Art
[0004] A triple-band portable telephone has been proposed which can operate in a plurality of frequency bands, such as those in a digital cellular system (DCS) using the 1.8 GHz band, a personal communication service (PCS) using the 1.9 GHz band, and a global system for mobile communications (GSM) using the 900 MHz, as a mobile communication apparatus.
[0005] [0005]FIG. 12 is a block diagram of a front-end section of a general triple-band portable telephone. FIG. 12 shows a case in which first to third communication systems having frequencies that are different from each other are set to the DCS using the 1.8 GHz, the PCS using the 1.9 GHz, and the GSM using the 900 MHz.
[0006] The front-end section of the triple-band portable telephone is provided with an antenna 1 , a diplexer 2 , first to third high-frequency switches 3 a to 3 c, first and second LC filters 4 a and 4 b, and first to third SAW filters 5 a to 5 c. The diplexer 2 couples a transmission signal sent from one of the DCS, the PCS, and the GSM with the antenna 1 during transmission, and distributes a receiving signal sent from the antenna 1 to one of the DCS, the PCS, and the GSM during receiving. The first high-frequency switch 3 a switches between the transmission-section side of the DCS and the PCS, and the receiving-section side of the DCS and the PCS. The second high-frequency switch 3 b switches between the receiving section Rxd side of the DCS and the receiving section Rxp side of the PCS. The third high-frequency switch 3 c switches between the transmission-section Txg side and the receiving section Rxg side of the GSM. The first LC filter 4 a passes transmission signals for the DCS and the PCS and attenuates the harmonics of the transmission signals. The second LC filter 4 b passes a transmission signal for the GSM and attenuates the harmonics of the transmission signal. The first SAW filter 5 a passes a receiving signal for the DCS and attenuates the harmonics of the receiving signal. The second SAW filter 5 b passes a receiving signal for the PCS and attenuates the harmonics of the receiving signal. The third SAW filter 5 c passes a receiving signal for the GSM and attenuates the harmonics of the receiving signal.
[0007] The operation of the triple-band portable telephone will be described for the DCS first. During transmission, the first high-frequency switch 3 a turns on the transmission section Txdp side to send a transmission signal that was sent from the transmission section Txdp and that has passed through the first LC filter 4 a, to the diplexer 2 , the diplexer 2 performs coupling, and then the signal is sent from the antenna 1 . During receiving, a receiving signal received by the antenna 1 is distributed by the diplexer 2 , the receiving signal sent from the antenna 1 is sent to the first switch 3 a, which is located on the DCS and PCS side, the first high-frequency switch 3 a turns on the receiving section side to send the signal to the second high-frequency switch 3 b, and the second high-frequency switch 3 b turns on the receiving section Rxd side of the DCS to send the signal to the receiving section Rxd of the DCS through the first SAW filter 5 a. A similar operation is also performed for transmission and receiving for the PCS.
[0008] A case in which the GSM is used will be described next. During transmission, the third high-frequency switch 3 c turns on the transmission section Txg side to send a transmission signal which was sent from the transmission section Txg and has passed the second LC filter 4 b, to the diplexer 2 , the diplexer 2 performs coupling, and the signal is sent from the antenna 1 . During receiving, a receiving signal received by the antenna 1 is distributed by the diplexer 2 , the receiving signal sent from the antenna 1 is sent to the third high-frequency switch 3 c, and the third high-frequency switch 3 c turns on the receiving section Rxg side to send the signal to the receiving section Rxg of the GSM through the third SAW filter 5 c.
[0009] Since the triple-band portable telephone, which is one of the conventional mobile communication apparatuses, uses three high-frequency switches, at least six diodes constituting the high-frequency switches are required. As a result, the triple-band portable telephone uses a very large amount of power, and a battery mounted to the triple-band portable telephone can be used only for a short period. Also, the operation of each diode is controlled in many operation modes, and thus, a complicated circuit is required.
SUMMARY OF THE INVENTION
[0010] In order to overcome the problems described above, preferred embodiments of the present invention provide a high-frequency module having a low power consumption and a compact circuit, and a mobile communication apparatus including such a high-frequency module.
[0011] According to a preferred embodiment of the present invention, a high-frequency module includes integrated front-end sections of first to third communication systems having frequencies that are different from each other, the high-frequency module includes a diplexer arranged to couple a transmission signal sent from any of the first to third communication systems to an antenna during transmission and arranged to distribute a receiving signal sent from the antenna to any of the first to third communication systems during receiving, a first high-frequency switch arranged to separate a transmission section for the first and second communication systems and receiving sections for the first and second communication systems, a SAW duplexer arranged to separate a receiving section for the first communication system and a receiving section for the second communication system, and a second high-frequency switch arranged to separate a transmission section and a receiving section for the third communication system.
[0012] The high-frequency module may further include at least one of a first filter arranged to pass a transmission signal sent from the first and second communication systems, a second filter arranged to pass a transmission signal sent from the third communication system, and a third filter arranged to pass a receiving signal for the third communication system.
[0013] In the high-frequency module, the SAW duplexer may include a SAW filter and a phase conversion component connected to the SAW filter.
[0014] According to another preferred embodiment of the present invention, a high-frequency module includes front-end sections of first to third communication systems having frequencies that are different from each other, the front-end sections including a diplexer arranged to couple a transmission signal sent from any of the first to third communication systems to an antenna during transmission and arranged to distribute a receiving signal sent from the antenna to any of the first to third communication systems during receiving, a first high-frequency switch arranged to separate a transmission section for the first and second communication systems and receiving sections for the first and second communication systems, a SAW duplexer arranged to separate a receiving section for the first communication system and a receiving section for the second communication system, and a second high-frequency switch arranged to separate a transmission section and a receiving section for the third communication system, wherein the diplexer, the first and second high-frequency switches, and the SAW duplexer are integrated in a laminated member including a plurality of laminated sheet layers.
[0015] The high-frequency module may be configured such that all elements of the diplexer and a portion of the elements of the first and second high-frequency switches and the SAW duplexer are built in the laminated member, and the remaining elements of the first and second high-frequency switches and the SAW duplexer are mounted on the laminated member.
[0016] According to a high-frequency module of various preferred embodiments of the present invention, since a diplexer, first and second high-frequency switches, and an SAW duplexer are provided, and the SAW duplexer separates a receiving section for a first communication system and a receiving section for a second communication system, the number of high-frequency switches is reduced. As a result, the number of diodes used is reduced, and the power consumption of the high-frequency modules is greatly reduced. This means that a low-power-consumption, high-frequency module is provided. In addition, a current is not required during the signal receiving operation.
[0017] Since the diplexer, the first and second high-frequency switches, and the SAW duplexer, which constitute the high-frequency module, are integrated into a laminated member obtained by laminating a plurality of sheet layers preferably formed of ceramic, the matching characteristic, the attenuation characteristic, or the isolation characteristic of each component is obtained. Therefore, a matching circuit is not required between the diplexer and the first and second high-frequency switches, or between the first high-frequency switch and the SAW duplexer. Consequently, the high-frequency module becomes much more compact than conventional devices.
[0018] The diplexer preferably includes inductors and capacitors. The first and second high-frequency switches preferably include diodes, inductors, and capacitors. The SAW duplexer preferably includes SAW filters and transmission lines. The first and second LC filters preferably include inductors and capacitors. These elements are built in, or mounted on a laminated member and are connected by connections disposed inside of the laminated member. Therefore, the high-frequency module is constituted by a single laminated member and is very compact. In addition, loss caused by wirings for connecting components is greatly reduced, and as a result, the loss of the entire high-frequency module is greatly reduced.
[0019] Since the lengths of the inductors and the transmission lines built in the laminated member are reduced by a wavelength reduction effect, the insertion losses of these inductors and the transmission lines are greatly reduced. Therefore, a compact and low-loss high-frequency module is provided.
[0020] According to another preferred embodiment of the present invention, a mobile communication apparatus includes a high-frequency module according to one of the preferred embodiments described above, which high-frequency module defines the front-end sections of the first to third communication systems, receiving sections for the first to third communication systems, and transmission sections for the first to third communication systems.
[0021] According to a mobile communication apparatus of a preferred embodiment of the present invention, since a front-end section defined by a high-frequency module which allows power consumption to be reduced is provided, the power consumption of the mobile communication apparatus itself can also be reduced.
[0022] According to a mobile communication apparatus of various preferred embodiments of the present invention, since a high-frequency module used can reduce power consumption and does not require a current during receiving, the mobile communication apparatus having this high-frequency module can have low power consumption and does not require any current when waiting for a call. As a result, a battery mounted in the mobile communication apparatus can be used for a much longer period than in conventional devices.
[0023] In addition, since the compact and low-loss high-frequency module is used, the mobile communication apparatus having this high-frequency module is made compact and has a high performance.
[0024] Other features, elements, characteristics and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a block diagram of a high-frequency module according to a preferred embodiment of the present invention.
[0026] [0026]FIG. 2 is a circuit diagram of a diplexer constituting the high-frequency module shown in FIG. 1.
[0027] [0027]FIG. 3 is a circuit diagram of a first high-frequency switch constituting the high-frequency module shown in Fig. 1.
[0028] [0028]FIG. 4 is a circuit diagram of a second high-frequency switch constituting the high-frequency module shown in FIG. 1.
[0029] [0029]FIG. 5 is a circuit diagram of a SAW duplexer constituting the high-frequency module shown in FIG. 1.
[0030] [0030]FIG. 6 is a circuit diagram of a first LC filter constituting the high-frequency module shown in FIG. 1.
[0031] [0031]FIG. 7 is a circuit diagram of a second LC filter constituting the high-frequency module shown in FIG. 1.
[0032] [0032]FIG. 8 is an exploded perspective view of a main portion of the high-frequency module shown in FIG. 1.
[0033] FIGS. 9 ( a ) to FIG. 9( h ) are top views of a first dielectric layer to an eighth dielectric layer constituting a laminated member of the high-frequency module shown in FIG. 8.
[0034] FIGS. 10 ( a ) to FIG. 10( e ) are top views of a ninth dielectric layer to a 13th dielectric layer constituting the laminated member of the high-frequency module shown in FIG. 8, and FIG. 10( f ) is a bottom view of the 13th dielectric layer constituting the laminated member of the high-frequency module shown in FIG. 8.
[0035] [0035]FIG. 11 is a block diagram showing a portion of the structure of a mobile communication apparatus using the high-frequency module shown in FIG. 1.
[0036] [0036]FIG. 12 is a block diagram showing the structure of a front end section of a general triple-band portable telephone (mobile communication apparatus).
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] Preferred embodiments of the present invention will be described below by referring to the drawings.
[0038] [0038]FIG. 1 is a block diagram of a high-frequency module 10 according to a preferred embodiment of the present invention. The high-frequency module 10 preferably includes a diplexer 11 , first and second high-frequency switches 12 and 13 , a SAW duplexer 14 , first and second LC filters 15 and 16 defining first and second filters, and a SAW filter 17 defining a third filter, and functions as a front end section of first to third communication systems, preferably, a DCS (1.8 GHz band), a PCS (1.9 GHz band), and a GSM (900 MHz band).
[0039] A first port P 11 of the diplexer 11 is connected to an antenna ANT, a second port P 12 is connected to a first port P 21 of the first high-frequency switch 12 , and a third port P 13 is connected to a first port P 31 of the second high-frequency switch 13 .
[0040] A second port P 22 of the first high-frequency switch 12 is connected to a first port P 51 of the first LC filter 15 , and a third port P 23 is connected to a first port P 41 of the SAW duplexer 14 .
[0041] A second port P 52 of the first LC filter 15 is connected to a transmission section Txdp shared by the DCS and the PCS, and second and third ports P 42 and P 43 of the SAW duplexer 14 are connected to a receiving section Rxd of the DCS and a receiving section Rxp of the PCS, respectively.
[0042] A second port P 32 of the second high-frequency switch 13 is connected to a first port P 61 of the second LC filter 16 , and a third port P 33 is connected to a first port P 71 of the SAW filter 17 .
[0043] A second port P 62 of the second LC filter 16 is connected to a transmission section Txg of the GSM, and a second port P 72 of the SAW filter 17 is connected to a receiving section Rxg of the GSM.
[0044] [0044]FIG. 2 is a circuit diagram of the diplexer 11 constituting the high-frequency module shown in FIG. 1. The diplexer 11 is provided with the first to third ports P 11 to P 13 , inductors L 11 and L 12 , and capacitors C 11 to C 15 .
[0045] Between the first port P 11 and the second port P 12 , the capacitors C 11 and C 12 are connected in series. The connection point between them is grounded through the inductor L 11 and the capacitor C 13 .
[0046] Between the first port P 11 and the third port P 13 , a parallel circuit including the first inductor L 12 and the first capacitor C 14 is connected. An end of the parallel circuit located at the third port P 13 side is grounded through the first capacitor C 15 .
[0047] In other words, a high-pass filter which passes transmission and receiving signals in the DCS (1.8 GHz band) and the PCS (1.9 GHz band) is defined between the first port P 11 and the second port P 12 . A low-pass filter which passes transmission and receiving signals in the GSM (900 MHz band) is defined between the first port P 11 and the third port P 13 .
[0048] [0048]FIG. 3 is a circuit diagram of the first high-frequency switch 12 constituting the high-frequency module shown in FIG. 1. The first high-frequency switch 12 is provided with the first to third ports P 21 to P 23 , a control terminal Vc 1 , diodes D 11 and D 12 , inductors L 21 to L 23 , capacitors C 21 and C 22 , and a resistor R 1 .
[0049] Between the first port P 21 and the second port P 22 , the diode D 11 is connected such that its anode is disposed at the first port P 21 side. The diode 11 is also connected in parallel to a series circuit including the inductor L 21 and the capacitor C 21 . The second port P 22 side of the diode D 11 , namely, its cathode, is grounded through the inductor L 22 defining a choke coil.
[0050] Between the first port P 21 and the third port P 23 , the inductor L 23 is connected. The third port P 23 side of the inductor L 23 is grounded through the diode D 12 and the capacitor C 22 . The connection point of the anode of the diode D 12 and the capacitor C 22 is connected to the control terminal Vc 1 through the resistor R 1 .
[0051] [0051]FIG. 4 is a circuit diagram of the second high-frequency switch 13 constituting the high-frequency module shown in FIG. 1. The second high-frequency switch 13 is provided with the first to third ports P 31 to P 33 , a control terminal Vc 2 , diodes D 21 and D 22 , inductors L 31 and L 32 , a capacitor C 31 , and a resistor R 2 .
[0052] Between the first port P 31 and the second port P 32 , the diode D 21 is connected such that its anode is disposed at the first port P 31 side. The second port P 32 side of the diode D 21 , namely, its cathode, is grounded through the inductor L 31 defining a choke coil.
[0053] Between the first port P 31 and the third port P 33 , the inductor L 32 is connected. The third port P 33 side of the inductor L 32 is grounded through the diode D 22 and the capacitor C 31 . The connection point of the anode of the diode D 22 and the capacitor C 31 is connected to the control terminal Vc 2 through the resistor R 2 .
[0054] [0054]FIG. 5 is a circuit diagram of the SAW duplexer 14 constituting the high-frequency module shown in FIG. 1. The SAW duplexer 14 is provided with the first to third ports P 41 to P 43 , SAW filters SAW 1 and SAW 2 , inductors L 41 and L 42 , and capacitors C 41 to C 44 . Between the first port P 41 and the second port P 42 , the capacitor C 41 , the SAW filter SAW 1 , and a phase conversion unit 141 are connected in series. Between the first port P 41 and the third port P 43 , the capacitor C 41 , the SAW filter SAW 2 , and a phase conversion unit 142 are connected in series.
[0055] The phase conversion unit 141 includes the inductor L 41 and the capacitors C 42 and C 43 . Both ends of the inductor L 41 are connected to the ground through the capacitors C 42 and C 43 . The phase conversion unit 142 includes the inductor L 42 and the capacitor C 44 . The SAW filter SAW 2 side of the inductor L 42 is connected to the ground through the capacitor C 44 .
[0056] In the phase conversion unit 141 , the inductance of the inductor L 41 and the capacitances of the capacitors C 42 and C 43 are specified such that the input impedance of the SAW filter SAW 1 is open in the frequency band (1.8 GHz band) of the DCS connected to the second port P 42 . In the same way, in the phase conversion unit 142 , the inductance of the inductor L 42 and the capacitance of the capacitors C 44 are specified such that the input impedance of the SAW filter SAW 2 is open in the frequency band (1.9 GHz band) of the PCS connected to the third port P 43 .
[0057] [0057]FIG. 6 is a circuit diagram of the first LC filter 15 constituting the high-frequency module shown in FIG. 1. The first LC filter 15 is provided with the first and second ports P 51 and P 52 , inductors L 51 and L 52 , and capacitors C 51 to C 53 .
[0058] Between the first port P 51 and the second port P 52 , a parallel circuit defined by the inductor L 51 and the capacitor C 51 , and a parallel circuit defined by the inductor L 52 and the capacitor C 52 are connected in series, and the connection point of these parallel circuits is grounded by the capacitor C 53 .
[0059] [0059]FIG. 7 is a circuit diagram of the second LC filter 16 constituting the high-frequency module shown in FIG. 1. The second LC filter 16 is provided with the first and second ports P 61 and P 62 , an inductor L 61 , and capacitors C 61 to C 63 .
[0060] Between the first port P 61 and the second port P 62 , a parallel circuit defined by the inductor L 61 and the capacitor C 61 is connected in series, and both ends of the parallel circuit are grounded through the capacitors C 62 and C 63 .
[0061] [0061]FIG. 8 is an exploded perspective view of a main section of the high-frequency module 10 having the circuit structure shown in FIG. 1. The high-frequency module 10 includes a laminated member 18 . The laminated member 18 includes in its inside, although not shown, the inductors L 11 and L 12 and the capacitors C 11 to C 15 of the diplexer 11 , the inductors L 21 and L 23 and the capacitor C 22 of the first high-frequency switch 12 , the inductor 32 and the capacitor C 31 of the second high-frequency switch 13 , the inductors L 41 and L 42 and the capacitors C 42 to C 44 of the SAW duplexer 14 , the inductors L 51 and L 52 and the capacitors C 51 to C 53 of the first LC filter 15 , and the inductor L 61 and the capacitors C 61 to C 63 of the second LC filter 16 .
[0062] The following elements are preferably mounted on the front surface of the laminated member 18 : the diodes D 11 and D 12 , the inductor (choke coil) L 22 , the capacitor C 21 , and the resistor R 1 of the first high-frequency switch 12 ; the diodes D 21 and D 22 , the inductor (choke coil) L 31 , and the resistor R 2 of the second high-frequency switch 13 ; the SAW filters SAW 1 and SAW 2 , and the capacitor C 41 of the SAW duplexer 14 ; and the SAW filter 17 .
[0063] From the side surfaces to the bottom surface of the laminated member 18 , eighteen external terminals Ta to Tr extend. The external terminals Ta to Tr are preferably formed by screen printing or another suitable method. The external terminals Ta and Tb define the second port P 42 of the SAW duplexer 14 . The external terminal Tc defines the control terminal Vc 1 of the first high-frequency switch 12 . The external terminal Td defines the second port P 62 of the second LC filter 16 . The external terminal Tf defines the second port P 52 of the first LC filter 15 . The external terminal Tg defines the control terminal Vc 2 of the second high-frequency switch 13 . The external terminal Ti defines as the first port P 11 of the diplexer 11 . The external terminals Tk and Tl define the second port P 72 of the SAW filter 17 . The external terminals Tn and To define the third port P 43 of the SAW duplexer 14 . The external terminals Te, Th, Tj, Tm, Tp, Tq, and Tr define the ground terminals.
[0064] A metal cap 20 is placed on the laminated member 18 so as to cover the front surface of the laminated member 18 . Protrusions 201 and 202 of the metal cap 20 are connected to the external terminals Th and Tq of the laminated member 18 .
[0065] [0065]FIG. 9( a ) to FIG. 9( h ) and FIG. 10( a ) to FIG. 10( f ) are the top views of dielectric layers constituting the high-frequency module shown in FIG. 8, and FIG. 10( g ) is the bottom view of the dielectric layer shown in FIG. 10( f ). The laminated member 18 is preferably formed by sequentially laminating first to 14th dielectric layers 18 a to 18 n preferably made from ceramic having barium oxide, aluminum oxide, and silica as main components from the top, by baking at a baking temperature of about 1000° C. or more, and by turning it upside down. In other words, the 14th dielectric layer 18 n defines the top layer of the laminated member 18 , and the first dielectric layer 18 a defines the bottom layer of the laminated member 18 .
[0066] On the upper surface of the first dielectric layer 18 a, the external terminals Ta to Tr are provided. On the upper surfaces of the second, fourth, and 13th dielectric layers 18 b, 18 d, and 18 m, ground electrodes Gp 1 to Gp 3 are provided, respectively. On the upper surfaces of the third to sixth and 10th to 12th dielectric layers 18 c to 18 f and 18 j to 18 l, capacitor electrodes Cp 1 to Cp 19 are provided.
[0067] In addition, on the upper surfaces of the seventh to ninth dielectric layers 18 g to 18 i, stripline electrodes ST 1 to ST 26 are provided. On the upper surface of the 14th dielectric layer 18 n, a wiring Li is provided.
[0068] Furthermore, on the lower surface of the 14th dielectric layer ( 18 nu in FIG. 10( g )), lands La for mounting the diodes D 11 , D 12 , D 21 , and D 22 , the inductors L 22 and L 31 , the capacitors C 22 and C 41 , the resistors R 1 and R 2 , and the SAW filters SAW 1 , SAW 2 , and 17 on the front surface of the laminated member 18 are provided. Viahole electrodes Vh are formed at predetermined positions in the third to 14th dielectric layers 18 c to 18 n.
[0069] With this structure, the inductor L 11 (see FIG. 2) of the diplexer 11 includes the stripline electrodes ST 4 , ST 13 , and ST 22 , and the inductor L 12 (see FIG. 2) includes the stripline electrodes ST 2 , ST 11 , and ST 21 . The capacitor C 11 (see FIG. 2) preferably includes the capacitor electrodes Cp 16 , Cp 17 , and Cp 19 . The capacitor C 12 (see FIG. 2) preferably includes the capacitor electrodes Cp 16 , Cp 18 , and Cp 19 . The capacitor C 13 (see FIG. 2) preferably includes the capacitor electrode Cp 4 and the ground electrodes Gp 1 and Gp 2 . The capacitor C 14 (see FIG. 2) is preferably includes the capacitor electrodes Cp 7 , Cp 8 , and Cp 12 . The capacitor C 15 (see FIG. 2) preferably includes the capacitor electrodes Cp 7 and Cp 12 and the ground electrodes Gp 1 and Gp 2 .
[0070] The inductor L 21 (see FIG. 3) of the first high-frequency switch 12 includes the stripline electrodes ST 7 , ST 17 , and ST 25 , and the inductor L 23 (see FIG. 2) includes the stripline electrodes ST 3 and ST 12 . The capacitor C 22 (see FIG. 3) includes the capacitor electrode Cp 5 and the ground electrodes Gp 1 and Gp 2 .
[0071] The inductor L 32 (see FIG. 4) of the second high-frequency switch 13 includes the stripline electrodes ST 6 and ST 15 . The capacitor C 32 (see FIG. 4) includes the capacitor electrode Cp 6 and the ground electrodes Gp 1 and Gp 2 .
[0072] The inductor L 41 (see FIG. 5) of the SAW duplexer 14 includes the stripline electrodes ST 5 , ST 14 , and ST 23 , and the inductor L 42 (see FIG. 5) includes the stripline electrodes ST 1 , ST 10 , and ST 20 . The capacitor C 42 (see FIG. 5) includes the capacitor electrode Cp 3 and the ground electrodes Gp 1 and Gp 2 , the capacitor C 43 (see FIG. 5) includes the capacitor electrode Cp 2 and the ground electrodes Gp 1 and Gp 2 , and the capacitor C 44 (see FIG. 5) includes the capacitor electrode Cp 1 and the ground electrodes Gp 1 and Gp 2 .
[0073] The inductor L 51 (see FIG. 6) of the first LC filter 15 includes the stripline electrodes ST 8 , ST 18 , and ST 26 , and the inductor L 52 (see FIG. 6) includes the stripline electrodes ST 9 and ST 19 . The capacitor C 51 (see FIG. 6) includes the capacitor electrodes Cp 11 and Cp 14 , the capacitor C 52 (see FIG. 6) includes the capacitor electrodes Cp 11 and Cp 15 , and the capacitor C 53 (see FIG. 6) includes of the capacitor electrode Cp 11 and the ground electrode Gp 2 .
[0074] The inductor L 61 (see FIG. 7) of the second LC filter 16 includes the stripline electrodes ST 16 and ST 24 . The capacitor C 61 (see FIG. 7) includes the capacitor electrodes Cp 10 and Cp 13 , the capacitor C 62 (see FIG. 7) includes the capacitor electrode Cp 9 and the ground electrode Gp 2 , and the capacitor C 63 (see FIG. 7) includes the capacitor electrode Cp 10 and the ground electrode Gp 2 .
[0075] The operation of the high-frequency module 10 having the circuit structure shown in FIG. 1 will be described next. When a transmission signal is transmitted from the DCS (1.8 GHz band) or from the PCS (1.9 GHz band), a voltage of 1 V is applied to the control terminal Vc 1 in the first high-frequency switch 12 to connect the first port P 21 and the second port P 22 in the first high-frequency switch 12 to transmit the transmission signal sent from the DCS or sent from the PCS, from the antenna ANT through the first LC filter 15 , the first high-frequency switch 12 , and the diplexer 11 .
[0076] In this case, the first LC filter 15 passes the transmission signal sent from the DCS or the PCS and attenuates the harmonics of the transmission signal. In the second high-frequency switch 13 , a voltage of 0 V is applied to the control terminal Vc 2 to disable the second high-frequency switch 13 .
[0077] When a transmission signal is transmitted from the GSM (900 MHz band), a voltage of 1 V is applied to the control terminal Vc 2 in the second high-frequency switch 13 to connect the first port P 31 and the second port P 32 in the second high-frequency switch 13 to transmit the transmission signal sent from the GSM, from the antenna ANT through the second LC filter 16 , the second high-frequency switch 13 , and the diplexer 11 .
[0078] In this case, the second LC filter 16 passes the transmission signal sent from the GSM and attenuates the harmonics of the transmission signal. In the first high-frequency switch 12 , a voltage of 0 V is applied to the control terminal Vc 1 to disable the first high-frequency switch 12 .
[0079] When a receiving signal for the DCS is received, a voltage of 0 V is applied to the control terminal Vc 1 of the first high-frequency switch 12 to connect the first port P 21 and the third port P 23 in the first high-frequency switch 12 , and the DCS receiving signal is sent to the second port P 42 side in the SAW duplexer 14 , so that the DCS receiving signal received by the antenna ANT is sent to the receiving section Rxd of the DCS through the diplexer 11 , the first high-frequency switch 12 , and the SAW duplexer 14 .
[0080] In this case, the SAW duplexer 14 passes the DCS receiving signal and attenuates the harmonics of the receiving signal. In the second high-frequency switch 13 , a voltage of 0 V is applied to the control terminal Vc 2 to disable the second high-frequency switch 13 .
[0081] When a receiving signal for the PCS is received, a voltage of 0 V is applied to the control terminal Vc 1 in the first high-frequency switch 12 to connect the first port P 21 and the third port P 23 in the first high-frequency switch 12 , and the PCS receiving signal is sent to the third port P 43 side in the SAW duplexer 14 , so that the PCS receiving signal received by the antenna ANT is sent to the receiving section Rxp of the PCS through the diplexer 11 , the first high-frequency switch 12 , and the SAW duplexer 14 .
[0082] In this case, the SAW duplexer 14 passes the PCS receiving signal and attenuates the harmonics of the receiving signal. In the second high-frequency switch 13 , a voltage of 0 V is applied to the control terminal Vc 2 to disable the second high-frequency switch 13 .
[0083] When a receiving signal for the GSM is received, a voltage of 0 V is applied to the control terminal Vc 2 in the second high-frequency switch 13 to connect the first port P 31 and the third port P 33 in the second high-frequency switch 13 to send the GSM receiving signal received by the antenna ANT to the receiving section Rxg of the GSM through the diplexer 11 , the second high-frequency switch 13 , and the SAW filter 17 .
[0084] In this case, the SAW filter 17 passes the GSM receiving signal and attenuates the harmonics of the receiving signal. In the first high-frequency switch 12 , a voltage of 0 V is applied to the control terminal Vc 1 to disable the first high-frequency switch 12 .
[0085] According to the high-frequency module of the above-described preferred embodiment, since the diplexer, the first and second high-frequency switches, and the SAW duplexer are provided, and the SAW duplexer separates the receiving section of the first communication system and the receiving section of the second communication system, the number of high-frequency switches is reduced. As a result, the number of diodes used is reduced, and the power consumption of the high-frequency modules is greatly reduced. In addition, a current is not required during a signal receiving operation.
[0086] Since the diplexer, the first and second high-frequency switches, and the SAW duplexer, which constitute the high-frequency module, are integrated into the laminated member obtained by laminating a plurality of sheet layers formed of ceramic, the matching characteristic, the attenuation characteristic, or the isolation characteristic of each component is obtained. Therefore, a matching circuit is not required between the diplexer and the first and second high-frequency switches, or between the first high-frequency switch and the SAW duplexer. Consequently, the high-frequency module is very compact. In on example of preferred embodiments of the present invention, the resulting laminated member had approximate dimensions of 7.0 mm by 5.0 mm by 1.8 mm, and the laminated member included the diplexer, the first and second high-frequency switches, the SAW duplexer, the first and second LC filters, and the SAW filter.
[0087] The diplexer preferably includes inductors and capacitors. The first and second high-frequency switches preferably includes diodes, inductors, and capacitors. The SAW duplexer preferably includes SAW filters and transmission lines. The first and second LC filters preferably include inductors and capacitors. All of these elements are preferably built into, or mounted on the laminated member, and are preferably connected by connection members located inside of the laminated member. Therefore, the high-frequency module is defined by a single laminated member and is very compact. In addition, a loss caused by wirings for connecting components is greatly reduced, and as a result, the loss of the entire high-frequency module is greatly reduced.
[0088] Since the lengths of the inductors and the transmission lines built in the laminated member are reduced by a wavelength reduction effect, the insertion losses of these inductors and transmission lines are greatly reduced. Therefore, a compact and low-loss high-frequency module can be produced, and a compact and high-performance mobile communication apparatus on which the high-frequency module is mounted can also be produced.
[0089] [0089]FIG. 11 is a block diagram showing a portion of the structure of a triple-band portable telephone, which is a mobile communication apparatus. In this telephone, a DCS using the 1.8 GHz band, a PCS using the 1.9 GHz band, and a GSM using the 900 MHz band are preferably combined.
[0090] The triple-band portable telephone 30 is provided with the high-frequency module 10 (see FIG. 1), in which an antenna ANT and the front end sections of the DCS, the PCS, and the GSM are integrated, a transmission section Txdp shared by the DCS and the PCS, a receiving section Rxp of the PCS, a receiving section Rxd of the DCS, a transmission section Txg of the GSM, and a receiving section Rxg of the GSM.
[0091] The port P 11 of the high-frequency module 10 is connected to the antenna ANT, and the ports P 43 , P 42 , P 52 , P 62 , and P 72 are connected to the receiving section Rxp of the PCS, the receiving section Rxd of the DCS, the transmission section Txdp common to the DCS and the PCS, the transmission section Txg of the GSM, and the receiving section Rxg of the GSM, respectively.
[0092] According to the triple-band portable telephone described above, since the high-frequency module greatly reduces power consumption and does not require a current during receiving, the mobile communication apparatus having this high-frequency module can have low power consumption and does not use any current when waiting for a call. As a result, a battery mounted in the mobile communication apparatus can be used for a much longer period.
[0093] In addition, since the compact and low-loss high-frequency module is used, the mobile communication apparatus having this high-frequency module is very compact and provides excellent performance.
[0094] In the high-frequency module of various preferred embodiments described above, the laminated member preferably includes in the inside thereof, all of the elements of the diplexer, and a portion of the elements of the first and second high-frequency switches and the SAW duplexer, and the remaining elements of the first and second high-frequency switches and the SAW duplexer are mounted on the laminated member. A structure in which all the elements of the diplexer, the first and second high-frequency switches, and the SAW duplexer are mounted on the same printed circuit board may be used. Alternatively, a structure in which all the elements of the diplexer, and a portion of the elements of the first and second high-frequency switches and the SAW duplexer are built in a laminated member, and the remaining elements of the first and second high-frequency switches and the SAW duplexer are mounted on the same printed circuit board may be used.
[0095] In the above case, the phase conversion units of the SAW duplexer are preferably defined by lumped constant elements obtained by combining inductors and capacitors. Even if the phase conversion units are defined by distributed constant elements such as striplines, the same advantages are obtained.
[0096] In the above case, the SAW filters are mounted on the front surface of the laminated member. They may be mounted in a cavity formed on the lower surface or each surface of the laminated member.
[0097] In the above case, the SAW filters are bare chip elements but may also be disposed in a package.
[0098] While the present invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details can be made without departing from the spirit and scope of the invention. | A high-frequency module includes a diplexer, first and second high-frequency switches, a SAW duplexer, first and second LC filters functioning as first and second filters, and an SAW filter functioning as a third filter. The module defines a unit that integrates front-end sections of first to third communication systems, a digital cellular system (1.8 GHz band), a personal communication service (1.9 GHz band) and a global system for mobile communications (900 MHz band). | 8 |
BACKGROUND
[0001] 1. Field
[0002] The present disclosure relates generally to moisture resistant gloves and more particularly to moisture resistant gloves enabling a user to operate capacitive touch sensitive devices such as cell phones and media players while wearing the gloves.
[0003] 2. Background
[0004] Consumers are increasingly becoming accustomed to operating interactive devices with touchscreen technology based on capacitive sensing. This technology generates a continuing demand for devices with user friendly and intuitive interfaces, such as, for example, smart phones like the Apple iPhone™ and tablets like the Apple iPad™. Such demand includes access to such user friendly devices under varied and often less than user friendly circumstances. For example, outdoor winter sports enthusiast, such as snow boarders and skier, wear insulated water repellant or water resistant gloves for comfort. At the same time, widespread cellular coverage enables a sports enthusiast to communicate while also enjoying the winter outdoor environment. Gloves for such extreme weather conditions often include an outer shell of leather, waterproof, water resistant, or water repellant material, such as GORE-TEX® fabric, water repellant aerosol treated fabric, and the like. Unfortunately, extreme weather gloves are not equipped with capacitive touch sensitive capability to operate a touchscreen device, and the glove has to be removed to operate the device. There is a need, therefore, for a water resistant extreme weather glove compatible with interactive touch screen devices.
SUMMARY
[0005] In an aspect of the disclosure, a capacitive touch sensitive glove includes a glove having a moisture penetration resistant material forming interior and exterior portions of the glove, and an electrically conductive element extending through the material from the interior to the exterior portions, wherein the conductive element is arranged with the material to prevent transmission of moisture between the interior and exterior portions.
[0006] In an aspect of the disclosure, a method of making a capacitive touch sensitive glove compatible with capacitive touchscreen devices includes providing a glove comprising a moisture penetration resistant material forming interior and exterior portions of the glove, and attaching at least one electrically conductive element to the glove extending through the material from the interior to the exterior portions, wherein the conductive element is arranged with the material to prevent transmission of moisture between the interior and exterior portions.
[0007] In an aspect of the disclosure, a glove operable with a touchscreen device, includes a moisture penetration resistant material arranged to define an interior and an exterior portion of the glove, wherein the interior portion is arranged to receive a user's hand, and an electrically conductive element extending through the moisture penetration resistant material to permit electrical conduction from the user's hand interior to the glove to the device touchscreen exterior to the glove.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a conceptual illustration of a glove compatible with capacitive touchscreen devices in accordance with an aspect of the disclosure.
[0009] FIG. 2A is a cross-section of a conceptual illustration of an electrically conductive element for use in the glove of FIG. 1 .
[0010] FIG. 2B is a cross-section view of a conceptual illustration of the electrically conductive element of FIG. 2A arranged with a finger of the glove of FIG. 1 .
DETAILED DESCRIPTION
[0011] FIG. 1 is a conceptual illustration of a snow glove 100 compatible with capacitive touchscreen devices. The glove comprises a back 10 (indicated with a phantom lead line), a palm 11 , and a plurality of fingers including a thumb 12 , an index finger 13 and additional fingers 14 to accommodate the hand and fingers of a user within an interior 15 of the glove. The glove includes an outer surface that is waterproof and/or resistant to penetration of moisture. Various materials that may be used in such gloves include leather, GORE-TEX® fabric, water repellant aerosol treated fabric, and the like, but are not limited to the materials mentioned.
[0012] The thumb 12 and index finger 13 are shown arranged with an electrically conductive element 20 preferably in the vicinity of the finger tips, although the electrically conductive element may be arranged elsewhere on any portion of the fingers 12 , 13 , 14 , or even on the back 10 or palm 11 of the glove.
[0013] Referring to FIG. 2 , the electrically conductive element 20 includes an exterior portion 21 that is arranged with an outer surface of the glove 100 and an interior portion 22 that penetrates through a hole 30 in the glove at a selected location, such as the thumb 12 , index finger 13 , or elsewhere. The interior portion 22 is arranged in contact with the user's skin when worn by the user.
[0014] The electrically conductive element 20 is arranged with the glove 100 through the hole 30 to prevent moisture from passing through the hole 30 , with the intention of keeping the user's hand dry when, for example, the user is engaged in outdoor winter sports, such as skiing, snowboarding, ice climbing, etc. To that end, the electrically conductive element 20 and hole 30 may be configured with a water impermeable seal 40 to prevent the moisture from passing through the hole 30 along or around the electrically conductive element 20 .
[0015] In one aspect of the disclosure, the water impermeable seal 40 may be a curable adhesive sealant, such as a curable polymer, for example, between the electrically conductive element 20 and the hole 30 . Alternatively, the water impermeable seal 40 may be obtained by sewing the electrically conductive element 20 into the hole 30 and sealing with an adhesive sealing tape or material placed over the stitching, such as GORE-SEAM® tape, or the like.
[0016] In another aspect of the disclosure, the electrically conductive element 20 may be formed from a one or more conductive fibers substantially impregnated with the water impermeable seal 40 , where the water impermeable seal 40 may be a curable adhesive sealant. Thus, the impregnated electrically conductive element 20 may be positioned in the hole 30 of the glove 100 , and the sealant allowed to cure. Alternatively, the sealant in the electrically conductive element 20 may be cured first, and then additional sealant applied at the hole 30 when the electrically conductive element 20 is positioned in the hole 30 , and the additional sealant may be cured.
[0017] In another aspect of the disclosure, the electrically conductive element 20 may be formed from a water impermeable seal 40 comprising, for example, the curable sealant, which has been impregnated with one or more conductive fibers. The conductive fiber impregnated water impermeable seal 40 may be installed in the glove using additional sealant applied at the hole 30 , as above, which is then cured. Alternatively, as described above, adhesive sealing tape may be applied to provide the water impermeable seal 40 .
[0018] The conductive fibers may be any of filamentary conductive carbon fibers, filamentary metal wires, filamentary semiconductor fibers, or the like.
[0019] In an aspect of the disclosure, the electrically conductive element 20 may terminate at the fingertip in a conductive cap 50 or plate, and the cap 50 or plate may be positioned at the exterior portion 21 to enable conductive contact to a touchscreen, at the interior portion 22 to enable conductive contact the user's skin, or both. The cap 50 may be in electrical contact with the one or more conductive fibers or other conductive material from which the electrically conductive element 20 is formed. The interior portion 22 is positioned to be in contact with the user's skin when the glove 100 is properly worn.
[0020] When the user wished to access applications on a touchscreen device, the electrically conductive element 20 provide continuity between the capacitive touch sensitive screen and the users skin as if the user had applied his fingertips directly to the screen.
[0021] In an aspect of the disclosure, the electrically conductive element 20 may include an inelastic or elastic material, such as plastic, rubber, a curable polymer, or the like, charged with conductive particles, such as silver or other conductive granules.
[0022] It is to be understood that the specific order or hierarchy of steps in the methods disclosed is an illustration of exemplary processes. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the methods may be rearranged. The accompanying method claims present elements of the various steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented unless specifically recited therein.
[0023] The claims are not intended to be limited to the various aspects of this disclosure, but are to be accorded the full scope consistent with the language of the claims. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. §112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for.” | A capacitive touch sensitive glove includes a glove having a moisture penetration resistant material forming interior and exterior portions of the glove, and an electrically conductive element extending through the material from the interior to the exterior portions, wherein the conductive element is arranged with the material to prevent transmission of moisture between the interior and exterior portions. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of my copending application Ser. No. 020,916, filed Mar. 14, 1979, now U.S. Pat. No. 4,280,469, and entitled "Powertrain and Apparatus Using a Continuously Variable Ratio Transmission to Improve Fuel Economy."
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to feedback systems used to control both the throttle valve of an internal combustion engine and the ratio setting of an associated continuously variable transmission, usually in response to the position of the accelerator pedal in a passenger car.
2. Description of the Prior Art
The prior art includes many systems for controlling the throttle setting and the transmission ratio in a passenger car equipped with a continuously variable transmission (C.V.T.). A few of these C.V.T. control systems can be recalibrated or slightly modified to implement the extensive wide open throttle engine operating schedule as advanced for improving fuel economy in U.S. Pat. No. 4,023,641. For instance, an appropriate change in cam profile will extend the invention disclosed in Canadian Pat. No. 665,093 to include a predominantly full throttle engine operating schedule. Nevertheless, such modifiable prior art systems have no provision for dealing with engine speed errors which result from a limited transmission ratio range. In other words, transmission ratio is used to limit full throttle engine operating speed, and thus also the engine power output. When the transmission reaches its most extreme overdrive ratio, however, both engine speed and power output may continue to climb well beyond their intended values. Engine power can still be regulated to the desired level, but only through bothersome manipulation of the accelerator pedal.
Recalibrated prior art systems would also have no provisions for the deviations from predominantly full throttle operation that are sometimes desirable for driveability and usually necessary for cold engine operation. Finally, the engine throttle valve is opened too abruptly relative to accelerator pedal movement when the prior art systems are modified to secure the fuel economy advantages of extensive wide open throttle engine operation.
SUMMARY OF THE INVENTION
In light of the above, it is therefore a principle object of the invention to present a C.V.T. control system which inherently follows a predominantly full throttle engine operating schedule, but which automatically reduces the engine throttle valve setting to counteract the extra power output caused by engine speeds higher than desired.
It is also an object of the invention to present a C.V.T. control system which inherently follows a predominantly full throttle engine operating schedule, but which may be conveniently adapted to automatically avoid full throttle engine operation when the engine is below its normal operating temperature range, or when driveability problems would otherwise occur.
It is another object of the invention to present a C.V.T. control system which can initiate full throttle engine operation within a fraction of the total movement of an associated accelerator pedal, but which avoids both abrupt engine response at low engine speed and sluggish response at high engine speed.
These and other objects, features and advantages will become apparent to those skilled in the art from the following detailed description when read in conjunction with the appended claims and the accompanying drawing.
In accordance with the present invention, apparatus for promoting unthrottled operation of an Otto engine which delivers its power output through a continuously variable transmission is presented. The apparatus includes a feedback control system for adjusting the ratio of the transmission to limit engine speed to a desired value. This value is selected through an input device such as the accelerator pedal in a passenger car. Also included are a control system for opening the engine throttle valve to an essentially wide open position, even at low engine speeds, and an override arrangement for closing the throttle from the wide open position in the event the transmission does not limit engine speed to the desired value. Thus the override system will automatically move the throttle to limit engine power when it is undersirable or impossible to do so with the transmission.
BRIEF DESCRIPTION OF THE DRAWING
The present invention is illustrated in the accompanying drawing, in which FIG. 1 is a diagram of a control system constructed according to a preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The arrangement of components revealed by FIG. 1 would form a preferred embodiment of a control system according to the present invention. In the automotive application of this embodiment, the existing accelerator pedal (not shown) would be connected to move an electrically insulating input element 1 upward as the pedal is depressed. The input element 1 moves only vertically in FIG. 1 to slide an attached electrical contact 2 along an exposed resistor element 3, with which the contact 2 thereby forms a potentiometer. Progressive depression of the accelerator pedal would cause the voltage on contact 2 to progressively increase from ground potential to about 300 volts above ground because a power supply 4 is connected to apply a constant D.C. Potential of about 300 volts to the uppermost end of resistor 3, while the lower end of resistor 3 is grounded. The power supply 4 may derive its input energy from an existing vehicle storage battery (not shown) or from any other convenient source.
A branched conductor 5 carries the master command voltage signal from contact 2 to an electromagnetic coil 6, which is connected through a rectifier 7 to an auxiliary sliding contact 8 on the resistor 3. For the positions of the contacts 2 and 8 shown in FIG. 1, contact 2 will of course have a higher potential than contact 8, thereby reverse biasing rectifier 7 to prevent any current through coil 6. As a result, the force of an integral spring (not shown) will keep the double-throw switch 9 in the position shown and the command signal will be passed from conductor 5 to a conductor 10. In the event that the potential of auxiliary contact 8 exceeds that of contact 2, current will pass through rectifier 7 and coil 6 to electromagnetically pull switch 9 into the position connecting auxiliary contact 8 to conductor 10. In other words, the components within the dashed rectangle identified by reference numeral 11 act as a selector circuit connecting conductor 10 to receive the higher of the potentials on contacts 2 and 8. If the polarity of the rectifier 7 were reversed, this selector circuit 11 would select the lower of the potentials on contacts 2 and 8. The circuit 12 is such a low voltage selecting circuit, but its function will be considered later.
Conductor 10 delivers the resulting engine speed command signal to an error correction circuit, the components of which are enclosed within the dashed rectangle identified by reference numeral 13, and a branched conductor 14 brings an engine speed feedback signal to the error correction circuit 13 from a speed sensor that will be described later. As will become evident, the engine speed feedback potential on conductor 14 is substantially in direct proportion to the operating speed of the associated engine.
Within the correction circuit 13, current can pass between conductors 10 and 14 through one of two electromagnetic coils 15 and 16, depending on whether the engine speed command signal or the engine speed feedback signal has greater potential. Rectifier 17 connects coil 15 across conductors 10 and 14 with a polarity such that coil 15 will electromagnetically overcome a spring force to close an associated switch 18 when the command potential on conductor 10 exceeds the feedback potential on conductor 14 by more than a volt or two. In this case where the command signal exceeds the feedback signal, switch 18 will forward bias the base terminal of the connected power transistor 19 through the resistor 20. Transistor 19 in turn powers a winding in gear reduction motor 21 which responds by rotating an attached torque arm 22 in the downshift direction, to increase the numeral ratio of the associated continuously variable transmission (C.V.T.). Link 23 completes the connection between the motor 21 and associated C.V.T. Of course an increase in numerical transmission ratio will tend to increase the operating speed of the associated engine and thereby equalize the voltage signals on conductors 10 and 14.
The unshift coil 16, switch 25, rectifier 26 and transistor 27 are similarly active to decrease transmission ratio by powering a reverse-rotation upshift winding in motor 21 when the feedback potential on conductor 14 exceeds the command potential on conductor 10. Although not shown in FIG. 1, position switches may be used to open-circuit the appropriate one of the coils 15 and 16 when the torque arm 22 occupies the extreme positions of minimum and maximum transmission ratio. The single resistor 20 limits the base current from an existing 12 volt vehicle storage battery (not shown) to both power transistors 19 and 27 because both transistors cannot be active simultaneously. For this same reason, only the single resistor 28 limits current to both windings in motor 21, and rectifiers 29 and 30 prevent the power transistors from being damaged by reverse voltage generated in the inactive motor windings. Finally, collector current through either of the power transistors 19 and 27 must pass through an electromagnet 31 before reaching ground. This electromagnet 31 releases a brake within the motor 21 so that application of the brake greatly reduces overshoot as well as helping maintain a fixed transmission ratio when the motor 21 is not energized.
Although the switches 18 and 25 are shown for clarity in FIG. 1 as being distinct from the cores of the coils 15 and 16, electromagnetic reed switches are in fact preferred to conventional relays. With mercury-wetted contacts, reed switches have a very long lifetime, and the coils 15 and 16 may have high resistance values which reduce the effect the contacts 2 and 8 have on the voltage distribution along the resistor 3.
If a variable correction rate is desired, a second correction circuit identical in operating principle to the circuit 13 can be added. The additional circuit would power high speed windings in the motor 21, but have a reduced sensitivity to the voltage difference between the conductors 10 and 14. Or alternatively, optical couplers would allow a continuously variable correction rate because they can amplify as well as just detect potential difference between the conductors 10 and 14. The arrangement of FIG. 1 is preferred for its simplicity and reliability.
The engine speed feedback signal originates in a small A.C. generator 35 driven in direct proportion to the operating speed of the associated engine. For instance, the generator 35 may often be conveniently located in the ignition distributor of the associated engine, where the distributor shaft would drive the generator 35 at one-half of crankshaft speed. Rectifiers 36, 37, 38 and 39 comprise a full-wave bridge circuit for rectifying the current passing from generator 35 to conductor 14, and a filter capacitor 40 reduces ripple in the feedback voltage on conductor 14.
The branched conductor 14 delivers the engine speed feedback signal to a resistor 41 as well as to the engine speed correction circuit 13 just considered. Resistor 41 has a total resistance value which loads the generator 35 to cause maximum depression of the associated accelerator pedal to command the operating speed at which the associated engine develops maximum power. Or equivalently, the constant voltage delivered to resistor 3 by the power supply 4 equals the engine speed signal on conductor 14 when the engine reaches its maximum power speed. Generator 35 should be designed to provide a voltage signal on conductor 14 in direct proportion to the operating speed of the associated engine.
Just as the master command signal entered a first selector circuit 11 to emerge as the engine speed command signal, the same master signal on conductor 5 enters a second selector circuit 12 to become the engine power command signal. The selector circuit 12 connects a conductor 42 to receive the lower of the potentials on the conductors 5 and 14. A method for constructing the selector 12 has already been explained with reference to the first selector circuit 11. In all but a few transient situations, the selector 12 will connect conductor 42 to receive the potential on sliding contact 2.
An engine power feedback signal is derived from resistor 41 by a sliding contact 43 which touches the exposed element of resistor 41 and is moved vertically along the resistor 41 by an attached piston 44. A tension spring 45 pulls upward on the piston 44, and the intake manifold vacuum of the associated engine is present in a cylinder 46 to which piston 44 is fitted. Since the upper face of piston 44 experiences atmospheric pressure, increasing values of engine intake manifold vacuum on the lower face of piston 44 stretch spring 45 to reduce the resistance between ground and contact 43. The resistance value of this portion of the resistor 41 located between its ground connection and the contact 43 is in the same proportion to the total resistance of resistor 41 as the existing brake torque output of the associated engine is to the maximum torque output of the engine. Consequently, the voltage on contact 43 approximates a signal in direct proportion to the power output of the associated engine. If resistor 41 has a carbon strip element, then the width of the strip may be varied to effect the desired calibration. In the case of a wire wound resistor, the coils of the resistor may be wound on a form of appropriately varying circumference.
In more detail, the calibration of resistor 41 is accomplished as follows. First, the maximum brake torque of the associated engine is measured on a stationary dynamometer under conditions of normal engine operating temperature and the extreme open position of the throttle valve 47 which controls air flow to the associated engine. This measurement requires that the engine operating speed be varied at the extreme open throttle position to locate the maximum torque, and resistor 41 is then positioned to locate the contact 43 just at the uppermost end of the element in the resistor 41. A position limiter 48 should also be adjusted at this time to prevent further upward movement of piston 44, but the limiter 48 must not interfere with the free movement of piston 44 while the engine speed of maximum torque is being located.
The next step using the engine dynamometer includes decreasing engine operating speed by a small percentage of the difference between a slightly slow engine idling speed and the maximum torque speed just determined in the first step. At this new speed, the throttle valve 47 is closed from the wide open position until brake torque drops, from the maximum torque value first determined, by the same small percentage just applied to the specified engine speed difference. The resistance value of the portion of resistor 41 now remaining between contact 43 and the ground connection of resistor 41 should be in the same proportion to the total resistance of resistor 41 as the existing brake torque is to the maximum brake torque first determined. Finally, larger and larger percentage values are chosen to repeat this procedure until the slightly slow engine idle speed is reached, but resistor 41 should include a zero resistance segment to avoid an open circuit at contact 43 in the event vacuum in the cylinder 46 exceeds the normal value for engine idle conditions. A conventional adjustable idle stop (not shown) locates an idle position of throttle valve 47 to restore normal idle speed.
A few additional considerations influence the calibration of resistor 41 as just explained. First, any vacuum spark advance ports located in the throttle bore adjacent the throttle plate 47 should be eliminated, before calibrating the resistor 41, in favor of a transfer slot such as commonly used in the idle system of a conventional carburetor. The much more gradually increasing vacuum signal from the transfer slot will help insure that the intake manifold vacuum is higher at idle than under any slightly loaded offidle condition. Without this insurance, the engine might not always return to the normal idle speed upon decelerating the associated vehicle to a stop. Second, all of the dynamometer testing should include any dilution of the air-fuel charge that is used to improve engine operating efficiency. As an example, my U.S. Pat. No. 4,023,641 reveals that lean air-fuel mixtures can improve engine operating efficiency, and consequently, the maximum torque measured in the dynamometer testing may be distinctly less than the absolute maximum. As also disclosed in U.S. Pat. No. 4,023,641, engine design features which provide a flat torque curve over a broad engine speed range often enhance engine operating efficiency and are therefore also preferred for use with the present invention. Furthermore, a flat torque curve contributes to the accuracy with which the signal on contact 43 indicates engine power output. And finally, the throttle valve 47 follows conventional automotive practice in that the pressure drops associated with the extreme open position of the valve 47, and with any associated fuel metering components such as a venturi, total only a few inches of mercury or less, even when the associated engine is operating at maximum crankshaft speed. Although only a single throttle plate 47 is shown, the associated engine could of course be controlled by a throttle valve assembly or device with multiple bores and corresponding multiple throttle plates.
Another calibration concerns the resistor 41, and this second calibration should be done only following the calibration procedure just explained. An auxiliary sliding contact 49 shunts the engine speed signal on conductor 14 across a variable amount of the upper portion of resistor 41. As a result, extra throttling becomes available to enhance cold operation of the associated engine. The main components for controlling the position of this auxiliary contact 49 are absent from FIG. 1 because they already exist, for example, in the choke system of a conventional carburetor or the auxiliary air device used with many fuel injection systems. The calibration can be accomplished empirically, but in any case, the contact 49 should not short-circuit any portion of the resistor 41 once the associated engine reaches its normal operating temperature range. Actuation of contact 49 does reduce the voltage signal on conductor 14 at a given engine speed, but the resulting limitation on maximum engine speed is by no means undesirable during cold operation. The existing cold enrichment system on the associated engine may also be used to position contact 8 on resistor 3, to thereby permit fast idle speeds which exceed the minimum engine speed used for wide open throttle operation once the engine is warm.
A second reversible motor 50 opens and closes the throttle valve 47 through torque arms 51 and 52 and their connecting link 53. A second error correction circuit 54 power the motor 50 in response to potential difference between the conductor 42 and the contact 43. The correction circuit 54 causes the throttle valve 47 to open when the power command signal on conductor 42 exceeds the measured power output signal on contact 43, and to close when the measured feedback signal exceeds the command signal. The method of construction already explained for the engine speed correction circuit 13 also applies to the power correction circuit 54, and an electromagnet 55 may be used to reduce control system overshoot in a manner identical to that already explained for the electromagnet 31.
In operation, the engine speed correction circuit 13 will act to equalize the command and feedback voltages on conductors 5 and 14, respectively, whenever the voltage on main contact 2 exceeds that on auxiliary contact 8. From another viewpoint, each position of the associated accelerator pedal will command a unique engine speed, provided that the pedal has been depressed far enough to raise contact 2 above contact 8, and continued depression of the pedal will command increasing engine speed. The speed correction circuit 13 causes the ratio setting of the associated continuously variable transmission to be changed until either the commanded engine speed or an extreme of the available transmission ratio range is reached.
Assuming the commanded engine speed is reached with contact 2 still above contact 8, the second correction circuit 54 will seek an effectively wide open position of the throttle valve 47 because the feedback signal residing at the very top portion of resistor 41 already equals the command signal on conductors 5 and 42. At quite low engine speeds, the contact 43 will reach the top of resistor 41 before the throttle 47 is wide open, but this allows faster response to a sudden command for significantly throttled engine operation. More importantly, the loss in engine efficiency associated with this slight throttling at low speed is usually negligible, especially if fuel injection is used. (The throttle 47 is herein defined to be effectively wide open when the resulting pressure drop and engine efficiency are essentially equal to the wide open throttle values). In addition, the stiffness of the spring 45 can be increased slightly to guarantee the availability of the actual wide open position of the throttle 47 at low engine speeds.
In contrast to the situation just considered, a limited transmission ratio range can combine with moderate driving conditions to create circumstances where the commanded engine speed cannot be reached. As an illustration of this, downhill driving might allow an existing vehicle cruising speed to be maintained by the power available from wide open throttle (w.o.t.) engine operation at only 800 r.p.m., while the available transmission ratios could not limit engine speed to below 1600 r.p.m. at the same vehicle speed. In this case, the feedback signal on conductor 14 would reach equilibrium at twice the 800 r.p.m. command signal on conductors 5 and 42. Consequently, the throttle 47 will close until contact 43 samples half the feedback voltage on conductor 14, or, until engine torque is reduced to about half the w.o.t. value.
In summary of this last example, the equilibrium engine speed exceeded the commanded value by a factor of 2, but engine power output remained at approximately the commanded value because engine torque output was reduced by this same factor of 2. Thus, the resistor 41, contact 43, piston 44 and spring 45 may be thought of as being a torque sensor. In conjunction with other components, this torque sensor reduces w.o.t. engine torque by the factor equal to the ratio of actual engine speed to commanded engine speed. Until now, the contact 43 and its associated hardware have been viewed in alliance with the engine speed sensor components as being a power sensor. Either view is correct, but the torque sensor viewpoint emphasizes the following features important in the calibration of the associated engine.
First, if the engine air-fuel charge is diluted during w.o.t. operation with the excess air of lean combustion, or with recirculated exhaust gas, then the dilution must taper off gradually as engine intake manifold vacuum increases. In other words, for example, abruptly terminating the flow of recirculated exhaust gas as soon as intake manifold vacuum first reaches, say, 5 inches of mercury would precipitate an actual increase in engine torque as the throttle 47 closed to first reach the threshold value of 5 inches of vacuum. As is almost always the case with completely conventional automotive engine calibration, more closed positions of the throttle 47 should always, at any constant engine speed, reduce engine torque output. Furthermore, the preferred engine calibration should produce an engine brake torque output that remains relatively independent of engine speed whenever intake manifold vacuum is held at any constant value less than about 15 inches of mercury. Alternatively, a true torque sensor can replace the vacuum actuated arrangement shown to provide an accurate torque signal in spite of there being no consistent relationship between torque and intake manifold vacuum.
To this point, only operation with contact 2 above auxiliary contact 8 has been considered. Without the minimum engine speed signal from contact 8, however, the apparatus of FIG. 1 would institute full throttle engine operation at unacceptably low engine speeds.
As already suggested, engine operating efficiency can be improved both by w.o.t. dilution of the air-fuel charge and with engine design characteristics which provide a flat torque curve. Both of these features also contribute to as little as about 15% of maximum engine power being available at w.o.t. and with the engine running at about 20% of the speed at which it develops its absolute maximum power output. Extensive w.o.t. operation at less that 20% of maximum engine speed typically entails undesirable vibration and even the possibility of engine damage, especially to bearings. In brief, relatively minor changes in engine design, such as using a flywheel with an increased moment of inertia, will often remove the final barriers to practical w.o.t. engine operation at only 20% of the maximum power engine speed.
Contact 8 samples from resistor 3 a voltage which would normally command the minimum practical w.o.t. operating speed, or, usually about 20% of the maximum power engine speed. The selector circuit 11 then introduces an intentional error in commanded engine speed (as compared with the value which would force w.o.t. operation) whenever the commanded value on contact 2 is less than the minimum value practical for w.o.t. operation. As already explained with reference to downhill driving and limited transmission ratios, the effect of an engine speed error is to initiate throttling, but without introducing significant error between the actual and the commanded power output. In this way, throttling plays a major part in establishing engine power levels less than about 15% of the maximum. On the other hand, throttling is not used when both more than 15% of power is commanded and the associated transmission is able to limit engine speed to the commanded value.
Driveability considerations, as well as cold engine temperatures, can have an influence on the minimum engine speed commanded by contact 8. For instance, if higher vehicle speeds are found to be incompatible with the normal minimum w.o.t. engine speed, then the contact 8 can be moved upward as a function of increasing vehicle speed. In addition, intentional engine speed errors can be introduced at other points in the apparatus as a function of driveability parameters continually being monitored by sensors.
Below the normal range of engine temperatures, full throttle engine operation might often be impractical. During cold engine operation, therefore, movement of the contact 49 down resistor 41 allows the voltage signals on conductors 14 and 42 to be equalized well before the throttle 47 reaches its wide open position. If, however, the accelerator pedal is suddenly depressed, the voltage on contact 2 will temporarily rise above that on contact 49. Without the low voltage selector circuit 12, the voltage on conductor 42 would also rise above the voltage on contact 49, causing the throttle 47 to be momentarily opened past the limiting position dictated by contact 49 during steady-state conditions. The selector circuit 12 thus serves its purpose only during transient conditions when the engine is cold.
Sudden accelerator pedal movements may similarly trigger only momentary opening or closing of the throttle 47 during the period when the correction circuit 13 is seeking the newly commanded engine speed. Such dynamic behavior of the system simply imparts a more responsive feel to the associated accelerator pedal.
The throttle 47 must traverse the entire range from idle to w.o.t. during a quite abbreviated portion of the total travel of the associated accelerator pedal. Again, this is because a maximum of only about 15% of engine power is always developed with throttling. As a result of the abbreviated pedal travel, a conventional mechanical throttle linkage with amplified movement would open the throttle 47 to cause an abrupt rise in engine torque at low engine speeds. Since a given small throttle opening establishes much less torque at higher engine speeds, a mechanical linkage will have either low speed abruptness or lack of response at high speed. Because the present invention opens the throttle 47 in response to measured torque, this compromise is totally avoided.
Most gasoline engine fuel injection systems control engine torque output by varying the time width of the pulses used to actuate the fuel injectors. When such a torque signal (in this case, more closely approximating indicated than brake torque) is already available, the sensor which includes resistor 41 and contact 43 could be eliminated. Going further, a mechanical linkage could position the throttle valve 47, regardless of the disadvantage just noted. And finally, an override mechanism could close the throttle from the position determined by the mechanical linkage to a new position causing the injector pulse width (torque signal) to be reduced by a factor equal to the ratio of measured to commanded engine speed. This example helps illustrate the great many variations of the present invention that may be resorted to without departing from the spirit and scope of the following claims. | A feedback control system includes an actuator for selecting engine throttle position and another actuator for adjusting the ratio setting of an infinitely variable transmission through which the engine delivers its output power. Also included are sensors for measuring engine crankshaft speed and engine power output. When the control system is used in a passenger car, the accelerator pedal position is employed to command engine power output according to a predetermined relationship. The throttle actuator then adjusts throttle opening until the actual output as measured by the power sensor equals the commanded power output. Similarly, the transmission ratio is adjusted to establish a specific relationship between accelerator pedal position and engine crankshaft speed, but the commanded crankshaft speed is usually low enough to require full throttle engine operation to achieve the correspondingly commanded power output. When lacking an overdrive transmission ratio extreme enough to limit engine speed to the commanded value, the control system will nevertheless establish the commanded power level by closing the throttle an appropriate amount from its wide open position. Thus the control system seeks wide open throttle engine operating conditions whenever consistent with practical engine speeds and available transmission ratios. | 1 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] This invention relates to inspection of thermal barrier coatings, and more particularly to inspection of coatings on turbine components.
[0003] (2) Description of the Related Art
[0004] Gas turbine engine components (e.g., blades, vanes, seals, combustor panels, and the like) are commonly formed of nickel- or cobalt-based superalloys. Desired operating temperatures often exceed that possible for the alloys alone. Thermal barrier coatings (TBCs) are in common use on such components to permit use at elevated temperatures. Various coating compositions (e.g., ceramics) and various coating methods (e.g., electron beam physical vapor deposition (EBPVD) and plasma spray deposition) are known.
[0005] An exemplary modern coating system is applied to the superalloy substrate by an EB-PVD technique. An exemplary coating system includes a metallic bondcoat layer (e.g., an overlay of NiCoCrAlY alloy or diffusion aluminide) atop the substrate. A thermally insulating ceramic top coat layer (e.g., zirconia stablized with yttria) is deposited atop the bondcoat. During this deposition, a thermally grown oxide layer (TGO), e.g., alumina, forms on the bondcoat and intervenes between the remaining underlying portion of the bondcoat and the top coat.
[0006] The coatings are subject to potential defects. For example, the TGO to bondcoat interface tends to suffer from separations/delaminations. Such defects tend to be inherent, so threshold degrees of defect may determine the utility of a given component. Defects may also form during use.
[0007] Much of existing inspection involves destructive testing used to approve or reject batches of components. Exemplary destructive testing involves epoxy-mounting and sectioning a component followed by microscopic examination. The TGO is a critical element. This may be viewed via scanning electron microscope (SEM) at 1,000× or higher. Quality standards are used to approve or reject the batch based upon visual interpretation of the SEM images.
[0008] Destructive testing suffers from many general drawbacks as do its various particular techniques. The former includes the cost of destroyed components, the inaccuracy inherent in batch sampling, and the cost of time. U.S. Pat. No. 6,352,406 discloses an alternate system involving coating of a pre-couponed turbine blade facsimile in lieu of cutting an actual blade. This may slightly reduce the time spent, but does not address the fundamental problems of destructive testing.
[0009] Laser fluorescence has been used for nondestructive evaluation of limited coating parameters. In one example, the beam of a ruby laser is shined on the ceramic top coat and passes therethrough to reach the TGO. The TGO fluoresces and the emitted light passes through the top coat to a sensor. Characteristics of the flurorecence indicate stress in the TGO. Separation/delamination voids are associated with reduced stress and can thus be detected. U.S. Pat. No. 6,072,568 discloses such inspection.
[0010] There remains a substantial need for improvement in testing techniques.
BRIEF SUMMARY OF THE INVENTION
[0011] Accordingly, one aspect of the invention is a method for inspecting a multi-layer coating on a substrate of a turbine element airfoil. At each of a number of locations along the airfoil, a number of frequencies of alternating current are passed through the airfoil. At least one impedance parameter is measured. Based upon the measured impedance parameters, a condition of the coating is determined.
[0012] The current may pass through an electrolyte wetting the airfoil. The method may determine thicknesses of one or more layers of the coating and may identify or characterize voids within the coating or between the substrate and the coating. The method may advantageously be performed in situ with the turbine element installed on a turbomachine. The method may be performed seriatim on a number of turbine elements on the turbonmachine.
[0013] Another aspect of the invention is an inspection apparatus. The apparatus may have a source of the current and electrodes for passing the current through the airfoil. The apparatus may have means for measuring the impedance parameter and means for determining the coating condition.
[0014] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a view of a coating test/inspection system.
[0016] [0016]FIG. 2 is a sectional view of a coated item.
[0017] [0017]FIG. 3 is an alternate view of a test/inspection system.
[0018] [0018]FIG. 4 is a circuit equivalent model of a coating.
[0019] [0019]FIG. 5 is a graph of impedance and phase angle against frequency for an exemplary coating.
[0020] Like reference numbers and designations in the various drawings indicate like elements.
DETAILED DESCRIPTION
[0021] [0021]FIG. 1 shows an apparatus 20 for testing/inspecting a coated item such as a turbine element (e.g., a turbine engine blade 22 ). The exemplary blade 22 includes an airfoil 24 extending from a root 26 at a platform 28 to a tip 30 . The airfoil has leading and trailing edges 32 and 34 separating pressure and suction sides 36 and 38 . The platform has an outboard portion 40 for forming an inboard boundary/wall of a core flowpath through the turbine engine. A mounting portion or blade root 42 depends centrally from the underside of the platform 40 for fixing the blade in a disk of the turbine engine. In an exemplary embodiment, the portion 40 and airfoil 24 are coated.
[0022] The exemplary system 20 includes an impedance analyzer 50 coupled by conductors 51 and 52 to a pair of electrodes 53 and 54 . The first electrode 53 may be a standard reference electrode contacted with an uncoated portion of the platform. The second electrode 54 is contacted with a coated portion of the blade and, therefore, is advantageously provided as a wetting electrode. The wetting electrode 54 includes a standard reference electrode 56 mounted in a proximal end of a tubular vessel 58 and contacting an electrolyte 60 within the vessel. A check valve 62 is mounted in a distal end of the vessel 58 . When the check valve 62 is contacted with the coating, it establishes fluid communication between the contact site and the interior of the vessel providing a small wetting of the coated surface with the electrolyte and providing an electrical path through the electrolyte from the coating to the reference electrode 56 .
[0023] [0023]FIG. 2 shows further details of the coating 70 on a metallic substrate 72 of the blade. The blade has an outer surface 74 atop which the coating layers are deposited. The layers include a metallic bondcoat 76 atop the substrate surface 74 , an in situ formed TGO layer 78 atop the bondcoat, and a ceramic topcoat 80 atop the TGO and having an external surface 82 . Contact is made between the electrode 54 and the surface 82 via the wetting electrolyte 84 . Direct electrical contact is made between the electrode 53 and an exposed uncoated surface 86 of the substrate.
[0024] In a laboratory setting, the system 20 of FIG. 1. may include an environmental control chamber 100 (FIG. 3) for containing the blade 22 during testing and that controls various properties of temperature, humidity, pressure, and the like. The current is provided by a current amplifier 102 coupled to an impedance analyzer 104 for measuring impedance parameters. The impedance analyzer 104 is coupled to analysis equipment such as a computer 106 . The computer may display results of the measured parameters and perform analyses to determine quantitative and qualitative properties of the coating based on the received parameters.
[0025] Various theoretical, empirical or hybrid models may be used to determine coating properties. Such properties may include the layer thicknesses and the presence, size, and quantity of imperfections (e.g., voids within layers or between layers (e.g., separations and delaminations)). FIG. 4 shows a basic electric circuit model. From one end of the circuit to the other, the resistance of the electrode 54 (FIG. 1) is shown as R p in series with an electrolyte solution resistance R s . This, in turn, is in series with the parallel combination of a topcoat resistance R c and a topcoat capacitance C c . This, in turn, is in series with the parallel combination of a TGO resistance R o multiplied by a Warburg coefficient W o and a TGO capacitance C o . This is, in turn, in series with the parallel combination of a resistance R T of the interface between the superalloy and bondcoat and an interface capacitance C T .
[0026] [0026]FIG. 5 shows an exemplary graph 120 of impedance Ω against frequency w. An exemplary impedance scale is 0-1500 Kohm/cm 2 . FIG. 5 further shows an exemplary graph 122 of phase angle θ against frequency. An exemplary phase angle scale is 0 to 80°. In this model, roughly the location of the impedance peak 130 is indicative of R T . The location of the impedance tail 132 is indicative of R p . In the location of the transition 134 is indicative of R c and R o . The location of a low frequency phase angle peak 140 is indicative of C o and the location of a high frequency phase angle peak 142 is indicative of C c . The location of a tail 144 is indicative of C T . The wetting electrode may be moved seriatim to a plurality of positions on the blade and impedance measurements taken. Analysis of data from such multiple positions may be used to even better determine coating properties.
[0027] Less environmentally controlled tests may be performed in situ on an assembled engine such as performing periodic tests on an aircraft engine. Such testing may be used to determine wear and other degradation parameters and determine remaining life of the turbine element. Alternative tests may involve contacting two probes with the coating. This may be appropriate where convenient access to uncoated portions is difficult. Relatively complex models could be used for such a situation.
[0028] One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, details of the particular turbine elements, coatings, test conditions, and examination criteria may influence the structure of the inspection apparatus and implementation of the inspection methods. Accordingly, other embodiments are within the scope of the following claims. | A method and apparatus are provided for inspecting a coated substrate such as a multi-layer coating on a substrate of a turbine airfoil. At each of a number of locations along the airfoil a number of frequencies of alternating current are passed through the airfoil. At least one impedance parameter is measured. The measured impedance parameters are utilized to determine a condition of the coating. | 6 |
RELATED PATENT DATA
This patent application is a divisional application resulting from U.S. patent application Ser. No. 09/266,456 now U.S. Pat. No. 6,180,494, which was an application filed on Mar. 11, 1999.
TECHNICAL FIELD
This invention relates to integrated circuitry, to methods of fabricating integrated circuitry, to methods of forming local interconnects, and to methods of forming conductive lines.
BACKGROUND OF THE INVENTION
The reduction in memory cell and other circuit size implemented in high density dynamic random access memories (DRAMs) and other circuitry is a continuing goal in semiconductor fabrication. Implementing electric circuits involves connecting isolated devices through specific electric paths. When fabricating silicon and other semiconductive materials into integrated circuits, conductive devices built into semiconductive substrates need to be isolated from one another. Such isolation typically occurs in the form of either trench and refill field isolation regions or LOCOS grown field oxide.
Conductive lines, for example transistor gate lines, are formed over bulk semiconductor substrates. Some lines run globally over large areas of the semiconductor substrate. Others are much shorter and associated with very small portions of the integrated circuitry. This invention was principally motivated in making processing and structure improvements involving local interconnects, although the invention is not so limited.
SUMMARY OF THE INVENTION
The invention includes integrated circuitry, methods of fabricating integrated circuitry, methods of forming local interconnects, and methods of forming conductive lines. In one implementation, a method of fabricating integrated circuitry comprises forming a conductive line having opposing sidewalls over a semiconductor substrate. An insulating layer is deposited over the substrate and the line. The insulating layer is etched proximate the line along at least a portion of at least one sidewall of the line. After the etching, an insulating spacer forming layer is deposited over the substrate and the line, and it is anisotropically etched to form an insulating sidewall spacer along said portion of the at least one sidewall.
In one implementation, a method of forming a local interconnect comprises forming at least two transistor gates over a semiconductor substrate. A local interconnect layer is deposited to overlie at least one of the transistor gates and interconnect at least one source/drain region of one of the gates with semiconductor substrate material proximate another of the transistor gates. In one aspect, a conductivity enhancing impurity is implanted into the local interconnect layer in at least two implanting steps, with one of the two implantings providing a peak implant location which is deeper into the layer than the other. Conductivity enhancing impurity is diffused from the local interconnect layer into semiconductor substrate material therebeneath. In one aspect, a conductivity enhancing impurity is implanted through the local interconnect layer into semiconductor substrate material therebeneath.
In one implementation, field isolation material regions and active area regions are formed on a semiconductor substrate. A trench is etched into the field isolation material into a desired line configuration. A conductive material is deposited to at least partially fill the trench and form a conductive line therein.
In one implementation, integrated circuitry comprises a semiconductor substrate comprising field isolation material regions and active area regions. A conductive line is received within a trench formed within the field isolation material.
Other implementations are disclosed, contemplated and claimed in accordance with the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
FIG. 1 is a diagrammatic sectional view of a semiconductor wafer fragment at one processing step in accordance with the invention.
FIG. 2 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 1 .
FIG. 3 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 2 .
FIG. 4 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 3 .
FIG. 5 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 4 .
FIG. 6 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 5 .
FIG. 7 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 6 .
FIG. 8 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 7 .
FIG. 9 is a view of the FIG. 1 wafer at a processing step subsequent to that shown by FIG. 8 .
FIG. 10 is a diagrammatic sectional view of an alternate embodiment semiconductor wafer fragment at one processing step in accordance with the invention.
FIG. 11 is a view of the FIG. 10 wafer at a processing step subsequent to that shown by FIG. 10 .
FIG. 12 is a view of FIG. 11 taken through line 12 — 12 in FIG. 11 .
FIG. 13 is a view of the FIG. 10 wafer at a processing step subsequent to that shown by FIG. 11 .
FIG. 14 is a view of FIG. 13 taken through line 14 — 14 in FIG. 13 .
FIG. 15 is a view of the FIG. 10 wafer at a processing step subsequent to that shown by FIG. 13 .
FIG. 16 is a view of FIG. 15 taken through line 16 — 16 in FIG. 15 .
FIG. 17 is a diagrammatic sectional view of another alternate embodiment semiconductor wafer fragment at one processing step in accordance with the invention, and corresponds in sequence to that of FIG. 16 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
Referring to FIG. 1, a semiconductor wafer in process is indicated generally with reference numeral 10 . Such comprises a bulk monocrystalline silicon substrate 12 . In the context of this document, the term “semiconductor substrate” is defined to mean any construction comprising semiconductive material, including, but not limited to, bulk semiconductive materials such as a semiconductive wafer (either alone or in assemblies comprising other materials thereon), and semiconductive material layers (either alone or in assemblies comprising other materials). The term “substrate” refers to any supporting structure, including, but not limited to, the semiconductor substrates described above.
A gate dielectric layer 14 , such as silicon dioxide, is formed over semiconductor substrate 12 . A conductively doped semiconductive layer 16 is formed over gate dielectric layer 14 . Conductively doped polysilicon is one example. An insulative capping layer 18 is formed over semiconductive layer 16 . An example material is again silicon dioxide. Intervening conductive layers, such as refractory metal silicides, might of course also be interposed between layers 16 and 18 . An etch stop layer 20 is formed over insulative capping layer 18 . An example preferred material is polysilicon.
Referring to FIG. 2, the above-described layers over substrate 12 are patterned and etched into a plurality of exemplary transistor gate lines 22 , 24 and 26 . Lines 22 , 24 and 26 have respective opposing sidewalls 27 and 28 , 29 and 30 , and 31 and 32 . Lines 22 , 24 and 26 are shown in the form of field effect transistor gates, although other conductive lines are contemplated. LDD implant doping is preferably conducted to provide illustrated implant regions 33 for the transistors. One example implant dose for regions 33 would be 2×10 13 ions/cm 2 . Alternately, the LDD implant doping can implanted after source/drain regions have been formed (or a combination of both). Forming LDD regions later in the process reduces the D t seen by such implants.
Referring to FIG. 3, an insulating layer 34 is deposited over substrate 12 and lines 22 , 24 and 26 . The thickness of layer 34 is preferably chosen to be greater than that of the combined etch stop layer, capping layer and semiconductor layer, and to be received between the transistor gate lines to fill the illustrated cross-sectional area extending between adjacent gate lines. Example and preferred materials include undoped silicon dioxide deposited by decomposition of tetraethylorthosilicate, and borophosphosilicate glass.
Referring to FIG. 4, insulative material layer 34 has been planarized. Such is preferably accomplished by chemical-mechanical polishing using etch stop layer 20 of gates 22 , 24 and 26 as an etch stop for such polishing.
Referring to FIG. 5, a layer of photoresist 36 has been deposited and patterned. Insulative material 34 is etched to effectively form contact openings 38 , 39 and 40 therein to proximate substrate 12 , and preferably effective to outwardly expose material of semiconductor substrate 12 . For purposes of the continuing discussion, the exposed portions of semiconductor substrate 12 are designated as locations 42 , 43 and 44 . The depicted etching constitutes but one example of etching insulating layer 34 proximate lines 22 and 24 along at least a portion of facing sidewalls 28 and 29 . Such portion preferably comprises a majority of the depicted sidewalls, and as shown constitutes the entirety of said sidewalls to semiconductor substrate 12 .
With respect to line 26 , the illustrated insulating layer 34 etching is conducted along at least a portion of each of opposing line sidewalls 31 and 32 . Further with respect to lines 22 and 24 , such etching of insulating layer 34 is conducted along portions of sidewalls 28 and 29 , and not along the respective opposing sidewalls 27 and 30 . Further, such insulating layer 34 etching exposes conductive material of at least one of the transistor gates, with such etching in the illustrated example exposing conductive material 16 of sidewalls 28 , 29 , 31 and 32 of the illustrated transistor gates. Further with respect to gate lines 22 and 24 , the insulative material is etched to remain/be received over the one sidewalls 27 and 30 , and not sidewalls 28 and 29 .
After etching of layer 34 , at least one of the exposed sidewalls is covered with insulating material. Such preferably comprises deposition of an insulating layer 46 over substrate 12 ; lines 22 , 24 and 26 ; and planarized and etched insulative material 34 to a thickness which less than completely fills at least some of the contact openings. Such layer preferably comprises a spacer forming layer, with silicon dioxide and silicon nitride being but two examples.
Referring to FIG. 7, spacer forming layer 46 is anisotropically etched to form insulative sidewall spacers 47 , 48 , 49 , 50 and 52 . Such constitutes but one example of forming the illustrated insulative sidewall spacers. In one implementation, insulating layer 34 is received between at least one of the sidewalls and one of the sidewall spacers, for example as shown with respect to line 24 between sidewall 30 and spacer 49 . Further with respect to this example line 24 , insulative material 34 is received between the one sidewall 30 and the one insulative spacer 49 formed thereover, and is not received between the opposing sidewall 29 and the other spacer 48 formed thereover. Yet, in the depicted section, insulative sidewall spacers 48 and 49 , and 50 and 52 are formed over each of the respective opposing line sidewalls of lines 24 and 26 , wherein in the depicted section only one insulative spacer 47 is formed over one sidewall of line 22 . Further, insulative material 34 received between sidewall 30 and insulative spacer 49 of line 24 has a maximum lateral thickness which is greater than or equal (greater as shown) to a maximum lateral thickness of sidewall spacer 49 . Source/drain implanting may occur at this point in the process, if desired.
Referring to FIG. 8, a local interconnect layer 56 is deposited to overlie at least one of the transistor gates, and ultimately interconnect locations 42 , 43 and 44 of substrate 12 , and is thus provided in electrical connection therewith. An example preferred material for layer 56 is polysilicon. Due to the spacing constraints between the insulative spacers of lines 22 and 24 versus that of lines 24 and 26 , layer 56 completely fills contact opening area 38 and less than completely fills contact opening areas 39 and 40 .
Depending on the circuitry being fabricated and the desires of the processor, layer 56 might be in situ conductively doped as deposited and/or separately implanted with conductivity enhancing impurity subsequent to deposition. Further, any such subsequent implantings might be masked to only be provided within portions of layer 56 where, for example, both n-type and p-type substrate regions are being conductively connected by an ultimately conductive interconnect formed from layer 56 . Most preferably, interconnect layer 56 will ultimately comprise suitably conductively doped semiconductive material. Where such will comprise both n-type and p-type doping material, another conductive strapping layer, such as a refractory metal silicide, will ideally be formed atop layer 56 to avoid or overcome an inherent parasitic diode that forms where p-type and n-type materials join. Further with respect to combined n-type and p-type processing, multiple local interconnect layers might be provided and patterned, and perhaps utilize intervening insulative layers, spacers or etch stops. Further prior to deposition of layer 56 , a conductive dopant diffusion barrier layer might also be provided.
Example preferred implantings, whether p-type, n-type, or a combination of the same, is next described still with reference to FIG. 8 . Such depicts two preferred implantings represented by peak implant locations or depths 58 and 60 . Such are preferably accomplished by two discrete implantings which provide peak implant location 60 deeper relative to layer 56 than implant 58 . For example within layer 56 in contact openings 38 and 39 , regions of layer 56 are shown where peak implant 60 is deeper within layer 56 than is peak implant 58 . Yet, the peak implant location or depth for implant 60 is preferably not chosen to be so deep to be within conductively doped material 16 of lines 22 , 24 and 26 . Further in contact opening locations 39 and 40 , the implanting to produce depicted implant 60 is conducted through local interconnect layer 56 and into semiconductor substrate material 12 therebeneath. Diffusing of the conductivity enhancing impurity provided within layer 56 might ultimately occur from local interconnect layer 56 into semiconductor substrate material 12 therebeneath within locations 42 , 43 and 44 to provide the majority of the conductivity enhancing impurity doping for the source/drain regions of the illustrated transistor lines. Depending on the processor's desire and the degree of diffusion, such source/drain regions might principally reside within semiconductor substrate material 12 , or reside as elevated source/drain regions within layer 56 .
Further and as shown, layer 56 in certain locations acts as a spacer for the deeper implant. Further, such may actually reduce junction capacitance by counter doping halo implants that are further away from gate polysilicon. This can provide flexibility in the settings of the halo implants.
Referring to FIG. 9, local interconnect layer 56 is formed (i.e., by photopatterning and etching) into a local interconnect line 57 which overlies at least portions of illustrated conductive lines 24 , 26 and 28 , and electrically interconnects substrate material locations 42 , 43 and 44 .
Further considered aspects of the invention are next described with reference to FIGS. 10-16. FIG. 10 illustrates a semiconductor wafer fragment 10 a comprising a bulk monocrystalline silicon substrate 12 . Semiconductor substrate 12 has been patterned to form field isolation region 64 and active area region 62 . In the illustrated example, material 66 of field isolation region 64 comprises silicon dioxide fabricated by LOCOS processing. Such might constitute other material and other isolation techniques, for example trench and refill resulting from etching trenches into substrate 12 and depositing oxide such as by CVD, including PECVD.
Fragment 10 a in a preferred and exemplary embodiment comprises an extension of fragment 10 of the first described embodiment, such as an extension in FIG. 10 starting from the far right portion of FIG. 4 of the first described embodiment. Accordingly, insulating layer 34 is shown as having been deposited and planarized.
Referring to FIGS. 11 and 12, a trench 68 is etched into field isolation material 66 and is received within insulating layer 34 . Such includes opposing insulative sidewalls 77 and a base 79 . Trench 68 in this illustrated example extends to an edge 70 of isolation material 66 proximate, and here extending to, active area substrate material 12 of region 62 . An example preferred depth for trench opening 68 is 10% to 20% greater than the combined thickness of the conductive and insulating materials of gate stacks 22 , 24 and 26 .
Referring to FIGS. 13 and 14, a conductive material 72 is deposited to at least partially fill trench 68 , and electrically connects with substrate material 12 of active area region 62 . As shown, material 72 is preferably deposited to overfill trench 68 . The width of trench 68 is preferably chosen to be more narrow than double the thickness of layer of material 72 . Such preferred narrow nature of trench 68 facilitates complete filling thereof with conductive material 72 in spite of its depth potentially being greater than the globally deposited thickness of layer 72 .
Referring to FIGS. 15 and 16, conductive layer 72 has been etched to produce the illustrated local interconnect line 75 which includes a line segment 76 received within trench 68 over isolation material 66 . A small degree of overetch preferably occurs as shown to assure complete removal material 72 from over the outer surface of insulating layer 34 . Ideally, the shape of trench 68 is chosen and utilized to define the entire outline and shape of the conductive line being formed relative to isolation material 66 . Further, conductive material of line 75 preferably contacts material 66 of trench sidewalls 77 and base 79 .
FIG. 17 illustrates an exemplary alternate wafer fragment 10 b embodiment corresponding to FIG. 16, but using a trench isolation oxide 66 b as opposed to LOCOS oxide 66 . An exemplary preferred trench filled line 68 b is shown.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | A method of fabricating integrated circuitry comprises forming a conductive line having opposing sidewalls over a semiconductor substrate. An insulating layer is then deposited and planarize polished using an outer etch stop cap of the line as an etch stop. The insulating layer is etched proximate the line along at least a portion of at least one sidewall of the line. An insulating spacer forming layer is then deposited over the substrate and the line. It is anisotropically etched to form an insulating sidewall spacer. Methods of forming conductive lines and methods of forming local interconnects, as well as other methods of forming integrated circuitry, are disclosed and claimed. | 7 |
FIELD AND BACKGROUND OF INVENTION
[0001] This invention relates to a head and hair cover, a hair scarf and related items. The invention has particular advantage when used by people having long hair, and is designed to cover the head, and contain the person's hair, during sleep, as protection or for sanitary purposes during working, or in such other applications as may be beneficial.
[0002] The use of hair covers, hair scarves and hair ties are well known in the prior art. Hair scarves and ties can range widely in variety from the most simple forms, such as clips, elastic bands, barrettes, or the like, for keeping the hair in the desired place, to more elaborate forms of head covers intended to cover part of the head and/or keep the head covered. Such hair covers may be used by workers operating dangerous machinery in which the hair could be become ensnared and thus pose a danger to the individual, or by others, such as those in the service industry, such as at restaurants where personnel handling food may be required, for health and sanitary reasons, to keep their hair covered.
[0003] An example of a hair scarf or tie shown in the prior art is illustrated in U.S. Pat. No. 5,878,756 (Bilodeau). In this patent, there is disclosed an athletic hair tie having a distinct cap portion, which is attached to a hair sleeve 20 . The cap portion fits over the head, while the sleeve portion, including a plurality of tabs, keeps the hair in place. Means for securing the cap portion snugly on the head of the user are provided.
[0004] Other types of head gear for containing the hair are also known, such as simple donned caps with elasticized edges, which can be fitted over the head and will remain there due to the elasticity properties about the periphery.
SUMMARY OF THE INVENTION
[0005] In one aspect, the present invention is for a head and hair cover which may be easy to put on and remove, is adjustable in various manners for maximum comfort, and is intended to cover the hair without deforming it or squashing it in an undesirable manner.
[0006] Preferably, the head and hair cover of the invention is a continuously configured tube-like structure, having a head portion which is easily adjustable and variable to provide a comfortable fit, and a hair portion continuous therewith which accommodates the hair, preferably in a manner which would interfere as little as possible with the hair style or shape.
[0007] The head and hair cover of the invention is preferably comprised of a soft, light-weight fabric, and may preferably be slightly expandable so that it will not compress the hair or head of the user.
[0008] According to one aspect of the invention, there is provided a head-hair cover comprising: a body defining a chamber; an opening in the body, the opening having a peripheral edge and permitting communication between the chamber and outside of the cover; adjustment means at or near the peripheral edge for selectively varying the dimensions of the opening; and constricting means associated with the peripheral edge for gently crimping at least a portion of the peripheral edge.
[0009] Preferably, the body is formed of two lateral panels stitched together along their respective peripheral edges, the opening being defined by corresponding portions of the peripheral edges of the two lateral panels which remain unattached. The body may comprise a head portion, in which the opening is located, and a hair containing portion therebelow.
[0010] In a preferred embodiment, the cover has a body which is comprised of a soft, elasticized fabric.
[0011] Preferably, the adjustment means comprises a channel formed by a hem along at least a portion of the peripheral edge of the opening, and a cord extending from inside the channel to the outside thereof, the arrangement of the cord relative to the channel being adjustable to vary the dimensions of the opening.
[0012] The constricting means may comprise a length of elastic band along at least a portion of the peripheral edge for crimping the peripheral edge over the portion thereof at which it is located.
[0013] In another embodiment, the body is formed as a single piece to define the chamber and has a cut therein in the upper portion of the body to define the opening.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a side view of the head and hair cover of the invention;
[0015] [0015]FIG. 2 is a perspective view of the head and hair cover of the invention as shown in FIG. 1, in an open position and illustrating the various components thereof;
[0016] [0016]FIG. 3 is a front view of the head and hair cover of the invention shown in FIG. 1 of the drawings; and
[0017] [0017]FIG. 4 is a side view of one of the panels of the head and hair cover of the invention as shown in FIG. 1 of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0018] With reference to the drawings, there is shown various perspectives of a head and hair cover in accordance with the present invention. The head and hair cover contains a number of features which facilitate putting on the cover, and adjusting it in a manner which is comfortable, and assumes the shape of the user's head and hair. The head and hair cover of the invention is intended to keep the hair contained therewithin, but without disturbing the style of the hair.
[0019] The head and hair cover of the invention may be used in a number of contexts. It may be used when sleeping to keep the hair from spreading or losing its shape, or it may be used as a sanitary cover (such as when the user is preparing food), or a protector when the user is operating machinery in which the hair may become entangled, thus posing a danger to the user.
[0020] [0020]FIG. 1 of the drawings shows a side view of the head and hair cover 10 in accordance with the invention. The cover 10 is essentially comprised of two identical panels, which are mirror images of each other. Thus, there is provided a first lateral panel 14 and a second lateral panel 16 (clearly illustrated in FIG. 3 of the drawings), the two panels 14 and 16 being of substantially identical shape, and overlying each other.
[0021] Each panel 14 and 16 comprises a back edge 18 , a base edge 20 , and a front edge 22 . Each of the first and second lateral panels 14 and 16 is comprised of preferably a soft and light-weight fabric, such as nylon, polyester, cotton and the like, although any suitable material may be used. Further, a preferred embodiment of the invention would be one where each of the first and second lateral panels 14 and 16 is comprised, at least in part, of a material which has some elastic properties, so that it is capable of, at least to a small extent, expanding and contracting back to its normal size depending upon use requirements.
[0022] Each of the first and second lateral panels 14 and 16 is connected to each other preferably by stitching along the back edge 18 thereof, from approximately point 24 to the point 26 . Further, the base edges 20 of each of the first and second lateral panels 14 and 16 are also connected to each other, preferably by stitching, between the points 26 and 28 . With respect to the front edge 22 , the first and second lateral panels 14 and 16 are partially attached to each other, once more preferably by stitching. The front edges 22 of the first and second lateral panels 14 and 16 are attached to each other between the point 28 , near the base edge 20 , and the point 30 , about midway up the length of the front edge 22 . Therefore, it will be appreciated that the first and second lateral panels 14 and 16 are sewn together along substantially their entire periphery, from point 24 to 26 , point 26 to 28 , and point 28 to 30 . However, the front edge 22 of the first and second lateral panels 14 and 16 respectively remains unattached between points 24 and 30 , creating an opening 34 . The opening 34 provide access to a chamber 36 , which is of a generally tube-like shape.
[0023] The opening 34 is defined by first peripheral edge 38 , which forms part of the front edge 22 of the first lateral panel, and the second peripheral edge 40 , which forms part of the front edge 22 of the second lateral panel 16 .
[0024] Each of the first and second peripheral edges 38 and 40 comprises a hem 44 , each hem 44 having a sealed or closed end 46 and an open end 48 . The hem 44 defines a channel 50 between the sealed end 46 and open end 48 respectively. A cord 52 , which generally comprises a fabric strip, is located within the channel 50 , and has one inside end 54 fastened near the sealed end 46 . The inside end 54 is preferably fastened near the sealed end by appropriate stitching. The cord 52 extends through the channel 50 , through the open end 48 , so that outside portion 56 of the cord 52 hangs loosely. The outside portion 56 of each cord 52 along the first and second peripheral edges 38 and 40 respectively can be used, as will be described in further detail below, to tighten or loosen the cover 10 , thereby varying the size of the opening 34 so as to be customized and comfortable for the user.
[0025] The first peripheral edge 38 and second peripheral edge 40 each have an elastic band 60 extending therealong from points 62 and 64 respectively down to the point 30 . The elastic bands 60 are sewn along the peripheral edges 38 and 40 , or may be contained within a hem formed along this portion of the edge. It is not important to the invention exactly how the elastic band 60 is fastened along the edge, only that it is present. The purpose of the elastic band 60 is to provide a light pressure, tending to gather or fold slightly the peripheral edges 38 and 40 along the length at which they, the elastic bands 60 , are located, providing a small, but comfortable and effective, pressure tending to close the opening 34 . As will be described below, the elastic band 60 , together with the cords 52 , provide an advantageous mechanism for adjusting the size of the opening 34 to the precise requirements of the wearer.
[0026] In use, the cover 10 of the invention is designed and configured to carefully hold the hair, and to fit about the head in a comfortable and proper location. This is achieved by the overall configuration of the cover 10 , as well as the features defining the opening 34 , and the mechanisms for adjusting the size of the opening 34 to desired dimensions.
[0027] In use, the wearer's hair is carefully lifted and inserted through the opening 34 so that it will be contained within the chamber 36 . The size of the chamber 36 can, of course, be determined according to the size and shape of the first and second lateral panels 14 and 16 . These panels 14 and 16 can therefore be cut and dimensioned in different ways, to suit the needs of different users. The hair passed through the opening 34 and into the chamber 36 will remain there, and, depending upon the length of the hair, may extend all the way to the base edge 20 , or it may simply hang without the ends touching the base edge 20 .
[0028] The cover 10 is therefore essentially divided into a head portion 68 and a hair container portion 70 . The hair, when passing through the opening 34 , enters the head portion 68 of the chamber 36 , and then, according to the length of the hair, will fall, to some extent or another, within the hair container portion 70 .
[0029] The cover 10 is then pulled over the head such that the point 24 is approximately on the forehead of the wearer, while the point 30 rests more or less on the back of the neck of the wearer. The first and second peripheral edges 38 and 40 extend from the forehead, across the cheeks, either in front or behind the ears, and towards the back of the neck. FIG. 3 of the drawings shows in phantom outline the face 74 of the user relative to the cover 10 .
[0030] The cover 10 remains comfortable on the head, and the tightness thereof, and particularly the opening 34 , can be adjusted. First, the elastic band 60 tends to crimp or fold the peripheral edges 38 and 40 so as to draw the opening 34 tightly around the head and face. However, the cover 10 is still loose enough, and can be elastically extended, so as to make the opening 34 bigger or smaller for putting on or removing. In addition, the user is able to pull the cord 52 along the first and second peripheral edges 38 and 40 , thus gathering the hem 34 and thereby constricting the opening 34 until a comfortable sized opening 34 has been achieved. At that point, the outside portions 56 of the cord 52 are knotted or bowed to keep the cords held and tensioned in the desired position.
[0031] Thus, between the operation of the elastic bands 60 , and the cords 52 , appropriately joined and connected to each other, the size of the opening 34 can be carefully and comfortably adjusted by the user.
[0032] While the cover 34 worn, the hair is contained within the soft and somewhat elasticized lateral panels 14 and 16 , and the hair is able, to a large extent, to hang substantially naturally within the hair container portion 70 . One potential advantage of the cover 10 is therefore that the hair will not be flattened or pressed into undesired positions by the action of the cover 10 , which, in one embodiment, essentially surrounds and contains the hair without significantly altering its position.
[0033] Variations of the invention are possible. For example, instead of having first and second lateral panels 14 and 16 , a single piece may be used, and stitched together, or molded as a tube, to the desired shape. Further, the elastic bands 60 may not necessarily be only, or even, at the lower portion of the opening 34 , but can be effectively located at one or more points along the periphery of the opening. Further still, the cords 52 may be near the bottom of the opening, or at the side thereof, rather than at the top. The cords may also be kept together and fastened by means of a clip or other device instead of the requirement that they be knotted or tied by their loose ends only.
[0034] Further, the position of the cords 52 and elastic band 60 may be reversed, so that the elastic is at the top, and the cords at the bottom. | A head-hair cover comprises a body defining a chamber and an opening in the body. The opening has a peripheral edge and permits communication between the chamber and outside of the cover. An adjustment mechanism is provided at or near the peripheral edge for selectively varying the dimensions of the opening. Additionally, a constricting band is provided and associated with the peripheral edge for gently crimping at least a portion of the peripheral edge. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to plug containers and more particularly, but not by way of limitation, to a compact plug container having a split-ring retained, splined coupling for connecting with a casing collar adaptor.
One operation which is often conducted during the completion of an oil or gas well is a cementing operation wherein fluid cement is pumped down the central bore of a well casing and out around the bottom of or the side of the well casing into an annulus between the well casing and the oil well borehole where the cement is allowed to harden to provide a seal between the well casing and the well borehole.
At the beginning of a typical cementing job, in rotary drilled wells, the well casing and the well borehole are usually filled with drilling mud. To reduce contamination at the interface between the drilling mud and the cement which is pumped into the well casing on top of the drilling mud, a bottom cementing plug is pumped ahead of the cement slurry so that the interface between the cement slurry and the drilling mud already in the well casing is defined by the bottom cementing plug.
As the cement is pumped into the well casing, the bottom cementing plug is pumped down the well casing. As it travels, the plug wipes mud from the walls of the casing ahead of the cement slurry, thereby reducing dilution of the cement slurry. When this bottom cementing plug reaches a predetermined plug stop, generally a float collar or float shoe located in a portion of the well casing, the bottom cementing plug seats and the differential pressure due to the high pressure cement located above the bottom cementing plug ruptures a diaphragm of the bottom cementing plug to allow the cement slurry to proceed down through the plug and then through the appropriate ports into the annulus between the well casing and the borehole.
At the completion of the mixing of the cement slurry, a top cementing plug is pumped into the well casing to similarly define an interface between the upper level of the cement slurry within the well casing and displacement fluid which is pumped in on top of the cement slurry. This top cementing plug is solid and when it is pumped to a pressure shut-off, the displacement of cement is terminated.
It is desirable to be able to place the cementing plugs in the well casing without opening the well casing. In such a situation, a plug container is mounted on top of the well casing. This plug container holds one or more of the cementing plugs and includes a mechanical retaining means which keeps the plugs from entering the well casing until the desired time.
Prior types of such plug containers have central bodies for holding one or more plugs, which bodies can have a plurality of ports for receiving the cement flows either above or below the positions where the plugs are held. These prior types of plug containers generally have casing adapters which are either threaded or integrally formed with the main bodies of the plug containers. The free ends of these adapters are threaded or clamped to the casing for connecting the plug container to the casing. Some prior types of plug containers have plug-receiving chambers with internal diameters which are greater than the outer diameters of the plugs retained within the chambers. Some prior art plug containers have internally threaded end plugs with pressure-energized seals and solid plug abutments. These end plugs, or caps, permit ready access to the internal chamber of the plug container such as for placing a plug therein or for connecting another plug container thereto.
Although there are prior art types of plug containers which include one or more of the aforementioned features, I am not aware of any plug container which combines each of these features in a single compact, versatile plug container. Furthermore, I am not aware of any such plug container which also enables the casing adapter to be quickly connected in a splined, clamped relationship to the main body of the plug container. Because plug containers can be bulky and hard to handle, there is the need for such a compact, versatile plug container which can be readily used at a well site.
SUMMARY OF THE INVENTION
The present invention meets the aforementioned needs by providing a novel and improved plug container which has a splined, clamped coupling with a casing adapter. Furthermore, the present invention has a relatively large diameter chamber or cavity for receiving a plug so that the fluid within the cavity can circulate around the plug without the need for an external bypass mechanism. The present invention also has an internally threaded end plug or cap with pressure-energized seals. This cap has a plug abutment with an opening therethrough for pressure equalization to preclude the development of a pressure differential which could prevent the plug from moving out of the plug container into the casing at the appropriate time. The present invention also has two ports for connecting in a manifold configuration with fluid sources, such as from a fluid cement source. These features provide in the present invention a compact, versatile plug container which can be quickly connected with a variety of casing adapters. In particular, the preferred embodiment of the present invention provides a short, light-weight plug container for medium duty pressure service.
Broadly, the present invention provides a plug container for holding a plug having an outer diameter. The plug container comprises housing means for receiving the plug, casing adapter means for engaging with a casing, and a split ring retainer means for releasably connecting the casing adapter means with the housing means. More particularly, the housing means has first spline means associated with an end thereof and the casing adapter means has second spline means for coupling with the first spline means.
The housing means also has an open end opposite the first spline means. The plug container further comprises closure means for closing the open end of the housing means. The closure means includes a closed outer wall, a central wall extending across and transverse to the outer wall, and an interior wall extending from the central wall to an end surface of the interior wall. When the plug is disposed in the housing means, it can abut the end surface. To prevent this abutment from establishing a pressure seal, the interior wall has an opening defined therethrough so that the pressure within an interior region defined by the interior wall is equalized with the pressure adjacent the exterior of the interior wall.
The housing means also has an interior surface defining a chamber in which the plug is disposed. The chamber has a diameter larger than the outer diameter of the plug so that fluid and pressure can pass between the interior surface of the housing means and the exterior of the plug.
The housing means also has associated therewith two ports for connecting with a fluid source containing a fluid to be pumped through the plug container into the well.
Therefore, from the foregoing, it is a general object of the present invention to provide a novel and improved plug container. Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art when the following description of the preferred embodiment is read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1B form a sectional view of the preferred embodiment of the present invention shown oriented as it would be connected to the casing in a well.
FIG. 2 is a sectional view of the split-ring retainer collar of the preferred embodiment of the present invention taken along line 2--2 shown in FIG. 1B.
FIG. 3 is a sectional view taken along line 3--3 shown in FIG. 1B.
FIG. 4 is an end view of the splined end of the illustrated plug container housing.
FIG. 5 is an end view of the splined end of the illustrated casing adapter member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference initially to FIGS. 1A-1B, a plug container 2 constructed in accordance with the preferred embodiment of the present invention will be described. Broadly, the plug container 2 comprises a housing 4 for receiving a plug (not shown) having an outer diameter of a type as known to the art. The plug container 2 also includes a casing adapter member 6 which is connected to the housing 4 by a clamp mechanism 8. A closure means 10 is also associated with the housing 4. Sealing means as subsequently described are used between the housing 4 and the casing adapter member 6 as well as between the housing 4 and the closure means 10.
The housing 4 of the preferred embodiment comprises a substantially cylindrical member having an internally threaded box end portion 12 connected to a flanged, splined end portion 14 by means of an integral side wall 16. The side wall 16 has a cylindrical inner surface 18 defining a plug-receiving chamber or cavity having a constant diameter 20 through the length thereof between the box end portion 12 and the flanged, splined end 14. The diameter 20 is larger than the outer diameter of the plug which is to be disposed, via the open end of the box end portion 12, in the cavity defined by the inner surface 18; therefore, this larger diameter defines an annular flow space between the plug and the side wall. This significantly larger inner diameter of the plug container body makes the cementing plug free-fitting, thereby allowing pressures to always be equalized across the plug without the need of an external bypass mechanism which would make the device less compact. This larger diameter also makes the loading of the cementing plug through the open end of the box end portion 12 easier.
The splines of the flanged, splined end portion 14 are more clearly shown in FIG. 4. The end portion 14 is shown in FIG. 4 as including two outwardly extending splines 22, 24 which are circumferentially spaced diametrically opposite each other by two spline-receiving sections 26, 28. Extending radially inwardly from the spline portions 22, 24, 26, 28 are an annular circumferential shoulder 30 and an annular circumferential shoulder 32 disposed longitudinally or axially back from the shoulder 30 as viewed in FIG. 4.
The side wall 16 has a longitudinal slot 34 defined therein for receiving an indicator mechanism of a type as known to the art for indicating when the plug has been released from the plug container 2. The side wall 16 also has three openings 36, 38, and 40 defined therein.
The openings 36, 38 form part of the manifolding structure of the present invention. That is, the opening 36 has an externally threaded sleeve 42 coaxially retained in a countersunk exterior portion of the opening 36 by means of a weld bead 44, and the opening 38 has an externally threaded sleeve 46 coaxially associated therewith by means of a weld bead 48. The sleeves 42, 46 enable the plug container 2 to be connected to a fluid source, such as a source of liquid cement which is to be pumped through the plug container 2 into the casing to which the plug container 2 is connectible. The flow can be either through the sleeve 42, whereby the fluid would flow on top of a plug contained in the cavity defined by the inner surface 18, or through the sleeve 46, whereby the fluid would enter the plug container 2 below the plug. The port members provided by the openings 36, 38 and their respective sleeves 42, 46 extend transversely through the side wall 16. The inclusion of this manifold capability in the present invention allows the cementing plug to be pumped out of the plug container 2 without rigging an additional line to the plug container 2. Therefore, cementing plugs may be easily launched under all conditions, such as from conventional casing jobs where the vacuum created by the falling cement is sufficient to launch the plug to bull-head squeeze jobs where the cementing head may be under high pressure and the plug must be pumped out of the head by necessity.
The opening 40 of the side wall 16 also extends transversely through the side wall 16 and provides an aperture through which a plug release plunger mechanism 50 of a type as known to the art can extend into the cavity of the plug container 2. The mechanism 50 is threadedly connected to a sleeve member 52 welded at 54 to the side wall 16 in coaxial relationship with the opening 40. The mechanism 50 includes a movable pin member or plunger 56 which is moved transversely into and out of the cavity defined in the plug container 2 by means of a rotatable wheel handle 58 as known to the art. Although not shown in the drawings, the mechanism 50 has a conventional flipper-type plug release indicator associated therewith to give a visual indication that the cementing plug has been launched successfully when the pin 56 is retracted from its position shown in FIG. 1B through the opening 40 whereby the plug retained thereabove is released. This conventional flipper-type plug release indicator is disposed in association with the slot 34. It is to be noted that the plug release mechanism can be of any suitable type which may be either locally or remotely controllable. The plug release indicator can also be of any suitable type, such as the aforementioned flipper-type, or a rotary wheel type, or an electromechanical type, for example.
The cylindrical plug retaining body provided by the housing 4 is connected to the casing adapter member 6 at the flanged, splined end 14. FIG. 1B shows that the casing adapter member 6 has a substantially cylindrical side wall 58 having an externally threaded lower end portion 60. The threaded portion 60 of the preferred embodiment couples with a casing collar of a type as known to the art. Generally, the end portion 60 can be of any suitable construction for connecting with casing either having a casing collar (such as by the illustrated threaded configuration or by a coupling device of the type disclosed in U.S. patent application Ser. No. 374,869, filed May 4, 1982, and assigned to the assignee of the present invention) or not having a collar (such as in flush joint casings).
At the opposite end of the casing adapter member 6 there is defined by the side wall 58 a splined end portion 62. The configuration of this portion is more particularly illustrated in FIG. 5. FIG. 5 shows the end portion 62 has two outwardly extending splines 64, 66 circumferentially spaced diametrically opposite each other. Disposed between the splines 64, 66 are spline-receiving sections 68, 70. Extending axially outwardly from, or in front of, the sections 64, 66, 68, 70 (as viewed in FIG. 5) are a neck portion 72 having an end surface 74 and having an intermediate shoulder defined by a radial circumferential surface 76. The end portion 62 is configured for mating engagement with the flanged, splined end portion 14 of the housing 4. More particularly, the spline 22 and the spline 24 of the housing end portion 14 are received in the portions 68, 70, respectively, of the casing adapter member 6. The splines 64, 66 of the casing adapter member 6 are received in the portions 28, 26, respectively, of the housing end portion 14. The neck portion 72 of the casing adapter member 6 is received in the throat of the housing end portion 14 so that the end surface 74 abuts the receiving shoulder 32 of the housing end portion 14. This relationship is illustrated in FIG. 1B.
The casing adapter member 6 can be of any suitable construction so that the housing 4 can be connected with a selectable one of a plurality of members 6 depending upon the type of casing thread to which the plug container 2 is to be connected. So that such connections with different casing adapter members can be easily accomplished, the aforementioned splined construction is used in combination with the clamp means 8 construction. Additionally, the splined construction enables torque applied to the housing 4 to be transferred to the casing adapter member 6.
The clamp means 8 secures the flanged, splined end portion 14 with the splined end portion 62 (which end portion is also flanged) so that the mating splines are securely retained relative to each other. In the preferred embodiment the clamp means 8 includes a split ring retainer mechanism 78 shown in FIG. 2. Although split ring retainer mechanisms of the type disclosed herein are known and have been used to hold slip rings with packers, for example, I am not aware of a split ring retainer mechanism combined with a plug container housing and casing adapter member as disclosed herein.
Although the split ring retainer mechanism can be of any suitable type including two or more members (preferably of identical shape and size), the split ring retainer mechanism 78 of the preferred embodiment includes three arcuate members 80, 82, 84. Each arcuate member has two end surfaces, each of which abuts a respective end surface of one of the other arcuate members. Considering the arcuate member 80, for example, FIG. 2 shows that this member has an end surface 86 having two threaded openings, one of which is shown in FIG. 2 and identified by the reference numeral 88. The arcuate member 80 includes another end surface 90 having two shank-receiving opening defined therein, one of which is shown in FIG. 2 and identified by the reference numeral 92. The arcuate member 80 includes an outer surface 94 having a countersunk opening 96 defined therein in communication with the shank-receiving opening 92. The arcuate member 80 also includes an inner surface 98 having a groove or notch defined therein (see FIG. 1B for a similar groove or notch 100 in the arcuate member 84). The groove or notch 100 is sized for receiving the coupled flanged portions of the end portions 14, 62 as illustrated in FIG. 1B. The other two arcuate members 82, 84 are similarly constructed. FIG. 1B shows shank-receiving openings 102, 104 of the arcuate member 84. The shank-receiving opening 102 communicates with a countersunk opening 106 and the threaded opening 88 as illustrated in FIG. 2.
To hold the arcuate members together, the clamp means 8 of the preferred embodiment further includes at least three bolt means which are disposed through respective countersunk openings, shank-receiving openings, and threaded openings of adjacent ones of the arcuate members 80, 82, 84. Three of these bolt means are shown in FIG. 2 as standard hex-head bolts 108, 110, 112. Three other similar bolts are used in the preferred embodiment in corresponding openings lying in front of those shown in FIG. 2, which other openings include the shank-receiving opening 104 shown in FIG. 1B.
The foregoing constructions of the housing end portion 14, the end portion 62 of the casing adapter member 6 and the clamp means 8 provide the plug container 2 of the present invention with an interchangeable pin end or casing adapter end which permits converting from one type of casing thread or connector to any other oil field casing thread or connector by simply changing the casing adapter member 6 rather than using changeover couplings in those situations where that is permitted or rather than having a different plug container to fit each casing thread or connector. This present coupling arrangement also permits the economical replacement of a casing thread in the field should the casing adapter member 6 become damaged or excessively worn. Such changes can be readily effected because of the split-ring clamp mechanism of the present invention which replaces the threaded or integral connections of the prior art. Additionally, by having the housing end portion 14 and the casing adapter end portion 62 splined so that they rotate with each other, the casing adapter member 6 may be tightened into and broken out of the casing by applying torque through the plug container body. This construction also provides a means for reducing or minimizing the length of the plug container 2.
At the end of the housing 4 opposite the splined end 14, the closure means 10 provides a removable cap for closing or opening the box end portion 12. The closure means 10 of the preferred embodiment includes a hollow cylindrical outer wall 114 having an externally threaded surface for threadedly engaging with the internally threaded surface of the box end portion 12. The wall 114 has an interior surface 116 radially inwardly offset from another surface 118 by a radial annular shoulder surface 120. The wall 114 is circumferentially closed except for openings 122 defined therein for receiving ring connectors 124 of a chain 126 used for lifting the plug container 2 in a manner known to the art and except for the spaces defined between four "ears" defined at the outer end of the wall 114. Parts of three of these "ears" are identified in FIG. 1A by the reference numerals 123a, 123b, 123c. These "ears" can be hammered on to tighten or loosen the cap.
The closure means 10 also includes a transversely extending central wall 128 having a circular cross-sectional area in its plan view. The central wall 128 has a central opening defined therethrough for threadedly receiving a closure plug 130. The closure plug 130 permits access to the interior cavity of the housing 4 for introducing a wire line, for example. The central wall 128 has an upper surface 132 which abuts the annular surface 120 and the surface 118 along the circumferential edge of the wall 128 and which is attached by a weld bead 134 to the surface 116. The central wall 128 has a conical or tapered end wall 136 extending from a longitudinal cylindrical end surface 138 to a bottom surface 140. The tapered surface 136 is welded to the surface 118 by a weld bead 142.
Extending longitudinally or axially from, and in coaxial relationship with, the central wall 128 and its central opening is an interior wall 144 having an annular or sleeve shape. The wall 144 is welded to the central wall 128 at a weld bead 146. Extending radially through the interior wall 144 are two openings 148, 150. The openings 148, 150 permit fluid communication between the exterior of the wall 144 and a hollow interior opening 152 defined by the annular interior wall 144. This fluid communication is important for enabling pressure equalization between the exterior and interior of the wall 144 so that a vacuum or pressure differential between the exterior and interior of the wall is not created when the cementing plug abuts a bottom end surface 154 of the wall 144. The length of the wall 144 is such that a standard cementing plug cannot abut the surface 140 and thereby form a seal against the surface 140. In the embodiment shown in FIG. 1A, the length of the wall 144 is also such that it extends beyond the lower (as viewed in FIG. 1A) edge of the closed outer wall 114 so that an annular space is defined between the sleeve defined by the wall 144 and the surface 118 of the wall 114 of the cap body.
The foregoing construction of the closure means 10 provides a totally fabricated, internally threadable cap without using any castings. Utilization of an internal cap, as opposed to an external cap, provides means for reducing or minimizing the length of the plug container 2.
To provide a fluid-tight seal between the closure means 10 and the housing 4, the plug container 2 further comprises a sealing member 156 which in the preferred embodiment is an O-ring disposed in a circumferential groove 158 defined adjacent the threaded surface in the interior of the box end portion 12 of the housing 4. By positioning the sealing member 156 on the internal wall of the box end portion 12, rather than on the exterior surface of the outer wall 114 of the closure means 10, internal pressure exerted outwardly against the outer wall 114 within the annulus defined between the outer wall 114 and the interior wall 144 will expand the outer wall 114 into (or against) the seal member 156 to maintain a positive seal as pressure within the plug container 2 increases.
A similar type of fluid-tight sealing arrangement is utilized between the flanged, splined end portion 14 of the housing 4 and the casing adapter member 6. FIG. 1B shows that this sealing arrangement includes a seal member 160 disposed in a circumferential groove 162 defined around the interior surface of the flanged, splined end portion 14 of the housing 4.
To utilize the plug container 2, it is lifted by means of the chain 126 to a position above the casing and casing collar to which it is to be connected. The plug container 2 is then lowered and attached to the casing collar in a manner as known to the art.
When the plug container 2 is used in a manifold system, a dual fluid entry manifold is connected to both of the sleeves 42, 46 as known to the art. When the plug container 2 is used in a free-fall system, the sleeve 42 is capped by a suitable cap member of a type as known to the art and a single entry manifold fluid line is connected to the sleeve 46.
To insert a plug into the housing 4, the closure means 10 is unscrewed from the box end portion 12 of the housing 4 and the plug inserted through the open end of the housing 4. The plug is retained by means of the retaining pin 56 in the plug-receiving chamber of the housing 4 between the openings 36, 38.
When the plug retained by the pin 56 is to be released, the handle 58 is suitably actuated as known to the art to retract the pin 56 radially outwardly through the opening 40. The plug then drops into the casing through the casing adapter member 6, thereby actuating the indicator mechanism disposed in the slot 34.
While the plug is retained in the cavity within the housing 4, its end adjacent the closure means 10 can abut the lower end surface 154, but it cannot abut the surface 140. To prevent this abutment from creating a seal which might hold the plug thereagainst, thereby preventing proper release of the plug, the openings 148, 150 are provided to insure pressure equalization between the inside and outside of the interior wall 144 against which the plug can abut.
From the foregoing features of the plug container 2, a shorter and more versatile plug container than heretofore available is provided. Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While a preferred embodiment of the invention has been described for the purpose of this disclosure, numerous changes in the construction and arrangement of parts can be made by those skilled in the art, which changes are encompassed within the spirit of this invention as defined by the appended claims. | A plug container has a flanged, splined end which mates with a complemental end of a casing adapter member. These two ends are secured to each other by a clamping mechanism which permits easy connecting and disconnecting of the two ends, thereby affording easy interchanging of different adapter members. The plug container has a cavity with a diameter larger than the outer diameter of the plug to be retained in the cavity so that pressure equalization around the plug is maintained without an external bypass. Pressure equalization is also maintained adjacent a cap which closes an end of the plug container. This pressure equalization of the cap is achieved by one or more radial openings in an abutment wall of the cap. The cap is sealed by a pressure-energized seal disposed in the interior surface of the housing into which the plug is threadedly connectible. Two manifold ports are disposed near the two ends of the cavity in which the plug is to be disposed. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. 119(e) and 37 C.F.R. 1.78(a)(4) based upon copending U.S. Provisional Application, Ser. No. 61/304,580 for SYSTEM AND PROCESS FOR FLUE GAS PROCESSING, filed Feb. 15, 2010, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a system and process for flue gas processing, more specifically to a system and process for processing and sequestration of flue gas constituents in subsurface structures. The present invention also relates to a system for using the gas processing to enhance hydrocarbon recovery from low pressure subsurface geological formations.
BACKGROUND OF THE INVENTION
[0003] Increasing concentrations of greenhouse gases, including carbon dioxide, in the atmosphere are a subject of concern. It is feared that emission of these gases into the atmosphere could lead to global warming, sea-level changes, and different weather patterns, among other detrimental effects. Controlling the release of these gases into the atmosphere is thus an increasingly important concern. Response to this concern has lead to governmentally limited prohibitions and restrictions on carbon dioxide emissions, or fees associated with the emissions of such gases. Those approaches lead to high economic costs for industries that emit green house gases, especially those that emit flue gases into the atmosphere.
[0004] In order to meet past and new emissions standards, several approaches have been developed to make flue gases cleaner. Some approaches to reduce the emissions of undesired particulates within various gases include using above ground technologies such as adsorption by micro porous solids and absorption by chemical solvents. Other approaches include the geosequestration of purified gas in underground formations. However, current technologies have not developed systems or processes that make large scale sequestration of CO 2 financially feasible.
[0005] Rather than sequestering the CO 2 , which currently is not financially feasible for most large-scale operations, some methods utilize it in purified form to enhance oil recovery from underground formations. However, using purified CO 2 for this purpose also presents a number of problems for the producer of the well. In most large-scale enhanced oil recovery operations utilizing purified CO 2 , the primary cost of the recovery is the purchase of CO 2 , which may represent operating costs as much as 68% of the total cost of the revenue from the project. The cost of acquiring purified CO 2 in large quantities is driven by the very high cost of separation of CO 2 from flue gases and its subsequent transportation to the sequestration site where it can then be injected into the subsurface formation. Moreover, the relative cost of large scale CO 2 capture, injection, and sequestration increases as oil prices decline.
[0006] Traditional configurations for hydrocarbon recovery processes require subterranean depths of greater than eight hundred meters, with a sufficient trapping mechanism and sufficiently porous geological texture to handle large volumes of injected gases. Different trapping mechanisms occur which vary depending on the associated structure and desired duration of the sequestration. In addition, traditional configurations require subsurface containment regions capable of receiving high flow injection rates under very high injection pressures to sustain CO 2 sequestration. Using the present invention, CO 2 sequestration is achievable at relatively shallower levels with reduced injection flow rates and pressures.
[0007] Despite the prior art's predominant usage of purified CO 2 in enhanced recovery methods, it is also possible to enhance the oil recovery process by using gases of differing compositions, such as those with compositions similar to common flue gases. Constituents of these mixtures may be at least partially soluble in hydrocarbons contained in the underground formation and in many situations the resulting solutions will experience a more favorable mobility due to decreased viscosity. In addition, the resulting low-cost pressurization of the underground containment region may promote increased recovery.
[0008] Moreover, potential sequestration locations for CO 2 injection are seldom located in close proximity to coal-fired electric power plants and other large scale flue gas sources. The cost of transporting purified liquid CO 2 by truck or pipeline is considerable. This circumstance exists for nonsequestration commercial markets of CO 2 as well. Therefore, the significant costs of carbon capture include the additionally significant costs of transporting liquefied CO 2 by tanker truck or pipeline. The combination of such energy costs and limited commercial demand for CO 2 do not make the sale of CO 2 captured by above-ground mechanical technologies commercially viable in many situations. For these reasons, neither sequestration nor the commercial sale of purified CO 2 are generally considered sufficient, practical, or financially feasible for utilizing all of the CO 2 contained in flue gases.
[0009] Additionally, the capital costs of the equipment necessary for large-scale separation and capture of CO 2 from power plant flue gases are enormous, generally in excess of $1.2 billion per plant.
[0010] Furthermore, the cost of large-scale separation and capture of CO 2 from flue gases has generally been considered commercially prohibitive for waste disposal due to the enormous volumes of energy required to condense the gases to the point where liquid CO 2 can be extracted. For a coal-fired electric power plant, estimates are that the energy cost of CO 2 separation can exceed by 30% to 40% the electricity production capacity of the plant. The result of combined capital and energy cost of large-scale CO 2 separation and capture from power plant flue gases could be very substantial increases in the price of electricity to consumers. Some estimates are that costs to consumers would need to double for the method of disposal to become commercial viability.
[0011] Some prior attempts at utilizing hydrocarbon recovery techniques have been described in Screening and Ranking of Hydrocarbon Reservoirs for CO 2 Storage in the Alberta Basin, Canada by Buchu, which is incorporated by reference.
[0012] Heretofore, there exists a need for an improved system and process for hydrocarbon recovery using emission gases sequestered in geological strata.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a method for sequestration of carbon dioxide, said method comprising the steps of injecting a carbon dioxide-containing injection gas into a subsurface containment region, said containment region further comprising a series of captures zones; providing sufficient time for said injection gas to at least partially stratify forming constituent gas mixtures and for said constituent mixtures to at least partially accumulate in said capture zones; providing a vent associated with one of said capture zones; and, evacuating at least a portion of one of said constituent mixtures through said vent.
DETAILED DESCRIPTION OF THE INVENTION
[0014] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0015] An exemplary embodiment of the system and process for production of hydrocarbon using the sequestration of carbon dioxide is comprised of a flue gas source, a subsurface containment region, which may include a brine zone, an oil zone, and plural capture zones. The subsurface containment region is in communication with a compression source spaced apart from the subsurface containment region. Additionally, the subsurface containment region includes a vessel, a formation, or other structure which surrounds its perimeter. As illustrated, the flue gases are injected into the subsurface containment region from the compression source and are dispersed throughout. Flue gases associated with a brine zone would permeate through the brine material separating some of the constituent gases from the flue gas into soluble CO 2 and other insoluble gases. As these constituent gases are separated, they are allowed to migrate. Exemplary processes include the migration of at least a portion of the insoluble gases into a hydrocarbon fluid reservoir, where the additional soluble CO 2 permeates the fluid hydrocarbons, enhancing the transport characteristics of the hydrocarbon and thereby enhancing the hydrocarbon production. In other processes, the insoluble CO 2 is allowed to migrate to structurally higher areas of the subsurface containment region. Any CO 2 retained in the hydrocarbon zone may be extracted through hydrocarbon production, captured at the surface, and reinjected into the subsurface containment region for use in various embodiments of this invention.
[0016] Flue gases from various industrial processes may be utilized in the present invention and may be processed prior to introduction into the subsurface containment region. Alternatively, the present invention may remove some contaminants from the flue gas through a filtering or separation processes. Typically, the industrial flue gas may be processed during or in association with the industrial process by strippers or scrubbers.
[0017] In one embodiment, the flue gas 14 is processed to remove at least a portion of (1) undesirable particles, (2) sulfur dioxide, (3) nitrous oxides and (4) moisture content. The resulting flue gas may have a composition that is, for example, 10.73% CO 2 , 1.39% CO 0.76% NO x , 0.03% SO 2 , and 87.09% air, although percentages of constituent gases may vary. The greater the concentration of CO 2 , the more desirable the flue gas is for application of this invention. Carbon Capture And Storage (CCS) in Nigeria: Fundamental Science and Potential Implementation Risks, Galadima & Garba (2008 SWJ Vol 3, No. 2): pgs 95-99; and The Future of Carbon Capture and Storage (CCS) in Nigeria, Anastassia et al., (2009 SWJ Vol. 4, No. 3):1-6 which are attached hereto and incorporated by reference.
[0018] The composition and proportions of the flue gas and its contaminants may vary depending on the specific industrial process utilized. If solvent absorption of carbon dioxide is used for the sequestration, and monoethanolamine is the solvent, reactions with diatomic oxygen, nitrous oxides, and sulfoxides may lead to numerous operational problems such as foaming, fouling, increased viscosity, and formation of undesirable salts. Diatomic oxygen concentrations in the range of about 3% to 12% in typical flue gas streams are known to induce oxidative degradation of alkanolamines, resulting in severe corrosion of associated piping. Thus the proportion of oxygen should be minimized or oxygen inhibitors employed. Additional information on contaminants and flue gas processing is disclosed in Supap, T; Idem, R.; Tontiwachwuthikul, P.; Saiwan, C. Analysis of monoethanolamine and its oxidative degradation products during CO 2 absorption from flue gases: A comparative study of GC-MS, HPLC-RID, and CE-DAD analytical techniques and possible optimum combinations. Industrial & Engineering Chemistry Research, 2006, 45 (8), 2437 which is incorporated by reference.
[0019] While the invention discloses using flue gas, other CO 2 containing gases may be utilized in the present invention. While pressurization of subterranean formations may be generally understood, by using a CO 2 enriched gas, unexpected benefits may be achieved through the enhanced liquidity of the fluid hydrocarbon as well as a reduction in the pressures necessary to achieve hydrocarbon recovery.
[0020] In one embodiment, the flue gases may be injected into the subsurface containment region through a compression source such as an injection well extending from the surrounding structure opposite the subsurface containment region into the subsurface containment region. See for example American Petroleum Institute, 2007, Background Report, “Summary of Carbon Dioxide Enhanced Oil Recovery (CO 2 EOR) Injection Well e Technology”, 1220 L Street NW, Washington, DC, attached hereto and incorporated by reference. In addition, various textured surfaces may enhance the capacity of the subsurface containment region as well as allowing for an increase in the efficiency of the sequestration and hydrocarbon recovery. Some exemplary subsurface containment regions may include depleted oil and gas reservoirs, saline aquifers, coal beds and artificial vessels designed to sustain the hydrocarbon production. The injection well, which may be in communication with a production well, would inject the flue gases into the subsurface containment region. As the flue gases enter the subsurface containment region, through the process described above, the flue gas would separate for immersion of the fluid hydrocarbon by the separated soluble CO 2 . Optionally, the subsurface containment region may be sealed from the ambient surface environment allowing for additional separation of the CO 2 from the flue gas and for additional saturation of the fluid hydrocarbon by soluble portions of the separated CO 2 .
[0021] The flue gas when initially injected into the subsurface containment region is a mixture of constituent gases. Subsequent to the injection, the flue gas stratifies, at least partially, into zones of concentration of individual constituent gases dispersed throughout the subsurface containment region. Multiple molecular processes contribute to the stratification. Additionally, the proportions of a constituent gas in a zone of concentration vary over time depending on the stratifying molecular process. The constituent gases have different relative densities, thus after being injected into the subsurface containment region, there is some tendency for the constituent gases to partially stratify over time. Because CO 2 is about 50% heavier than the average molecular weight of other constituent gases in air, those other constituent gases will tend to rise relative to the CO 2 resulting in at least two zones of concentration, with air concentrating above the CO 2 . Because gaseous CO 2 is lighter than oil and water, insoluble CO 2 will tend to rise above those oil and water zones.
[0022] Other molecular processes that contribute to zones of concentration include but are not limited to adsorption. The adsorption properties of constituent gases in relationship to the within the subsurface containment region leads to zones of concentration. For example, if the subsurface containment region is an abandoned coal seam, affinity for adsorption of carbon dioxide over methane may be exploited to achieve a zone of concentration of carbon dioxide. This affinity may result in enhanced production of methane gas form the coal seam. If the subterranean structure has capillary structure, the different constituent gases of the flue gas travel through that capillary structure at different rates and thus zones of concentration may form. Further disclosure of apparatus and processes in separation of gases in this environment is in Effect of Heterogeneity in Capillary Pressure on Buoyancy Driven Flow of CO 2 , Ehsan Saadatpoor, Steven L. Bryant, Kamy Sepehrnoori, available at http://www.cpge.utexas.edu/gcs/pubs/buoyancy_driven_flow_slides.pdf, which is incorporated by reference.
[0023] Upon stratification, a capture zone is associated with a given constituent gas. The constituent gas can then be directed for containment, reinjection, or elsewhere in the process. Gas vents, such as evacuation ducts, are associated with a desired capture zone in order to direct the contents of the capture zone to another desired location. In the case of a capture zone associated with carbon dioxide, the gas may be redirected to an injection well for resequestration into a non-capture zone such as a hydrocarbon zone to achieve incrementally enhanced hydrocarbon recovery. It may also be directed to a system for enhanced hydrocarbon recovery. The evacuation ducts are associated with capture zones and thus may be placed at varying depths or associated with any location where stratification may occur.
[0024] After a portion of the CO 2 is sequestered from the flue gas, it may diffuse through the pores of the subsurface containment regions or the associated brine and hydrocarbon zones. Saline structures may also present additional characteristics for containing the sequestered CO 2 or an impermeable capping material may be located between the injection well and the injected flue gases to seal the injected gases. The impermeable cap may include but is not limited to solid, liquid, or gaseous materials which limit undesired migration of sequestered CO 2 .
[0025] In an alternative embodiment, surface compression may be utilized to inject the flue gas into the subsurface containment region passing at least one subsurface geological zones comprised of brine, hydrocarbons, a mixture of brine and hydrocarbons, air, soil, or artificial structures. Generally, “brine” consists of non-potable water and “hydrocarbons” consist of crude oil and/or natural gas. “Miscibility” is the ability of two or more substances to form a single homogeneous phase when mixed in certain proportions. For petroleum reservoirs, miscibility is the physical condition between two or more fluids that will permit them to mix in certain proportions without the existence of an interface. If two fluid phases form after some amount of one fluid is added to others, the fluids are considered “insoluble” under those conditions.
[0026] In order to enhance the oil recovery, the carbon dioxide is preferably soluble with the associated reservoir oil. The solubility of CO 2 and other injected gases depends upon factors such as reservoir temperature, reservoir pressure, injected gas composition, and oil chemical composition. The enhanced recovery processes involve manipulating these conditions to achieve miscibility between the injected gas and the oil.
[0027] The oil reservoir pressure at the start of a conventional CO 2 flood should be at least 1.38 MPa above the minimum miscibility pressure (MMP) to achieve miscibility between CO 2 and reservoir oil. This means that the ratio between reservoir pressure and minimum miscible pressure normally should be >1. During the enhanced oil recovery (EOR) also referred to as the secondary stage of oil recovery, the typical subsurface containment region for EOR may have various degrees of suitability, depending on the intrinsic subsurface characteristics and the chemical composition of the oil mixture. The range of reservoir and fluid properties suitable for CO 2 miscible injection is quite wide; however, exemplary reservoirs should have oil API gravity >27° (light oils with density <900 kg/m3), oil saturation So >25%, reservoir pressure >7.6 MPa and ideally 1.4 MPa higher than the minimum miscible pressure (MMP) at the time of CO 2 injection. In addition, the containment barrier porosity should be greater than 15% with permeability >1 md. Immiscible CO 2 flooding is much less common; nevertheless it may be applied to heavy and medium oils (10-25° API; 900-1000 kg/m3 density) and in-situ viscosities of 100 to 1000 mPa/s (cp).
[0028] Some limited studies have shown that, under cyclic immiscible recovery conditions, gas injection mixtures containing from 10-25% CO 2 have achieved exceptional oil recovery. More discussion on enhanced oil recovery results in varying conditions is disclosed in Rivas, O., Embid, S., and Bolivar, F., 1994. Ranking reservoirs for carbon dioxide flooding processes. SPE Paper 23641, SPE Advanced Technology Series, v. 2 (Rivas et al., 1994), which is incorporated by reference.
[0029] In another alternative embodiment, the flue gas may be injected directly into an oil zone or a brine zone of the subsurface containment region, where at least some quantity of CO 2 from a capture zone is employed. Disclosure of sequestration of CO 2 is included in U.S. Pat. App. Nos. 20070215350 and 20100000737, which are incorporated by reference.
[0030] After sequestering the CO 2 from the flue gases, the sequestered gases may be further separated by the Brine Zone, physically, mechanically or chemically through a reaction process such as but not limited to forming carbonic acid, and then any remaining sequestered gases may be transported to the Oil Zone, where at least some additional quantity of CO 2 is extracted from the flue gas via a molecular process. The non-soluble gases may be separated from the Oil Zone and be transported for capture at Zones 1, 2 or 3 depending on the specific configuration and relative density of the separated gases.
[0031] Optionally, the extraction of quantities of CO 2 from the flue gas injected into the brine zone or oil zone may be further increased if the subsurface containment region is pressurized. The pressurization may be increased to a point approaching but not equaling the fracture gradient of the subsurface containment region in order to achieve pressures and temperatures of greater solubility of CO 2 with formation liquids and/or to increase the drive mechanism to enhance the recovery of hydrocarbons. “Fracture gradient,” measured in pounds per square inch per feet depth, is the pressure that if applied to rock or similar object within a subsurface containment region, will cause that rock to physically fracture. The subsurface pressure of said subsurface containment region may be increased by one or more means such as mechanical compression at the surface of the injected flue gas, flooding the formation with water, and adding chemical agents to the flue gas and/or to the subsurface brine and/or hydrocarbon bearing zones. U.S. Pat. Nos. 6,491,053, 7,506,690, 7,341,102, 6,318,468 and 4,744,417 involve processes and apparatus for enhanced hydrocarbon recovery using CO 2 at varying pressures and is incorporated by reference.
[0032] In yet another embodiment, the non-soluble gases that filter through the brine zone or through the oil zone may be isolated from the ambient environment to allow the CO 2 and other gases to separate according to their relative densities. Because CO 2 is about 50% heavier than air, the air component of the flue gas will tend to rise relative to the CO 2 resulting in at least two zones of concentration, with air concentrating above the CO 2 . Because CO 2 is lighter than oil and water, non-soluble CO 2 will tend to rest on top of those zones.
[0033] In yet another embodiment, the contents of a capture zone having a constituent gas other than CO 2 may be directed outside the subsurface containment region into the atmosphere under controlled conditions, making the evacuated capture zones available for receipt of additional gasses. In this embodiment, at least one vent associated with at least one of the capture zones and associated with at least one constituent gas is used to extract at least some of the constituent gas through the associated vent at the desired capture zone.
[0034] The nature of CO 2 leakage behavior will depend on properties of the subterranean structure, primarily its permeability, and on the thermodynamic and transport properties of CO 2 as well as other fluids with which it may interact in the subsurface. At typical temperature and pressure conditions in the shallow crust (depth <5 km), CO 2 is less dense than water, and therefore is buoyant in most subsurface environments. Upward migration of CO 2 will occur whenever appropriate vertical permeability is available. Potential pathways for CO 2 migration to structurally high areas of subsurface containment regions include (1) migration through porous rock, and (2) migration along faults or fractures. More disclosure on CO 2 migration is in Assessment of the CO 2 Sealing Efficiency of Pelitic Rocks: Two-Phase Flow and Diffusive Transport, paper 536, presented at 7th International Conference on Greenhouse Gas Control Technologies, Vancouver, Canada. Sep. 5-9, 2004; Zweigel, P., E. Lindeberg, A. Moen and D. Wessel-Berg. Towards a Methodology for Top Seal Efficacy Assessment for Underground CO 2 Storage, paper 234, presented at 7th International Conference on Greenhouse Gas Control Technologies, Vancouver, Canada. Sep. 5-9, 2004; Gibson-Poole, C. M., R. S. Root, S. C. Lang, J. E. Streit, A. L. Hennig, C. J. Otto and J. Underschultz; Conducting Comprehensive Analyses of Potential Sites for Geological CO2 Storage, paper 321, presented at 7th International Conference on Greenhouse Gas Control Technologies. Vancouver, Canada. Sep. 5-9, 2004; Lindeberg, E. The Quality of a CO 2 Repository: What is the Sufficient Retention Time of CO 2 Stored Underground?, in: J. Gale and Y. Kaya (eds.), Greenhouse Gas Control Technologies, Elsevier Science, Ltd., Amsterdam, The Netherlands, 2003; and Espie, T. Understanding Risk for the Long-Term Storage of CO 2 in Geologic Formations, paper 42, presented at 7th International Conference on Greenhouse Gas Control Technologies. Vancouver, Canada. Sep. 5-9, 2004, which are incorporated by reference.
[0035] In yet another embodiment, a portion of any CO 2 and other constituent gases not associated with capture zones is captured proximately in the upper portion of the subsurface containment region. The gas composition is optionally monitored to detect higher proportions of the flue gas constituent gases and pressure flows. The subsurface containment region may be provided with a mechanical body, such as a gas containment layer, disposed near its upper portion. Disclosure of monitoring and gas containment systems is in U.S. Pat. Nos. 7,448,828 and 5,063,519, which are incorporated by reference. The contents of the mechanical body are re-injected through secondary compression back into the subsurface containment region under miscible or immiscible conditions, repeating the injection process previously described as desired.
[0036] In yet another embodiment, the contents of a CO 2 associated capture zone are directly produced via conventional gas production means. In this embodiment, at least one vent associated with a CO 2 capture zone within the subsurface containment region is used to direct at least some of the constituent gas through the associated vent. In a further embodiment, the constituent gas directed from a CO 2 associated capture zone is re-injected through secondary compression back into the subsurface geological formation under miscible or immiscible conditions using secondary compression. Optionally, the gas directed from the CO 2 associated capture zone is injected directly into an oil zone.
[0037] In yet another embodiment, the injected flue gas may be shut-in for a period of time to allow the injected gases to soak in the brine and/or hydrocarbon zones of the subsurface containment region. The injected flue gas may alternatively be shut-in for a period of time to allow the partial or complete stratification of flue gases, where the constituent gases stratify according to their relative densities. Each constituent gas is associated with a relative capture zone for release from the subsurface containment region.
[0038] In yet another embodiment, gaseous CO 2 from the flue gas not associated with a capture zone or not directed from a capture zone is stored in the subsurface containment region by sealing its surrounding surface using known techniques, such as a containment barrier around the perimeter of the subsurface containment region. The containment barrier is composed of material with low gas permeability. The barrier may be composed of existing natural material such as caliche, calcrete, silicrete. Alternatively, the containment barrier may be composed of manmade material. U.S. Pat. App. No. 20090220303 discloses using containment barriers in sequestration and is incorporated by reference.
[0039] While the foregoing detailed description has disclosed several embodiments of the invention, it is to be understood that the above description is illustrative only and not limiting of the disclosed invention. It will be appreciated that the discussed embodiments and other unmentioned embodiments may be within the scope of the invention. | The present invention is directed to a new and improved method for sequestration of carbon dioxide, the method including the steps of injecting a carbon dioxide-containing injection gas into a subsurface containment region with a series of captures zones; providing sufficient time for said injection gas to at least partially stratify and form constituent gas mixtures which at least partially accumulate in the capture zones; providing a vent associated with one of the capture zones; and, evacuating at least a portion of the constituent mixtures through the associated vent. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority from German Patent Application No. 10 2009 013 412.3 dated Mar. 18, 2009, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus on a carding machine for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing.
It is known in a card flat bar for the card flat clothing, preferably wire hooks, to be arranged in a strip-like support layer, the clothing being attached to the card flat bar and lying opposite the clothing of a roller, for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar comprising an iron material, especially of steel, with at least one magnetic means (element) being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar.
The revolving card top of a carding machine is the crucial technological element for reducing the number of neps in the fibre material, for example, cotton, in its most highly opened state. In its interaction with the cylinder, the revolving card top loosens the fibre knots, it being necessary for the spacing to be as small as possible but for mutual contact between the clothings to be prevented. Contact results in unnecessary wear. Premature wear in turn results in a reduction in quality. The flexible revolving card top is also the only element which can be set to extremely narrow carding nips without significant adverse technological secondary effects.
In order reliably to manage extremely narrow carding nips, precision components are a prerequisite. The revolving card flats used simultaneously on a machine are referred to as a card flat set. The differences in dimensions from card flat to card flat in the card flat set should be as small as possible. Likewise, each individual card flat should have a high degree of evenness across the width of the machine. Because increased precision is always associated with increased cost, it is necessary to combine increased precision with optimum handling at an acceptable cost. In practice, the clothings are clipped onto the card flats using enormous forces. The clipping-on operation, which has to be made reversible for re-clothing, has an adverse effect on precision and is not possible without destruction of the clothing.
In a known apparatus (DE 10 2006 005 605 A), the card flat clothing is adhesively bonded, in a tolerance compensating manner, to a metal backing sheet and is held in the revolving card top by a planar magnetic strip. The magnetic strip itself is in turn adhesively bonded, in a tolerance compensating manner, to the card flat bar. The magnetic force absorbs the process forces during the carding process with a high degree of reliability. As a result, many of the disadvantages of the old clip-on card flat system have been eliminated. The card flat sets have a high degree of precision even without an additional grinding process. Handling during re-clothing is optimum, because the clothing can be demounted, without being destroyed, using a single movement. The new clothing can be inserted again just as quickly.
The magnetic connection is a force-based connection. If a threshold force opposite to the attractive force of the magnet is applied, the clothing strip becomes detached from the card flat bar. The threshold force is such that the normal process forces can be transmitted with a high degree of reliability. This has been demonstrated by a large number of practical tests and experiments. The “old” mounting technique using clips was an interlocking connection. That connection could be broken only by overcoming the rigidity of the component. The forces necessary for that purpose are in turn a multiple greater than the threshold force of the “new” magnetic connection.
If operating conditions that can be considered abnormal then arise in a carding machine, forces can develop which exceed the threshold force of the magnet but still lie significantly below the connection strength of the clip-on technique. Abnormal operating conditions arise when the nips used are too narrow; when the fibre/clothing combination has been incorrectly selected and therefore cylinders become clogged; when, as a result of fibres that are difficult to process, temperatures suddenly rise very rapidly and there is substantial contact between clothings; when operators do not recognise the abnormal operating conditions in good time and allow the machines to continue running, and so on. It can also happen that an unusually large or solid disruptive element, for example a trash particle, fibre knot or the like, projects at least partly beyond the circle of tips of the cylinder and thus exerts undesirable pressure on the forwardly arranged regions (front regions) of the clothing of at least one card flat bar. In summary, there are situations which occur extremely rarely (exceptional cases) but give rise to enormous adverse forces.
In normal operation, the magnet absorbs all the operating forces and provides for precision support. In an abnormal operating state, the interlocking connection safeguards against contact with the cylinder clothing.
SUMMARY OF THE INVENTION
It is an aim of the invention to create an apparatus which, in particular, provides a structurally simple way of holding the clothing element against the card flat bar in the event of an increase in pressure on the card flat clothing, especially of preventing the card flat clothing from making contact with the cylinder clothing, and allows quick replacement of the card flat clothing strip.
The invention provides a card flat bar for use in a carding machine opposite a clothed roller of said machine, having a card flat bar body having a material inlet side at which in use fibre material is received, and a card flat clothing strip which is magnetically attachable to the card flat bar body, wherein the card flat bar body includes a counter-bearing associated with said material inlet side and the card flat clothing strip comprises a counter-element arranged to co-operate, in use, with the counter-bearing in a direction towards said opposed clothed roller.
Because there is associated with the card flat bar, on the fibre material inlet side of the card flat clothing, a counter-bearing, stop or the like with which the base and/or the support member co-operate(s) in the direction towards the roller, for example carding cylinder, undesirable forces are compensated for. In this structurally simple way, in the event of an increase in pressure on the clothing, the clothing element is held against the card flat bar, that is to say contact between the card flat clothing and the cylinder clothing is reliably avoided even if there is local detachment from the magnet. The invention has the further substantial advantage that in the event of replacement the card flat clothing strip can be removed or inserted without problems, because there is no counter-bearing, stop or the like on the fibre material outlet side of the card flat clothing.
Advantageously, the clothing strip has a support layer and a base for attachment to the card flat bar, and the counter-element is the base. The counter-element may be, for example, a shoulder or the like on the base. In another embodiment, the counter-element may be the support layer. For example, the counter-element may be a shoulder or the like on the support layer. In certain embodiments the base or the support layer co-operates with the card flat bar by means of an interlocking connection. The counter-bearing may be in any suitable form. Illustrative arrangements for the counter-bearing include those in which the counter-bearing is a shaped portion of the foot of the card flat bar body, for example, an angled edge on the card flat foot, an undercut, a nose, an angled side on the card flat foot, or a groove in the card flat foot; and arrangements in which a bearing element is inserted into or attached to the foot of the card flat body, for example, a bent-over sheet metal element or the like, a screw, a bolt or the like, a resilient element, or a clip-like element. In the case of a groove, the base of the clothing , advantageously projects into the groove. Advantageously, the base projects beyond the support layer of the clothing. The counter-bearing may extend under the base or the support layer of the clothing at a spacing of about from 1 to 3 mm. Advantageously, the counter-bearing, for example the stop, is present at least partially along the longitudinal edge of the card flat foot on the fibre material inlet side. Advantageously, there is a spacing (play) between the upper side of the counter-bearing and the underside of the base or support layer. Advantageously, during normal carding conditions, the spacing (play) is smaller than the spacing between the card flat clothing and the clothing of the cylinder (carding nip).
In some embodiments, there is a counter-bearing in the region of each of the two end faces of the card flat foot (card flat heads). Advantageously, when the threshold force of the magnet is exceeded the clothing strip is supported on the counter-bearing. That prevents the clothing strip from contacting the opposed roller. For example, the base may be supported on the counter-bearing in the event of abnormal carding conditions resulting in detachment of the clothing strip. Where the counter-element is the support layer, the support layer may be supported on the counter-bearing in the event of detachment of the carding strip.
In some embodiments, magnetic means are attached to the card flat bar, for example, by means of an adhesive layer or the like, or by means of a screw connection or the like. In some embodiments, the magnetic means consists of a permanently magnetic material. It will be appreciated that, under normal carding conditions, the magnetic force is greater than other forces acting on the clothing, for example carding force, force of a rotating cleaning roller or the like. Preferably, the clothing is removable from the magnetic means. Preferably, the clothing is joined to the card flat bar by means of the magnetic means as attachment element. Preferably, the clothing is removably detachable from the magnetic means. In one preferred embodiment, the clothing, which is inserted into a substrate, for example fabric or the like, consists of wires or the like which are bent into approximately a U-shape and inserted in such a way that the crosspiece of the U-shaped wires or the like runs on the rear side of the substrate. Preferably, between the card flat bar and the card flat clothing there is a compensating layer which is able to compensate for the different spacings between the card flat bar and the card flat clothing. In certain embodiments, an adhesive layer is provided. The clothing is preferably a clothing strip. In certain embodiments, the card flat bar comprises a neodymium magnet. In certain advantageous forms of clothing, a thin metal support is advantageously provided. Advantageously, the clothing is a flexible clothing. Preferably, the flexible clothing comprises a support and clothing tips, wires, hooks or the like. Preferably, the support is strip-shaped. In other embodiments, the clothing consists of sawtooth wire strips, for example all-steel clothing.
Advantageously, the clothing is attached to the card flat bar in the region of the foot surface. Advantageously, a plastics material, a synthetic resin, for example epoxy resin, or the like, is provided as compensating composition. Preferably, the card flat bar is an extruded profile made from a lightweight metal, for example aluminium. Preferably, the extruded profile is a hollow profile. Preferably, the card flat bar comprises a supporting member, with which are associated two end head parts (card flat heads). Preferably, the end head parts are pins made of hardened steel or the like. Preferably, a supporting element of the clothing (for example, of textile material) and the compensating layer are arranged in a recess in the foot face (supporting member). Preferably, the recess is defined by at least two lateral ribs or the like on the longitudinal sides of the supporting member of the card flat bar. In some embodiments, the underside of the clothing strip against which the backs of bent wires of the clothing are located is held by means of a magnet fixed to the card flat bar. In certain embodiments, a clothing strip is included, to which there is additionally attached, by way of a compensating adhesive layer, a metal sheet which is brought into connection with the magnet of the card flat bar. In preferred embodiments of the invention, a vertical linkage on the fibre material inlet side is supported mechanically.
Advantageously, the magnetic means comprises an elongate magnetic element, for example magnetic tape, magnetic strip, magnetic bar or the like, that runs in the longitudinal direction of the card flat bar. In some embodiments, a plurality of magnetic elements are present in the longitudinal direction of the card flat bar. Preferably, the magnetic elements are arranged spaced apart from one another. In certain embodiments, the magnetic structural elements are arranged offset with respect to one another. Preferably, the offset runs in the working direction. In certain embodiments, a base made of a magnetic material is arranged on the rear side of the card flat clothing. Advantageously, the base is a steel tape, metal sheet or the like. Advantageously, the base has, on the fibre material inlet side, shoulders, ribs or the like which are bent at an angle at the side.
In some embodiments, the card flat clothing has at least two clothing groups which are each held by a magnet. For example, there may be at least two clothing groups each having a heel zone opposite the roller clothing. In certain embodiments the card flat clothing consists of a multiplicity of all-steel clothing wires which are arranged in the axial direction with respect to the clothed roller, for example the cylinder. Preferably, the card flat clothing is held against the card flat bar by at least, one magnetic element.
In certain preferred embodiments, magnetic means is integrated into the card flat bar. Advantageously, a base made of a fine material is provided on the rear side of the card flat clothing. In one advantageous embodiment, magnetic means is formed with the card flat bar by casting. In another advantageous embodiment, the magnetic means is incorporated into the card flat bar by casting or compression moulding. Advantageously, the magnetic means is simultaneously incorporated during the manufacture of the card flat bar. In one advantageous embodiment, at least one and preferably each of the marginal regions bordering the longitudinal edges is provided with tips. Advantageously, the magnetic element is at least partly in contact with the sheet-form metal support of the clothing.
The invention also provides a card flat bar for a carding machine for cotton, synthetic fibres and the like, having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attached to the card flat bar and at least the regions of the card flat clothing that face the card flat bar consist of an iron material, especially of steel, with at least one magnetic means being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
Further, the invention provides a flexible clothing for a card flat bar on a carding machine for cotton, synthetic fibres and the like, having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attachable to the card flat bar and at least the regions of the card flat clothing that are arranged to face the card flat bar consist of an iron material, especially of steel, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
Moreover, the invention provides a carding machine having a revolving card flat assembly for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-shaped support layer, is attached to the card flat bar and lies opposite the clothing of a roller, for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar are provided with at least one magnetic element wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which the base co-operates in the direction towards the cylinder.
The invention also provides an apparatus on a carding machine for cotton, synthetic fibres and the like, in which there is at least one card flat bar having a card flat clothing, wherein the card flat clothing, preferably wire hooks, which is arranged in a strip-like support layer, is attached to the card flat bar and lies opposite the clothing of a roller; for example the cylinder, and at least the regions of the card flat clothing that face the card flat bar consist of an iron material, especially of steel, with at least one magnetic means (element) being provided between the card flat bar and the regions of the card flat clothing that face the card flat bar, wherein on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the cylinder—there is associated with the card flat bar a counter-bearing, stop or the like with which a counter-element associated with the card flat clothing co-operates in the direction towards the cylinder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of a carding machine having a revolving card top with card flat bars according to a first embodiment of the invention;
FIG. 2 shows card flat bars of the revolving card top and a portion of a slideway, of a setting bend (flexible bend) having a side screen and of the cylinder, as well as showing the carding nip between the clothings of the card flat bars and the cylinder clothing;
FIG. 3 a is a side view in section through a portion of a card flat bar with a counter-bearing and with magnetic strip and clothing strip (wire hook clothing) in the assembled position;
FIG. 3 b shows the card flat bar with counter-bearing and magnetic strip in accordance with FIG. 3 a , but with a separately detached clothing strip;
FIG. 4 is a side view in section of a further card flat bar according to the invention, showing diagrammatically the installation of the clothing strip in the card flat foot of the card flat bar or the demounting of the clothing strip therefrom;
FIG. 5 shows the force application point and the angle of application with respect to the card flat clothing on the fibre material inlet side;
FIG. 6 a shows on the fibre material inlet side of a card flat bar according to FIG. 4 , a spacing between the underside of a shoulder of the base and the counter-bearing;
FIG. 6 b shows the card flat bar according to FIG. 4 with a spacing between the upper side of the base and the magnet
FIG. 7 shows an embodiment having an angled side on the counter-bearing and on the base;
FIG. 8 shows an embodiment having a screw as counter-bearing;
FIG. 9 shows an embodiment having a flexible metal sheet as counter-bearing;
FIG. 10 shows an embodiment having a counter-bearing with which the support layer of the clothing strip co-operates, and
FIG. 11 shows an embodiment having a shoulder on the supporting element which co-operates with the counter-bearing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
With reference to FIG. 1 , a carding machine, for example a flat card TC 07 (trademark) made by Trützschler GmbH & Co. KG of Mönchengladbach, Germany, has a feed roller 1 , feed table 2 , lickers-in 3 a, 3 b, 3 c, cylinder 4 , doffer 5 , stripper roller 6 , nip rollers 7 , 8 , web guide element 9 , web funnel 10 , delivery rollers 11 , 12 , revolving card top 13 with card top guide rollers 13 a, 13 b and card flat bars 14 , can 15 and coiler 16 . The directions of rotation of the rollers are indicated by curved arrows. Reference letter M denotes the centre point (axis) of the cylinder 4 . Reference numeral 4 a denotes the clothing and reference numeral 4 b denotes the direction of rotation of the cylinder 4 . Reference letter B denotes the direction of rotation of the revolving card top 13 in the carding position and reference letter C denotes the return transport direction of the card flat bars 14 , with reference numerals 30 ′, 30 ″ denoting functional elements and reference numerals 13 a and 13 b denoting card top guide rollers. The arrow A denotes the working direction.
In accordance with FIG. 2 , on each side of the carding machine there is provided a setting bend 17 (flexible bend) which is integrated integrally into the associated side screen 19 . The setting bend 17 has a convex outer surface 17 a and an underside 17 b. On top of the setting bend 17 there is a slideway 20 , for example made of low-friction plastics material, which has a convex outer surface 20 a and a concave inner surface 20 b. The concave inner surface 20 b rests on top of the convex outer surface 17 a and is able to slide thereon in the direction of arrows D, E. Each card flat bar 14 consists of a rear part 14 a and a card flat foot 14 b. Each card flat bar 14 has, at each of its two ends, a card flat head, each of which comprises two steel pins 14 1 , 14 2 . Those portions of the steel pins 14 1 , 14 2 that extend out beyond the end faces of the card flat foot 14 b slide on the convex outer surface 20 a of the slideway 20 in the direction of the arrow B. A clothing 18 is attached to the underside of the card flat foot 14 b. Reference numeral 21 denotes the circle of tips of the card flat clothings 18 . The cylinder 4 has on its circumference a cylinder clothing 4 a, for example a sawtooth clothing. The tooth height of the sawteeth is, for example, h=2 mm. Reference numeral 22 denotes the circle of the tips of the cylinder clothing 4 a. The spacing (carding nip) between the circle of tips 21 and the circle of tips 22 is denoted by reference letter a and is, for example, 3/1000″. The spacing between the convex outer surface 20 a and the circle of tips 22 is denoted by reference letter b. The spacing between the convex outer surface 20 a and the circle of tips 21 is denoted by reference letter c. The radius of the convex outer. surface 20 a is denoted by reference letter r 3 and the radius of the circle of tips 22 is denoted by reference letter r 1 . The radii r 1 and r 3 intersect at the centre point M of the cylinder 4 . Reference numeral 19 denotes the side screen. The card flat bars 14 are extruded hollow profiles made of aluminium having an internal cavity 14 c.
FIGS. 3 a and 3 b show a first embodiment of card flat bar according to the invention. The card flat clothing 24 consists of clothing tips 18 (wire hooks) and a supporting element 25 (support layer) made of a textile material. The wire hooks 18 are approximately U-shaped and, punched through the surface 25 ′, are fixed in the supporting element 25 . The turn regions 18 ′ (see FIG. 4 ) of the wire hooks 18 project beyond the surface 25 ′. The ends of the wire hooks 18 , the clothing tips, are free. The wire hooks 18 consist of steel wire.
Two ribs 14 d, 14 e are provided laterally on the card flat foot 14 a in the longitudinal direction, so that in the region of the foot face there is a recess 14 f, by means of which the card flat clothing 24 is held, protected and embedded. In the recess 14 f there is arranged a magnetic element 29 , for example a magnetic tape, magnetic strip, magnetic bar or the like, which is attached to the foot face by means of an adhesive layer 30 . The magnetic element can also be formed on the card flat bar by casting, compression moulding or the like, for example magnetic powder with a curable resin. The magnetic element is advantageously a permanent magnet, for example a neodymium magnet. In the lower recess 14 f there is arranged the card flat clothing 24 . The card flat clothing 24 is attached to, i.e. held against, the magnetic element 29 by its region remote from the free clothing tips 18 (teeth).
In the arrangement shown in FIGS. 3 a and 3 b , the card flat clothing 24 (clothing strip) consists of wire hooks 18 and supporting element 25 . The arrangement additionally has a compensating layer 32 which enables card flat precision to be improved and the attachment surface area to be enlarged. The compensating layer 32 is advantageously an adhesive layer to which there is attached a metal sheet 33 (base) or the like, for example a steel sheet, which is in contact with the magnet 29 .
FIG. 3 a shows the card flat bar 14 and the card flat clothing 24 in the assembled state, the card flat clothing 24 being held so securely by the magnet 29 by way of the steel sheet 33 that, during operation, forces acting through the carding machine on the card flat clothing 24 hold the card flat clothing 24 against the magnet 29 . According to FIG. 3 b , the card flat clothing 24 has, for example in the event of wear, damage or the like to the clothing hooks 18 including the base 33 , been separated from the magnet 29 and removed from the recess 14 f. Separation from the magnet 29 can be effected by means of a suitable tool with which the holding force of the magnet is overcome. The separation can be effected manually even while the carding machine is running, during operation, on the return transport of the card flat bars 14 (see arrow C in FIG. 1 ). The card flat bars 14 are removable from the toothed drive belt (not shown).
In the card flat bar of FIG. 3 a , 3 b , on the fibre material inlet side ES of the clothing 18 —seen in the direction of rotation 4 a of the cylinder 4 (see FIG. 1 )—a counter-bearing 34 is present only on the rib 14 d. The counter-bearing 34 , which projects into the recess 14 f in the form of a shoulder on the rib 14 d, is formed in one piece with the rib 14 d during the extrusion of the card flat bar 14 . In this arrangement, rib 14 d and counter-bearing 34 are merged integrally in one piece. The width of the rib 14 d is denoted by reference letter d. According to FIG. 3 b , the counter-bearing 34 has a width e and a height f. The width e is about from 1 to 3 mm and projects beyond the width d. The length l (not shown) of the counter-bearing 34 corresponds to the working width of the card flat bar 14 across the cylinder 4 and can be, for example, 1000 mm, 1200 mm or 1500 mm or more. The counter-bearing 34 can be of one-part or multi-part construction in the longitudinal direction.
In the embodiment of FIG. 3 b , the supporting element 25 has a width g. The width of the adhesive layer 32 corresponds to the width g of the supporting element 25 . The width h of the sheet metal strip 33 is greater than the width g of the supporting element 25 . In that way, the edge region 33 ′ of the sheet metal strip 33 on the fibre material inlet side ES of the clothing 18 projects beyond the supporting element 25 by amount i. As shown in FIG.3 a , reference letter k denotes the width of the magnetic element 29 .
FIG. 4 shows diagrammatically the installation of the clothing strip 24 in the card flat foot 14 b of the card flat bar 14 and the demounting of the clothing strip therefrom. Because the rib 14 e is not associated with a counter-bearing, stop or the like, the clothing strip 24 , for example having a worn or damaged clothing 18 , can —after separation of the sheet metal strip 33 from the magnetic element 29 —be rotated clockwise in the direction of arrow F out of the recess 14 f. The edge region 33 ′ of the sheet metal strip 33 that projects by amount i (see FIG. 3 b ) is rotated about the upper edge region of the counter-bearing 34 in direction F, the edge region 33 ′ at the same time being withdrawn from a groove 35 in the rib 14 d, which groove runs in the longitudinal direction l of the card flat bar 14 . A new clothing strip 24 is installed in the card flat foot 14 b of the card flat bar 14 in a corresponding way. First the edge region 33 ′ is introduced, around the upper edge region of the counter-bearing 34 , into the groove 35 , so that the clothing strip 24 is rotated anti-clockwise in the direction of arrow G until the sheet metal strip 33 adheres firmly to the magnetic element 29 . In that way, handling during installation and demounting of the clothing strip is problem-free.
By way of illustration with reference to a card top bar according to FIG. 4 , FIG. 5 shows, by the force application point 36 and the angle of application a on the fibre material inlet side ES. Reference letters AS denote the fibre material outlet side. The force that arises in any particular case can vary greatly in magnitude but the force application point 36 and the application angle a is limited. It is therefore possible to create geometric conditions which absorb the forces through an interlocking connection. FIG. 5 shows an exemplary configuration of such an interlocking connection. It will be apparent from, for example, the illustrative embodiment of FIGS. 4 and 5 that the counter-bearing provided, in accordance with the invention, presents on obstacle to removal of the clothing strip in the direction towards the roller, during use, at the position most prone to abnormal carding conditions, that is at the material inlet side of the card flat. On the other hand, the counter-bearing does not impede removal of the strip when desired (see, for example, FIG. 4 ).
Reference letter 4 b denotes the direction of rotation of the cylinder (flow of fibre material). The angle of application a represents a possible variation of the direction of application of the threshold force. The curved arrow I indicates the direction in which in an abnormal operating state, that is to say in the event of the limit force being exceeded, the clothing strip 24 is rotated minimally about a pivot point in the region of the rib 14 e (see FIG. 6 b ).
In accordance with FIG. 6 a , on the fibre material inlet side ES there is a spacing m between the underside of the sheet metal strip 33 serving as base and the upper side 34 ′ of the counter-bearing, 34 . FIG. 6 a represents the normal operating state. According to FIG. 6 b , on the fibre material inlet side ES there is a spacing n between the upper side 33 ′ (see FIG. 3 b ) of the sheet metal strip 33 serving as base and the underside 29 ′ (see FIG. 3 b ) of the magnetic element 29 . FIG. 6 b represents the abnormal operating state. Whereas during normal operation in accordance with FIG. 6 a there is no contact between the marginal regions 33 ′ of the sheet metal strip 33 and the counter-bearing 34 , in the abnormal operating state according to FIG. 6 b the marginal region 33 ′ of the sheet metal strip 33 is supported by, i.e. presses against, the counter-bearing 34 in direction H.
In order that handling during mounting is not appreciably limited, the interlocking connection must be designed to have some play. The spacing m in accordance with FIG. 6 a allows for play. In a case of abnormal operation in which the limit force of the magnet 29 is overcome, the clothing strip 24 together with its metal backing sheet 33 tilts away from the planar magnetic surface 29 ′ (arrow H in FIG. 6 b ) and is supported on the counter-bearing 34 (aluminium edge) of the card flat bar.
The clearance m is significantly smaller than the spacing a (see FIG. 2 ) between the card flat clothing 18 and the cylinder clothing 4 a, so that there is no risk of contact.
In normal operation ( FIG. 6 a ), the magnet 29 absorbs all the operating forces and provides for precision support. In the abnormal operating state ( FIG. 6 b ), the interlocking connection safeguards against contact between the card flat clothing 18 and the cylinder clothing 4 a.
In another embodiment of the invention shown in
FIG. 7 , a card flat bar has an angled side on the counter-bearing 34 ′ and an angled side 33 ″ on the sheet metal strip 33 is provided, the respective angled sides being in interlocking engagement.
In a further embodiment, shown in FIG. 8 , a screw 37 passing through the rib 14 d is provided as counter-bearing. The screw 37 is removable, and the screw 37 allows a settable depth into the recess 14 f for the support of the edge region 33 ′ of the sheet metal strip 33 .
In yet another embodiment, shown in FIG. 9 , a flexible metal sheet 38 is mounted on the outside of the rib 14 d, the limb 38 ′ of which, bent over, serves as counter-bearing.
FIG. 10 shows an embodiment in which there is a counter-bearing 39 on the rib 14 d with which the support layer 25 of the clothing strip 24 co-operates.
In the embodiment of FIG. 11 , a shoulder 25 ′ is present on the supporting element 25 , which shoulder co-operates with the counter-bearing 34 . In this arrangement the turn regions 18 ′ of the clothing 18 are in contact with the magnetic element 29 .
The invention has been explained by way of illustration with reference to the embodiments shown. Further arrangements are included in the scope of protection. For example, in the region of the two end faces of the card flat foot 14 b of the card flat bars 14 there can be provided, in addition or on its own, at least one counter-bearing with which a shoulder on the base 33 and/or on the support member 25 in that region co-operates. The card flat clothing can also be semi-rigid or can be in the form of all-steel clothing, for example sawtooth clothing.
Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims. | In a card flat bar having a card flat clothing, the card flat clothing is magnetically attached to the card flat bar body and, in use, lies opposite a clothed roller. In order to hold the clothing element against the card flat bar in a structurally simple way in the event of an increase in force on the clothing, especially to prevent the card flat clothing from making contact with the cylinder clothing, and to allow quick replacement of the card flat clothing strip, on the fibre material inlet side of the card flat clothing—seen in the direction of rotation of the roller—there is associated with the card flat bar a counter-bearing, stop or the like with which a base of the clothing co-operates in the direction towards the cylinder. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a variable venturi carburetor for an internal combustion engine which may suppress fluctuation in air-fuel ratio by preventing vaporization of fuel at engine idle operation.
In recent years, as a part of development of automobiles having good fuel economy, there has been significant development of reducing fuel consumption wherein the engine is run stably with leaner air-fuel ratio at idle operation and yet with lower idling engine speeds. In a conventional variable venturi carburetor, when temperature of the carburetor body rises after running of the engine at high speeds, temperature of the main fuel jet in the carburetor body also rises and fuel temperature in the fuel well in the main fuel jet rises to create fuel vapor. The fuel vapor influences fuel metering operation at the main fuel jet or it is mixed with air/fuel mixture in the air intake passage, thus fluctuating the air-fuel ratio. Particularly, at idle engine operation at low idling speeds and with leaner air-fuel ratio, fuel combustion condition becomes unstable, and it sometimes causes engine stall.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a variable venturi carburetor which may prevent vaporization of fuel at idle operation and suppress fluctuation of air-fuel ratio to ensure low idling speeds with lean air-fuel mixture.
According to the present invention, the variable venturi carburetor having a carburetor body, a float chamber, a main fuel jet, and a fuel well defined in the main fuel jet comprises means for insulating heat transmitted from the carburetor body to the fuel well which means is provided at the outside of the main fuel jet as surrounding the same. With this arrangement, increase in temperature of the fuel in the fuel well may be suppressed, especially when the temperature of the carburetor body is high, thereby preventing creation of fuel vapor in the fuel well. As a result, fluctuation of air-fuel ratio at idle operation may be suppressed, thereby achieving lower idling speeds with leaner air-fuel ratio; reduced fuel consumption and simplification of the associated exhaust has purifying system.
Various general and specific objects, advantages and aspects of the invention will become apparent when reference is made to the following detailed description of the invention considered in conjunction with the related accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view of the variable venturi carburetor of a first embodiment;
FIG. 2 is an enlarged cross section of the essential part of FIG. 1;
FIG. 3 is a cross section taken along the line III--III in FIG. 2;
FIG. 4 is an enlarged cross section of the essential part of a second embodiment;
FIG. 5 is a cross section taken along the line V--V in FIG. 4;
FIG. 6 is an enlarged cross section of the essential part of the variable venturi carburetor in the prior art;
FIG. 7 is a cross section taken along the line VII--VII in FIG. 6; and
FIGS. 8 and 9 show operational characteristics of the invention as compared with the prior art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1 which shows a variable venturi carburetor of a first embodiment according to the present invention, reference numeral 1 designates a carburetor body of a variable venturi type having a float chamber 2, an air intake passage 3, a throttle valve 4 and a venturi portion 5. Reference numeral 6 designates a fuel passage communicating with the float chamber 2 and the venturi portion 5. The fuel passage 6 is provided with a main fuel jet 7 on the way thereof. The venturi portion 5 is defined upstream of the throttle valve 4 by the inside wall 3a of the air intake passage 3 and the right-hand end portion 8a of a suction piston 8. A suction chamber 9 is defined by a cylindrical portion 1a of the carburetor body 1 and the suction piston 8 slidably mounted in the cylindrical portion 1a. A compression spring 8b is disposed in the suction chamber 9 and serves normally to urge the suction piston 8 toward the inside wall 3a of the air intake passage 3. A vacuum communication port 9a is provided at the right-hand end portion 8a of the suction piston 8 and is adapted to communicate with the suction chamber 9 and the venturi portion 5. An atmospheric pressure chamber 10 is defined by the sliding flange portion 8c of the suction piston 9 and the carburetor body 1 and is provided with an atmospheric pressure communication port 10a in the vicinity of the inlet of the air intake passage 3, whereby ambient air is induced through the port 10. A fuel metering needle 11 is fixed to the right-hand end portion 8a of the suction piston 8 at its central portion. The free end of the metering needle 11 projects into the interior of the main fuel jet 7 for lateral reciprocation therein. The main fuel jet 7 is formed with an opening 7c upstream of a jet portion 7a, and with a fuel well 7b therein. The fuel well 7b is communicated with a slow fuel passage 14 through the opening 7c, an annular chamber 12 and a slow jet 13. The slow fuel passage 14 is communicated with an idle port 15 opened to the air intake passage 3 downstream of the throttle valve 4, passing through the carburetor body 1 and the inside wall plate 3a. The slow jet 13 is communicated with an air bleed passage 17 leading through a bleed jet 16 to the inlet of the air intake passage 3. The slow fuel passage 14 joins the air bleed passage 17 directly downstream of the bleed jet 16.
As shown in FIG. 2, the main fuel jet 7 is provided with an annular recess extending possible maximum length longitudinally on the outer circumference thereof to define an air layer 21. A cylindrical space is defined between the main fuel jet 7 and the carburetor body 1, into which a heat insulator layer 22 is inserted for insulating heat transmitted from the carburetor body 1. As is best seen in FIG. 3, the heat insulator layer 22 is provided with a plurality of elongated grooves extending longitudinally and arranged substantialy equally spaced apart from each other on the outer circumference thereof, whereby another air layer 22a is defined between the heat insulator layer 21 and the carburetor body 1. The main fuel jet 7 and the heat insulator layer 22 are fixed by a fixture member 18 threaded into the carburetor body 1 at their rear end or at their right-hand end in FIG. 2. A compression spring 21a is inserted in the air layer 21 for rearwardly urging the main fuel jet 7 by the preload thereof. The heat insulator layer 22 is preferably made of ceramics and may be made of polyphenylsulphide resin, phenol resin and the like.
As is apparent from FIGS. 2 and 4 in comparison with FIG. 6, the opening 7c and the annular chamber of the invention are reduced in size so as to reduce the area on which the fuel in the fuel well 7b contacts with the carburetor body 1.
Referring next to FIGS. 4 and 5 showing a modified embodiment of the invention, a cylindrical cavity is defined in the carburetor body 1 as surrounding the inner air layer 21, which cavity extends longitudinally along the main fuel jet 7 to define an outer air layer 23. In this embodiment, a heat insulating material is advantageously obviated.
In operation, when the engine is running at idle operation, temperature in the vicinity of the variable venturi carburetor increases and accordingly heat tends to be transmitted to the main fuel jet 7. However, the heat transfer speed may be lowered by the provision of the heat insulator layer 22 and the air layer 22a in the first embodiment, and by the provision of the outer air layer 23 in the second embodiment. The heat transfer speed may be further lowered by the provision of the inner air layer 21. Accordingly, the fuel temperature in the fuel well 7b rises more slowly until it reaches the surrounding temperature as compared with the carburetor in the prior art. As a result, fuel vapor is hardly created in the fuel well 7b, thereby obviating fluctuation of an air-fuel ratio and ensuring stable engine idle operation at low engine speeds and with lean air-fuel ratio even when the temperature in the vicinity of the carburetor body 1 is high.
FIG. 8 shows a change in the temperature of the surrounding of the carburetor body, the fuel temperature in the float chamber and the fuel temperature in the fuel well in the invention in comparison with the prior art at engine idle operation after running of high speeds as a function of time elapsed. As is apparent from the graph in FIG. 8, in the prior art, the fuel temperature in the fuel well is higher than that in the float chamber. On the contrary, in the present invention, it is lower than that in the float chamber due to the effect of the provision of the heat insulator. The fuel temperature in the fuel well in the prior art reaches a peak level after about thirteen minutes are elapsed under the engine idle condition. On the contrary, in the present invention, it reaches a peak level after about nineteen minutes are elapsed.
FIG. 9 shows fluctuations of CO 2 concentration and intake manifold vacuum after about ten minutes are elapsed under the engine idle condition where they are likely to become most unstable. The fluctuations in the invention are reduced more than those in the prior art.
Having thus described the preferred embodiment of the invention it should be understood that numerous structural modifications and adaptations may be restored to without departing from the spirit of the invention. | A variable venturi carburetor for an internal combustion engine in an automobile comprising means for insulating heat transmitted from a carburetor body to a fuel well defined in a main fuel jet of the carburetor. The heat insulating means is provided at the outside of the main fuel jet as surrounding the same. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to vehicle transmissions. More particularly, the present invention relates to transmissions for work vehicles having a Power-Take-Off (PTO). Specifically, the present invention relates to a method of using a PTO clutch for measurement of auxiliary loads.
BACKGROUND OF THE INVENTION
[0002] Conventionally, when shifting gears, many powershift transmissions use solenoid controlled valves to control pressure to each clutch and rely on a signal that is representative of engine load to determine the pressure applied to the on-coming clutches.
[0003] A problem that may occur is that the engine load signal may be misleading. For example, in agricultural tractor applications, there are conditions where much of the engine load may be used to power auxiliary functions such as a hydraulic pump or PTO implements. This may cause problems where the shift quality is harsh because the oncoming clutch pressure is commanded at high pressure when instead it should have been commanded low because there was actually only a small amount of the engine power that was going to the drive wheels.
[0004] A method of overcoming this problem is described in U.S. Pat. No. 6,022,292. In this reference the load signal from the engine is adjusted to assume that part of the load is going to any auxiliary function that is engaged. The load signal is continuously adjusted automatically based upon the resulting shift characteristics. If the tractor slows down excessively during a shift, it is an indication that the assumption of engine load that is going to the wheels is too low. If the tractor speeds up during a shift, it is an indication that the assumption of engine load that is going to the wheels is too high. The problem with this method is that it can only react to a bad shift. It does not prevent the bad shift from occurring in the first place.
[0005] Another problem is that vehicle drivetrains must be designed to handle maximum engine power. However, in some cases some of the engine power is going to auxiliary functions such as PTO implements or hydraulic pumps. In, these cases, it may be desireable to increase engine power because the limiting factor (the drivetrain) is not being loaded to it's capabilities.
[0006] A method of determining the power going to the PTO implement is described in U.S. Pat. No. 6,729,459. In this method the PTO clutch pressure is brought down and maintained at a pressure that produces a constant small amount of slip in the clutch. By knowing the commanded pressure that caused slip, the amount of power going through the PTO clutch can be calculated. Besides providing torque measurment, this method also provides a method of protecting the PTO driveline from shock loading. This primary disadvantage of this system is the power loss that is inherent with continuously slipping the clutch.
[0007] Accordingly, there is a clear need in the art for a method of determining the amount of engine load going to an auxiliary function that avoids the foregoing problems.
SUMMARY OF THE INVENTION
[0008] In view of the foregoing, it is an object of the invention to provide a method for determining the auxiliary load on an engine.
[0009] A further object of the invention is to provide such a method that is compatible with known drivetrain systems and operating techniques.
[0010] The foregoing and other objects of the invention together with the advantages thereof over the known art which will become apparent from the detailed specification which follows are attained by a method for determining the auxiliary load on an engine of a vehicle equipped with a Power-Take-Off (PTO) for driving an auxiliary function, comprising the steps of: monitoring a shaft speed into a PTO clutch as well as a shaft speed downstream of the PTO clutch to determine clutch slippage; periodically ramping down the PTO clutch in pressure until slippage is detected in the clutch; determining a commanded pressure at the point where slippage occurred; calculating an equivalent engine power that is going to the auxiliary function from the commanded pressure at slippage to determine the proportion of the engine load signal that is going to the auxiliary function versus the drive wheels.
[0011] In general, when an auxiliary device is being powered by the PTO driveline the PTO clutch is periodically slowly ramped down in pressure until slippage is detected in the clutch. Slippage is determined by monitoring the shaft speed into the clutch as well as the shaft speed downstream of the clutch. By determining the commanded pressure where slippage occurred, the equivalent engine power that is going to the auxiliary function is calculated. With this information, the proportion of the engine load signal that is going to the auxiliary function versus the drive wheels is determined. After slip is detected in the PTO clutch, pressure is ramped back up in the clutch so as to minimize the amount of slippage.
[0012] The primary difference between this method and that described in U.S. Pat. No. 6,729,459 is that the PTO clutch is only periodically brought down in pressure until it slips versus being brought down in pressure to the point where it would be continuously slipping. This is advantageous in that it reduces the power loss that is a result of continuously slipping a clutch.
[0013] To acquaint persons skilled in the art most closely related to the present invention, one preferred embodiment of the invention that illustrates the best mode now contemplated for putting the invention into practice is described herein by and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to show all of the various forms and modifications in which the invention might be embodied. As such, the embodiment shown and described herein is illustrative, and as will become apparent to those skilled in the art, can be modified in numerous ways within the spirit and scope of the invention—the invention being measured by the appended claims and not by the details of the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a complete understanding of the objects, techniques, and structure of the invention reference should be made to the following detailed description and accompanying drawings, wherein:
[0015] FIG. 1 is a schematic block diagram of a transmission control system according to the present invention;
[0016] FIG. 2 is a logic flow diagram illustrating an algorithm executed by the transmission controller of FIG. 1 ; and,
[0017] FIG. 3 is a logic flow diagram illustrating an algorithm represented by step 126 of FIG. 2 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] With reference now to the drawings, and more particularly to FIG. 1 , it can be seen that a microprocessor-based transmission control system to which the present invention is applicable is designated generally by the numeral 10 . A vehicle power train includes an engine 12 which is controlled by electronic engine control unit 14 , and which drives a power shift transmission (PST) 16 via input shaft 13 . Transmission 16 has an internal countershaft (not shown), and an output shaft 18 which is connected to drive wheels (not shown). The PST 16 includes a set of pressure operated control elements or clutches 20 which are controlled by a corresponding set of solenoid operated proportional control valves 22 . The transmission 16 may be a transmission such as described in U.S. Pat. No. 5,011,465, issued Apr. 30, 1991 to Jeffries et al., and assigned to the assignee of this application. The valves 22 may be two-stage electro-hydraulic valves as described in U.S. Pat. No.4,741,364, issued May 3, 1988 to Stoss et al. and assigned to applicant's assignee.
[0019] The PST 16 is controlled by a transmission control unit 24 , an armrest control unit 26 which receives and interprets shift lever commands from shift command lever unit 28 . Shift command lever unit 28 is preferably a conventional shift command lever unit used on production John Deere tractors, and includes a gearshift lever 29 . Such a shift command lever unit is described in U.S. Pat. No. 5,406,860, issued Apr. 18, 1995 to Easton, et al., and assigned to the assignee of this application. A display unit 30 may display information relating to the system 10 . The transmission control unit 24 and the armrest control unit 26 are preferably microprocessor-based electronic control units.
[0020] Manual control is achieved via an operator-controlled gearshift command lever unit 28 . Unit 28 provide signals representing the position of the lever 29 to the armrest control unit 26 . The armrest control unit 26 sends gear command information to transmission control unit 24 via a vehicle communication bus 31 .
[0021] A clutch engagement sensor 32 and a clutch disengagement switch 34 provide signals representing the position of a clutch pedal 36 . The engine control unit 14 receives signals from an engine speed sensor 38 , as well as other sensors (not shown) which enable the engine control unit to transmit engine load information on the vehicle communication bus 31 . The transmission controller 24 receives signals from an axle speed sensor 40 , a counter-shaft speed sensor 42 which senses the speed of an intermediate shaft or counter-shaft which is internal to the transmission 16 , and a transmission oil temperature sensor 44 . The transmission controller 24 sends wheel speed (calculated from the axle speed based on tire size), and oil temperature information to the display 30 via the vehicle communications bus 31 . The intermediate shaft speed information is used only for control purposes and is not displayed under normal operating conditions.
[0022] The transmission 16 further includes a PTO drive 46 for driving an auxiliary device or implement (not shown) by way of a PTO output shaft 48 . The PTO drive 46 is engaged via a PTO clutch 50 . The speed of the PTO output shaft 48 is measured by a PTO speed sensor 52 which communicates with the transmission controller 24 .
[0023] The transmission control unit 24 includes a commercially available microprocessor which supplies control signals to a set of valve drivers (not shown) which provide variable duty cycle pulse-width-modulated voltage control signals to the valves 22 . The transmission control unit 24 generates control signals as a function of various sensed and operator determined inputs in order to achieve a desired pressure in the clutches and to thereby control the shifting of the transmission 16 in a desired manner.
[0024] The transmission controller 24 executes a known production main loop algorithm (not shown) which controls the time varying hydraulic pressures which are applied to the various transmission clutch elements. In accordance with the present invention, the controller also executes an algorithm represented by FIGS. 2 and 3 . The conversion of the flow charts of FIGS. 2 and 3 into a standard language for implementing the algorithm described by the flow chart in a digital computer or microprocessor, will be evident to one with ordinary skill in the art.
[0025] FIG. 2 illustrates how the method is executed in a microcomputer based control system. The sequence from Start to End in FIG. 2 is executed by a task manager type of a real time operating system at some periodic interval running in the transmission controller. The scope of the invention does not include the normal engagement strategy of the PTO. At the start of this algorithm, it is assumed that the PTO has been turned on and is fully engaged. If the PTO is not turned on and fully engaged, the algorithms of the invention do not run. The result of this logic at the End is a PTO commanded pressure in kPa. The downstream processes that apply this commanded pressure electronically to the PTO Clutch via the EH PTO Valve and other factors which might influence the final commanded pressure are not within the scope of the invention.
[0026] In FIG. 2 at 100 it can be seen that the first step in the PTO Torque Measurement process is to determine if the transmission clutch is fully engaged and the transmission is in gear. If this criterion is not met, the PTO Torque Measurement will be disabled by resetting the PTO Torque Measurement Timer at 108 (referred to simply as “timer” in the description that follows) and at 116 the commanded pressure will remain unchanged. The timer then provides an initial time delay to the first torque measurement in the event that the transmission clutch becomes fully engaged and the transmission fully shifts into a gear.
[0027] At 102 the second criteria for a PTO Torque Measurement attempt is checked to see if a transmission shift is in progress. If so, then the PTO Torque Measurement will either not begin, in which case at 112 the timer is simply incremented and the commanded pressure maintained at 100%, or in the event that a PTO Torque Measurement is in progress at the time of the shift as at 104 , the current torque measurement will be aborted as shown at 106 and the commanded pressure will be ramped back up to full pressure at 122 , if the commanded pressure is less than 100% of full pressure as at 114 at the time the shift is initiated.
[0028] If a transmission shift is not in progress, then the timer is incremented and limited to prevent overflow at 110 and checked to see if a new PTO Torque Measurement should be taken at 118 . If it is not time to start a PTO Torque Measurement, the commanded pressure is not changed. If it is time to start a new PTO Torque Measurement, clutch slip is checked at 124 before clutch slip logic is executed at 126 . If slip has been detected, then pressure is ramped back up to 100% and the timer is reset for the next measurement cycle. If slip has not been detected, then the clutch slip logic is executed.
[0029] The output of the clutch slip logic is a commanded pressure to the PTO clutch while the algorithm is running. When slip is detected, the PTO Torque is calculated as a function of the pressure command at which slip was detected. The pressure is then ramped back up to full pressure at 130 , 134 and the timer reset for the next measurement attempt.
[0030] The details of the clutch slip logic of block 126 of FIG. 2 are now discussed with reference to FIG. 3 . The first step 200 in the clutch slip logic is to obtain current data on engine speed 200 A, engine load (i.e. brake torque) 200 B, PTO shaft speed 200 C, and the PTO to engine speed ratio 200 D. If at 202 it is the first pass through the software routine for the clutch element, then a predicted slip pressure is calculated based on the engine load at 204 , assuming that all the engine load is going to the PTO. The equation that relates the amount of engine torque going through the transmission to the slip pressure is the following:
Engine torque(Nm)=slip pressure(kPa)* m+b
[0031] The slope m and the intercept b are found empirically. A predicted slip pressure can be calculated by using the above equation, solving for slip pressure. The equation is as follows:
Predicted slip pressure (kPa)=(engine torque− b )/ m
[0032] In this algorithm, the empirically found intercept b is made relative to the value of the calibrated fill pressure for the PTO clutch element by subtracting the product of the calibrated fill pressure and slope m. Thus, the equation developed from a set of experimental data can be applied to all vehicles to which the invention applies.
[0033] Each time the algorithm is executed, a decision is made at 206 to determine if the algorithm is in the fast ramp down phase. The PTO clutch has a loop counter associated with it in software that indicates the number of passes through the clutch slip function since the torque measurement started. The decision of whether or not the algorithm should execute the fast ramp down phase or proceed to the gradual ramp down phase is based solely on the value of this loop counter. If the Loop Counter is less than some value, 6 for example, the algorithm executes a fast ramp down in pressure on the clutch. The predicted slip-pressure mentioned above, sets the target pressure for the initial fast ramp down software at 208 . An example equation that might be used to calculate the commanded pressure output during this fast ramp down phase is:
Commanded Pressure=Previous Pressure Output−(Target Change*2/3)
[0034] In the above equation, the Target Change is the difference between the Previous Pressure Output and predicted slip pressure mentioned above, where the previous pressure output is initialized to full system pressure. Another approach would be to base the pressure output on a lookup table. An example might be:
Pressure Output Loop Counter Predicted Slip Pressure + Offset 1 Predicted Slip Pressure + Offset 2 Predicted Slip Pressure + Offset 3 System Pressure 4 System Pressure 5 Predicted Slip Pressure + Offset 6
[0035] The intent of the fast ramp down phase is to decrease pressure on the PTO clutch rapidly to a pressure that is slightly above where the engine load signal indicates the clutch element will just begin to slip, if the entire engine load is going to the PTO. This method is used simply in an effort to minimize the algorithm's overall execution time. The profile of the pressure command during the fast ramp down phase is determined empirically to minimize pressure undershoot.
[0036] Once this pressure is reached, the algorithm moves on to the gradual pressure ramp down phase at 210 . During this phase, the pressure command is reduced gradually, by a fixed amount each time through the routine, 2 kPa for example, while the software attempts to detect slip in the PTO clutch. Slip is defined as relative motion between the PTO clutch plates. Slip Ratio is calculated as follows:
Slip Ratio=(PTO shaft speed*PTO gear ratio)/engine speed
[0037] In this algorithm, the slip ratio is calculated with a precision of 0.1%.
[0038] The slip ratio is passed through a noise rejection algorithm at 212 that consists of an N/(N+1) digital average filter and additional logic. Actual slip is calculated based on the filtered value of the slip ratio. If negative slip is being detected, a slip ratio of 0.980 would correspond to an actual slip of 2.0%. If positive slip is being detected, a slip ratio of 1.020 would correspond to an actual slip of 2.0%. The additional logic consists of checking the direction of the slip (positive or negative) and comparing the current slip measurement with the value from the previous pass through the algorithm. Valid slip detection is made at 214 if the current slip is greater in magnitude than the previous value of slip, in the same direction, and is greater than some threshold. Furthermore, a control parameter exists in memory for each clutch element to set how many of these valid slip events must be seen before slip is detected. In practice, it has been found that the following parameters are effective for the PTO clutch:
N=3 Required Valid Slip Events=1 Slip Detection Threshold=2.0%
[0042] For PTO Torque Measurement, negative slip is the desired detection option. If slip is not detected at 214 , then a fixed amount of pressure is subtracted from the previous pressure command and this becomes the new desired pressure at 218 . If slip is detected at 214 , then at 216 the pressure command is processed back through the linear equation above to produce a calculated PTO Torque, and the commanded pressure remains unchanged at 220 . This calculated PTO Torque is then made available in software for other processes that can benefit from it, transmission shift algorithms for example. A flag in software is also available that indicates when the slip is detected and the torque calculation is made. This flag is used by parent processes in order to effectively take back control of the commanded pressure (i.e. in order to know when to ramp pressure back up on the PTO clutch), as would be the case in the “YES”path of block 124 in FIG. 2 .
[0043] A downstream process that is always executed after the clutch slip logic is a boundary check on the commanded pressure that is output from the clutch slip logic. If the commanded pressure is reduced to a minimum value without clutch slip being detected, then the parent process described in FIG. 2 will set the slip detected flag and calculate the PTO Torque from that minimum pressure value at 136 . Then, the pressure would be ramped back up to 100%, etc.
[0044] Those having skill in the art will now recognize that by knowing how much of the engine power is going to the drive train and how much is going to auxiliary loads it is possible to improve Powershift transmission shift quality during conditions of auxiliary load such as PTO implements. Further, the transmission clutch pressure used during the shift can be matched to handle only the engine load that is going to the drive wheels. Additionally, engine power can be increased without compromising drive train life (when part of the engine power is going to the auxiliary load).
[0045] Thus it can be seen that the objects of the invention have been satisfied by the structure presented above. While in accordance with the patent statutes, only the best mode and preferred embodiment of the invention has been presented and described in detail, it is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly and legally entitled.
Assignment
[0046] The entire right, title and interest in and to this application and all subject matter disclosed and/or claimed therein, including any and all divisions, continuations, reissues, etc., thereof are, effective as of the date of execution of this application, assigned, transferred, sold and set over by the applicant(s) named herein to Deere & Company, a Delaware corporation having offices at Moline, Ill. 61265, U.S.A., together with all rights to file, and to claim priorities in connection with, corresponding patent applications in any and all foreign countries in the name of Deere & Company or otherwise. | A method is provided wherein when an auxiliary device is being powered by the PTO driveline the PTO clutch is periodically slowly ramped down in pressure until slippage is detected in the clutch. Slippage is determined by monitoring the shaft speed into the clutch as well as the shaft speed downstream of the clutch. By determining the commanded pressure where slippage occurred, the equivalent engine power that is going to the auxiliary function is calculated. With this information, the proportion of the engine load signal that is going to the auxiliary function versus the drive wheels is determined. After slip is detected in the PTO clutch, pressure is ramped back up in the clutch so as to minimize the amount of slippage. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to exercise devices, and more particularly of the type having a rotatable foot platform and poles grasped by hand and moved reciprocatingly. The body motions induced by the devices include twisting about the pelvis and reciprocating projection of the forearm. The present invention adds a system for controlling music accompanying use of the apparatus, as well as a computerized calculator and display for totalizing and reporting movement repetitions and calories expended in performing the exercise.
2. Description of the Prior Art
Fitness and physiological condition have become ever more popular over the years, and equipment and facilities for providing exercise have developed accordingly. Small devices and machines for enabling a single person to exercise are available in commercial exercise establishments and for sale to individual consumers. Exercise equipment enables a person to focus muscular development of individual muscles and groups of complementing muscles. Cardiovascular development has also received attention from exercise apparatus.
One of the popular forms of exercise equipment is that class providing a rotating foot platform for the feet and handles for the hands. In this type of equipment, the user stands on one or more rotatable foot platforms and grasps one handle in each hand. The handles may be joined to a common member or may be individually mounted to dedicated poles pivotally mounted to the equipment. Resistance to pivoting the handles is typically provided to increase effort required by the hands and arms. This resistance may be adjustable. Such devices are typically purely mechanical in their operation, and examples are set forth below.
This type of equipment is seen in U.S. Pat. Nos. 5,284,461, issued to William T. Wilkinson et al. on Feb. 8, 1994, 5,344,376, issued to James R. Bostic et al. on Sep. 6, 1994, and 5,527,253, issued to William T. Wilkinson et al. on Jun. 18, 1996. These features are found in the present invention. However, these prior art inventions lack a system for controlling accompanying music and a calculator and associated display for counting movement repetitions and calculating effort, and reporting calories expended while exercising and number of movement repetitions performed. The music control system, calculator, and display as described form part of the present invention.
U.S. Pat. Nos. 5,433,690, issued to Stewart B. N. Gilman on Jul. 18, 1995, and 5,599,262, issued to Ching-Fu Shih on Feb. 4, 1997, set forth exercise apparatus including a rotatable foot platform and hand bars.
However, the hand bars of Gilman and Shih are solidly fixed to one another, lacking reciprocation in opposing directions, as seen in the present invention. Gilman and Shih also lack the music control system, calculator, and display of the present invention.
Automated counting and calculation of effort, and displays for reporting totalized counts and summed effort are known in other types of equipment. However, the present inventor is unaware of any such calculating and displaying scheme similar to that of the present invention.
It is also known to perform exercises offering cardiovascular benefits, popularly known as aerobic exercises, to the accompaniment of music or audible rhythmic beats. Once again, the present inventor is unaware of devices for reproducing music and audible rhythmic beats similar to those of the present invention.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention includes three rotatable foot platforms and a pair of levers or poles each of which is grasped by one hand by the user. The novel exercise machine improves upon otherwise similar prior art exercise devices in that the three foot platforms enable both dance routines as well as twisting exercises, and also in that the invention incorporates a music synthesizer for directing use and a microprocessor and display for sensing and reporting aspects of exercise and controlling the music synthesizer. The music synthesizer produces audible accompaniment such as music or a beat or rhythm attuned to the pace of bodily motions. The pace or rhythm is adjustable to the user's preference.
The levers enable a person performing exercises to pull and push with his or her arms against an adjustably variable resistance while exercising. Alternatively, the levers may be fixed in a generally vertical position. The three foot platforms enable the body position of the user to be oriented squarely with respect to the hand levers, or to be oriented in an oblique stance wherein one leg is closer to the hand levers than is the other leg.
Exercises range from uncomplicated repetitive twisting of the torso to more complicated motions simulating dance routines. The arms of the user react to twisting of the torso move in a resistive effort wherein the hand is thrust out forwardly and subsequently drawn back towards the body, or alternatively the hands maintain constant position even as the arms move to accommodate motion of the torso.
The foot platforms have sensors which send signals to an onboard microprocessor. The signals indicate the extent or magnitude of twisting bodily motion. This data may be related to other data, such as body weight, frequency of motions, and others, and may lead to calculation of energy expended while exercising. Cumulative count of motion repetitions and energy expenditure in the form of calories consumed, as well as information relating to operating the novel exercise device are shown on the display.
The role of audible accompaniment provides great psychic encouragement and stimulation while exercising. This function replicates separate audible and videotapes which are commercially available for automated supervision of exercising. Many exercises and dance routines become onerous in the absence of stimulation and encouragement by audible accompaniment. The invention improves upon the stimulation provided by videotapes, televised audible and visual accompaniment, and similar remote supervision of exercises and dance routines by enabling the user to adjust the tempo or pace of the stimulus, the sound volume, and other characteristics according to individual preferences. At the same time, the user is advised of sensed and calculated quantified parameters of a session's efforts. This type of quantified feedback is frequently greatly encouraging, since it provides a reference or benchmark against which the user may measure progress and attainment of milestones relative to physical conditioning. The invention thus provides necessary apparatus, sensory stimulation, and quantified feedback which together enable the novel exercise device to satisfy most psychological requirements leading to psychologically and physiologically successful exercise on a machine.
Accordingly, it is a principal object of the invention to provide an exercise machine of the type enabling twisting of the torso and simultaneous reactive effort by the arms.
It is another object of the invention to provide audible stimulus or accompaniment for exercises, which stimulus is attuned and adjustable to a desired pace of bodily motions.
It is a further object of the invention to calculate repetitions and magnitude of bodily motions and to calculate energy expenditure while exercising.
Still another object of the invention is to provide a visual display for displaying sensed repetitions and calculated energy expenditures.
An additional object of the invention is to enable body stances in which the body is selectively squarely and obliquely to the hand levers.
It is again an object of the invention to selectively enable pivoting of the hand levers against variable resistance to movement of the hand levers and to immobilize the hand levers.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features, and attendant advantages of the present invention will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 is a front perspective view of the apparatus of the invention.
FIG. 2 is an exploded, exaggerated detail view of components seen at the center of FIG. 1.
FIG. 3 is a diagrammatic exploded detail view typical of circular components seen towards the bottom of FIG. 1.
FIG. 4 is a rear elevational detail view of a component seen towards the center of FIG. 1.
FIG. 5 is a block diagram illustrating control and logic components of the invention and their relationship.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to FIG. 1 of the drawings, novel exercise machine 10 is seen to comprise a base 12 for supporting the other components on a horizontal surface (not shown). The components of exercise machine 10 engaging the body of a user while exercising include three rotatable foot platforms 14, 16, 18 and two hand levers 20, 22. Hand levers 20, 22 generally project upwardly from their mounting at an axle arrangement comprising a threaded bolt 24, the head 26 of which is seen at the left. The axle arrangement is supported on a mast 28 fixed to base 12.
Hand levers 20, 22 can pivot relative to bolt 24 and therefore relative to base 12. In use, they are grasped by the user, one in each hand. The user places one foot on one foot platform 14, 16, or 18, one foot platform 14, 16, or 18 being unoccupied. Foot platforms 14 and 16 are located proximate and equidistantly from hand levers 20, 22. Foot platform 18 is located distally and preferably equidistantly from hand levers 20, 22. With each foot placed off center on its selected foot platform 14, 16, or 18, the user grasps hand levers 20, 22 and performs exercises causing the torso to twist about a vertical axis. The user has previously determined whether to enable hand levers 20, 22 to pivot about bolt 24 or whether to immobilize hand levers 20, 22 relative to base 12. A mechanism for immobilizing hand levers 20, 22 is provided in the form of a pin 30 which is inserted through openings 32, 34, and 36 formed respectively in hand levers 20 and 22 and mast 28. Obviously, many stances are possible given the choice of foot positions and selection of immobilization or pivoting of hand levers 20, 22.
Exercise machine 10 has a display, such as liquid crystal display 38 fixed to mast 28 such that the user may monitor his or her performance. A microprocessor 42 (see FIG. 5) and controls (see FIG. 4) for controlling automated functions of exercise machine 10 are contained in or on an enclosure 44 preferably fixed to base 12.
Details of an adjustment mechanism of the axle arrangement providing pivotal mounting of hand levers 20, 22 are shown in FIG. 2. Each hand lever 20 or 22 has an associated mounting disc 46 or 48. Each mounting disc 46 or 48 is surrounded at two sides by low friction washers 50 and 52 or 54 and 56. Washers 50, 52, 54, 56 are faced with a low friction material such as polytetrafluoroethylene. A compression fitting having discs 58, 60 connected by a spanning member 62 surround mast 28, washers 50, 52, 54, 56, and mounting discs 46, 48. The compression fitting and each one of the components surrounded by the compression fitting has a smooth bore (shown but not identified by reference numeral) enabling passage of bolt 24 therethrough and smooth lateral faces for abutting adjacent components.
A compression nut 64 having a suitable hand grip 66 threads onto the threaded end 68 of bolt 24. Compression nut 64 has a threaded hole 70 compatible with threaded end 68 of bolt 24. Resistance to free or unimpeded pivoting of hand levers 20, 22 about bolt 24 is adjusted by tightening and slackening compression nut 64. The low friction characteristics of washers 50, 52, 54, 56 cause resistance to increase and decrease gradually and progressively responsive to tightening and slackening of compression nut 64.
Details of a rotatable mounting typical of each foot platform 14, 16, or 18 are shown in FIG. 3. Each foot platform 14, 16, or 18 has a rubber tread member 72 mounted to a wooden platform 74. Wooden platform 74 is fixed to an upper bearing race 76 which rides rotatably on a lower bearing race 78. A bearing assembly 80 having a bearing retainer 82 holding ball bearings 84 in place is disposed between bearing races 76 and 78. Lower bearing race 78 is fixed to base 12. Upper bearing race 76 is suitably constrained against escaping from a captive position mounted to base 12. This may be accomplished by any known structure and method, details of which need not be set forth in further detail herein. Preferably, only tread member 72 projects above the upper surface of base 12 when foot platforms 14, 16, 18 are assembled and operable.
Automated functions of exercise machine 10 include counting repetitions of twisting motions, determining energy expended while exercising, displaying the aforementioned data, and producing musical or rhythmic audible accompaniment for exercising. The user may select and adjust these functions by operating controls shown in FIG. 4. The controls may be mounted on the rear panel of enclosure 44. Controls include an on-off switch 86 controlling electrical power obtained from a power cord and plug assembly 87, a selector switch 88 selecting the style of music or beat to be produced by sound synthesizer 90 (see FIG. 5), an adjusting controller 92 selecting a pace or tempo of the music or beat, and a volume control 94 governing sound volume of the music or beat.
Optionally, display 38 may be controlled by pushbuttons 96, 98, 100 for displaying calculation of energy expended in the form of calories, the number of repetitions of twisting motions, and real or elapsed time.
Referring now to FIG. 5, apparatus enabling the automated functions is described. Each foot platform 14, 16, or 18 has mounted to wooden platform 74 or to upper bearing race 76 a signal generator, such as a magnet 102. A series of transducers 104 are disposed proximate each foot platform 14, 16, or 18 so as to sense passing of its associated signal generator 102. In the example depicted in FIG. 5, each foot platform 14, 16, or 18 has a first transducer 104 disposed at a position corresponding to the neutral position wherein signal generator 102 faces forwardly towards mast 28 (see FIG. 1). Additional transducers 104 are disposed at thirty degree intervals of deviation from the neutral position, so that each foot platform 14, 16, or 18 can signal the extent or magnitude of twisting motion achieved by the user. Each transducer 104 has a communications cable 108 transmitting a signal generated by proximity or passing of signal generator 102 with respect to each transducer 104 to pulse generator 106. Thus, signal generators 102 and transducers 104 combine to form sensors for sensing degree of pivot of each foot platform 14, 16, or 18 relative to base 12. Pulse generator 106 transforms signals derived from transducers 104 to a form compatible with microprocessor 42.
Microprocessor 42 receives inputs from pulse generator 106, from a real time clock or counter 110, and from controls 112. Controls 112 are collectively those described with reference to FIG. 4. Microprocessor 42 has a data processor (not separately shown), memory (not separately shown), and software (not separately shown) suitable for carrying out commands entered by controls 112 and for making calculations as described prior. Microprocessor 42 drives display 38 and controls sound synthesizer 90 according to commands entered by controls 112. Additional components, such as suitable relays, drivers, and other intermediate components well known in the art will be understood to be furnished where required. These components, as well as those of microprocessor 42 and suitable software, may be those employed for prior art computerized equipment, sound or music synthesizers, and need not be set forth in greater detail.
There has been set forth an exercise machine 10 capable of accommodating aerobic exercises and dance routines and having the further ability to generate music or other sounds for accompanying and directing exercises and dance routines, for counting and displaying the number of motions performed, and for calculating and displaying energy expended while exercising. The invention thus improves over prior art devices by providing the automated functions set forth above, thereby rendering the improved machine 10 complete and self-contained, obviating necessity for auxiliary audiovisual equipment, and enabling adjustments to be made according to the individual user's preferences. This invention is susceptible to variations and modifications which may be introduced without departing from the inventive concept.
For example, controls 88, 92, and 94 (see FIG. 4) are dedicated to specific characteristics of music or other sound generated by sound synthesizer 90 (see FIG. 5). Of course, other characteristics of the audible output of sound synthesizer 90 may be provided. Many musical and non-musical effects are known within the field of music generators, and any of these may be adapted to the present invention.
It would also be possible to locate controls 112 on or near display 38, so that they are readily available to the user, who may then control exercise machine 10 without dismounting. Microprocessor 42, sound synthesizer 90, pulse generator 106, time clock 110, and other components may be contained within enclosure 44 or alternatively within base 12, mast 28, the housing of display 38, or within any other suitable part of exercise machine 10.
Microprocessor may have software for relating magnitude and frequency of sensed twisting motions to energy expended.
The calculations performed thereby may be improved in accuracy by entering into memory data corresponding to body weight of the user or other parameters.
Hand levers 20, 22 may be mounted within base 12 rather than on mast 28. Foot platforms 14, 16, 18 may be rearranged as desired. The tension arrangement for adjusting resistance of hand levers 20, 22 may take other forms, such as by incorporating springs, fluid resistance, and other devices for imposing resistive forces on hand levers 20, 22.
Similarly, the arrangement utilizing pin 30 for immobilizing hand levers 20, 22 may take other forms, such as a threaded set screw.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | An exercise machine providing selectively variable rhythmic audible accompaniment for torso twisting and arm thrusting motions. The machine has three rotatably mounted foot platforms and two upwardly projecting, pivotable hand levers. Two of the three foot platforms are located proximate to and equidistant from the hand levers and the remaining foot platform is located distally from the hand levers. The hand levers are adjustable as to resistance to pivoting, and alternatively may be fixed in place if arm motions are not desired. A music synthesizer controls tempo of exercises. Tempo, beat, volume, and other characteristics of the music may be controlled by the user. A microprocessor sums the number and frequency of body motions and calculates energy expended while exercising. This information is transmitted to a display visible to the user. | 0 |
TECHNICAL FIELD
[0001] The present invention relates to a dewatering apparatus for a gas hydrate slurry, and more specifically, to a dewatering apparatus in a production plant of gas hydrate in which a gas hydrate slurry is generated by being subjected to a hydration reaction of raw material gas such as methane or the like, and raw material water.
BACKGROUND ART
[0002] In recent years, natural gas which contains methane or the like as a major component has captured much of the spotlight as a clean energy source. Then, for purpose of transportation and storage, a practice of transforming such a natural gas into a liquified natural gas (hereinafter, referred to as LNG) is being conducted. Since, however, the transportation and storage of a gas in the form of a LNG requires maintaining it in a cryogenic state, not only a generation system but also a transportation system and a storage system have become quite expensive. As a consequence, they are limited to only large-scale gas fields, and were economically unfeasible for smaller-scale gas fields.
[0003] Under these circumstance, studies on manufacturing natural gas hydrate (hereinafter, simply referred to as gas hydrate) by causing natural gas to react with water, and transporting or storing it through the gas hydrate are being carried out. With regard to this gas hydrate, it is well known that the raw material gas and the raw material water are introduced into a reactor in which a predetermined temperature and pressure selected from among, for example, temperatures of 1 to 10° C. and atmospheric pressures of 30 to 100 atmosphere are retained, to generate a slurry which contains a crystalline-like gas hydrate. Then, this slurry is introduced into a dewatering apparatus to separate and remove unreacted water, and is subsequently again brought into contact with the raw material gas to manufacture a powdery gas hydrate having low water content.
[0004] In a production plant for such a gas hydrate, a horizontal screw press-type dewatering apparatus and a vertical gravity-type dewatering apparatus are proposed as a dewatering apparatus (e.g., Patent Document 1).
[0005] A horizontal screw press-type dewatering apparatus as described in such a Patent Document 1 is made of a double construction combined with a mesh-processed inner wall, and a cylindrical body constituting an outer shell situated at the outside of the inner wall, and it is configured such that a gas hydrate is drained from meshes processed on the inner wall by advancing the gas hydrate while forcedly squeezing it by a screw shaft mounted inside the inner wall.
[0006] In such a dewatering apparatus, the gas hydrate was consolidated and was adhered to the surface of a screw, during said process of dewatering said gas hydrate. As a result a load of the screw shaft was increased, and thus such a dewatering apparatus was required to be driven at a high torque.
[0007] Thus, in order to solve the problem with said dewatering apparatus, the present inventors have studied a dewatering apparatus in which the gas hydrate slurry is supplied into the cylindrical body by a slurry pump, and water is drained naturally from a porous portion of the cylindrical body while causing it to move up in succession, through the use of a vertical-type dewatering apparatus having a separating section formed to be porous at an intermediate section of a cylindrical body (e.g., Patent Documents 2, 3).
[0008] The vertical-type dewatering apparatus as described in Patent Document 2, the present inventors previously proposed, includes a cylindrical main body with drain holes formed at substantially intermediate section, and a dewatering collecting section (drainage chamber) provided around said drain holes. Then, the gas hydrate slurry supplied to the dewatering apparatus is designed to be dewatered resulting from unreacted water being drained from said drain holes.
[0009] Further a vertical-type dewatering apparatus as described in Patent Document 3, the present inventors previously proposed, is configured such that a dewatering column is made of a double cylindrical construction consisting of two cylindrical bodies of an internal tube and an external tube, and dewatering filtration elements are provided on both side walls of the internal tube and external tube respectively, then the unreacted water is caused to outflow to the outside of the column through both the filtration elements provided on the internal tube and the external tube.
[0010] Incidentally, since a dewatering apparatus as described in said Patent Document 2 is configured such that water and hydrate are separated by the action of gravity, there was a problem of slow rates at which the unreacted water is drained from said drain holes. In addition, the dewatering column must be high enough to enhance dewatering efficiency, and thus there was a problem with the increase in size of the apparatus.
[0011] A dewatering column as described in the other Patent Document 3 includes an annular-shaped bottom plate, an annular-shaped shielding plate, a gas hydrate-crushing device, and plural tabular blades provided in radial form at the lower end and so on, to form a complicated construction. Therefore, there was a problem that a period required to manufacture the dewatering column becomes longer, along with a higher cost.
Patent Document 1: Japanese Patent Application Kokai Publication No. 2003-105362
Patent Document 2: Japanese Patent Application Kokai Publication No. 2006-111769
Patent Document 3: Japanese Patent Application Kokai Publication No. 2006-257359
DISCLOSURE OF THE INVENTION
Subject to be Solved by the Invention
[0012] Thus, the present inventors, in view of the problems in said Patent Documents 2 and 3, have sought to provide a dewatering column of a simple construction that restricts the height of a cylindrical main body of the dewatering column and improves a drainage capability in the middle part of a gas hydrate layer.
Means for Solving Subject
[0013] The present invention was made to solve the above-described conventional problems, and a dewatering method in a production plant of a gas hydrate according to the present invention is a method for dewatering unreacted water contained in a gas hydrate slurry generated through gas-liquid contact between raw material water and raw material gas, characterized in that an external tube is arranged around an internal tube of said dewatering apparatus to form a drainage section, and a pressure difference between said drainage section and a gas hydrate layer formed at the upper level than a drainage section of said internal tube is generated by exhausting a gas of said drainage section and/or introducing a gas from the upper part of said internal tube.
[0014] Then, the dewatering apparatus in the production plant of the gas hydrate according to the present invention is an apparatus to dewater the unreacted water contained in the gas hydrate slurry purified through gas-liquid contact between the raw material water and the raw material gas, characterized in being configured such that an external tube is arranged around an internal tube of said dewatering apparatus to form a drainage section, and a pressure difference between said drainage section and the gas hydrate layer formed at the upper level than the drainage section of said internal tube is generated by exhausting a gas in said drainage section and/or introducing a gas from an upper part of said internal tube.
EFFECT OF THE INVENTION
[0015] With a dewatering method for a gas hydrate according to the invention of claim 1 , a difference between a pressure inside a drainage chamber and a pressure inside an internal tube where the gas hydrate comes up is detected by a differential pressure detector, and an operation of an intake blower and/or a gas feed blower are controlled according to its signal. Therefore, a pressure difference between inside the drainage chamber and inside the internal tube can be retained at a predetermined value and its differential pressure can be increased, and as the unreacted water contained in the gas hydrate is squeezed from the drainage section, dewatering efficiency is improved.
[0016] With a dewatering apparatus of the gas hydrate according to the invention of claim 2 , a difference between a pressure inside the drainage chamber and a pressure inside an internal tube where the gas hydrate comes up is detected by a differential pressure detector, and an operation of an intake blower and/or gas a feed blower is controlled according to its signal. Therefore, a pressure difference between inside the drainage chamber and inside the internal tube can be retained at a predetermined value, and its differential pressure can be increased, and the unreacted water contained in the gas hydrate is squeezed and drained from the drainage section. As a result, a dewatering apparatus having good performance and in a small size can be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic view of the first exemplary embodiment of a dewatering apparatus in a production plant of a gas hydrate according to the present invention.
[0018] FIG. 2 is a schematic view of the second exemplary embodiment of a dewatering apparatus in a production plant of a gas hydrate according to the present invention.
[0019] FIG. 3 is a schematic view of the third exemplary embodiment of a dewatering apparatus in a production plant of a gas hydrate according to the present invention.
EXPRESSION OF REFERENCE LETTERS
[0000]
1 reactor
2 gas supply line
3 water supply line
4 coolant
5 slurry line
6 dewatering apparatus
7 separating section
8 internal tube
9 external tube
10 drainage chamber
11 exhaust line
12 drainage line
13 hydrate layer
14 storage section
15 screw conveyor
16 gas supply line
17 first external tube
18 second external tube
19 partition wall
20 communicating chamber
B 1 raw material gas supply blower
B 2 exhaust blower
B 3 gas feed blower
P 1 slurry pump
P 2 drainage pump
S slurry
G gas
W water
H gas hydrate
x 1 differential pressure detector
x 2 level gauge
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0051] Hereinafter, exemplary embodiments of a dewatering apparatus in a production plant of a gas hydrate according to the present invention will be described with reference to FIG. 1 to FIG. 3 .
Example 1
[0052] FIG. 1 is a schematic view for illustrating the first exemplary embodiment of a dewatering apparatus in a production plant of a gas hydrate according to the present invention. In FIG. 1 , a reactor 1 is retained at predetermined pressure and temperature. A raw material gas G 1 from a gas supply line 2 to the reactor 1 , and raw material water W 1 from a water supply line 3 are respectively introduced, wherein a gas hydrate slurry S is generated.
[0053] Then, the slurry S is supplied via a slurry line 5 having a slurry pump P 1 to a dewatering apparatus 6 , where being separated into unreacted water W 2 and a gas hydrate H. To describe it in detail, the dewatering apparatus 6 is configured such that an internal tube 8 having a separating section 7 constituted by, for example, porous elements or the like, and an external tube 9 arranged to have a predetermined spacing from the internal tube 8 form a drainage chamber 10 , one end of an exhaust gas line 11 having an exhaust blower B 2 is connected to the upper part of said drainage chamber 10 , one end of a drainage line 12 having a drainage pump P 2 is connected to the lower part of said drainage chamber 10 , then a differential pressure detector x 1 for detecting a differential pressure between a pressure inside said internal tube 8 and a pressure inside said drainage chamber 10 is provided, and thereby said exhaust blower B 2 is controlled according to the signal from the differential pressure detector x 1 .
[0054] In addition, there is provided a supply line 16 for raw material gas connected to the upper part of a reactor where a gas hydrate slurry S is generated, as well as being connected to the upper end side of the internal tube 8 , and a gas feed blower B 3 is provided on the supply line 16 , and configured to be controlled according to the signal from said differential pressure detector x 1 .
[0055] In such a configuration, a pressure in the internal tube 8 is maintained higher by a predetermined value of pressure than a pressure in the drainage chamber 10 by driving either one or both of the exhaust blower B 2 and the gas feed blower B 3 under the action of the differential pressure detector x 1 .
[0056] Then, when the gas hydrate slurry S generated in said reactor 1 is introduced from the lower par of the internal tube 8 constituting the dewatering apparatus 6 , the slurry S moves up in the internal tube 8 to reach a separating section 7 , where the unreacted water W 2 forming the slurry S is drained into the drainage chamber 10 .
[0057] A gas hydrate H from which the unreacted water W 2 has been drained moves further up in the internal tube 8 , which forms a gas hydrate layer 13 at the upper side of the internal tube 8 . At this moment, a part of the unreacted water W 2 moves up to the lower part of the gas hydrate layer 13 (near the separating section 7 ) due to capillarity and it is likely to form a gas hydrate layer having a high water content. But, as a raw material gas G 1 is introduced into the internal tube 8 and thus a pressure inside the internal tube 8 becomes higher than a pressure inside the drainage chamber 10 , the unreacted water W 2 is squeezed from the holes of the separating section 7 , thereby to be drained into the drainage chamber 10 .
[0058] The unreacted water W 2 which has been drained into the drainage chamber 10 is sucked by a drainage pump P 2 , and returned via a drainage line 12 to the reactor 1 . A level gauge x 2 is equipped in said drainage chamber 10 , and the drainage pump P 2 is controlled according to the signal from the level gauge x 2 such that a fluid level of the unreacted water W 2 that has been drained into the drainage chamber 10 is controlled to be maintained at a predetermined position.
[0059] Then, the gas hydrate H which has been dewatered is supplied to equipment on the downstream side thereof by a screw conveyor 15 as a discharge device.
[0060] According to the present Example, a pressure inside the drainage chamber can be reduced lower than a pressure inside the internal tube 8 by sucking a gas in the drainage chamber 10 with the use of the exhaust blower B 2 , which enables to suck the unreacted water W 2 contained in the slurry.
[0061] In addition, a raw material gas G 1 is circulated by the gas feed blower B 3 from the upper part of the internal tube 8 to the drainage chamber 10 , and thus the raw material gas can be brought into countercurrent contact with the hydrate layer 13 and the unreacted water W 2 can be purged and removed. In this case, it is enough to put the exhaust blower B 2 at a standstill and to allow the raw material gas G 1 to flow into a bypass line (not shown).
[0062] In the case of the dewatering process, a part of the unreacted water W 2 is subjected to a hydration reaction so as to become hydrated through the contact with the raw material gas G 1 , which thus exerts effectiveness that the water content of the hydrate layer 13 can further be reduced. In addition, it is easy to control a pressure inside the internal tube 8 so as not to be lower than that inside a generator 1 , whereby there is also no risk that the hydrate may be decomposed during the process of dewatering.
[0063] Further, a gas in the drainage chamber 10 may be sucked by the exhaust blower B 2 , while circulating the raw material gas G 1 by the gas feed blower B 3 from the upper part of the internal tube 8 to the drainage chamber 10 . In that case, since the above-described effectiveness can be obtained at the same time, an excellent dewatering effectiveness can be obtained.
Example 2
[0064] FIG. 2 is a schematic view for illustrating the second exemplary embodiment of a dewatering apparatus of a gas hydrate according to the present invention, the same reference letters as those of FIG. 1 denote the same names, and their descriptions will be omitted.
[0065] In the FIG. 2 , a dewatering apparatus 6 includes an internal tube 8 having a separating section 7 , an external tube 9 arranged to have a predetermined spacing from the internal tube 8 , and a partition wall 19 situated between the external tube 9 and the internal tube 8 and attached to the upper part of said separating section 7 , wherein a communicating chamber 20 that communicates with an interior of the internal tube 8 over the partition wall 19 and a drainage chamber 10 below the communicating chamber 20 are formed.
[0066] A differential pressure detector x 1 is designed to detect a differential pressure between inside the communicating chamber 20 and inside the drainage chamber 10 and to control the exhaust blower B 2 and/or the gas feed blower B 3 .
[0067] A level gauge x 2 is provided in said drainage chamber 10 , and the drainage pump P 2 is controlled according to the signal from the level gauge x 2 such that a liquid level of the unreacted water W 2 drained into the drainage chamber 10 is maintained at a predetermined position.
[0068] In the dewatering apparatus 6 configured in this way, a pressure inside the internal tube 8 is maintained higher by a predetermined value of pressure than a pressure inside the drainage chamber 10 by driving the gas feed blower B 3 , while being under the action of said differential pressure detector x 1 . Then, when a gas hydrate slurry S generated in said reactor 1 is introduced from the lower part of the internal tube 8 constituting the dewatering apparatus 6 , the slurry S moves up in the internal tube 8 to reach the separating section 7 , where the unreacted water W 2 forming the slurry S is drained into the drainage chamber 10 .
[0069] A gas hydrate H from which the unreacted water W 2 has been drained moves further up in the internal tube 8 , which forms a gas hydrate layer 13 at the upper side of the internal tube 8 . At this moment, a part of the unreacted water W 2 moves up to the lower part of the gas hydrate layer 13 (near the separating section 7 ) due to capillarity and it is likely to form a gas hydrate layer having a high water content. But, as a raw material gas G 1 is introduced into the internal tube 8 and thus a pressure inside the internal tube 8 becomes higher than a pressure inside the drainage chamber 10 , the unreacted water W 2 is squeezed from the holes of the separating section 7 , thereby to be drained into the drainage chamber 10 .
[0070] The unreacted water W 2 which has been drained into the drainage chamber 10 is sucked by a drainage pump P 2 , and is returned via a drainage line 12 to the reactor 1 . A level gauge x 2 is equipped in said drainage chamber 10 , and the drainage pump P 2 is controlled according to the signal from the level gauge x 2 such that a fluid level of the unreacted water W 2 that has been drained into the drainage chamber 10 is controlled to be maintained at a predetermined position.
[0071] Then, the gas hydrate H which has been dewatered is supplied to equipment on the downstream side thereof by a screw conveyor 15 as a discharge device.
[0072] According to the present Example, the dewatering apparatus 6 is made of a double tube construction with the drainage chamber 10 in the outer side and the internal tube 8 in the inner side, which has improved pressure resistance compared with a construction in which the external tube is provided in a part of the internal tube. Therefore, a pressure difference (differential pressure) between inside the drainage chamber 10 and inside the internal tube 8 can take a larger value by the activation of the exhaust blower B 2 and/or the gas feed blower B 3 , and the unreacted water W 2 of the slurry S can be drained more powerfully than the above-described Example.
[0073] Further, since a dewatering column is made of a double tube construction, the separating section 7 can be provided from the lower side to the upper side of the internal tube, and thus a dewatering performance of the slurry is improved. Therefore, the size of the dewatering apparatus can be made significantly smaller than that of the conventional vertical gravity-type dewatering apparatus.
[0074] In the present Example also, a gas contained in the drainage chamber 10 is sucked via an exhaust gas line 11 , and the raw material gas G 1 can be introduced into the internal tube 8 via the supply line 16 . In addition, by sucking a gas contained in the drainage chamber 10 through the use of the exhaust blower B 2 , a pressure inside the drainage chamber 10 can be reduced lower than a pressure inside the internal tube 8 , and the unreacted water W 2 contained in the slurry can be also sucked.
Example 3
[0075] FIG. 3 is a schematic view for illustrating the third exemplary embodiment of a dewatering apparatus of a gas hydrate according to the present invention. In the FIG. 3 , the same reference letters as those in FIG. 1 and FIG. 2 denote the same names and their descriptions will be omitted.
[0076] In the FIG. 3 , a first external tube 17 is a skirt-shaped partition wall in which the upper part is a periphery of an internal tube 8 and is attached to the upper part of a separating section 7 , and the lower part is opened. The first external tube 17 and the internal tube 8 form a drainage chamber 10 and a communicating chamber 20 whose lower parts are opened. Difference between a pressure inside the communicating chamber 20 and a pressure inside the drainage chamber 10 is detected by a differential pressure detector x 1 , and an exhaust blower B 2 and/or a gas feed blower B 3 are controlled according to its signal.
[0077] In addition, an operation of a suction pump 14 is controlled by a level gauge 18 such that the lower end of the first external tube 17 may become lower than a fluid level of unreacted water W 2 which has been drained from a slurry S. The inside of the first external tube 17 (drainage chamber 10 ) and that of the communicating chamber 20 are sealed by the unreacted water W 2 .
[0078] In the dewatering apparatus 6 configured in this way, a pressure inside a second external tube 18 is kept higher by a predetermined value of pressure than s pressure inside a first external tube 17 by driving the gas feed blower B 3 , while being under the action of said differential pressure detector x 1 . Then, when a gas hydrate slurry S generated in the reactor 1 is introduced from the lower part of the internal tube 8 , the slurry S moves up in the internal tube 8 to reach the separating section 7 , where the unreacted water W 2 forming the slurry S is drained into the first external tube 17 .
[0079] A gas hydrate H from which the unreacted water W 2 has been drained moves further up in the internal tube 8 , which forms a gas hydrate layer 13 at the upper side of the internal tube 8 . At this moment, a part of the unreacted water W 2 moves up to the lower part of the gas hydrate layer 13 (near the separating section 7 ) due to capillarity and it is likely to form a gas hydrate layer having high water content. But, as a raw material gas G 1 is introduced into the internal tube 8 and thus a pressure inside the internal tube 8 becomes higher than a pressure inside a first external tube 17 , the unreacted water W 2 is squeezed from the holes of the separating section 7 , thereby to be drained into the first external tube 17 .
[0080] The unreacted water W 2 drained into the first external tube 17 is sucked by a drainage pump P 2 and returned via a drainage line 12 to a reactor 1 . A level gauge x 2 is provided on said first external tube 17 , and the drainage pump P 2 is controlled according to the signal from the level gauge x 2 such that a fluid level of the unreacted water W 2 that has been drained into the first external tube 17 is controlled to be maintained at a predetermined position.
[0081] Then, the gas hydrate H which has been dewatered is supplied to equipment on the downstream side thereof by a screw conveyor 15 as a discharge device.
[0082] In the exemplary embodiment, since it is designed to detect a difference between a pressure inside the communicating chamber 20 and a pressure inside the drainage chamber 10 , a drainage pump P 2 will be activated so as to attain a predetermined differential pressure that has been preset in a level gauge x 2 , for example, even if a pressure inside the internal tube 8 is changed by changing operation status. As a consequence, the apparatus can continue to operate without deterioration of a dewatering ratio or a dewatering speed or the like. In addition, if said differential pressure is changed, a fluid level of the unreacted water W 2 that seals the interior of the drainage chamber 10 and that of the communicating chamber 20 is designed to be changed in water level depending on a magnitude of its differential pressure. Consequently, possible damages to the dewatering apparatus when sporadic pressure changes occur will be prevented. | A gas hydrate slurry dewatering apparatus adapted to feed a raw as into a cylindrical main body of dewatering column so gas to attain pressurization and so suction any gas from the interior of a drainage chamber disposed around the cylindrical main body so as to attain depressurization. An internal tube ( 8 ) as a constituent of a dewatering apparatus ( 6 ) in which the gas hydrate slurry (S) is introduced is provided with a separating section ( 7 ). A drainage chamber ( 10 ) is formed by the internal tube ( 8 ) and, disposed with a given spacing therefrom, an external tube ( 9 ). An exhaust blower (B 2 ) and a drainage pump (P 2 ) are connected to the drainage chamber ( 10 ). A gas feed blower (B 3 ) for a raw gas (G 1 ) is connected to the internal tube ( 8 ). A differential pressure detector (x 1 ) is provided for detecting any pressure difference between the interior of the internal tube ( 8 ) and the interior of the drainage chamber ( 10 ). Control of the exhaust blower (B 2 ) and/or the gas feed blower (B 3 ) is performed by the signal from the differential pressure detector (x 1 ). | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application Ser. No. 61/839,847 filed on Jun. 26, 2013, the contents of which are hereby incorporated in their entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND INCORPORATION-BY-REFERENCE OF THE MATERIAL
Not Applicable.
BACKGROUND OF THE INVENTION
Field of Endeavor:
The present invention relates to systems and devices for draining the bilge of a vessel in a body of water. More particularly, the invention relates to systems and devices having no moving parts and which may be used to drain a boat bilge.
Background Information
Since boats were first built, water collecting in the bilge, or the bottom of the interior of the hull, has been a problem. Numerous methods of been developed to remove bilge water from a boat. Automatic drains have been developed which open while a boat is in motion, allowing water to drain out. When the boat comes to a stop, the drain closes. However, because even when a boat is at rest, it is still subject to wind, current and other forces, such automatic drains often do not remain completely closed while a boat is at rest.
Another difficulty encountered with automatic drains is that they typically include components exterior to the hull. Prior to the advent of powered boats, this did not present a significant problem. However, many boats today are designed to operate at high speed. The hulls of most boats are streamlined to minimize water resistance and drag. Pumps, which include bulky devices on the exterior of the hull are thus not desirable.
Most boats today come with an automatic bilge pump. While these pumps are typically effective, they generally consist of an electric motor and some sort of pump mechanism. Because many boats are subjected to harsh conditions, it is not unusual for a bilge pump to become damaged or to cease functioning. Bilge pumps may require maintenance and may be inefficient. Further, pumping mechanisms generally require seals, rings, or other components made of rubber or other pliable substance. These substances often wear out when subjected to salt water. This further complicates maintenance of the system's.
In view of the foregoing, there is a need to provide a device and system for draining the bilge of a boat. It is therefore desirable to provide a device and system for draining the bilge of a boat that requires little maintenance, does not increase drag substantially, and is efficient.
BRIEF SUMMARY OF THE INVENTION
Accordingly, the primary object of the present invention is to provide a static bilge pump.
In greater detail, the invention provides a bilge pump having no moving parts and which removes water from the bilge without any application of force or energy. In one embodiment, a static bilge pump comprises an inlet tube, a body and at least one eductor.
In another embodiment the static bilge pump further comprises one or more of an inlet tube having an inlet duct and a drain conduit extending to a drain plug, a body having a frame and a conduit in fluid communication with the inlet duct, an eductor having a buttress, an eductor inlet in fluid communication with the conduit of the body, a nozzle in communication with an aperture, an annular vacuum chamber, an eduction chamber and an exhaust, a siphon hose attached to the inlet tube, plugs providing access to one or more of a drain, a conduit in the body, and an induction inlet.
In a further embodiment, the static bilge pump is attached to the stern of a boat.
In another embodiment a static bilge pump comprises an inlet tube housing a pump conduit and a drainage conduit, a body housing an internal conduit in fluid communication with the pump conduit, and at least one eductor in fluid communication with the internal conduit in the body. The static bilge pump is capable of being attached to the exterior of a boat hull and it removes water from a bilge of a boat when the boat is moving forward. The drainage conduit provides fluid communication between an aperture on the side of the inlet tube and a drainage outlet on the body, and is not in fluid communication with the pump conduit. The pump may have a plurality of eductors, and the body may have a frame. A siphon hose may be removably attached to the inlet tube.
In another embodiment, the static bilge pump may have one or more eductors comprising an eductor housing having an eduction chamber, an intake aperture, an intake nozzle providing fluid communication between the eduction chamber and the intake aperture, an eductor inlet providing fluid communication between an eduction port and the internal conduit, an annular vacuum chamber in fluid communication with the eductor port and eduction chamber and an exhaust port.
In another embodiment, the eductor housing is cylindrical, the intake aperture includes a screen to prevent debris from entering the eductor housing, and/or the body further has an internal frame. A siphon hose is removably attached to the inlet tube.
In another embodiment, the static bilge pump of claim 6 wherein the drainage conduit provides fluid communication between an aperture on the side of the inlet tube and a drainage outlet on the body, and is not in fluid communication with the pump conduit.
In another embodiment, a static bilge pump has an inlet tube housing a pump conduit and a drainage conduit, a body having a frame and housing an internal conduit in fluid communication with the pump conduit, and at least one eductor in fluid communication with the internal conduit in the body. The static bilge pump is capable of being attached to the exterior of a boat hull and removes water from a bilge of a boat when the boat is moving forward. The drainage conduit provides fluid communication between an aperture on the side of the inlet tube and a drainage outlet on the body, and is not in fluid communication with the pump conduit. The eductor comprises a cylindrical eductor housing having an eduction chamber, an intake aperture having a screen to prevent entry of debris, an intake nozzle providing fluid communication between the eduction chamber and the intake aperture, an eductor inlet providing fluid communication between an eduction port and the internal conduit, an annular vacuum chamber in fluid communication with the eductor port and eduction chamber and an exhaust port.
It is therefore an object of the present invention to provide a static bilge pump having no moving parts and which may be easily integrated with existing boat hulls.
These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIG. 1 is a perspective view of a static bilge pump in accordance with the principles of the invention;
FIG. 2 is another perspective view of a static bilge pump in accordance with the principles of the invention;
FIG. 3 is a a lateral cross-sectional view of an inlet tube of a static bilge pump in accordance with the principles of the invention;
FIG. 4 is a transverse cross-sectional view of a body of a static bilge pump in accordance with the principles of the invention;
FIG. 5 is a lateral cross-sectional view showing the interior of an eductor of a static bilge pump in accordance with the principles of the invention;
FIG. 6 is a perspective view of a static bilge pump with a siphon hose in accordance with the principles of the invention.
FIG. 7 is a perspective view of a static bilge pump in accordance with the principles of the invention.
FIG. 8 is an environmental view of a static bilge pump with a siphon hose in accordance with the principles of the invention.
FIG. 9 is a lateral cross-sectional view of an alternative embodiment of an eductor of a static bilge pump in accordance with the principles of the invention;
FIG. 10 front plan view of an alternative embodiment of an eductor of a static bilge pump in accordance with the principles of the invention;
FIG. 11 is a graph showing the amount of gallons per minute a static bilge pump in accordance with the principles of the invention may be capable of pumping, as a function of speed of the boat.
DETAILED DESCRIPTION
Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
Disclosed is a static bilge pump for watercraft requiring no moving parts. The static bilge pump may be attached to the hull over the drain hole commonly found at the back of the boat adjacent to the lowest point of the bilge. The static bilge pump may remove water from the bilge of a boat. When the boat is not submerged, the boat's original drain may still be utilized.
In the following description, the term “distal” generally refers to a direction away from a boat to which the static bilge pump is attached, and the term “proximal” generally refers to a direction toward the boat. Thus, “distal” could optionally be considered “back” or “rear” and “proximal” could optionally be considered “forward” or “front.”
Referring to FIGS. 1-6 , the static bilge pump 10 may include an inlet tube 12 , a body 14 and one or more eductors 17 . The inlet tube 12 may house a drainage conduit 40 and a pump conduit 34 , as shown in FIG. 3 , that are not in fluid communication with each other. The drainage conduit 40 may extend from the drain aperture 26 to the drainage outlet 28 . Drainage outlet 28 may be located on the distal end of the body 14 as shown in FIG. 1 , or may optionally be located on the side of the body 14 . Drainage outlet 28 may be sealed by inserting a drain plug 18 . Fluid communication between the drain aperture 26 and the drainage outlet 28 may allow a boat to be drained while out of the water, in the same manner used in the absence of an attached static bilge pump. When a boat is in the water, it may be preferable to have the drain plug inserted into the drainage outlet.
An attachment mechanism may be used to affix the static bilge pump 10 to a boat's hull. In the embodiment shown in FIGS. 1-6 , the attachment mechanism comprises a bolt 20 and bolt holes 32 . Other attachment mechanisms suitable for attaching devices to the exterior of a boat hull may be used. For example, the inlet tube 12 may include an annular sleeve that may be inserted about the portion of the inlet tube that extends into the interior of the boat hull.
In this embodiment, the body 14 includes an interior frame 22 to provide strength and rigidity to the body 14 . The body 14 may optionally be formed as a solid block. The body 14 may house an internal conduit 38 in fluid communication with the pump conduit 34 and the eductor inlets 46 . In this embodiment, a conduit plug 24 may provide access to the internal conduit 38 which may be desirable for inspection, repair and/or manufacturing. Other plugs, for example inlet plugs 26 may also provide access to the internal conduit 38 and facilitate inspection, repair, cleaning and/or manufacturing.
In FIG. 2 conduit 38 , bolt holes 32 , suction duct 34 and nozzle access ports 36 may be seen. Drain aperture 26 may be located within a recess 27 on the side of the inlet tube 12 . The opening to suction duct 34 may be located on the proximal end of inlet tube 12 and may be designed to accommodate removable fluid connection with a hose, pipe, tube or other device for moving fluids.
FIG. 3 shows a lateral cross-section of the inlet tube 12 of the static bilge pump 10 . Within inlet tube 12 , a drainage conduit 40 extends from the drainage aperture 26 to the drain 28 , which may be sealed using drain plug 18 . Suction conduit 34 extends the length of inlet tube 12 from the proximal end 36 to the internal conduit 38 . Thus, pump conduit 34 provides fluid communication from the proximal end 36 of the inlet tube 12 to the internal conduit 38 . The pump conduit 34 and the drainage conduit 40 may not be in fluid communication with each other. However, in some alternative embodiments, it may be desirable to optionally provide fluid communication between these or other conduits or valves for adjusting fluid communication between the various conduits.
FIG. 4 shows a transverse cross-section of the body 14 of the static bilge pump 10 . The body 14 includes the internal conduit 38 housed inside the body. The conduit plug 24 seals the end of the internal conduit 38 and also allows access to the conduit 38 from the exterior of the body 14 . Bolt holes 32 may extend through body 14 . As shown in FIG. 3 , conduit 38 is in fluid communication with the suction duct 34 . Conduit 38 is also in fluid communication with eductor inlets 46 .
Referring now to FIG. 5 , a lateral cross-section of the static bilge pump 10 shows the interior of an eductor 17 and the body 14 . Internal conduit 38 is in fluid communication with the eductor inlet 46 . Plug 28 may be removed from the body 14 to access the interior of eductor inlet 46 .
The eductor 17 may include several components. In this embodiment, the eductors include a cylindrical body housing the components of the eductor 17 . The eductor inlet 46 may be in fluid communication with an annular vacuum chamber 58 by means of eduction port 55 . Eduction inlet 46 may be integral to buttress 50 . Buttress 50 extends from the body 14 to provide additional rigidity and support to the static bilge pump 10 and may be optional. The annular vacuum chamber 58 may surround a cylindrical motive nozzle 56 , which may in fluid communication with intake aperture 30 . When a boat is in motion, water may enter intake aperture 30 and enter eduction chamber 54 through intake nozzle 56 . Water introduced into eduction chamber 54 through nozzle 56 creates a vacuum, courtesy of Bernoulli's Principle, within annular vacuum chamber 58 . This creates suction at induction port 55 . The suction, or negative pressure, applied to induction port 55 provides suction through eductor inlet 46 , conduit 38 and pump conduit 34 . Water and other items in eduction chamber 54 exit through exhaust port 56 .
FIG. 6 shows the static bilge pump 10 with a siphon tube 60 . The static bilge pump 10 may be placed on the exterior of a boat such that inlet tube 12 extends through a boats drain hole. Alternatively, a separate hole may be made in the hull of a boat through which the inlet tube may be extended. Body 14 may then be affixed to the exterior of the hull such that the front apertures of the eductors 16 are exposed to oncoming water when the boat is in motion. The inlet to 12 may then be attached to siphon 60 . When in use, when a boat is traveling, the eductors 16 create vacuum suction which travels through the eductor inlets, the conduits and the inlet duct through siphon 60 . The end 62 of siphon to 60 may be placed at or near the bottom of the bilge. Alternatively, siphon 60 may be flexible such that the end 62 of siphon 60 may be used as a vacuum hose such that a person in the boat may move the end 62 about to suck up and remove bilge water wherever it is located. The arched, “upside-down U” characteristic shape of the siphon 60 may prevent water from entering a bilge while the boat is at rest or in reverse.
FIG. 7 shows a perspective view of the static bilge pump 10 . The static bilge pump 10 may be attached to the stern of a boat but may also be attached to other objects. For example, a static bilge pump in accordance with the principles of the invention may include fins or other devices to facilitate proper orientation when dragged through water. Such an embodiment may be attached to the end of a hose and dragged by a boat. The motion through the water will generate suction and may provide an emergency back up alternative bilge pump for boats. The exhaust ports 56 of the eductors 17 may be swept back or swept together for hydrodynamic and/or aesthetic purposes. FIG. 8 shows a static bilge pump attached to the stern of a boat. In this Figure, the static pump is retrofit to a boat through its drain hole. The pump may have a very low profile, not significantly increasing drag.
Static bilge pump 10 may include two eductors 17 housed in cylindrical eductor bodies 16 . It may be desirable to optionally utilize one eductor or 3 or more eductors, each having its own housing, which may be cylindrical or optionally parallelepiped or other shape. As shown in the Figures, the forward end of the inductors 17 are angled. This swept back design may minimize drag created by the eductor's and may also minimize the possibility of flotsam and jetsam lodging in and obstructing the apertures 30 . The eductor's 17 may be made larger or smaller and may have a front end that is not swept back. It may also be desirable to provide simpler eductors having a smaller body or having no housing at all. Optionally, the inlet apertures of the eductors may include a grate or screen to prevent debris from entering the eductor housings.
Buttresses 50 extending between the body and the eductor housings 16 may provide additional stability to the static bilge pump 10 . They also may house the induction inlets. It may be desirable to include additional buttresses or to use none at all. The inlet tube 12 of the invention incorporates both atypical drain as well as and inlet duct for the static bilge pump 10 . It may be desirable to not include the simple drain aspects of the inlet tube 12 .
FIGS. 9 and 10 show components of an alternative embodiment of the invention. FIG. 9 shows an eductor assembly 80 in accordance with the principles of the invention. An eductor inlet 86 may be in fluid communication with annular vacuum chamber 88 by means of eduction port 85 . As with the embodiment of the invention shown in FIGS. 1-9 , the eductor inlet 86 may be integral to a buttress 90 . An annular vacuum chamber 58 may surround a cylindrical motive nozzle 92 , which may be in fluid communication with aperture 94 . When a boat is in motion, water may enter aperture 94 and may be ejected out of nozzle 92 and into eduction chamber 84 . The movement of water through nozzle 92 and into eduction chamber 84 creates a vacuum within annular vacuum chamber 88 . This in turn results in suction applied to eduction port 55 and through eductor inlet 86 . Water and any other items in eduction chamber 84 may exit through exhaust port 98 . Eductor assembly includes an integration block 100 . Integration block 100 may include a conduit 102 . A bolt hole 99 may be located just above integration block 110 .
In FIG. 10 is shows an alternative embodiment of a body 110 in accordance with the principles of the invention. Body 110 includes an integration socket 112 . Integration block 100 is sized to fit snugly with in integration socket well. Body 10 also includes bolt holes 114 for attaching the body 110 to a boat Hull. In this embodiment, body 110 also includes bolt holes 116 . Bolt holes 116 may correspond to bolt holes 99 of the eductor assembly 80 . Because bolt holes 116 may be located both above and below socket 112 , and because the integration block 100 and socket 112 are bilaterally symmetric, and eductor assembly 80 may be integrated with a body 110 . So that may be positioned either to the left or to the right of a boat hull's drain plug. It is not uncommon for various devices, such as trim tabs, sonar devices or other objects, to be installed close to a drain plug. If one or more devices are located adjacent to and left of a drain plug of a hole, it may not be possible to attach an eductor as shown in FIGS. 1-8 to the hull. The embodiment shown in FIGS. 9 and 10 allow for reversing and creating a mirror of the device as shown in FIG. 9 . Making an eductor of the present invention ambidextrous, or capable of being flipped over to either side of a drain plug, facilitates an easier integration of the device into a boat hull.
FIG. 11 shows a graph of the amount of suction produced by the static bilge pump as a function of the speed of the boat to which it is attached. As may be seen, the static bilge pump, requiring no external power and having no moving parts, is capable of pumping 15 gallons per minute when a boat is traveling at only 20 miles per hour.
Whereas, the present invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. | A static bilge pump has an inlet tube, a body and one or more eductors. It may be attached to the back of a boat using bolts, or other means such that the inlet tube may be inserted into the drain at the bottom of the bilge of a boat. A siphon tube connected to the inlet tube hasn't ends that may be placed at the bottom of the bilge or moved about by an operator. The eductor's are streamlined to minimize drag and prevent blockage by debris and flotsam. Buttresses may extends between the body and the doctors to improve stability. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This Application is a national stage of PCT/GB2012/051643 filed Jul. 11, 2012 claiming priority to GB 1112058.1 filed Jul. 13, 2011.
TECHNICAL FIELD
[0002] The present invention relates to improved capsules containing beverage preparation ingredients for the preparation of beverages in dispensing equipment by injection of water into the capsules.
BACKGROUND OF THE INVENTION
[0003] A number of beverage making systems are known in which the beverage is made by inserting a capsule containing a particulate beverage making ingredient, such as ground coffee, into a beverage making station of a beverage making apparatus. The apparatus then injects water into the capsule, where the beverage making ingredient dissolves in, or infuses into, the water to form the beverage. The beverage flows out of the capsule through a suitable outlet, which may be simply an opening or perforation in the capsule, or it may comprise an outlet tube that pierces an outlet region of the capsule. The capsule may incorporate a filter to prevent passage of solid components such as coffee grounds out of the capsule. Beverage making systems of this general type are described for example in WO94/01344, EP-A-0512468 and EP-A-0468079 (all Nestle), in EP-A-0272922 (Kenco), in EP-A-0821906 (Sara Lee) and in EP-A-0179641 and WO02/19875 (Mars).
[0004] FR-A-2556323 describes a capsule for the preparation of drinks, in particular such as coffee, tea and other infusions, that includes an impermeable, yieldably pierceable, frustoconical base having an open, flanged top and a closed, yieldably piercable bottom. A beverage making ingredient such as ground roasted coffee is provided in the capsule, and the top of the capsule is covered in a sealed manner at its top by a piercable cover and closed at its bottom by a filter sheet. The filter sheet may be profiled to provide a liquid outflow chamber in the bottom of the capsule. In use, the top of the capsule is pierced by a water injection tube, and the bottom of the capsule below the filter sheet is pierced by a beverage extraction tube.
[0005] U.S. Pat. No. 5,840,189 and U.S. Pat. No. 5,325,765 describe further beverage capsules of the above type. A self-supporting wettable filter element is disposed in the base and is permanently sealed to an interior surface of the base, near the top of the base or at the top rim of the base. The filter element subdivides the base into first and second chambers, an upper chamber for storing the beverage making ingredient such as ground coffee, and a lower empty chamber for accessing the beverage after the beverage outflow from the filter has been made by combining a liquid with the ingredient. An impermeable, yieldably pierceable, imperforate cover is sealingly engaged with the top of the base to form an impermeable cartridge.
[0006] Beverage making capsules of the above type have found widespread use. However, they suffer from certain drawbacks. The manufacture of these capsules requires assembly of appropriately shaped base, filter and lid in precise and secure manner. The rate of flow of the beverage through the ingredient and/or the filter sheet may not be as fast and/or as uniform as would be desirable for optimum beverage preparation. A difficulty that can arise with the above systems is incomplete dissolution or extraction of the beverage ingredients inside the capsule, for example due to channeling of water through the bed of ingredient inside the capsule. Another difficulty that can arise is excessive system back-pressure due to blocking of the filter by the particulate ingredient inside the capsule. In addition the filter sheet can become relatively weak when wet, and can burst unless structural elements are provided to support the filter sheet during beverage preparation. Finally, the capsules require a significant quantity of packaging material and are difficult to recycle, since recycling requires separation of the spent beverage ingredient (e.g. coffee grounds) from the plastic components before recycling.
[0007] Several patent applications address one or more of the above technical problems.
[0008] WO-A-02082963 describes a beverage capsule of the above type that can be disassembled and refilled for multiple uses.
[0009] WO-A-2005026018 describes a beverage capsule of the above type in which the filter element has a flat base and fluted sides to improve flow of liquid through the filter and the beverage ingredient.
[0010] EP-A-1529739 describes a beverage capsule of the above type that eliminates the impermeable base portion. The capsule has a rigid top and a flexible, pouch-like body formed of filter material with regions of higher liquid permeability and lower liquid permeability to optimise flow of liquid through the pack.
[0011] WO-A-0160712 and WO-A-01060219 describe beverage capsules of the above type wherein the base side wall is provided with circumferentially spaced reinforcing flutes or ledges which are positioned to enhance resistance of the cartridge to buckling when the outlet nozzle is inserted into the base of the cartridge and/or to support the filter sheet during beverage preparation.
BRIEF SUMMARY OF THE INVENTION
[0012] In a first aspect, the present invention provides a sealed beverage preparation capsule comprising:
[0013] a sealed hollow body having a top and a bottom;
[0014] a beverage preparation ingredient inside said body; and
[0015] a layer of filter material at least about 2 mm thick located inside said body and abutting said bottom of said body.
[0016] In use, a water injection tube is inserted into the body through a nozzle in the capsule, or by piercing a wall of the capsule, and water is injected into the beverage preparation ingredient inside the capsule to prepare the beverage or beverage component. A water outlet tube is inserted into the body through the bottom of the capsule, for example by piercing the bottom of the capsule, such that the opening of the outlet tube resides just below, or inside, the layer of filter material. The filtered beverage then escapes through the outlet tube. The filter material is supported by the bottom of the capsule, whereby the problem of bursting filter sheets is avoided. Moreover, the capsules are easy to assemble simply by placing or gluing the layer of filter material into the bottom of the capsule. Finally, the overall size of the capsule required for a given amount of ingredient is reduced since the whole volume of the capsule can be filled with the ingredient and the filter layer.
[0017] The products according to this aspect of the invention are sealed capsules. That is to say, they enclose the beverage preparation ingredient in substantially air-tight fashion to maintain the freshness of the ingredient before use. Suitably, the capsules are also substantially moisture-impermeable before use.
[0018] Typically, each capsule comprises at least one sheet of plastic and/or metal foil material. The sheet may be semi-rigid, e.g. thermoformed or injection molded, or it may be a flexible film material. The sheet or flexible film material may be a laminate comprising at least one of the following layers: a thermoplastic sealant layer for bonding the sheet to other members of the package; a substantially gas-impermeable barrier layer, which suitably is a metal film such as aluminum film; adhesion layers to improve adhesion between other layers of the laminate; structural layers, for example to provide puncture resistance; and/or a printing substrate layer. The structural layers could be made of polyolefins, polystyrene, polyester, nylons, or other polymers as is well known in the art.
[0019] In one group of embodiments, the capsule may comprise two similar or identical sheets of flexible film material bonded together around a margin to form a film sachet or capsule, for example a capsule having a lenticular shape. In another group of embodiments the capsules may comprise a first sheet that has been formed, e.g. by thermoforming, into a cup or bowl shape with a flanged rim, and a second sheet that is bonded across the flanged rim to form the capsule. For example, the first sheet may be a relatively stiff thermoplastic sheet that has been thermoformed into a cup or bowl shape with a flanged rim, and the second sheet is a flat sheet, which may be of flexible film material, that is bonded across the flanged rim. In these embodiments, the capsule may have a frustoconical shape, suitably with a piercable top and base. The bottom of the capsule is pierceable or otherwise provided with means for insertion of an outlet tube into the filter layer, for example a hole with a removable cover or a hinged cover, or a septum, or a split septum, or a nozzle with a frangible freshness barrier for example as described in WO-A-0219875.
[0020] The dimensions of the capsules may be similar to those used in the existing systems described above so that the capsules of the invention can be used in existing beverage preparation equipment without modification of the equipment.
[0021] The filter layer is applied to at least a region of the bottom of the capsule, in particular adjacent to the location where outlet tube is inserted into the capsule. The terms “top” and “bottom” herein are relative terms denoting the locations, respectively, where the water inlet and water outlet of the capsule are located. The filter layer is relatively thick, and abuts the inside surface of the capsule, whereby the inserted outlet tube projects into, but not all the way through the filter layer. The thickness of the filter layer is suitably from about 2 mm to about 20 mm, for example from about 3 mm to about 15 mm, typically from about 5 mm to about 10 mm. The filter layer may suitably be secured to the inside surface of the capsule body by an adhesive, or in other embodiments it may be held in place by retaining flanges on the inside of the capsule body, or it may even be retained by a liquid-permeable sheet extending over the filter layer and bonded to an internal surface of the capsule body around the periphery of the filter layer. The area of the filter layer is suitably from about 1 cm 2 to about 20 cm 2 , for example from about 2 cm 2 to about 10 cm 2 .
[0022] Suitable materials for forming the filter layer are water-insoluble but preferably hydrophilic, food-acceptable materials. For example, they may comprise a liquid permeable foam material such as a polyurethane foam or an open-cell polyolefin foam. More suitably, the matrix comprises or consists essentially of fibers of substantially water-insoluble material, for example a woven or nonwoven fabric. The fibers making up the matrix may be any suitable food-acceptable fibers such as cellulose fibers, polyolefin fibers or nylon fibers.
[0023] In certain embodiments, the filter layer may comprise or consist essentially of a compostable material. The term “compostable” signifies that the material is substantially broken down within a few months, preferably within a few weeks, when it is composted. Typically, the material is at least about 90% composted within six months, as determined by the method of IS014855, as in EN13432. Thermoplastic compostable polymers that could be used for the matrix filter include polymers and copolymers of lactic acid and glycolic acid, polyhydroxybutyrates, polyvinyl alcohols (PVOH), ethylene vinyl alcohols (EVOH), starch derivatives, cellulose and cellulose derivatives, and mixtures thereof.
[0024] Suitably, the filter layer comprises or consists essentially of one or more nonwoven textile webs or bodies. That is to say, a fibrous web or body characterized by entanglement or point bonding of the fibers. The nonwoven web or body may, for example, comprise or consist essentially of a web prepared by conventional techniques such as air laying, carding, needling, melt-blowing, or spun-bond processes, or combinations of two or more of such processes. The integrity of the web may be increased by melt-bonding of the fibers, for example achieved by the melt-blowing method or by thermal bonding of thennoplastic (e.g. bicomponent) fibers.
[0025] In certain embodiments the beverage ingredient is a particulate, extractable beverage ingredient such as leaf tea or ground coffee. Alternatively or additionally the beverage ingredient may comprise a particulate, soluble beverage ingredient such as a particulate whitener, hot chocolate, sweetener, flavouring agent, coloring agent or fortifying agent.
[0026] Suitably, the capsule contains sufficient beverage preparation ingredients for the preparation of a single portion of beverage, i.e. from about 25 to about 500 ml, preferably from about 100 ml to about 250 ml of beverage. For example, the capsule may contain from about 2 g to about 25 g of ground coffee or from about 1 g to about 9 g of leaf tea. The internal volume of the capsule is suitably from about 1 cm 3 to about 100 cm 3 , for example from about 5 cm 3 to about 50 cm 3 .
[0027] In a second aspect, the present invention provides a kit for assembling a plurality of beverage preparation capsules, comprising:
[0028] a cup-shaped base having a bottom, and side walls extending from said base to an upper rim defining an open top of said base component;
[0029] a plurality of ingredient pods, each said ingredient pod comprising a top, side walls and a bottom, each formed of sheet material, wherein the pod contains a beverage preparation
[0030] ingredient, wherein the ingredient pod is shaped and configured to be engaged with the base component with the top of said pod forming a lid for the base component and the bottom of the ingredient pod spaced from the bottom of the base inside the base.
[0031] The kits according to this aspect of the invention permit assembly of a plurality of capsules, for example capsules containing different beverage making ingredients, by combining different pods with a single base. The pods are demountable from the base after use, whereby the base can either be re-used, or it may be recycled, thereby reducing the total amount of packaging waste. The pods are relatively compact, and the bases can suitably be stacked in nested stacks, thereby reducing the total volume occupied by a given number of capsules during transport and storage. A further advantage of these kits over conventional pre-assembled piercable capsules is that the base can be provided with a pre-pierced bottom, e.g. with a hole already provided for the liquid outlet tube, thereby reducing the force required to insert the outlet tube during beverage preparation and allowing the base to be made from thinner sheet material than for the pre-assembled capsules which require a minimum strength to withstand the piercing force without distortion.
[0032] The materials of the base component and of the beverage pod lid are as described hereinbefore in relation to the first aspect of the invention. Likewise, the types and amounts of the beverage preparation ingredient are suitably as described hereinbefore in relation to the first aspect of the invention.
[0033] Suitably, the side walls of the base component and the lid of the pod component are provided with complementary engagement elements to secure the lid to the pod. Suitable elements are complementary projections or recesses, for example threads, bayonet fittings or snap-fitting elements. Suitably, the engagement elements are releasable to permit disassembly of the capsules into the pod and the base after beverage preparation. Therefore, suitably the capsules are not formed by adhesive or melt bonding of the pod to the base.
[0034] At least a region of the bottom and/or the side walls of the pod may be made of a liquid permeable material, which functions as a filter for the beverage produced by injecting water through the lid of the pod. In these embodiments, the pod is suitably packaged in an air-and moisture-impermeable package such as a sachet to maintain freshness of the beverage ingredient before assembly of the capsule.
[0035] In other embodiments, the bottom and side walls of the pod are formed from air- and moisture-impermeable material as hereinbefore described so as to maintain freshness of the beverage ingredient before use. In these embodiments, the pod comprises an outlet that is opened before or during beverage preparation to release the beverage formed inside the pod. For example, the outlet may be an opening in the pod that is sealed by a cover sheet adhered to the pod by a pressure-sensitive adhesive. The cover sheet is removed and discarded immediately prior to assembling the capsule. Alternatively, the sheet material of the pod may be provided with a line of weakness, e.g. a die-cut line of weakness, defining an opening, for example a C-shaped or U-shaped line of weakness. The user presses down on the sheet material to open the pod along the line of weakness immediately before assembling the capsule. In yet other embodiments the opening is sealed by a flap that is adhered around the opening by an adhesive that is releasable by heat or pressure inside the pod arising from injection of hot water into the pod.
[0036] In these embodiments a layer of filter material may be provided inside the pod covering the outlet so as to filter the beverage before it escapes from the pod. No such filter may be necessary for pods that contain fully soluble/dispersible ingredients such as milk, concentrated liquid milk, chocolate, etc.
[0037] In a further aspect, the present invention provides a method of preparing a beverage, comprising the step of passing an aqueous liquid through a beverage preparation capsule according to the present invention. The aqueous liquid is usually water, for example at a temperature of 85° C. to 99° C. The method may be performed in the beverage preparation apparatus already known for use with existing capsule formats, for example as described in the patent references listed above, without modification of the apparatus. The method suitably comprises piercing the top of the capsule with a water inlet tube and piercing the bottom of the capsule with a beverage outlet tube.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Specific embodiments of the present invention will now be described further, by way of example, with reference to the accompanying drawings, in which:
[0039] FIG. 1 shows a cross-sectional view through a first beverage preparation capsule according to the invention;
[0040] FIG. 2 shows a schematic cross-sectional view through the capsule of FIG. 1 being used to prepare a beverage;
[0041] FIG. 3 shows a cross-sectional view through a second beverage preparation capsule 30 according to the invention;
[0042] FIG. 4 shows a cross-sectional view through a pod and cup element of a first kit according to the present invention;
[0043] FIG. 4 a shows a top plan view of the cup element of FIG. 4 ;
[0044] FIG. 5 shows a beverage preparation capsule assembled from the kit elements of FIG. 4 being used to prepare a beverage;
[0045] FIG. 6 shows a cross-sectional view through a beverage preparation capsule assembled from a pod and cup element of a second kit according to the present invention;
[0046] FIG. 7 shows a schematic cross-sectional view through the beverage preparation capsule of FIG. 6 being used to prepare a beverage; and
[0047] FIG. 8 shows a beverage capsule assembled from a third embodiment of the kit according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0048] Referring to FIG. 1 , the beverage preparation capsule 1 comprises a cup element 2 having a substantially flat base 3 , a flanged top 4 , and frustoconical side walls 5 extending from the base to the top 4 . The cup element is formed for example by thermoforming from a suitable thermoplastic for example polystyrene. The thickness and material of the cup element are selected so that the cup element has sufficient rigidity to allow piercing of the base during beverage preparation, as described below, without collapse of the cup. The flanged top 4 of the cup is sealed with a flexible film lid 6 of a suitable laminate sheet material as hereinbefore described. The lid 6 is bonded to the lip 4 by melt bonding or adhesive bonding in conventional fashion.
[0049] A layer 8 of nonwoven textile filter material is provided inside the capsule 1 adjacent to the flat base 3 . The layer 8 is approximately 10 mm thick, and may be bonded to the base 3 by a suitable water-insoluble adhesive (not shown). The beverage brewing ingredient 9 , which in this embodiment is ground coffee is deposited on top of the filter layer 8 inside the capsule 1 .
[0050] In use, the capsule 1 is held inside a clamp of a beverage making apparatus as shown in FIG. 2 . The clamp has a lower part 12 with a recess for mating engagement with the cup element 2 of the capsule, and an upper clamp part 14 that is movable to abut the lid of the capsule. In this embodiment the capsule is completely enclosed by the clamp during 30 beverage preparation, which permits the use of elevated pressures during beverage preparation without bursting the capsule. It is a further advantage of the present invention that high water injection pressures can be used because there is no risk of bursting a filter sheet. In other embodiments, the capsule may be merely gripped by a clamp but not fully enclosed thereby, or the flange 4 may simply be supported by an annular collar of the apparatus. The beverage preparation apparatus comprises a source of water (not shown), suitably a source of hot water, for supplying water to an injection tube 16 that pierces the lid of the capsule to inject water into the capsule for preparation of the beverage. The beverage preparation apparatus further comprises an outlet tube 18 that pierces the base of the capsule and projects a short distance into the capsule, whereby the open end 19 of the outlet tube is located entirely inside the filter layer 8 . The inlet and outlet tubes may be in fixed spatial relationship to the respective clamp parts, in which case the piercing of the capsule takes place when the clamp is closed around the capsule. Alternatively, the inlet and outlet tubes may be associated with mechanisms to provide reciprocating motion of the respective tubes into the capsule after the capsule has been clamped, and out of the capsule after beverage preparation is complete. It will be appreciated that more than one inlet and/or outlet tube may be provided if appropriate.
[0051] It can be seen that the capsule 1 according to this embodiment of the invention is extremely simple and inexpensive to manufacture, and can be adapted to capsules for use in any existing beverage preparation equipment that uses beverage capsules that are pierced by an outlet tube. Problems arising from the use of conventional thin-sheet filters, such as bursting of the filter and excessive back pressure, are avoided. A further advantage is that the volume occupied by the filter layer of the capsule 1 is quite small, which allows either a larger charge of beverage making ingredient for a capsule of given size than in prior capsules, or better fluidization of the beverage making ingredient if the amount of beverage ingredient is not increased.
[0052] Referring to FIG. 3 , this embodiment is substantially similar to that of FIG. 1 . The sole difference is that the cup element 20 of the embodiment of FIG. 3 is provided with a circumferential indentation 22 for retaining the filter pad 24 in the base of the cup.
[0053] Referring to FIG. 4 , the kit according to this embodiment comprises a cup element 30 and a separate pod 40 . The cup element comprises a bottom 32 , and a frustoconical side wall 34 terminating in an open flanged top 36 . The material of the cup element 30 may be the same as for the embodiment of FIGS. 1-3 . The material of the cup element may advantageously be made of a thermoplastic that can be recycled or that is compostable. In embodiments where the cup element 30 is intended for multiple use, the cup element may be made of a thicker plastic, or even of metal.
[0054] In this embodiment, the base 32 of the cup element is provided with a hole 35 for receiving an outlet tube of a beverage preparation apparatus. This removes the need for piercing of the base 32 during beverage preparation, since an outlet tube can simply be inserted through the hole 35 . In embodiments wherein the cup element is intended to be disposable (including recycling or composting), this allows the cup element may have thinner walls than for the embodiment of FIGS. 1-3 , because it is no longer necessary to sustain a piercing force to insert the outlet tube. It can be seen that, in this embodiment, the hole 35 is offset from the center of the base 32 for use with beverage preparation machines having a similarly offset outlet tube in the clamp. In these embodiments, therefore, it is desirable for the cup element to be provided with indicia, or preferably with one or more circumferential projections or recesses for engagement with complementary projections or recesses on the clamp, to ensure correct orientation of the base 32 over the outlet tube during beverage preparation.
[0055] Suitably, a plurality of the cup elements 30 can be stacked in a nested stack, thereby reducing the total volume taken up in packaging and storage.
[0056] The pod 40 in this embodiment comprises a lid element 42 similar to the lid element of the embodiments of FIGS. 1-3 . A bowl-shaped filter sheet 44 of conventional filter sheet material is bonded around the periphery of the lid element 42 to define, with the lid, an enclosed pod cavity that contains the beverage preparation ingredient 43 . The pod may be provided in sealed packaging to preserve freshness, for example in a sachet or bag made from air-and moisture-impermeable sheet material. The pods 40 may be individually packaged in this way, or multiple pods may be sealed in one package.
[0057] Referring to FIG. 5 , the kit of FIG. 4 is assembled into a beverage preparation capsule by inserting the pod 40 into the cup element so that the lid 42 of the pod abuts the lip 36 of the cup element 30 as shown. The beverage is then prepared from the capsule in a clamp as described in relation to FIG. 2 . Assembly of the capsule may be performed by inserting the cup element 30 into the recess in the bottom clamp part of the beverage preparation apparatus, followed by inserting the pod 40 into the cup element 30 , and closing the clamp, whereby the clamp holds the cup and pod together during the beverage preparation. Alternatively, the capsule may be assembled prior to insertion into the clamp, in which case it can be advantageous to have adhesive or snap-fitting elements to hold the cup and pod together for insertion into the clamp. The resulting capsule is used to prepare a beverage in a clamp as for FIG. 2 , as shown schematically in FIG. 5 . The water is injected through the lid 42 into the pod 40 by means of injector tube 16 , and the beverage escapes through the filter wall 44 of the pod into the cup element, from where it is collected by the outlet tube 18 .
[0058] Referring to FIG. 6 , the capsule 50 shown in the drawing is assembled from a kit comprising a cup element 30 as for the embodiment of FIG. 4 , and a pod 52 . The pod 52 comprises a lid 54 as for the embodiment of FIG. 4 and a bowl 55 formed of a liquid impermeable sheet material that is sealed around the periphery of the lid 54 to form a sealed pod cavity containing the beverage ingredient. A hole 56 in the bottom of the bowl portion 54 is sealed by a removable flap 58 of air- and liquid-impermeable material. A layer of filter sheet material 59 is bonded to the inside surface of the bowl covering the hole 56 . The flap 58 is attached to the outside surface of the bowl around the hole 56 by adhesive to form an air- and liquid-tight seal. The pods according to this embodiment are completely sealed and do not require secondary packaging to preserve freshness of the ingredient.
[0059] In use, a beverage is prepared from the kit of FIG. 6 as shown in FIG. 7 . A capsule is assembled in similar fashion as for the embodiment of FIGS. 4-5 . In certain embodiments the cover flap 58 is peeled from the pod before assembly of the capsule. In other embodiments, the cover flap 58 is attached to the pod by a heat-releasable adhesive, whereby the flap opens automatically when hot water is injected into the pod. Alternatively or additionally, the flap may open automatically as a result of pressure inside the pod due to injection of water into the pod.
[0060] Referring to FIG. 8 , the capsule 60 assembled from the kit according to this embodiment has snap-fitting elements 62 around the circumference of the lip of the cup element 64 for retaining the pod 40 as described in FIG. 4 on the lip following assembly of the capsule from 60 the cup element 64 and the pod 40 .
[0061] The kits according to the invention comprise at least one cup element and at least two pods. The at least two pods may contain different beverage preparation ingredients. For example, a first pod may contain ground coffee or leaf tea, and a second pod may contain a beverage whitener or powdered chocolate drink composition. In certain embodiments, the cup element may be intended for multiple use with a plurality of pods. These embodiments result in improved sustainability, less waste, and less materials required for a given number of beverage servings. In other embodiments, the cup element may be intended for disposal or recycling after a single use. These embodiments still require less packaging, because the plurality of cup elements can be stored as a nested stack. Moreover, the cup element can be formed of a plastic suitable for recycling, and can readily be separated from the pod for recycling after use. The pods are more difficult to recycle because they contain the beverage ingredient residue. However, the total amount of packaging material used for the pods is quite small. Suitably, the pods are made essentially or completely from compostable materials so that they can be composted with the beverage ingredient residue.
[0062] Any feature that has been described above in relation to any one aspect or embodiment of the invention is also disclosed hereby in relation to all other aspects and embodiments. Likewise, all combinations of two or more of the individual features or elements described above may be present in any aspect or embodiment. For brevity, all possible features and combinations have not been recited in relation to all aspects and embodiments, but they are expressly contemplated and hereby disclosed.
[0063] The above embodiments have been described by way of example only. Many other embodiments falling within the scope of the accompanying claims will be apparent to the skilled reader. | A sealed beverage preparation capsule includes a sealed hollow body having a top and a bottom, a beverage preparation ingredient inside the body and a layer of filter material at least about 2 mm thick located inside the body and abutting said bottom of said body. A kit is also provided for assembling a plurality of beverage preparation capsules. The capsules include a cup-shaped base having a bottom, and side walls extending from the base to an upper rim defining an open top of the base component, and a plurality of ingredient pods. Each ingredient pod includes a top, side walls and a bottom, each formed of sheet material, wherein the pod contains a beverage preparation ingredient. The ingredient pod is shaped and configured to be engaged with the base component to assemble a beverage making capsule, with the top of the pod forming a lid for the base component and the bottom of the ingredient pod spaced from the bottom of the base inside the base. | 0 |
BACKGROUND OF THE INVENTION
A number of process variables are associated with the operation of a paper making machine headbox, the control of which directly affect the quality of paper produced. For example, at the wet end the slice jet velocity and total head will greatly affect such things as formation and tensile ratio as well as interply bonding.
A significant factor in controlling these properties is believed to be the ideal distance (I.D.) or eddy decay length. In a so called "bunched tube headbox" in which the stock supply chamber communicates with the slice through a plurality of rows of tubes, the ideal distance or eddy decay length, for the eddies created by the changes in velocity as the stock is discharged from the multiple tubes into the slice chamber immediately preceding the slice outlet, may be calculated by the following formula based on a formula by Jasper Mardon:
I.D. = K × V.sub.AV × (d.sub.H).sup.1/2 /(d.sub.R).sup.1/3
wherein K is a coefficient, V AV is the average velocity through the flow channel interconnecting the stock supply chamber and the slice at 100% open area in feet per second, d H is the inside diameter of the tubes in the flow channel in inches, and d R is the depth of the flow passage in a direction normal to the cross machine direction and the length of the tubes.
From the above it will be seen that the ideal distance is directly proportional to V AV and d H and inversely proportional to d R . Thus, the ideal distance or eddy decay length can be increased by increasing the velocity through the flow channel or increasing the diameter of the tubes or by decreasing the effective depth of the flow channel. However, with the head of the stock delivered to the slice being fixed by other considerations and the length and diameter of the tubes in the flow channel also fixed, it would appear that, as a practical matter, the ideal distance or eddy decay length would be a fixed character of a particular headbox. This is the case in almost all current designs.
SUMMARY OF THE INVENTION
The present invention provides means for varying the ideal distance or eddy decay length of a headbox to provide improved quality paper for particular grades and weights thereof, and to correct for an incorrect estimate of operating flow volume made when originally sizing a headbox flow system. The present invention is particularly adapted for use with a headbox of the bunched tube type which includes a flow channel defined by a plurality of rows of tubes extending from the stock supply chamber to the slice chamber between the discharge ends of the tubes and thereby creating a corresponding plurality of eddies as the stock enters the slice chamber.
In a preferred embodiment of the invention the slice of the headbox is defined by a pair of opposed slice blades, one of which is a pivotally mounted nozzle blade, and one of the blades is then attached to the headbox in a manner which permits sliding movement thereof in a direction normal to the flow through the flow channel.
Thus, depth of the flow channel may be varied by sliding one of the blades across the outlet ends of the rows of tubes from the flow channel, thereby varying V AV and d R to obtain the optimum I.D. for a particular grade and weight of paper and machine speed to provide improved formation and tensile ratio.
After the slidable blade is positioned as desired with respect to the outlet end of the tubes, the inclination of the pivotally mounted nozzle blade may then be adjusted to establish the desired slice opening. With the ideal distance determined by adjustment of the slidable blade with respect to the outlets of the tubes, the inlet ends of the tubes blocked by the slidable blade can then be plugged semipermanently, with, for example, rubber stoppers. Thereafter if the grades, speeds, etc., should be changed, the tubes can be unplugged and the slidable blade readjusted to original position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a headbox, with parts in section, incorporating the present invention; and
FIG. 2 is a cross sectional view of a second preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning initially to FIG. 1 of the drawings, a headbox 10 is shown which is particularly adapted to deposit stock in a vertically oriented forming zone of a double wire paper making machine. The headbox 10 includes a stock supply chamber 12 fed by a plurality of feed pipes, one of which is shown at 14, which in turn are fed from a cross manifold 16 communicating with a supply of paper making stock.
A flow channel from the stock supply chamber 12 is defined by a plurality of rows of tubes 18 providing a corresponding plurality of passages which empty at their downstream ends into the slice chamber within a slice assembly 20. The upstream ends of the tubes 18 are preferably curved, as indicated at 22, and an apertured rectifier roll 24 can be mounted for rotation in closely spaced relationship to the upstream ends of the tubes 18. Of course, the danger of tube plugging decreases with increases in tube diameter, so that in a particular installation the diameters of the tubes may be great enough that a rectifier roll is unnecessary.
The slice assembly 20 comprises a nozzle blade 26 pivotally mounted, as at 28, and an apron blade 30 extending in opposing relationship to the nozzle blade 26 to define therewith the slice chamber which extends from the downstream ends of the tubes 18 to the slice outlet between the downstream ends of the blades 26 and 30. The apron blade 30 includes a downwardly extending leg 32 and a horizontally extending leg 34 joined to the leg 32 and reenforced by gusset means, as at 36. Leg 34 is slotted, as indicated at 38, and a bolt or the like 40 is received through the slot 38 and threaded into a portion of the supporting structure of the headbox. Thus the flow area of the channel defined by the tubes 18 has a first pair of opposed boundaries defined by the upper ends of the blades 26 and 30 which extend in the cross-machine direction and are therefore relatively long and a second pair of boundaries which are determined by the spacing between the upper ends of the blades 26 and 30 and are therefore relatively short.
A bracket 42 extends down one side of the headbox and threadably receives a jack screw 44 which bears at its inner end against the leg 34. With this construction it will be seen that the depth (d R ) of the flow channel may be adjusted to obtain the optimum ideal distance (I.D.) by loosening the bolt 40 and turning the jack screw 44 in the bracket 42.
This will cause the apron blade to shift, to the left as seen in FIG. 1, decreasing the effective flow area of the flow channel along a line extending in the cross machine direction of the paper making machine with which the headbox 10 is associated. In other words, such movement of the apron blade 30 will change the effective distance between the pair of relatively long boundaries of the flow channel and thus corresondingly change its depth.
After the optimum ideal distance or eddy decay length has been determined by adjusting the apron blade 30, the bolt 40 can be tightened to fix the apron blade in the desired position blocking one or more rows of the tubes 18. Assuming that the condition thus established is to remain stable for a relatively long period of time, the upstream ends of the tubes can be semipermanently blocked with, for example, rubber stoppers.
Thereafter, when paper machine speed or the type or weight of paper to be produced changes, the tubes can be unplugged and the apron blade 30 is adjusted for the optimum ideal distance or eddy decay length for the new grade, weight or machine speed.
In the above description the invention is described is conjunction with a headbox particularly adapted for use in a paper making machine having a vertically disposed forming zone. It will be apparent, however, that the present invention is also adapted to use in paper making machines having the forming zones thereof disposed other than vertically.
For example, and as seen in FIG. 2, a headbox 50 incorporating the present invention may be utilized with a fourdrinier type paper making machine. Thus, headbox 50 includes a stock supply chamber 52 fed by a plurality of pipes 54 which are in turn fed by a supply manifold 56 communicating with a source of paper making stock.
The flow channel from the headbox 50 is defined by a plurality of horizontally disposed rows of tubes 58 having their curved, upstream ends 60 communicating with the stock supply chamber 52 and their downstream ends 62 communicating with the slice assembly 64. Preferably an apertured rectifier roll 66 will be positioned in closely spaced relationship to the upstream ends 60 of the tubes 58.
The slice assembly 64 is defined by an apron blade 68 extending substantially parallel to the tubes 58 and a nozzle blade 70 mounted for pivotal movement at 72. The pivotal mounting for the nozzle blade includes an upstanding plate 74 slotted, as at 76, and receiving a bolt 78 which is threaded into an upstanding portion of the headbox 50.
With this construction it will be seen that the nozzle blade 70 may be moved vertically adjacent the downstream ends of the tubes 58 by loosening the bolt 78 and sliding the plate 74 downwardly across the outlet ends of the tubes 58, thereby decreasing the effective flow area of the flow channel defined by the tubes 58 progressively along a line extending parallel to the cross machine direction of the paper making machine with which the headbox 50 is associated.
This has the effect of decreasing the depth (d R ) of the flow channel and thereby varying the ideal distance or eddy decay length while maintaining the pressure of the stock supply substantially constant. As in the embodiment described above, after the nozzle blade 70 has been adjusted for optimum conditions, the upstream ends 60 of the tubes 58 can be plugged semipermanently with, for example, rubber stoppers.
This prevents stock from stagnating in the covered tubes but yet permits the tubes to be reopened when changing process conditions require a readjustment of the nozzle blade to reestablish the ideal distance or eddy decay length for the new grade or weight of paper or new machine speed.
From the above it will be seen that the present invention provides a system for obtaining the optimum ideal distance or eddy decay length for a paper machine headbox without varying the headbox pressure, dilution or slice opening to suit paper making requirements to thereby provide improved paper formation and sheet test.
While the forms of apparatus herein described constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise forms of apparatus, and that changes may be made therein without departing from the scope of the invention. | A paper machine headbox in which the ideal distance or eddy decay length may be varied to provide improved formation and tensile ratio for different grades and types of paper. The slice for the headbox is defined by a pivotally mounted nozzle blade and an apron blade, and one of the blades is mounted for sliding movement toward and away from the other. With this construction, the effective flow area through the flow channel to the slice may be varied, thereby varying the velocity of the paper making stock delivered to the slice and the ideal distance or eddy decay length. | 3 |
FIELD OF INVENTION
This invention relates to the reduction of noise produced by jet engines, and more particularly to an engine nacelle exhaust nozzle having an Irregular edge that forms a plurality of exhaust mixing tabs adapted to improve mixing of exhausts to attenuate noise produced by the engine.
BACKGROUND OF THE INVENTION
With present day jet aircraft, structures typically known in the industry as “chevrons” have been researched to attenuate noise generated by a jet engine. The chevrons have traditionally been fixed (i.e., immovable), triangular, tab-like elements disposed along a trailing edge of a primary and/or a secondary exhaust nozzle of the jet engine nacelle such that they project into the exhaust gas flow stream exiting from the exhaust nozzle. The chevrons have proven to be effective in reducing the broadband noise generated by the mixing of primary-secondary and secondary/ambient exhaust streams for high thrust operating conditions. Since the chevrons interact directly with the exhaust flow, however, they also generate drag and loss of thrust. Consequently, there is a tradeoff between the need to attenuate noise while still minimizing the loss of thrust due to the presence of the chevrons,
Noise reduction is typically needed for takeoff of an aircraft but not during cruise. Thus, any noise reduction system/device that reduces noise at takeoff (i.e., a high thrust condition) ideally should not significantly degrade the fuel burn during cruise. A compromise therefore exists between the design of static (i.e. immovable) chevrons for noise abatement and the need for fuel efficient operation during cruise.
Thus, there exists a need for a noise reduction system which provides the needed noise attenuation at takeoff but does not produce drag and a loss of thrust during cruise conditions. More specifically, there is a need for a noise reduction system which permits a plurality of chevrons to be used in connection with an exhaust nozzle of a jet engine to attenuate noise during takeoff, but which also permits the chevrons to be moved out of the exhaust gas flow path of the engine during cruise conditions to prevent drag and a consequent loss of thrust during cruise conditions.
BRIEF SUMMARY OF THE INVENTION
The above limitations are overcome by a noise reduction system in accordance with preferred embodiments of the present invention. In one preferred form the noise reduction system comprises a plurality of exhaust mixing tabs spaced apart from one another and extending from a lip of an exhaust nozzle of a jet engine nacelle adjacent a flow path of an exhaust flow emitted from the exhaust nozzle. Each of the exhaust mixing tabs are constructed to be controllably deformable from a first position adjacent the flow path to a second position extending into the flow path of the exhaust flow in response to a stimulus applied to each of the exhaust mixing tabs. In the first position, the exhaust mixing tabs either have no affect on the thrust produced, or increase the momentum (thrust) of the exhaust flow exiting from the exhaust nozzle. In the second position, that is, the “deployed” position, the exhaust mixing tabs are deformed to extend into the flow path. In this position the exhaust mixing tabs promote mixing of the exhaust flow with an adjacent air flow. This results in the attenuation of noise generated by the jet engine.
In one preferred embodiment each exhaust mixing tab has a plurality of sleeves attached to an inner surface of the respective exhaust mixing tab. A shape memory alloy (SMA) tendon is disposed within each of the sleeves. Each SMA tendon is attached at a first end to a forward edge of the respective exhaust mixing tab and attached at a second end along an aft portion of the respective exhaust mixing tab, offset from an aft edge of the respective exhaust missing tab. The SMA tendons are adapted to constrict when activated by heat. The constriction applies a linear pulling force on the aft portion to cause the exhaust mixing tabs to be deployed into an exhaust flow emitted from the nozzle. This causes intermixing of the exhaust flow with adjacent air flow, thereby attenuating noise generated as the exhaust flow exits the nozzle. An outer layer of each exhaust mixing tabs acts a biasing component to return the exhaust mixing tabs to a non-deployed position when the SMA tendons are deactivated.
Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. Furthermore, the features, functions, and advantages of the present invention can be achieved independently in various embodiments of the present inventions or may be combined in yet other embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and accompanying drawings, wherein;
FIG. 1 is a simplified side view of a nacelle for housing a jet engine of an aircraft, with the nacelle incorporating a plurality of exhaust mixing tabs of the present invention along a trailing circumferential lip portion of the secondary exhaust nozzle of the nacelle;
FIG. 2 is a partial side view of one of the exhaust mixing tabs taken in accordance with section line 2 — 2 in FIG. 1 ;
FIG. 3A is an illustration of a inner side of an exhausting mixing tab shown in FIGS. 1 and 2 , having a plurality of shape memory alloy tendons attached, in accordance with a preferred embodiment of the present invention;
FIG. 3B is a cross-sectional view of a shape memory alloy tendon encased in a sleeve shown in FIG. 2 ;
FIG. 3C is an illustration of the inner side of an exhausting mixing tab shown in FIGS. 1 and 2 , having the shape memory allow tendons attached, in accordance with another preferred embodiment of the present invention; and
FIG. 4 is a simplified side view of the nacelle shown in FIG. 1 in accordance with another preferred embodiment of the present invention.
Corresponding reference numerals indicate corresponding parts throughout the several views of drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application or uses. Additionally, the advantages provided by the preferred embodiments, as described below, are exemplary in nature and not all preferred embodiments provide the same advantages or the same degree of advantages.
Referring to FIG. 1 , there is shown an engine nacelle 10 for housing a jet engine 14 . The nacelle 10 includes a primary exhaust gas flow nozzle 18 , also referred to in the art as a core exhaust nozzle that channels the exhaust flow of from a turbine (not shown) of the engine 14 out the aft end of the nacelle 10 . The nacelle 10 additionally includes a secondary exhaust gas flow nozzle 22 , also referred to in the art as a bypass fan exhaust nozzle, that directs the exhaust flow from an engine bypass fan (not shown) out of the aft end of the nacelle 10 . A plug 24 is disposed within the nacelle 10 . In a preferred embodiment, the secondary exhaust flow nozzle 22 includes a plurality of exhaust mixing tabs 26 . The exhaust mixing tabs 26 extend from a lip area 30 of the secondary flow nozzle 22 . As will be described in greater detail in the following paragraphs, in operation each of the exhaust mixing tabs 26 is deformed (i.e., bent or deflected) in response to a stimulus that causes shape memory allow (SMA) tendons 34 (shown in FIGS. 2 , 3 and 4 ) attached to the exhaust mixing tabs 26 to be heated. When heated the SMA tendon 34 constrict in a one-dimensional linear direction, thereby causing the exhaust mixing tabs 26 to extend (i.e., “be deployed”) partially into the exhaust gas flow path exiting from the secondary exhaust gas flow nozzle 22 . This is indicated by dashed lines 38 near the uppermost and lowermost exhaust mixing tabs 26 in the drawing of FIG. 1 . The exhaust mixing tabs 26 are preferably arranged circumferentially around the entire lip portion 30 of the secondary exhaust gas flow nozzle 22 .
Referring to FIG. 2 , a portion of one of the exhaust mixing tabs 26 is illustrated. It will be appreciated that in the industry the exhaust mixing tabs 26 are often referred to as “chevrons”. However, it should be appreciated that while the term “chevron” implies a triangular shape, the exhaust mixing tabs 26 are not limited to a triangular configuration, but may comprise other shapes such as, but not limited to, rectangles, trapezoids or portions of circles. The exhaust mixing tabs 26 each include a distal portion 42 , a root portion 46 and a nozzle extension portion 50 . The distal portion 42 is the principal portion that projects into the exhaust gas flow path discharged from the secondary exhaust gas flow nozzle 22 . The root portion 46 forms an intermediate area for transitioning from the distal portion 42 to the nozzle extension portion 50 . In a preferred embodiment, the nozzle extension portions 50 of the exhaust mixing tabs 26 are integrally formed with the lip portion 30 of the nacelle 10 . Alternatively, the nozzle extension portion 50 is secured the exhaust mixing tab 16 to the lip portion 30 of the secondary exhaust flow nozzle 22 using any suitable fastening means. For example, the nozzle extension portions 50 of the exhaust mixing tabs 26 can be secured to the lip 30 of the nacelle 10 with rivets, by welding, or any other suitable securing means.
Referring now to FIGS. 2 , 3 A, 3 B and 3 C the exhaust mixing tab 16 includes an outer layer 54 (best shown in FIG. 2 ) constructed of any material suitable for the construction of jet engine nacelles. In a preferred embodiment, the outer layer 54 is integrally formed with the nacelle lip 30 . As best shown in FIG. 3B , each SMA tendon 34 is enclosed in a sleeve 58 having an inner diameter that is slightly larger than an outer diameter of the SMA tendons 34 such that an air gap 60 exists between the SMA tendon and the sleeve 58 . The air gaps 60 allow the diameter of SMA tendons 34 to expand when the lengths of SMA tendons 34 shorten during activation without interference, as described further below. For clarity and convenience, only the SMA tendons 34 are shown in FIGS. 3A and 3C , the sleeves 58 are not shown. Thus, although the sleeves 58 are not shown, it should be understood that each SMA tendon 34 shown in FIGS. 3A and 3C are enclosed within a related sleeve 58 . The sleeves 58 are attached to and conform with the contour of the an inner side 64 of the exhaust mixing tabs 26 . The sleeves 58 retain the SMA tendons 34 in effectively the same contour when the SMA tendons 34 are activated to generate a pulling force that bends the respective exhaust mixing tabs 26 into the exhaust flow.
A first end 62 (best shown in FIGS. 3A and 3C ) of each SMA tendon 34 is attached to the inner side 64 of the related exhausting mixing tab 26 at a forward edge 66 that is adjacent the nacelle lip 30 . An opposing second end 68 of each SMA tendon 34 is attached to the inner side 64 of exhaust mixing tab 26 along an aft edge 70 , i.e. the trailing edge. In a preferred form, the second ends 68 are offset from the aft edge 70 to generate a greater end moment and resultant inward deflection, when the SMA tendons 34 are activated. That is, the second ends 68 are attached to the inner side 70 a short distance from the aft edge 70 , as shown in FIG. 2 . The first and second ends 62 and 68 of the SMA tendons 34 are attached to the exhaust mixing tabs 26 using any suitable means, such as termination by swaged ferrule or clamping into an end block.
Each sleeve is affixed, bonded or otherwise suitably secured to the inner side 64 of the related exhaust mixing tab 26 using any suitable means, such as adhesive bonding or embedding in a compliant filler material. In a preferred embodiment, the length of each sleeve 58 is shorter than the length of the SMA tendon 34 enclosed therein. Therefore, at least one end of each SMA tendon 34 extends past the end of the respective sleeve 58 . This allows the SMA tendon 34 to constrict, i.e. shorten in length, when activated. The SMA tendons 34 are activate by heating the SMA tendons 34 . For example, the SMA tendons 34 can be heated by the ambient air temperature exhaust gas flow emitted from the secondary exhaust gas flow nozzle 22 or by a separately controlled heat source.
When the SMA tendons 34 constrict, i.e. in an austenitic state) force is applied to the inner sides 64 of the respective exhaust mixing tabs 26 . This force causes the exhaust mixing tabs 26 to deploy, i.e. curve or curl inward, into the bypass fan exhaust flow, thereby causing an improved mixing of the exhaust with the ambient air. Therefore, noise generated by the engine 14 is attenuated. In one preferred form the SMA tendons 34 comprise wires constructed of a nickel-titanium alloy. More preferably, nickel-titanium shape-memory alloy is used for the SMA tendons 34 . The geometry or pattern in which the SMA tendons are attached to the inner sides 64 of the exhaust mixing tabs 26 is dependent on the desired shape of the exhaust mixing tabs 26 when deployed. That is, it may be desirable to deploy the exhaust mixing tabs 26 such that each exhaust mixing tab 26 curls inward in a linear roll fashion, whereby the exhaust mixing tabs 24 have a non-cupped curvature. Or, it may be desirable to deploy the exhaust mixing tabs 26 such that each exhaust mixing tab 26 curves inward to take on a concave or cupped form.
For example, as shown in FIG. 3A , the SMA tendons can be disposed on the inner side 64 of each exhaust mixing tab 26 in essentially a ‘parallel line’ pattern. Alternatively, as shown in FIG. 3C , the SMA tendons can be disposed on the inner side 64 of each exhaust mixing tab 26 in a ‘fan-like’ pattern. Thus, the SMA tendons can be disposed on and attached to the inner sides 64 of the exhaust mixing tabs 26 in any desirable geometry or pattern or any mixture of patterns based on the form the exhaust mixing tabs are desired to take on when the SMA tendons 26 are activated. Furthermore, the SMA tendons 34 may be attached to various exhaust mixing tabs 26 in a first pattern while other exhaust mixing tabs 26 have the SMA tendons 34 disposed on their inner sides 64 in a second pattern, based on the desired mixing of exhaust with the ambient air. Further yet, the number of SMA tendons 34 attached to each exhaust mixing tab 26 is determined based on the amount of deflection or deformation desired. That is, if a more severe deformation is desired, such that the exhaust mixing tabs 26 are deployed further into the exhaust flow, a greater number of SMA tendons 34 will be attached to each exhaust mixing tab 26 . Even further, the number of SMA tendons 34 attached to each exhaust mixing tab 26 can be different for various exhaust mixing tabs 26 included as part of a single nacelle 10 .
In a preferred implementation, a compliant coating 74 , shown in FIG. 2 , is disposed across the inner side 64 and over the sleeves 58 of each SMA tendon 34 . The compliant coating 74 can be any material suitable for coating the inner sides of each exhaust mixing tab 26 and other nacelle components such that an aerodynamically smooth surface is created. For example, the compliant coating 74 could comprise an elastomer that is sufficiently flexible to allow the exhaust mixing tabs 26 to be deployed without adding any significant resistance. Additionally, the compliant coating 74 can comprise thermal insulation properties to protect the sleeves 58 and the SMA tendons 34 from being damaged by the bypass fan exhaust or other exhausts produced by the engine 14 .
The SMA tendons 34 have a predetermined length when secured to the inner sides 64 of the exhaust mixing tabs 26 . When the environment surrounding the SMA tendons 34 is below a transition temperature of the SMA tendons 34 , i.e. an actuation temperature, for example −20 to +20° F., the rigidity of the composite layer 54 is greater than that of forces applied to the exhaust mixing tabs 26 by SMA tendons 34 . Therefore, the rigidity of the composite layer 54 causing the SMA tendons 34 to be held taut across the inner sides 64 . This may also be referred to as the “martensitic” state of the SMA tendons 34 (i.e., the “cold” state).
When the environment surrounding the SMA tendons 34 is greater than the transition temperature, for example when the SMA tendons 34 are exposed to the bypass fan exhaust, the SMA tendons 34 are activated and constrict significantly (i.e., also known as its “austenitic” state). That is, the SMA tendons 34 shorten in length, which in turn causes the exhaust mixing tabs 26 to deploy, i.e. bend or deform into the exhaust gas flow 38 . In their activated condition, the forces applied by the SMA tendons 34 overcome the rigidity of the composite layer 54 , thus causing the exhaust mixing tabs 26 to deploy. Once the temperature of the surrounding environment cools and begins drops below the transition temperature, the rigidity of the composite layer 54 gradually overcomes the forces from the constricting, i.e. activated, SMA tendons 34 . This effectively “pulls” the SMA tendons 34 back to their original length and returns the exhaust mixing tabs 26 to their non-deployed position. Thus, the composite layer 54 acts as a ‘return spring’ to return the exhaust mixing tabs 26 to their non-deployed positions. It should be understood that the non-deployed position is when the exhaust mixing tabs 26 are positioned adjacent the exhaust flow path and not being deformed by the constriction of the SMA tendons 34 to extend into the exhaust flow path.
In an alternate preferred embodiment the composite layer 54 comprises a shape-memory allow such as nickel-titanium shape-memory alloy. An advantage of utilizing a super-elastic alloy is that it is extremely corrosion resistant and ideally suited for the harsh environment experienced adjacent the exhaust gas flow 38 . Also of significant importance is that it can accommodate the large amounts of strain required of the deformed shape.
In a preferred embodiment, the SMA tendons are heated using the exhaust gases from the secondary exhaust gas flow nozzle 22 . In actual operation, the heat provided by the exhaust gases emitted from the secondary exhaust gas flow nozzle 22 is typically sufficient in temperature (approximately 130 degrees Fahrenheit) to produce the needed constriction of the SMA tendons 34 . The actual degree of deformation may vary considerably depending upon the specific type of shape memory alloy used, as well as gauge or diameter of the SMA wire used to construct the SMA tendons 34 . When the aircraft reaches its cruising altitude, the significant drop in ambient temperature effectively acts to cool the SMA tendons 34 . The cooling of the SMA tendons 34 allows the composite layer 54 to stretch the SMA tendons 34 back to their non-activated length and exhaust mixing tabs 26 to return to their non-deployed positions.
In an alternative preferred embodiment, the SMA tendons 34 are heated by connecting the SMA tendons 34 to a controllable current source (not shown). To heat the SMA tendons 34 the current source is turned on such that current flows through the SMA tendons 34 . This causes the SMA tendons 34 to generate heat that in turn causes the the SMA tendons 34 to constrict significantly. As described above, this constriction of the SMA tendons 34 the exhaust mixing tabs 26 to deploy into the exhaust gas flow 38 . When it is desired that the exhaust mixing tabs 26 no longer be deployed, e.g. when the aircraft reaches cruising altitude, the current source is turned off. This allows the SMA tendons 34 cool so that the rigidity of the composite layer 54 gradually overcomes the constricting forces of the SMA tendons 34 , thereby returning the exhaust mixing tabs 26 to their non-deployed positions.
When each of the exhaust mixing tabs 26 is deployed, and thus protruding into the exhaust gas flow path 38 , the exhaust gas is intermixed with the ambient air flowing adjacent the secondary exhaust gas flow nozzle 22 . This intermixing produces a tangible degree of noise reduction. Most advantageously, as the aircraft reaches its cruise altitude, the retraction of the exhaust mixing tabs 26 to the non-deployed position, for example the exhaust mixing tabs 34 have essentially shape shown in FIG. 2 , prevents the drag and loss of thrust that would otherwise be present if the exhaust mixing tabs 26 each remained deployed.
Referring to FIG. 4 , in another preferred embodiment the primary exhaust nozzle 18 includes a plurality of exhaust mixing tabs 78 that extend from a lip area 82 of the primary flow nozzle 18 . SMA tendons are attached to the exhaust mixing tabs 78 in the same manner as described above with reference to SMA tendons 34 and exhaust mixing tabs 26 . The exhaust mixing tabs 78 and associated SMA tendons are essentially the same in form and function as the exhaust mixing tabs 26 , described above with reference to FIGS. 1-3C , with the exception that the exhaust mixing tabs 78 deploy to increase the mixing of core exhausts, i.e. turbine exhaust, with the ambient air. Thus, although the above description of the present invention with respect to exhaust mixing tabs 26 will not be repeated with reference to exhaust mixing tabs 78 , it should be understood that exhaust mixing tabs 78 are deployed utilizing SMA tendons in essentially the identical manner as described above with reference to exhaust mixing tabs 26 . Furthermore, it should be understood that FIGS. 2 , 3 A, 3 B, and 3 C and the related description set forth above can be used to describe the present invention with reference to both exhaust mixing tabs 26 and 78 , with the understanding that the exhaust mixing tabs 78 are associated with the primary flow nozzle 18 while the exhaust mixing tabs 26 are associated with the secondary flow nozzle 22 . Furthermore, it should be understood when the embodiment described above, whereby the SMA tendons 34 are heated via the by-pass fan exhaust, is applied to the SMA tendons associated with the exhaust mixing tabs 78 , the core exhaust would be utilized to activate the exhaust mixing tabs 78 SMA tendons.
The preferred embodiments described herein thus provide deployable exhaust mixing tabs connected to the bypass fan exhaust nozzle, and/or the core exhaust nozzle. The exhaust mixing tabs are deployed, i.e. temporarily bent, into the exhaust flow(s) using shape memory tendons that constrict when activated to apply a one-dimensional linear force at an aft edge area of each exhaust mixing tabs. The constriction pulls on the aft edge area to bend each exhaust mixing tab into the respective exhaust flow(s), which provides a desired degree of noise attenuation provided upon takeoff of an aircraft. Additionally, the preferred embodiments allow unobstructed or accelerating exhaust gas flow from the secondary and/or primary exhaust gas nozzle(s) when the aircraft is operating at a cruise altitude. Due to the use of SMA actuators, the preferred embodiments of the invention do not add significant weight to the engine nacelle nor do they unnecessarily complicate the construction of the nacelle.
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims. | A system for controlling a position of jet engine exhaust mixing tabs includes a plurality of exhaust mixing tabs spaced apart from one another and extending from a lip of an exhaust nozzle of a jet engine nacelle adjacent a flow path of an exhaust flow emitted from the exhaust nozzle. Each of the exhaust mixing tabs are constructed to be controllably deformable from a first position adjacent the flow path to a second position extending into the flow path of the exhaust flow in response to a control signal applied to each of the exhaust mixing tabs. In the first position, the exhaust mixing tabs either have no affect on the thrust produced, or increase the momentum (thrust) of the exhaust flow exiting from the exhaust nozzle. In the second position, that is, the “deployed” position, the exhaust mixing tabs are deformed to extend into the flow path. In this position the exhaust mixing tabs promote mixing of the exhaust flow with an adjacent air flow. This results in the attenuation of noise generated by the jet engine. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/456,445, entitled “Telescoping Mast,” filed on Jun. 16, 2009.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Aspects of the present invention relate in general to cable storage in a retractable telescoping mast. Aspects include a drive mechanism apparatus capable of efficiently storing cable in an extending and retracting the telescoping mast. Further aspects of the invention include an apparatus that spools cable during the extension and retraction of an antenna mast.
[0004] 2. Description of the Related Art
[0005] Telescoping masts of various types have been used in broadcasting and receiving radio messages in many different environments. Included in such developments are telescoping masts, which can be extended vertically or retracted vertically so that they can be mounted on a vehicle and transported to a desired site.
[0006] Telescoping masts are frequently used in mobile applications where a radio frequency antenna, temporary cell phone tower, camera, microwave television broadcast antenna or other payloads need to be placed in a position quickly and efficiently.
[0007] A mast can be retractable—wherein the mast can be retracted into a storage position in which the mast is relatively short in its overall height dimension. When fully extended or deployed, the overall height is many times larger than its retracted storage height dimension.
[0008] Most telescoping masts take a long time to deploy. For example, a four section steel mast might deploy from a 30 foot nested position to a 90 foot deployed position, in about 15 minutes. The energy requirement to move such a heavy and unwieldy mast is also enormous, resulting in the use of expensive motors in a mast drive mechanism.
[0009] Faster deploying units require greater power requirements to move the mast, and suffer from even greater problems. Usually the mast payload contains sensitive equipment, which can be damaged if the extension or retraction of the mast is sudden, or results in a jarring movement.
[0010] A payload will have electrical requirements. Typically, in such an environment, masts externally route electrical cable to the payload mounted on top of the mast.
SUMMARY
[0011] A telescoping mast has a cabling system designed to cover and store cable within the structure of the mast. The telescoping mast has a hollow mast housing. A telescoping section is nested within the interior of the mast housing. A set of upper pulleys affixed to the upper end of the mast housing, while a set of lower pulleys affixed to the lower end of the telescoping section. A cable is threaded through the first upper pulleys and first lower pulleys such that a first end of the cable is attached to the mast housing and the cable remains taut when the telescoping section is raised or lowered.
[0012] The mast is able to efficiently extend and retract multiple telescoping sections without jar and minimal energy.
BRIEF DESCRIPTION OF THE DRAWING
[0013] FIGS. 1A-D illustrates an embodiment of a telescoping mast and cabling system deployed in an extended and retracted positions.
[0014] FIG. 2 is a diagram of a telescoping mast drive mechanism used to efficiently extend and retract the telescoping mast.
[0015] FIG. 3 is a block diagram of a telescoping mast computation unit used to control the drive mechanism.
[0016] FIG. 4 is a flow chart of a method to control the extension and retraction of a telescoping mast without jar.
DETAILED DESCRIPTION
[0017] One aspect of the present invention includes the understanding that when cable is routed external to the mast, damage to unprotected cable easily occurs due to contact with objects; consequently, embodiments of the present invention route cable (electrical, optical, or any other cable known in the art) internally within the mast. Consequently, embodiments protect cable from external objects and environmental conditions by keeping the cable completely covered and stored within the structure of the mast.
[0018] In some embodiments, cable runs from the base of the mast to the payload mounted at the top of the mast. The cable is stored internally within the mast housing by spooling up over a set of pulleys. The pulleys move in relation to the mast height and payout or retract the proper length of cable to match the length of mast extension.
[0019] Another aspect of the present invention includes the realization that motors driving a telescoping mast may be supplemented by alternate power sources, and that controlling the motors with a computation unit may be used to eliminate jar in telescoping mast movement, resulting in a “soft landing” at any position.
[0020] Additionally, the speed of telescoping masts carrying camera payloads may have additional design considerations. For example, such masts deployed in hostile or combat areas may need to rapidly ascend and descend to avoid enemy fire.
[0021] Embodiments of the present invention include an apparatus, method, and computer-readable medium configured to control antenna movement to eliminate jar. Other embodiments of the present invention may include supplemental power sources to assist and reduce the power requirements of an electric motor.
[0022] Operation of embodiments of the present invention may be illustrated by example. FIGS. 1A-D depict an example telescoping mast, constructed and operative in accordance with an embodiment of the present invention. Telescoping mast 1000 , as shown in FIG. 1A , is a mast assembly extended with telescoping sections 1200 A-G. For illustrative purposes only, seven telescoping sections 1200 A-G are depicted supporting a payload 1100 . It is understood by those known in the art that in embodiments of the present invention may be utilized with any number of telescoping sections 1200 . An example mast assembly is U.S. Pat. No. 6,046,706, entitled “Antenna Mast and Method of Using Same.” Payload 1100 may be any a radio frequency antenna, temporary cell phone tower antenna, camera, microwave television broadcast antenna or other payload known in the art.
[0023] In FIGS. 1A-D , a drive mechanism 2000 is used to power and control the extension and retraction of the mast 1000 .
[0024] Similarly, FIG. 1B depicts an external view of telescoping mast 1000 in a retracted (or “nested”) state.
[0025] Moving on, we now discuss a cabling system of pulleys within the telescoping mast 1000 . FIGS. 1C-D illustrate a system of pulleys within only a single telescoping section. This example is for illustrative purposes only. It is understood by those known in the art that this concept applies equally to any number of telescoping sections. Furthermore, it is worth noting that multiple cabling systems may be run in parallel to support multiple types of cable. Embodiments may include a separate cabling systems for electrical power, digital or analog video/audio, packetized electronic data, or all of the above.
[0026] FIG. 1C illustrates internal features of telescoping mast 1000 in a retracted position. As shown, cable 1300 runs from the base of the mast to the payload 1100 mounted at the top of the mast. The cable is stored internally within the mast housing by spooling up over sets of pulleys, 1400 A-B, 1500 A-B. The relative position of pulleys 1400 A-B and 1500 A-B is shown when the mast is in the nested or retracted position. Pulleys 1500 A-B are attached near the bottom of largest moving telescoping section 1200 B of the mast 1000 . The bottom of the largest moving telescoping section 1200 B is directly driven vertically by a lead screw, which is further discussed below. The pulleys move in relation to the mast height and payout or retract the proper length of cable to match the length of mast extension. The mast housing may also serve to protect the cable from external elements such as rain, dirt, tree limbs, moving objects or other external elements. Pulleys 1400 A-B are attached on the inside and near the top of outer stationary section 1200 A of the mast 1000 . The outer stationary section 1200 A of the mast 1000 may also referred to as the mast housing.
[0027] As depicted, cable 1300 is a multi-conductor flexible electrical cable that will move through pulleys 1400 A-B and 1500 A-B as the mast 1000 is extended and retracted. As understood by one of ordinary skill in the art, other embodiments may use electrical, optical, computer-networking, or any other cable known in the art. Connectors 1600 A-B may be attached to either end of the cable 1300 , allowing quick electrical/mechanical disconnect of the payload at the top and the control/monitor equipment at the base of the mast 1000 .
[0028] FIG. 1D depicts the position of pulleys 1400 A-B and 1500 A-B when mast 1000 is extended. As can be seen, pulleys 1400 A-B and 1500 A-B are closer together, allowing the stored cable 1300 to pay out for any extended mast height. This system of pulleys 1400 A-B and 1500 A-B, along with their relative attachment points 1600 A-B, keeps the cable 1300 under constant tension whether the mast is fully extended, nested or anywhere in between.
[0029] FIG. 2 illustrates an embodiment of a drive mechanism 2000 controlled by a computation unit 3000 , constructed and operative in accordance with an embodiment of the present invention. Drive mechanism 2000 includes a drive shaft 2010 with multiple bearings 2020 A-B, coupled to an electric motor 2040 through gears 2050 A-B. The drive mechanism 2000 further includes a position feedback sensor 2030 , a motor 2040 , and a computation unit 3000 . In some instances, drive mechanism 2000 may include a crank 2100 , to enable manual extension or retraction of the mast 1000 .
[0030] The drive shaft 2010 itself may be connected to the internal portions of the telescoping sections 1200 via a lead screw attachment point 2070 . It is understood that any attachment point 2070 known in the art capable of transferring the motion of drive shaft 2010 to telescoping sections 1200 would be sufficient.
[0031] Position feedback sensor 2030 may any sensor known in the art configured to communicate the telescoping mast 1000 position to computation unit 3000 . The operation of computation unit 3000 is described below.
[0032] Motor 2040 may be any motor known in the art capable of raising or lowering telescoping mast 1000 . For illustrative purposes only, motor 2040 is assumed to be an electric motor. The capacity of electric motor 2040 is determined by the mast size. Larger masts require greater horsepower motors. For example, electric motor 2040 could be a ⅛ horsepower DC permanent magnet motor.
[0033] Electric motor 2040 may be further supplemented with power from electrical energy storage unit 2060 and/or spring motor 2080 .
[0034] Electrical energy storage unit 2060 may be any electrical energy storage unit known in the art, including, but not limited to an ultra capacitor or battery. Electrical energy storage unit 2060 provides a “power buffer” between the peak demands of mast (during mast raising and lowering) and the average load on the electric motor 2040 . Moreover, electrical energy storage unit 2060 allows telescoping mast 1000 to extend or retract if motor 2040 is inoperable or damaged.
[0035] Spring motor 2080 may be any potential energy storage unit known in the art. Spring motor 2080 may assist or replace motor 2040 in extending or retracting mast 1000 . Additionally spring motor 2080 is balanced and designed to match the weight and mass of the mast 1000 and its payload 1100 .
[0036] In some embodiments, spring motor 2080 may be a constructed from a stressed constant force spring, such as B-Motor springs. B-Motor springs provide high amounts of torque in a small package. An example of such a spring motor 2080 is a constant torque motor from Spiroflex Division of the Kern-Liebers Ltd., part of the Kern-Liebers Group of Companies, of Schramberg, Germany. These spring motors 2080 provide rotational energy from the torque output drum, or linear motion with the use of a pulley, cable, or webbing. While it is convenient for the design that the spring motor 2080 to have constant torque, other spring motors known in the art, such as torsion bars, may be equally applicable.
[0037] Crank 2100 may be any manual crank known in the art to enable manual extension or retraction of telescoping mast 1000 . Crank 2100 allows users to manually extend or retract telescoping mast 1000 when motor 2040 is inoperable. In some instances, energy from crank 2100 may also be stored by spring motor 2080 .
[0038] FIG. 3 depicts a computation unit 3000 , constructed and operative in accordance with an embodiment of the present invention. Computation unit 3000 comprises a central processing unit 3100 capable of communicating to electric motor 2040 , and position feedback sensor 2030 . Computation unit 3000 may run an embedded operating system (OS) and include at least one processor or central processing unit (CPU) 3100 . In some alternate embodiments, computation unit 3000 runs a standard non-real-time operating system. Central processing unit 3100 may be any microprocessor or micro-controller as is known in the art.
[0039] The software for programming the central processing unit 3100 may be found at a computer-readable storage medium (not shown) or, alternatively, from another location across a communications network. Central processing unit 3100 is connected to computer memory. Computation unit 3000 may be controlled by an operating system that is executed within computer memory.
[0040] Storage medium may be a conventional read/write memory such as a magnetic disk drive, floppy disk drive, compact-disk read-only-memory (CD-ROM) drive, digital versatile disk (DVD) drive, flash memory, memory stick, transistor-based memory or other computer-readable memory device as is known in the art for storing and retrieving data.
[0041] Turning to the functional elements contained within central processing unit 3100 , central processing unit 3100 comprises mast controller 3200 , data processor 3300 , and application interface 3400 . Mast controller 3200 further comprises position monitor 3202 and drive control unit 3204 . It is well understood by those in the art, that these functional elements may be implemented in hardware, firmware, or as software instructions and data encoded on a computer-readable storage medium.
[0042] Data processor 3300 interfaces with storage medium, electric motor 2040 , and position feedback sensor 2030 . The data processor 3300 enables mast controller 3200 to locate data on, read data from, and send data to, these components.
[0043] Application interface 3400 enables central processing unit 3100 to take some action with respect to a separate software application or entity. For example, application interface 3400 may take the form of a windowing or other user interface, as is commonly known in the art.
[0044] The function of position monitor 3202 and drive control unit 3204 are described below.
[0045] FIG. 4 is a flow chart of a process 4000 to control the extension and retraction of a telescoping mast without jar, coming in a smooth stop (also known as a “soft landing”) in accordance with an embodiment of the present invention. Soft landings help prevent damage to sensitive payloads 1100 , such as cameras, radio-frequency antennas, microwave television broadcast antennas, cellular phone towers, satellite communication dishes, and the like.
[0046] Initially, a user sets the desired position of the telescoping mast 1000 . In some embodiments, telescoping mast 1000 may simply be set to extended or retracted positions. In other embodiments, variable telescoping mast 1000 heights may be specified, where the height is set in between the fully extended or fully retracted positions. In either case, the application interface 3400 reads the set position at block 4002 .
[0047] Position monitor 3202 reads the actual (or “current”) mast position, block 4004 . In some embodiments, the extension and retraction of mast 1000 is measured by resistance or voltage fed into an analog-to-digital converter. In such embodiments, mast position may be indicated as a voltage on a variable resistor or potentiometer.
[0048] When the mast set position is greater than the actual position, as determined by mast controller 3200 , flow continues at decision block 4008 . Otherwise, flow continues at decision block 4014 .
[0049] At decision block 4008 , if the actual mast position is close to the set position, drive control unit 3204 decelerates electric motor upward, block 4010 . If the actual mast position is not close to the set position, drive control unit 3204 accelerates electric motor upward, block 4012 .
[0050] At block 4022 , the mast controller 3200 compensates for movement by spring motor 2080 .
[0051] When the mast set position is less than the actual position, as determined by mast controller 3200 at decision block 4014 , flow continues at decision block 4016 .
[0052] At decision block 4016 , if the actual mast position is close to the set position, drive control unit 3204 decelerates electric motor downward, block 4018 . If the actual mast position is not close to the set position, drive control unit 3204 accelerates electric motor downward, block 4020 .
[0053] When the mast set position not less than the actual position, as determined by mast controller 3200 at decision block 4014 , drive control unit 3204 disables the motor 2040 , stopping mast movement at block 4024 .
[0054] The previous description of the embodiments is provided to enable any person skilled in the art to practice the invention. The various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of inventive faculty. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | A telescoping mast with a cabling system configured to cover and store cable within the structure of the mast and able to efficiently extend and retract multiple telescoping sections without jar and minimal energy. The telescoping mast has a hollow mast housing. A telescoping section is nested within the interior of the mast housing. A set of upper pulleys affixed to the upper end of the mast housing, while a set of lower pulleys affixed to the lower end of the telescoping section. A cable is threaded through the first upper pulleys and first lower pulleys such that a first end of the cable is attached to the mast housing and the cable remains taut when the telescoping section is raised or lowered. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of and claims priority to U.S. application Ser. No. 12/851,981, entitled “Wire Bonding Method and Device Enabling High-Speed Wedge Bonding of Wire Bonds” filed on Aug. 6, 2010, which is hereby incorporated by reference for all purposes.
TECHNICAL FIELD
The present invention relates generally to semiconductor device packaging and interconnection technologies. In particular wedge bonding technologies are discussed. More particularly, apparatus, methods, software, hardware, and systems are described for achieving high-speed wedge bonding of wire bonds.
BACKGROUND OF THE INVENTION
In the field of semiconductor packaging, wire bonding can be used to interconnect integrated circuits and other associated components together. In particular, two main modes of wire bonding are in common usage. Ball bonding and wedge bonding. Both methods are well known in the art and have been in use for many years. As is known, ball bonding is commonly known and is frequently used with gold materials. However gold is relatively expensive. Additionally, such gold ball bonding requires surface plating (for example using silver) and heat to maintain good adhesion to bond pad materials. Additionally, attempts have been made to use ball bonding with copper materials. However, at the high temperatures required for copper ball formation oxide formation is a common problem. The problem is quite pronounced as copper oxides are insulating materials that have proven difficult to bond. Additionally, deformation of the electrical connections made at high temperatures lead to reliability issues. Methods of avoiding oxide formation require the use of oxygen free ambient conditions. This comes with its own set of problems. Similar oxide formation issues make aluminum a difficult material for ball bonding applications as well. An advantage to ball bonding is its high rate of processing speed. In many applications, average bonding speeds of the order of 12-14 bonds per second can be attained.
However, because some materials are difficult to work with using high temperature ball bonding, an alternative wedge bonding approach can be used. A disadvantage of such prior art wedge bonding technique is that it is a comparatively slow process with average bonding speeds of the order of 2-3 bonds per second being common.
Moreover, although ball bonding and wedge bonding have been used in the industry for many years, wedge bonding has up until this point been a relatively slow process even after 30 years of use. Accordingly, ways of improving wedge bonding speeds would be advantageous. Thus, while existing systems and methods work well for many applications, there is an increasing demand for wedge bonding methodologies that enable increased speed using a variety of materials including aluminum. This disclosure addresses some of those needs.
SUMMARY OF THE INVENTION
In a first aspect, an embodiment of the invention describes method for high-speed wired bonding. The method involves positioning a distal end of a wire-bonding capillary near a first bonding site. Extruding a length of bonding wire from an aperture in the end of the capillary. Imposing a movable deflector against the extruded length of bonding wire to bend the bonding wire to form a bent portion at an end of the bonding wire. Moving the bent portion of the bonding wire into contact with first bonding site. Wedge bonding the bent portion of the bonding wire with the first bonding site. In one approach, the wedge bonding can comprise, compressing and/or ultra-sonic bonding the bent portion of the bonding wire between the bonding site and a facing surface of the capillary and ultrasonically bonding the bent portion of the bonding wire to the first bonding site. To further continue an example method, the capillary can be moved away from the first bonding site toward a second bonding site where another end of the bonding wire is wedge bonded to the second bonding site to establish a wire bond connection between the first and second bonding sites.
In another aspect, embodiments of the invention include a wire bonding apparatus comprising a support for holding wire bonding substrates, a wire bonding capillary with an aperture for carrying and extruding bond wire and enabling bond wire attachment to wire bonding substrates, a movable deflector element arranged to enable movement of the deflector element to bend an extruded length of bonding wire such that the bent extruded length of bonding wire can be articulated at different bond line angles while maintaining a constant rotational orientation for the capillary, and a controller configured to enable control the operation of the wire bonding apparatus.
In another aspect, embodiments of the invention describe a movable deflector element module for use in wire bonding operations. One such module includes a deflection member configured to enable movement in an x axis and y axis direction. The member includes an aperture oriented in a z-axis with the aperture having inner wall that defines a wire contact surface having a plurality of wire guide features. Also, a deflection actuator is configured to move the deflection member in said x and y axis directions as directed by a control element configured to specify x and y axis movement for the deflection actuator.
In another aspect, embodiments of the invention describe a capillary element for use in high speed wire bonding operations. One such capillary comprises a capillary including a facing surface at a tip end of the capillary. Also including an aperture that penetrates through the capillary to an opening in the facing surface of the shaft to enable a bond wire to pass through the aperture exiting the opening in the facing surface. The facing surface defines a substantially ring-shaped roughened surface area with a substantially flat surface angled in a range of about 0° to about 4°.
General aspects of the invention include, but are not limited to methods, systems, apparatus, and computer program products for enabling improved high speed wedge bonding of wire bonds.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and the advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings in which:
FIGS. 1( a ) and 1 ( b ) are views of a prior art wedge bonding bond head as shown in side and top section view.
FIG. 1( c ) is a top down diagrammatic view of a prior art bonding tool showing the changing rotational orientation of the wedge bonding tool as it progresses around a die forming a series of wire bonds.
FIG. 2 is a block diagram illustrating an example wedge bonding apparatus in accordance with the principles of the present invention.
FIG. 3( a ) is a block diagram illustrating an operational relationship between an inventive deflector element and associated actuator element in a deflector module in accordance with the principles of the present invention.
FIG. 3( b ) is illustration of a specific embodiment of a deflector module in accordance with the principles of the present invention.
FIGS. 3( c )- 3 ( e ) are a set of illustrations depicting a method embodiment of using selected embodiments of a deflector module to position and deflect a wire bond wire in accordance with the principles of the present invention.
FIGS. 4( a )- 4 ( g ) are a set of illustrations illustrating one example process embodiment of using a wedge bonding tool in accordance with the principles of the present invention in conjunction with a deflector element to form directional wire bonds used for connecting IC elements with external connectors such a lead frames.
FIG. 4( h ) shows an example of a bond angle and an alignment approach for one embodiment of wedge bonding in accordance with the principles of the invention.
FIGS. 5( a ) and 5 ( b ) show an example embodiment of deflector element and aperture in accord with one example embodiment of the invention.
FIG. 6 is a flow diagram illustrating one approach to implementing wedge bonding in accordance with the principles of the invention.
FIGS. 7( a )- 7 ( d ) illustrate some aspects of one embodiment of a wedge bonding capillary suitable for employment in accordance with the principles of the invention.
In the drawings, like reference numerals are sometimes used to designate like structural elements. It should also be appreciated that the depictions in the figures are diagrammatic and not to scale.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Reference is made to particular embodiments of the invention. Examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with particular embodiments, it will be understood that it is not intended to limit the invention to the described embodiments. To contrary, the disclosure is intended to extend to cover alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
Aspects of the invention pertain to methods and apparatus for enabling high speed wedge bonding in semiconductor wire bonding applications.
The diagrammatic illustrations of FIGS. 1( a )- 1 ( c ) provide an understanding of some of the problems inherent in state of the art wedge bonding technologies. FIG. 1( a ) is a diagrammatic side view of a portion of a wedge bonding tool 100 . A bond head 101 feeds a bonding wire 102 downward and can use a guide 103 to help position the wire 102 in desired proximity to a bond pad 104 . When the bond head 101 is moved in a direction toward the bond pad 104 and downward pressure is applied against the bond pad 104 and the wire 102 and typically ultrasonic energy is applied to the wire 102 to bond the wire 102 to the pad 104 . The tool 100 lifts the bond head 101 and moves it to an associated lead (or other bonding site) that is to be connected with the bond pad 104 by a wire bond. The wire is then typically broken off to complete the wire bond between the two bonding pads.
FIGS. 1( a ) and 1 ( b ) illustrate a facing surface 101 f of the bond head 101 . FIG. 1( b ) is a top down section view of the bond head 101 of FIG. 1( a ). The wire 102 runs under the bond head 101 . In particular, this view shows that during wedge bonding the head move 105 in a direction toward the eventual other end of the wire bond connection (i.e., the other bonding surface). Thus, the motion of the wire and head is essentially a straight line motion between the first bonding site and the target bonding site.
As shown in FIG. 1( c ), it is this straight line motion between beginning bond pad bonding site and target bond location that defines a “bond line” between the two locations. FIG. 1( c ) presents a simplified top down view of an integrated circuit die 110 and bond connections to external contacts. As shown here the die 110 includes a plurality of bond pads 111 arranged around a top surface of the die 110 . Also shown are a few of the many electrical connectors ( 112 - 114 ) arranged around the circumference of the die 110 .
In examining a first wire bond connection 122 connecting one of the pads 111 with a first external connector 112 the wire bond 122 defines a bond line between the two contact locations. Here we arbitrarily identify the bond line 122 as having angle of 0°. The diagrammatic illustration includes a first bubble 131 that shows a top down view of the associated bond head 101 and the bond wire 102 . During wedge bonding, the bond head is moved in direction 141 from the bond pad 111 toward the final bonding site at connector 112 . In the wedge bonding process, this process is repeated for each pair of pads and contact for the die 110 . Thus, the bonding proceeds around the circumference of the die until completed.
For example, as the process has moved clockwise around the die another wire bond 123 is briefly discussed. A second external bond site 113 is wire bonded with an associated one of the pads 111 thereby defining the wire bond 123 and its associated bond line. With reference to the first bond line ( 122 ) it is shown that the bond angle has changed. Here that angle change 135 is represented as 90°. Thus the bond line 123 lies at 90° from the first bond line 122 . This has consequences in how the wire bond is formed. The diagrammatic illustration includes a second bubble 132 that shows a top down view of the associated of the same bond head 101 and a bond wire 102 . Because the bond line is significantly changed, the rotational orientation of the bond head 101 must also significantly rotate. This rotation enables wedge bonding between the external bond site 113 and its associated bond pad. During wedge bonding, the bond head 101 is moved in second direction 142 from the bond pad 111 toward the final bonding site at connector 113 .
Likewise, as the process continues moving clockwise around the die another wire bond 124 is briefly discussed. Here, an example third external bond site 114 is shown wire bonded with an associated one of the pads 111 thereby defining the wire bond 124 and its associated bond line. With reference the to the first bond line ( 122 ), it is shown here that the bond angle 136 has further to about 120°. Thus the bond line 124 lies at 90° from the first bond line 122 . Again, this has consequences in how the wire bond is formed. The diagrammatic illustration includes a third bubble 133 that shows a top down view of the associated of the same bond head 101 and a bond wire 102 . Because the bond line is again significantly changed, the rotational orientation of the bond head 101 must also significantly rotate. At this point the rotation is about 120 degrees. Also, as before, this rotation enables wedge bonding between the external bond site 114 and its associated bond pad. During wedge bonding, the bond head 101 is moved in third direction 143 from the bond pad 111 toward the final bonding site at connector 114 . And so it continues until the die 110 is completely bonded.
It is very important to consider that the bond head 101 realignment process takes a considerable amount of time. In fact, it is what accounts for the majority of the disparity in bond rates between the ball bonding process (e.g., about 14 bonds/s) and the prior art wedge bonding process (e.g., about 2-3 bonds/s). Accordingly, an approach for removing this step from the process has considerable advantage in a wedge bonding process.
Accordingly, FIG. 2 is a block diagram describing a novel wedge bonding apparatus 200 in accordance with one embodiment of the invention. Several of the many listed components are optional or can be substituted for other elements. The apparatus includes a wedge bonding module 210 arranged to enable wedge bonding of an IC chip 202 to another substrate during a wedge bonding process. The wedge bonding module includes a control arm 211 , an associated wire bonding capillary 213 , and a deflector module 220 arranged to enable deflection of a portion of supplied by a capillary 213 as needed. The wedge bonding device 200 typically includes a control module 230 configured to run software and change operating conditions and parameters prior to and during use. The apparatus can also include a viewing station 204 that enables viewing and can be used to assist in adjusting, and positioning of bonding module 210 .
The wedge bonding module 210 typically includes a control arm 211 that can include an ultrasonic head (not shown in this view) with a capillary 213 used as a bonding tool mounted on a distal end thereon. The module 210 can include a linear motor (not shown) that drives the capillary 213 and bonding arm 211 (as can optionally move the deflector module 220 ) in the vertical direction, that is, in the Z-direction. The linear motor is but one of many examples of a suitable motive device that can be used to accomplish the desired movement in the module 210 . This Z-axis movement enables the bond tool 213 to apply wire to various locations on the substrate 202 . An XY table 214 is used as an XY positioning unit that holds the bonding module 210 (including control arm 211 , bonding capillary 213 , deflector module 220 , and image pickup unit 204 ) and moves the module two-dimensionally a substantially horizontally arranged X-direction and Y-direction, and positions the same capillary 213 for wire bonding.
The control module 230 can include one or more microprocessors for controlling the entire wire bonding apparatus 210 . For example, a drive device 231 can provide control signals to the bonding head 213 and the XY table 214 in response to a command signal from a controller 232 . Commonly, software (or firmware) is executed on a microprocessor of the controller 232 and the operation of wire bonding or the like is performed by implementing the program. A support 205 holds the IC device 202 so that it can be wire bonded to another substrate. In this depicted embodiment, the other substrate comprises a lead frame 203 . Additionally, in some embodiments, the support can include a heater unit. In one implementation, the semiconductor chip 202 is mounted on a lead frame 203 which can be mounted on the heater plate of a heater unit at the top of the support 205 . The lead frame 203 can be heated by the heater unit.
Also, the wire bonding apparatus 200 typically includes an operation panel 233 having, for example, data input features that can include, but are not limited to track balls, alphanumeric value entering keys, and operating switches for enabling input and output of data such as process parameters and further display of the data for operation of the device 200 . Such data can be input into the controller 232 to, for example using a track ball, enable manual movement of the XY table 214 . The control unit 232 and the operation panel 233 are collectively referred to as an operating unit, hereinafter. The wire bonding apparatus 200 can be operated manually or automatically by the operation of the operating unit.
The wedge bonding module 210 which drives the bonding arm 211 vertically in the Z-direction includes a position detection sensor 216 for detecting the position of the bonding arm 211 , and the position detection sensor 216 is adapted to output the position of the capillary 213 mounted to the distal end of the bonding arm 211 from the position of a preset original point of the bonding arm 211 to the control device 232 . The linear motor of the wedge bonding module 210 drives the bonding arm vertically in response to instructions from the controller 232 which also controls the magnitude and the duration of a load to be applied to the capillary 211 at the time of bonding.
Additionally, an ultrasonic oscillator (not shown) can be located within the arm 211 which, in one embodiment, can use a piezoelectric transducer to cause the capillary 213 to generate the requisite ultrasonic oscillations that can be applied to the capillary 213 , for example, upon reception of a control signal from the controller 232 .
Additionally, the controller 232 provides signals to the deflector module 220 that enable it to deflect wire extruded from the capillary 213 in accord with certain aspects of the invention. This will be discussed in greater detail in the following paragraphs.
In general, the wire bonding apparatus 200 is configured to connect bond pads of the IC device 202 to external bonding sites, for example, bonding sites on a lead frame 203 . These bond connections are made using bond wire such as aluminum wire. Also, gold and copper can be used in accord with this invention. Aluminum being attractive because it is a softer material than both copper and gold thus reducing stress on the underlying substrate (the die 202 ) during wedge bonding. The approach disclosed in this application has several advantages over prior art methods. Unlike ball bonding, the present invention can be practiced at room temperature thus removing a large array of heat related problems from the system. Additionally, the need for non-oxygen ambient is also removed from the system. Also, it provides a high-speed method for achieving wedge bonding which has been a slow process for over 30 years. Thus, this invention meets a long unmet need and is particularly advantageous when used with materials like aluminum bonding wires.
A novel feature of the invention includes a deflector element 220 which is position in an operational arrangement with a bonding capillary 213 . Typically, but not exclusively, the deflector element 220 is mounted with the bonding arm 211 . The deflector element 220 comprises a movable deflector member and an associated actuator that enables controlled motion for the movable deflector member. The motion of the movable deflector member is intended to execute x-axis and y-axis movement and bending of an extruded portion of a bond wire extending from a capillary 213 .
In general, the deflector element 220 and capillary 213 are controlled by software and hardware enabling their integrated operation with the wire bonding recipe of the bonding processes executed by the apparatus 200 .
Such a movable deflector member can comprise one or more separate elements configured alone or in combination to enable such x, y movement and bending in a bond wire. The actuator can comprise a drive motor(s), magnetic actuators, and other motive elements. FIG. 3( a ) is a block diagram schematically illustrating an embodiment of a deflector element 220 . In particular there is a movable deflector member 301 and an associated actuator system 302 .
FIG. 3( b ) is a diagrammatic depiction schematically illustrating an embodiment of a deflector element 220 . In particular there is a movable deflector member 311 and an associated actuator system 312 . In this particular embodiment, the member 311 includes an aperture 313 used to manipulate the position of the bond wire. In such case the bond wire is deflected by the inner surfaces of the aperture 313 . For example, the aperture 313 is made in a working end of a deflector wand 311 that includes an arm portion 311 a used to engage the working end with the actuator 312 . The actuator system can comprise any system of motive devices suitable for moving the deflector member (or wand) 311 in the desired directions.
FIGS. 3( c ) & 3 ( d ) are diagrammatic depictions of the deflector member 311 embodiment such as shown in FIG. 3( b ). The aperture 313 has a diameter that is greater than a diameter of an associated capillary 213 . One example of a set of ranges for capillary outer diameter is on the order of about 2-100 mils. Such ranges are very flexible and depend largely on the size of the bonding wires and bonding pads (or other contacts) used. A complementary aperture 313 has a larger aperture. In one embodiment, the aperture can range from about 10-25% larger than the capillary diameter. For example, an aperture diameter for a 10 mil diameter capillary is on the order of about 11-13 mils. In one example, a capillary has an outer diameter of about 30 mils, with an associated deflector inner diameter of about 40 mils. Referring back to FIG. 3( b ), in one example the thickness of the deflector 311 can be on the order of about 4-30 mils. It should be specifically pointed out that although specific dimensions are identified, a considerably larger range of dimensions, shapes, and configurations are expressly contemplated by this patent. Additionally, such deflector members can be made using a number of different materials or combinations of materials. In one example, the deflector member 311 can be made of a tungsten material.
FIG. 3( d ) is a bottom up view of an example embodiment. The aperture 313 of the deflector member 311 includes an inner surface 313 d that can operatively deflect the bond wire 314 . Also, the cross-section 315 of FIG. 3( d ) is used to describe the process illustrated in FIG. 4 .
FIG. 3( e ) is a simplified view (as in FIG. 3( d )) of an example embodiment showing deflection of a wire 314 . The deflector member 311 moves in an arbitrary direction 316 , shown here as having an x-component and a y-component. Importantly, the wire 314 is deflected by a surface of the inner wall of the aperture 313 d . Thus, the wire 314 is bent and orient in a desired direction. Importantly, the orientation of the capillary 213 does not change (in an x, y direction) to accommodate changing angles of the bent bond wire. The capillary 213 maintains the same orientation regardless of bond angle (or wire angle) in the bent bonding wire.
It is particularly pointed out that the deflection of the wire 314 is achieved by the relative motion of the wire with respect to the deflector 311 . In other words, it can be that the capillary 213 itself is moved relative to a stationary deflector 311 .
FIGS. 4( a )- 4 ( g ) illustrate an implementation of a process used to establish a high speed wedge bond.
FIG. 4( a ) shows a capillary 213 in position above a bond pad 401 preparatory to bonding a wire 314 to the pad. This view is similar to the cross-section axis 315 shown in FIG. 3( d ). In this embodiment, a deflector member 311 is in position to deflect an extruded portion 314 e of a bonding wire 314 extending from a capillary.
In one feature of the invention, the facing surface of the capillary 317 is a substantially flat surface. The surface 317 generally having a face angle of in the range of about 0-4°. This is important because it is desirable to have the greatest amount of surface area of the facing surface applied against a bend bonding wire.
In describing the process, the capillary 213 is positioned above the desired bonding site 401 , a portion of wire 314 e is extruded from the wire in a desired length. For example, the length 314 e is on the order of a radius of a flat facing surface 317 of the capillary. For example, using an 8 mil diameter capillary, the extruded portion 314 e can be on the order of about 3-4 mils in length. The bonding wire can be made of any material and any thickness. Gold, copper, aluminum, and allots of the same provide some examples of suitable materials. Such wires are on the order of 15 μm-to 2 mil as well as other thicknesses. In one example, a capillary 213 extrudes a portion of a bond wire 314 e a desired length through the aperture 313 and then fixed in length. For example, the wire can be extruded through an open wire clamp to the desired length, then the wire clamp fixes the wire in place (stabilizing the length) and then relative movement of the deflector and capillary bend the wire as appropriate.
The bond angle required to connect the bond pad 401 to a desired external bonding site is determined. This enables the correct x, y deflection to be applied to the bent portion of the wire 403 . Then, as shown in FIG. 4( b ), the deflector 311 is moved in direction 402 that bends the extruded wire portion 314 e in the desired direction to form a bent wire portion 403 oriented in a desired direction.
After bending, as shown in FIG. 4( c ), the deflector 311 is moved back 404 into a centered position (centered on the capillary 213 ).
Then, as shown in FIG. 4( d ), the capillary 213 is stamped downward 405 into the bonding site 401 such that the bent wire 403 is compressed (See, FIG. 4( e )) between the facing surface 317 of the capillary 213 and the surface of the bond pad 401 . One advantage of using aluminum wire is that aluminum is softer than gold and copper. Relative to gold, this means that the downward force applied to an aluminum wire and bond pad 401 is less than half the pressure applied to a similar diameter gold wire. This places a good deal less stress on the underlying semiconductor device. This lack of stress is particularly advantageous in that it substantially reduces stress induced damage in the underlying devices.
Thus, as is shown in FIG. 4( e ) the stamping process compresses the bent portion of bond wire. Additionally, to establish a solid bond ultrasonic energy is applied to the wire to ultrasonically bond 314 b the wire to the bond pad 401 .
Once bonded, as shown in FIG. 4( f ), the wire 314 is lifted away from the wedge bond 314 b and moved to the complementary bonding site (e.g., on an associated lead frame). Once, the capillary is moved to the complementary bonding site a second wedge bond is made and then the wire 314 is broken off. The capillary 213 is retracted back upward through the deflector aperture 313 (See, FIG. 4( g )). The capillary is also moved to a next bond pad and a new length of wire 314 e is extruded for bonding to the second bond pad. The illustrated process is repeated again and again until a desired number of wire bonds are made with the die substrate.
Additionally, when the wire portion 403 ( 314 e ) is bent in direction 402 (See, e.g., FIG. 4( b )) the direction of deflector 311 movement 402 is generally aligned to facilitate a direct connection between the subject bond site (bond pad 401 ) and the desired target bond site (e.g., the lead frame attachment point). For example, with reference to FIG. 4( h ) a bond pad 111 is positioned in an example arrangement with an associated connector 115 (e.g., a portion of a lead frame) onto which a second bond site is located and a second wire bond is to be made. A bond wire 116 is bent in an appropriate direction (as shown) generally aligned with a direct line to the second bond site 115 . The bond angle 117 can change for each wire bond connection between first site (e.g., 111 ) and second associated bond site (e.g., 115 ) as a wire bonding process is executed around an integrated circuit die. The methods and devices described herein are flexible and robust enabling a 360° change in bond angles. Advantageously, the disclosed embodiments do not require any change in rotational bond head configuration as the process proceeds around the circumference of the die. This allows the process to continue with no rotational adjustment of the bond head (the capillary) as it moves from wire bond to wire bond to wire bond. This eliminates the constant readjustments required of prior art wedge bonding tools as they move from wire bond to wire bond. Thus, it is far faster than these tools, having bond rate similar to that of ball bonding tools and processes. This has been a major jump forward solving a 30 year old problem and will likely find broad wedge bonding application across the entire semiconductor industry.
It is pointed out that the wire can be positioned and held in place using standard clamp and wire tensioners as can be found in ball bonding tools. The clamp holds the wire in place while the deflector bends the wire into the desired configuration and then releases the wire once it is positioned at the desired bonding site. Moreover, in some embodiments the wire tensioner (or other associated vacuum systems) can be dispensed with altogether.
FIG. 5( a ) shows another embodiment of a deflector aperture. In this depiction, a deflector arm 511 a supports a working end 512 of a deflector element 511 . In particular, a different embodiment of aperture is shown. The aperture 513 comprises a flower-shaped aperture 513 arranged with a plurality of wire guiding features 514 . The inner surface of the aperture 513 is shaped generally like a “flower” having petal portions. These petal portions 514 are the guide features 514 . They are arranged such that when the aperture is moved across ( 402 ) the extruded wire (e.g., 314 e ) the wire can be generally centered at a nadir 515 of one of the features 514 . Importantly, the presence of apexes 516 between the petals can prevent the wire from deviating from one petal to another as the deflector moves across the capillary. As shown in this embodiment, the aperture 513 includes 8 “petals” that serve as the guide features 514 . Different embodiments can, of course, have more or fewer petals. Also, a wide range of petal shapes or configurations can be employed as might be suggested to one of ordinary skill by this disclosure.
An example depiction of the operation of a guide feature 514 is shown with reference to FIG. 5( b ) which shows a portion of an aperture of one possible embodiment of a deflector element 511 . As shown here each of the petals 514 has a curvature defining a nadir 515 portion located at the sidewall of the aperture 513 for each petal 514 . Moreover, separations between petals 514 are defined at each petal end by an apex feature 516 . In one example bending operation, as the deflection aperture 513 begins to deflect an extruded length of wire 314 e , the wire 314 e may attempt to move or bend in an undesirable direction. To assist in keeping the wire 314 e on track, the shape of the guide feature 514 guides the wire 314 e into a more desirable location to achieve bending at a desired angle. In one embodiment, each petal 514 can have a curvature with outer nadir 515 and a series of apex features 516 separating the petals 514 . Thus, during bending the wire 314 e is caught with one of the guide features 514 (for example at a starting position 540 wherein during the bending operation the wire 314 e slides (e.g., in direction 541 ) to a desired position 542 . In particular, the apexes 516 can serve as restraining members ( 516 ) between the petals 514 prevent free motion of the wire 314 e from petal to petal, thereby working to restrain the radial motion of the wire 314 e as it is bent. This assists the deflector element 511 in correctly aligning the bent wire during use.
It is specifically pointed out that many different implementations of such guide features can be used. For example, the inner surface of the aperture can comprise a set of slots or grooves in the inner surface to engage and fix the wire during wire bonding. In one example implementation a series of notches can be arranged in a spaced apart arrangement around the inner surface of the aperture. For example, the spacing can be such that grooves are spaced every 5°, 4°, 3°, 2°, 1°, or even tighter. It is pointed out that these intervals are examples only and that the invention is not limited to these intervals with those of ordinary skill appreciating that the spacing can be set at any desired interval. It is also pointed out, that alignment features can also be arranged on the capillaries. However, the inventors note that it is advantageous to place them on the deflector element. This is because the formation of the guide features is time consuming and difficult. Additionally, the lifespan of an average capillary is considerably less than that of a deflector. Thus, although the invention contemplates the placement of alignment features on the capillaries and/or the deflector element 511 , there are certain advantages to placing them on the longer lived deflector element.
In a continuing description of the invention one method of applying this technology is described. In one embodiment, a method of employing a wire bonding apparatus 200 in accordance with an aspect of the invention is described. This embodiment describes a wedge bonding method and associated method of establishing wire bonds between bond sites. An aspect of this invention will be discussed in association with the embodiment addressed in the flow diagram of FIG. 6 .
Once the die (or other target subject) is positioned on the inventive wedge bonding tool bonding can begin. It is to be noted that appropriate adjustments and software instructions can be applied to the tool 200 .
Accordingly, the distal end of a wire-bonding capillary is positioned near a first bonding site (Step 601 ). The capillary supports a bonding wire and can have an entire strand of appropriate wire in readiness for a bonding process. The wire can be of any material, with aluminum, copper, and even gold providing attractive materials. Aluminum in particular provides some process advantages. In particular, aluminum is soft and also aluminum is compatible with many bond pad and bonding site materials (e.g., copper). Accordingly, it is not necessary to plate the target bond pads to obtain good bond adhesion between wire and pad as is the case with some other materials (e.g., gold). Generally, such positioning involved positioning the capillary right above the bond site. The capillary head must be positioned above the bond pad a distance that is thicker (e.g., 316 ) than the thickness (height) of the associated deflector arm (e.g., 311 ). Thus, for a deflector arm 30 mils thick, the capillary head will be at least 35 mil and possibly much higher above the bond pad. In one example implementation the capillary head (the tip of the capillary) is positioned about 50 mils above the target surface (the bond site) in readiness for bonding. In general, the capillary head is a distance above the bond pad that takes into consideration the height of the deflector above the bond pad, the thickness of the deflector, the thickness of the wire, and any desired tolerances.
A length of wire is extruded from the aperture in the end of the capillary (Step 603 ). In one implementation, a bond wire is fed down through an inner diameter of the capillary to extend a distance beyond a facing surface of the capillary. The extruded length can be on the order of about the radius of the capillary face. Thus, for a capillary having a diameter of about 6 mils, an extruded length of up to 3-4 mils can be used. It is pointed out that greater or shorter extruded lengths can be used. In particular, for greater diameter capillaries greater lengths can be used and vice versa. As mentioned above, aluminum, copper, gold and other materials can be used with aluminum being a particularly attractive candidate. Additionally, a wide range of wire thicknesses can be employed with this methodology. One example range of wire thicknesses can include wire diameters ranging from about 5 μm to about 2 mils and other thicknesses. One example can be a 50 μm aluminum wire extruded to a length of about 3 mils using a capillary having a diameter of about 6 mils. Of course this is but one example with many others apparent to those of ordinary skill.
Once the desired length of wire is extruded, a movable deflector is imposed against the extruded length of bonding wire to bend the bonding wire to form a bent portion at an end of the bonding wire (Step 605 ). A deflector (for example, a deflector 311 as is shown in FIGS. 4( a )- 4 ( g )) is brushed under the extruded portion of wire (for example, the wire 314 e of FIGS. 4( a )- 4 ( g )) bending the wire against the bottom face of the capillary (for example, capillary 213 of FIGS. 4( a )- 4 ( g )) to form the bent portion of the wire (for example, bent wire 403 of FIGS. 4( a )- 4 ( g )). Importantly, as already discussed, the deflector bends the wire to attain the desired orientation (bond angle) relative to the associated second bond site to which the wire is to be connected in the wire bonding process.
Additionally, the bending process requires that the deflector pass beneath the capillary. For example, in one embodiment the facing surface of the capillary can lie a distance of about 1.1 to about 1.5 wire diameters above the top surface of the deflector 311 . Of course, the distance can be less or greater. The general idea being that the desired amount of bend is imparted to the bent portion of wire 403 by the motion of the deflector under the capillary.
Once bent, the deflector is repositioned such that the capillary can pass through the aperture of the deflector. Then the capillary is moved through the aperture toward the bonding site such that the bent portion of the bonding wire is moved into contact with the first bonding site (Step 607 ). Additionally, the facing surface of the capillary compresses the bent portion of the bonding wire between the bonding site and a facing surface of the capillary to establish a wedge bond of the bonding wire with the first bonding site (Step 609 ). This process is typically enhanced using ultrasonic energy. For example ultrasonic bonding or scrubbing can enhance the bond between the wire and bonding surface. Also, in some embodiments thermosonic bonding can be used enhance the bond between the wire and bonding surface. This will be discussed in some detail below with respect to certain capillary heads. This process results in a low temperature wedge bond that can be established in any direction without need for changing the rotational orientation of the capillary. This first novel aspect of this embodiment is completed in the formation of this novel type of wedge bond.
Once the bond is established, the method can move the bonding wire to a second bonding site to establish a completed wire bond electrical connection with another circuit element. For example, the capillary is moved away from the first bonding site (the location of the first bond) toward a second bonding site (where the bond that completes the connection can be made) (Step 611 ). Once in the desired location the capillary is positioned operative arrangement with the second bonding site and the wire is wedge bonded to the second bonding site to establish a wire bond connection between the first and second bonding sites (Step 613 ). A standard wedge bonding technique can be used here and the wire can be broken off in a standard fashion to complete the bond. At this point the capillary can be removed to another bonding site to repeat the process. Importantly, the rotational orientation of the capillary is not changed in this move.
FIG. 7( a ) is a cross-section view of one example of a capillary device 213 suitable for use with some embodiments described in this specification. The capillary 213 can be made of any material. But when used with aluminum wire, a hard material like aluminum oxide crystals (ruby, sapphire, etc.) can provide an excellent capillary material. In aluminum applications such materials are harder than aluminum oxide materials that sometimes form on bond wires. Such oxides are damaging to prior art ceramic capillaries. And such ruby materials also suffer from less aluminum build up. Additionally, similar advantages can be obtained with tungsten carbide capillary materials. It is pointed out that this technology has applicability beyond aluminum wedge bonding and can be used with copper, gold, silvers, their alloys as well as various other materials. In addition to the materials described above, in some implementations capillaries formed of ceramics (e.g., Zirconar ceramic and others) can also be used.
In one important attribute, the face surface 701 of the capillary is flat or very near flat. The face angle 702 (not drawn to scale) that describes an angle that the facing surface 701 makes with a perfectly flat plane should be less than about 4-5°. This very flat surface enables a maximum contact area of the surface 701 with the bent wire. Additional implementations can include faces with slight inverse angles (those having surfaces that become higher as they extend inward from the face edges). In general, these more flat surfaces are very different from capillaries used to ball bond gold wires. Such ball bonding capillaries are designed to optimize ball formation. Accordingly, they have relatively steep face angles. In a typical gold ball bonding application the face angle will be 8°, 12°, 15°, or even steeper. These tools cannot provide the needed contact area required to enable the present methodology. Additionally, when using gold processes, the facing surface 701 is very smooth. However, in an aluminum bonding capillary, a great deal of “scrubbing” is required to break up the surface oxides present on aluminum wires. Hence a rough surface is required. This is amplified through the effect of ultrasonic scrubbing. Such a roughened matte surface can be used with a ruby or tungsten carbide capillary.
It is also noted that a pattern of raised features can be used to good effect in this manner. For example a criss-crossed (cross-hatched) pattern of raised features (e.g., a waffle-shaped pattern) can provide good results. FIG. 7( b ) is a side-section view of a facing surface 701 having a number of raised features 703 . Such a pattern is particularly useful when used with tungsten carbide capillaries. For example, in the embodiment shown, the pattern of features 703 can comprise a series of ridges that are spaced and sized at dimensions that are dependent on the diameter of wire used. For example, the ridges can be spaced a distance about 10-25% of the wire diameter, on center, and can have a height of about 10-25% of the wire diameter, width a ridge width of on the order of about 4-15% of the wire diameter. For example, when applied to a 1 mil wire, example features can include ridges spaced apart by about 0.20 mils, with a height of about 0.20 mils, and being about 0.05 mils wide. It will be readily appreciated that smaller feature dimensions as well as larger can be used.
In another embodiment, FIGS. 7( c ) and 7 ( d ) depict a facing surface (e.g., 701 ) of another capillary 713 facing surface 701 . The facing surface 701 includes a series of guide features formed in the facing surface 701 . As shown here, the guide features comprise positioning grooves 711 arranged in the facing surface 701 . The grooves 711 are configured to aid in the position of bonding wires as the wired will slide into the grooves during bonding making the wire positioning more secure and precise. In the depicted embodiment, the grooves 711 are arranged like spokes around a centralized aperture 714 through which the extruded wire is supplied for wire bonding. Depending on the needs of the user more (or less) spokes can be employed.
Referring to side section view of FIG. 7( d ), the seating grooves can be configured having shallow or deep depths. Preferred embodiments are arranged with the depth of seating grooves 711 being in the range of about 25-405 of the thickness of the wire used. In one example, a 15 μm wire can have a groove 711 depth of on the order of about 5 μm. The idea being that a wire will slide into the groove, during bonding, and prevented from further substantial radial movement once lodged in the groove 711 . As for the remaining portions of the surface, they can be smooth or roughened depending on the needs of the user.
Returning to a discussion of FIG. 7( a ), the outer edges 704 of the capillary are also different from known geometries. This difference is intended to provide a larger surface area for contacting the wire. Thus, a radius of curvature for the outer edge 704 of the capillary is much less than that used for a gold ball bonder. For example, in the present invention, the radius of curvature for the outer edge 704 is on the order of 12 μm or less. This, radius is very small as compared with the 20 μm or greater radii commonly found in gold ball bonding capillaries.
Additionally, the chamfer angle in the present capillary is steeper than that of an ordinary ball bond capillary. This can be characterized by the interior chamfer angle (ICA) depicted in FIG. 7( a ) as ICA 704 . In a suitable embodiment used for the wedge bonding applications described here, angles in the range of about 0° to about 120° can be suitable. With angles of 70° of less being preferred in some implementations. This enables a tighter chamfer and thereby increases the surface area of the facing surface 701 . In this application, a chamfer diameter 705 is about 1.5 times the diameter of the bond wire used. Additionally, the bore diameter 706 is sized to be in the range of about 6-10 μm more than the diameter of the bond wire used. However, in some implementations the outer chamfer diameter 705 may be arranged only slightly larger or of the same diameter as that of the bore 706 . Another feature is a bore length 707 that defines a length of the bore shaft that is vertical walled to enable the wire to remain straight as the deflector bends the wire. In one implementation this is one the order of about 1-2× the bond wire diameter. It is pointed out that this is just one example implementation and is not the only way such a capillary can be formed. In one embodiment, it is important that the facing surface be flat (or nearly so), that the facing surface have a roughened or patterned surface rather than a smooth face, and that the facing surface be generally round (a typical facing surface being shown for 213 in FIG. 3) .
The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | Methods and systems are described for enabling the efficient fabrication of wedge-bonding of integrated circuit systems and electronic systems. | 7 |
This is a continuation of application Ser. No. 194,975, filed Oct. 8, 1980, now abandoned.
This invention relates to blended polyesterimide-polyesteramideimide coating compositions and to electrical conductors coated therewith.
BACKGROUND OF THE INVENTION
Schmidt et al., U.S. Pat. No. 3,697,471, disclose a family of polyesterimide resins made by reacting together at least one polybasic acid or a functional derivative thereof, and at least one polyhydric alcohol or functional derivative thereof, at least one of the reactants having at least one five-membered imide ring between the functional groups of the molecule. It is further disclosed that the reactants can be heated in a commercial cresol mixture, then further diluted in a mixture of naphtha and cresol and used as an enamel for coating copper wire to produce a hard, thermally resistant insulation therefor. Meyer et al., U.S. Pat. No. 3,426,098, describe polyesterimide resins in which all or part of the polyhydric alcohol comprises tris(2-hydroxyethyl) isocyanurate.
Sattler, U.S. Pat. No. 3,555,113, describes blends of polymeric amideimideester wire enamels and conductors coated therewith. In Sattler it is suggested that cold blends of polymeric amide-imide-esters and from 20 to 60% of a terephthalic polyester form block copolymers when deposited on a conductor and cured. Such coatings are stated to have better thermal life than coatings from the polyamideimide ester resins alone.
Applicant herein, Pauze, U.S. Pat. No. 3,865,785, describes polyesteramideimide coating compositions with better heat shock properties than the polyesterimide resins alone.
In all cases where polyesterimide resin is used as a coating, smoothness is a problem, especially if higher coating speeds are attempted. Lack of smoothness and blistering not only do not look well, but electrical properties suffer, as is measured by the number of breaks in the insulation in a given length of wire, e.g., 200 feet. The problems can be overcome to some extent by slowing down the coating speed, but this causes losses in energy and productivity.
It has now been discovered that blending a surprisingly small amount of an ester terminated amideimide resin into a major proportion of polyesterimide resin provides a composition which runs rapidly and smoothly on conventional wire coating equipment. The coated wire, as will be seen, is superior both in appearance and in electrical properties to the best coated wires currently obtainable with polyesterimide alone. The blended composition can be used itself, it can be used in heavy builds alone, and it can be used as an undercoat or as an overcoat in dual- or poly-coated conductors of all conventional types.
DESCRIPTION OF THE INVENTION
According to the present invention, there are provided soluble coating compositions suitable for the insulation of electrical conductors comprising a blend of:
A. a polyesterimide obtained by heating ingredients comprising
(a) an aromatic diamine;
(b) an aromatic carboxylic anhydride containing at least one additional carboxylic group;
(c) terephthalic acid or a reactive derivative thereof;
(d) a polyhydric alcohol having at least three hydroxyl groups;
(e) an alkylene glycol; and from 1 to 20 percent by weight of total solids of:
B. a polyesteramideimide obtained by heating
(a) a tricarboxylic acid compound;
(b) a polyamine; and
(c) an aliphatic dicarboxylic acid, and thereafter heating with
(d) an alkylene glycol.
Among the preferred features of the present invention are electrical coating compositions as defined above in which the solids content is at least 25 parts by weight; those in which heating is carried out at a temperature from about 190° to about 250° C.; those which are homogeneously dispersed in a solvent comprising cresylic acid, alone, or in combination with an aromatic hydrocarbon; and those which also include an alkyl titanate.
Also contemplated by the present invention are electrical conductors provided with a continuous coating of the new wire enamels, as a sole coat, or as an undercoat, or as an overcoat, and cured at elevated temperatures.
With respect to polyesterimide components A.(a)-(e), inclusive, these are conventional and well known to those skilled in this art by reason of the teachings, for example, in the above-mentioned U.S. Pat. Nos. 3,697,471 and 3,426,098.
By way of illustration, aromatic diamine component A.(a) can comprise benzidine, methylene dianiline, oxydianiline, diaminodiphenyl ketone, -sulfone, -sulfoxide, phenylene diamine, tolylene diamine, xylene diamine, and the like. Preferably, component A.(a) will comprise oxydianiline or methylenedianiline, and, especially preferably, methylenedianiline.
Illustratively, the aromatic carboxylic anhydride containing at least one additional carboxylic group component A.(b) can comprise pyromellitic anhydride, trimellitic anhydride, naphthalene tetracarboxylic dianhydride, benzophenone-2,3,2',3'-tetracarboxylic dianhydride, and the like. The preferred components A.(b) are pyromellitic anhydride or trimellitic anhydride and especially trimellitic anhydride.
Typically, terephthalic acid or a di(lower) alkyl ester (C 1 -C 6 ) or other reactive derivative, e.g., amide, acyl halide, etc., will be used as component A.(c). A minor amount of the terephthalic acid can be replaced with another dicarboxylic acid or derivative, e.g., isophthalic acid, benxophenone dicarboxylic acid, adipic acid, etc. Preferably component A.(c) will comprise dimethyl terephthalate or terephthalic acid, and especially preferably, terephthalic acid.
As additional polyester forming ingredient A.(d) there will be employed a polyhydric alcohol having at least three hydroxyl groups. There can be used glycerine, pentaerythritol, 1,1,1-trimethylolpropane, sorbitol, mannitol, dipentaerythritol, tris(2-hydroxyethyl)isocyanurate (THEIC), and the like. Preferably as component A.(d) there will be used glycerine or tris(2-hydroxyethyl) isocyanurate, preferably the latter.
Illustratively, the alkylene glycol component A.(d) will comprise ethylene glycol, 1,4-butanediol, trimethylene glycol, propylene glycol, 1,5-pentanediol, 1,4-cyclohexane dimethanol and the like. Preferably, the alkylene glycol will be ethylene glycol.
With respect to polyesteramideimide components B.(a)-(d), inclusive, these are conventional and well known to those skilled in this art by reason of the teachings, for example in the above-mentioned U.S. Pat. No. 3,865,785.
While trimellitic anhydride is preferred as the tricarboxylic acid material B.(a), any of a number of suitable tricarboxylic acid constituents will occur to those skilled in the art including 2,6,7-naphthalene tricarboxylic anhydride; 3,3'-4-diphenyl tricarboxylic anhydride; 3,3',4-benzophenone tricarboxylic anhydride; 1,3,4-cyclopentane tetracarboxylic anhydride; 2,2',3-diphenyl tricarboxylic anhydride; diphenyl sulfone-3,3',4-tricarboxylic anhydride;diphenyl isopropylidene-3,3'-4-tricarboxylic anhydride; 3,4,10-preylene tricarboxylic anhydride; 3,4-dicarboxyphenyl- 3-carboxyphenyl ether anhydride; ethylene tricarboxylic anhydride; 1,2,5-naphthalene tricarboxylic anhydride; 1,2,4-butane tricarboxylic anhydride; etc. The tricarboxylic acid materials can be characterized by the following formula: ##STR1## where R is a trivalent organic radical.
The aromatic polyamines useful as component B.(b) may be expressed by the formula
X--R'--(NH.sub.2).sub.n
where R' is a diorgano radical, for example, a heterocyclic radical, an alkylene radical, an arylene radical having from 6 to 15 carbon atoms and YGY, where Y is arylene, such as phenylene, toluene, anthrylene, arylenealkylene, such phenyleneethylene, etc.; G is divalent organo radical selected from alkylene radicals having from 1 to 10 carbon atoms, ##STR2## where Z is selected from methyl and trihalomethyl such as trifluoromethyl, trichloromethyl, etc., n is at least 2, X is hydrogen, an amino or organic group such as alkylene, arylene, etc. including those also containing at least one amino. Among the specific amines useful for the present invention, alone or in admixture, are the following:
4,4-diamino-2,2'-sulfone diphenylmethane
ethylenediamine
benzoguanamine
meta-phenylene diamine
para-phenylene diamine
4,4'-diamino-diphenyl propane
4,4'-diamino-diphenyl methane benzidine
4,4'-diamino-diphenyl sulfide
4,4'-diamino-diphenyl sulfone
3,3'-diamino-diphenyl sulfone
4,4'-diamino-diphenyl ether.
Again, the preferred polyamines are oxydianiline or methylenedianiline.
The aliphatic dicarboxylic acid material B.(c) can be saturated or unsaturated, and can have up to about forty carbon atoms in the chain, such materials being illustrated by adipic acid, sebacic acid, azelaic acid, suberic acid, pimelic, oxalic, maleic, succinic, glutaric and dodecanedioic acid and fumaric acid. The anhydrides can be used.
Any of a number of diols or glycols can be used as B.(d). For example, those having the general formula
OH--R").sub.m OH
can be used where m ranges typically from about 2 through 12 or higher and R" is preferably, although not necessarily, an alkylene group. Among such diols or glycols are ethylene glycol, propanediols, butanediols, pentanediols and hexanediols, octanediols, etc. Ethylene glycol is preferred.
In making the polyesterimide A. there should normally be an excess of alcohol groups over carboxyl groups in accordance with conventional practice. The preferred ratios of ingredients, and of ester groups to imide groups, are entirely conventional, see the patents cited above, and the especially preferred ratios of ingredients will be exemplified in detail hereinafter. The polyesterimide can be prepared in two ways, both of which will yield enamels suitable for blending in accordance with this invention. In one manner of proceeding, all of the reactants are added to the vessel at the beginning of the polymerization. The reaction is carried out in the usual manner, e.g., under by-product distillation conditions, e.g., at 190° to 250° C., until the acid number drops below about 6-7 mg. KOH/per gram of sample, and preferably down to less than 1.0 then the reaction heating is discontinued. The solvent can then be added to the hot mixture and it is maintained hot for the time needed to insure homogeniety. In another way, a two-stage reaction is conducted. First a hydroxyl rich polyester is prepared from ingredients (c), (d) and (e), and at the completion of this reaction, then ingredients (a) and (b) are added and the reaction carried further under by-product distillation conditions until, the acid number again falls below 6-7, e.g. to 1.0 or below. Heating is discontinued, then the solvent is again added to the hot reaction mixture, as before.
To make the polyesteramideimide, the equivalent ratio of tricarboxylic acid material such as trimellitic anhydride to aliphatic dicarboxylic acid material such as azelaic acid ranges from about 1:3 and 9:1, and is preferably 3:1. The ratio of equivalents of tricarboxylic acid material to polyamide such as methylene dianiline ranges from about 1:4 to 9:10, and is preferably about 3:4. The equivalent ratio of polyamine such as methylene dianiline to glycol such as ethylene glycol ranges from about 99:1 to 4:1 and most preferably is about 9:1. Generally, the ingredients are reacted at 190° C. to 250° C. until the desired carboxyl content is reached which is about 2.5 to 2.7 percent. The glycol is added when the tricarboxylic acid material, aliphatic acid and polyamine have been reacted to the desired carboxyl content. The tricarboxylic acid and aliphatic acid can be added together or separately to the polyamine.
As to those embodiments using a solvent, cresylic acid is the preferred aromatic solvent used in connection with the present invention. Used in connection with the cresylic acid are any of a number of hydrocarbon solvents including Solvesso 100 which is a mixture of mono-, di- and trialkyl (primarily methyl) benzenes having a flash point of about 113° F. and a distillation range of from about 318° F. to 352° F., such solvent being made by the Exxon Company. Another solvent useful in the present connection is Exxon 670 solvent, a mixture of mono-, di-, and trialkyl (primarily methyl) benzenes having a gravity API 60° F. of 31.6 percent, specific gravity at 60° F. of 0.8676, a mixed aniline point of 11° F. and a distillation range of about 288° F. to 346° F.
Enamels for coating conductors are made by blending the resins or solutions of resins A and B within the ratios set forth above and exemplified hereinafter.
The wire enamels thus made are applied to an electrical conductor, e.g., copper, aluminum, silver or stainless steel wire, in conventional application. Illustratively, wire speeds of 15 to 65 feet/min. can be used with wire tower temperatures of 250° and 920° F. The build up of coating on the wire can be increased by repetitive passes through the resin composition. The coatings produced from the present enamels have excellent smoothness, flex retention or flexibility, continuity, solvent resistance, heat aging, dissipation factors, cut through resistance, heat shock, abrasion resistance and dielectric strength.
When used as an undercoat the enamels of this invention are applied to the conductor as above-mentioned, and built up to the conventional thickness, e.g., with multiple passes. Then a lesser wall of a different, overcoat enamel is applied. This can be, without limitation, a polyamideimide, e.g., the heat reaction product of trimellitic anhydride and methylene dianiline diisocyanate, or an etherimide, a polyester, a nylon, an isocyanurated polyester polyamide, and the like. When used as an overcoat, the enamels of this invention are applied as a lesser wall over a conductor previously provided with an undercoat of a different enamel, such as polyester or a polyester imide, etc. Suitable second-type enamels are shown, e.g., in Precopio et al., U.S. Pat. No. 2,936,296; Meyer et al., U.S. Pat. No. 3,342,780; Meyer et al., Pat. No. 3,426,098; George, U.S. Pat. No. 3,428,486; and Olson et al., U.S. Pat. No. 3,493,413, all of which are incorporated herein by reference to save unnecessarily detailed description.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples illustrate the present invention. They are not intended to limit the scope of the claims in any manner whatsoever.
EXAMPLE 1
(a) Polyesterimide--A polyesterimide wire enamel is made by charging a suitably sized flask with the following ingredients:
______________________________________ Parts by weight______________________________________Ethylene glycol 214.2Terephthalic acid 582.5Tris(2-hydroxyethyl)isocyanurate 820.7Tetraisopropyl titanate 22.2Cresylic acid 1076.4Methylene dianiline 298.1Trimellitic anhydride 574.0______________________________________
The ingredients are heated during about 2 hours at about 215° C. and held at this temperature for about 8 to 10 hours. Then enough cresylic acid is added to reduce the solids content to 27% by weight and the mixture is maintained at about 200° C. for 8 hours, until it is completely homogeneous.
(b) Polyesteramideimide--A vessel equipped with a thermometer, Dean Stark trap, stirrer, condenser, addition inlet and nitrogen inlet is charged with 211.5 parts of azelaic acid, 648 parts of trimellitic anhydride, 892 parts of methylene dianiline, one part of tetraisopropyl titanate and 1227 parts of a solvent consisting of 55 parts of cresylic acid and 45 parts of phenol. The contents are heated to 200° to 205° C., water being collected and the temperature maintained until a carboxyl content of 3.4 is reached. Then 3070 additional parts of the above cresylic acid-phenol solvent are added, heating being continued at about 200° C. until the carboxyl percent is about 1.8. At this point, 40 parts of ethylene glycol are added and a temperature of approximately 200° C. maintained until the percent carboxyl is 0.55. The contents are then diluted to approximately 25% solids using a solvent consisting of 75 parts cresylic acid and 25 parts of Solvesso 100 hydrocarbon. The Gardner-Holt viscosity is Z 13/4 or about 3400 centistokes at 25° C.
Shown below in the Table are the results of actual wire coating tests using a polyesterimide wire enamel of the type set forth in Example 1(a) (General Electric Company's Imidex-E) and a blend of such enamel with a polyesteramideimide enamel of the type set forth in Example 1(b). The blend is prepared by mixing 95 parts of the 27% polyesterimide enamel with 5 parts of the 25% solids polyesteramideimide enamel. The electrical conductor being coated is a copper magnet wire 0.0403 inch in diameter, the wire being cured in a 15 foot tall gas fired tower having a bottom temperature of 245° C. and a top temperature of 400° C. The wire after coating and curing are visually inspected for smoothness in the usual manner and tested for flexibility at 25% elongation; for heat shock at 220° C. after having been stretched 20% and for burnout, which is an indication of the resistance to high temperature in the winding of a stalled motor. Such tests are well known to those skilled in the art and are described, for example, in U.S. Pat. Nos. 2,936,296; 3,297,785; and 3,555,113, and elsewhere. Specifically, the flexibility of the coatings are determined by stretching the coated electrical conductor 25 percent of its original length and winding it about a stepped mandrel having diameters of one, two and three times the wire diameter, the smallest mandrel diameter at which failure does not occur being taken as the test point. Dissipation factor (D.F.) is done by immersing a bent section of coated wire in hot mercury and measuring at 60 to 1,000 hertz by means of a General Radio Bridge, or its equivalent, connected to the specimen and the mercury. The values are expressed in units of % at the specified temperature in degrees Centigrade (Reference National Electrical Manufacturers Association Publ. No. MW 1000 Part 3, paragraph 9.1.1). Heat aging is carried out by placing a coil of unstretched, unbent coated wire in an oven under the specified conditions and evaluating it after 21 hours. The values are expressed in mandrel diameters withstanding failure after 21 hours, at 175° C., and 0% stretch. Cut through temperature is done by positioning two lengths of wire at right angles, loading one with a weight and raising the temperature until thermoplastic flow causes an electrical short and the values are expressed in units comprising degrees Centigrade at 2,000 g. (Reference NEMA method 50.1.1). Dielectric strength is determined on twisted specimens to which are applied 60 hertz voltage until breakdown occurs. The breakdown voltage is measured with a meter calibrated in root-mean-square volts. The values are expressed in units comprising kilovolts (kv) (Reference NEMA Method 7.1.1).
The coated wires have the following properties:
TABLE______________________________________Wires Coated With Polyesterimide And WithPolyesterimide-PolyesteramideimideExample 1A** 1______________________________________Composition (parts by weight)Polyesterimide (a) enamel 100 95Polyesteramideimide (b) enamel -- 5ConditioningWire Speed 57'/min. 57'/min.Build, Mils ˜3.0 ˜3.0PropertiesSmoothness Smooth SmootherFlex, 25%, Diameters 1 1Continuity, breaks/200' 3 0Dissipation factor, 220° C. 4.4 5.5Cut Through, °C. 397 384Diel. strength, KV 8 11Heat aging, 21 hrs./175° C. 1X 1XAbrasion, single scrape 1100 1300Repeat Scrape 27 30______________________________________
The wire according to this invention was smoother, and had better continuity and abrasion resistance. When the coating speed was increased to 65'/min., the polyesterimide control started to become wavy, blister and deteriorate. The blended composition according to this invention, on the other hand, coated as well at 65'/min. as it did at 57'/min.
EXAMPLE 2
Following the general procedure of Example 1, 95 parts by weight of a commercial polyesterimide derived from ethylene glycol, tris(2-hydroxyethyl)isocyanurate, methylenedianiline, trimellitic anhydride and terephthalic acid at 25% solids in cresylic acid solvent and 5 parts by weight of a commercial polyesteramideimide derived from azeleic acid, trimellitic anhydride, methylene dianiline, and ethylene glycol in a cresylic acid-phenol/hydrocarbon solvent at 27% solids are blended for 30 minutes, then filtered. The resulting composition according to this invention has a solids content of 26.0-28.0 at 200° C. and a viscosity in the range of 350-550 cps. at 30° C.
EXAMPLE 3
The general procedure of Example 2 is repeated, lowering the polyesterimide content to 93 parts by weight and raising the polyesteramideimide content to 7 parts by weight. The solids content is in the range of 26-28% by weight at 200° C., and the viscosity is in the range of 350-550 cps. at 30° C. In comparison with Example 2, this produces coated conductors with somewhat improved thermal properties.
Dual coated wires are made in a tower as described above.
In this first, a base coat of a polyester of dimethyl terephthalate, ethylene glycol and glycerine made according to Precopio et al., U.S. Pat. No. 2,936,296 is applied to a build of about 2.3 mls. To this coating is then applied a thinner, 0.3 mil. overcoating of the blended polyesterimide-polyesteramideimide of the Example. A coated copper conductor according to this invention is obtained.
In the second, a wire coated with the blended polyesterimide-polyesteramideimide of this invention (Example 1) has applied to it a thin outer coating of an amide-imide made by mixing and heating trimellitic anhydride and the diisocyanate of methylene dianiline. A coated copper conductor according to this invention is obtained.
All of the foregoing patents and publications are incorporated herein by reference. It is obviously possible to make many variations in the present invention in light of the above, detailed description. For example, the alkyl titanate can be omitted. Blocked polyisocyanates and/or phenol-formaldehyde resin can be added or they can be substituted with a melamine-formaldehyde resin. Metal driers can also be added, e.g., 0.2 to 1.0% based on total solids, of zinc octoate, cadmium linoleate, calcium octoate, and the like. All such obvious variations are within the full intended scope of the appended claims. | Electrical coating compositions comprise blended polyesterimides and from 1 to 20 percent by weight of total solids of an ester terminated amide imide. Such compositions provide insulation coatings on electrical conductors which have superior smoothness, even after high speed coating operations. | 8 |
BACKGROUND OF THE INVENTION
1. Technical Field of the Invention
The invention relates to a device for dividing floor coverings by means of a vertically adjustable rail having a substantially uniform cross section, extending under a door and sunk into the floor.
2. Brief Description of the Prior Art
Devices, e.g. rails, strips or the like, are generally applied between different floor coverings in adjoining rooms in order to define each floor covering. These dividing rails often also serve to form a threshold and also to improve the seal of the door closure. A device of this kind of threshold rails on doors is disclosed in DE-A 33 04 685.9 and in DE-A 35 27 113.2.
In order to ensure that these rails are fixed securely during installation, they must be arranged in such a manner that they are not displaced, e.g. until the floor covering has secured the rails sufficiently. They are generally fixed to the inner face of the door opening or to a previously mounted metal frame.
It is often desirable to provide additional seals on doors in order, in particular, to close the gap under the door securely and thereby to prevent draughts. A device of this kind is disclosed in, for example, DE-A 37 08 176.
SUMMARY OF THE INVENTION
An object of the invention is to provide a device which satisfies the various requirements of rail-like devices of this kind in the region of the door.
Another object of the invention is to provide a device which is versatile.
A further object of the invention is to provide a device, mounting of which is as simple as possible, so that it can be installed in a simple manner, even by unskilled workers.
In order to solve this problem, the invention is based on a device as disclosed in DE-A 33 04 685.9. It is proposed according to the invention that the rail has a substantially H-shaped design, comprising a crossbar and arms projecting upwards and downwards from the crossbar. The upwardly projecting arms and the crossbar together forming a receiving groove for a magnetic sealing strip which can be raised and can be moved in the groove. The arms projecting downwards from the crossbar guide, in recesses, a polygonal nut for a set screw which stands on the sub-floor.
The device according to the invention provides excellent division of the floor coverings in adjoining rooms or even on an entrance door between the external covering and the covering in the hall or the like. Vertical adjustment of the rail, i.e. aligning it with the finished floor, is carried out in the invention by a simple screwing process. Two set screws are generally used, in the vicinity of the ends of the rail. However, it is also possible to provide more set screws, e.g. in the case of a rail of larger dimensions. As the strip has a uniform cross section, the set screws can be inserted laterally with the nuts.
The device according to the invention also provides means for sealing the gap under the door. This has the advantage that the sealing device is sunk into the floor, i.e. it does not form any upwardly projecting stop.
The receiving groove for the magnetic sealing strip can also be used to support stationary side portions or wall portions on either side of the door. For example, a square profile of sufficient height can be inserted into the receiving groove, which profile supports the side portions through its upper region. The inserted profile can consist, for example, of plastics, whereby side or wall portions made of wood can be connected to the rail.
The device according to the invention can also be readily used when the adjoining floors are of different heights, so that a gradation must be provided.
DETAILED DESCRIPTION OF THE INVENTION
The recesses for the polygonal nut are preferably designed in such a manner that they form shoulders, so that the rail can rest on the polygonal nuts. It is particularly advantageous in this connection for the downwardly projecting arms to have opposing U-shaped receiving grooves for the polygonal nut. This facilitates installation as the grooves surround the nuts and prevent them from dropping out.
In order to connect the rail to the inner face of the door opening or the metal frame which receives the door, it is advantageous for a dovetailed groove to be provided on the inner face of one of the downwardly projecting arms. A resilient element can be inserted into a groove of this kind, as is known from DE-A 33 04 685.9. This resilient element can then be secured to the masonry.
It is further advantageous for another dovetailed groove to be provided on an outer face of one of the downwardly projecting arms. This groove can receive a strip, by means of which the device according to the invention can be fixed to a metal frame mounted in the door opening. The strip can also be magnetic, so that adhesion to the metal frame is obtained without additional measures. The usual means then serve for precise securing, e.g. screws, clamps, or even mortar or the like. The set screw used in the invention can be a conventional screw. However, the set screw is preferably provided at its lower end with a base plate by means of which it stands on the sub-floor. In this case, the set screw is preferably made of plastics material, in order to achieve good sound and thermal insulation. The nut used by the invention, on the other hand, can be a conventional hexagonal nut made of metal.
According to a further feature of the invention, a metal piece having a C-shaped cross section can serve as the base plate. This profile section, like the rail, receives a polygonal nut or a screw head. The profile section can then be rigidly connected to the set screw with a lock nut.
Particularly if the rail according to the invention is to be used on an external door, it is advisable to provide an extension on the downwardly projecting arm which can be broken off at breaking notches. In this manner, firm and permanent division of the interior and exterior can be simply achieved.
Fixing means, in particular a downwardly-open receiving groove for an insulating strip on the outer face of one arm, also serve this end.
An angled plate which serves to support the insulating strip can also be arranged in the receiving groove for the insulating strip. Such an angled plate preferably has arms of different lengths with breaking notches so that the plate can be adapted to situations of different dimensions.
In one type of construction, used on external doors, it is further advantageous for the receiving groove of the magnetic sealing strip to have lateral outlet openings on its base. Any moisture penetrating under the door can be collected by these openings and diverted to the exterior.
According to a further feature of the invention, a cover strip is provided for the receiving groove of the magnetic sealing strip. This cover strip has two clamping bars which engage in recesses in the sealing strip, which is inserted in an inverted manner into the groove, and clamp the sealing strip in the groove under deformation.
The proposal according to the invention enables the device to be completely mounted, even where the finishing of the floors, doors, etc. is not yet far advanced. The cover strip prevents contamination of the receiving groove and damage to the sealing strip during construction work. If the door is mounted, the cover strip is removed and the magnetic strip is simply turned round and brought into the operating position. Then only the magnetic counterpart has to be mounted in an appropriate manner on the bottom edge of the door.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section through a device according to the invention after mounting;
FIG. 2 is a section through a modified embodiment of the invention, in use;
FIG. 3 is a section through a rail forming part of the device of FIG. 1;
FIG. 4 is a section through a cover strip;
FIGS. 5 and 6 are sections through further embodiments of the invention, and
FIGS. 7 and 8 are cross-sections through profile sections used in the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1, a footstep sound insulating layer 25 is applied to a sub-floor 24. The base plate 15 of a set screw 10 stands on this insulating layer 25. This set screw 10 is screwed into a hexagonal nut 9 of conventional design. The hexagonal nut 9 can consist of, e.g., steel. The set screw 10 and the base plate 15 preferably consist of plastics material.
The nut 9 into which the set screw 10 is screwed is held in a rail 1 in two opposing receiving grooves 11,12. Short arms 26 (see FIG. 3) define these receiving grooves. In this arrangement, the set screw 10 can be displaced laterally in the rail 1 together with the nut, so that the rail can be supported by, for example, two or three set screws at different points. The desired vertical position can be set precisely by rotating the set screw.
The base plate 15 can simply be placed on the floor. However, it is also possible to fasten the base plate by pegs or by some other means.
In the embodiment shown in FIG. 1, a foam or cellular rubber strip 27 is stuck onto the outer face of the rail 1. The width of this strip 27 can be adapted to the respective height in a simple manner. If the strip is too wide, the strip concertinas of folds over. Good division of the floor layers 28,29 is achieved by means of the strip 27, thereby ensuring good sound insulation.
The floor coverings in the two adjoining rooms are designated by the reference numerals 30 and 31.
The rail 1 used in the invention consists essentially, as can be seen from FIG. 3, of a crossbar 2 with upwardly directed arms 3,4 and downwardly directed arms 5,6. Whereas the downwardly directed arms 5,6 essentially serve to form receiving grooves 11,12 for the set screw 10 and the nut 9, the upwardly directed arms 3,4 and the crossbar 2 together form a groove 7 for a magnetic sealing strip 8. As shown in FIG. 1, the sealing strip 8, which has an E-shaped cross section, is inserted into the groove 7 in an inverted manner and is covered by a cover strip 21. This cover strip has two clamping bars 22 which engage in recesses 23 of the elastically deformable magnetic sealing strip 8 and deform the sealing strip in such a manner that it is clamped in the groove 7. This is facilitated by the fact that the internal walls of the groove 7 taper towards the top.
The rail 1 can be securely and completely mounted. The magnetic sealing strip is protected and is only brought into operation when the door leaf is mounted.
Grooves 13,14 are provided and may be used to ensure correct arrangement of the rail 1 with respect to the door opening 39 or frame or case mounted in the opening 39. The groove 13 is situated oh the inner face of the downwardly directed arm 6 and can receive a leaf spring, by means of which the rail can be fixed in the door opening. This type of construction is used in particular in wooden frames which are only mounted once the floor is finished. If metal frames are provided, the groove 14 is in a shape of dovetail, into which an appropriately shaped strip 32 can be inserted. By virtue of this strip 32 which, e.g. may also be magnetically active, the rail can be secured on the metal frame, in the correct position without further alignment being necessary.
It will be noted that the strip 32 or the spring which is inserted into the groove 13 only occupies the end region of the rail in order to connect the rail to the frame or the wall soffit at that point.
Whereas the embodiment of FIG. 1 is intended for dividing the floors of internal rooms on the same level, the same rail 1 can also be used as a threshold rail.
The embodiment of FIG. 2 is a device according to the invention for use on an external door. To this end, it is advisable for the profile of the rail 1 to be slightly modified. In this embodiment, the arm 6 is provided with a downwardly projecting extension 16 having breaking notches 17. The extension can thus be adapted to the height of the floor covering and a solid boundary towards the outside can be obtained.
A receiving groove 18 for an insulating sheet 19 is further provided on the outer face of the arms 6. Outlet openings 20 are provided in the groove 7, by means of which rainwater passing under the door 33 into the groove 7 is diverted towards the outside into a gravel fill 38. The reference numeral 34 designates a water outlet. Another groove 35 for a cover profile 36 pressed into the groove 35 can also be integrally moulded on to the rail 1.
In FIG. 2, the magnetic sealing strip 8 is in the operating position. This sealing strip cooperates with a magnetic counterpart 37 which is inserted in a groove in the underside of the door 33. FIG. 2 shows the raised sealing position of the sealing strip 8. If the door 33 is opened by a certain amount, the magnetic contact between the strip 8 and the magnetic counterpart 37 is interrupted and the sealing strip 8 falls back into the groove 7. In the closed position of the door, on the other hand, the sealing strip 8 springs back towards the top and provides sealing.
In the embodiment of FIG. 2, the base plate 15 for the set screw 10 stands directly on the sub-floor 24, while the footstep sound insulation 25 is situated above the base plate 15. In this case, the base plate 15 is asymmetrical with respect to the set screw 10, whereas in the embodiment of FIG. 1 the base plate can be, for example, disc-shaped.
The embodiment of FIG. 5 differs from that of FIG. 2 essentially in that the receiving groove 18 is slightly larger, so that it is able to receive not only the insulating sheet 19, but also an angled plate 42. This angled plate 42 replaces the downwardly projecting extension 16 of the embodiment of FIG. 2 and also has breaking points 17, so that the angled plate 42 can be adapted to the appropriate dimensions. The angled plate 42 has two arms 43,44 of different lengths which in many cases allow rapid adaptation to the respective dimensions without the arms having to be shortened by means of the breaking points 17.
In the embodiment of FIG. 5, the base plate 15 of FIG. 2 is replaced by a profile section 40. This profile section 40 receives the hexagonal screw head 45 of the set screw 10. Lock nuts 46,47 thus provide a firm connection between the rail 1 and the profile section 40 after mounting.
The profile section 40 has a substantially C-shaped design, comprising a crossbar 48, upwardly directed arms 49, and edge flanges 50 (see FIG. 7). A bend in the crossbar 48 allows for the arrangement of fixing screws 51 without having an adverse effect on the displaceability of the screw head 45 in the profile section during mounting.
FIG. 8 shows a simplified embodiment of a C-shaped profile section 41.
In FIG. 5, dotted lines 52 indicate a groove which is arranged in side parts beside the door 33. This groove 52 is thus situated at the side of the sealing strip 8, the magnetic counterpart 37 and the fixing means 53 arranged in the door 33. The groove 52 can then receive a rectangular profile which completely fills the groove 52 and also extends into the groove 7. In this manner, the rail 1 according to the invention can also be used for mounting side portions of this kind beside the door, this then being advantageous if these side portions consist of wood.
During mounting of the rail 1 and the insulating sheet 19 on the angled plate 42, it is advisable to fill the space 54 behind the angled plate 42 with assembly foam which also extends into the space between the two arms 5,6.
The embodiment according to FIG. 6 of the invention is a variant which is preferably used on external doors. Insulation 55 is provided on the inner face of the rail 1 and is rigidly connected to the rail 1. | A device for dividing coverings on a floor at a door opening, comprises a rail sunk into the floor across the door opening. The rail has a substantially uniform H-shaped cross-section, comprising a cross-member with first arms extending upwardly therefrom to define a first groove and second arms extending downwardly therefrom to define a second groove. A magnetic sealing strip is received within the first groove and is vertically moveable within it. A set screw extends upwardly into the second groove and engages a nut which is held within the second groove. | 4 |
BACKGROUND OF THE INVENTION
U.S. Pat. No. 3,196,617 discloses a way whereby air-borne contamination can be prevented from being communicated to a reservoir of a master cylinder. In this apparatus, a diaphragm which seals the reservoir from tha atmosphere will follow the brake fluid level as changes occur therein. Under some conditions, a pressure differential will occur across the diaphragm which will move the diaphragm into the brake fluid. When the diaphragm is moved in the brake fluid, a portion of this fluid will be displaced upward along the diaphragm and the walls of the reservoir creating a false fluid level indication of the quantity of brake fluid within the reservoir.
SUMMARY OF THE INVENTION
I have devised a cover means for a master cylinder which will limit the creation of a pressure differential across a diaphragm means to prevent the establishment of a false fluid level indication caused by displacement of fluid by the diaphragm means. The diaphragm means has an expandable section which has an opening therein into which a check valve means is secured. When a pressure differential sufficient to move the diaphragm into the fluid is developed between the reservoir and the atmosphere, the check valve means will open and attenuate the pressure differential sufficiently to prevent the development of a false fluid level signal for operating a fluid level indicator in the reservoir.
It is therefore the object of this invention to provide a master cylinder with a diaphragm means having a check valve means to limit the development of a pressure differential which could move the diaphragm means sufficiently to interfere with the output from a fluid level indicator.
It is another object of this invention to provide a master cylinder with a diaphragm means through which air from the atmosphere is communicated to the reservoir to prevent the diaphragm from being moved within the fluid retained in a reservoir.
It is a still further object of this invention to provide a diaphragm with a pressure relief means to limit the movement of the diaphragm as it follows the level of the fluid therein to assure that an accurate indication of the quantity of fluid within the reservoir is recorded by an indicator.
These and other objects of this invention will become apparent from reading this specification and viewing the drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a sectional view of a master cylinder reservoir and cover means having a diaphragm means through which air is communicated through a check valve means controlled by a pressure differential.
FIG. 2 is a view taken along line 2--2 of FIG. 1.
FIG. 3 is another embodiment of a check valve for use with the diaphragm means in FIG. 1.
FIG. 4 is another embodiment of a check valve for use with the diaphragm means in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The master cylinder 10 shown in FIG. 1 has a cylindrical power producing means 12 to which a reservoir means 14 is attached. The power producing means 12 retains a first piston (not shown) and a second piston (not shown) for developing a first fluid pressure, which is communicated to the front brakes of a vehicle through outlet port 16, and a second fluid pressure, which is communicated to the rear brakes of a vehicle through port 18, in response to an input force supplied through push rod 20 by an operator.
The first piston is connected through compensation port 22 to a first section 24 and the second piston is connected through compensation port 26 to a second section 28 of the reservoir means 14. A wall 30 which separates the first section 24 from the second section 28 permits restricted communication through passages 32 and 34.
A diaphragm 36 has a flat section with a peripheral surface 38 which overlies the outside wall 40 of the reservoir means 14 and a first expandable surface 42 and a second expandable surface 44 located over the first section 24 and the second section 28, respectively.
A cap means 46 has a flange 48 which engages the periphery 38 of the diaphragm 36, a first projection 56 into which the first expandable surface 42 of the diaphragm means 36 is nestled, and a second projection 58 into which the second expandable surface 44 is nestled.
A bail wire 50 has a first end 52 and a second end 54 attached to the housing 40 to resiliently bias the peripheral edge 38 against the housing 40 and seal the first chamber 24 and the second chamber 28 from the atmosphere upon engagement with the first projection 56 and the second projection 58. The cap means 46 has breather ports 60 and 62 for connecting the first projection 56 and the second projection 58 with the atmosphere.
A fluid level indicator 64 has a grommet 66, which passes through the cap means 46, and a cylindrical shaft 68 which extends into the second section 28 of the reservoir means 14. A float 70 which follows the level of the fluid in the reservoir is retained on the shaft 68 by a snap ring 72.
A first check valve means 74 is located in the center of the first expandable surface 42 and a second check valve means 76 is located in the center of the second expandable surface 44. The first check valve means 74 has an annular surface or shoulder 78 which projects from the expandable surface 42 toward the first section 24 of the reservoir 14. An axial passageway 80 extends into a control chamber 82. A series of smaller passageways or holes 84 connect the control chamber 82 with the reservoir 74. A spherical ball 86 having a diameter which is larger than the distance between seat 88 and resilient surface 90 is located in the control chamber 82. The resilient surface 90 urges the ball 86 againt seat 88 to seal the control chamber 82 from the atmosphere. Similarly, ball 92 in the second check valve means 76 is held against seat 94 by the resiliency of surface 96 to prevent air from the atmosphere from being communicated through passageway 98 to the control chamber 100 and out the plurality of passageways or holes 102 to the reservoir.
MODE OF OPERATION OF THE PREFERRED EMBODIMENT
Upon desiring to stop a vehicle, the operator will cause an input force to be applied to push rod 20 which will move the power pistons in the cylindrical bore 12 of the master cylinder 10. Initial movement of the power pistons will close the compensation ports 22 and 26 to allow fluid pressure to build up in the cylindrical bore 12 and be transmitted through output ports 16 and 18 to operate the front and rear braking systems of the vehicle. Upon termination of the input force on the push rod 20, return springs (not shown) in the cylindrical bore will move the power pistons to a rest position against a stop in the rear 106 of the cylindrical housing. If any fluid is lost from the braking system, a vacuum will draw fluid from the reservoir means 14 to maintain the quantity of operational fluid in the bore 12 within a predetermined level. At the same time, float 70 will correspondingly move on shaft 68 to provide the operator with an indication of a change in the fluid reservoir 14. As fluid is drawn out of the reservoir means 14, a vacuum will be created in this sealed chamber causing the first expandable section 42 and the second expandable section 44 to move toward the first section 24 and the second section 28 respectively. When the pressure differential reaches a predetermined level sufficient to displace the expandable sections 42 and 44 into the fluid, the balls 86 and 92 will move in opposition to the resilient surfaces 90 and 102, respectively, and allow air to flow through either passageway 80 or 98 to attenuate this pressure differential and prevent float 70 from being influenced by an erroneous fluid level. The fluid level in both the first section 24 and the second section 28 will be maintained at the same level since restrictive passages 32 and 34 will allow free communication therebetween. However, if the fluid level in either the first section 24 or the second section 28 falls below the restrictive passages 32 and 34, the float 70 will activate the fluid level indicator 64 causing a continual signal to forewarn the operator of an unsafe operating condition in the braking system. The restrictive ports 32 and 34 are so located from the compensating ports 22 and 26 to assure that both the front brakes and the rear brakes wll not fail from the loss of fluid through a single failure.
The check valve means 174 shown in FIG. 3 has a conical chamber 178 with a first radial passageway 180 and a second radial passageway 182 terminating in an annular groove 184 on the projection 170. A flexible ring 186 located in the annular groove 184 will interrupt any communication between the atmosphere present on the top side 188 of the expandable section 192 of the diaphragm and the reservoir side 190. When a pressure differential sufficient to move the expandable section 192 occurs, ring 186 will be moved away from passages 180 and 182 to allow air to enter and attenuate this pressure differential.
In the check valve embodiment shown in FIG. 4, an annular body 260 has a groove 262 which is snapped into an opening 264 in the expandable portion 266 of a diaphragm. The annular body has a channel 268 which extends from the top side 270 of the diaphragm to the bottom side. The channel has a first flat surface 274 and a second flat surface held together by the resiliency of the annular body to seal the reservoir side 272 from the atmospheric side 270. When a pressure differential sufficient to move the expandable portion in the fluid into the reservoir occurs, the first flat surface 274 will separate from the second flat surface and air will flow through the channel into the reservoir to attenuate this pressure differential.
Thus, I have devised a diaphragm means whereby the fluid in the reservoir is protected from being contaminated by foreign particles in the air which could be detrimental to the braking system and yet the operation of a fluid level indicator is not presented with a false fluid level signal which indicates a greater quantity of fluid present in the reservoir than is actually present. | A cover apparatus for a master cylinder reservoir which has a diaphragm with an expandable surface. A check valve is located in an opening in the expandable surface to limit the pressure differential created thereacross by air at atmospheric pressure on one side thereof and vacuum in the reservoir on the other side thereof upon a depletion of fluid from the reservoir. With a change in the pressure differential, the expandable surface will be prevented from moving into the fluid and influencing the output from a fluid level indicator located therein. | 8 |
FIELD OF THE INVENTION
This invention relates to containers for fibrous materials such as straw and hay. More particularly, this invention relates to techniques for confining bales of fibrous materials to prevent waste.
BACKGROUND OF THE INVENTION
Fibrous materials such as straw and hay are normally compressed and baled in the field and stored in stacks until they are needed. Then the bales are typically opened one at a time by cutting the twines (either string or wire) to access the straw or hay.
Unfortunately, once a bale is opened, the entire contents of the bale are loose. Consequently, unused portions of the bale are not confined and can become easily separated or scattered. This is not only untidy but it also leads to waste of some of the loose material. Much time can be spent attempting to sweep or rake loose material from the floor area.
There has not heretofore been provided a convenient means for confining baled material after a bale has been opened.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention there is provided a bale saver container for confining and supporting a bale of fibrous material in an upright manner. The container includes a floor member and four upright wall members. Each wall is attached at its bottom edge to the floor member. The front wall includes a slotted aperture extending vertically downward from the top edge to a point in close proximity to the floor member. The container includes handle means for carrying or moving the container.
A bale of fibrous material such as hay or straw can be slidably received in the open end of the container. For example, the container can be laid on one side (e.g., the front), after which the bale can be slid into the container. Then the container can be tipped up and rested on its bottom. After the strings on the bale have been severed, the fibrous material can be accessed and any desired amount can be removed from the open top of the container.
The contents of the container are confined and supported by the walls of the container to prevent the fibrous material from being scattered over a wide area. The presence of the slotted aperture allows a person to easily reach and access the fibrous material regardless of the depth of such material in the container.
Optionally, there may be wheels attached to the lower portion of the container so that it can be wheeled from one location to another.
Other advantages of the bale saver container of the invention will become apparent from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail hereinafter with reference to the accompanying drawings, wherein like reference characters refer to the same parts throughout the several views and in which:
FIG. 1 is a perspective view of one embodiment of bale saver container of the invention;
FIG. 2 is a perspective view of the container of FIG. 1 with a bale of fibrous material therein; and
FIG. 3 is a perspective view of another embodiment of bale saver container of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIGS. 1 and 2 there is illustrated one embodiment of bale saver container 10 of the invention comprising upright side walls 11, rear wall 12, and front wall 14. The bottom edge of each wall member is attached to a floor member 15.
The front wall 14 includes an elongated slotted aperture 14A extending from the top edge of the front wall to a point in close proximity to the floor of the container. The width of the slotted aperture is at least about 3 to 6 inches to allow a person's hand(s) to reach through it to grasp and lift fibrous material out of the container as needed.
The height of the container is preferably about 36 to 40 inches (i.e., nearly the length of an ordinary bale 20 of fibrous material such as hay or straw). The cross-section of the container is preferably rectangular and just slightly larger than the size of the bale. For example, the side walls may have a width of about 18 inches, and the front and rear walls have a width of about 21 inches.
One or more openings 13 may be provided in the rear wall and the side walls to function as handles for carrying or moving the container. Of course, other handles could be attached to the upper end of the container, if desired. Wheels may also be rotatably supported on the lower portion of the container, if desired, to facilitate moving the container from one location to another.
To insert a bale 20 into the open end of the container, it is preferred to lay the container on its front side and then slide the bale into the container. FIG. 2 shows such a bale in the container after the container has been raised back to its upright position. Then the strings 21 (either plastic twine or wire) can be severed. This allows any desired amount of fibrous material to be easily removed from the container for use.
FIG. 3 illustrates another embodiment 30 of bale saver container for the invention. In the embodiment the front wall 32 includes forwardly projecting ear members 32A at the upper edge. These ears are intended to engage or grip the ground when the container is laid on its front face. Then when a bale is pushed into the container, the ears resist rearward movement of the container. The ears may project forwardly about 1 to 2 inches, for example.
Handle means 34 at the upper end of the rear wall projects rearwardly to facilitate movement of the container. Wheels 37 are rotatably supported on axle 36 carried by the lower end of the rear wall of the container. The wheels greatly facilitate movement of the container from one location to another. Alternatively, the wheels could be attached under the floor of the container and may be recessed, if desired.
Preferably the side walls are parallel to each other, and the front and rear walls are also parallel to each other.
The container may be composed of any suitable rigid material. Preferably it is composed of plastic (e.g., polyethylene, fiberglass, etc.) although it could be made of metal or wood or composite materials.
Other variants are possible without departing from the scope of the present invention. | A bale saver container is described for confining and supporting a bale of fibrous material in an upright position. The container confines the material (e.g., hay or straw) after the strings of the bale have been severed so as to prevent loose material from being scattered and wasted. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] A copending United States patent application commonly owned by the assignee of the present document and incorporated by reference in its entirety into this document is being filed in the United States Patent and Trademark Office on or about the same day as the present application. This related application is: Hewlett-Packard docket number 100200821-1, Ser. No. ______, titled “DETECTION OF BIT ERRORS IN MASKABLE CONTENT ADDRESSABLE MEMORIES.”
FIELD OF THE INVENTION
[0002] This invention relates generally to content-addressable memories (CAMs) and more particularly to detecting bit errors that may occur in the data stored in a CAM.
BACKGROUND
[0003] CAM structures perform pattern matches between a query data value and data previously stored in an entry of the CAM. A match causes the address of the matching entry to be output. Bit value errors may occur in CAM entries at any time due to external energy being imparted to the circuit. For example, an alpha particle strike may cause one of the storage elements in a CAM to change state. If this occurs, an incorrect query match may result causing an incorrect address to be output from the circuit. If the CAM address is used to drive a RAM, this error will also cause incorrect data to be output from the RAM. Since the contents of the CAM entries are typically not known external to the CAM, this incorrect (or false) query match may not be detected.
SUMMARY OF THE INVENTION
[0004] Parity bit(s) are stored in a random access memory (RAM) that is coupled to a CAM. The parity bits(s) are stored in conjunction with the CAM entry write. Upon a CAM query match, the reference parity bit(s) stored at the address output by the CAM are output from the RAM. These reference parity bit(s) are compared to parity bit(s) generated from the query data value. In the absence of a CAM or RAM bit error, the reference parity bit(s) from the RAM and the parity bit(s) generated from the query data will match. If a CAM or RAM bit error occurred, these two sets of parity bit(s) will not match and thus an error will be detected. This error may be used as an indication that a false CAM match has occurred.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] [0005]FIG. 1 is a block diagram illustrating the detection of CAM bit errors.
[0006] [0006]FIG. 2 is a block diagram illustrating the detection of CAM bit errors with maskable bits.
[0007] [0007]FIG. 3 is a flowchart illustrating steps to detect CAM bit errors.
[0008] [0008]FIG. 4 is a flowchart illustrating steps to detect CAM bit errors in a CAM with maskable bits.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0009] [0009]FIG. 1 is a block diagram illustrating the detection of CAM bit errors. In FIG. 1, arrow 102 represents data being written into CAM 120 at an address represented by arrow 109 . Data 102 is also supplied to a parity generator 122 . Parity generator 122 generates one or more input parity bits 105 from data 102 . The input parity 105 generated by 122 may be a simple single bit parity such as odd or even parity, or a more complex multi-bit parity such as an error correcting code (ECC). The input parity bit(s) generated by parity generator 122 are represented by arrow 105 . The input parity 105 is written into RAM 121 at an address corresponding to the address shown as arrow 109 . Accordingly, after an entry is written in CAM 120 at a particular address, there will be a corresponding input parity entry stored in RAM 121 at a corresponding address.
[0010] When query data is supplied to CAM 120 , CAM 120 may output the address that contains that query data, or indicate that that query data is not in the CAM. In FIG. 1, the query data is represented by arrow 101 . This query data is also supplied to parity generator 123 . In the case of a query match, the address being output by CAM 120 is represented by arrow 103 . The address of the query match 103 is forwarded to RAM 121 to retrieve (at least) the parity stored in the RAM at the corresponding address. The stored parity output by the RAM is represented by arrow 107 . Any additional data stored in RAM 121 at the corresponding address may also be output. This additional data is represented by arrow 104 .
[0011] Parity generator 123 outputs query parity bit(s) represented by arrow 106 . The query parity bit(s) 106 generated by parity generator 123 would typically be the same encoding as those produced by parity generator 122 . However, it may differ from the encoding generated by parity generator 122 by certain inversions, or other transformations etc. depending upon the functioning of parity compare 124 and RAM 121 . Parity bit(s) 106 and stored parity output 107 are compared by a comparator 124 . The results of this compare 108 indicate whether or not there was a bit error in the queried entry in the CAM or in the stored parity corresponding to that entry.
[0012] [0012]FIG. 2 is a block diagram illustrating the detection of CAM bit errors with maskable bits. In FIG. 2, arrow 202 represents data being written into CAM 220 at an address represented by arrow 209 . Data 202 is also supplied to a mask block 225 . Arrow 210 represents input mask bits. Input mask bits 210 are supplied to CAM 220 , mask block 225 , and RAM 221 . Input mask bits 210 are stored in CAM 220 at the same address 209 as data 202 and tell CAM 220 which bits to consider or not consider when determining if a query matches the entry at address 209 .
[0013] Mask block 225 takes data 202 and mask bits 210 and sets certain bits in data 202 to a predetermined value (i.e. logical 1 or 0). The bits that are set to this predetermined value are given by the values of mask bits 210 . For example, if data 202 was four bits wide (and it could be any arbitrary length) and its binary value was “1100” and mask bits 210 's binary value was “1010” (and 1 was chosen to mean pass, 0 to mean mask), mask block 225 may output “1000”—effectively masking bits 0 and 2 (numbering bits from right-to-left with bit 0 being the rightmost, bit 3 the leftmost) of data 202 to a logical 0. Data 202 could also have been masked to logical l's making the mask block output 211 “1101”. Mask block output 211 is supplied to parity generator 222 .
[0014] Parity generator 222 generates one or more input parity bits 205 from mask block output 211 . The input parity 205 generated by 222 may be a simple single bit parity such as odd or even parity, or a more complex multi-bit parity such as an error correcting code (ECC). Note that parity calculations should be limited to those bits which affect or control query matches. This is because errors in masked bits will not result in incorrect matches since masked bits are ignored when determining if there is a match. For example, if data bit 13 is masked in a CAM entry, the parity for that entry should be the same regardless of the value of bit 13 of the query data. Accordingly, bit 13 should be masked before the parity calculation related to that entry. The input parity bit(s) generated by parity generator 222 are represented by arrow 205 . The input parity 205 is written into RAM 221 along with mask bits 210 at an address corresponding to the address shown as arrow 209 . Accordingly, after an entry is written in CAM 220 at a particular address, there will be a corresponding input parity entry and mask bit entry stored in RAM 221 at a corresponding address.
[0015] When query data is supplied to CAM 220 , CAM 220 may output the address that contains that query data 201 , or indicate that that query data 201 is not in the CAM. In FIG. 2, the query data is represented by arrow 201 . This query data is also supplied to mask block 226 . In the case of a query match, the address being output by CAM 220 is represented by arrow 203 . The address of the query match 203 is forwarded to RAM 221 to retrieve (at least) the parity and mask bits stored in the RAM 221 at the corresponding address. The stored parity output by the RAM is represented by arrow 207 . The stored mask bits are represented by arrow 212 . Any additional data stored in RAM 221 at the corresponding address may also be output. This additional data is represented by arrow 204 .
[0016] Mask block 226 takes query data 201 and stored mask bits 212 and sets certain bits in query data 201 to a predetermined value (i.e. logical 1 or 0). The function of mask block 226 is similar to mask block 225 . The output of mask block 226 is represented by arrow 213 and is supplied to parity generator 223 .
[0017] Parity generator 223 outputs query parity bit(s) represented by arrow 206 . The query parity bit(s) 206 generated by parity generator 223 would typically be the same encoding as those produced by parity generator 222 . However, it may differ from the encoding generated by parity generator 222 by certain inversions, or other transformations etc. depending upon the functioning of parity compare 224 , mask blocks 225 and 226 , parity generators 222 and 223 , and RAM 221 . Parity bit(s) 206 and stored parity output 207 are compared by a comparator 224 . The result of this compare 208 indicates whether or not there was a bit error in the queried entry in the CAM 221 , the mask bits either in the CAM 221 , or in the stored parity or mask bits corresponding to that entry.
[0018] [0018]FIG. 3 is a flowchart illustrating steps to detect CAM bit errors. These steps are applicable to the block diagram in FIG. 1, but are not limited to application with only that arrangement of blocks. Other arrangements of blocks may be used to complete these steps. In FIG. 3, in a step 302 input parity is generated on input data that is being written into the CAM. The generated input parity may be a simple single bit parity such as odd or even parity, or a more complex multi-bit parity such as an error correcting code (ECC). In a step 304 , the input data is stored in a CAM at an input address. In a step 306 , the input parity is stored in a RAM at an address that corresponds to the address the input data was stored at in the CAM. In other words, the input parity is stored at an address that, when a query matches in the CAM and the CAM outputs an address, the RAM will output the input parity when the address the CAM outputs is used either directly as an address or as an index to an address that is applied to the RAM's address inputs.
[0019] In a step 308 , the CAM is queried by supplying the appropriate inputs of the CAM with query data. In a step 310 , query parity is generated on the query data that is being applied to the CAM. This parity algorithm should produce a result that matches the algorithm used in step 302 or only differs by insignificant factors such as an inversion or other insignificant transformations. In a step 312 , a stored parity is retrieved from the RAM by accessing a RAM location that corresponds to the address supplied by the CAM when it was queried in step 308 . In a step 314 , the generated query parity and the stored parity from the RAM are compared. If they match, no bit error in either the CAM contents or RAM stored parity contents has been detected. If they do not match, a bit error in either the CAM contents or RAM stored parity content has been detected.
[0020] [0020]FIG. 4 is a flowchart illustrating steps to detect CAM bit errors in a CAM with maskable bits. These steps are applicable to the block diagram in FIG. 2, but are not limited to application with only that arrangement of blocks. Other arrangements of blocks may be used to complete these steps. In FIG. 4, in a step 401 , the input data is masked according to a set of mask bits. In a step 402 input parity is generated on the masked input data from step 401 . The generated input parity may be a simple single bit parity such as odd or even parity, or a more complex multi-bit parity such as an error correcting code (ECC). Note that parity calculations should be limited to those bits which affect or control query matches. For example, if data bit 13 is masked in a CAM entry, the parity for that entry should be the same regardless of the value of bit 13 of the query data. Accordingly, bit 13 should be masked before the parity calculation related to that entry. In a step 404 , the input data and the set of mask bits are stored in a CAM at an input address. In a step 406 , the input parity and the set of mask bits are stored in a RAM at an address that corresponds to the address the input data was stored at in the CAM. In other words, the input parity and mask bits are stored at an address that, when a query matches in the CAM and the CAM outputs an address, the RAM will output the input parity and mask bits when the address the CAM outputs is used either directly as an address or as an index to an address that is applied to the RAM's address inputs.
[0021] In a step 408 , the CAM is queried by supplying the appropriate inputs of the CAM with query data. In a step 412 , a stored parity and stored mask bits are retrieved from the RAM by accessing a RAM location that corresponds to the address supplied by the CAM when it was queried in step 408 . In a step 413 , the query data is masked according to the stored mask bits retrieved in step 412 . In a step 410 , query parity is generated on the masked query data from step 413 . This parity algorithm should produce a result that matches the algorithm used in step 402 or only differs by insignificant factors such as an inversion or other insignificant transformations. In a step 414 , the generated query parity and the stored parity from the RAM are compared. If they match, no bit error in either the CAM contents, or RAM stored parity contents, or RAM stored mask bits has been detected. If they do not match, a bit error in either the CAM contents, RAM stored parity contents, or stored mask bits has been detected.
[0022] One use of a CAM with or without mask bits is in a translation look-aside buffer or TLB. In this application, a virtual address (or portion thereof) is sent to the CAM. If a hit occurs, the CAM causes at least a portion of the physical address to be output by a RAM. A bit error in the CAM of a TLB may cause one of two things to happen. The first, is the bit error will prevent an otherwise valid TLB entry from getting hit (i.e. the bit error causes a TLB entry that should match not to match). In this case, since the replacement of entries in a TLB is often done on a least-recently used basis, the erroneous entry will eventually be replaced because it never matches. This type of bit error won't be detected. However, since the offending entry is eventually replaced or re-written, this type of bit error does not tend to cause serious problems. The second is a bit error that causes a TLB entry to match when it should not. This type of bit error can cause serious problems in the operation of the computer and, since it causes matches, may not be eventually replaced for lack of use. However, the methods and apparatus described above facilitate the detection of this type of bit error so that this entry may be invalidated, re-written, or otherwise handled before the bit error causes problems. | Parity bit(s) are stored in a random access memory (RAM) that is coupled to a CAM. This CAM may be part of a TLB. The parity bits(s) are stored in conjunction with the CAM entry write. Upon a CAM query match, the reference parity bit(s) stored at the address output by the CAM are output from the RAM. These reference parity bit(s) are compared to parity bit(s) generated from the query data value. In the absence of a CAM or RAM bit error, the reference parity bit(s) from the RAM and the parity bit(s) generated from the query data will match. If a CAM or RAM bit error occurred, these two sets of parity bit(s) will not match and thus an error will be detected. This error may be used as an indication that a false CAM match has occurred. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the construction of modular styled system such as furniture, supports, organizers, and toys, from modular components, panels, or building blocks. Specifically, it relates to the design, manufacture, and utilization of such modular components, panels or building blocks, each having specifically designed slots or openings.
[0003] 2. Discussion of the Related Art
[0004] A piece of furniture is made of different components of different sizes and shapes. As disclosed in prior art references such as U.S. Pat. No. 3,811,728, a furniture assembly begins with a set of different sized and shaped modules such as furniture bases that has one particular shape, furniture top surfaces, and other additional components such as walls. To interconnect the various modular components, the various components often have a periphery accessory structure. For example, a top surface may be recessed with several criss-crossed slots. The top surface is also recessed along the four sides of its perimeter with slender, rectangular openings. For coupling two such modules together, inverted-U shaped clips are employed, with legs having cross-sections in the shape of slender rectangles, for insertion one apiece into the slender, rectangular openings of the top surfaces. Thus two modules can be coupled together to build a modular assembly of a furniture base. This known furniture assembly further includes several kinds of auxiliary components, for releasably coupling with the furniture base. Some additional auxiliary components are needed to couple with the furniture base to build chair or sofa assemblies. Still others are needed to build table, shelf or bed assemblies. For coupling purposes, each auxiliary component has a downwardly extending, stubby flange looped around in a rectangle, for insertion into the criss-crossed network of slots in the top surfaces of the furniture base
[0005] There is a need to reduce the number of modular components that is needed to construct a piece of furniture, for everyday use as well as modern day travelers and urban residents. There is also a need to pack the modular components more efficiently so that the dismantled components of a modular style furniture or object can be easily transferred, or stored to create living space. For example, packing the modular components in a compact manner would allow users, such as in schools, homes, apartment, business, studio spaces, a multipurpose access to the floor space. Imagine a “room” that can be converted into empty space for exercise, or a dining-room or a bedroom. When stored, there is also need for a modular component to blend into the surrounding area without the intrusion into the floor space.
[0006] There is an additional environmental need for modern day travelers and urban resident to loan, share, and moved in parts among the users. A standardized modular component allows for reuse and sharing. It also allows for mass production.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention relate the utilization of modular panels, components, objects, and/or building blocks to construct a modular styled system, such as pieces of furniture, supports, organizers and toys. One example of such modular panel, component, object, and/or building block is a rectangular or square object that has a) predetermined length and width, b) various set combinations of carved-out openings or slots that extend perpendicular from the edges of such panels, and/or c) a set number of drill-holes with specific diameters and their lengths. Such modular panel can be solid or hollow, and can be constructed from any material, such as wood, metal, glass, plastic, etc. This modular panel can be used as a building block of various viable accessories such as tables of various sorts, shelves, beds, and book stands etc. This modular panel can be used to also construct de novo structures for a given time and situation.
[0008] Embodiments of the present invention provide a plurality of modular elements for building pieces of furniture, supports, organizers, toys and other objects that can be easily dismantled, compacted neatly so that a big storage place is not needed, and they can be conveniently transported.
[0009] Embodiments of the present invention further provide modular furniture, support, organizer, toy pieces formed from individual modular units that do not require the use of tools, fasteners, or the like for assembly.
[0010] The above and other aspects, features and advantages of embodiments of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a perspective view of embodiments of a modular panel of the present invention, showing a solid panel that is made from wood and a hollowed panel that is made of metal.
[0012] FIG. 2 shows a perspective view of two modular panels of the embodiments of present invention interlocked to construct a larger system in the form of a furniture component.
[0013] FIG. 3 shows a side and perspective view of a modular panel of one of the embodiments of the present invention, having various accessory elements to be used in connection with the modular panel.
[0014] FIG. 4 shows a perspective view of two panels of the embodiments of the present invention.
[0015] FIG. 5 shows a cross-sectional view of the two panels that are shown on FIG. 4 .
[0016] FIG. 6 shows an enlarged view of the various accessory elements that can be used in connection with embodiments of the present invention.
[0017] FIG. 7 illustrates an exemplary packing of embodiments of the present invention for easy storage.
[0018] FIG. 8 shows one of the embodiments of the present invention whereby small panels can be combined to form a large panel.
[0019] FIG. 9 shows various ways by which modular panels can be combined with each other to form bigger and complex furniture structures.
[0020] FIG. 10 shows a perspective view of a plurality of modular panels constructed according to the concepts and principles disclosed in embodiments of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the embodiments described herein. The scope of the invention should be determined with reference to the claims. The embodiments of the present invention address the problems described in the background while also addressing other additional problems as will be seen from the following detailed description.
[0022] Referring now to FIG. 1 , there is shown a piece of panel that can be used as the building block to construct a piece of furniture such as a dining table, a coffee table, a book shelf, a bed, etc. Such panel is rectangular in shape (including squares). The material for the panel can be plastic, wood, glass, metal, or other types of material that is known to one of ordinary skill in the art. The panel can also be made solid or hollow, as shown in FIG. 1 a and FIG. 1 b. The panel contains a number of opening or elongated slots that extend perpendicularly from the edges of the panel ( 100 , 200 , 300 , 400 , 500 , and 600 ). As shown in FIG. 2 , the opening or elongated slots carved out of the panels are used for interlocking one panel to another. The length of an elongated slot is preferably equal to half of the length of the edge of the panel to which the elongated slot runs parallel so that the interlocked panels provide a leveled fit, as shown in FIG. 2 . In another embodiment, the terminal end of the slot that is distal from the edge is preferably round and extends slightly beyond the half length point to make it aesthetic.
[0023] As shown in FIG. 2 b, the panel may also contain a number of holes drilled from one reference edge of the panel and runs perpendicular through the length of the panel till another reference edge of the panel. Metal bars of various configurations may be used to thread through the holes to enforce the strength and durability of the panel. The inserted metal bars take the weight of the panel it carries. The metal bars may also re-enforce the connections of two or more panels when necessary. In addition, rubber tips may be applied to the ends of the metal bars. The function of such rubber tips is versatile. It smoothes the contacts between the furniture components and further protects the furniture components from scratches or heavy weight.
[0024] FIG. 3 provides a more detailed three dimensional view of the panel and its various elements. As the Figure shows, the panel has six openings or elongated slots that cut perpendicular into three of its reference edges. Three openings or elongated slots extend from a first reference edge, the vertical edge of the panel that is facing away from the drawing, and runs in the horizontal direction, or parallel to one side of the panel, as shown in FIG. 3 . One of these openings or elongated slots is located at approximately the midpoint of said first reference edge. The other two are located at approximately the one quarter and three-quarter points of said first reference edge. There are three more openings or elongated slots that extend from either a second reference edge and a third reference edge and run in the vertical direction. The second reference edge is the upper horizontal edge of the panel shown in FIG. 3 , and the third reference edge is the bottom edge. One of the three openings or elongated slots extends from said second reference edge, and the other two extends from said second reference edge. Preferably, the location for the opening or elongate slot in said second reference edge is at a three-quarter point, and the locations for the openings or elongated slots are at respectively a three-eighth point and a seven-eighth point.
[0025] The panel could also have drill holes that run across the length of the sides of the panels. The bore of these drill holes are preferably small in relation to the thickness of the panel so as not to harm the integrity of the panel itself. Metal bars may be used to thread through the drill holes to enforce the strength and durability of the panel. Longer metal bars could also be used to connect different panels to each other. Half-sphere shaped or oblong-half-sphere shaped rubber cushions are provided at the distal ends of the metal bar. The function of such rubber cushions is versatile. It provides gripping force between the horizontal and vertical modular panels as disclosed in this invention. It also smoothes the contacts between the components of a piece of furniture constructed from the panels disclosed in this invention and further protects the furniture components from scratches or heavy weight.
[0026] FIG. 3 also includes additional accessory elements that can be used in conjunction with the panels disclosed in this invention. For example, one could use a single slot filler to fill in the elongated slots that are cut out, or use a double slot filler to fill in the elongated slots and connect two panels together. Again, the material for the slot fillers can be plastic, wood, glass, metal, or other types of material that is known to one of ordinary skill in the art. The size and shape of a single slot filler should correspond to the size and shape of the elongated slot so that the slot can be filled in. The length of a double slot filler should be twice the size of a single slot filler. Such double slot filler could be used to connect two modular panels together. In addition, the edges of the panels could also be covered with side panel covers if the rubber cushions are not used.
[0027] FIG. 6 provides further illustration of these accessory elements. FIG. 6 a - 6 c show configurations of the metal bars comprised of a slim steel rod that is encapsulated in both ends by cylindrical tubes. The tip ends of the bar are further covered by rubber cushions that have either half-sphere or oblong-half-sphere shapes. FIG. 6 e, 6 f, 6 h, and 6 i show a single slot filler having various configurations. It can be a single solid piece as shown in FIG. 6 e, or have either a flat end shown in FIG. 6 h or a rounded end shown in FIG. 6 i. FIG. 6 f shows a double slot filler. The round-end ( FIG. 6 i ) or the flat-end ( FIG. 6 h ) pieces are provided so that the slot filler would dovetail a slot having a matching configuration with recessed round ends. Both the single and double slot fillers has a protruding ( FIG. 3 : 3 f or FIG. 6 : 6 e/ 6 f ) sides on the either side of the fillers. This is to fit snugly when inserted into the slots ( FIG. 8 ) where there are notches on the either side of the slot. FIG. 6 g shows an exemplary configuration for a side panel cover.
[0028] Preferably, the locations of the elongated slots and drill holes inside the panels are pre-determined and uniform so that it allows for manufacture in mass quantities and easy assembly. The locations of the elongated slots at the reference edges from which the slots extend are preferably selected at half-point, quarter points, and one-eighth points of the reference edges, adjusted slightly to accommodate the width of the slot which substantially equals the thickness of the panels. The symmetry built into these slots makes the interlocking of such panels easy and precise. It is also preferred that the panels that are used to construct a piece of furniture have a uniform or standardized dimension. This way the panels can be tightly compacted. FIG. 7 shows how the various modular panels with uniform dimensions can be packed together.
[0029] FIGS. 4 & 5 illustrate preferred arrangements of the slots and drill holes in the panels. FIG. 5 a, which provides a cross-section view of an embodiment of the panel, designates the following slot and drill hole locations: slot 100 , slot 200 , slot 300 , slot 400 , slot 500 , slot 600 , slot 700 , and slot 800 ; drill hole 1001 , drill hole 1002 , drill hole 3001 , drill hole 3002 , drill hole 4001 , drill hole 4002 , drill hole 8001 , and drill 8002 . As an initial matter, provided below is a list of all the keys and terms that will be used to define the formula of the design of the panel that can have variable combinations of the slots based upon dimensions of an rectangular panel.
[0000]
Terms
Key
Descriptions of the Key or Terms
First Reference
The left vertical edge of the panel shown in
Edge
FIG. 5.
Second
The top horizontal edge of the panel shown in
Reference Edge
FIG. 5.
Length of a first
X
The length of the First Reference Edge of the
reference edge
panel shown in FIG. 5
Length of a
Y
The length of the Second Reference Edge of
second reference
the panel shown in FIG. 5.
edge
Thickness
T
The dimension of the thickness of the panel is
preferably between 1 to 8 percentage of X.
Half-Thickness
@
Half of T
Slot Location
S
The distance of the slot as measured from
either the First Reference Edge or the Second
Reference Edge of the panel
Drill hole
D
The distance of the drill hole as measured from
location
either the First Reference Edge or the Second
Reference Edge of the panel
Drill-Hole Finder
U
This key “U” equals for half of (S 600 − S 400 )
[0030] The locations of the slots and drill holes can be calculated according to the following formulas.
[0000]
Description of the Formula for the Location of the Slots where X = Y
Slot location measured as a
percentage point of either the First
Reference Edge or the Second
Slot
Reference Edge
Location
Formula
T = 5% of X
T = 3% of X
S 100
(X/2 − @)/2
23.75
24.25
S 200
X/2
50
50
S 300
X − S 100
76.25
75.75
S 400
Y − S 800
76.25
75.75
S 500
Y/2 + ((Y/2 + @)/4)
63.125
62.875
S 600
Y − S 700
89.375
88.625
S 700
((Y/2 − @)/2 − @)/2
10.625
11.375
S 800
(Y/2 − @)/2
23.75
24.25
Description of the Formula for the Location of the Drill-Holes where
X = Y
Drill hole location measured as a percentage
point of either the First Reference Edge or the
Drill-Hole
Second Reference Edge
Locations
Formula
T = 5% of X
T = 3% of X
D 1001
S 100 − u
17.1875
17.8125
D 1002
S 100 + u
30.3125
30.6875
D 3001
S 300 − u
69.6875
69.3125
D 3002
S 300 + u
82.8125
82.1875
D 4001
S 400 − u
69.6875
69.3125
D 4002
S 400 + u
82.8125
82.1875
D 8001
S 800 − u
17.1875
17.8125
D 8002
S 800 + u
30.3125
30.6875
[0031] Length and the Diameters of the Drill-Holes
[0000]
Description of the Formula for the Length and the Diameters of the
Drill-Holes (FIG. 5a & 5b)
Description
Formula
T = 5% of X
T = 3% of X
Length of the broader part
X − S 500 − @
34.375
34.625
of the drill-holes, that is
the portion of drill-holes
starting from the edge of
the plane to the center of
the plane
Diameter of the broader
T/5x3
3
3
(above) segment
Diameter of the thinner
T/5x2
2
2
segment
[0032] Dimensions in Notches in the Slots and Protrusion on the Slot-Fillers
[0000]
Description of the Formula for the Length and the Diameters of the
Notches in the Slots and the Protrusion on the sides of the Slot-Fillers
(FIG. 3: 3f, 3e, and 3h)
Description
Formula
Dimension
Rounded notches (with the
T/5x1
1
same dimension in the
depth of the notches)
Protrusion on the sides of
T/5x1
1
the slot-fillers (with the
same dimension in the
thickness of the protrusion)
[0033] As described earlier, the panels disclosed in FIG. 5 do not need to have all eight elongated slots 100 , 200 , 300 , 400 , 500 , 600 , 700 , and 800 cut out for it to function as a modular piece. While having all elongated slots would make a panel versatile and facilitate its interconnections with multiple other panels to make more complex furniture arrangement, only two slots are required. Preferably, a panel should have one slot 200 , and another slot 400 . A panel with such configuration is the most versatile as a building block for a modular styled furniture built according to the concepts and principles of the present invention. Yet another embodiment would have elongated slots 100 , 200 , 300 , 400 , 500 , and 600 , as shown in FIG. 10 a. Yet another embodiment would have elongated slots 300 , 400 , 500 , 600 , 700 , and 800 , as shown in FIG. 10 b.
[0034] In yet another embodiment of this invention, a panel can be made that is twice the size of the panel that is depicted on FIG. 5 a. The configurations of the slots and drill holes in one such panel are illustrated on FIG. 5 b. As the figure demonstrates, the panel is essentially a combination of two panels depicted on FIG. 5 a placed next to each other in a mirror image. Therefore, the panel would have an extra set of slots (slots 110 , 210 , 310 , 410 , 510 , 610 , 710 , and 810 ) and an extra set of drill holes (drill holes 4101 , 4102 , 8101 , and 8102 ). The location of the extra sets of slots and drill holes mirrors the set of slots and drill holes in the leaf half part of this panel. In addition, an extra slot, slot 900 is provided in the middle of the long edge of this twin-panel. An extra length that equals to the thickness of the panel is added in between the two mirror images to allow for the addition of slot 900 . In other words, the length of this twin-panel is 2Y+T.
[0035] In yet another embodiment of this invention, bigger planar combination panels can be constructed by connecting a number of panels with double length slot fillers. Shown on FIG. 8 is an example where four square panels by the size of X*X can be combined together for form a bigger square panel by the size of 2X*2X.
[0036] The versatility of how these panels can be engaged to one another to form complex furniture arrangement is further illustrated in FIG. 9 .
[0037] It is noted that the use of panels is not limited to the construction of modular styled furniture such as tables, bookshelves, beds, and sofa etc. One can construct a cup holder or ornamental structures if the size of the modular panels is small. It can also be used as desk organizer of various sorts. Finally, a miniature panel can be used by young children as toys.
[0038] It is appreciated that the dismantled panels are storable, transferable and pack-able into nearly a 100% compactness of the item itself, thus creating, by default, the benefit of allowing users in schools, homes, apartment, business, studio spaces alike a multipurpose access to the floor space. The storage of the panels would not take up too much storage place. In addition, the panels can be easily loaned, shared, and moved in parts among the users, thus preventing wastes often associated with used furniture.
[0039] While the invention herein disclosed has been described by means of specific embodiments and applications thereof, other modifications, variations, and arrangements of the present invention may be made in accordance with the above teachings other than as specifically described to practice the invention within the spirit and scope defined by the following claims. | A modular component, panel, or building block, is used to construct modular styled systems. Such module contains specifically designed slots or openings. Such slots extend substantially perpendicular from the modules' edges and into the center of the panel. The interlocking mechanism provided by the slots allows the modules to be combined to form a modular styled system. The module further contains a number of drill holes that runs across its edges and can be threaded with metal rods for structural support. | 0 |
FIELD OF THE INVENTION
The invention relates generally to a heat exchanger assembly for a compressor and, more particularly, to a high pressure shell and tube type heat exchanger assembly having dual tube sheets, an axially expanding floating header assembly, and an expansion limiting feature for controlling the axial expansion of the floating header assembly due to internal pressure forces without preventing the normal thermal expansion of the tube bundle.
BACKGROUND OF THE INVENTION
In intercoolers employed in multi-stage centrifugal compressors, as well as in other related heat exchangers, gas introduced into the heat exchanger is caused to pass over coolant containing tubes whereby heat is transferred from the gas to the coolant with the gas being subsequently emitted through a discharge outlet.
One known embodiment of heat exchanger of the above-described type is disclosed in U.S. Pat. No. 4,415,024. An elongated cylindrical shell is provided with a gas inlet and a gas outlet and a rectangularly-shaped array of coolant tubes contained within a tube bundle. The tube bundle is fixedly attached to tube sheets at opposite ends of the shell. Typically, one tube sheet is rigidly held against the shell assembly by a fixed header assembly and the opposite tube sheet is connected to a floating header assembly which is allowed axial movement with respect to the shell assembly to allow for thermal expansion of the tube bundle relative to the shell assembly. The rigidly held tube sheet is provided with a gasket to seal between the tube sheet and shell assembly. The floating tube sheet and header assembly is usually provided with an O-ring seal to seal between the sliding header assembly and shell assembly flange. The coolant is introduced into the header assemblies to provide a flow of coolant through the tube bundle to cool the gas circulating through the shell assembly.
However, this design has certain limitations and is not particularly well suited for high shell pressure use. The sealed connections between the tube bundle and tube sheets can leak due to thermal stresses therebetween and/or by the interaction of the high pressure gas within the shell assembly acting on the tube sheet and seals. If leakage occurs, the gas and coolant mediums will be mixed thereby causing contamination of the mediums. Furthermore, the gasket between the floating header assembly and tube sheet can leak, providing an alternate contamination path mixing the two mediums.
It is, therefore, desirable to provide a heat exchanger assembly having a pair of tube sheets at each end of the tube bundle, the pair of tube sheets being spaced with said space being communicated exteriorly of the heat exchanger. Heat exchangers utilizing such a dual tube sheet design are not necessarily new in the industry. U.S. Pat. No. 2,152,266 to McNeal shows a heat exchanger utilizing dual tube sheets as described above. However, there is no provision contained therein limiting the axially expansion of the floating header assembly. In high shell pressure applications it is necessary to provide a counteracting force on the outer side of the floating header assembly and tube sheet to prevent the tube bundle from excessive axial movement due to internal shell pressure forces which can create harmful stresses between the tube bundle and tube sheet thereby breaking the fluid-tight container connections therebetween.
U.S. Pat. No. 1,962,170 to Blemerhassett shows a dual tube sheet design for a heat exchanger further utilizing a pressure balancing means to prevent pressure from within the shell to overly expand the tube bundle. This is accomplished by totally enclosing the floating header assembly and tube sheet within the shell to allow the high pressure fluid within the shell to act upon all sides of the floating assembly. However, to accomplish this and provide for dual tube sheets, a complex passage system must be provided to vent the space between the dual floating tube sheets. Furthermore, it is impossible to remove the floating header assembly from the tube sheet to clean or inspect the tube bundle without exposing the main shell casing to contaminates. And, if the gaseous medium is corrosive, a multiplicity of parts relating to the floating header assembly are subjected to corrosion and possible premature failure.
There remains a substantial need for an efficient heat exchanger such as shown in U.S. Pat. No. 4,415,024 which maintains the advantages described therein and which is adapted for use as a high pressure intercooler in centrifugal compressors, as well as in other environments, wherein double tube sheets are provided between the shell assembly and header assemblies providing a space therebetween to allow leakage from either fluid medium to escape exteriorly of the intercooler. Additionally, it is desirable to counter-balance the high pressure forces existing within the shell cavity acting on the floating tube sheet to prevent undue axial expansion of the tube bundle and floating tube sheet.
SUMMARY OF THE PRESENT INVENTION
The above-described need has been met by the present invention.
The present invention is an improved high pressure heat exchanger which includes an elongated shell having a supply end, a return end, fluid inlet and fluid outlet means and an elongated bundle assembly which has a plurality of longitudinally extending tubes. The inlet and outlet provide passage of a first fluid into and out of the shell representing the fluid medium to be cooled.
Dual tubing sheet assemblies are positioned at each of the supply and return ends of the shell to close in the ends of the shell space. The dual tube sheet assemblies each include an inner tube sheet and an outer tube sheet separated by a plurality of spacers to create an open space between the inner and outer tube sheets. The space is left substantially open to the atmosphere. The elongated tubes of the bundle assembly are received through both the respective inner and outer tube sheets of the return end tube sheet assembly and supply end tube sheet assembly. The tubes are sealingly affixed to each of the inner and outer tube sheets.
A supply header and a return header are fixedly connected to the outer tube sheets of the respective supply end tube sheet assembly and return end tube sheet assembly for communicating a second fluid through the elongated tubes of the tube bundle for cooling the first fluid medium. The open space between the respective inner and outer tube sheets directs any first or second fluids fluid escaping through or about the inner or outer tube sheets to the exterior of the heat exchanger assembly. The first and second fluid mediums are thereby isolated from each other preventing intermixing therebetween.
The heat exchanger assembly of the present invention also includes a floating tube sheet structure to allow for thermal expansion of the tube bundle as necessitated by the high pressures and high temperatures existing in the shell cavity. The assembly includes a floating return header assembly rigidly connected to the floating dual tube sheet which slidably seals against the shell flange. To counteract the high pressure forces existing in the shell cavity from overly expanding the floating tube sheet assembly to break the fluid-tight seals between the tubes and tube sheets, a retaining securing means is utilized for biasing the return header assembly toward the shell flange. The resilient retaining means includes a plurality of belleville washers or springs urging the return header towards the shell assembly upon application of an opposite force by the internal shell pressure forces acting on the inner face of the inner tube sheet.
It is an object of the present invention to provide a high pressure heat exchanger which utilizes double tube sheets to minimize the potential for mixing the two fluid mediums being processed through the heat exchanger.
It is another object of the present invention to provide a floating header design which allows the thermal expansion and limited high pressure induced growth of the tube bundle material relative to the shell assembly.
It is another object of the present invention to provide a floating header assembly having resilient retaining means to bias said assembly towards the shell to provide an opposing force acting towards the shell to counteract the internal high shell pressure forces acting on the interior of the floating tube sheet and relieve the stresses acting on the fluid-tight connections between the tubes and tube sheets created by the high pressure internal shell cavity forces.
It is another object of the present invention to provide a heat exchanger including a shell assembly and independent header assemblies, the assemblies being relatively separable for the purpose of cleaning and inspecting the tubes without exposing the interior of the shell assembly to contaminants.
These and other objects of the invention will be more fully understood from the following description of the invention with reference to the illustrations appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view in partial cross-section of a heat exchanger assembly of the present invention.
FIG. 2 is a partially broken away end elevational view of the supply end of the heat exchanger assembly shown in FIG. 1.
FIG. 3 is a fragmentary cross sectional view taken through 3--3 of FIG. 2.
FIG. 4 is a end elevational view of the return end of the heat exchanger assembly shown in FIG. 1.
FIG. 5 is a fragmentary cross-sectional illustration taken through 5--5 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in more detail and initially to FIG. 1, there is shown a side elevational view in partial cross-section depicting generally the features of the present invention. An outer generally cylindrical shell casing is indicated by the reference number 2. An inner cavity of the shell within which the bundle assembly and associated components are received is generally indicated at 4. A bundle assembly 6 consists of a plurality of elongated tubes 8 which extend generally longitudinally within the bundle assembly and a plurality of transversely oriented fin plates 10 which are generally parallel to each other. Only a small number of tubes 8 have been shown in the drawings, however, in actuality, a large number of such tubes would exist in the bundle assembly 6. In operation of the heat exchanger, coolant flows through the tubes 8 and the gas to be cooled flows along the openings between adjacent fin plates 10. The gas would enter the shell 2 through a gas inlet 12 and discharge via gas outlet 14 longitudinally spaced from one another.
The particular flow path of the gaseous fluid passing through the shell portions of the heat exchanger are substantially similar to that shown in U.S. Pat. No. 4,415,024 assigned to the same assignee as the present invention. For further details concerning that flow path, reference is made to the above-named patent, the entire disclosure of which is incorporated herein by this reference.
FIG. 1 generally shows the structure of the outer shell 2. As can be seen on the right side of the drawing, shell 2 has an annular radially outwardly projecting flange 16 formed on outer shell 2. On the left side of FIG. 1, a similar flange 18 is shown formed with outer shell 2.
For ease of description, the right side of the cylindrical shell 2 and any further extending additions are generally labeled the supply end of the heat exchanger because typically the coolant medium will be supplied or attached to this end. The left side of the cylindrical shell 2 and any further extending additions appended thereto are generally referred to as the return end of the heat exchanger because here typically the shell will be sealed and structure added to permit the coolant to return to the supply end of the shell for removal.
As shown in FIG. 1, in partial cross-section the tube bundle 6 is positioned within the shell cavity 4 between first and second pairs of tube sheet assemblies 20 and 22, respectively. The elongated tubes 8 within tube bundle 6 extend longitudinally all the way through inner shell 4 beyond the dimensions of cylindrical flanges 16 and 18. The first tube sheet assembly 20 is located at the supply end of the shell 2 and receives the tubes 8 there through. The first tube sheet assembly is generally circular in cross-section and is of substantially larger cross-sectional area than the bundle assembly 6. A supply header 24 is received adjacent the first pair of tube sheets 20 which rigidly fixes or secures the tube sheets 20 to the supply end shell flange 16 by a plurality of studs 28 and nuts 29. Cooling fluid, such as water, is introduced in the supply header 24 through coolant inlet 26.
At the return end side of the shell 2 as shown in FIG. 1, an adapter flange 30 is provided adjacent to the cylindrical flange 18 and is fastened thereto. The adapter flange 30 is generally cylindrical about its outer perimeter and has a rectangular bore 31 therethrough generally conforming to the cross-sectional shape of the tube bundle 6. The second tube sheet assembly 22 located at the return end of the shell 2 is partially received within the adapter flange 30 which will be more fully described below. A return header 32 is connected to the outside of the return end tube sheet assembly 22 by use of a plurality of studs 34 and nuts 35. A resilient retaining means 36 is utilized to bias the return header 32 and tube sheet assembly 22 toward the adapter flange 30 and shell cavity 4 which will be more fully described below.
The bundle assembly 6 as shown in FIG. 2 has a substantially rectangular cross-sectional configuration as partially shown at 38. This configuration facilitates ease of manufacture, as well as ease of insertion and removal of the bundle assembly 6 from the shell 4. In addition, this configuration contributes to the efficiency of performance of the heat exchanger of the present invention as fully described in U.S. Pat. No. 4,415,024. The return end tube sheet assembly is also rectangular in configuration to conform generally with the cross-sectional shape of the tube bundle and inner perimeter of the adapter flange 30.
Referring to FIG. 2, there is shown a partially broken away view of the supply end of the heat exchanger assembly. Also shown is the coolant inlet 26 and coolant outlet 40, with the former serving to provide a fresh supply of cooling medium, such as water, and the latter serving to withdraw coolant at an elevated temperature after passing through the heat exchanger.
Referring now to FIG. 3, the supply end of the heat exchanger is shown in more detail. The supply header 24 is secured to flange 16 by any suitable means and as shown here by studs 28 and nuts 29 positioned about the outer perimeter of the supply header 24.
The supply end tube sheet assembly 20 can now be clearly seen to be made up of an inner, generally cylindrical, tube sheet 42 positioned adjacent the front flange 16, and an outer, generally cylindrical, tube sheet 44. The inner and outer tube sheets 42 and 44, respectively, are separated by a plurality of spacers 46 which are affixed therebetween by any conventional method and as shown herein by welding. Inner and outer directions utilized herein denote a structure placed closer in a longitudinal direction to the inside of the shell assembly. An annular gasket 48 serves to provide a seal between the inner tube sheet 42 and the shell flange 16 to isolate the gaseous medium within the shell cavity 4. A second gasket 50 serves to provide a seal between supply header 24 and the outer tube sheet 44 when the studs 28 and nuts 29 are in a secured position.
The elongated tubes 8 of tube bundle 6 are sealed within both the inner and outer tube sheets 42 and 44, respectively. Typically, this connection is accomplished by inserting a special tool (not shown) into the tubes 8 to expand the diameter of the tubes within the dimensions of the inner and outer tube sheets 42 and 44. In this manner, a substantially fluid-tight seal is maintained between the tube sheets and elongated tubes.
A particularly important feature of the present invention is created by the provisions of the spacers 46 between the inner and outer tube sheets 42 and 44. A space 52 is created by use of spacers 46 which is vented to atmosphere such that if any of the fluid-tight joints between tubes 8 and the inner tube sheet 42 leaks, the gaseous fluid leaking thereby will be vented exteriorly of the heat exchanger. Similarly, if the fluid-tight joint between tubes 8 and the outer tube sheet 44 springs a leak, the coolant fluid leaking therethrough will vent exteriorly of the heat exchanger. In previous heat exchanger designs, such a leak between a tube and a tube sheet would allow mixing of the gaseous and coolant mediums thereby contaminating the gaseous or coolant mediums being discharged from the heat exchanger.
Referring now to FIGS. 4 and 5 in detail, further features of the invention will be considered. FIG. 4 shows a end elevational view depicting the return header 32. It will be appreciated from FIGS. 4 & 5 that the return end tube sheet assembly is generally 22 rectangular to conform with the generally cross-sectional shape of the tube bundle 6 and bore 31 of the adapter flange 30. The rectangular portion 54 of return header 32 represents a bulge in the header to provide a reservoir 55 between the header assembly 32 and tube sheet assembly 22 for receiving coolant from the supply header 24. The supply and return headers 24 and 32, respectively, usually have a number of baffles contained therein (not shown) for providing a particular coolant path through the shell assembly. Reference to U.S. Pat. No. 4,415,024 is made for a better understanding of the particulars of the coolant flow path.
Referring now to FIG. 5, which shows a fragmentary cross-sectional view of the return end of the heat exchanger, the particulars of a floating tube sheet assembly and resilient retaining means 36 are shown in detail. The return end tube sheet assembly shown at 22 include an inner tube sheet 56 and an outer tube sheet 58 separated by a plurality of spacers 60 to provide an open space 62 therebetween which is vented exteriorly of the heat exchanger. The spacers 60 are similarly welded to the tube sheets 56 and 58 as described in relation to spacers 46 utilized between inner and outer tube sheets 42 and 44 positioned at the supply end of the exchanger.
The elongated tubes 8 of the tube bundle 6 are received within both the inner and outer rear tube sheets 56 and 58. The tubes 8 are fixedly secured within both tube sheets 56 and 58 in a similar manner to that described above, relative to the supply end tube sheet assembly 20. Therefore, the distance between the first and second tube sheet assemblies 20 and 22, respectively, is initially predetermined and fixed. However, when a high pressure or high temperature gas is introduced within the fluid inlet 12 of shell 2 and an appropriate coolant is introduced through supply header 24 and tubes 8, the tube bundle 6 will expand and, subsequently contract under the thermal stresses created therein. The high pressure gas also acts on the inner faces of the two inner tube sheets 42 and 56 creating a force which pushes the two tube sheet assemblies 20 and 22 outwardly away from one another. It is, therefore, appreciated that it is necessary to provide the tube bundle 6 with a floating tube sheet and header assembly to help relieve the thermal stresses and high pressure growth caused by these interacting forces within the shell assembly.
As shown in FIG. 5, such a floating tube sheet design is provided in the present invention. The inner tube sheet 56 of the second tube sheet assembly 22 has a rectangular outer perimeter 64 which closely fits within the rectangular inner perimeter 31 of the adapter flange 30. The outer perimeter 64 of the inner rear tube sheet 56 has a groove shown at 66 to accept a finely machined O-ring 68 conforming generally to the inner perimeter of the adapter flange 30. O-ring 68 prevents the gaseous medium from escaping exteriorly of the shell assembly 2 while allowing the inner rear tube sheet 56 to expand axially with respect to the shell assembly 2.
The return header 32 is securely fastened to the outer rear tube sheet 58 by use of the studs 34 and nuts 35. A gasket 70 is positioned between header 32 and outer tube sheet 58 to provide a seal therebetween to prevent coolant from escaping from the return header assembly. It can be appreciated from FIG. 5 that if either the gasket 70, O-ring 68 or tube 8 to tube sheet 56 and 58 connections leak that any fluid emitting from either the shell cavity or header assembly reservoir will vent exteriorly of the heat exchanger due to the dual tube sheet design incorporated herein.
FIG. 5 also shows further details of the resilient retaining means 36 which slidingly biases the return header 32 toward the adapter flange 30 and shell flange 18. A plurality of axial bores 74 are placed through the return header 32 in a generally circular pattern to conform to similar bores 77 in the adapter flange 30. Studs 76 pass through said bores 74 and bores 77. Nuts 78 are received thereon to rigidly secure the adapter flange 30 to shell flange 18. A gasket 72 is provided to seal between shell flange 18 and adapter flange 30. The return header 32 also receives studs 76 through its bores 74. The return header 32 is secured to the outer tube sheet 58 via studs 34 and nuts 35. The return header 32 is then additionally held in place by a plurality of belleville washers or springs 80 which are secured on studs 74 by use of nuts 82.
The resilient attachment means 36 permits a slight preload to be applied against the return header 32. Th nuts 82 are rotated such that the belleville washers 80 apply a small pressure force against the return header 32, and, consequently, against the second tube sheet assembly 22 and tube bundle 6. The relationship between the floating tube sheet assembly 22 and tube bundle is important and must be critically controlled. In the initial installation of the washers 80 and nuts 82, it is desirable for the belleville washers 80 to apply a minimal amount of force biasing the return header 32 and floating tube sheet assembly 22 towards the shell assembly 2. Upon the introduction of a high pressure gaseous fluid within shell cavity 4, the floating tube sheet assembly 22 will be expanded outwardly away from the fixed tube sheet assembly 20 in reaction to the high pressure fluid interacting on the cross-sectional area of the inner face of the inner tube sheet 56. The return header 32 is rigidly connected to the outside of the second or floating tube sheet assembly 22 and, therefore, it will also expand outwardly with the floating tube sheet assembly 22 to compress the belleville washers 80 of the resilient retaining means 36. A spring force is applied back onto the return header 32 which is opposite to the high pressure force applied to the inner face of the inner rear tube sheet 56. Therefore, the high pressure forces within the shell assembly acting on the tube sheet and tube bundle are minimized. Otherwise, the high internal pressures existing within the shell cavity 4 would cause the floating tube sheet assembly 22 to expand outwardly faster than the thermal expansion of the elongated tubes 8 thereby breaking the fluid-tight seals between tubes 8 and tube sheets 56 and 58 of the floating tube sheet assembly 22. It is important that the spring force be large enough to counteract the high pressure forces existing in the shell cavity 4, but not sufficient to prevent normal thermal expansion of the tube bundle 6 created by extreme temperature differentials between the gaseous and coolant mediums.
The use of an external reaction force is advantageous because it allows the floating return header to be located externally to the shell assembly and pressures. Furthermore, the metal parts of the return header 32 are protected from a possibly corrosive gaseous fluid medium.
It will be appreciated that the heat exchanger assembly of the present invention may advantageously function as a high-pressure intercooler in a multi-stage centrifugal compressor, as well as functioning in a wide range of environment wherein cooling of gaseous media is desired.
It will be appreciated, therefore, that the present invention provides a double tube sheet design which minimizes the potential for mixing the gaseous and coolant mediums through the heat exchanger. Any leaks between the gaskets, seals or tube to tube sheet connections will be vented to atmosphere. Such features allows for early detection of any such leaks allowing for less machine down time and loss of efficiency created by such leaks. Furthermore, the return and supply headers may be removed so that the tubes 8 can be cleaned and/or inspected without opening the shell cavity 4 to atmosphere and possible contaminants.
It will be further appreciated that the present invention provides a floating return header and tube sheet assembly which allows for thermal expansion of the tube bundle, as well as limited high pressure expansion of the floating tube sheet assembly without over-stressing the connections between the tubes and tube sheets in an undesirable manner.
It will be further appreciated that the present invention provides a resilient retaining means for interacting on the return header and floating tube sheet assembly to help relieve the high pressure forces acting against the inner face of the tube sheets. The counteracting spring force acts in the opposite direction to the pressure expanding force to minimize the pressure stresses acting on the tube sheets and tube bundle thereby, protecting the tube to tube sheet connections.
Whereas, particular embodiments of the invention have been described above, for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details may be made without departing from the invention as defined in the appended claims. | A high pressure heat exchanger assembly for a compressor having a shell and tube-type design. An elongated bundle assembly is received within the shell. The bundle assembly has a plurality of elongated tubes extending generally longitudinally through the shell. The tubes are securely affixed to fixed and floating tube sheet assemblies positioned at opposite ends of the shell. The fixed tube sheet assembly is securely attached to one end of the shell and the floating tube sheet assembly is allowed to float with respect to the other end of the shell. A seal between the floating tube sheet assembly and the end of the shell prevents the escape of internal fluids. Each tube sheet assembly is provided with an inner and outer tube sheet member separated by a plurality of spacers to create a vented space therebetween open to the outside atmosphere. The elongated tubes are sealingly press-fit within the inner and outer tube sheets of the fixed and floating tube sheet assemblies to provide a fixed connection therebetween. A plurality of spring devices are utilized to bias the floating tube sheet assembly towards the shell to counteract opposing internal shell pressure forces created within the shell assembly which may stress the press-fit tube-to-tube sheet connections. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to fish skinning devices, and more particularly to improved hand-held fish skinning devices incorporating both means for cutting the skin of a fish into separate panels and means for firmly gripping said panels for easier removal by tearing from the body of the fish.
2. Description of the Prior Art
The prior art includes numerous fish skinning devices of a kind far more elaborate than the device of the present invention. For instance, in at least one prior art fish skinning device a crank-operated roller is provided onto which the fish skin is wound in the provess of removing it from the body of the fish.
SUMMARY OF THE INVENTION
I have discovered, however, that many fishermen require a simple, hand-held fishing skinning device which provides means for cutting the fish skin into panels while still attached to the fish and gripping means for use in tearing the skin panels from the fish, all in one instrument.
I have also discovered that the skin of a fish can most easily be panelized by means of a type of cutter which I call a push-knife, that is, a cutter having a prow or beak which can be pressed through the skin of the fish, and above the prow or beak a curved knife-edge formed as a recess for receiving the fish skin as the prow or beak is thrust forward under the skin of the fish, the prow or beak being mounted at an oblique angle to a handle and the curved knife-edge being located between the beak and the handle.
I have also discovered that when using a cutter of the kind just described, having a prow or beak and a knife-edged recess of the kind just described, fish skinning can be most efficiently and expeditiously carried out if gripping means including jaws opening in the opposite direction from the direction in which the prow or beak is thrust under the skin of the fish.
Therefore, it is an object of my invention to provide hand-held fish skinning means by which the skin of the fish may be panelized by thrusting a pointed prow or beak under the skin of the fish and then pushing the beak forward under the skin of the fish and along the side of the fish, the skin of the fish being cut by means of a knife-edged recess adjacent the beak.
It is a further object of my invention to provide, in a fish skinning device having such a beak and adjacent knife-edged recess, gripping jaws for gripping the skin of the fish, said jaws being located near the beak and opening in a direction opposite to the direction in which the beak points.
Other objects of my invention will in part be obvious, and will in part appear hereinafter.
My invention, accordingly, comprises the features of construction, combinations of elements, and arrangements of parts which are exemplified in the constructions hereinafter set forth, and the scope of my invention will be indicated in the appended claims.
For a full understanding of the nature and objects of my invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the preferred embodiment of the present invention as it would be seen lying upon a workbench or other horizontal surface in its unoperated state;
FIG. 2 is a plan view of the preferred embodiment of the present invention as it would be seen lying upon a workbench or other horizontal surface, but in its operated state;
FIG. 3 is a plan sectional view of the preferred embodiment of the present invention, showing in detail the working parts and their cooperation in the unoperated state of the preferred embodiment;
FIG. 4 is a plan sectional view of the preferred embodiment of the present invention, showing in detail the internal parts and their cooperation in the operated state of the preferred embodiment;
FIG. 5 is a view in elevation of the device of the preferred embodiment as it appears when lying upon a workbench or other horizontal surface, taken from above in FIG. 3;
FIG. 6 is a view in elevation of the preferred embodiment of the present invention as it appears when lying upon a workbench or other horizontal surface, taken from below in FIG. 4;
FIG. 7 is a transverse sectional view showing certain details of the preferred embodiment, the plane of the section being indicated by the line 7--7 of FIG. 2;
FIG. 8 is a tranverse sectional view of the device of the preferred embodiment, the plane of the section being indicated by the line 8--8 of FIG. 1; and
FIG. 9 is a transverse sectional view of the preferred embodiment of the present invention, the plane of the section being taken on line 9--9 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now had to FIG. 1, which shows the device of the preferred embodiment of the present invention as it appears when unused and lying upon a workbench or other horizontal surface.
As may be seen in FIG. 1, the device of the present invention comprises a main handle and body portion 10 within which a jack-knife blade 12 is disposed in the well-known manner. It is to be understood, however, that the present invention is not limited to devices comprising such jack-knife blades.
As may further be seen in FIG. 1, a tee-head 14 comprising a working head 16 is affixed to one end of body 10, as by means of rivets 18 and 20. The device of the preferred embodiment as shown in FIG. 1 further comprises an operating handle 24 which is pivotably mounted on a rivet 26. As also seen in FIG. 1, a hole 30 may be provided in the outer end of handle 24 for receiving a lanyard 32 whereby loss of the device may be prevented, as, for instance, by securing the outer end of lanyard 32 around the wrist of the user.
The device of the preferred embodiment further comprises a rocker member 36 which is pivotably mounted on rivet 37. The outer end of rocker member 36 (i.e., the leftmost end as seen in FIG. 1) takes the form of a safety jaw 38, which will be described hereinafter. The inner end 40 of rocker member 36 (rightmost in FIG. 1), sometimes called the "gripping jaw", carries a serrated pad or plate 42 the function of which will be explained hereinafter.
As further seen in FIG. 1, safety jaw 38 contacts or lies close to the outer end 46 of working head 16 when operating handle 24 is in its unoperated position, i.e., its position most remote from main body 10. As also shown in FIG. 1, the serrated pad 42 of gripping jaw 40 is most remote from the inner end 50 of working head 16 when operating handle 24 is in its unoperated position.
Going now to FIG. 2, and comparing it with FIG. 1, it will be seen that rocker member 36 is rocked about rivet 16 when the device of the invention is squeezed in the hand of the user, and thus operating handle 24 is pressed into main body 10. As will further be seen by comparison of FIGS. 1 and 2, the pressing of operating handle 24 into main body 10, and the consequent rocking of rocker member 36, causes safety jaw 38 to be withdrawn from close proximity to the outer end or beak 46 working head 16. As may also be seen by comparison of FIGS. 1 and 2, the pressing of handle 24 into body 10, and the consequent rocking of rocker 36 brings the serrated pad 42 of gripping jaw 40 (sometimes called the inner gripping jaw) into contact with the inner end 50 of working head 16. The inner end 50 of working head 16 is sometimes called the outer gripping jaw.
In accordance with a principal feature of the present invention the shank or neck portion 52 of tee-head 14 is provided with an indenture 54. A knife-edge or cutting edge 56 extends substantially around the periphery of indenture 54, and also may extend along the inner edge of beak 46 to the point 46' or close to the joint 46'. As may be seen by comparison of FIGS. 1 and 8, point 46' of beak 46 is a sharp point, such as will easily penetrate the toughest of fish skins.
OPERATION
Before describing its inner structural details, the manner of using the device of the preferred embodiment will be described.
In removing the skin of a fish by the use of the device of the present invention, the skin of the fish is first divided into sections by incisions made with cutting edge 56, and then these skin sections are ripped off the body of the fish with the aid of gripping jaws 40 and 50 acting together.
In making the above-described incisions, the user firmly grasps the device in his closed hand, and thus presses handle 24 fully inwardly, withdrawing safety jaw 38 from beak 46 as shown in FIG. 2. Grasping the fish firmly in his other hand, by the tail for instance, the user forces the point 46' of beak 46 into the skin of the fish, until the skin of the fish (60 in FIG. 2) is in contact with the cutting edge 56. After thus locating the beak 46 of the device of the invention in the body of the fish the user, maintaining his grasp on the fish tail and on the device, forces the device forward, toward the head of the fish, while maintaining beak 46 at approximately the same depth in the body of the fish. When beak 46 has thus been forced to the head of the fish, the first incision is completed, and the device is then lifted out of the incision.
Assuming said first incision to have been made along the dorsal area of the fish body, a second incision may then be made along the ventral area of the fish body, substantially from tail to head, using the device of the invention in the aforedescribed manner.
After making the two longitudinal incisions as just described, additional incisions may be made between these two incisions, the incisions together outlining panels of fish skin which are to be removed with the aid of the gripping jaws 40 and 50 of the device of the invention.
In accordance with one mode of employing the device of the invention, said panels may be removed before the tail is removed from the fish. In carrying out this mode the fish is grasped by the tail, with the fish head nearer the user than the tail, and the sharp space end 50' of outer gripping jaw 50 is thrust under the caudal end of one of the aforesaid panels, the device then being in the operating state illustrated in FIG. 1 because operating lever 24 is released by the usuer. user. is to be noted that at this stage of the skinning operation, when the sharp point 46' is necessarily located close to the hand of the user which is grasping the tail of the fish, safety jaw 38 covers point 46' (see FIG. 1), thus preventing possible accidental injury to the user.) After the outer gripping jaw 50 is thus thrust beneath the caudal end of the skin panel, the user squeezes the device in his closed hand, thus pressing handle 24 into the main body 10, and firmly gripping the skin panel between the gripping jaws 40 and 50. When the skin panel is thus firmly gripped by the gripping jaws, and the fish tail is firmly grasped in the user's other hand, the skin panel may be torn from the fish. The remaining skin panels may then be removed from the fish using the device of the invention in the same maner, whereafter the fish head and tail may be removed in the usual manner using folding blade 12 if desired.
Going to FIGS. 3 ad 4, the inernal structural details of the device of the preferred embodiment will now be described.
As will be understood by comparison of these Figures with FIGS. 1 and 2, main body 10 is comprised of a back cover member 62 and a front cover member 64, which are maintained in spaced apart relation by means of spacing members 66 and 68, said cover members and said spacing members being joined together by suitable means (not shown). As best seen in FIGS. 3 and 4, tee-head 14 is affixed between said cover members by means of a pair of fasteners 18 and 20, e.g., rivets. As may also be seen in FIGS. 3 and 4, the aforedescribed folding jack-knive blade 12 is pivotably mounted on rivet 70. A cantilever leaf spring 72 is provided for the purpose of maintaining jack-knife blade 12 in either of its positions, i.e., the retracted position shown in FIGS. 1 through 4 and the operative position in which blade 12 extends substantially rightwardly as the device is seen in these figures. As seen in FIG. 3, cantilever leaf spring 72 is mounted upon a rivet 74, which extends from cover member 62 to cover member 64. In addition, cantilever spring 72 bears against a cylindrical sleeve 76. which is itself mounted upon a rivet 78 (FIG. 3).
As further seen in FIG. 3, an additional cantilever leaf spring 80 is provided for normally resiliently maintaining operating handle 24 in its unoperated position (FIGS. 1 and 3). The left-hand end of leaf spring 80 as seen in FIG. 3 is tight-fittingly received in a slot 82 cut in lever 24. The right-hand end of leaf spring 80 bears against the lower surface of leaf spring 72 closely adjacent rivet 74. As further seen in FIG. 3, a tongue 84 projecting from the inner end of operating handle 24 closely interfits with a recess 86 in rocker 36. The cooperation of tongue 84 and recess 86, as illustrated in FIGS. 3 and 4 taken together, brings about the conjoint action of rocker 36 and operating handle 24 as described hereinabove. Further, the cooperation of tongue 84 and recess 86 also serves to limit the movement of operating handle 24 out of main body 10 to the extreme position shown in FIG. 3. Also, as shown in FIG. 4, the cooperation between tongue 84 and recess 86 results in the gripping engagement between pad 42 of inner gripping jaw 40 and the inner face of outer gripping jaw 50 which is required for the stripping of the fish skin panels described hereinabove.
Referring now to FIG. 5, it will be seen that folding knife blade 12 is received in a recess 90 defined by cover members 62 and 64, which are held in spaced relation by spacing members or bosses 66 and 67. As will also be seen in FIG. 5, cover members 62 and 64 are provided, respectively, with serrated areas 92 and 94 which are juxtaposed when the device of the preferred embodiment is assembled as to present a single serrated area adapted to be engaged by the thumb of the user, whereby to prevent slipping of the device of the preferred embodiment in the hand of the user. In addition, it may be seen in FIG. 5 that safety jaw 38 directly overlies tee-head 14, whereby to prevent injury to the user by point 46' of beak 46 when the sharp space end 50' of outer gripping jaw 50 is being thrust under a panel of the skin of a fish being cleaned, as hereinabove described.
Referring now to FIG. 6, it will be seen that operating handle 24 is received in a recess 96 defined by cover members 62 and 64, said cover members being spaced by spacing members or bosses 66, 67, 68, and 69, all as explained hereinabove. The cooperation between safety jaw 38 and beak 46 of tee-head 14 is also illustrated in FIG. 6. Comparing FIGS., 1 and 6, it may be seen that beak 46' of tee-head 14 is tapered inward, in both the horizontal and the vertical sense, to point 46'; while the inner end 50 of tee-head 14 is reduced only in the vertical sense (i.e., as shown in FIG. 1), whereby a flat blade 50' (sometimes called herein the space end), resembling an adze blade in miniature, is formed. It will further be seen in FIG. 6 that the transverse handle plate 100 of operating handle 24 in the preferred embodiment is mounted so as to be symmetrical about the central place of handle 24 hwereby to prevent cocking and binding of operating handle 24 when operating handle 24 is squeezed by the user in the use of the device of the invention.
Going now to FIG. 7, there is shown the relative positions of gripping haws 40 and 50, and pad 42 and spade edge 50', when operating handle 24 is pressed into recess 96 (FIGS. 2 and 4).
The configuration of the tee-head 14 of the preferred embodiment is particularly shown in FIG. 8. As there shown, the periphery of indenture 54 (FIGS. 1 and 2) is the line of intersection of surfaces 56' and 56", constituting the curved knife edge 56 (FIGS. 1 and 2). As also seen in FIG. 8, when compared with FIG. 1, the sharp spade edge 50' of the inner end 50 of tee-head 14 (sometimes called the outer gripping jaw 50 herein) extends substantially from side to side of the inner end 50 of tee-head 14.
Referring now to FIG. 9, there is shown the juxtaposition of operating handle 24 and folding knife blade 12 when folding knife blade 12 is folded into recess 90, and operating handle 24 is forced into recess 96 by the user (i.e., the operating condition of the device of the preferred embodiment is illustrated in FIG. 2).
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and, since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not in a limiting sense.
It is particularly noted that although the invention has been disclosed as incorporating a safety jaw 38, safety jaw 38 may be eliminated without departing from the scope of the invention. Furthermore, while a folding knife blade 12 is conveniently incorporated in the preferred embodiment, it is to be understood that knife blade 12 may be eliminated without departing from the scope of the present invention.
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, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | A hand-held fish skinning device is disclosed having a tee-head at one end of a handle body adapted to be held in the user's hand. The end of the tee-head remote from the handle body is formed as a sharp beak which can be readily pressed through the skin of the fish. The neck or shank joining the tee-head to the handle body is provided with a sharp edge so contoured that after the beak is pressed through the skin of the fish the tee-head can be pressed forward under the skin of the fish, making a continuous cut through the skin of the fish and thus the skin of the fish can be cut into panels, while yet on the body of the fish, by successive cuts made with the blade on the neck or shank of the tee-head. The nearer end of the tee-head (nearer the handle body) is formed as a gripping jaw for use in gripping the skin of the fish. A second, movable gripping jaw is provided which when forced toward the nearer end of the tee-head by means of a lever adapted to be squeezed into the handle body by the user cooperates with the nearer end of the tee-head to grip the skin of the fish for removal from the body of the fish by tearing it therefrom. | 0 |
The present invention relates to equipment for the metered supply of arrays of products.
This equipment has been developed for its possible use in the metered supply of arrays of dry fruits (typically shelled hazel-nuts) intended to be used as fillings in food products such as confectionery products of the type described in the prior European Patent Application EP-A-0083324.
Confectionery products of this type comprise essentially a spherical wafer shell constituted by a pair of hemispherical shells kept adhering to each other by the mutual contact of their fillings.
These products are usually manufactured by placing one shell in a hemispherical cavity of a first die while the other shell is force-fitted into a cavity in a second die alongside the first die. After each shell has been filled with a filling which will adhere to the wafer, the second die is overturned on the first die to bring the two shells into mating contact, with the consequent closure of the product casing.
For organoleptic reasons, it is preferred to introduce a core constituted by a dry fruit, such as a shelled hazel-nut, into the filling.
On the industrial scale, this choice necessitates an operation being carried out in the line in which the dies containing the filled wafer shells advance in order to locate the dry fruits constituting the additional filling in the shells in every other die.
Usually the number of shells in each die is very large (for example of the order of 100) and the rate of advance of the dies on the respective conveyor lines, being commensurate with the production rate, is correspondingly high.
In order to satisfy this requirement, various solutions have been proposed in the past. The solutions have not, however, been entirely satisfactory from the qualitative point of view, particularly with regard to the possibility of a certain number of positions, although small, remaining empty, that is, there being shells in which, for various reasons, the dry fruit is not inserted. In the past, attempts have been made to overcome this problem by the provision of a control station immediately upstream of the station in which the dies are turned over on one another to complete the products, at which control station one or more operators act to insert the missing fillings manually.
Apart from other considerations, it has been found that, at least in some cases, the absence of dry fruit is not constant, but rather shows sane variability, with periods of more numerous absences that are difficult to overcome by manual intervention, even when able and attentive operators are available.
SUMMARY OF THE INVENTION
The present invention is directed towards upstream intervention to overcome the absences of fillings and to ensure that all the necessary fillings are available for insertion in the dies, in each case and at every moment in the process, Without any absences occurring.
Moreover, although developed for use as described above, the invention is, in fact, of general application in that its object is to provide equipment which is able to supply in a metered way arrays of products of any type (thus not only dry fruits intended for use as fillings), even if these are very densely packed and in large numbers, while avoiding as surely as possible the presence of "voids", that is even occasional absences of products in the array.
According to the present invention, this object is achieved by a device having the characteristics set forth in Claim 1.
DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of non-limiting example, with reference to the appended drawings, in which:
FIG. 1 is a perspective view of equipment according to the invention, and
FIG. 2 is a section view taken along lines II--II in FIG. 1.
DETAILED DESCRIPTION
As stated above in the introduction to the present specification, the equipment of the invention, generally indicated 1, can be used, for example, in the process for the manufacture of confectionery products comprising a spherical wafer casing containing a creamy filling. The wafer casing is constituted by a pair of hemispherical shells kept together by the mutual contact of their respective fillings with the insertion therein of a dry fruit, such as a shelled hazel-nut, as an added element of the filling.
For a general description of the characteristics of a product of the type specified above and its method and manufacture, reference may usefully be made to the document EP-A-0083324 already mentioned in the present specification. This is true particularly with regard to the arrangement of pairs of complementary dies 11, 12 of which one of each pair is intended to be turned over on the other so as to close and complete the products.
In the solution described in EP-A-0083324, the insertion of the core constituted by a dry fruit is not explicitly explained. For an understanding of the invention it will, however, suffice to remember that, to achieve this result, it is necessary to arrange a corresponding array of dry fruits, e.g., shelled hazel-nuts N, in each of the shells located in alternating dies in a sequence, i.e., in one die but not the next.
The equipment 1 according to the invention has been illustrated in its normal position of use above a conveyor line 10 on which the dies 11 and 12 housing the shells intended to constitute each half of a finished product advance in alternating sequence, in accordance with known criteria, and therefore does not require further description here. It will be assumed below, however, that the shells in which the hazel-nuts N are to be inserted are those located in the dies indicated 11.
The equipment 1 of the invention is constituted essentially by a structure intended to be located like a bridge over the line 10 and which includes a pair of sides 22 which may be pivotable about an axis 24 transverse to the direction of advance of the line 10 to allow access to the part of the line beneath the equipment 1. The sides 22, together with a flat base plate 26 (also termed an abutment formation below), form a structure which may be defined essentially as a body to which the products N intended to serve as fillings are supplied. In the embodiment illustrated here, explicit reference is made to shelled hazel-nuts; it will, however, be understood that the invention is readily usable for the formation of an ordered array of products of any type, even outside the specific field of application indicated here.
The hazel-nuts N are supplied to the body of the equipment 1 by any known means, for example by a conveyor belt T which carries the products so that they fall into a part of the equipment located generally towards the upstream end relative to the direction of advance of the dies 11 and 12, which serve as receiver elements for the products N and which, as illustrated in the drawings, are moved from right to left by the line 10.
Two pairs of wheels or rollers indicated 28 and 30 are located at opposite ends of the body of the equipment 1. The rollers are connected in pairs by respective shafts 28a and 30a, and a belt structure passes around them. The belt structure is constituted by plates which are alternately blind, i.e., free from holes, and apertured, i.e., with holes whose geometric distribution reproduces the distribution of the cavities in the dies 11 and 12 for receiving the shells. The dimensions of the plates in question, indicated 32 (apertured plates) and 34 (blind plates) are thus such as to correspond with the dimensions of the dies 11 and 12. Preferably, neither the plates 32 nor the plates 34 are rigid elements, but rather comprises a plurality of articulated parts, like the slats of a roller blind, to facilitate their movements around the rollers 28 and 30 and to make these movements more precise.
Moreover, again for preference, the structure of the belt is continuous. Spacer slats (free from apertures), which have widths equal to the spacings between the dies 11 and 12 in the direction of advance of the line 10, are provided between the plates 32 and 34.
Those plates 32 and 34 of the belt structure which are in the lower pass of the belt at any time are thus advanced over the dies 11 and 12, immediately above them apart from the (partial) interposition of the base plate 26. The movement of the belt structure (which has associated drive means not illustrated explicitly) is controlled by the movement of the line 10, for example by a transmission connection of known type, such that the plates 32 and 34 advance in exact synchronization with the dies 11, 12. That is, the apertured plates 32 advance "in register" above the dies 11 while the blind plates 34 advance above the dies, 12.
The term "in register" has been used here to indicate a condition of exact vertical alignment, which means that the holes provided in the apertured plates 32 are exactly in line with the cavities in the dies 11.
As stated above, it is assumed here that the dies 11 are those in which the shells defining the "lower" parts of the products are located, that is, the parts in which the dry fruit fillings are to be inserted. The dies 12 are those intended to be turned over onto the dies 11 so as to complete the products, as described in EP-A-0083324.
It will be noted that the body of the equipment 1 is closed by the base plate 26 for a substantial portion of the length of its "upstream" part (reference is again made to the direction of advance of the dies 11 and 12 and, consequently, to the direction of advance of the plates 32 and 34 in the lower pass of the belt structure). The base plate does, however, have a window or opening 35 toward the downstream end of the equipment 1.
In particular, the part of the body of the equipment 1 located above the lower closed portion of the body (that is, the portion of the body enclosed by the wall 26) is divided into several sections or compartments indicated 36, 37, 38, and 39 respectively, in order from upstream to downstream of the equipment 1. The most upstream compartment 36 is the one to which the hazel-nuts N are supplied. The compartments 36, 37, 38, and 39 are bounded by transverse sheet-metal partitions, indicated 40, 42, and 44, in the body, the first partition preferably being continuous, and the other two partitions preferably being apertured and extending for a given height within the body 1. The partitions 40, 42, and 44 do not, however, reach the base plate 26, but are held at a certain distance (for example, a couple of centimeters in the embodiment illustrated here for supplying and metering hazel-nuts N) from this plate. At their lower edges, the partitions 40, 42, and 44 each have a flexible lip, indicated 40a, 42a, and 44a respectively, made from soft rubber or flexible sheet metal.
A rotary brush indicated 48, preferably motor driven, cleans the plates 32, 34 of any nut residues before the plates are returned to the compartments 36, 37, 38, and 39.
In correspondence with these compartments, the plates 32 and 34 are advanced through the base regions of the compartments 36, 37, 38, and 39 above the base plate 26. The hazel-nuts N located in these compartments may fall freely into the holes in the apertured plates 32.
Usually, the nuts fall so as to fill nearly all the holes in a given plate 32 while that plate is in correspondence with the most upstream compartment indicated 36. Any remaining spaces, however, may easily be filled as the plates move beneath the compartments 37, 38, and 39, which always contain a certain quantity of nuts N that are transferred from the compartment 36 by means of entrainment by the plates particularly the apertured plates 32 and the nuts in the apertures thereof acting against the small retaining force exerted by the lips 40a, 42a, and 44a and, possibly, by means of overflow of the nuts N through the apertures in the partitions 42 and 44 induced by the movement of the belt structure. Moreover, the lips 40a, 42a, and 44a cause a certain degree of resilient pressure to be exerted on the nuts N so as to force them into any holes 32 which might still be empty.
A rotary brush 50 mounted in the most downstream compartment, indicated 39, prevents any nuts N which might be in this compartment from being drawn further downstream. For this purpose, the brush 50 is rotated by drive means (not illustrated) in the opposite sense from the sense of rotation of the belt, that is, counter clockwise as illustrated in the drawings.
Level sensors (not illustrated but of known type) located inside the chamber 36 as well as inside the chamber 39 enable the supply of hazel-nuts N to the compartment 36 furthest upstream to be regulated selectively so as to avoid any undesirable accumulation of nuts.
In any case, due to the combined action of entrainment and forcing of the nuts N described above, all the holes in the apertured plates 32 which reach the most downstream end of the body of the device 1, where the base plate 26 is interrupted, are filled with the nuts N with certainty.
Consequently, when the plates 32 move so as to be located over the dies 11 and in correspondence with the opening or window 35 where there is no base plate 26, the nuts N which are located in all the holes, there being no voids in the array in any plate 32, pass directly into the shells in the underlying die 11.
This falling movement may occur either under gravity, to the extent that the peripheries of the holes in the plate 32 do not exert any retaining force on the nuts N, or by the action of a rotary pusher element 56. The rotary pusher element is constituted essentially by a roller which rotates in the concordant sense and in synchronization with the belt of plates 32 and 34 and has, at least on its periphery, an array of finger-like pusher elements 58. The movement of the roller 56 is controlled (for example through a mechanical transmission) by the movement of the belt of plates 32 and 34 and/or the movement of the line 10. At the same time, the pusher elements 58, which extend radially from the roller 56, are arranged in an array to correspond exactly identically and homologously to the array of holes in the plates 32, and hence to the array of cavities in the dies 11. This so as enables them to penetrate the holes in the plates 32 and give a positive, downward push to any hazel-nuts N therein which do not fall into the underlying die 11 simply under gravity.
Whatever means cause the nuts to transferred into the underlying dies 11, the solution of the invention ensures that hazel-nuts N are present in all of the shells in the die 11, as is desired, without any being missing. This has been proven experimentally by the Applicant in mass production at high production rates.
It will be appreciated that numerous aspects of the structure described above are given purely by way of example.
In particular, the fact that the plates 32 and 34 are arranged in an alternating sequence of apertured and unapertured plates results strictly from the specific example of use in which the dies 11 and 12 must receive the nuts N, or not receive them, in alternating fashion.
Clearly, if the requirements for the supply of the product--here given by way of example as the hazel-nuts N--were to differ, the arrangement of the plates could be different; for example, all the plates might be apertured.
Furthermore, although the embodiment in which the plates 32 and 34 are arranged as a closed loop structure, i.e. as a belt, is preferred, it is not imperative. The same functional effect described above could, in fact, be achieved in a different manner, for example by moving the plates 32 and 34 linearly, following the movements of the dies 11 and 12, and, once the products N have been supplied to the dies themselves, following a return path towards a collection zone for the products N.
Conversely, instead of the plates 32 and 34 being moved relative to an abutment formation constituted by the plate 26, the same relative movement described above could be achieved by moving a plurality of such plates 26.
Furthermore, the plates 32 and 34 could be replaced by elements of a different type, for example grids, etc.
Other embodiments will occur to those having skill in the art and are deemed to be within the scope of the following claims. | Product to be supplied in an ordered manner is supplied to the upstream end of an apparatus according to the invention, the bottom of which is substantially closed by a base plate that leaves only the extreme, downstream end of the apparatus open. The apparatus includes a belt-like structure composed of plates that are alternatingly apertured and non-apertured. Transverse partitions define compartments for receiving product at the upstream portion of the apparatus, the bottom portions of the compartments being bounded by the lower portion of the belt structure which, in turn, moves across the base plate. Product falls into the apertures in the apertured plates by means of gravity and pressure exerted by flexible lips located at the lower edges of the transverse partitions. The configuration ensures complete filling of the apertures in the apertured plates. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates to a two-wheel axle suspension for an agricultural machine, the suspension having a housing which accommodates at least two axle carriers, each connected to a wheel axle.
BACKGROUND OF THE INVENTION
[0002] Steadily increasing demands for productivity and performance placed on agricultural machines and implements, especially soil tilling implements and combined cultivating and sowing machines, is resulting in larger machines. These include soil tilling implements and cultivating machines such as ploughs, harrows, cultivators, rotary hoes and planters, sowing machines and drilling machines, or cultivating and sowing machines which are a combination of two or more of the aforementioned implements. The increasing geometric dimensions of these machines and implements in turn lead to an increase in the weight. The resulting increased pressure exerted on the soil by the wheels increases compaction of the soil, which may have a negative effect on soil cultivation and tilling.
[0003] One possible way of reducing compaction is to distribute the weight of the machine or the implement over a larger soil contact area. Typically this is achieved by distributing load to two wheels rather than one to thereby create a larger contact area. Machines and implements fitted with two-wheel arrangements therefore exert a lesser soil pressure than similar machines and implements with single-wheel arrangements. Less soil pressure and compaction has a positive effect on soil cultivation and tilling. Axle suspensions with two wheel axles rigidly connected together are used to transmit loads evenly to both wheels.
[0004] Such two-wheel arrangements are disclosed in EP 1179289 A2, for example, wherein an attachment frame for soil tilling implements is provided with two-wheel arrangements. Each wheel arrangement includes an axle suspension with a wheel axle that extends on both sides of an axle suspension housing. The wheel axles are rigidly connected relative to one another so the weight of the frame and the implement acting on the wheel arrangement is distributed to both wheel axles and to the wheels. The fact that the wheel axles are rigidly connected to one another has a disadvantageous effect since the wheels cannot move independently of one another in a vertical direction, and in certain situations the weight cannot be optimally distributed. If one of the wheels is raised by an elevation or irregularity in the ground, the second wheel is also raised and lifted from full soil contact. If just one of the wheels encounters a depression in the ground, the second wheel keeps the first wheel out of ground contact. Similar effects occur when the soil tilling implement is used on inclines.
SUMMARY OF THE INVENTION
[0005] The object of the invention is to provide an improved axle suspension of the aforementioned type which overcomes the aforementioned problems. According to the invention pivoting axle carriers mounted within a housing are connected to the respective wheel axles and are connected together so that pivoting of one of the carriers about its axis results in pivoting of the other carrier in the same direction about its axis.
[0006] The axle arrangement includes pivoting bodies, each of which comprise a first member connected to the respective wheel axle and a second member. The first members extend on opposite sides of the housing and are rigidly connected to the second members. The pivoting bodies are supported from at least one pivot axis fixed in the housing. Connecting structure constrains the pivoting bodies for rotation together so that a pivoting movement of one pivoting body about its pivot axis produces a pivoting movement of the other pivoting body in the same direction about its pivot axis. It should be pointed out that a member connected to the wheel axle can be either a member that is integrally and permanently connected to the wheel axle in the form of a cast, forged or welded part, for example, or an assembly detachably connected to the wheel axle, such as an assembled socket connection, for example. The term connected here to be interpreted as including an integral connection, so that the member and the wheel axle may constitute a single component. The axle carriers take the form of pivoting bodies and the wheel axles are connected to the axle carrier on both sides of the housing, and such a construction allows the wheel axles and hence also the wheels mounted on the wheel axle to swivel or tilt. The pivoting movements of the pivoting bodies are restricted or controlled by the connecting structure. When one pivoting body is pivoted or swiveled in one direction of rotation, the other pivoting body is pivoted or swiveled to the same extent in the same direction of rotation. At the same time the connecting structure ensures that the leverage acting on the respective pivoting body is also transmitted to the other pivoting body so that forces are distributed uniformly to both pivoting bodies. If, when running over an irregularity in the ground surface, for example, a wheel connected to the one pivoting body by one wheel axle is deflected, this deflection is transmitted to the other pivoting body, which in turn deflects the other wheel axle and the wheel connected thereto in an opposite direction to the first wheel. If the wheel on one side of the wheel suspension is raised, the wheel on the other side is correspondingly lowered. This action ensures that both wheels maintain equal ground contact. The pivoting body itself may assume widely varying geometric shapes and is not confined to a two-member structure. Rather, the term member is here intended to signify the moment levers acting about the pivot axis, which in a pivoting movement of the pivoting body about the pivot axis or due to deflection of one member or the moment lever give rise to a deflection of the other member or moment lever on the kinematic lever principle.
[0007] A fixedly supported pivot axis is preferably provided for each pivoting body. Design advantages can ensue from this, especially with regard to a compact construction. The functionality of the axle suspension, both with a common pivot axis and with two separate pivot axes is assured, however, provided that the connection established by the connection structure constrains the pivoting bodies to swivel in the same direction of rotation. This can be achieved, both for a common pivot axis and for two separate pivot axes, through a corresponding design of the pivoting arrangement members. The appropriate design and the geometric dimensions of the connecting structure and the pivoting bodies in each particular case will be readily feasible for a person skilled in the art on the basis of his specialized knowledge, for which reason this will not be explored further here.
[0008] The connecting structure preferably comprise a connecting strut and connecting pins pivotally connecting strut to the pivoting bodies. The connecting strut is firmly but torsionally and pivotally connected, that is to say articulated, to the pivoting body by the connecting pins. The connecting strut constitutes a rigid connecting element which is capable of transmitting forces in at least two directions. The connecting strut serves to couple the pivoting bodies together and ensures that the distance between the connection points at which the connecting strut is pivotally fixed to the pivoting body by the connecting pins always remains constant so that as the pivoting bodies swivel the angle of rotation of one pivoting body is equal to the angle of rotation of the other pivoting body.
[0009] The connecting structure preferably is arranged at a distance from the pivot axis of each pivoting body so that the second member can exert a lever action on the first member about the pivot axis. The greater the distance, the greater the lever action exerted on the first member. At the same time, the distance selected should not be too great so that the deflections of the second members and the amount of swivel at the end of the members remain within the design limits for the housing of the axle suspension. A design compromise has to be found here between the nature of the material in terms of strength and the requisite transmission of force, and the geometrical dimensions and compactness.
[0010] The connecting structure preferably is arranged on the second member, so that the length of the second member acts as a lever on the first member about the pivot axis. The connecting structure here is preferably arranged at the ends of the second member in order to obtain a compact construction. It is also feasible, however, to arrange the connecting means elsewhere.
[0011] The pivot axis of each pivoting body is preferably arranged between the first and the second member. It may be arranged at any other point on the pivoting body, however, provided that a lever to the connecting means is created so that a pivoting movement of the pivoting body about the pivot axis produces a swiveling travel at the connection points of the connecting structure.
[0012] The members of each pivoting body are rigidly arranged at an angle of preferably 90° to one another. However, differing angular arrangements, other than 0° and 180°, may also be chosen.
[0013] Pivot pins, which at their ends are supported in bearing apertures, are preferably provided for the pivot axis or pivot axes. The bearing apertures are preferably formed on a housing wall of the housing. The apertures, for example, can take the form of recesses in the housing wall or bushings fixed to the housing.
[0014] A guide aperture, running between the bearing apertures on each of the pivot pins, is formed on the pivoting bodies between the first and the second members. Obviously, the chosen arrangement can also be reversed so that, for example, the pivot axis and the bearing apertures of the pivot pins are formed on the pivoting body and guide apertures are formed on the housing. The guide aperture and/or the bearing apertures may be provided with a bearing bushing in order to improve the bearing characteristics and the sliding characteristics in the apertures.
[0015] The second members or an area of the second members preferably has shackle-shaped or bifurcated end areas in which bearing apertures are formed and in which the connecting pins are supported.
[0016] For proper mating with the bifurcated ends, the connecting strut preferably has two ends with guide apertures journaling the respective connecting pin and pivotally connecting the second members of the pivoting bodies or the area of the swiveling bodies acting as moment lever. Here too the chosen arrangement can obviously be reversed so that the bearing apertures can alternatively also be formed on the connecting strut and the guide apertures correspondingly formed on the pivoting body. In this case, the connecting strut would be shackle-shaped at its ends and the second members would be provided with a guide aperture at their end. The guide aperture and/or the bearing apertures may be provided with a bearing bushing in order to improve the bearing characteristics and the sliding characteristics in the apertures. Articulated and/or pivot connections other than those described above are feasible in respect of the pivoting bodies and connecting structure, provided that a pivoting connection is established between pivoting body and connecting means and between pivoting body and pivot axis.
[0017] The pivot pins and the connecting pins preferably extend horizontally to the ground and transversely to the direction of extension of the first members (that is, generally transverse to the axes of rotation of the wheels) so that the wheels can move vertically and ride up and down over ground surface irregularities. Correspondingly adapted geometries of the swiveling bodies and members of course mean that other alignments and pivoting directions which permit vertical movements of the wheels are feasible.
[0018] The first member of the pivoting bodies preferably has a mounting area in the form of a tube in which a wheel axle can be mounted. Other embodiments enabling the pivoting body to be connected to the wheel axle may also be selected. Thus, for example, the wheel axle might be flange mounted on the pivoting body or directly attached to the pivoting body by a welded connection.
[0019] In a preferred exemplary embodiment an agricultural machine, in particular a soil tilling implement or a combined cultivating and sowing machine, at least one axle suspension according to the embodiment described above provides support for the relatively massive implement frame. Here the axle suspension is connected to an implement frame of the machine and supports this in relation to the ground. Multiple axle suspensions connected to the implement frame ensure that the weight of the machine is distributed over the entire construction. The pivoting wheel axle suspension ensures better ground following characteristics than conventional rigid systems so that any lifting of and improper weight distribution on individual wheels due to ground irregularities can largely be prevented.
[0020] The invention and further advantages and advantageous developments and embodiments of the invention will be described and explained in more detail with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a perspective exploded view of a wheel suspension according to the invention;
[0022] FIG. 2 is a cross-sectional view of the wheel suspension in FIG. 1 ; and
[0023] FIG. 3 is a view of a tractor-drawn tillage implement having an axle suspension according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Referring to FIGS. 1 and 2 , a two-wheel axle suspension 10 according to the invention comprises a housing 12 , in which axle carriers 15 , 16 are arranged. The carriers 15 , 16 extend out of the housing 12 through apertures 13 , 14 on opposite sides of the housing 12 . The axle carriers 15 , 16 are of an articulated knuckle-joint design and comprise a first member 18 , 20 and a second member 22 , 24 , which are arranged at right angles to one another.
[0025] The first members 18 , 20 have ends with tubular shaped mounting areas 26 , 28 which mount wheel axles 30 , 32 . Suspended on the wheel axles 30 , 32 in a conventional manner are wheels 34 , 36 which support the axle suspension 10 above the ground. The first members 18 , 20 extend transversely to the direction of rotation of the wheels 34 , 36 or generally parallel to the axes of rotation of the wheels 34 , 36 .
[0026] The second members 22 , 24 , which are generally upright and extend vertically relative to the ground, are rigidly connected to the first members 18 , 20 . The end areas of the second members 22 , 24 are of shackle-shaped or bifurcated design and have bearing points in the form of bearing apertures 38 , 40 which receive and accommodate connecting pins 42 , 44 .
[0027] The axle suspension 10 further comprises a rigid connection or connecting strut 46 having ends with guide apertures 48 , 50 formed therein. A guide aperture 52 , 54 which seats a pivot pin 56 , 58 therein is formed between the first and the second members 18 , 20 and 22 , 24 , respectively. The ends of the pivot pins 56 , 58 are inserted into bearing apertures 60 , 62 , which are formed on a housing wall 64 of the housing 12 .
[0028] The interaction of the components represented in FIG. 1 is illustrated in FIG. 2 . The axle carriers 15 , 16 are pivotally supported by their guide apertures 52 , 54 on the pivot pins 56 , 58 supported on the housing 12 in the bearing apertures 60 , 62 . The structure facilitates a pivoting movement of the axle carriers 15 , 16 relative to the housing 12 about the longitudinal axes of the pivot pins 56 , 58 forming the pivot axes. The axle carriers 15 , 16 therefore constitute pivoting bodies which allow an up and down movement of the first members 18 , 20 and the wheel axles 30 , 32 , and hence of the wheels 34 , 36 in an upright or vertical direction relative to the ground.
[0029] The second members 22 , 24 rigidly arranged at right angles to the first members 18 , 20 consequently pivot respective first member 18 , 20 is deflected as the wheels 34 , 36 roll over an undulation in the ground, for example. The two second members 22 , 24 extending vertically are constrained for articulated together via connecting strut 46 and the connecting pins 42 , 44 carried in the bearing apertures 38 , 40 . The connecting strut 46 transmits a resulting pivoting movement of the one axle carrier 15 , 16 to the other axle carrier 15 , 16 , so that a pivoting movement of the one axle carrier 15 , 16 gives rise to a pivoting movement of the other axle carrier 15 , 16 in the same direction. The connecting strut 46 and the connecting pins 42 , 44 (together with the bearing apertures 38 , 40 ) therefore constitute connecting means which connect the second members 22 , 24 together. If the right-hand wheel 36 on the right-hand side of the axle suspension 10 represented in FIG. 2 runs over a ground elevation, for example, the first right-hand member 20 moves upwardly, so that the right-hand axle carrier 16 performs an anticlockwise pivoting movement. The right-hand second member 24 is automatically swiveled to the left. At the same time the connecting structure (the connecting strut 46 with the connecting pins 42 , 44 ) constrains the left-hand second member 22 into a leftward pivoting movement so that the left-hand axle carrier 15 also performs an anticlockwise pivoting movement, which in turn moves the left-hand first member 18 downwardly. The two axle carriers 15 , 16 therefore perform a swiveling movement in the same anticlockwise direction. As a result, the left-hand wheel 34 moves downwardly, compensating for a difference in height between the wheels 34 , 36 and keeping both wheels 34 , 36 in uniform contact with the ground. In the opposite case (clockwise pivoting movement of the axle carriers 15 , 16 ) the leftward pivoting movement of the left-hand first member 22 is transmitted to the right-hand first member 24 , so that the left-hand wheel 34 moves upwardly and the right-hand wheel 36 moves downwardly.
[0030] FIG. 3 shows an applied example of an axle suspension 10 according to the invention on a combination cultivating and sowing machine 100 . The combined cultivating and sowing machine 100 has a frame 112 which extends in the forward direction (from left to right in the drawing) and which is supported on the ground by the wheels 34 , 36 connected to the axle suspension 10 . The front end the frame 112 is connected by a drawbar 116 , via a detachable coupling 120 , to a towing vehicle 118 such as an agricultural tractor.
[0031] Forwardly of the wheels 34 , 36 the frame 112 carries a seed box 122 for holding seed. Metering systems, not represented in the drawing, measure out the seed from the seed box 122 and deliver the seed through seed lines to conventional planting units 124 arranged at the rear of the frame 112 . The units 124 as shown comprise a furrow opener 126 , closing wheels 128 and seed coulters 130 . Seed is delivered to the furrow produced by the furrow opener 126 , and the closing wheels 128 subsequently closing the furrow over the seeds.
[0032] Multiple units 124 are supported side by side on an implement carrier 132 supported on the frame 112 and extending transversely to the forward direction. In front of the seed box 122 a carrier frame 136 is fixed beneath the frame 112 . The carrier frame 136 carries a pivoting frame 138 supporting a soil tilling implement 140 such as a disk harrow. Other soil tilling implements 140 may be used instead of the disk harrow.
[0033] Although the invention has only been described with reference to one exemplary embodiment, many different alternatives, modifications and variants coming with the scope of the present invention will become apparent to the person skilled in the art in the light of the description above and the drawings. | An axle suspension for first and second implement ground support wheels, the axle suspension comprising a housing connected to the implement frame and having an interior portion supporting first and second axle carriers for pivoting about first and second pivotal axes. The axle carriers each include outwardly extending members projecting from opposite sides of the housing and upright members fixed to the outwardly extending members for pivoting therewith about the first and second pivotal axes. A connector extending between the upper ends of the upright members constrains the axle carriers for rotation in the same direction about their respective pivotal axes. | 1 |
FIELD OF THE INVENTION
[0001] The invention pertains to a roll-bar system for motor vehicles with a roof, which can be extended and retracted in motorized fashion by means of a roof displacement mechanism, consisting of a roll-bar body that is associated with each seat and does not comprise a sensor-controlled crash drive, which can be forcibly displaced autonomously, in conjunction with the roof displacement mechanism, between a first rigid position, when the roof is closed, and a second, raised rigid position, when the roof is open.
BACKGROUND OF THE INVENTION
[0002] Such roll-bar systems are used to protect the passengers in motor vehicles without a protective roof, typically in convertibles or sports cars during a roll-over, so that the vehicle can roll over onto the upwardly projecting roll-bar body.
[0003] It is known how to provide a permanently installed roll bar spanning the entire width of the vehicle. In this solution, the increased wind drag and the occurrence of driving noise is perceived as a drawback, apart from impairing the appearance of the vehicle.
[0004] It is also known how to assign a so-called constant-height, rigid, vertically upwardly projecting roll bar to each seat of the vehicle. This solution is typically used in sports cars to underscore the sporty appearance, but it is also used in convertibles.
[0005] Also widespread in convertibles are structural solutions in which, as an alternative to the rigid roll bars, the roll-bar body is retracted in the normal condition, and in event of an accident, i.e., during an impending roll-over, it is quickly extended into a protecting position, in order to prevent the passengers from being crushed by the overturned vehicle.
[0006] These roll-bar systems typically have a U-shaped roll-bar body or one made of other profiled sections, guided in a guide body fixed to the vehicle, the guide body being secured in a cassette-type housing. This roll-bar body in the normal condition is held in a lower position of rest by a holding device against the biasing force of at least one actuating compression spring, and in the event of a roll-over a sensor releases the holding device and the force of the actuating compression spring can bring it into an upper, protecting position, and then a locking device, or retraction brake, is engaged and prevents the roll bar from being pushed in. This so-called crash drive in the form of the actuating compression spring can also be combined with a continuously displaceable drive, the so-called comfort drive.
[0007] Typically, each seat in the vehicle is assigned a cassette, especially the front seats. In the rear, the cassettes can also be integrated in a rear wall structural unit. Such a cassette type construction of a roll-bar system with a U-shaped roll bar is presented, for example, by DE 43 42 400 A 1; an alternative cassette construction with a roll-bar body in the form of a profiled body is shown, in particular, by DE 198 38 989 C1.
[0008] The invention is based on the roll-bar system which is rigid relative to the vehicle seats.
[0009] Yet in sports cars with retractable roof (top), and also in convertibles in any case, one must take into account the rigid, upwardly projecting roll-bar body, since the top has to travel over it. In particular during the presently popular automatic opening and closing movement of the top, the upwardly projecting roll-bar body must not hinder the path of movement of the top.
[0010] But since the height of the roof is limited by reasons of design, as well as engineering (especially the C W value), the height of the roll-bar tangent, dictated by the upwardly projecting dimension of the roll-bar body, is also limited, which necessitates a compromise between the structural requirements, on the one hand, and passenger protection, on the other.
[0011] From DE 44 25 954 C1 there is known a roll-bar system for motor vehicles with retractable roof, having a roll bar providing sufficient passenger protection with either an open or a closed roof, and not hindering the path of movement of the roof either when opening or closing, since the roll bar is placed in a lower setting position when the roof is closed and in an upper setting position when the roof is opened, having a lift mechanism provided for the movement of the roll bar between the lower and the upper setting position, being connected by means of a forcible mechanical guidance to the control mechanism provided for opening or closing of the roof.
[0012] This known roll bar has the benefits of a rigid roll bar, since it cannot be fully retracted into the car body, but instead can only move between two raised positions, both of which offer sufficient protection to a person situated in the particular vehicle seat. Because the roll bar is in a lower raised position when the roof is closed, it is possible to design a stable and aerodynamic roof, so that the closed roof merges elegantly in the overall vehicle contour and also the somewhat lowered roll bar means that the roof can be drawn more shallowly across the passenger compartment by design. The forcible mechanical guidance of the setting and lifting mechanism accomplishes a forcible linkage between the particular setting position of the roll bar and the opening or closing movement of the roof.
[0013] In the known application, the mechanical lifting mechanism for placing the roll bar, accommodated in a sleeve-like stowage, into the two raised positions by means of a bar lever is linked mechanically and frictionally to the control mechanism for the roof movement via a roof lever. The bar lever itself is connected via a transmission rod with a link guidance in the sleeve-like stowage to the roll bar at a link block.
[0014] The mechanical lifting mechanism for adjusting the height of the roll bar, i.e., for raising and lowering the roll bar in the vertical plane into the two raised positions and its mechanical coupling to the mechanical forcible guidance mechanism, mechanically actuated by the roof control mechanism, produces a highly complex kinematic construction with high installation and adjustment expense, and what is more it is prone to malfunctions.
[0015] DE 600 01 224 T2 shows a roll bar for a convertible with folding roof, not consisting, as is usual, of a naturally rigid single-piece bar, but rather of two bar elements linked at the tips of the bar, the lower free ends of each bar element being able to move between two positions by means of a frictional roller, having an interior thread, along a horizontal slideway by means of a spindle drive, coupled to the roof displacement mechanism. In the first position, the free ends are at a distance from each other, so that the linked connection and thus the tip of the bar is lowered and thus the roof can move freely. In the second position, which is adopted when the roof is opened, the free ends lie closer to each other, so that the bar elements are raised relatively steeply and the bar has the necessary height to provide protection.
[0016] However, due to the upper link of the two-element roll bar the strength of the roll bar is quite substantially impaired. What is more, during a roll-over the two frictional rollers with the interior thread in connection to the actuating spindle need to absorb the large forces, which require a corresponding expensive dimensioning of these elements.
[0017] DE 197 52 068 A1 discloses a roll-bar system for a motor vehicle with a multipart folding roof, consisting of a front roof element, which is hinged to the car structure and able to fold into a stowage position toward the rear, and a rear roof element, hinged to the rear. The front roof element is pivoted on the car structure by two roof pillars, arranged at opposite sides, and the side roof pillars can be guided further downward via the pivot axes on the car structure to form a roll bar extending across the width of the vehicle with two U-shaped bar segments associated with the seats. The arrangement is such that the roll bar in the stowage position of the front roof element is forced to adopt its upward lying, protecting position.
[0018] This known system requires, first of all, a costly roof construction, prone to malfunction, and second, the two linkages of the roof pillars on the car structure must absorb the large forces during a roll-over, which necessitates a correspondingly strong design of the linkage, which can impair the appearance of the vehicle. Moreover, the swivel movement of the roll bar about the transverse axis requires a correspondingly large structural space, which is in scarce supply as it is for vehicles having an open roof.
SUMMARY OF THE INVENTION
[0019] The basic problem of the invention is, starting from the above-indicated, known roll-bar system for motor vehicles with retractable roof, to significantly simplify the latter in regard to the raising and lifting mechanism and the forcible guidance mechanism with the roof controls, i.e., to avoid a complex kinematic construction as in the known instance.
[0020] The solution of this problem, according to the invention, in a roll-bar system for motor vehicles with a roof, which can be extended and retracted in motorized fashion by means of a roof displacement mechanism, consisting of a roll-bar body that is associated with each seat and does not comprise a sensor-controlled crash drive, which can be forcibly displaced autonomously, in conjunction with the roof displacement mechanism, between a first rigid position, when the roof is closed, and a second, raised rigid position, when the roof is open, is that the roll-bar body is mounted and guided in a cassette type housing that is fixed to the vehicle and said body is associated with a drive, which is coupled to the roof displacement mechanism and used to displace said body vertically in the housing and with a position-dependent forcibly guided locking device, which is used to lock said body in the raised position.
[0021] Thanks to the steps of the invention, one achieves a kinematically uncomplicated, simple, forcibly guided raising and lowering of the roll-bar body.
[0022] Embodiments of the invention are characterized in subsidiary claims and also appear from the description of the figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The invention shall be explained more closely by means of sample embodiments depicted in the drawings.
[0024] These show:
[0025] FIG. 1 , in an isometric view, a first embodiment of the invention with a roll bar, guided in a cassette, which can be raised into two positions by means of an electric motor type spindle drive, electrically controlled by the roof raising mechanism, with a locking of the roll bar in its raised position with the roof opened by a double thread on the nut of the spindle drive,
[0026] FIG. 2 , in three longitudinal sections A-C of the system per FIG. 1 , three different positions of the roll bar,
[0027] FIG. 3 , in an isometric view, a variant of the embodiment per FIG. 1 with the electric motor type spindle drive, but with a locking by two locking ratchets controlled according to position,
[0028] FIG. 4 , in seven longitudinal views A-G of the system per FIG. 3 , seven different states of the roll bar and of the locking ratchets,
[0029] FIG. 5 , in a magnified isometric view, the position-dependent control of the locking ratchets of the system per FIG. 3 by the nut of the spindle drive, with ratchets locked in Fig. A and ratchets unlocked in Fig. B,
[0030] FIG. 6 , in four figure parts A-D in longitudinal section views, another embodiment of the invention with raising of the roll bar by a spring drive in conjunction with a locking by locking ratchets according to FIG. 5 , as well as resetting and guiding of the roll bar by means of Bowden cable dependent on the roof displacement mechanism, showing different operating states of the system in the figure parts, and
[0031] FIG. 7 , likewise in four figure parts A-D in longitudinal section views, another embodiment of the invention with raising and resetting of the roll bar by a Bowden cable controlled by the roof displacement mechanism in conjunction with the locking system according to FIG. 5 , likewise showing different operating states of the system in the figure parts.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIGS. 1 and 2 show a first sample embodiment of a seat-assigned roll-bar system according to the invention for motor vehicles with retractable roof, having a U-shaped roll bar 1 , which can be raised by means of electric motor adjustment from a lower ground position with closed roof into a higher locked and raised position in dependence on the opening process of the roof, and which can also be returned to its ground position by means of the electric motor drive before the roof is closed.
[0033] Since the roll bar has no so-called crash quick drive, i.e., it cannot be raised from its respective position under sensor control in event of an impending roll-over, but instead must perform its protective function in the respective position as is, it is “related” to the rigid roll bars explained at the outset, with the distinction that it can assume two “rigid” raised positions each time.
[0034] The roll bar 1 consists of a U-shaped tube 2 with a head piece and two legs, as well as a cross arm 3 , which firmly and mechanically join together the free ends of the legs.
[0035] The roll bar 1 is mounted in a cassette-type housing 4 with two essentially U-shaped side pieces 4 a , 4 b and a bottom piece 4 c , as well as with a guide block 5 firmly arranged on the side pieces. The two legs are led into corresponding openings of the guide block, whereas the cross arm is introduced by its lateral ends into the side pieces. The housing, the guide block and the cross arm advisedly consist of extruded sections, similar to the known cassette construction per DE 100 40 642 C1 (=EP 1 182 098 A2) for systems with roll bars that can be raised into the upper protection position by means of a crash drive under sensor control.
[0036] Between the guide block 5 and the housing bottom 4 c , a threaded spindle 6 is mounted so as to rotate, but not move axially. The corresponding bearings, shown only schematically in the parts of FIG. 2 , e.g., the upper bearing 5 b in the guide block 5 , possess a conventional layout.
[0037] On the cross arm 3 is firmly mounted an electric motor 7 with transmission 8 . Moreover, a nut 9 , rotating in connection with the threaded spindle 6 , is mounted on the cross arm so that it can rotate in connection with the transmission but not move axially.
[0038] The inner thread of the nut 9 engages with the thread of the threaded spindle 6 in such a way that the cross arm 3 , and with it the roll bar 1 , travels UP or DOWN on the threaded spindle 6 in dependence on the direction of turning of the electric motor.
[0039] In the lower raised position per FIG. 1 and figure part 2 A, the cross arm 3 is basically resting on the bottom piece 4 c , while the openings for the tube leg ends are accommodated free of wobble in centering pieces 4 d made of elastic material, secured at the bottom, i.e., the roll bar cannot be pushed down in event of a roll-over. However, if it is in the upper raised position (Fig. part 2 C), it could move downward as the threaded spindle rotates. It must therefore be locked in the upper raised position. For this, an inner thread 5 a , being larger in diameter than that of the threaded spindle 6 , is formed in the guide block 5 , being used to lock the roll bar in the raised position by entering into a thread interaction with an outer thread 9 a , matched up with the inner thread 5 a in the guide block 5 .
[0040] To accomplish this locking, the locking threads 5 a and 9 a and the thread of the threaded spindle must be coordinated with each other in regard to the thread pitch. The thread of the threaded spindle 6 can be, for example, a trapezoidal thread TR 10×2, 3-thread series, and the locking thread a trapezoidal thread TR 22×6, 1-thread series. Thus, the two threads have the same pitch per turn, which is absolutely essential so that, when the nut 9 travels up on the threaded spindle, the outer locking thread 9 a of the nut can turn smoothly in the inner thread 5 a in the guide block 5 .
[0041] The depicted roll-bar system works as follows:
[0042] After the roof of the vehicle has been opened and stowed away in the trunk space, the electric motor 7 is placed under the vehicle voltage supply, preferably automatically, i.e., via an end switch. The threaded spindle turns and raises the roll bar 1 via the nut 9 and the cross arm 3 . Shortly before the highest position (shown in FIG. 2B ), the nut 9 is screwed by its external thread 9 a into the guide block 5 and thus brings about the locking of the roll bar relative to the housing.
[0043] When the roof is closed once again, the electric motor at first undergoes pole reversal and is again furnished with the vehicle voltage supply, so that the roll bar is taken to its lower raised position, while the centering pieces 4 d on the bottom piece 4 c ensure a shock-absorbed impact of the roll bar. The roof can then be closed without hindrance from the roll bar.
[0044] FIGS. 3 to 5 show a variant of the embodiment of FIGS. 1 and 2 with the electric motor spindle drive, which is coupled to the electrical controls of the roof, differing in particular by the mechanical locking of the roll bar situated in the raised position when the roof is open. Functionally identical parts have been given the same reference numbers.
[0045] In the present variant, the electric motor 7 with transmission 8 is mounted beneath the bottom part 4 c of the cassette, firmly attached to the vehicle. The transmission 8 interacts by rotation with the threaded spindle 6 , mounted in the cassette and able to rotate, but not able to move axially. The upper bearing 5 b is likewise situated in the guide block 5 .
[0046] The threaded spindle interacts in this variant with a T-shaped nut 9 , which is mounted in the cross arm 3 of the lifting roll bar 1 , firm against rotation, but able to move axially by a control stroke of around 10 mm.
[0047] Furthermore, two locking ratchets 10 are mounted on the cross arm 3 and able to pivot, each being prestressed in the locking direction by a torsion spring 11 ( FIG. 5 ). These are supposed to prevent the roll bar 1 in the raised position from being pushed down under load, by entering into a detachable engagement with corresponding lock bolts 12 , arranged in the guide block 5 and guided by the T-shaped nut 9 , as shall be explained more closely by FIG. 5 . FIG. 5A shows the condition of the locking in which the cross arm 3 with the locking ratchets 10 lies against the lower edge of the guide block 5 , in which the locking ratchets 10 are inserted. FIG. 5B shows the release condition for subsequent retraction of the roll bar 1 via its cross arm 3 .
[0048] For the activating of the locking ratchets 10 by the nut 9 , the latter has an upper and a lower essentially rectangular control stop 13 and 14 . The lower control stop 14 is configured or dimensioned such that it can come to lie against the cross arm 3 ( FIG. 5A ), but not be inserted into the hollow profile of the cross arm 3 . The upper control stop 13 is staggered at 90 degrees from the lower control stop 14 and dimensioned so that it can be inserted into the cross arm so as to engage with the locking ratchets 10 .
[0049] On the upper bearing 5 b of the threaded spindle, a central stop 15 for the cross arm 3 is additionally provided, being mounted firmly on the guide block 5 , and also preventing, along with two stopping bolts 16 , too wide an opening of the locking ratchets 10 .
[0050] The operation as depicted in FIG. 4A to G is as follows: only the relevant components are provided with the respective reference numbers.
[0000] Raising:
[0051] Figure A shows the roll-bar system in the basic condition with roof closed. The upper control stop 13 , retracted into the cross arm 3 , holds the locking ratchets 10 in the released state.
[0052] After the opening of the roof, the electric motor 7 is activated by the electrical roof controls, the threaded spindle 6 starts turning, the nut 9 initially moves upward by the control stroke, until the lower control stop 14 bears against the bottom of the cross arm. At the same time, the upper control stop has released the locking ratchets 10 , which turn into the “locking” position under the action of the torsion springs 11 . This condition is shown by FIG. 4B .
[0053] As the threaded spindle continues to turn, the nut 9 lying against the cross arm 3 exerts a raising force on the cross arm 3 and thereby raises the roll bar 1 in the cassette 4 or in the guide block 5 . Before reaching the uppermost position, the locking ratchets 10 push with their rounded outer contour against the locking bolts 12 ( FIG. 4C ), firmly mounted in the guide block 5 . Upon further raising into the uppermost position (the upper control stop 13 lies against the center stop 15 of the guide block 5 ), the locking ratchets 10 swing back against the pretensioning force of the torsion springs 11 ( FIG. 4D ) and then engage with the locking bolts 12 to produce the locking ( FIGS. 4E and 5A ).
[0054] The motor 7 is automatically shut off, e.g., by an end switch.
[0000] Stowing Away the Roll Bar:
[0055] If the roof of the vehicle is to be opened once more, the electric motor 7 is automatically activated to turn in reversed direction by the roof controls. The threaded spindle 6 , turning in the opposite direction, at first moves down by the control stroke. The upper control stop 13 comes to bear against the shoulders 10 a of the locking ratchets 10 , oriented toward the threaded spindle, and these swivel in the opening direction ( FIGS. 4F and 5B ). The roll bar is thus ready to retract. Thanks to the threaded spindle 6 continuing to turn, the nut 9 by its upper control stop 13 situated in the cross arm 3 pulls down the cross arm 3 and thus the roll bar 1 until the retracted starting or ground position of the roll bar is reached ( FIG. 4G = 4 A). The electric motor 7 is then shut off automatically, e.g., by means of an end switch.
[0056] According to one variant of the embodiment per FIG. 3 to 5 , the drive of the threaded spindle can come from above, i.e., the electric motor with transmission is flanged onto the upper end of the threaded spindle and the lower end of the threaded spindle is mounted and able to turn in the cross arm.
[0057] FIG. 6 shows a third embodiment of the invention in four operating states per A-D. The cassette type layout 4 of the roll-bar system with guide block 5 , and the locking of the roll bar 1 with cross arm 3 raised into the uppermost position by means of the locking ratchets 10 , corresponds to the embodiment per FIG. 3 to 5 , and therefore functionally identical components are given the same reference numbers. What is different is the drive system for raising and lowering (resetting) the roll bar 1 . Instead of an electric motor type spindle drive, the embodiment of FIG. 6 provides for a raising of the roll bar 1 when the roof is opened with pretensioned lifting springs 17 , controlled by a Bowden cable 18 , which is mechanically coupled to the roof displacement mechanism, and which also retracts the roll bar into the starting position when the roof is closed. The sheath 18 a of the Bowden cable is firmly mounted on the bottom 4 c of the cassette housing 4 . The free end of the pull cable 18 b of the Bowden cable has a T-shaped holding fork 19 with a configuration similar to the nut 9 in the sample embodiment of FIG. 3 to 5 . The T-shaped holding fork 19 therefore likewise ensures that the two spring-loaded locking ratchets 10 are in the opened state in the ground condition ( FIG. 5A ). Furthermore, the T-shaped holding fork 19 holds the roll bar 1 by its cross arm 3 against the force of the two raising springs 17 in the ground condition, because the other end of the corresponding pull cable 18 b of the Bowden cable 18 is firmly restrained.
[0058] The two raising springs 17 are received into the two legs of the U-shaped bar tube 2 and are guided by spring guide bolts 20 secured to the bottom piece 4 c . The two raising springs 17 each thrust against the bottom piece 4 c below and against an insert 21 in the upper part of the legs above.
[0059] The raising springs 17 are not so-called crash springs, as in the case of sensor-controlled cassette systems. The latter must raise a roll bar in less than half a second in event of an accident. A much larger time span is available for the raising of the raising springs 17 after opening of the roof, e.g., around 5 seconds, so that the spring force can be substantially less, which also allows the roll bar to retract into the ground position when the roof is closed without any additional helping means.
[0060] In the context of the opening of the roof, the pull cable 18 b is released by the roof displacement mechanism. The cross arm 3 with the bar tube 2 is lifted as the pull cable 18 b is pulled out, the locking ratchets being still open ( FIG. 5B ). After this, the excess stroke of the holding fork 19 is released in the corresponding opening of the cross arm 3 , so that the two locking ratchets 10 swing outward under spring force and engage with the locking bolts 12 . Thus, as in the sample embodiment of FIG. 3 to 5 , the extended roll bar is protected against retraction from the force of a roll-over ( FIG. 6C ).
[0061] Before closing the roof, the pull cable 18 b of the Bowden cable is pulled in, controlled by the roof displacement mechanism, and at first travels back over the excess stroke, so that the locking ratchets 10 are again released by the holding fork 19 and rest against the stop bolts 16 ( FIG. 5D ). Since the T-piece of the holding fork rests against the shoulders 10 a of the locking ratchets 10 , the pull cable 18 b can pull the bar tube into the ground position of FIG. 5A against the force of the lifting springs 17 .
[0062] FIG. 7 shows a fourth embodiment of the invention in four operating states per Fig. A-D. The cassette type layout 4 of the roll-bar system with guide block 5 , and the locking of the roll bar 1 with cross arm 3 raised into the uppermost position by means of the locking ratchets 10 , corresponds to the embodiment per FIG. 3 to 5 and FIG. 6 , and therefore functionally identical components are given the same reference numbers.
[0063] The fourth embodiment also has an activation of the locking ratchets 10 and the cross arm 3 of the roll bar by means of a Bowden cable 18 ; thus, it is ultimately a variant of the third embodiment per FIG. 6 . In contrast with this third embodiment, the embodiment of FIG. 7 has no lifting springs, i.e., when the roof is opened the roll bar is not automatically raised, but instead it is pulled up by the pull cable 18 b of the Bowden cable 18 , which is coupled to the roof displacement mechanism, either directly mechanically or indirectly electrically by means of an electric drive such as a winch.
[0064] In the ground position ( FIG. 7A ), the roll bar is not held by a separate device, but rather it is merely “set down” and rests by its own weight against the bottom piece 4 c of the housing. Centering pieces 4 d per the first embodiment ( FIG. 2 ), not shown in FIG. 7 , center the leg tubes of the bar in the ground state.
[0065] The sheath 18 a of the Bowden cable is secured to the guide block 5 , which is fixed to the car body. The pull cable 18 b is connected at the pulling end to a T-shaped holding piece 22 and by its other end it is coupled in suitable manner to the roof displacement mechanism. The T-shaped holding piece 22 is configured similar to the T-shaped nut 9 of FIG. 5 with two control stops molded on it and staggered apart by 90 degrees. The method of operation is also similar.
[0066] The locking ratchets 10 basically assume the closed position and are only briefly opened for the unlocking.
[0067] The embodiment shown in FIG. 7 works as follows:
[0068] FIG. 7A shows the roll bar 1 lowered, the lower control stroke has been traveled in the cross arm 3 and the lower control stop of the holding piece 22 has come to bear against the lower edge of the cross arm.
[0069] When the roof is opened, the pull cable 18 b of the Bowden cable is forcibly pulled inward in the direction of the arrow. In this way, it pulls the cross arm 3 upward by its lower control stop via the holding piece 22 and thus raises the roll bar 1 . FIG. 7B shows the raised roll bar just before the highest raised position, i.e., the locking ratchets 10 are just about to engage with the locking bolts 12 , which is then attained after a further brief lifting of the cross arm (Fig. C).
[0070] To reset the roll bar before closing the roof, the pull cable 18 b of the Bowden cable is pulled downward, guided by the roof displacement mechanism. At first, only the T-shaped holding piece is pushed down by the control or switching stroke of around 3-5 mm, until the upper control stop of the holding piece engages with the shoulders 10 a of the locking ratchets 10 and opens them (FIG. 7 D). The pull cable 18 b of the Bowden cable can then push the cross arm 3 with the bar tube 2 downward, and the roll bar assisted by its own weight then retracts into its ground position per FIG. 7A .
[0071] The traveling of the control or switching stroke with the control stops of the T-shaped holding piece 22 occurs in detail in the same manner as described by means of FIG. 5 .
[0072] The foregoing has described a novel kind of roll-bar system with a roll bar which is automatically transported into the active or resting position depending on the opening or closing process of the convertible or sports car roof.
[0073] The roll bar has no sensor-controlled crash activation. After opening the roof, the roll bar is automatically lifted into its active position and locked there. Before closing the roof, the roll bar is automatically released and retracted into its resting position. The adjusting of the roll bar is done by a control system coupled to the control system of the roof or by a direct mechanical coupling to the roof drive. Different embodiments have been described, which can be summarized as follows:
[0000] 1. Lifting and resetting by means of electric motor and spindle, electrically controlled by the roof controls, with two variants in respect of the locking.
[0000] 2. Lifting by means of lifting springs and resetting as well as control by means of Bowden cable, directly coupled to the roof displacement mechanism.
[0000] 3. Lifting and control by means of Bowden cable, likewise coupled directly to the resetting/roof displacement mechanism.
[0074] The drawings show roll-bar systems with a U-shaped roll bar. In theory, it is also conceivable to have a roll bar in the shape of a box profile, instead of the former. Other locking designs are also conceivable.
LEGEND
[0000]
1 roll bar
2 U-shaped bar tube
3 cross arm
4 housing
4 a,b U-shaped side pieces
4 c bottom piece
4 d centering pieces
5 guide block
5 a inner thread
5 b upper bearing of the threaded spindle
6 threaded spindle
7 electric motor
8 transmission
9 nut
9 a external thread
10 locking ratchets
10 a shoulders
11 torsion springs
12 locking bolts
13 upper control stop
14 lower control stop
15 center stop
16 stopping bolt
17 raising springs
18 Bowden cable
18 a sheath
18 b pull cable
19 holding fork
20 spring guide bolt
21 insert
22 holding piece | The invention relates to a roll-bar system for vehicles comprising a roof, which can be retracted and raised in a motor-driven manner by means of a roof-displacement mechanism. Said system consists of a roll-bar body that is associated with each seat and does not comprise a sensor-controlled crash drive. The body can be forcibly displaced autonomously, in conjunction with the roof-displacement mechanism, between a first rigid position, when the roof is closed, and a second raised, rigid position, when the roof is open. The aim of the invention is to raise said rigid roll-bar system into the respective rigid positions in a kinematically simple, forcibly guided manner. To achieve this, the roll-bar body is mounted and guided in a cassette-type housing that is fixed to the vehicle and said body is associated with a drive, which is coupled to the roof-displacement mechanism and used to displace said body vertically in the housing and with a position-dependent forcibly guided locking device, which is used to lock said body in the raised position. | 1 |
FIELD OF THE INVENTION
This invention relates to a steerable drill bit arrangement, in particular for the use in drilling boreholes for oil and gas extraction.
DESCRIPTION OF THE PRIOR ART
To extract oil and gas from underground reserves, it is necessary to drill a borehole into the reserve. Traditionally, the drilling rig would be located above the reserve (or the location of a suspected reserve) and the borehole drilled vertically (or substantially vertically) into the reserve. The reference to substantially vertically covers the typical situation in which the drill bit deviates from a linear path because of discontinuities in the earth or rock through which the borehole is being drilled.
Later, steerable drilling systems were developed which allowed the determination of a path for the drill bit to follow which was non-linear, i.e. it became possible to drill to a chosen depth and then to steer the drill bit along a curve until the drill was travelling at a desired angle, and perhaps horizontally. Steerable drill bits therefore allow the recovery of oil and gas from reserves which were located underneath areas in which a drilling rig could not be located.
To facilitate drilling operations, a drilling fluid (called “mud”) is pumped into the borehole. The mud is pumped from the drilling rig through the hollow drill string, the drill string being made up of pipe sections connecting the drill bit to the drilling rig. The mud exits the drill string at the drill bit and serves to lubricate and cool the drill bit, as well as flushing away the drill cuttings. The mud and the entrained drill cuttings flow to the surface around the outside of the drill string, specifically within the annular region between the drill string and the borehole wall.
To allow the mud to return to the surface, the drill string is of smaller cross-sectional diameter than the borehole. In a 6 inch (approx. 15 cm) borehole, for example, the outer diameter of the bottom hole assembly will typically be 4.75 inches (approx. 12 cm), with the majority of the drill string comprising drill pipe sections of smaller diameter.
It is necessary to stabilise such a drill string, i.e. during drilling (when the drill string rotates) the gap between the drill string and the borehole wall allows the drill string to move transversely relative to the borehole, possibly causing directional errors in the borehole, damage to the drill string, and/or lack of uniformity in the cross-section of the borehole. To avoid this, stabilizers are included at spaced locations along the length of the drill string, the stabilizers having a diameter slightly less than the diameter of the borehole (e.g. a diameter of 5 31/32 inches (15.16 cm) for a 6 inch (15.24 cm) borehole, or 1/32 of an inch (0.08 cm) less than the diameter of the borehole). The stabilizers substantially prevent the unwanted transverse movement of the drill string. To allow the passage of mud the stabilizers necessarily include channels, which are usually helical.
Stabilizers such as those described above are available for example from Darron Oil Tools Limited, of Canklow Meadows, West Bawtry Road, Rotherham, S60 2XL, England (GB).
An early steering arrangement employed a downhole mud motor and a bent housing, in which only the drill bit would rotate (driven by the mud motor for which the motive force is the flow of the drilling fluid). Such arrangements have the disadvantage that the non-rotating drill string incurs greater frictional resistance to movement along the borehole, which limits the horizontal reach of the system.
Another early system utilised the effect of gravity upon the drill string to “steer” the drill bit towards and away from the vertical. However, this system had the major shortcoming of not allowing steering of the drill bit in the horizontal direction.
More recent systems employ a steering component having actuators which are controlled from the surface, and which act directly or indirectly upon the borehole wall to push the drill string transversely relative to the borehole. The drill bit is also be pushed transversely, and can therefore be forced to deviate from a linear path, in any direction, (i.e. upwards, downwards and sidewards).
In some of these systems the outer part of the steering component (i.e. that part which can engage the borehole wall) is arranged to rotate with the drill string, and in others the outer part of the steering component does not rotate with the drill string.
A steering component with a non-rotating outer part is described in EP-A-1 024 245 and its equivalent U.S. Pat. No. 6,290,003. This system has a pipe through which mud can flow towards the drill bit, and a sleeve surrounding the pipe. The sleeve carries actuators which act upon the pipe within the sleeve to decentralise the drill string.
Such systems are generally known as “push the bit” systems, since the steering component pushes the drill bit sideways relative to the borehole.
A disadvantage of the “push the bit” systems is that the drill bit is designed to work most efficiently when it is urged longitudinally against the earth or rock, and “push the bit” systems force the drill bit to move transversely, so that a transverse cutting action is required in addition to the longitudinal cutting action. The result is that the borehole wall becomes roughened and/or striated, which can affect the drilling operation by impairing the passage of the stabilizers, and can also detrimentally affect the operation of downhole measuring tools which are required to contact the borehole wall.
To overcome this disadvantage, systems known as “point the bit” have been developed, in which a stabilizer is added between the steering component and the drill bit, the stabilizer acting as a fulcrum and reducing or eliminating the transverse force component acting upon the drill bit, so ensuring that the drill bit would always be cutting longitudinally. Thus, in “point the bit” systems, the axis of the drill bit is substantially aligned with the axis of the borehole whether a steering force is being applied or not.
“Point the bit” steering arrangements have been used successfully in many drilling operations. However, as with other steering arrangements they have the disadvantage that the degree of curvature they are able to provide is dependent to large extent upon the structure of the rock through which the borehole is being drilled. Thus, in softer rock there is a significant tendency for the hole to be made oversize, in particular by the undesirable cutting action of the stabilizers, and an oversize borehole will affect the steering force which can be applied at the bit.
Also, if the borehole is required to pass from softer rock into harder rock with the border between the two rock types being at a shallow angle to the longitudinal axis of the drill bit, the drill bit will tend to deviate from the desired curvature as it moves more easily in the softer rock and tends to move along the border rather than through it. It is rare for a borehole to be drilled through rock of consistent hardness, so that the variable conditions present a significant disadvantage to users of the known steering arrangements and reduce the drilling accuracy (both in terms of direction and size of the borehole) which can be obtained from such systems.
SUMMARY OF THE INVENTION
The present inventors have realised that in “point the bit” arrangements the positions of the steering component and stabilizer in relation to the drill bit has a significant effect upon the drilling performance in each type of rock encountered, and that different relative positions can be used in different types of rock to achieve a greater accuracy in the direction and size of the borehole.
It is therefore the object of the present invention to reduce or avoid the above-stated disadvantage with the known drill steering systems, and in particular the known “point the bit” steering systems.
According to the invention, therefore, there is provided a steerable drill bit arrangement comprising a drill bit, a steering component and a stabilizer, the steering component comprising means to drive the drill bit along a non-linear path, the stabilizer being located between the drill bit and the steering component and providing a fulcrum for steering forces provided by the steering component, characterised in that the position of the fulcrum provided by the stabilizer is adjustable relative to the drill bit and the steering component.
Adjustment of the position of the fulcrum relative to the drill bit and the steering component alters the mechanical advantage and therefore the performance of the steering arrangement. Specifically, the present inventors have realised that if the fulcrum is closer to the steering component and further from the drill bit the deviation rate or curvature of the borehole is large but the lateral force upon the drill bit is small, whereas if the stabilizer is closer to the drill bit and further from the steering component the deviation rate is small but the lateral force upon the drill bit is large, and the drill bit can for example be forced to deviate from softer rock into harder rock.
The stabilizer preferably comprises a pipe through which drilling mud can flow towards the drill bit and a number of blades which can engage the surface of a borehole being drilled. Preferably, the blades are located at one end of the stabilizer and the orientation of the stabilizer can be reversed to alter the position of the blades relative to the drill bit and the steering component. Since it is the blades which engage the borehole which act as the fulcrum for the drill string, reversing such a stabilizer will alter the relative position of the fulcrum. The steerable drill bit arrangement allows the stabilizer to be located between the drill bit and the steering component in either of two orientations, the relative position of the fulcrum being determined upon assembly of the bottom hole assembly at the surface.
Alternatively, the position of the fulcrum can be adjusted remotely, for example downhole, perhaps by allowing the blades of the stabilizer to move relative to the pipe. Such movement can be longitudinal, i.e. the blades comprising the fulcrum can be arranged to slide along the pipe (towards/away from the drill bit and away from/towards the steering component respectively) between one of two (or more) positions of use. Alternatively, such movement can be radial, i.e. the stabilizer can have two (or more) sets of blades which are selectively retracted or expanded so that only a chosen set of blades, at a chosen position relative to the drill bit and steering component, engage the surface of the borehole.
Preferably, the leading and trailing edges of the blades of the stabilizer are tapered or curved to match the maximum design curvature of the borehole. Thus, the corners present at the leading and trailing edges of the blades are removed, avoiding the tendency of these corners to cut into the borehole, inadvertently increasing the diameter of the borehole. It has been discovered that such shaping of the blades is required in the present arrangement since the deviation rate of the borehole is far greater than with prior arrangements, increasing the likelihood that the leading and trailing edges of the blades would otherwise cut into the surface of the borehole.
With the present arrangement it is therefore possible to set the position of the stabilizer (or more properly the fulcrum point provided by the stabilizer) to suit the rock type being drilled and the deviation rate required. The rock type being drilled can readily be determined by examination of the drill cuttings or from conventional downhole analysis.
In test drilling through a block of concrete, a deviation rate of up to 300 per hundred feet has been achieved with the present arrangement, which is at least three times greater than could normally be achieved with prior art systems.
There is also provided a stabilizer for use in a steerable drill bit arrangement, the stabilizer having a first end part comprising a pipe through which drilling mud can flow towards the drill bit and a second end part having a number of blades which can engage the surface of a borehole being drilled, the stabilizer having a first end connector adapted for connection to a drill bit and a second end connector adapted for connection to the steering component, the first end connector and the second end connector being similarly-formed so that alternatively the first end connector can be connected to the steering component and the second end connector connected to the drill bit. Providing similarly-formed connectors at both ends of the stabilizer allow the stabilizer to be reversible, and this provides an easy and effective way to adjust the position of the fulcrum provided by the stabilizer when used between a steering component and a drill bit.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows a schematic representation of the arrangement according to the invention, in a first orientation;
FIG. 2 shows a representation as FIG. 1 , in a second orientation;
FIG. 3 shows a side view of a stabilizer used in the arrangement;
FIG. 4 shows a side view of the stabilizer body prior to machining of the blades;
FIG. 5 shows a side view of an alternative stabilizer for use in the arrangment;
FIG. 6 shows a side view of another alternative stabilizer; and
FIG. 7 shows an alternative steerable drill bit arrangment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The steerable drill bit arrangement 10 according to the invention comprises a drill bit 12 , a stabilizer 14 and a steering component 16 . The drill bit 12 can be of any known design suited to drilling through the rock type to be encountered.
The steering component 16 comprises a pipe 20 and a sleeve 22 , and serves to decentralise the pipe 20 within the sleeve (and therefore also the borehole (not shown)), so that the drill bit 12 is forced to deviate from a linear path. For example, if the steering component 16 is used to force the pipe 20 downwardly in the orientation shown, then the drill bit 12 will be forced upwardly, the stabilizer 14 acting as the fulcrum.
In known fashion, the pipe 20 , the stabilizer 14 , and the other pipe sections which make up the drill string, are hollow so as to allow the passage of mud from the surface to the drill bit 12 . Also, the steering component 16 and the stabilizer 14 include channels 24 which permit the passage of mud (and entrained drill cuttings) from the drill bit 12 back to the surface.
In preferred embodiments the steering component 16 is constructed as described in U.S. Pat. No. 6,290,003, which document is incorporated by reference herein, and which steering component will not be described further.
As in all “point the bit” drilling arrangements, the stabilizer 14 is located between the drill bit 12 and the steering component 16 , and so acts as a fulcrum for the drill string, causing the drill bit 12 to be urged to deviate from a linear path when the steering component 16 moves the pipe 20 relative to the sleeve 22 .
In this embodiment, the stabilizer 14 comprises a pipe section 26 , only one end of which carries blades 30 . As with other stabilizers, the maximum diameter of the blades 30 is designed to be slightly smaller than the diameter of the borehole drilled by the drill bit 12 . Both ends 32 and 34 of the stabilizer 14 are correspondingly formed (this feature being shown in the embodiment of FIG. 5 in which both ends 132 and 134 have a tapered female threaded opening 56 as commonly used in drill strings) so as to connect to both of the drill bit 12 and to the steering component 16 , so that the stabilizer 14 can be fitted into the drill string in one of two orientations. In the first orientation shown in FIG. 1 the blades are close to the drill bit 12 , whilst in the second orientation shown in FIG. 2 they are further from the drill bit 12 (and correspondingly closer to the steering component 16 ).
The operation of the steerable drill bit arrangement according to the invention can be represented by a simple geometrical model. Using FIGS. 1 and 2 , the force applied by the steering component 16 acts at its approximate centre-line B, the fulcrum is provided at the approximate centre-line of the stabilizer 14 at plane F, and the resultant force on the drill bit 20 acts approximately at plane A. The distance between planes A and F in the orientation of FIG. 1 is x 1 , and the distance between planes B and F is y 1 .
The mechanical advantage (M) of such an arrangement is given by:
M=y 1 /x 1 ,
so that the transverse force applied to the drill bit 12 is y 1 /x 1 times the transverse force applied by the steering component 16 .
Also, the ratio of the resultant transverse deflection at the drill bit (ΔA) to the applied transverse deflection at the steering component (ΔB) is:
Δ A/ΔB=x 1 /y 1
In the orientation of FIG. 2 , on the other hand, the distance between planes A and F is x 2 and the distance between planes B and F is y 2 .
The mechanical advantage (M) of the arrangement in this orientation is given by:
M=y 2 /x 2 ,
so that the transverse force applied to the drill bit is y 2 /x 2 times the transverse force applied by the steering component, and the ratio of the resultant transverse deflection at the drill bit (□A) to the applied transverse deflection at the steering component (□B) is:
□ A/□B=x 2 /Y 2
It will be understood that the greater the (steering) force which can be applied at the drill bit 12 the smaller will be the resulting deflection at the drill bit, and therefore the smaller the deviation rate or curvature of the drilled borehole.
In the orientation of FIG. 1 therefore, the mechanical advantage, and the transverse force which can be applied to the drill bit, is large. This orientation is therefore suitable for ensuring that the drill bit most closely follows the desired path through rock types of varying hardness, the arrangement being particularly suitable for driving the drill bit through an angled interface from softer rock into harder rock. In the orientation of FIG. 2 on the other hand the mechanical advantage is lower but the applied deflection is greater so that the deviation rate or curvature of the borehole is also larger.
In one practical embodiment the dimension x 1 is approximately 12 inches (30.5 cm), the dimension y 1 is approximately 36 inches (91.4 cm), the dimension x 2 is approximately 20 inches (50.8 cm), the dimension y 2 is approximately 28 inches (71.1 cm), giving two possible mechanical advantages for such an embodiment of approximately 3 and 1.4.
It has been determined that arrangements in which the mechanical advantage can be altered from around 1 to around 4 will enable the arrangement to satisfy the requirements of borehole accuracy and deviation rate for most rock types, but clearly mechanical advantages outside this range could be used if this is determined to be appropriate for particular applications.
Also, it is expected that the arrangement requires only two different mechanical advantages, i.e. two different relative positions for the fulcrum, and an arrangement such as that of FIGS. 1 and 2 provides only two possible adjustment positions. However, more than two adjustment positions can be provided by the use of spacers such as the spacer 54 in FIG. 7 which is located between the drill bit 12 and the stabilizer 314 , but which may alternatively or additionally be located between the stabilizer 314 and the steering component 16 , i.e. the spacer 54 is movable between these two positions, or a spacer may be used in both of these positions.
In the above-described arrangements, the distance between the drill bit 12 and the steering component 16 remains the same and this reduces the complexity of the calculations of mechanical advantage which are undertaken. However, if spacers are used the addition or removal of a spacer from the drill string can vary that distance and affect the resulting mechanical advantage.
In the embodiment shown in FIGS. 1 and 2 the blades 30 are fixed upon the pipe section 26 , and so adjustment of the mechanical advantage can only be undertaken at the surface. This will be acceptable in many applications where the rock type being drilled is not too variable.
In the alternative embodiments shown in FIGS. 5 and 6 it is arranged that the stabilizer 114 and 214 can be adjusted downhole. In the embodiment of FIG. 5 the blades 130 are carried by a sleeve 50 which can be driven along the pipe section 126 , the sleeve 50 having two (or in other embodiments more than two) designated positions in which it can be secured relative to the pipe section during drilling operations. The alternative embodiment of FIG. 6 utilises two (or in other embodiments more than two) sets of blades 230 a , 230 b which can be moved radially between an extended position (shown for the blades 230 a ) in which they can engage the borehole and a retracted condition shown for the blades 230 b ) in which they cannot engage the borehole, the stabilizer 214 being controlled remotely by a controller 52 to cause a selected one of the sets of blades 230 a,b to engage the borehole at a given time.
The form of the preferred embodiment of the blades of the stabilizer 14 are shown in FIG. 3 . Thus, whilst for simplicity the blades 30 (and channels 24 ) in FIGS. 1 and 2 are shown to be linear, in most practical embodiments the blades (and therefore also the channels therebetween) will be helical in common with most conventional stabilizers. Importantly, in the present arrangement the leading and trailing ends of the blades are tapered rather then ending at a 90° corner. The taper is relatively shallow, and designed to match the maximum curvature of the borehole (e.g. 30° per hundred feet), and so is not visible in this figure. In practice, this will result in the removal of material to a depth of up to around ten thousandths of an inch (around one quarter of a millimeter), but the removal of even this small amount of material will avoid the tendency of the corners of the leading and trailing edges of the blades to cut into the borehole and inadvertently increase the diameter of the borehole.
FIG. 4 shows a side view of the stabilizer body prior to machining of the blades 30 , for the purpose of showing the taper applied to the blades (though it will be understood that in some cases the blades are machined before the taper). Ideally, the edge of the blades 30 should be curved with a radius of curvature corresponding to the maximum curvature of the drilled hole, such curvature reducing the likelihood that the leading or trailing edges 36 will cut into the borehole. In practice, however, it is easier to taper the edges of the blades, and it has been found that a central non-tapered section 40 , a first tapered section 42 to either side thereof, and a second tapered section 44 at the ends of the blades 30 provides sufficient curvature. As with FIG. 3 , the tapering applied to a practical stabilizer such as that of FIG. 4 is too shallow to be visible in the drawing, but the stabilizer 314 in FIG. 7 has significantly exaggerated tapered end sections for the purpose of showing the angle α of the taper of the sections 144 , and the smaller angle β of the taper of the sections 142 .
The length of the sections 40 , 42 and 44 along the longitudinal axis A-A of the stabilizer 14 can be varied, as can the relative angles between neighbouring sections, to suit the particular application and degree of curvature required. Typically, the smaller the borehole diameter the greater the curvature desired, so that the relative angles between the neighbouring sections would typically be greater in a smaller diameter stabilizer.
In one stabilizer 14 , the diameter of the central section 40 is nominally 5.974 inches (15.174 cm), the diameter at the junction between the sections 42 and 44 is nominally 5.946 inches (15.103 cm), and the diameter at the leading and trailing edges 36 is nominally 5.912 inches (15.016 cm).
It will be understood that the drilling of an oversize borehole has a direct effect upon the deviation rate which can be achieved at the drill bit 12 ; with an oversize borehole the predetermined deflection of the pipe 20 within the sleeve 22 of the steering component 16 will result in a smaller than expected deflection at the drill bit 12 both because the sleeve 22 must first be moved laterally to engage the oversize borehole, and also because the stabilizer 14 will move laterally before it begins to act as a fulcrum.
Tests conducted prior to filing the patent application have demonstrated that orientations such as that of FIG. 2 (having a lower mechanical advantage) are less likely to drill an oversize borehole in most of the rock types likely to be encountered. An oversize borehole arises not only because of the cutting effect of the stabilizer blades, but also because of unwanted vibrations induced into the drill bit and stabilizer during drilling.
The type of drill bit used, and the rock type being drilled, will also both affect the likelihood of drilling an oversize borehole. In a test drilling on concrete a 6⅛ inch (15.56 cm) hole was drilled with the arrangement in the orientation of FIG. 2 which was measured at only approximately 15 thousandths of an inch (0.038 cm) oversize.
Because of the accuracy of the sizing of the borehole which is achievable with use of the present invention, and in particular by matching the mechanical advantage of the steering arrangement to the rock type being drilled, certain other modifications to the bottom hole assembly can be made. For example, a tricone drill bit was used to which lug pads were added. Lug pads are known to be used to add stability to such drill bits, but generally it is understood that the addition of lug pads will reduce the deviation rate achievable. With the present invention, however, by matching the mechanical advantage of the steering arrangement to the rock type being drilled, the deviation rate was increased by the addition of lug pads (it is understood because of the improved accuracy of sizing of the borehole and the consequent effect that had upon the deviation rate at the drill bit).
When using a stabilizer adjacent to the drill bit as in the present invention, it is desired that the stabilizer does not cut into the surface of the borehole, since that would reduce its effectiveness as a fulcrum for steering the drill bit. The removal of material from the leading and trailing edges of the stabilizer blades, and the detailed profiling of the stabilizer blades, is designed to enable the stabilizer blades to provide bearing surfaces rather than cutting surfaces. Alternatively or additionally, the stabilizer can incorporate a rotatable sleeve so that the blades can rotate relative to the pipe and can remain (substantially) stationary relative to the surface of the borehole.
Also, it is desirable that the stabilizer acts to stabilise the drill bit against unwanted vibrations or other movements during drilling, and (particularly when in the orientation of FIG. 1 ) the stabilizer blades provide a means to dampen out bit oscillations and enable a variety of drill bit designs to be used. Furthermore, if the drill bit is cutting an undersized hole, and notwithstanding that the blades are profiled not to cut, the movement of the stabilizer along the undersized hole will act to ream (increase the diameter of) the borehole, and will ensure that the steering component acts within a more correctly dimensioned borehole.
It can be arranged that the stabilizer 14 provides a greater, lesser, or equal flow restriction to the mud and entrained drill cuttings than the steering component 24 . For example, the channels 24 in the stabilizer 14 can be of different or similar cross-sectional area to the channels 24 in the steering component 16 , as desired. It may for example be desirable to ensure that the stabilizer is the greatest restriction to the flow of mud and entrained drill cuttings as this will reduce the pressure drop across the steering component 16 and reduce the likelihood of damage to that component. | This invention relates to a steerable drill bit arrangement, in particular for the use in drilling boreholes for oil and gas extraction. According to the invention there is provided a steerable drill bit arrangement comprising a drill bit, a steering component and a stabilizer, the steering component being adapted to provide a steering force which in use can drive the drill bit along a non-linear path, the stabilizer being located between the drill bit and the steering component and in use providing a fulcrum for the steering force provided by the steering component, the position of the fulcrum provided by the stabilizer being adjustable relative to the drill bit and the steering component. In use, the position of the fulcrum can be adjusted to vary the maximum curvature of the borehole and to suit the rock type(s) being drilled. | 4 |
RELATED MATERIALS AND DEFINITIONS
This application is related to the following co-pending applications:
METHOD FOR EDITING AN OBJECT WHEREIN STEPS FOR CREATING THE OBJECT ARE PRESERVED, Ser. No. 08/954,851; filed Oct. 21, 1997;
COLOR AND SYMBOL CODED VISUAL CUES FOR RELATING SCREEN MENU TO EXECUTED PROCESS, Ser. No. 08/954,851; filed Oct. 21, 1997; and
POP-UP DEFINITIONS WITH HYPERLINKED TERMS WITHIN A NON-INTERNET PROGRAM, Ser. No. 08/954,850; filed Oct. 21, 1997.
BACKGROUND OF THE INVENTION
Portions of the disclosure of this patent document, in particular Appendix A, contain unpublished material which is subject to copyright protection. The copyright owner, International Business Machines Corporation, has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent files or records, but otherwise reserves all rights whatsoever.
FIELD OF INVENTION
The present invention relates generally to the field of Data mining. More specifically, the present invention is related to a GUI to assist user development of data mining objects.
The following definitions may be useful to the understanding of the terminology as cited throughout the background, specification and claims of the present invention. Terms not specifically defined may be reviewed in available technical dictionaries, such as the IBM Dictionary of Computing, New York: McGraw-Hill, 1994. The terms "SmartGuide", "Guide", "Intelligent Guide" or "GUI Guide" or their plurals are considered equivalent and may be interchanged without modifying the scope or interpretation of the supporting text. In addition, the terms "panel", "template" or "page" or their plurals are considered equivalent.
Adaptive connection: A numeric weight used to describe the strength of the connection between two processing units in a neural network. The connection is called adaptive because it is adjusted during training. Values typically are in the range from zero to one, or -0.5 to +0.5.
AFS: A distributed file system developed by IBM and Carnegie-Mellon University.
Aggregate: To summarize data in a field.
Application Program Interface (API): A functional interface supplied by the operating system or a separately orderable licensed program that allows an application program written in a high-level language to use specific data or functions of the operating system or the licensed program.
Architecture: The number of processing units in the input, output and hidden layers of a neural network. The number of units in the input and output layers is calculated from the mining data and input parameters. An intelligent data mining agent calculates the number of hidden layers and the number of processing units in those hidden layers.
Associations: The relationship of items in a transaction in such a way that items imply the presence of other items in the same transaction.
Attribute: Characteristics or properties that can be controlled, usually to obtain a required appearance. For example, the color of a line. In object-oriented programming, a data element defined within a class. Same as instance variable.
Back Propagation: A general purpose neural network model named for the method used to adjust its weights while learning data patterns. This model is used by the Neural Classification mining function.
Boundary Field: In the range data source used in the discretization using ranges processing function, the upper limit of an interval.
Bucket: A planning period. A bucket may be any group of time, such as a day, week, month, quarter, semi-annual period, year or number of years. Buckets may vary in size according to the function performing the planning.
Categorical Values: Discrete, non-numerical data represented by character strings, for example, colors or special brands.
Class: In object-oriented design or programming, a group of objects that share a common definition and that therefore share common properties, operations and behavior. Members of the group are called instances of the class. A collection of defined entities (users, groups and resources) with similar characteristics. Any category to which things are assigned or defined. The specification of an object, including its attributes and behaviors.
Classification: The assignment of objects in groups or categories based on their characteristics.
Cluster: A group of records that have similar characteristics.
Cluster Prototype: The attribute values that are typical of all records in a given cluster. Used to compare the input records to determine if a record should be assigned to the cluster represented by these values.
Clustering: To partition a database into groups of records that have similar characteristics. A cluster profile represents the typical values of the fields for records in their assigned cluster.
Confidence Factor: Indicates the strength or the reliability of the associations detected.
Continuous Field: A field in which, given any two unequal values, there exists a value that falls between the two.
Control: In SAA Advanced Common User Access architecture, a component of the user interface that allows a user to select choices or type information; for example, a check box, an entry field, a radio button.
DATABASE2 (DB2): An IBM relational database management system.
Database View: An alternative representation of data from one or more data tables. A view can include all or some of the columns contained in the data table or data tables on which it is defined.
Data Field: In a data table, the intersection from table description and table column where the corresponding data is entered.
Data Format: There are different kinds of data formats, for example, database tables, database views or flat-file tables.
Data Table: A data table, regardless of the data format it contains.
Data Type: There are different kinds of data types, for example, categorical, integer or discrete.
DBCS: A set of characters in which each character is represented by two bytes. See also Double-byte Character Set.
Discrete: Pertaining to data that consists of distinct elements, such as characters or to physical quantities having a finite number of distinctly recognizable values.
Discretization: The act of making mathematically discrete.
Distributed File System: A file system composed of files or directories that physically reside on more than one computer in a communication network.
Equality Compatible: Pertaining to different data types that can be operands for the=logical operator.
Euclidean Distance: The square root of the sum of the squared pairwise differences between two numeric vectors. The Euclidean distance is used to calculate the error between the calculated network output and the target output in Neural classification.
Field: A set of one or more related data items grouped for processing. In this document, with regard to database tables and views, field is synonymous to column.
File-selection Box: A box that enables the user to choose a file to work with by it selecting a file name from the ones listed or by typing a file name into the space provided.
File Specification (filespec): In the AIX operating system, the name and location of a file. A file specification consists of a drive specifier, path name and file name.
File System: In the AIX operating system, the collection of files and file management structures on a physical or logical mass storage device, such as a diskette or minidisk. See also Distributed File System, Virtual File System.
Flat-File Table: (1) A one-dimensional or two-dimensional array: a list or table of items. (2) A file that has no hierarchical structure residing in a simple file.
Formatted Information: An arrangement of information into discrete units and structures in a manner that facilitates its access and processing. Contrast with narrative information.
Fuzzy Logic: In artificial intelligence, a technique using approximate rules of inference in which truth values and quantifiers are defined as possibility distributions that carry linguistic labels.
Hidden Layers: A set of processing units in a neural network used to calculate its outputs. Hidden layer processing units take their inputs from the preceding hidden layer units, or from the input layer. Their outputs are passed to either a succeeding hidden layer or the network's output layer. The number of hidden layers and the number of processing units in each hidden layer is part of the network architecture.
Index: In SQL, pointers that are logically arranged by the values of a key. Indexes provide quick access and can enforce uniqueness on the rows in a table.
Input Data: Data that is entered into a data processing system or any of its parts for storage or processing. Data received or to be received by a functional unit or by any part of a functional unit. Data to be processed. Pertaining to Intelligent Miner, the meta-data of the database table, database view or flat-file table containing the data you specified to be mined.
Input Layer: A set of processing units in a neural network which present the numeric values derived from user data to the network. The number of fields and type of data in those fields is used to calculate the number of processing units in the input layer.
Instance: In object-oriented programming, a single, actual occurrence of a particular object. Any level of the object class hierarchy can have instances. An instance can be considered in terms of a copy of the object type frame that is filled with particular information.
Interval Boundaries: Values that represent the upper and lower limits of an interval.
Item Category: A categorization of an item. For example, a room in a hotel can have the following categories: Standard, Comfort, Superior, Luxury. The lowest category is called child item category. Each child item category can have several parent item categories. Each parent item category can have several grandparent item categories.
Item Set: A collection of items. For example, all items bought by one customer during one visit to a department store.
Key: In SQL, a column or an ordered collection of columns identified in the description of an index.
Kohonen Feature Map: A neural network model comprised of processing units arranged in an input layer and output layer. All processors in the input layer are connected to each processor in the output layer by an adaptive connection. The learning algorithm used involves competition between units for each input pattern and the declaration of a winning unit. Used in Neural clustering to partition data into similar record groups.
Large Item Sets: The total volume of items above the specified support factor returned by the association data-mining function.
Learning Algorithm: The set of well-defined rules used during the training process to adjust the connection weights of a neural network. The criteria and methods used to adjust the weights define the different learning algorithms.
Learning Parameters: The variables used by each neural network model to control the training of a neural network which is accomplished by modifying network weights.
Lift: Confidence factor divided by expected confidence.
Meta-data: In databases, data that describes data objects.
Mining: Synonym for analyzing, searching.
Mining Base: A repository where all the information about the input data, the mining run settings, and the corresponding results is stored.
Mining Run Setting: Contains the different parameters defined for a mining run.
Model: A specific type of neural network and its associated learning algorithm. Examples include: Kohonen Feature Map and back propagation.
Name Mapping: A table containing descriptive names or translations of other languages mapped to the numerals or the character strings of a data table.
Named Pipe: A named buffer that provides client-to-server, server-to-client, or full duplex communication between unrelated processes.
Neural Network: A plurality of connections between computer processing elements, wherein the organization and weights of the connections determine the output.
Neural Network Utility (NNU): A family of IBM application development products for creating neural network and fuzzy rule system applications.
Output Data: Data that a data processing system or any of its parts transfers outside of that system or part. Data being produced or to be produced by a device or a computer program. Data delivered or to be delivered from a functional unit or from any part of a functional unit. Pertaining to the Intelligent Miner, the meta data of the database table, database view, or flat-file table containing the data being produced or to be produced by a function.
Output Layer: A set of processing units in a neural network which contain the output calculated by the network. The number of outputs depends on the number of classification categories or maximum clusters value in Neural classification and Neural clustering, respectively.
Pass: The number of records in a training data source presented before the weights in a neural network are update, typically the number of records in the file.
Pipe: A named or unnamed buffer used to pass data between processes.
Predicting Values: The dependency and the variation of one field's value within a record on the other fields within the same record. A profile is then generated that can predict a value for the particular field in a new record of the same form, based on its other field values.
Processing Unit: A processing unit in a neural network is used to calculate an output value by summing all incoming values multiplied by their respective adaptive connection weights.
Quantile: One of a finite number of non-overlapping subranges or intervals, each of which is represented by an assigned value.
Radial Basis Function: In the data-mining functions, radial basis functions are used to predict values. They represent functions of the distance or the radius from a particular point. They are used to build up approximations to more complicated functions.
Record: A set of one or more related data items grouped for processing. In reference to a database table, record is synonymous to row.
Root: In the AIX operating system, the user name for the system user with the most authority.
Rule: A clause in the form head &ldarrow.body. It specifies that the head is true if the body is true.
Rule Body: Represents the premise, the specified input data for a mining function.
Rule Group: Covers all rules containing the same items in different variations.
Rule Head: Represents the derived items detected by the associations data-mining function.
SAA: The Common User Access architecture, the Common Programming Interface, and the Common Communications Support.
Schema: A logical grouping for database objects. When a database object is created, it is assigned to one schema, which is determined by the name of the object. For example, the following command creates table X in schema G: CREATE TABLE C.X
Self-organizing Feature Map: See Kohonen Feature Map.
Sensitivity Analysis Report: An output from the Neural Classification mining function that shows which input fields are relevant to the classification decision. Sequential Patterns: Intertransaction patterns such that the presence of one set of items is followed by another set of items in a database of transactions over a period of time.
Similar Time Sequences: Occurrences of similar sequences in a database of time sequences.
Structured Query Language (SQL): An established set of statements used to manage information stored in a database. By using these statements, users can add, delete or update information in a table, request information through a query, and display the results in a report.
Supervised Learning: A learning algorithm that requires input and resulting output pairs to be presented to the network during the training process. Back propagation, for example, uses supervised learning and makes adjustments during training so that the value computed by the neural network will approach the actual value as the network learns from the data presented. Supervised learning is used in the techniques provided for predicting classification, as well as for predicting values.
Support Factor: Indicates the occurrence of the detected association rules and sequential patterns based on the input data.
Swapping: A process that interchanges the contents of an area of real storage with the contents of an area in auxiliary storage.
Symbolic Name: In a programming language, a unique name used to represent an entity such as a field, file, data structure or label. In Intelligent Miner, you specify symbolic names, for example, for input data, name mappings or taxonomies.
Taxonomy: Represents a hierarchy or a lattice of associations between the item categories of an item. These associations are called taxonomy relations.
Taxonomy Relation: The hierarchical associations between the item categories you defined for an item. A taxonomy relation consists of a child item category and a parent item category.
Trained Network: A neural network containing connection weights that have been adjusted by a learning algorithm. A trained network can be considered a virtual processor; it transforms inputs to outputs.
Training: The process of developing a model which understands the input data. In neural networks, the model is created by reading the records of the input data and modifying the network weights until the network calculates the desired output data.
Translation Process: Converting the data provided in the database to scaled numeric values in the appropriate range for a mining kernel using neural networks. Different techniques are used depending on whether the data is numeric or symbolic. Also, converting neural network output back to the units used in the database.
Transaction: A set of items or events that are linked by a common key value, for example, the articles (items) bought by a customer (customer number) on a particular data (transaction identifier). In this example, the customer number represents the key value.
Transaction ID: The identifier for a transaction, for example, the date of a transaction.
Transaction Group: The identifier for a set of transactions. For example, a customer number represents a transaction group. It includes all purchases of a particular customer during the month of May.
Unsupervised Learning: A learning algorithm that requires only input data to be present in the data source during the training process. No target output is provided; instead, the desired output is discovered during the mining run. Kohonen Feature Map, for example, uses unsupervised learning.
Weight: The numeric value of an adaptive connection representing the strength of the connection between two processing units in a neural network.
Winner: The index of the cluster which has the minimum Euclidean distance from the input record. Used in the Kohonen Feature Map to determine which output units will have their weights adjusted.
1. Background
Data mining is defined as the recognition of previously unknown or unrecognized patterns within data. Prior art Data Mining techniques typically extract patterns found in large quantities of data (i.e., in the Giga-byte range). Data mining techniques may be used to analyze a company's quarterly results using its financial data as the subject data. Data mining algorithms are used, based on user defined profiles, to recognize patterns such as profit, efficiency and inventory. In addition, time sequence pattern recognition may provide useful information for forecasting future liabilities, personnel requirements and scheduling of product deliveries. Data mining techniques are used in the scientific community to analyze test or sensor data to determine patterns useful in developing medical applications, reliability standards or other machinery operational parameters, etc. To date, only a very limited number of data mining algorithms have been developed, the three most common ones being:
1. Associations--determining associations between selected fields.
2. Clustering--reviewing large amounts of data (Giga-byte range) and extracting large portions of data with similar characteristics. This algorithm may be repeating for multiple clusters.
3. Time Sequences--historical data determining a series of trends that always occur in a particular time sequence (e.g., every four weeks). This algorithm is used to predict future behavior.
At the present time, IBM has developed eight data mining algorithms, including the above three, plus support functions (Statistical processing). The specific mining algorithms, however, are not essential to the proper understanding of the GUI of the present invention. It is envisioned that any present and future mining algorithms can be used within the present invention.
2. Discussion of Prior Art
The Intelligent Miner version 1.0--GUI, by International Business Machines (generally available through IBM Branches) is the predecessor to the present invention. The GUI of this version is implemented as a single interface requiring the intelligent manipulation and selection of parameters directly by the user.
A data mining package "Clementine", by Integral Solutions, and generally available by contacting http:\\WWW.ISL.CO.UK\TOPCLEM.HTML provides for a data mining GUI using a graphical icon approach, but fails to provide guided assistance to the user to develop a data mining profile.
The overwhelming restriction on the implementation of data mining is the requirement of Ph.D.-level diagnostics (mathematics, statistics) to fully develop appropriate mining profiles. As the data mining industry expands, it becomes imperative to reduce the intelligence requirement to enable users less familiar with the mathematics and statistical aspects of mining to have access to valuable results created by data mining.
In the past, the enormous numbers of variables/input parameters needing intelligent management was overwhelming. The intelligence requirement was satisfied by the highly developed knowledge of the user and provided to the system through a single panel, specifying all possible parameters available for tweaking (Developers GUI). What is needed is a GUI guiding the less knowledgeable user through a series of simpler steps to develop the data mining profiles.
Whatever the precise merits, features and advantages of the above cited references, none of them achieves or fulfills the purposes of the present invention. Accordingly, it is an object of the present invention to provide for a plurality of steps which take the user through low-level decision making processes to define data mining objects. Each step presents a small number of possible choices with assistance, intelligently leading a user through the entering of parameters appropriate for the user's desired mining goals, while restricting access to choices not necessary to accomplish these goals.
It is another object of the present invention to provide an interface consistent with well known Windows® environment GUIs.
It is an additional object of the present invention to provide a sequence object which strings together various data mining objects to create a data mining profile.
It is an additional object of the present invention to provide a single interface displaying a summary of data mining object parameters.
These and other objects are achieved by the detailed description that follows.
SUMMARY OF THE INVENTION
The present invention improves on the prior art and eliminates many problems associated with the prior art including, but not limited to, those previously discussed above.
A GUI guide is a mechanism by which the large task of creating data mining objects is broken into smaller steps. The following list provides generic headings for a sequence of GUI panels used in developing data mining objects according to the present invention:
Introduction (Welcome) panel
Selection of technique and settings name panel
Selection of a data source (when appropriate)
Setting of general parameters particular to the selected technique (one or more panels)
Specifying fields for the output data (when appropriate)
Specifying the name for the output data (when appropriate)
Specifying the name of the result object(when appropriate)
Summary page (completed)
The GUI method of the present invention is used to reduce the large task of creating data mining objects into one of a structured series of smaller steps. The generic headings for the sequence of GUI panels used in developing data mining objects listed above are modified to intelligently lead a user through a series of low level decisions. Each succeeding panel is chosen by the data input during the previous panel. At completion, the user may review the series of GUI panels for selections and entries made to modify the resulting mining object.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a window showing a main window illustrating a directory listing of data mining objects and sub-objects.
FIG. 2 illustrates a welcome page for a data mining object development system.
FIGS. 3a and 3b, collectively, illustrate format and settings and technique selection templates for developing data and discretization mining objects, respectively.
FIG. 4 illustrates a data source template for developing a data mining object.
FIG. 5 illustrates a parameters, specifically computed fields, template for developing a data mining object.
FIG. 6 illustrates a naming settings template for developing a data mining object.
FIG. 7 illustrates a summary template for developing a data mining object.
FIG. 8 illustrates the settings notebook GUI of the present invention.
FIGS. 9a and 9b collectively illustrate the graphical interface for creating a sequence object.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is illustrated and described in a preferred embodiment, the device may be produced in many different configurations, forms and materials. There is depicted in the drawings, and will herein be described in detail, a preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and the associated functional specifications of the materials for its construction and is not intended to limit the invention to the embodiment illustrated. Those skilled in the art will envision many other possible variations within the scope of the present invention.
The main window of the present invention, illustrated in FIG. 1, is the window that appears when the Intelligent Miner V2.0 client is started and after the user has logged on to the server on which Intelligent Miner is running (see Appendix A-4.5 Miscellaneous: Preferences notebook for details on servers, userids, passwords, and stand-alone mode). FIG. 1 illustrates a main panel 10 which includes a tree breakout 11 of various data mining objects 20, 30 and 40. The tree styled display of objects is very common and is not unlike that found in the Windows®95 Explorer system. Each data mining object 20, 30 and 40 includes a folder 21, numeric indicator 22 of the number of sub-objects located therein and the name 20, etc., given to the particular object. Objects are typically directory or file names, but are not limited thereto. In the preferred embodiment, the data mining objects 20, 30 and 40 represent data mining objects used to develop a data mining profile.
A general overview of the main window is as follows:
A dynamic title bar 150 which is changed based on the name of the currently open mining base; it also reflects the name of the server on which the mining base resides.
A menu bar 160 which contains menu items providing access to a variety of Intelligent Miner functions.
A customizable toolbar 170 which provides access to commonly used Intelligent Miner functions.
A Mining Base container 12 which displays the structure of the objects 20, 30, 40 in the mining base. The Mining Base container includes the left side of the main window and label above the container, as shown in FIG. 1. An icon of a closed or open padlock 80 is placed above the container to indicate if the user is in read-only or read/write mode, respectively. In FIG. 1, the user is in the read/write mode. The label 100 above the container 12 reads as follows: Mining base: [untitled] when no mining base is opened, or when the mining base has not been saved and named. The label reads mining base: <mining base name>, where <mining base name> is the name of the mining base, when a mining base has been opened. For example, in the screen capture of FIG. 1, the mining base banking mining base is open. The container is comprised of entries which include a uniquely color-coded folder 21, a number in parentheses 22, denoting the number of mining base objects in that folder, and a text description 20, 30, 40 describing the type of mining base objects in that folder. The exception to this is the Mining, Processing and Statistics folders, where the number in parentheses denotes the total number of mining base objects contained in its child folders. The container, by default, does not have any of the Mining, Processing or Statistics folders expanded. Selection in the container is 1-based; by default, the Data folder is selected. Single selection is supported.
Any folder in the tree view can be selected, causing the objects in that folder (or child folders for the Mining, Processing and Statistics folders) to be displayed in the Contents container 70 and the label of the Contents container 110 to change to contents of folder: <folder description>, where <folder description> is the text description associated with the selected entry. The user cannot change the order of the entries, the text descriptions of the entries, or the color-coded folder graphics of the entries. The user cannot add or remove entries from the container.
Also, the Mining, Processing and Statistics folders in the Mining Base container contain child folders (not illustrated-see Appendix A, section 1.3)--one for each function type in each category. For instance, the Mining folder contains child folders Discover associations, Discover clusters, Discover sequential patterns, Discover similar time sequences, Predict Classifications and Predict Value.
A Contents container 70 displays the contents of the folder selected in the Mining Base container. The Contents container 70 refers to the top, right-side of the main window, including the label above the container, as in shown in FIG. 1. The label above the container reads as follows: Contents of folder: <folder description>, where <folder description> is the text description associated with the selected entry in the Mining Base container. The container itself is a customizable view (can be Large Icons, Small Icons, List or Details view) of the selected entry in the Mining Base container. When the selected entry in the Mining Base container is a folder other than the Mining, Processing or Statistics folders, the Contents container has the following characteristics:
The container contains one object for each mining base object in the selected Mining Base container folder.
Double clicking on an object causes its settings notebook to open (in the case where the object is a non-Result object) or the first visualizer in the (client-side) list of visualizer associated with the result type to open with the result loaded (in the case where the object is a Result object).
Selection in the container is 0-based; by default, no object is selected. Multiple selection is supported.
Any object in the view can be selected and actions appropriate for that object are reflected in the enabling and disabling of menu choices and toolbar buttons.
Context menus are provided for both the objects and the container itself. The context menu contains only those choices appropriate for the current selection.
When the selected entry in the Mining Base container is the Mining, Processing or Statistics folder, the Contents container has the following characteristics:
The container contains one folder for each child folder of the selected folder. Double clicking on a folder in the Contents container invokes the same behavior as selecting the folder in the Mining Base container, i.e. the folder is given selection emphasis in the Mining Base container and its contents are displayed in the Contents container. Selection in the container is 0-based; by default, no object is selected. Multiple selection is not supported.
The Workarea container 130 is a customizable view (can be Large Icons, Small Icons, List or Details view) of references to the objects that the user has dragged and dropped from the Contents container. The container contains one object for each mining base object reference that the user has placed here. Selection in the container is 0-based; by default, no object is selected. Multiple selection is supported. The workarea entries are saved at the client when the mining base is saved from the client. If, when the user re-opens the mining base from the same client entries that were in the workarea have been deleted, the user is informed via a message that entries have been deleted, which entries were deleted, and the workarea is populated with the entries that still exist in the mining base. If an object is dragged from the Contents container to the Workarea container, and a reference of the object already exists in the Workarea, the `no-drop` cursor is displayed indicating that the action is not permitted. Also, see the discussion relating to Edit|Paste and Edit|Paste Shadow. The graphics associated with this container are the same as those associated with the Contents container.
A dynamic information area 140 displays helpful information about the GUI based on the location of the mouse; it also displays one icon for each currently running setting and one for each setting that has completed running. The information area 140 of the main window is located at the bottom of and spans the width of the main window, and is strictly read-only. It contains text that provides assistance to the user. When a mining base is first opened, and the user is in read/write mode, and there are currently running or as-yet unconfirmed failed or successful mining runs associated with the mining base, one graphic for each of these types of mining runs is shown in the information area. The progress indicators are not shown for these types of mining runs until the user double clicks on a graphic in the information area.
A font and color scheme that reflects the client's system settings for font and colors.
The menu bar 160 is an area near the top of the main window, just below the title bar 150 and above the rest of the window, that contains routing choices that provide access to pull down menus. The menu item is changed to Paste Shadow when the Workarea has focus and there is a mining base object in the clipboard.
The title bar 150 of the main window is Intelligent Miner mining base: [untitled] on <IMServerName>, where <IMServerName> is the name of the Intelligent Miner server to which the client is currently connected. The user is presented with a window which lists existing mining bases from which the user can choose one to open. If changes have been made to the current mining base since it was last saved, the user is asked to confirm this action. The confirmation will allow the user to save the current mining base and open a new one, do not save the mining base and open a new one, or cancel the action entirely. (If there are settings object currently running at the server when the user selects this menu choice, the user is given the option of saving the current mining base and opening a new one, or canceling the action. The user is not given the option of not saving the mining base and opening a new one.) If no changes have been made to the current mining base since it was last saved, and there are no settings object currently running at the server, the current mining base is closed and a new, empty mining base is created.
In the preferred embodiment, the title bar 150 of the main window is Intelligent Miner mining base: <Mining Base Name> on <IMServerName>, where <Mining Base Name> is replaced by the name of the mining base and <IMServerName> is the name of the Intelligent Miner server to which the client is currently connected.
Selections in the Mining Base container are 1-based and do not support multiple selection; this means that one and only one item MUST be selected and the selected folder is indicated even when the Mining Base container does not have focus. See the screen captures in Appendix A which illustrate how selection is indicated in the Mining Base container when the Mining Base container has focus vs. when it does not: Also, note that, except when child folders are displayed in the Contents window, selection in the Contents and Workarea containers is 0-based, supports multiple selection, and is indicated only when the container has focus (in fact, there is no concept of selection when the container does not have focus). Finally, note that the Contents container contains a homogeneous set of objects, while the Workarea container may contain a heterogeneous set of objects.
When a heterogeneous group of objects is selected, the context menu is the intersection of the menu items that would appear if each item were to be selected individually. For example, if a Result and a Mining object were selected, the Selected menu would be Open, (Separator), Remove, Delete, Rename . . . . If more than one object is selected and the Run menu choice or toolbar button is selected, multiple asynchronous jobs are started for those objects that are runnable, i.e., non-Result objects, and multiple progress indicators are displayed.
If the selected item is a setting (i.e. not a Result or a sub-folder) and the item is opened using a menu choice or toolbar button, the tabbed settings notebook associated with that object is opened to the first page. If the selected mining base object is a Result object 60, and there is only one visualization tool installed on the client, the visualizer associated with the result type is opened and the selected Results object is loaded into the visualizer. If the selected mining base object is a Result object, and there is more than one visualization tool installed on the client, the menu choice reads Open with and leads to a cascaded menu listing the visualizers installed on the client from which the user can choose. Then, the result is opened and the selected Results object is loaded into the selected visualizer.
If the selected item is a sub-folder of Mining, Processing or Statistics, the Open choice opens the selected folder such that its contents are displayed in the Contents container 70 and the sub-folder 50 becomes selected in the Mining Base container.
The user may create any of the listed mining objects: Data 20, Discretization 30, Mining 40, Name Mapping, Processing, Sequence, Statistics, Taxonomy and Value Mapping (Result objects do not have a GUI guide, as they are created through the running of Mining or Statistics settings object.) For example, if the user selects create a new "data" object, the "Data" SmartGuide is opened; if the user selects create a new "discretization" object, the "Discretization" SmartGuide is opened, etc.
The specific contents of the selected menu are dynamic and depend primarily on the chosen container (Mining base, Contents, Workarea) in the main window which currently has focus, and secondarily on the currently selected object/folder in that container.
Opening a Smartguide initiates a sequence of intelligent GUI templates or panels to guide the user through a series of low level decisions until completion of the development of the selected data mining object. Each guide begins in essentially the same manner with a welcome window 200, FIG. 2. The generic window 200 includes a welcome message 210 and an outline of the development sequence for the particular type of object selected 220-250. Please note that different objects will navigate different paths through the series of GUI templates. FIGS. 2-8 will illustrate a sequence of templates to create a data object 20. Each of the remaining template paths are fully described in the attached Appendix A. What is essential to the present invention is the reduction in intelligence needed by the user to develop objects and further that the GUI templates are not static, but rather dynamic, based on a particular chosen decision while traversing the templates (e.g. parameter, technique, value, etc.)
FIG. 2 includes a graphic 251 comprising: a background color 280 the same as the background color of folder 21 and object icon 50; a larger, more detailed image 260 of the object's icon 50 and a superimposed image, in the preferred embodiment, a rough nugget 270. A complete description of the elements and schema of graphic 251 may be found in the co-pending application entitled, "COLOR AND SYMBOL CODED VISUAL CUE FOR RELATING SCREEN MENU TO EXECUTED PROCESS." In addition, hypertext-based help is available to the user as suggested by line 290. A user may select any highlighted term (underlined for emphasis) to receive instant pop-up definitions and help screens. This help function is persistent throughout the GUI templates. A complete description of the hypertext help functions may be found in the co-pending application entitled, "POP-UP DEFINITIONS WITH HYPERLINKED TERMS WITHIN A NON-INTERNET PROGRAM." The next button 299 is always enabled and leads the user into the next template in the sequence of panels that should be displayed based on earlier user inputs.
FIG. 3a illustrates a data GUI guide for selecting a particular data format and settings 300. The panel includes a listing of the available formats 320 (DB2 Table/View), 330 (Flat files). These are but examples of possible choices. Any existing or future file types may be selected. In addition, files of various formats may be imported from sources external to the user's system. Objects 340 and 350 represent previously designated data sub-objects. Element 360 notes a name of a selected settings sub-object.
To illustrate the variations in template path presentation to the user based on active decisions, FIG. 3b has been included. FIG. 3b illustrates the variation encountered by the user when trying to create a discretization object. By selection of the create discretization object, a different second panel 301 is displayed. In this case, a user is given the option of selecting a technique 311 for object creation. Elements 321 and 331, respectively suggest creation using a data source or through manual input.
FIG. 4 illustrates the third generic common GUI guide template. Please note that many additional panels, not specifically discussed herein, but fully described in the attached Appendix A, are selectively inserted between the generic common panels specifically illustrated in FIGS. 2-8. The specific additional panels are selected according to the inputs of the user while making selections to requested elements on previous panels. The third generic common template 400 requests the user to select a data source type 420 (DB2 table or view) or 430 (flat files). These are but two examples of data sources. Additional types, both local and imported, can be selected.
FIG. 5 illustrates the fourth generic common GUI guide template, parameters/fields 500. Each object requires a plurality of data parameters or specific designation of selected fields. In the illustrated panel, computed fields 510 are being designated by the user. In box 520, a computed field name is selected from available selections or is created. In box 530, a data type is selected from available selections or is created. In box 540, a computed field technique is selected from available selections or is created. In box 550, the logical or mathematical expression is selected from available selections or is created. Specific parameter/fields are chosen based on the type of mining object and the related previous GUI template inputs.
FIG. 6 illustrates the fifth generic common GUI guide template, Naming 600. This template enables created object naming 620 and comments 630. Element 640 allows previous versions of similar named sub-objects to be updated or overwritten.
FIG. 7 illustrates the sixth generic common GUI guide template, Summary 700. The Summary template concludes the development of a data mining object. Unique features of this panel are its persistence of color 740, icon 720 and graphic representation of the completion of the sub-object development process--diamond 730. The rough stone 270 of FIG. 2 has been transformed into a completed polished diamond 730. Further details of these elements may be found in the co-pending application entitled, "COLOR AND SYMBOL CODED VISUAL CUE FOR RELATING SCREEN MENU TO EXECUTED PROCESS." Element 740 reveals the completion of the development process. Element 750 enables backward sequencing to modify previous parameters. Element 760 reveals a summary of the previous template selections.
FIG. 8 illustrates a graphical tabular 801-804 settings notebook to allow the user to modify selections made during the development process. The example shown in FIG. 9 relates to a sequence object but illustrates the general structure of the graphical notebook. A user can quickly review at a summary of the GUI templates traversed during creation of the selected object. The illustrated tabs include: settings 801, parameters 802, additional parameters 803 and summary 804. Selections made during the original object development may be modified through the graphical tabular notebook. A full discussion of this feature may be found in the co-pending application entitled, "METHOD FOR EDITING AN OBJECT WHEREIN STEPS FOR CREATING THE OBJECT ARE PRESERVED."
Once the user has established a plurality of data mining sub-objects, the sub-objects must be ordered in a sequence to create a data mining object(profile). The present invention provides a method of graphical ordering (sequence) of created sub-objects. FIG. 9 illustrates the welcome panel for creating a sequence object. The creation of the sequence object preserves selected sequence strategies for data mining. In addition the sequence object enables future integration into additional sequences and enables quick modification (i.e. by reordering the sequence, selection of different sub-objects or providing additional parameters) to adapt to variances in strategies.
Sequences contain settings that run consecutively. Sequences can contain Processing settings, Mining settings, Sequence settings and Statistic settings. The present invention Smartguide leads the user through the steps of: selecting the settings in the sequence, specifying parameters for the sequence and specifying the name of the sequence. FIG. 9b illustrates the creation of a standard sequence panel (previously shown in settings notebook example as shown in FIG. 8). To create a sequence the user navigates the mining base tree view 805 to select the folder 806 containing the settings desired to be inserted into the sequence. Next the user drags, using conventional drag and drop technology, the settings icons 807 from the contents container 808 and drops them into the sequence container 809. The settings is inserted into the sequence at the point where it was dropped. These steps are then repeated until the desired sequence is completed. Upon completion, the created sequence object is named and saved.
The sequence of objects in the sequence represents order of execution only and does not imply data flow. The sequence container behaves similarly to the workarea container described in the 1.5 Mining base (see Appendix A.) For example, the rules describing the context menus for objects in the workarea container also apply to the objects in the sequence container. One exception to this, the rules describing the context menus for the workarea container itself also apply to the sequence container itself. Also, objects can be dragged and dropped from the contents container (of this window only, i.e. drag and drop from any other container in any other window is not supported) into the sequence container. The sequence container differs from the workarea container in the main window in that the location of the cursor when the item is dropped has meaning. Specifically: 1. When an object is dropped to the left of the first item in the sequence (or anywhere if the sequence is empty), the object is inserted at the beginning of the sequence and all other object (if any) are moved down position in the sequence; 2. When an object is dropped below all other object in the sequence, the object is inserted at the end of the sequence; 3. When an object is dropped between two other objects or to the far right of any row of objects other than the last row, the dropped object is inserted between the two object in the sequence and all objects to the right of the inserted object are moved down one position in the sequence; 4. When an object is dropped on top of another object in the sequence, the object is inserted after that object in the sequence and all objects to the right of the inserted object are moved down one position in the sequence.
The context menu of the objects in the sequence include a checkable menu choice (Exclude) which excludes the running of the object when the sequence itself is run. When an object is excluded from the sequence, the object's graphic changes to a black and white bitmap to reflect this fact. The object remains excluded until reversed by user action, i.e. by unchecking the menu choice. When the user drags one or more settings from the contents container to the sequence container, and it is possible to determine that at least one of the dragged settings already exists in the sequence, then the cursor should change to a "no drop" cursor. If it is not possible to determine this information, then when the user attempts to drop the dragged settings into the sequence container, the system will check to make sure that none of the settings already exist in the container; if so, it will present a message to the user and cancel the drop. This check is made at all levels of nesting for both the dragged settings and the sequence settings being modified. The message reads "It is not possible to include more than one instance of a settings in a sequence." This restriction applies to all levels of nested sequences.
The present invention has greatly simplified the task of creating data mining objects. Each object can be created by traversing an intelligent sequence of GUI template guides. Furthermore, each object can be edited though the graphical tabular notebook which replicates the look and order of the templates encountered during creation. Upon creating a plurality of objects, a GUI template enables the creation of a sequence object comprising an ordered set of created objects thus preserving the order. The sequence object further enables future modification.
The above data mining GUI and its individually described elements are implemented in various computing environments. For example, the present invention may be implemented on a conventional IBM PC or equivalent, multi-nodal system (e.g. LAN) or networking system. All programming, mining algorithms, GUIs, display panels and dialog box templates, metadata and data related thereto are stored in computer memory, static or dynamic, and may be retrieved by the user of the Intelligent Mining system in any of: conventional computer storage, display (i.e. CRT) and/or hardcopy (i.e. printed) formats. The programming of the present invention may be implemented by one of skill in the art of object-oriented and/or statistical programming. For each algorithm there are parameters specific thereto.
CONCLUSION
A system and method has been shown in the above embodiments for the effective implementation of a GUI guide for data mining. While various preferred embodiments have been shown and described, it will be understood that there is no intent to limit the invention by such disclosure, but rather, it is intended to cover all modifications and alternate constructions falling within the spirit and scope of the invention as defined in the appended claims. For example, the present invention should not be limited by a specific software/program, computing environment, specific computing hardware or GUI template configurations. | A GUI is used to reduce the large task of creating data mining objects into a structured series of smaller steps. Generic headings for a sequence of GUI panels used in developing data mining objects are: Introduction (Welcome) panel; Selection of technique and settings name panel; Selection of a data source (when appropriate); Setting of general parameters (one or more panels); Output/results created and named for executable objects particular to the technique selected (depends on object selected); Naming the settings object and Finish page (completed). Each GUI panel intelligently leads the user through a series of low-level decisions. Each succeeding panel is chosen by the data input during the present panel. At completion, the user may review the series of GUI panels and selections and entries made to modify the resulting mining object. Once created, the objects are graphically ordered to create a sequence object which is then named and saved, thus preserving the sequence for future use. | 8 |
This application claims the benefit of the Korean Application No. P2002-22549 filed on Apr. 24, 2002, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a vegetable compartment in a refrigerator for fresh storage of vegetable.
2. Background of the Related Art
The refrigerator is an appliance for fresh, and long time storage of food. The refrigerator is provided with food storage chambers therein, which is always kept at a low temperature by means of a refrigerating cycle for maintaining a fresh state of the food.
The food storage chambers are provided with different characteristics so that the user selects a storage method suitable for different kinds of food taking kinds, characteristics and storage periods of the food into account. Of the food storage chambers, typical ones are the freezing chamber, the refrigerating chamber, and the vegetable compartment.
Of the storage chambers, the vegetable compartment is provided with optimal temperature and humidity for fresh storage of vegetable having a storage period shorter than processed food, always. The vegetable compartment is an independent space partitioned with a partition in the refrigerating chamber which is in general at a low temperature. A related art vegetable compartment in the refrigerator will be described.
The related art vegetable compartment in the refrigerator is a separate space partitioned from other space of the refrigerating chamber by a partition plate, also serving as a shelf, on a lower side of the refrigerating chamber. The vegetable compartment is provided with a container, top of which is opened, for putting vegetable therein. Since the container is right below the partition plate, the partition plate actually serves as a cover of the container, for covering the opened top side of the container.
For using the vegetable compartment, the user is required to open a door to the refrigerator, pull out the container, and put vegetable into the container through an inlet to the container, i.e., a part not covered with the partition plate of the opened top part of the container. However, if the container is pulled out longer than a predetermined length from the vegetable compartment, a bottom plate of the vegetable compartment can not support the contained. Therefore, for preventing the container from falling off the vegetable compartment, it is required that the pulling out length of the container is limited. However, the limitation of the pulling out length of the container substantially reduces a size of the inlet to the vegetable compartment too, which disables storage of large sized vegetable storage.
In the meantime, if it is intended to store large sized vegetable by all means, the user is required to cut the vegetable into pieces, or remove the partition plate, put the vegetable into the container and place the partition plate again.
However, the cutting of vegetable deteriorates freshness of the vegetable and can not keep proper tastes of the vegetable.
In the case of removal of the partition plate, since the partition plate also serves as a shelf, it is required to remove all the food stored on the partition plate, remove the partition plate, put the vegetable into the container, and return the partition plate and the food to original positions, which is very cumbersome.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a vegetable compartment in a refrigerator that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a vegetable compartment in a refrigerator, in which an inlet structure of a container is improved for convenient putting of large sized vegetable into the container.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the vegetable compartment in a refrigerator includes a container, a guide member, and a partition member. The container has an opening in a top side for pushing in or pulling out of the refrigerator. The guide member is fitted to the container along a direction the container is pushed in or pulled out and has a sloped part adjacent to a door of the refrigerator, which is sloped such that the sloped part becomes the higher as it goes in a direction the container is pushed in. The partition member in the refrigerator for covering a top of the container has a first plate adjacent to the door for enlarging an opened area of the opening as the first plate moves up guided by the sloped part when the container is pulled out.
The guide member includes, for an example, at least one first rail fitted to a side surface of the container. The guide member includes, for an example, the sloped part, and a horizontal part extended from an end at a high side of the sloped part to a direction the container is pushed in.
The sloped part includes a moderate straight slope rising along a direction the container is pushed in, or a moderate curved slope rising along a direction the container is pushed in. The first rail is fitted to each of opposite side surfaces of the container.
The partition member includes, for an example, a second plate, a first plate, and a link member. The second plate provided to be pushed in or pulled out of the refrigerator, for covering a part of the opening of the container. The first plate connected to the second plate, such that the first plate can make relative motion with respect to the second plate, for enlarging the opened area of the opening when the container is pulled out. The link member extended a predetermined length from the first plate such that a part thereof is in contact with the first rail, for moving up or down the first plate when the container is pushed in or pulled out, respectively. The first plate and the second plate are coupled with a hinge, or connected with a connection member of a flexible material.
The partition member further includes, for an example, a second rail fitted to an underside of the first plate for making smooth sliding in a state a part of the container is in contact therewith when the container is pushed in or pulled out. In this instance, the container further includes, for an example, a second roller for making a contain movement smooth as the second roller is in contact with the second rail and slides thereon.
The partition member further includes, for an example, a stopper at an end of the second rail for preventing the second roller from failing off the second rail and limiting a maximum pulling out range of the container when the container is pulled out to the maximum.
The link member is, for an example, in contact with the guide member, and includes, for an example, a first roller for reducing friction between the guide member and the link member as the first roller rotates when the container is pushed in or pulled out.
The vegetable compartment in a refrigerator of the present invention further includes a supplementary contained under the container for pushing in or pulling out of the refrigerator.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention:
In the drawings:
FIG. 1 illustrates a section showing one preferred embodiment of the present invention, schematically;
FIG. 2 illustrates a plan view of a vegetable compartment in FIG. 1, schematically;
FIGS. 3 A˜ 3 C illustrate the steps of a process for pulling out the container from the vegetable compartment in FIG. 1, schematically; and
FIG. 4 illustrates a section showing an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. In describing the embodiments, same parts will be given same names and reference symbols, and repetitive description of which will be omitted.
Referring to FIG. 1, the vegetable compartment of the present invention is a separate space partitioned from a refrigerating chamber 12 with a partition member 300 provided to the refrigerating chamber 12 in a refrigerator 10 . The vegetable compartment 100 includes a container 200 , a guide member, and the partition member 300 .
An embodiment will be described in detail, in which the vegetable compartment is provided under the refrigerating chamber 12 , with reference to FIG. 1 . However, a position of the vegetable compartment 100 is not limited to under the refrigerating chamber 12 , but may be a separate space partitioned with the partition member 300 and the container 200 in a middle part of the refrigerating chamber 12 , if necessary. A detailed structure of the vegetable compartment is as follows.
Referring to FIG. 1, the container 200 is provided to be pushed in and pulled out of the refrigerator 10 . The container has an opening 210 in a top side for putting/taking out vegetable.
In the meantime, the refrigerator designed to have a small capacity of the vegetable compartment 100 is provided with, for an example, one container 200 , and the refrigerator designed to have a large capacity of the vegetable compartment 100 is provided with, for an example, a supplementary container 250 additionally as shown in FIG. 1 . Of course, the supplementary container 250 has an opening in a top side, and, for maintaining freshness of the vegetable stored in the supplementary container 250 , there is a cover 255 provided to the opening of the supplementary container 250 additionally for covering the opening of the supplementary container 250 . A number of the supplementary containers provided thus are not limited.
The container 200 or the supplementary container 250 may be one piece or two or more pieces.
FIG. 1 illustrates an embodiment in which a guide member is a rail. However, the guide member is not limited to the rail, and the rail provided as the guide member is called as a first rail for convenience of description.
The first rail 400 provided as the guide member is provided to side surfaces of the container 200 , for an example, inside or outside surfaces of the side surfaces of the container 200 along a direction the container 200 is pushed in or pulled out. One first rail may be provided to one of the side surfaces of the container 200 , or one pair of the first rails may be provided to the side surfaces of the container 200 .
The first rail provided thus includes a sloped part 410 and a horizontal part 420 . As shown in FIG. 1, the sloped part 410 is provided to a part adjacent to the door 15 of the refrigerator 10 in the side surfaces of the container 200 . The sloped part 410 is provided such that a horizontal height thereof becomes the higher as it goes the farther in a direction the container 200 is pushed in, in a direction of a rear wall 17 of the refrigerator 10 in a case of the embodiment shown in FIG. 1 .
Referring to FIG. 1, the sloped part 410 of the first rail 400 provided thus has a moderate straight slope rising in a direction the container 200 is pushed in. However, the sloped part 410 is not limited to this, but may have a moderate curved sloped part 410 in the direction the container 200 is pushed in, for example, as shown in FIG. 4 .
Referring to FIG. 1, the horizontal part 420 of the first rail 400 is extended a predetermined distance from one end of the sloped part 410 , in more detail, from one of ends of the sloped part 410 at a side a horizontal height is higher toward the direction the container 200 is pushed in.
Referring to FIG. 1, the partition member 300 , provided to be pushed in/pulled out of the refrigerating chamber 12 , partitions the vegetable compartment 100 from the refrigerating chamber 12 . For supporting the partition member 300 in a state the partition member 300 is inserted in the refrigerating chamber 12 , ledges (not shown) are projected from both sides of inside walls of the refrigerating chamber 12 in the refrigerator 10 along the direction the partition member 300 is inserted. Therefore, the partition member 300 is supported in a state both edges of the partition members 300 are placed on the ledges.
The partition member 300 serves, not only as a partition for separating the refrigerating chamber 12 from the vegetable compartment, but also as a shelf. That is, in a case of the embodiment shown in FIG. 1, since an upper space of the partition member 300 is the refrigerating chamber 12 , if food is placed on the partition member 300 , the partition member 300 serves as a shelf of the refrigerating chamber 12 .
Moreover, since the partition member 300 is on top of the container 200 , the partition member 300 covers the opening 210 of the container 200 , serving to form an inside space of the container 200 as an independent space.
The partition member 300 with the foregoing services includes a first plate 310 , a second plate 320 , and a link member 330 , of which details are as follows.
Referring to FIG. 1, the second plate 320 , provided to be pushed in or pulled out of the refrigerating chamber 12 , covers a part of the opening 210 of the container 200 , i.e., a region adjacent to the rear wall 17 of the refrigerator 10 . Since the second plate 320 serves as a shelf in a state inserted into the refrigerating chamber 12 fully, the second plate 320 has a flat top surface. It is preferable that the second plate 320 is fitted such that the second plate 320 does not move together with the container 200 when the container 200 is pulled out or pushed in.
The first plate 310 is connected to an end of the second plate 320 adjacent to the door 15 to the refrigerator 10 , such that the first plate 310 can make relative motion with respect to the second plate 320 . The first plate 310 and the second plate 320 are connected with a hinge 340 or a connecting member (not shown) of a flexible plastic. The connecting member includes a first end connected to the first plate 310 and a second end connected to the second plate 2 .
Referring to FIG. 2, one pair of the hinges 340 or the connection members (not shown) may be provided for connecting both sides of a width direction of the first plate 310 or the second plate 320 . However, the connection method is not limited to this, but one the hinge 340 or the connection member can be provided to connect a middle part of the width direction of the first plate and the second plate 320 . Moreover, a plurality of the hinges 340 or the connection members may be provided at regular or irregular intervals along a width direction of the first plate 310 and the second plate 320 .
Once the first plate 310 and the second plate 320 are connected with the hinge or the flexible connection member, the first plate 310 becomes rotatable with respect to the second plate 320 around the hinge or the connection member. As shown in FIG. 1, once the first plate 310 has the foregoing structure, the first plate 310 can enlarge an opened area of the opening 210 as an end of the first plate 310 adjacent to the door 15 moves up guided by the sloped part 410 when the container 200 is pulled out, and the first plate 310 can cover an opened area of the opening 210 fully as the end of the first plate 310 adjacent to the door 15 moves down guided by the sloped part 410 when the container 200 is pushed in.
In the meantime, when the container 200 is pushed in, or pulled out, the first plate 310 moves down or up as the first plate 310 rotates around the hinge. Therefore, no food is placed on the first plate 310 , and, consequently, different form the second plate 320 , the first plate 310 does not serve as a shelf.
Referring to FIG. 1, the link member 330 is extended from the first plate 310 for a predetermined length, for an example, such that an end thereof is in contact with the guide member, in the case of the first embodiment, the first rail 400 . When one first rail 400 is provided, one link member 330 is extended from the first plate 310 so as to contact with the first rail 400 . As shown in FIG. 2, when one pair of the first rails 400 are provided, one pair of the link members 330 are extended from the first plate 310 and in contact with the first rails 400 , respectively.
A part where the link member 330 and the first plate 310 are joined are rigid unable to make a relative motion. The link member 330 and the first plate 310 may be attached after the link member 330 and the first plate 310 are fabricated as individual pieces, or may be formed as one unit.
If the link member 330 is extended from the first plate as above, the link member 330 and the first plate 310 are always movable altogether. That is, since the link member 330 is always in contact with the first rail 400 as above, the link member 330 moves up or down guided by the sloped part 410 and the horizontal part 420 of the first rail 400 when the container 200 is pushed in, or pulled out, according to which the first plate 310 rigidly joined with the link member 330 moves up or down as the first plate 310 rotates around the hinge 340 . According to this, as shown in FIG. 1, when the container 200 is pulled toward the door side, the first plate 310 is lifted as the first plate 310 rotate upward, to enlarge an opening of the container 200 , i.e., an opened area of the opening 210 actually. When the container 200 is pushed toward the rear wall 17 of the refrigerator 10 , the link member 330 is moved down guided by the sloped part 410 , and the first plate 310 is restored to an original position.
Meanwhile, the link member 330 may be provided with a roller for reducing friction with the guide member and making smooth relative motion between two members. For convenience of description, the roller provided to the link member 330 is called as a first roller 335 .
The first roller 335 is provided to a contact part with the guide member, for an example, a contact part with the first rail 400 in the case of the embodiment shown in FIG. 1 . In the case of FIG. 1, the first roller 335 is provided to an end of the link member 330 . The first roller 335 provided thus keeps contact with the guide member, the first rail 400 in the case of the embodiment in FIG. 1, and rotates when the container is pulled out or pushed in, to reduce friction between the first rail 400 and the link member 330 .
In the meantime, the vegetable compartment of the present invention is provided with a structure for making the pushing in and pulling out of the container 200 smooth. To do this, the partition member 300 includes a rail, and the container 200 includes a roller, further. For convenience of description, the rail provided to the partition member 300 is called as a second rail 325 , and a rail provided to the container 200 is called as a second roller 220 .
Referring to FIG. 1, the second rail 325 is fitted to an underside of the partition member 300 , in more detail, underside of the second plate 320 . The second rail 325 is fitted in the direction the container 200 is pushed in or pulled out, for guiding relative motion of the partition member 300 and the second plate 320 by designing a part of the container 200 , for an example, the second roller 220 , to slide smoothly in a state the second roller 220 is in contact with the second rail 325 when the container 200 is pushed in or pulled out.
The second roller 220 is provided to one side of the container 200 , for an example, to a top side of the container 200 as shown in FIG. 1 . The roller 220 is provided to, for an example, the top side of an end of the container 200 adjacent to the rear wall 17 of the refrigerator 10 , for smooth guidance of the relative motion of the container 200 and the partition member 300 as the second roller 220 is in contact with, and slides on the second rail 325 .
The vegetable compartment 100 , having the structure for making smooth relative motion of the partition member 300 and the container 200 by means of the roller and the rail, further includes means for limiting a pulling out range of the container 200 while preventing falling off of the container 200 . For this, the partition member 300 further includes a stopper 327 .
Referring to FIG. 1, the stopper 327 is provided to an end of the second rail 325 adjacent to the door 15 , for limiting a maximum pulling out range of the container 200 while preventing the second roller 220 from falling off the second rail 325 when the container 200 pulled out to the maximum.
The principle of enlargement/reduction of the opened area of the inlet to the container 200 , i.e., the opening 210 in using the vegetable compartment 100 will be described with reference to FIGS. 3 A˜ 3 B.
FIG. 3A illustrates a configuration of the partition member 300 and the container 200 when the container 200 is pushed in the vegetable compartment fully. In the case of FIG. 3A, the second plate 320 covers an area of the opening 210 in the container 200 in a state the second plate 320 is supported on the ledges on the inside wall of the refrigerating chamber 12 . The first roller 335 of the link member 330 is in contact with a lower part of the sloped part 410 , when the first plate 310 and the second plate 320 connected with the hinge 340 are leveled when seen from a side.
Under this state, if pulling out of the container 200 is started after the door 15 of the refrigerator 10 is opened, as shown in FIG. 3B, the link member 330 moves up guided by the sloped part 410 , and, according to this, the first plate 310 rotates upward around the hinge 340 . When the first plate 310 rotates upward around the hinge 340 , the end of the first plate 310 adjacent to the door 15 is lifted, to enlarge the opened area of the inlet to the container 200 , i.e., the opening 210 , actually.
Then, as shown in FIG. 3C, when the container 200 is pulled out further, the link member 330 comes from the sloped part 410 to the horizontal part 420 . After the link member 330 comes to the horizontal part 420 thus, only the container 200 is pulled out in a state the first plate 310 is left stationary.
When the container 200 is pulled out thus, since the first plate 310 moves up with a slope, to enlarge the opened area of the inlet of the container 200 , i.e., the opening 210 , even large sized vegetable can be put into the container 200 through the inlet of the container 200 .
After the vegetable is stored in the container 200 , the container 200 is pushed in toward the rear wall 17 of the refrigerator 10 . When the container 200 is pushed in, the link member 330 is guided by the horizontal part 420 of the first rail 400 , when the first plate 310 does not rotate. As the container 200 is pushed in further, the link member 330 comes from the horizontal part 420 to the sloped part 410 , when the first plate 310 rotates to move downward. As shown in FIG. 3A, once the container 200 is pushed in fully, the first plate 310 is on the same plane with the second plate 320 , and the opening 210 of the container 200 is covered by the first plate 310 and the second plate 320 , fully.
The vegetable compartment 100 of the present invention enlarges the opened area of the opening 210 of the container 200 as the first plate 310 rotates upward around the hinge 340 when the container 200 is pulled out. The second plate 320 serves both as a shelf of the refrigerating chamber 12 and the cover on the opening 210 of the container 200 .
In the present invention, a size of an area serving as the shelf for placing food thereon, and a size of the enlargeable opened area of the container 200 are fixed by adjusting sizes of the second plate 320 and the first plate 310 when a size of the partition member 300 is the same.
In the meantime, when the size of the first plate 310 is the same, the enlargeable opened area of the container 200 is fixed depending on an upward maximum rotation angle of the first plate 310 . In this instance, the length of the link member 330 extended from the first plate 310 , and an angle between the link member 330 and the first plate 310 , a joint point of the link member 330 and the first plate 310 , and a position and a sloped angle of the sloped part 410 are taken into account in the design.
Since the vegetable compartment in a refrigerator of the present invention enlarges the opened area of the container as a part of the partition member rotates upward in pulling out the container, the vegetable can be put into the container conveniently, even large sized vegetable can be put in.
It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention.
For an example, the guide means for guiding the link member is not limited to the rail.
As one example, if a system is designed such that a rail like long projection is formed on an inside or outside surface of the container, and the link member is made to contact with a top of the projection, the system will serve as the guide means, adequately.
As another example, if a system is designed such that a long groove is formed in the inside or outside surface of the container, and a part of the link member, such as the first roller is placed thereon, so that the link member moves with respect to the container in a state the first roller is placed in the groove, the system will serve as the guide means, adequately.
Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | A refrigerator compartment having a drawer-type container includes an opening in a top side thereof, and a first rail at a side surface thereof having sloped and horizontal parts. A partition member on the container has a first plate, a second plate, and a link member. The second plate covers an area of the opening of the container, and the first plate is connected to the second plate such that the first plate can pivot relative to the second plate. The link member extends from the first plate and contacts the first rail, for lifting the first plate as the link member moves up the sloped part of the first rail when the container is pulled out. The accessible area of the opening of the container is enlarged as the first plate moves up when the container is pulled out. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority of U.S. provisional application No. 61/215,887 filed May 11, 2009.
STATEMENT OF GOVERNMENT SUPPORT OF INVENTION
The work leading to the present application was done as part of DOE Grant Number: DE-FG02-07ER84714.
BACKGROUND OF THE INVENTION
This invention relates to the use of certain nanoscale particles as a sorbent to remove mercury from flue gas. Under the EPA's Clean Air Mercury Rule, coal fired power plants are required to drastically reduce the amount of mercury (Hg) emissions within the next several years. One of the technologies under consideration for removal of Hg is the use of chemically treated (brominated) activated carbon. It has been noted that utility companies may need to take into account the impact of a recent court decision, which specifies that a power plant cannot implement a mercury control solution that could potentially increase the amount of a secondary pollutant, unless additional controls for that pollutant are installed. This could be an issue in the case of brominated activated carbon, as bromine emissions can have adverse environmental effects. Compared to chlorine, bromine is considered to be more potent in depleting the atmospheric ozone layer. There are additional corrosion issues related to the presence of bromine in the system. Further, a majority of these activated carbons are not concrete-friendly, i.e. the fly ash containing the activated carbon particles cannot be used in concrete. This leads to loss of revenue to the power plants on two counts: (i) loss of revenue due to lack of usability of fly ash; and (ii) cost of disposing unusable fly ash in landfills. Additionally, the use of fly ash has an important consequence for the environment: if all of the fly ash produced can be used as replacement for cement, it can reduce CO 2 emissions equivalent to that generated by 25% of the world's automotives.
Coal fired power plants constitute ˜52% of the total electricity produced in the United States. As the demand for electricity increases, utility companies are increasing the generating capacity as well. Additionally, many of the current nuclear plants will be “retired” in the first quarter of the 21 st century. Due to poor public support for nuclear energy, these nuclear plants are likely to be replaced by coal fired plants. At the current consumption rate, it is estimated that the world has ˜1500 years of coal reserves. This leads to the recent steady increase in the amount of coal consumed in the world and in the US. This implies that the mercury emission issue associated with coal-fired power plants needs to be resolved in the long run.
An estimated total of 48 tons of mercury is emitted every year in the US from coal-fired power plants, which is ⅓ rd of the total mercury emissions per year in the US. On a worldwide scale, this is a much larger issue, since countries such as China and India are using increasing amounts of energy derived from fossil fuels. Under the Clear Skies Initiative, the target is to reduce mercury emission by about 45% by 2010, and about 70% by 2018. New technologies will need to be developed to reach these targets. According to DoE, the market penetration for mercury emission reduction technologies is an estimated 320,000 megawatts. In order to achieve the target reduction by 2018, the additional annual cost for energy generation will be $2 billion to $6 billion per year, if the existing activated carbon (current estimate is $18,000-$131,000 per pound of mercury removal, using activated carbon technology.
A major issue is the usability of fly ash containing mercury adsorbed activated carbon (it cannot be used if the mercury content is high), which further increases the cost of using activated carbon technology for mercury removal. Fly ash is a valuable by-product from coal-fired power plants. In making concrete, cement is mixed with water to act as an adhesive to hold strong aggregates. Fly ash is added during the process, as it is observed that concrete containing fly ash is easier to work with, and it uses 10% less water. Additionally, fly ash reacts with lime that is given off by cement hydration, creating more bonding agent to hold the concrete together, which makes concrete stronger with time, compared to concrete without fly ash. Further, it reduces the amount of cement required to make concrete. While a ton of cement costs $80-$100, fly ash costs only $32/ton making it more competitive than cement. Manufacturing one ton of cement requires 6.5 million BTUs of energy, and it is estimated that cement plants produce 7% of the total CO 2 emission by human sources. If all the fly ash produced can be used to partly replace cement in concrete, it can eliminate CO 2 emissions equivalent to that of 25% of the automotives in the world. Clearly, there are environmental and societal benefits that are derived from lower mercury and CO 2 emissions. Also, the use of fly ash will save landfill space. However, even the presence of less than 1% of activated carbon in fly ash can make it useless for mixing with concrete, by changing its properties.
Therefore, it is imperative that any sorbent used for removing mercury from flue gas be concrete-friendly. Conventional activated carbon is not concrete-friendly, and most brominated activated carbons are not concrete-friendly either. Recently, it has been reported that some brominated activated carbon may be concrete friendly, but the negative environmental effects of bromine are yet to be studied and not known at the moment. Additionally, bromine is a highly corrosive gas, and as such the impact on the exhaust ducts could be a problem.
Currently, various types of activated carbons are being extensively studied for mercury removal from flue gas. DOE/NETL has carried out several field tests of activated carbons due to their high removal efficiency. Three prominent brands of activated carbons which have been tested in the field are NORIT Americas (Darco® Hg-LH), Alstom Power Plant Laboratories (Mer-Clean™), and Sorbent Technologies Corporation (B-PAC™). Results indicated that activated carbon consistently performed well in mercury removal, on a full-scale test. However, secondary pollution (bromine), corrosion from bromine and concrete friendliness is still an issue, affecting their overall performance.
Another media which is used to remove mercury from flue gas is based on “clay”, and is manufactured by Amended Silicates. However, when the performance of this media was compared with various types of activated carbon sorbents the amended silicate media did not perform as well as activated carbon. Others used a fluidized bed of zeolite and activated carbon for the removal of organics and metals form gas streams. Zeolites are aluminosilicate materials that are extensively used as adsorbents for gas separation and purification, and they are also used as ion-exchange media for water treatment and purification. Zeolites have “open” crystal structures, constructed from tetrahedra (TO 4 , where T=Si, Al). It has been observed that the removal efficiency of metals present in gases by activated carbon is higher than that of zeolite, and the temperature only slightly influences the removal efficiency. A study tested treated Zeolite and observed 63% mercury removal efficiency.
U.S. Pat. No. 6,610,263 is directed to the use of high surface area MnO x to remove Hg. It is claimed that it has the capability to remove 99% of elemental Hg and 94% of the total mercury content in flue gas. However, the cost is likely to be a concern for using this media in practical applications.
Biswas et-al [T. M. Owens and P. Biswas, J. Air & Waste Manage. Assoc., n46, 1996, p 530] have developed a gas-phase sorbent precursor method, where a high surface area agglomerated sorbent oxide particle is produced in situ in the combustor. These sorbents are stable at elevated temperatures and provide a surface of metallic vapors (for condensation) and reaction. They used titanium isopropoxide as precursor, which decomposed at elevated temperature and formed particles of titania. Hg vapors were found to condense on these particles in the presence of UV radiation which helps in the oxidation of mercury vapors and formation of a strong bond between mercury and titania. They [P. Biswas and M. Zachariah, “In situ immobilization of lead species in combustion environments by injection of gas phase silica sorbent precursors”, Env. Sci. & Tech., v31, n9, 1997, p 2455] also used silica precursors for the removal of lead from flue gas, and were able to get 80-90% lead removal efficiency. The removal efficiency was found to be a function of the gas temperature. Additionally, the efficiency was observed to decrease with increase in temperature.
Another group has shown the feasibility of using a fluidized bed for the removal of metals, such as lead, from flue gas. They used limestone, bentonite, and alumina as sorbents, and observed that the effectiveness of the fluidized bed depends on sorbent species, sorbent particle size, amount of sorbent used, metal to sorbent ratio, metal concentration in the waste, air velocity, and temperature. Smaller particles showed better efficiency compared to larger particles (particle range 400-700 μm). In case of limestone, it increased from 60% to 70% when the particle size was decreased from 700 to 500 μm, all other conditions remaining same. The sorbents showed better efficiency at lower temperatures (˜750° C. vs. ˜900° C.). This is because at higher temperatures, the vapor pressure is high, so more metal escapes as vapor.
Still others have used zeolite materials for the removal of mercury by duct injection. They were able to get between 45 and 92% metal removal depending upon the amount of sorbent injected and the type of sorbent. In the case of zeolites, there was no effect of temperature on the removal efficiency.
Gullet et-al [B. Gullet and K. Raghunathan, “Reduction of coal based metal emissions by furnace sorbent injection”, Energy & Fuels, v8, 1994, p 1068] demonstrated the feasibility of using oxide minerals such as limestone, kaolinite, and bauxite as sorbents for toxic metal removal, by injecting them through the burner. They were able to get reduction in submicron size metal particles of antimony, arsenic, mercury, and selenium by hydrated lime and limestone.
SUMMARY OF THE INVENTION
The present invention is directed to sorbents for removing mercury from gas and their synthesis. The sorbent has a highly accessible surface, and selectivity towards mercury adsorption. These sorbents are halogen (bromine) free, making them environmentally safe as well as non-corrosive towards the power plant system. Certain of the non-activated carbon based sorbents, such as zeolites and oxides are concrete and environment friendly, however their mercury removal efficiency is significantly lower than activated carbon. The present invention overcomes the limitations of currently available carbon and non-carbon based sorbents by incorporation of a barrier layer on the surface of the particles.
The sorbent described in the present invention is based on carbon particles with a metal-oxide coating on the surface. The thin metal-oxide layer acts as a barrier for the adsorption of Air Entrainment Admixture (AEA, the component used to stabilize bubbles in cement), thereby enhancing its concrete friendliness. The metal-oxide is coated on the surface of carbon, using a solution-based method. The metal-oxide coated carbon was further modified with sulfur molecules, to increase their mercury removal capacity.
Two critical aspects that differentiate the newly developed carbon-based particles from other sorbent particles include: (i) suitable surface modification that leads to high affinity for mercury ions without having to use toxic elements such as bromine, and (ii) the ability to render the resulting fly ash usable in concrete and other applications, due to the low foam index. The overall mercury removal efficiency is comparable to that of the best performing commercial sorbent, which is a brominated compound.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, reference is made to the following drawings which are to be taken in conjunction with the detailed description to follow in which:
FIG. 1 depicts the mechanism to explain the effect of surface oxide layer on foam index: (A) the hydrophobic side of AEA molecule (small circle) is attracted towards carbon; (B) the hydrophobic side is repelled from silica coated carbon, due to the presence of negative charge on the surface of the carbon.
FIG. 2 is a TEM micrograph of coated carbon black
FIG. 3 is a TEM micrograph of the ash, after carbon burnout
FIG. 4 depicts the mercury removal efficiency of sorbents carbon black, the inventive sorbent C2 and Darco Hg-LH;
FIG. 5 depicts the foam index of C2 and Darco Hg-LH
FIG. 6 depicts the mercury removal efficiency of sorbent, the inventive sorbents AC-1, C1, C3, and Darco Hg-LH.
FIG. 7 depicts the foam index of C1, C3 and Darco Hg-LH
FIG. 8 depicts mercury removal efficiency of the inventive sorbent C5 and Darco Hg-LH.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Overview
A. The template material used as a sorbent is carbon black and activated carbon, as carbon-based materials are readily available. Other types of carbon particles that have a similarly open morphology can also be used. Additionally, other non-carbon materials, such as ceramic oxides, ceramic non-oxides, or clay-based particles can also be used as template for further surface modification.
B. The surface of the carbon particles was modified using a two-step process. During the first step, the surface was modified with aluminum hydroxide, to form a tie layer. This leads to the activation of the sorbent surface with aluminum hydroxide functional groups. An aqueous solution of sodium aluminate was used as the precursor for aluminum hydroxide deposition. Sodium aluminate was transformed to aluminum hydroxide, by treating it with an ion-exchange resin. The resin exchanges sodium ions to hydrogen ions. It should be noted that other inorganic compounds such as: titanium hydroxide, magnesium hydroxide, iron hydroxide, copper hydroxide can also be used as the tie layer prior to deposition of metal oxide layer.
C. The surface of carbon was further modified with a metal oxide, during the second step. In our work, we used silica because it is the least expensive among oxides and allows for easy surface modification. Other commonly known oxides, including aluminum oxide, titanium oxide, iron oxide and tin oxide can be used instead. Sodium silicate was used as silicon oxide source. An aqueous solution of sodium silicate was treated with ion-exchange resin to exchange sodium ions with hydrogen ions. The amount of silica on the surface of carbon is about 7-16% and preferably about 8-13% and more preferably about 10-12 wt %, of the total powder.
D. Silica coated carbon was further modified with sulfur molecules, to increase their mercury removal capacity. Addition of sulfur was achieved by mixing elemental sulfur with the silica coated carbon, and heating it under inert atmosphere. Other chemicals which can also be used for sulfur addition are mercaptosilane, mercapto acetic acid, and calcium polysulfide. The amount of sulfur is about 0.4-6% and preferably about 0.75-4% and more preferably about 2-3%.
E. The unique feature of the present sorbent is the presence of silica coating on the surface of carbon. It leads to enhancement in the mercury removal efficiency of the substrate, from the flue gas. This also leads to less adsorption of AEA on the surface of carbon, leading to a low foam index, and making it more concrete friendly. The AEA molecules are typically an aqueous mixture of anionic surfactants. In concrete, AEA molecules have their hydrophobic non-polar end group aligned toward the interior of the air bubble, while the polar end group is toward either water or the cement surface (which is also polar). This leads to the stabilization of air bubbles, hence preventing them from coalescing and leaving the system. However, when carbon is present in the system, the hydrophobic end of AEA is aligned toward the surface of carbon, due to the non-polar nature of the carbon surface. This leads to the adsorption of AEA on carbon. As a consequence, a lower amount of AEA is now available for the stabilization of air bubbles, leading to a smaller number of bubbles and a commensurate increase in the foam index, FIG. 1( a ). In the case of the present sorbent, the thin silica coating on the surface of the carbon particle leads to the formation of hydroxyl groups on the surface of the sorbents. This is shown in FIG. 1( b ). The typical pH of concrete mixture is in the basic range where O—H bond, of metal oxide layer, is broken and a proton (H + ) is removed from the hydroxyl group, leading to an overall negative charge. This negative charge repels the negatively charged AEA, and reduces its adsorption on the surface of the sorbent, leading to an overall reduction in the foam index.
EXAMPLE 1
Synthesis and Performance of Carbon-Black Based Sorbent
1.a. Surface Modification with Sodium Aluminate
A typical process for introducing aluminum hydroxide groups on the surface of carbon black is as follows: 60 g of carbon black was dispersed in 5400 mL of water, using a high shear mixer. 1.2 g of sodium aluminate was dissolved in 360 mL of water, in a separate container. The aqueous solution of sodium aluminate was passed through an ion-exchange resin (Dowex-HCR-W2), prior to the addition to carbon black slurry. The pH of the solution was maintained between 9.7 and 9.8, using an aqueous solution of sodium hydroxide and hydrochloric acid. The treated powder was filtered, and dried in an oven.
1.b. Surface Modification with Sodium Silicate
Aluminum hydroxide activated carbon black was further coated with silica. In a typical experiment 25 g of aluminum hydroxide activated carbon black was dispersed in 2250 mL of water using a high shear mixer. The temperature of the slurry was maintained between 75-80° C. In a separate container 18.70 g of 28% sodium silicate solution was mixed with 250 mL of water. The sodium silicate solution was treated with ion-exchange resin, and finally added to the carbon black slurry, at the rate of 4 mL/min. The pH of the solution was maintained around 4 using aqueous solutions of sodium hydroxide and hydrochloric acid. FIG. 2 shows a micrograph of carbon black after silica coating. FIG. 3 shows micrograph of silica ash obtained by burning silica coated carbon black in oxygen, which leaves silica residue. Note that the residue is in the form of silica shells (surface area: ˜600 m 2 /g). Thermo gravimetric analysis of silica coated carbon black showed that the silica content in the coated powder is 12-15%.
1.c Sulfur Modification of Silica Coated Carbon Black
To increase mercury removal efficiency of silica coated carbon, the powder was treated with elemental sulfur. In a typical example, silica coated carbon black powder was mixed with 5 wt % sulfur powder. 2 g of this powder was heated in a tube furnace at 400° C. for 6 hours in nitrogen atmosphere. The final amount of sulfur after heat treatment was 1.69%. This sample hereafter will be designated as C2. The specific area of the sorbent was 239 m 2 /g. The specific surface area of unmodified carbon black was 260 m 2 /g.
1.d Measurement of Mercury Removal Efficiency of C2
The sorbents were tested for total vapor-phase mercury removal in a baghouse scenario for plants burning Powder River Basin sub-bituminous coal (PRB). The sorbent injection rate was 0.5 lb/Macf. The beginning mercury concentration in flue gas was between 11-16 μg/Nm 3 . A commercial sorbent, Darco Hg-LH, with surface area ˜500 m 2 /g was also tested for comparison. FIG. 4 shows the specific mercury removal efficiency of carbon black, C2 and Darco Hg-LH, determined using per unit surface area of sorbent. The efficiency is calculated by dividing change in Hg concentration (Δμg/Nm 3 ) with surface area (m 2 ). The mercury removal efficiency of C2 is significantly higher than Darco Hg-LH, even though Darco Hg-LH has much higher surface area. This confirms that a higher internal accessible surface is needed for high mercury removal efficiency of the sorbent.
1.e Measurement of Foam Index of C2.
The concrete friendliness of the sorbents was evaluated by the foam index test. The fly ash used for foam index measurements was from the same plant where the sorbents were evaluated. The AEA used for the test was Darex-II, manufactured by Grace Construction. Initially, 1 wt % sorbent material was mixed with fly ash, to simulate the concentration observed in fly ash, when carbon based sorbents are used for Hg removal. Subsequently, 4 g of fly ash was mixed with 16 g of Portland cement (Type 1), which is used in concrete formulations. The mixture was then dispersed in 50 ml of water. 1 wt % solution of Darex-II in water was added to the slurry. The end point of addition of AEA was when stable foam was observed for 45 seconds. FIG. 5 shows the foam index of C2 and compares it with Darco Hg-LH. The foam index of C2 is lower than Darco Hg-LH, indicating that C2 is more concrete friendly than Darco Hg-LH.
EXAMPLE 2
Synthesis and Performance of Activated Carbon (AC-1) Based Sorbent
2.a Synthesis of Activated Carbon Based Sorbent
Activated carbon based sorbent was synthesized in a method similar to the method used to synthesize carbon black sorbent, as described before. In a typical experiment 30 g of activated carbon (surface area: 550 m 2 /g) was dispersed in 2700 mL of water using a high shear mixer. Subsequently, an aqueous solution of sodium aluminate (0.6 sodium silicate in 180 mL of water) was treated with ion-exchange resin, prior to its addition to activated carbon slurry. The pH of the slurry was maintained between 9.7-9.8, using aqueous solution of hydrochloric acid and sodium silicate. The treated powder was filtered, followed by drying. Aluminum hydroxide functionalized activated carbon powder was silica coated, using sodium silicate. In a typical experiment, 30 g of functionalized powder was dispersed in 2700 mL of water. Sodium silicate solution (20.28 g 28% sodium silicate solution in 262 mL of water), was treated with ion-exchange resin, prior to its addition to carbon slurry. The temperature of the solution was maintained between 75° C. and 80° C. The pH of the slurry was kept at 4, using aqueous solutions of sodium hydroxide and hydrochloric acid. The slurry was filtered and dried in oven. This powder is designated as C1. The surface area of this powder was 508 m 2 /g. C1 sorbent was further treated with sulfur to increase its mercury removal efficiency. In a typical experiment, C1 was mixed with 5 wt % of elemental sulfur powder. The mixture was heat treated at 400° C. in inert atmosphere. This sorbent is designated as C3. The sulfur content of C3 is 2.99%, and surface area is 479 m 2 /g.
2.b Performance of C1 and C3
C1 sorbent was tested for mercury removal efficiency, using the method described above. FIG. 6 shows the mercury removal efficiency of AC-1, C1 and C3, in conjunction with Darco Hg-LH. Once again, the mercury removal efficiency of C1 and C3 is higher than Darco Hg-LH, even though the surface areas are comparable. This is due to their more open structure of this carbon than Darco Hg-LH. FIG. 7 shows the foam index of C1 and C3, and compares it with Darco Hg-LH. The foam index of C1 is ⅓ rd that of Darco Hg-LH, indicating that it is significantly more concrete friendly than Darco Hg-LH.
EXAMPLE 3
Synthesis and Performance of Activated Carbon (AC-2) Based Sorbent Another activated carbon (AC-2) with different surface area (600 m 2 /g) and particle morphology was modified to increase its mercury removal efficiency. The sorbent was synthesized in a manner similar to the method described to synthesize C1. Silica coated sorbent synthesized using AC-2, is designated as C5. No sulfur modification was performed for this carbon. The silica content for the sorbent was around 20 wt %. The surface area of the modified AC-2 was 371.8 m 2 /g.
FIG. 8 shows the mercury removal efficiency of AC-2 and C5. The sorbent injection rate was 0.5 lb/Macf. The AC-2 increased significantly after surface modification.
The present invention clearly demonstrates that an open pore structure, with suitable surface modification can lead to significant improvement in the efficiency of the sorbent to remove mercury from flue gas.
As is well known, the formula parameters set forth herein are for example only, such parameters can be scaled and adjusted in accordance with the teaching of this invention. This invention has been described with respect to preferred embodiments. However, those skilled in the art will recognize, modifications and variations in the specific details which have been described and illustrated may be restored to, without departing from the sprit and scope of the invention as defined in the appended claims. | A new class of carbon-based sorbents for vapor-phase mercury removal is disclosed in this invention. The optimum structure of the sorbent particles, and a method to produce the sorbent, are described. The sorbent is based on carbon particles with a metal-oxide coating on the surface. The thin metal-oxide layer acts as a barrier for the adsorption of Air Entrainment Admixture (AEA), the component used to stabilize bubbles in cement), thereby enhancing its concrete friendliness. The metal-oxide is coated on the surface of carbon, using a solution-based method. The metal-oxide coated carbon was further modified with sulfur molecules, to increase its mercury removal capacity. | 8 |
This invention was made at least in part with funds from the Federal government under contract N00014-91-C-0084 awarded by the Department of the Navy. The Government therefore has certain rights in the invention.
This is a continuation of application Ser. No. 08/314,082, filed Sep. 28, 1994, now U.S. Pat. No. 5,669,916.
BACKGROUND OF THE INVENTION
This invention relates to removing hair from skin.
Currently used methods for hair removal include shaving, waxing, electrolysis, mechanical epilation, chemical depilation, the use of laser beams (see, e.g., U.S. Pat. Nos. 3,538,919 and 4,388,924), and the use of light-absorbing substances (see, e.g., U.S. Pat. No. 5,226,907). Some of these methods are painful, inefficient, or time consuming, and others do have not long-lasting effects.
SUMMARY OF THE INVENTION
I have discovered that mechanical epilation followed by topical applications causing inactivation of the hair follicle results in long-term inhibition of hair growth.
Accordingly, the invention features a method of removing a hair from the skin of a mammal, involving mechanically or chemically epilating to expose the hair follicle, then treating the follicle to inhibit its ability to regenerate a hair.
Epilation creates a channel which leads directly and deeply into the follicle and greatly increases the ability of the follicle to take up agents which can inactivate the hair growth-promoting properties of the follicle. Thus, the invention provides an efficient method for the removal of hair and for long-term inhibition of hair growth.
In preferred embodiments, epilation is performed using any method which removes the hair from its follicle, including cold waxing, warm waxing, and the use of mechanical devices to avulse the hair from its follicle.
Following epilation, the hair growth-promoting properties of the follicle are inactivated by any of a plurality of methods, including the use of photosensitizers followed by exposure to light, the use of mild toxins, and application of electric current. Generally, photoinactivation involves (1) application of a photosensitizer to the skin, (2) uptake of the photosensitizer by the follicle, and (3) activation of the photosensitizer so that it inactivates the hair growth-promoting properties of the follicle, resulting in inhibition of hair growth. Preferably, the photosensitizer is of low toxicity until it is activated by exposure to light of a specific wavelength. Preferably, the light is at a wavelength which is capable of reaching deep into the hair follicle; generally, a wavelength of 550-800 nm is suitable. Preferred photosensitizers include, but are not limited to, porphyrins, phthalocyanines, chlorins, and purpurins. Examples of suitable photosensitizers are aminolevulinic acid (ALA; activated at 630 nm), methlyene blue (activated at 660 nm), derivatives of nile blue-A, porphyrin derivatives such as benzoporphyrin derivative (BPD; activated at 690 nm), porfimer sodium (e.g., PHOTOFRIN™ porfimer sodium; activated at 630 nm), purpurins, chlorins, and phthalocyanines. The photosensitizer can act by either photochemical or photothermal mechanisms. Photothermal sensitizers include indocyanine green (activated at 690-800 nm) and other dyes.
Mild toxins can also be used to inactivate the hair follicle. In this embodiment, epilation of the hair prior to application of the toxin results in the targeting of the toxin to the follicle. The toxin is allowed to interact with the hair follicle for a period of time sufficient to inactivate the follicle without causing substantial damage (e.g., ulceration or scarring) to the surrounding skin; generally, 0.1-5 minutes is a sufficient length of time. Appropriate toxins include, but are not limited to, bleaches (e.g., hypochlorites and peroxides), antimetabolic drugs (e.g., 5-fluorouracil), solvents (e.g., acetone, alcohols, phenol, and ethers), iodine-releasing agents, detergents and surfactants, and aldehydes and other protein-crosslinking fixatives (e.g., gluteraldehyde, formaldehyde, and acetaldehyde).
In addition, more than one toxin can be used in the invention, with application of the toxins occurring sequentially or simultaneously (e.g., a surfactant, a solvent, and an antimetabolic drug can be combined or used in sequence). One skilled in the art of dermatology will, with the guidance provided herein, be able to determine the appropriate conditions required for uptake of the toxin.
The method of the invention can also employ iontophoretic techniques to target the follicle-inactivating compound to the hair follicle. In this embodiment, a solution which includes an ionic follicle-inactivating compound is applied to the skin following epilation, and an electric current is then applied to the skin. The electric current enhances the ability of the follicle-inactivating compound to penetrate the skin. Useful solutions include, but are not limited to, hypochlorite bleach, chloride salt solutions, ionic detergents, and ionic photosensitizers or their precursors (e.g., ALA and methylene blue). Appropriate methods and devices for applying electric current are known in the art (see, e.g., Instructions for use by Iomed Inc., Salt Lake City, Utah). Anesthetics (e.g., lidocaine) can also be iontophoresed in order to alleviate pain in this embodiment of the invention. A variety of other methods, including ultrasound or pressure waves, heating, surfactants, and simple capillary action, can also be used to target the follicle-inactivating compound to the follicle.
By "epilation" is meant removal of the hair from its follicle. Epilation can be accomplished by chemical or mechanical means, such as cold waxing, warm waxing, or grasping the hair and detaching it to expose the follicle.
By "hair follicle" is meant the downgrowth of the epidermis and the bulb-like expansion of tissue which houses and creates a hair. Components of the hair follicle include the external root sheath, the internal root sheath, the connective tissue papilla, the matrix, the pluripotential cells which are located approximately 1 mm below the skin surface, and sebaceous glands.
By "inactivation" of the hair follicle is meant inhibition of the follicle's ability to regenerate a hair and/or the sebaceous glands which are part of the hair follicle on the face, uppertrunk, and other body sites prone to acne. Inhibition of hair growth can be accomplished by destruction of one or more components of the follicle. The exact target to be destroyed can vary depending on the composition used to inactivate the hair follicle. Candidate components to be destroyed include, but are not limited to, the external root sheath, the internal root sheath, the connective tissue papilla, the matrix, the sebaceous glands, and the pluripotential cells which are located approximately 1 mm below the skin surface.
By "photosensitizer" is meant a compound which, in response to exposure to a particular fluence, is capable of inactivating a hair follicle, or a precursor of such a compound which is converted into a photosensitizer in living cells (e.g., ALA).
By "activation" of a photosensitizer or photosensitizer precursor is meant exposure of the photosensitizer or precursor to light in either a pulse or continuous mode, enabling the photosensitizer to inactivate a hair follicle.
Abbreviations used herein are
ALA: aminolevulinic acid
BPD: benzoporphyrin derivative
PPIX: protoporphyrin IX
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims.
DETAILED DESCRIPTION
The drawing will first be described.
Drawing
The Figure is a fluorescence image of PPIX in human skin following local epilation and application of 20% ALA.
SELECTIVE ABSORPTION BY EPILATED FOLLICLES
Epilation leads to selective uptake of follicle-inactivating compounds by the exposed follicles.
In the following procedure, epilation was accomplished by cold waxing a segment of skin of a human subject in order to remove the hair. Cold waxing is performed by application of a viscous, liquid wax or resin mixture (e.g., MYEPIL™ wax) which, when rapidly uplifted, avulses each hair from its follicle. As a control, other sites on the skin were shaved, but not epilated, and all sites on the skin were then treated as follows. A solution of 20% (wt./wt.) of the photosensitizer, ALA, was applied to the skin in an ethanol/water solution, and the treated skin was covered with plastic wrap for 2-4 hours. ALA is a precursor of protoporphyrin IX (PPIX), and it is converted into PPIX in living cells. Thus, the 2-4 hour time period is sufficient for uptake of ALA by the epilated follicle (which occurs within minutes) and conversion of ALA into PPIX. The absorption of ALA and its conversion to PPIX in the skin was followed by fluorescence imaging (420 nm excitation; 600+ nm emission). The intense fluorescence shown in the center of the Figure indicates that cells of the epilated follicles can convert ALA into PPIX. This image also indicates that epilation enables the photochemical to selectively penetrate the follicles of epilated follicles (located at the center of the Figure) as compared with non-epilated follicles. Thus, epilation facilitates targeting of the inactivating agent to the follicle.
Inhibition of Hair Growth
Following epilation or shaving (as a control), and application of ALA, the hair follicles were inactivated by exposing the skin to varying fluences from 0-300 J/cm 2 of 630 nm (argon-pumped dye laser) light. At 3 and 6 months after treatment, the number of regrowing hairs varied from 0% to about 50%. In contrast, 100% of the hairs on shaven, but not epilated, skin regrew. These data also indicate that the effectiveness of the method increased with increasing fluence.
OTHER EMBODIMENTS
Other embodiments are within the following claims. For example, a mechanical device, instead of waxing, can be used to remove the hair from the follicle. Chemical agents, e.g., chemical depilatory cremes which break disulfide bonds in the hair shaft, can be used as well.
Photosensitizers other than ALA can be used to inactivate the hair follicle; examples include porphyrins, phthalocyanines, chlorins, purpurins, and derivatives of rhodamine or nile blue. Indeed, I have found evidence of selective follicle destruction following topical application of methylene blue, enhancement of uptake by iontophoresis, and exposure to light at 660 nm. I also have detected follicle destruction following application of chloroaluminum sulforated phthalocyanine and exposure to light at 760 nm. Thus, the usefulness of this invention is not limited to ALA. Generally, a photosensitizer concentration of 0.1 to 20% is appropriate; more preferably, the concentration is about 0.5 to 5%; most preferably, the concentration is about 1%. Several examples of useful photosensitizers and the appropriate wavelength of light are provided herein; additional examples will be apparent to those of skill in the art of photochemistry.
Mild toxins such as bleaches, antimetabolic drugs, solvents, iodine-releasing agents, detergents, surfactants, and protein-crosslinking fixatives can be used at concentrations which inactivate the follicle without causing substantial damage (e.g., scarring and ulceration) to the surrounding skin. Generally, concentrations of 1 to 20% are suitable, with absorption by the follicle typically lasting 0.1 to 5 minutes.
A variety of dematologically acceptable excipients (e.g., alcoholic and aqueous solutions, oil-in-water or water-in-oil creams, emulsions, or ointments) can be used to carry the follicle-inactivating compound, and acceptable forms of the excipient include, without limitation, lotions, creams, and liquids. The vehicle used should carry the photosensitizer or toxin into the follicle, which is best achieved when a low surface tension exists between the vehicle and the skin to promote capillary action. The follicle-inactivating compositions can be delivered to the follicle by methods other than simple capillary action, such as those methods which employ ultrasound, heat, pressure waves, iontophoresis, or surfactants. The amount of time necessary for uptake of the follicle-inactivating composition will depend on factors such as the method of application, the properties of the follicle-inactivating compound, and the excipient which is used. Generally, the amount of time sufficient for uptake of the follicle-inactivating compound is 1 to 5 minutes.
Iontophoresis can also be used to facilitate uptake of the follicle-inactivating compound by the follicle. In skin, the stratum corneum acts as a barrier to electrical resistance. Following epilation, the empty follicles are the predominant pathway by which current flows from an external electrolyte solution into the skin. Therefore, iontophoresis can enhance the uptake of ionic follicle-inactivating compounds. In this embodiment, an electrode of the same polarity as the compound to be iontophoresed is applied to the skin following application of the follicle-inactivating compound. (see, instructions for use of iontophoresis by Iomed Inc., Salt Lake City, Utah). Examples of ionic follicle-inactivating compounds are ALA, methylene blue, hypochlorite bleach, chloride salt solutions, and ionic detergents.
Generally, photosensitizer precursors (e.g., ALA) are converted into the photosensitizer (e.g., PPIX) within 2-4 hours. The ability of the photosensitizer precursors to be absorbed by the follicle and converted into the photosensitizer by cells of the follicle can readily be assayed by fluorescence imaging as described above. For improved light coupling into the skin, a layer of mineral oil can be applied to the skin and covered by a lucite block or other transparent material which closely matches the skin's refractive index while activating the photosensitizer with light. The optimal conditions for hair removal and follicle inactivation can easily be determined by testing the method on a small segment of the skin and monitoring the skin for subsequent hair growth. | The invention features a method of removing a hair, involving mechanically or chemically removing the hair to expose the follicle of the hair, and then treating the follicle to inhibit its ability to regenerate a hair. Removing the hair facilitates the uptake of a follicle-inactivating compound and thus allows for long-term inhibition of hair growth. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to dynamic logic and, more particularly, to a system and method for reducing soft error rates in dynamic logic due to alpha-particle strikes.
BACKGROUND OF THE INVENTION
Dynamic logic gates are used in the conventional design of logic circuits which require high performance and modest size. Dynamic logic gates are much faster than static logic gates. Essentially, a dynamic logic gate is a circuit which requires a periodic electrical precharge, or refresh, such as with a dynamic random access memory (DRAM), in order to maintain and properly perform its intended logic function. Once the electrical precharge on the dynamic logic gate has been discharged, the dynamic logic gate can perform no other logic functions until subsequently precharged.
However, the use of conventional dynamic logic circuits in the construction of logic networks is problematic. Dynamic logic gates can be unreliable as a result of alpha-particle induced soft errors. Alpha-particle soft-errors occur when a semiconductor is exposed to extremely small quantities (on the order of, for example, parts per million) of uranium (U) or thorium (Th) contained in ceramic, glass, metals, or plastic filler semiconductor packaging materials.
Logic gates are formed via pn-junctions in semiconductors. When an alpha-particle strikes a pn-junction, as illustrated in FIG. 1, enhanced charge collection drastically distorts the junction field. The field, which is normally limited to the depletion region, extends radially into the bulk silicon along the length of the alpha-particle track, forming a "funnel". The alpha particles penetrate the oxide film, polysilicon layers, and aluminum conductive layer of a semiconductor device to reach the silicon semiconductor substrate, and collide against Si crystals to form electron-hole pairs. Some of the minority carriers (electrons, for n-channel devices having a p-type substrate) of the electron-hole pairs are stored in a depletion layer at the surface portion of the semiconductor substrate forming one electrode of the capacitor of the memory cell, and change a logic level "1" (minority carrier is absent) at the pn-junction to a logic level "0". At this time, the majority carriers (holes, for n-channel devices) flow to the substrate. Within less than a nanosecond, the field returns to its normal depletion-layer position, thereby invoking its label as a "soft" error.
Alpha-particle induced soft errors are becoming a serious problem in view of the recent tendency toward increasingly dense integrated logic circuits. The increase in the number of logic cells per unit area increases the probability that the logic circuit shall be struck by an alpha-particle, thereby increasing the alpha-particle induced soft error rate.
Proposed remedies to alpha particle induce soft errors include designing alpha particle immunity into circuits, reducing the amount of radioactive materials present in packaging materials, and the shielding of sensitive devices areas with coatings which absorb, but do not emit, alpha particles. One such solution is described in U.S. Pat. No. 4,604,639 to Kinoshita, whereby alpha-particle induced soft errors are reduced by forming the metal conductive layer overlaying the charge storage portion so as to have a width greater than the minimum width used in an integrated circuit at a portion thereof overlaying the substantial part of the charge storage portion. Another solution is described in U.S. Pat. No. 4,506,436 to Bakeman, Jr., et. al., whereby a buried layer, having a majority carrier concentration substantially equal to or greater than the concentration of free carriers generated by the radiation and being between one and four orders of magnitude greater concentration than that of the semiconductor substrate, is ion implanted within a few microns of the substrate surface after at least one major high temperature processing step in the manufacturing process has been completed. Previous evaluations have indicated that device shielding may provide up to a one-order magnitude reduction in failure rates.
Solutions to the alpha-particle induced soft error problem may be searched for in solutions to related causes of soft errors. One such related cause of soft error rates is known as storage decay. Storage decay occurs after a node within the dynamic logic gate has been precharged. Essentially, the node acts as a storage capacitance (C s ). As logic evaluations are performed in the dynamic logic gate, the precharge on the node may be "shared" with other nodes as a result of gate switching in the logic. The other nodes act as parasitic capacitances (C p ), depleting the precharge. As a result, the precharge may be substantially diminished and thereby cause the dynamic logic gate to convey erroneous results or otherwise malfunction.
One solution to the storage decay problem is to minimize parasitic capacitances by reducing the interstitial spacing between parallel transistor gates or by injecting charge at converging nodes. U.S. Pat. No. 5,317,204 to Yetter and Miller. This solution is not viable for the alpha-particle induced soft error problem, however, because it does not reduce or eliminate the probability of incurring alpha-particle strikes.
Another solution to the storage decay problem is described in "System and Method for Tolerating Dynamic Circuit Decay," U.S. Pat. No. 5,343,096 to Heikes and Miller. In this method, the logic state of a valid output is preserved before decay occurs using a slow clock detector configured to detect a slow clock condition of the clock pertaining to a dynamic logic circuit. A tolerant storage device is configured to preserve the data output by command of the slow clock detector upon a detection of the slow clock condition. This solution, however, requires detection of a slow clock condition and again does not reduce or eliminate the probability of incurring alpha-particle strikes.
Another solution to the storage decay problem is to insert a small feedback FET between the storage node and a voltage source. The feedback FET essentially acts like a current source to maintain the voltage potential at its rail. While this solution works well for the storage decay problem, the transient current generated by enhanced charge collection from an alpha-particle strike is too high for the feedback FET to be effective, and thus is not a viable solution to the alpha-particle induced soft error problem.
SUMMARY OF THE INVENTION
The present invention reduces the vulnerability of a dynamic logic circuit of incurring alpha soft errors by effectively trading an isolation circuit composed of only a few pn-junctions with a fast logic circuit having substantially more pn-junctions. By reducing the number of pn-junctions susceptible to alpha-particle strikes, the present invention significantly lowers the potential alpha-particle induced soft error rate. In one embodiment, isolation circuits used in the present invention are implemented using self-timed logic, to reduce the window in which a circuit is logically vulnerable to alpha strikes, in which a loss of state can occur.
In accordance with novel principles, isolation circuits are situated at the outputs of the fast portions of logic to maintain detected valid logical output values until the next refresh cycle. The essence of the invention is to trade a larger area portion of fast logic (i.e., having a large number of pn-junctions) with a smaller area isolation circuit (i.e., having a smaller number of pn-junctions) in order to reduce the probability of incurring alpha-particle strikes.
Although the novel principles of the present invention are applicable to a wide variety of dynamic logic circuits which include both fast logic portions and slow logic portions, a preferred embodiment of the present invention has particular applicability to a family of self-timed dynamic logic gates known as "mousetrap" logic gates. Self-timed mousetrap logic is known in the art, including U.S. Pat. No. 5,208,490 to Yetter, and is based on a system known as vector logic. The inherent advantages provided by mousetrap logic, including being functionally complete, self-timed, and having the ability to operate at high speed, render it particularly useful in implementing the techniques of the present invention to reduce alpha-particle induced soft errors.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the effect of an alpha-particle strike on a pn-junction, and in particular, the funneling effect due to enhanced charge collection.
FIG. 2 shows a typical logic pipeline, composed of a series of serially arranged data latches and corresponding logic blocks.
FIG. 3 shows a timing diagram including the clock and data signals of the typical logic pipeline shown in FIG. 2.
FIG. 4 shows a block diagram of a typical logic block of the typical logic pipeline of FIG. 2, including a plurality of slow and fast logic portions.
FIG. 5 shows a block diagram of a logic block embodying the present invention.
FIG. 6 shows a block diagram of an isolation circuit in accordance with the present invention.
FIG. 7 illustrates a high level block diagram of a family of mousetrap logic gates.
FIG. 8 illustrates a preferred embodiment isolation circuit, using mousetrap logic gates, for use in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with novel principles, the isolation circuit is contemplated for use in a dynamic logic circuit containing both fast and slow logic portions of the circuit. A plurality of logic isolator circuits, each corresponding to a respective fast logic portion, are situated to receive the outputs of their respective fast logic portions as an input signal. Each logic isolator circuit monitors the input signal to detect a valid logic state of the detected input signal. Upon detection of a valid logic state, the logic isolator holds the valid logic state at an output for use by subsequent circuitry. Each logic isolator is implemented with substantially fewer pn-junctions than its corresponding fast logic portion. The essence of the invention is to trade a larger area portion of logic with a smaller area isolation circuit in order to reduce the probability of incurring alpha-particle strikes.
The present invention may be best understood by first examining a typical dynamic logic circuit. FIG. 2 shows a portion of a typical dynamic logic circuit, arranged in a pipeline 200, composed of a plurality of serially arranged pipeline stages 202-208, each pipeline stage including an input data latch 232-238 and a corresponding logic block 242-248. Each of the pipeline stages 202-208 comprises any number of stages of logic gates. Data is introduced into the pipeline 200 as indicated by arrow 210. The data ultimately travels through and is independently processed by each of the pipeline stages 202-208 of the sequence, as shown by successive arrows 212-218.
Data is clocked through the pipeline 200 via clocks 222-228, which could be identical or staggered in phase as desired. Usually, successive pipeline stages are uniformly triggered by the same clock edge (either rising or falling) and are clocked a full cycle (360 degrees) out of phase.
FIG. 3 shows a timing diagram including the clock and data signals of the typical logic pipeline shown in FIG. 2. As shown in FIG. 2, each consecutive pipeline stage 202-208 is clocked by alternating complementary clock signals CK1 and CK2 which, as indicated in FIG. 3, are ideally staggered 180 degrees out of phase. Ideally, clocks CK1 and CK2 are intended by design to switch simultaneously, to be alternating (180 degrees out of phase), and to have a 50 percent duty cycle with respect to one clock state (t period ) of the system clock. However, because of unavoidable clock asymmetry, due to such factors as inherent physical inequities in the manufacture of clock generation circuits, a 50 percent duty cycle cannot exist in reality.
With respect to FIG. 2, pipelining means that new data is clocked into the pipeline 200, as indicated by the arrow 210, while old data is still remaining in the pipeline 200 being processed. Pipelining increases the useful bandwidth of high latency logic networks.
A typical logic block of the typical logic pipeline of FIG. 2 is shown in FIG. 4. As seen from FIG. 4, a typical logic block includes a plurality of slow 412, 414 and fast 402, 404, 406 logic portions. In general terms, fast logic portions contain fewer gate delays than slow logic portions. Typically, slow logic portions implement logic functions requiring either serial propagation or a large fan-in of inputs. Thus, the processing time from input to output is longer for slow logic portions 412, 414 than it is for the fast logic portions 402, 404, 406, and valid logic output values for the fast logic portions 402, 404, 406 are available to subsequent circuitry before valid logic output values for the slow logic portions 412, 414. When subsequent logic circuitry 422 depends on valid output values from both slow and fast logic portions, the valid output values for the dependent fast logic portions 402, 404, 406 must remain valid and correct while waiting for valid output values from the dependent slow logic portions 412, 414. During this waiting period, the dependent fast logic portions 402, 404, 406 are susceptible to alpha-particle strikes. If any logic gate (i.e., pn-junction) in the fast logic portions 402, 404, 406 incur an alpha-particle strike, an alpha-particle soft error may be induced and propagated to the output of the fast logic portion, causing a soft error in the output value of the fast logic portion. When the slow logic portions 412, 414 produce valid output values, the incorrect output value of the fast logic portion which incurred the alpha-particle strike is then propagated to the subsequent logic circuitry 422. The soft error is propagated through subsequent circuitry.
In dynamic logic circuits, alpha-particle strikes to the dependent slow logic portions 412, 414 is somewhat less problematic. Since the slow logic portions are critical-path, the subsequent logic circuitry 422 utilizes their valid output values almost immediately upon becoming valid (i.e., with negligible delay, less than 100 psec). Thus, the occurrence of an alpha-particle induced soft error depends on whether the alpha-particle strikes before or after the stricken logic gate has received and propagated valid data. If the stricken logic gate has already received and propagated valid data when the alpha-particle strikes, any induced soft-error will be propagated behind the valid data to the output of the slow logic portion with at least a 100 psec delay. Once the soft error is propagated to the output of the critical-path slow logic portion, the subsequent logic circuitry 422 has already accepted the correct valid output value and cannot accept further input until the subsequent logic circuitry 422 has been refreshed by the clock. However, if the striken logic gate has not yet received and propagated valid data at the time the alpha-particle strikes, any induced soft-error will be propagated ahead of the valid data to the output of the slow logic portion. Thus, alpha-induced soft errors are not completely eliminated by the present invention, but the probability of incurring alpha-particle induced soft errors is greatly reduced.
FIG. 5 shows a block diagram of a logic block embodying the present invention. As shown in FIG. 5, the logic block 500 of the present invention also includes a plurality of slow logic portions 512, 514 and a plurality of fast logic portions 502, 504, 506. In addition, the logic block 500 includes subsequent logic circuitry 522 which depends on valid output values from each of the slow 512, 514 and fast 502, 504, 506 logic portions. The essence of the present invention involves the use and placement of isolation circuits 532, 534, 536 at the output of each fast logic portion 502, 504, 506. The isolation circuit 532, 524, 536 contemplated by the present invention detects a valid input value. Upon detection of a valid input value, the isolation circuit 532, 534, 536 holds the valid input value at its output until refreshed by the clock signal CK, and ignores subsequent changes in input values. Thus, alpha-particle induced soft errors incurred by any of the logic gates of the fast logic portions 502, 504, 506 after a valid output value has been produced, and thereafter isolated by the associated isolation circuit 532, 534, 536, will be propagated to the input of the isolation circuit 532, 534, 536, but will be ignored. The correct valid output value of the soft-error producing fast logic portion shall be maintained at the output of the associated isolation circuit 532, 534, 536.
As will be appreciated from the preceding discussion, the isolation circuits 532, 534, 536 act to reduce alpha-particle induced soft errors by essentially trading the probability of alpha-particles striking a smaller number of pn-junctions of the isolation circuit with the probability of alpha-particles striking a larger number of pn-junctions of a fast logic portion. It will be appreciated by a person skilled in the art that a logic block may include any of an infinite variety of logic structures, including fast and/or slow logic portions arranged in any number of levels of dependent and/or independent subsequent logic circuits. Thus, the amount of reduction in alpha-particle induced soft-error rates is dependent upon the structure and type of logic implemented in the logic block.
FIG. 6 illustrates an isolation circuit 600 in accordance with the present invention. As shown in FIG. 6, it is contemplated that the isolation circuit 600 should include an arming mechanism 602, and a valid logic detection block 604. The arming mechanism 602 indicates to the valid logic detection block 604 to begin looking for a valid input value at its input 606. A valid input value triggers the valid logic detection block 604 to hold the valid input value at its output 608, and to ignore subsequent input values. In one preferred embodiment, the arming mechanism 602 is implemented with the dynamic logic system refresh clock, and the valid logic detection block 604 is implemented with "mousetrap" logic based on vector logic as discussed hereinafter.
The isolation circuits of the present invention may be implemented using any appropriate switching and logic detection mechanisms. A preferred embodiment, implemented for use in vector logic systems, is described in detail below.
The preferred embodiment of the present invention is directed to reducing alpha-particle soft error rates in dynamic logic circuits, for example but not limited to, a self-timed vector logic system with mousetrap logic gates. A complete discussion of self-timed vector logic may be found in "Self-Timed Clocking System and Method for Self-Timed Dynamic Logic Circuits", U.S. Pat. No. 5,329,176, to Miller, Jr. et al. The advantage of using self-timed vector logic for implementing the present invention is that two significant features can be determined from each vector output: (1) when the vector output is valid, thereby eliminating the need for a conventional valid clock signal, and (2) the value of the vector output when it is valid. Thus, using self-timed vector logic, the isolation circuit is armed at the beginning of a refresh cycle, and is triggered to hold the value of the vector input when it is determined to be valid. A change in input value is thereafter ignored. Alpha-particle induced errors resulting from alpha-particle strikes to a logic gate after the logic gate has detected and propagated valid data will always be at least 100 psec behind the valid values, so they also are ignored and soft-error propagation is halted by the isolation circuit.
For a better understanding of the preferred embodiment isolation circuit, a brief discussion follows in regard to the fundamental principles of self-timed mousetrap logic gates.
Typically, logic in a computer is encoded in binary fashion on a single logic path, which is oftentimes merely an electrical wire or semiconductor throughway. By definition, a high signal level, usually a voltage or current, indicates a high logic state (in programmer's language, a "1" or a "logic high"). Moreover, a low signal level indicates a low logic state (in programmer's language, a "0" or a "logic low").
By using mousetrap logic gates, "vector logic" may be implemented. Vector logic is a logic configuration where more than two valid logic states may be propagated through the logic gates in a computer. Unlike conventional binary logic having two valid logic states (high, low) defined by one logic path, the vector logic dedicates more than one logic path for each valid logic state and permits an invalid logic state.
For example, in accordance with one embodiment, in a vector logic system requiring two valid logic states, two logic paths are necessary. When both logic paths are at a logic low, i.e., "0,0", an invalid logic state exists by definition. Moreover, a logic high existing exclusively on either of the two logic paths, i.e., "1,0" or "0,1", corresponds with the two valid logic states of the vector logic system. Finally, the scenario when both logic paths are high, i.e., "1,1", is an undefined logic state in the vector logic system.
In a vector logic system requiring three logic states in accordance with another embodiment, three logic paths would be needed, and so on. In conclusion, in accordance with the foregoing embodiment, a vector logic system having n valid logic states and one invalid state comprises n logic paths.
Furthermore, encoding of vector logic states could be handled by defining a valid vector logic state by a logic high on more than one logic path, while still defining an invalid state when all paths exhibit a low logic signal. In other words, the vector logic states are not mutually exclusive.
For example, in a vector logic system using a pair of logic highs to define each valid vector logic state, the following logic scheme could be implemented. With three logic paths, "0,1,1" could designate a vector logic state 1, "1,0,1" a vector logic state 2, and "1,1,0" a vector logic state 3. With four logic paths, six valid vector logic states could be specified. Specifically, "0,0,1,1" could designate a logic state 1, "0,1,0,1" a logic state 2, "1,0,0,1" a vector logic state 3, "1,0,0,1" a vector logic state 3, "0,1,1,0" could designate a vector logic state 4, "1,0,1,0" a vector logic state 5, and "1,1,0,0" a vector logic state 6. With five logic paths up to ten valid vector logic states could be specified, and so on.
As another example, a vector logic system could be derived wherein three logic highs define each valid vector logic state. In conclusion, as is well known in the art, the above vector schemes can be summarized by a mathematical combination formula. The combination formula is as follows: ##EQU1## where variable n is the number of logic paths (vector components), variable m is the number of logic paths which define a valid vector logic state (i.e., the number of logic paths which must exhibit a logic high to specify a particular vector logic state), and variable i is the number of possible vector logic states.
FIG. 7 illustrates a high level block diagram of the family of mousetrap logic gates. Mousetrap logic gates, described in detail hereinafter, can implement vector logic at high speed, are functionally complete, are self-timed, and do not suffer adverse logic reactions resulting from static hazards when chained in a sequence of stages.
As shown in FIG. 7, each input to the mousetrap logic gate 700 is a vector, denoted by vector inputs I, J, . . . K (hereinafter, vectors are in bold print). No limit exists as to the number of vector inputs I, J, . . . , K. Further, each of vector inputs I, J, . . . , K may be specified by any number of vector components, each vector component having a dedicated logic path denoted respectively in FIG. 7 by I O -I N , J O -J M , and K O -K S .
Essentially each vector input specifies a vector logic state. As mentioned previously, an invalid vector logic state for any of the input vectors I, J, . . . , K is present by definition when all of its corresponding vector components, respectively, I O -I N , J O -J M , and K O -K S , are at a logic low.
The output of the generic mousetrap logic gate 700 is also a vector, denoted by a vector output O. The vector output O is comprised of vector components O O -O P . The vector components O O -O P are mutually exclusive and are independent functions of the vector inputs I, J, . . . , K. Further, the vector components O O -O P have dedicated mousetrap gate components 702-706, respectively, within the mousetrap logic gate 700. By definition, one and only one of the O O -O P is at a logic high at any particular time.
Moreover, no limit exists in regard to the number of vector components O O -O P which can be associated with the output vector O. The number of vector components O O -O P , and thus mousetrap gate components 702-706 depends upon the logic function to be performed on the vector inputs individually or as a whole, the number of desired vector output components, as well as other considerations with respect to the logical purpose of the mousetrap logic gate 700.
With reference to FIG. 7, each mousetrap gate component 702-706 of the mousetrap logic gate 700 comprises an arming mechanism 708, ladder logic 710, and an inverting buffer mechanism 712. The arming mechanism 708 is a precharging means, or energizing means, for arming and resetting the mousetrap logic gate 700.
The arming mechanism 708 essentially serves as a switch to thereby selectively impose a voltage V O defining a logic state on a line 716 upon excitation by a clock signal (high or low) on line 714. As known in the art, any type of switching element or buffer for selectively applying voltage based upon a clock signal can be used. Furthermore, when the logic of a computer system is based upon current levels, rather than voltage levels, then the arming mechanism 708 could be a switchable current source, which is also well known in the art. Any embodiment serving the described switching function as the arming mechanism 708 is intended to be incorporated herein.
The ladder logic 710 is designed to perform a logic function on the vector inputs I, J, . . . K. The ladder logic 710 corresponding to each mousetrap gate component 702-706 may vary depending upon the purpose of each mousetrap gate component 702-706. In the preferred embodiment, the ladder logic 710 is essentially a combination of simple logic gates, for example, logic OR gates and/or logic AND gates, which are connected in series and/or parallel. It should be noted that the ladder logic 710 is configured so that one and only one of the vector components O O -O P is at a logic high at any sampling of a valid vector output O.
The ladder logic 710 must operate at high speed because it resides in the critical logic path, unlike the arming mechanism 708 which initially acts by arming the mousetrap gate component, but then sits temporarily dormant while data actually flows through the mousetrap gate component, i.e., through the critical logic path. Furthermore, because the ladder logic 710 resides in the critical logic path which is essentially where the logical intelligence is positioned, a plurality of logic gates are generally required to implement the desired logic functions.
Also residing in the logic path is the inverting buffer mechanism 712. The inverting buffer mechanism 712 primarily serves as an inverter because in order to provide complete logic functionality in the mousetrap gate 700, it is necessary to have an inversion function in the critical logic path. Moreover, the inverting buffer mechanism 712 provides gain to the signal residing on line 714 and provides isolation between other potential stages of mousetrap gate components similar to the mousetrap logic gate components 702-706 of FIG. 7. The inverting buffer mechanism 712 is characterized by a high input impedance and low output impedance. Any buffer embodiment serving the described function as the buffer mechanism 712 is intended to be incorporated herein.
The operation of the mousetrap logic gate 700 is described below at a high conceptual level in regard to only the mousetrap gate component 702 for simplicity. The narrowing of the present discussion is well grounded because the various mousetrap gate components 702-706 are essentially redundant with the exception of their corresponding ladder logic functions implemented by ladder logics 710, 720, and 730. Consequently, the following discussion is equally applicable to the remaining mousetrap gate components 704 and 706.
In operation, upon excitation by a clock CK on the line 714, the arming mechanism 708 pulls up, or drives, the output 716 of the ladder logic 710 to a logic high. Concurrently, the arming mechanism 708 pulls the input at line 714 to the inverting buffer mechanism 712 to a logic high. Consequently, the corresponding vector component O O on a line 717 is maintained at a logic low, defined as an invalid state. In the foregoing initial condition, the mousetrap logic gate 700 can be analogized as a "mousetrap", in the traditional sense of the word, which has been set and which is waiting to be triggered by the vector inputs I, J, . . . , K.
The mousetrap logic gate 700 will remain in the armed predicament with the vector component O O in the invalid state, until being triggered by the ladder logic 710. The mousetrap logic gate 700 is triggered upon receiving enough valid vector inputs I, J, . . . , K to definitively determine the correct state of the vector component O O on the line 717. The number of vector inputs I, J, . . . K needed to make the definitive determination of the output state and also the timing of the determination is defined by the content and configuration of the simple logic gates within the ladder logic 710.
After the vector component O O on line 717 is derived, it is passed onto the next stage (not shown) of logic. The mousetrap logic gate component 702 will not perform any further function until being reset, or re-armed, or refreshed, by the arming mechanism 708. In a sense, the timing from mousetrap gate component to mousetrap gate component as well as gate to gate depends upon the encoded data itself. In other words, the mousetrap gate components are "self-timed."
Mousetrap logic gates directly perform inverting and non-inverting functions. Consequently, in contrast to conventional dynamic logic gates, mousetrap logic gates can perform multiplication and addition, which require logic inversions, at extremely high speeds.
Finally, it should be noted that the family of mousetrap logic gates 700 can be connected in electrical series, or cascaded, to derive a combinational logic gate which will perform logic functions as a whole. Thus, a mousetrap gate component, comprising an arming mechanism, ladder logic, and an inverting buffer mechanism, can be conceptualized as the smallest subpart of a mousetrap logic gate. Moreover, various mousetrap gate components can be connected in series and/or in parallel to derive a multitude of logic gates.
In a vector logic system, a mousetrap logic gate as described with respect to FIG. 7 provides an ideal isolation circuit device for reducing alpha-particle induced soft errors in fast logic portions in accordance with the present invention. As described in detail with respect to FIG. 7, the mousetrap logic gate includes an arming mechanism which is armed to begin detection of a valid input logic vector. Detection of a valid input vector triggers the mousetrap logic gate to hold the valid output vector at its output, and to ignore any further changes of the input vector, until it is rearmed.
FIG. 8 shows a preferred embodiment of an isolation circuit 800 for use in a vector logic system, which is implemented using mousetrap logic gates 802, 804 in accordance with the present invention. As shown in FIG. 8, the isolation circuit 800 receives a 2-input vector IL, IH. Thus, according to the vector logic system in which the isolation circuit 800 in FIG. 8 operates, there are only two valid states: "1,0" and "0,1".
A truth table indicating the operation of the isolation circuit 800 is set forth in Table A below.
TABLE A______________________________________i o IH IL OH IL______________________________________inv inv 0 0 0 00 0 0 1 0 11 1 1 0 1 0______________________________________
As indicated in Table A and shown in FIG. 8, vector input i specifies a vector logic state defined by two vector components IH and IL. The designation "inv" indicates an invalid vector logic state. Furthermore, vector output o specifies a vector logic state defined by two outputs OH and OL. In vector notation, the vectors are defined as: i=<IH,IL>; o=<OH,OL>.
As shown in FIG. 8, the isolation circuit 800 is implemented with two mousetrap gate components 802, 804, having respective arming mechanisms 812, 814 as well as inverting buffer mechanisms 822, 824. In the preferred embodiment, the arming mechanisms 812, 814 are p-channel metal-oxide-semiconductor field-effect transistors (MOSFETs), as shown in FIG. 8, which are well known in the art and are commercially available. As will be appreciated by one skilled in the art, n-channel MOSFETs could be substituted for the p-channel MOSFETs; however, the clocking obviously would be diametrically opposite. In addition, in the preferred embodiment isolation circuit shown in FIG. 8, the inverting buffer mechanisms 822, 824 are implemented with static CMOSFET inverters, which are also well known in the art and are commercially available.
Each of the mousetrap logic components 802, 804 also comprise ladder logic blocks 832, 834. Each ladder logic block 832, 834, includes an input trigger disabling mechanism 852, 854, and an input trigger mechanism 842, 844. A cross-over network, denoted by reference numerals 862, 864, has been implemented to create a flip-flop latch operation. As shown in FIG. 8, the preferred embodiment isolation circuit utilizes n-channel MOSFETs, as shown. N-channel MOSFETs provide superior drive capabilities, space requirements, and load specifications, than comparable p-channel MOSFETs. A typical n-channel MOSFET can generally switch approximately fifty percent faster than a comparable pchannel MOSFET having similar specifications. However, it will be appreciated by one skilled in the art that the ladder logic may be implemented using p-channel MOSFETs, which obviously will reverse the polarity of the signals in the logic ladder.
The operation of the preferred embodiment isolation circuit of the present invention is as follows. With reference to FIG. 8, the MOSFETs comprising the arming mechanisms 812, 814 essentially serve as switches to thereby impose a voltage V o on respective lines 872, 874 upon excitation by a low clock signal NCK on line 816. As known in the art, any type of switching element for voltage can be used.
The respective cross-over network lines 862, 864 impose voltage V o at the respective gates of the input trigger disabling mechanisms 852, 854, implemented with n-channel MOSFETs. The voltage V o at the gate of n-channel MOSFETs 852, 854 disables the input trigger disabling mechanisms 852, 854. The input trigger disabling mechanisms 852, 854 are reset by turning on the n-channel MOSFET switches 852, 854, thereby biasing the sources of n-channel MOSFET input trigger mechanisms 842, 844 to approximately 0.7 V. Assuming initially that a valid input state <IH, IL> is not yet available, and that <IH, IL>=<0,0>, the n-channel MOSFET input trigger mechanisms 842, 844 remain off, thereby isolating the respective lines 872, 874 to the inverting buffer mechanisms 822, 824 from the input vector <IH, IL>.
Upon presentation of a valid input vector, <IH, IL>=<0,1> or <1,0>, the input trigger mechanisms 842, 844 are triggered to cause the output vector <OH, OL> at the output of the inverting buffer mechanisms 822, 284 to hold the value of the input vector <IH, IL>. Further, the input trigger disabling mechanisms 852, 854 are triggered to disallow recognition of further input vectors until rearmed by the respective arming mechanisms 812, 814.
For example, if the valid input vector <IH, IL> is <0,1>, input trigger mechanism 844 turns on, pulling line 874 low. This causes the inverted buffer mechanism 824 to invert the low signal on line 874 and to hold output vector component OL high. Simultaneously, the low voltage on line 874 pulls the gate of input trigger disabling mechanism 852 low, via cross-over line 862. This disables recognition of further input vectors <IH, IL> until reset again (i.e. turned on), as follows. Since the input vector component IL is low, input trigger mechanism 842 remains off, causing line 872 to remain high. Thus, the inverted buffer mechanism 822 inverts the high signal on line 872 and holds output vector OH low. If input vector component IL switches high after the input trigger disabling mechanism 852 is triggered (i.e., it is turned off) and before it is reset, line 872 will remain high because input trigger disabling mechanism 852 isolates it from ground. If input vector component IH switches low before the mousetrap gate 804 is refreshed by the clock signal NCK to arming mechanism 814, line 874 will remain low even though input triggering mechanism 844 turns off. Thus, changes in the input vector components after a valid input vector is detected are ignored until the mousetrap logic gates 802, 804 are refreshed by clock signal NCK to arming mechanisms 812, 814.
The operation of the isolation circuit 800 in FIG. 8 where input vector <IH, IL> is <0,1>, is similar, but diametrically opposite.
While illustrative and presently preferred embodiments of the invention have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | A system and method for improving alpha-particle induced soft error rates in integrated circuits is provided. Logic isolation circuits implemented using a substantially fewer number of pn-junctions are situated at the outputs of fast logic portions containing a substantially greater number of pn-junctions. The present invention reduces the vulnerability of a dynamic logic circuit of incurring alpha soft errors by effectively trading the probability of an isolation circuit composed of only a few pn-junctions incurring alpha-particle strikes with the probability of a fast logic circuit having substantially more pn-junctions incurring alpha-particle strikes. By reducing the number of pn-junctions susceptible to alpha-particle strikes, the present invention significantly lowers the potential alpha-particle induced soft error rate. In one embodiment, isolation circuits used in the present invention are implemented using self-timed logic, to reduce the window in which a circuit is logically vulnerable to alpha strikes, in which a loss of state can occur. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to shuttleless looms wherein weft yarn is supplied from a stationary source and is inserted into sheds of warp threads by opposed carrier members that are attached to the free end of flexible tapes which are alternately wrapped about and extended from oscillating tape wheels located at each side of the loom. In timed sequence with the weaving cycle the weft yarn is acted upon by a presenting member which locates the weft in a position for reception by a so-called inserting carrier which carries said weft into the shed and presents it to a so-called extending carrier that draws the weft through the remainder of the shed to complete a single pick. In particular the invention pertains to an improved device for assuring positive positioning of the weft for reception into the inserting carrier by tensioning and preventing the development of slack in said weft in the area adjacent the edge of the fabric being formed.
2. Description of the Prior Art
Shuttleless looms to which the present invention is applicable can be of the type in which weft is supplied from one or more sources or which may employ either the Gabler or Dewas system of weft insertion. In such looms, a weft presenting member is actuated in timed sequence with the weaving cycle so as to locate said weft in a position where it will be received into and taken by the inserting carrier into a shed for presentation to the weft extending carrier.
Spring biased disc-type yarn tensioning devices are well known and have been utilized on shuttleless looms as well as vertically disposed spring biased friction plates such as shown and described in U.S. Pat. No. 3,561,488. These known types of tensioning devices are fixed on the loom and located intermediate the weft presenting member or members and the source or sources of weft supply. The known forms of weft tensioning devices have not been completely satisfactory in maintaining a positive tension on the weft in the area intermediate said devices and the edge of the fabric being formed. Relative to this particular area, many complaints were received on loss of tension and the development of slack in the weft which in many cases was sufficient to prevent the presenting member from properly locating the weft for reception by the inserting carrier. With the development of slack in the weft in the area intermediate the tensioning device and the fabric edge there is no way to recover the lost tension and will result in a cessation of loom operation due to lack of weft. The development of slack in the weft as described above can be caused in a number of ways such as dancing or linear movement of the presenting member which will actually withdraw a slight amount of weft from its source and when attempting to locate said weft for reception by the inserting carrier the slackness therein will cause the weft to be lowered beyond the carrier pick-up position. Vibration of the various loom elements during loom operation has frequently been responsible for loss of tension of the weft. Overhead air cleaners for removing lint from a loom have caused loss of tension on certain types of weft yarns which must be withdrawn from their source under a minimum amount of tension due to the strength thereof and the type of fabric being woven. Another cause of loss of tension to the weft is movement of the lay beam during beat-up of a pick which will actually pull a slight amount of weft through the tensioning device and create enough slack therein so as to effect a change in the position in which the presenting member places it for pick-up by the inserting carrier. It is very important that the weft yarn be precisely located when presented to the inserting carrier for the weft pick range of the latter is quite narrow and a small deviation in this position frequently results in failure to insert the intended pick.
A still further cause for loss of weft tension is the build-up of lint or other foreign matter between the spring biased elements through which the weft passes and which are intended to tension said weft.
The weft control device of the present invention has overcome the problems described above by providing a weft control device of the self-cleaning type which applies and maintains a predetermined amount of tension to the weft and assures positive positioning of the latter for presentation to the inserting carrier.
SUMMARY OF THE INVENTION
The weft control device according to the invention is of the opposed disc type in which a weft yarn is drawn between a pair of discs individual thereto. An adjustable biasing means continuously urges one disc toward the other and is set to apply a predetermined amount of tension on the weft. A separate pair of discs are provided for each source of weft yarn and are all mounted on a common shaft that is rotatably supported on the loom intermediate the sources of weft yarn and the presenting members for positioning a selected weft to the inserting carrier.
A drive means is operatively connected to the shaft on which the discs are mounted and is continuously rotated during loom operation. The manner in which the discs are mounted on this shaft causes them to rotate therewith and as seen looking from the front of the loom rotation of said discs is in a clockwise direction. By rotating the discs in this manner a directional force, opposite to the direction of feed of said weft, is applied to the latter and is effective in maintaining the weft relatively taut in the area intermediate said discs and the fabric being formed as well as immediately recovering any slack that should develop in this area for reasons heretofore described. Additionally the combination of the rotating discs and the weft yarn extending therebetween creates a wiping action which prevents the accumulation of lint or other foreign matter between said discs.
It is a general object of the invention to provide a weft control device for shuttleless loom for assuring the positive positioning of a selected weft yarn for reception by the inserting carrier.
A further object is to provide an improved weft control device for shuttleless looms for maintaining tension on the weft in the area where it is presented for insertion into a warp shed and which will automatically recover any slack that a weft yarn may develop in this area.
Another object is to provide an improved weft control device of simplified construction, having a minimum number of parts which are relatively inexpensive to manufacture and with long life expectancy.
These and other objects of the invention will become more fully apparent by reference to the appended claims and as the following detailed description proceeds in reference to the figures of drawing wherein:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a perspective view of a portion of a shuttleless loom showing the weft control device according to the invention applied thereto;
FIG. 2 is a perspective view in exploded form of one of the plurality of pairs of discs shown in FIG. 1; and
FIG. 3 is a view in side elevation and on an enlarged scale showing further detail of weft control device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now referring to the figures of drawing enough of a shuttleless loom is shown in FIG. 1 to serve as a basis for a detailed description of the invention applied thereto.
In FIG. 1 the forward upper right hand end of a shuttleless loom is shown and among the various parts thereof there is shown a portion of the framework at 10, the right hand tape wheel housing 11 from which extends the usual tape guide 12. The weft inserting carrier is depicted by numeral 13 and as is well known to those conversant in the weaving art, said carrier is fixed on the end of a tape 14, which in the performance of its intended function is caused to be wrapped about and unwrapped from a tape wheel (not shown) that is oscillatably driven within the housing 11.
A weft selector unit 15 is diagrammatically shown in FIG. 1 and is carried on the upper surface of a support stand 16 which is assembled to the framework 10 by a suitable means not shown.
A plurality of weft presenting members or yarn fingers generally indicated by numeral 17 are operatively associated with the selector unit 15. In accordance with the predetermined pattern the yarn fingers are selectively and independently moveable to locate a particular weft yarn individual thereto in an inactive position or one of which the weft will be taken by the inserting carrier and presented to a companion carrier within the shed of warp threads. In FIG. 1 four separate weft yarns are shown which are drawn from independent sources (not shown) and are identified by Y-1, Y-2, Y-3 and Y-4. The yarn fingers for positioning weft yarns Y-1, Y-2, Y-3 and Y-4 are identified by numerals 18, 19, 20 and 21 respectively.
The weft control device according to the invention is identified generally in FIGS. 1 and 3 by numeral 22. This device includes an elongated U-shaped mounting bracket 23 which is fixed on the loom intermediate the yarn fingers and sources of weft by means of a support member 24. A shaft 25 is rotatably carried in the mounting bracket 23.
As shown in FIGS. 1 and 3 shaft 25 has a pair of disc members for each source of weft yarn assembled thereon with each pair including individual positioning and biasing means associated therewith. As each of these pairs of disc elements are alike and include the same elements for biasing and locating them of shaft 25 is is only considered necessary for purpose of brevity to describe that pair of discs for controlling weft yarn Y-1. The discs for weft yarn Y-1 are identified by numerals 26 and 27 and are disposed in contiguous relation on shaft 25. Disc 27 is continuously urged into frictioned contact with disc 26 by means of a coil spring 28 which is assembled on shaft 25 in a slightly compressed manner. One end of this spring 28 is in contact with a collar 29 that is fixed on shaft 25 by means of a set screw 30, and the opposite end is in contact with disc 27. Disc 26 is prevented from moving longitudinally on shaft 25 by means of a collar 31 which is fixed on said shaft by means of a set screw 32. Shaft 25 is rotatably driven as will be described hereinafter and the biasing force of coil spring 28 for continuously urging disc 27 into contact with disc 26 is sufficient to cause both said discs to rotate with said shaft.
With reference to FIG. 1 the means for rotating shaft 25 includes a gear case 33 carried on the loom's so-called binder shaft 34. Shaft 34 is rotated by the gearing (not shown) contained within a gear case 35 which are driven from a suitable source of rotary motion (not shown) by means of a downwardly directed driving member 36. The gearing (not shown) within gear case 33 are rotated by the binder shaft 34 and this rotary movement is transmitted to shaft 25 by means of its connection to said gear case 33 which includes a coupling 37 and gear shaft 38.
Shaft 25 is rotated in the direction of the indicating arrow 39 in FIG. 2 which in turn rotates each of the pairs of discs in a clockwise direction as seen looking from the front of the loom. In FIG. 1 four pairs of disc members are shown which are utilized to control four separate sources of weft and it should be understood that a greater or lesser number of such pairs of discs can be utilized to accommodate whatever number of separate wefts that may be required to weave a desired type fabric.
To summarize the operation, the separate weft yarns Y-1, Y-2, Y-3 and Y-4 extend from their sources of supply through suitable guide elements (not shown), and thence between the pair of disc members individual thereto which are carried on shaft 25 of the weft control device 22. From the pairs of disc members each weft yarn passes through an eyelet formed in the particular yarn finger which is adapted to selectively move said weft yarns between their so-called active and inactive positions. From the eyelets in the yarn fingers the weft yarns extend to the edge of the fabric (not shown) where they are held in a manner well known to those conversant in the art of shuttleless weaving.
Each of the weft yarns extend between their particular pair of discs in the area above the shaft 25 which as seen looking from the front of the loom is caused to rotate in a clockwise direction. The means by which the pairs of discs are mounted on shaft 25 is combination with the biasing force for continuousing urging one of each pair of discs toward the other of each pair is effective in causing said pairs of discs to rotate with said shaft 25. Rotation of the pairs of discs in this manner in combination with the forces for urging said pairs of discs together applies a directional force to each weft yarn in a direction opposite to their direction of withdrawal from their sources. This directional force upon each weft yarn is effective in maintaining them relatively taut in the area intermediate the pairs of discs and the edge of the fabric to which they are connected. Additionally the rotating discs are effective in immediately recovering any slack which may develop in this area and the weft yarns extending between said rotating discs creates a wiping action which prevents any possible accumulation of lint or other foreign matter therebetween.
Although the present invention has been described in connection with a preferred embodiment, it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the invention and the appended claims. | A weft control device for shuttleless looms of the type having a pair of spring biased disc elements between which the weft is advanced for insertion into sheds of warp threads. The device is located intermediate the source of weft and the edge of the fabric being formed, and includes a driving apparatus for effecting rotation of the disc elements in a direction that will apply tension to the weft and automatically recover the development of any slack therein in the area intermediate the disc elements and the fabric edge. | 3 |
The benefit of provisional application Ser. No. 60/018,553 filed May 29, 1996 is claimed.
FIELD OF THE INVENTION
The invention relates generally to well head assemblies for the top of environmental extraction wells and more particularly to a well head assembly better adapted to operating, maintaining, monitoring, and measuring tasks associated with environmental extraction wells.
BACKGROUND OF THE INVENTION
Landfills or sites at which waste has been disposed, may over time generate toxic and combustible (notably methane) gases and polluting liquids. To prevent the escape of such gases, wells may be sunk in the landfill to draw off and collect the gases to prevent them from escaping into the atmosphere. The same wells may be used to extract groundwater and leachate to prevent them from migrating to the water table. As is standard practice after the wells are drilled, they are lined with a well pipe through which gases and liquids may be conducted.
The tops of the well pipes protrude from the surface of the landfill. A gas port may extend out the side of the pipe above the ground through a "T"-type fitting attached to a collection manifold communicating with a number of wells. The upper opening of the pipe or T-fitting is then capped to seal the pipe from the atmosphere.
The cap may be perforated by one or more couplings that communicate with hoses descending into the well pipe and through which liquid may be drawn or pressurized air or electricity introduced. The liquid recovered from the well is usually pumped by a submersible pump suspended at a depth within the well and communicating with one or more of these hoses. In order to prevent these hoses from the submersible pump from being placed under excessive tension, a separate support cable is usually tied to the pump. The other end of this cable may be anchored to the inside of the cap for ready access.
Periodically it becomes necessary to open the wells for the purpose of introducing test equipment or for replacing the pump or inspecting other components within the well. Opening the wells can expose personnel to toxic gases and liquids. It is therefore desirable to limit the number of personnel and time required for such procedures.
This is not always possible. The difficulty of unfastening and removing the cap and the weight of the hoses, pump, and anchor cable may require two or more people to remove the cap. Once the cap is raised, care must be taken not to damage the hoses, for example, as might occur if the cap were placed on the ground with the hoses catching against the edges of the well pipe. Finally, once the cap is removed, various hoses and cables typically interfere with the insertion of the measuring instruments.
SUMMARY OF THE INVENTION
The present invention eliminates many of the problems associated with well servicing by an improved well head design. The present invention recognizes that the well head need not be limited to the diameter of the well pipe but may be expanded to provide an access chamber. Once so expanded, hose couplings and cable anchor points may be attached to the walls of the chamber rather than the cap, allowing the cap to be unencumbered by such hoses and cables. The larger chamber area also permits hose couplings to be moved out of a clear access channel so as to provide for unencumbered pump removal and insertion of measurement equipment into the well pipe.
Specifically, the invention includes a chamber having a lower base surrounded by upstanding walls. The base includes an aperture hermetically connected to an upper lip of the well pipe, the base defining a chamber volume having an area measured across the bore axis substantially greater than an area of opening of the well pipe. An upper cover receivable by the upstanding walls hermetically seals the chamber volume when so received. A hose coupling has one half attached to a wall of the chamber and is positioned outside an imaginary access cylinder passing along the bore axis into the well pipe.
Thus, it is one object of the invention to simplify the servicing of environmental extraction wells by removing connection points from the well cap itself.
It is another object of the invention to permit equipment such as pumps to be drawn up out of the well pipe without interference from the connection points.
The upper cover may include a vertically extending access tube wherein the imaginary access cylinder corresponds in diameter with an inside bore of the access tube.
It is another object of the invention to provide a predefined clear access channel into the well, free of cables and hoses, for the rapid insertion of a pump and measurement equipment without the need to completely remove a lid to which cables and hoses are attached.
The foregoing and other objects and advantages of the invention will appear from the following description. In this description, reference is made to the accompanying drawings which form a part hereof and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessarily represent the full scope of the invention, however, and reference must be made therefore to the later filed claims for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cutaway perspective view of a prior art environmental extraction well and well cap;
FIG. 2 is a figure similar to that of FIG. 1 but showing the well head of the present invention;
FIG. 3 is a cross section of the well head of FIG. 2 but having an alternative embodiment of the top than that shown in FIG. 2 and taken along line 4--4 of FIG. 2; and
FIG. 4 is a cross-sectional view of the well head of FIG. 2 taken along line 4--4 in an embodiment without a gas port.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a prior art well head 10 caps a well pipe 12 passing through a bore 14 to a water table 16 in a landfill 18. The cap 11 is placed on top of T-fitting 20 which provides a port 22 for the collection of gases. A collar 24 holds a cap 11 to the top of the T-fitting 20. The cap 11 supports a number of couplings 26 which connect to hoses (not shown) inside the pipe 12 and outside the pipe 12, at least one of which connects to a submersible pump 28. Access to the well pipe 12 requires removal of the cap 11 and the raising of all the hoses and cables attached thereto.
Referring now to FIGS. 2, 3 and 4 in the present invention, the well pipe 12 is attached at its upper edge to a large diameter circular base 30 which provides a transition from the well pipe 12 to an expanded cylindrical chamber 32 of greater diameter 90 than the well pipe 12 and having a cap 34 of equal area to the base 30. A gas port 60 and leachate hose 38 exit from the sidewalls of the chamber 32 leaving the cap 34 unencumbered.
Referring now to FIG. 3, the well pipe 12 passes through a circular orifice 40 in base 30, the orifice 40 having a diameter matching the outer diameter of the well pipe 12. The base 30 attaches at its outer periphery to upstanding chamber walls 42 forming a cylindrical tube having a diameter 90 substantially greater than the inside diameter of the well pipe 12. The base 30 and walls 42 define a chamber volume 44 into which a continuation of leachate hose 38' and support cable 46 may be held. The support cable 46 may be tied to a hook 48 attached to the inner surface of the sidewalls 42 and extending inward therefrom. The continuation of the leachate hose 38' may be attached to an L-shaped hanger tube 50 extending radially through the sidewalls 42 and angling vertically downward to have, at its lowermost extension, a connector 52 attached to a corresponding connector on the end of the hose 38' within the chamber volume 44. Because hook 48 and connector 52 are close to the cap 34, they are easily accessible and can be recovered if the leachate pump must be removed.
A second connector 54 on the other end of the hanger tube 50 connects to a corresponding connector on the continuation of the hose 38.
In the preferred embodiment, the connector 52 as well as the hanger tube 50 and the hook 48 are placed outside a cylindrical volume 56 being, in this case, the continuation of the inner diameter of the well pipe 12. Thus, free access to the well pipe 12 via this volume 56 is assured.
A gas port 60 passes radially through sidewall 42 opposite the hanger tube 50 and provides a passageway from the chamber volume 44 outside the chamber 32 for connection to a gas collection manifold such as is well known in the art.
It will be appreciated from the above description that the cap 34 is free from all encumbrances from the hose 38 or cable 46 and thus may be raised once fasteners 64 are disconnected. The cap 34 is a cylindrical disk 66 fitting snugly against the upper edge of the walls 42 held in place by a wrapper 68 fitting over the disk 66 and extending a brief distance down the sidewalls 42 to be engaged by the fastener 64 which may be a stainless steel hose clamp or the like.
In the event that a pump must be removed or a measurement or inspection of the well is required, the cap 34 may be easily removed and replaced and once removed, access to the well pipe 12 is readily had.
Referring now to FIG. 4 in a second embodiment, the cap 34 is a single disk 70 having a notch removed around its circumference so as to fit a short distance inside the walls 42 and then to rest on top of those walls 42 providing a hermetic plug when held by fasteners 64. A cylindrical port 72 may be cut in cap 34 along an axis generally parallel to the axis of the well pipe 12 but offset therefrom by offset 91. The inner diameter of this port 72 allows a second cylindrical volume 76 that, as a result of the location of hook 48 and hanger tube 50 described above with respect to FIG. 3, is unobstructed as it extends into the well pipe 12. This cylindrical volume 76 has a lesser diameter than the inner diameter of well pipe 12 but is of sufficient diameter to accept a flow measuring tube such as that manufactured by several different companies. As a result of the design of the well head 10, equipment inserted through port 72 will be assured of clear passage into the well pipe 12 without the need to remove the cap 34 and even if a pump is needed in the well to extract leachate or other liquids.
The well head 10 herein described may be constructed of plastic or metal material and the ports 72 and 60 welded to this material by well known techniques. The well head may be attached to the well pipe 12 either directly or by means of an intermediary flange.
The above description has been that of a preferred embodiment of the present invention. It will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. | A well head for landfills or other sites at which waste has been disposed provides an enlarged chamber at the top of a well pipe holding hose and cable terminations on the walls of the chamber positioned out of the access path of the well pipe. A cover unattached to the hoses and cables can be removed for access without interference from the terminations. An extraction port in the cover defines a clear channel into the well pipe for sampling and monitoring equipment. | 4 |
FIELD OF THE INVENTION
The present invention relates to swimming pools and in particular to a winterizing plug assembly for protecting water lines associated with skimmers.
BACKGROUND OF THE INVENTION
Swimming pools subject to winter conditions are winterized to avoid damage to pipes caused when the water freezes.
Part of the winterizing process is to lower the level of the water within the pool and to drain various piping used in the circulation and heating system, such as from the filter and heater. Some of the pipes cannot be fully drained, for example, skimmers used in swimming pools have one line which is connected to the drain of the pool and the level of water within this line drops with, and is equal to, the level of water in the pool. By dropping the pool water level, the water in the pipe is lowered, however, it is desirable to maintain a certain amount of water in the pool to avoid inward collapsing of the pool, during a frost push, for example. With a lower pool level, damage can occur in the pipe connecting the skimmer to the drain. If damage does occur in this pipe, access to the pipe must be obtained and a replacement pipe inserted. This can be a substantial problem with respect to inground pools and can be relatively expensive to repair.
SUMMARY OF THE INVENTION
The present invention provides a simple method and a winterizing plug assembly to overcome the problem described above. In a swimming pool having a skimmer located for removal of water at the surface of the pool and having a water line connected thereto which extends downwardly to the drain of the pool, a winterizing plug assembly cooperates and seals with the skimmer where the water line connects to the skimmer. The plug assembly has valve means for introducing and maintaining air under pressure to the water line whereby water within the line may be displaced downwardly and exhausted through the drain to the swimming pool by introducing air under pressure to the line through the valve means. This air is held under pressure by the valve means. The introduction of pressurized air lowers the water within the pipe and marginally raises the level of the pool due to the amount of water displaced from the pipe. By maintaining the air pressure, the water within the pipe is at a level below the level of the pool.
From the above, it can be appreciated that the winterizing plug assembly allows for the water within the line to be exhausted, or partially exhausted, with the air pressure and the head of water remaining in the pipe being equal to the pressure exerted by the head of water in the pool.
According to an aspect of the invention, the plug assembly includes a compressible member extending from the bottom of the plug assembly and of a size to be received in the water line. The compressible member is elongate and of a length of preferably at least 20 inches. This member readily yields to dissipate expansion forces exerted thereon by ice. This compressible member provides a further means for reducing the possibility of damage to the pipe, even if the water within the pipe returns to the level of the pool. Any expansion forces exerted by the frozen water in the pipe can be at least partially absorbed by this compressible member whereby the force on the pipe, tending to burst the pipe, is reduced.
According to yet a further aspect of the invention, the compressible member is a tube sealed at one end to the plug assembly with the valve means connected to allow air to pass into the tube. The tube at the opposite end of the valve means is open whereby a pressurized air column may be produced in the water line by introducing pressurized air through the valve means into the water line. The tube is separately sealed to the plug assembly, such that even if leakage occurs between the skimmer and the plug raising the water level in the water line to cover the end of the tube, a pressurized column of air will be maintained within the tube. This pressurized column of air will be maintained as long as the valve means continues to form a seal.
According to yet a further aspect of the invention, the compressible member is a rubber hose.
According to yet a further aspect of the invention, the winterizing plug has a screw thread on the exterior thereof which cooperates with a threaded port in the skimmer to which the water line is connected. The threaded plug forms a seal with the threaded port of the skimmer.
The present invention is also directed to a method of reducing the risk of damage by freezing of a water line wherein the water line is associated with a drain of a swimming pool and a skimmer, serving to connect the skimmer to the drain in the bottom of the pool. The method comprises opening the drain to allow the water in the water line to be subject to the pressure exerted by the head of water in the pool, sealing the water line adjacent the skimmer, introducing pressurized air into the water line while maintaining the seal at the skimmer to thereby displace water in the water line to a level below the water level in the pool.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
FIG. 1 is sectional view showing a portion of a swimming pool and skimmer, with a water line connecting the skimmer with the drain of the pool;
FIG. 2 is a partial perspective view of the winterizing plug assembly;
FIG. 3 is a partial cross sectional view showing the plug assembly inserted in the skimmer and connecting to the water line;
FIG. 4 is a sectional view showing the winterizing plug in the skimmer wherein the seal between the skimmer and the plug has failed; and
FIG. 5 is a sectional view through the pool showing the skimmer and plug assembly where the valve means has failed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The winterizing plug assembly 2 includes a threaded plug 4 for receipt in the threaded port of a skimmer. The plug includes exterior threads 6 extending below a collar 8. The plug includes an air valve 10 through which air can be introduced through the plug, which air is discharged into the downwardly extending flexible tube or hose 12. The flexible tube or hose is preferably of a length of at least about 20 inches. The tube 12 is of a diameter less 0 than the diameter of the various water lines in a swimming pool and in particular, is less than the diameter of the line 32 connected to the drain of the pool and to the skimmer of the pool, generally shown as 22.
The swimming pool 20 has a skimmer 22 in a side wall of the pool. During normal operation of the pool, the skimmer mouth 23 has a lower edge slightly below the normal level in the pool, which level is indicated as 28. To winterize the pool, the water level is typically dropped to a level indicated as 36 in FIG. 3. By dropping the pool level to this point, the water within the line 32 connecting the skimmer 22 with the main drain 34 of the pool drops to the same point, i.e. level 36. Unfortunately, freezing and resultant damage can still occur in this line. The water level in the pool could further be lowered, however, from a practical point of view, there is a rationale for having the level 36 fairly close to the normal operating level 28 to avoid buckling of the pool walls. Typically, the level in the pool is dropped to below the ceramic tiles, as damage to the tiles can occur if the tiles remain submerged at the winter level 36.
In order to drop the level in line 32, the winterizing plug assembly is threaded into threaded port 26 located in the base 24 of the skimmer 22. Also connected in the base 24 of the skimmer 22 is a line 30 which is connected to the pump and filter unit of the pool. During the winterizing step, the drain 34 is open and the winterizing plug assembly 2 is inserted in the skimmer in the manner shown in FIG. 3. An air pump 40 is connected to the air valve 10 and air is forced through the air valve under pressure into line 32. The air is initially discharged through the tube 12. Air is forced into line 32 causing the air pressure in line 32 to increase. This air pressure will force the level of water in line 32 to be lowered to a level generally indicated as 44. As can be seen, level 44 is below the winterizing level 36 of the pool. The water forced from line 32 is being discharged through the drain 34 into the pool. In this way, line 32 has been cleared adjacent the winter level 36 of the pool, such that the pipe is less vulnerable to damage. The level 44 within the line 32 is determined according to the air pressure within line 32 and the head of water in the pool determined by the level 36. In this way, the user can depress the level of water in the line 32 and reduce the possibility of damage to the line 32.
The winterizing plug 2 also has a number of benefits, even if the seal or the valve stem fails. For example, in FIG. 4, it is shown that the seal between the plug 2 and the skimmer base 24 has failed and air can leak out, as indicated at 48. In this case, water can rise up to the exterior of tube 12, however, it cannot be discharged through tube 12 due to the fact that the valve 10 is still forming an air seal. In this way, there is still a compressed column of air within the tube 12 and this tube can accommodate movement to accommodate any ice expansion within the line 32.
In FIG. 5, it it shown that the valve 10 could fail, however, in this case, a seal is still maintained to the exterior of the tube 12. Therefore, water within the tube can expand against the tube 12 and may cause damage to tube 12, however, there is still a degree of protection for line 32 which is superior to the normal winterizing condition.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims. | A winterizing plug for water lines of a swimming pool is disclosed. The winterizing plug cooperates with a port in the skimmer to displace water in the line and reduce the possibility of damage thereto. Water is displaced by means of air pressure maintained within the line. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in part of U.S. Ser. No. 08/457,712, filed Jun. 2, 1995, abandoned, which is a continuation-in part of U.S. Ser. No. 08/392,697, filed Feb. 23, 1995, abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to di-N-substituted piperazines and 1,4-di-substituted piperidines useful in the treatment of cognitive disorders, pharmaceutical compositions containing the compounds, methods of treatment using the compounds, and to the use of said compounds in combination with acetylcholinesterase inhibitors.
Alzheimer's disease and other cognitive disorders have received much attention lately, yet treatments for these diseases have not been very successful. According to Melchiorre et al. (J. Med. Chem. (1993), 36, 3734-3737), compounds that selectively antagonize M2 muscarinic receptors, especially in relation to M1 muscarinic receptors, should possess activity against cognitive disorders. Baumgold et al. (Eur. J. of Pharmacol., 251, (1994) 315-317) disclose 3-α-chloroimperialine as a highly selective m2 muscarinic antagonist.
The present invention is predicated on the discovery of a class of di-N-substituted piperazines and 1,4-di-substituted piperidines, some of which have m2 selectivity even higher than that of 3-α-chloroimperialine. Logemann et al (Brit. J. Pharmacol. (1961), 17, 286-296) describe certain di-N-substituted piperazines, but these are different from the inventive compounds of the present invention. Furthermore, the compounds of Logemann et al. are not disclosed to have activity against cognitive disorders.
SUMMARY OF THE INVENTION
The present invention relates to compounds according to the structural formula I, ##STR2## including all isomers and pharmaceutically acceptable salts, esters, and solvates thereof,
wherein one of Y and Z is N and the other is N, CH, or C-alkyl;
X is --O--, --S--, --SO--, --SO 2 --, --NR 6 --, --CO--, --CH 2 --, --CS--, --C(OR 5 ) 2 --, --C(SR 5 ) 2 --, --CONR 20 --, --C(alkyl) 2 --, --C(H)(alkyl)--, --NR 20 --SO 2 --, --NR 20 CO--, ##STR3##
hydrogen, acyl, alkyl, alkenyl, cycloalkyl, cycloalkyl substituted with up to two alkyl groups, cycloalkenyl, bicycloalkyl, arylalkenyl, benzyl, benzyl substituted with up to three independently selected R 3 groups, cycloalkylalkyl, polyhaloacyl, benzyloxyalkyl, hydroxyC 2 -C 20 alkyl, alkenylcarbonyl, alkylarylsulfonyl, alkoxycarbonylaminoacyl, alkylsulfonyl, or arylsulfonyl, additionally, when X is --CH 2 --, R may also be --OH; in further addition, when X is not N, R may also be hydroxymethyl, in further addition, R and X may combine to form the group Prot--(NOAA) r --NH-- wherein r is an integer of 1 to 4, Prot is a nitrogen protecting group and when r is 1, NOAA is a naturally occuring amino acid or an enantiomer thereof, or when r is 2 to 4, each NOAA is a peptide of an independently selected naturally occuring amino acid or an enantiomer thereof;
R 1 and R 21 are independently selected from the group consisting of alkyl, alkenyl, cycloalkyl, cycloalkenyl, bicycloalkyl, alkynyl, cyano, aminoalkyl, alkoxycarbonyl, aminocarbonyl, hydroxyguanidino, alkoxycarbonylalkyl, phenyl alkyl, alkylcarbonlyoxyalkyl, ##STR4## H, --OH, (provided R 1 and R 21 are both not --OH and Y is not N), formyl, --CO alkyl, --COacyl, --COaryl, and hydroxyalkyl; additionally R 1 and R 21 together may form the group ##STR5## in further addition, R 1 and R 21 together with the carbon atom to which they are attached may form the group ##STR6## or R 1 and R 21 together with the carbon atom to which they are attached may form a saturated heterocyclic ring containing 3 to 7 carbon atoms and one group selected from S, O, and NH;
R 2 is H, alkyl, alkenyl, cycloalkyl, cycloalkyl substituted with 1 to 3 independently selected R 3 groups, cycloalkenyl, hydroxyC 2 -C 20 alkyl, alkynyl, alkylamide, cycloalkylalkyl, hydroxyarylalkyl, bicycloalkyl, alkynyl, acylaminoalkyl, arylalkyl, hydroxyalkoxyalkyl, azabicyclo, alkylcarbonyl. alkoxyalkyl, aminocarbonylalkyl, alkoxycarbonylaminoalkyl, alkoxycarbonylamino(alkyl)alkyl; alkylcarbonyloxyalkyl, arylhydroxyalkyl, alkylcarbonylamino(alkyl)alkyl, dialkylamino, ##STR7## (wherein q is an integer of 0 to 2) ##STR8## wherein n is 1-3 ##STR9## wherein m is an integer of 4 to 7, ##STR10## wherein t is an integer of 3 to 5, ##STR11## (wherein R 29 is H, alkyl, acyl, alkoxycarbonyl, aminocarbonyl, alkylaminocarbonyl, dialkylaminocarbonyl, alkylsulfonyl, arylsulfonyl), ##STR12## (wherein Q is O, NOH, or NO-- alkyl), or when Z is --CH--, R 2 may also be alkoxycarbonyl, hydroxymethyl, --N(R 8 ) 2 ;
R 3 , R 4 , R 22 , R 24 , and R 25 are independently selected from the group consisting of H, halo, alkoxy, benzyloxy, benzyloxy substituted by nitro or aminoalkyl, haloalkyl, polyhaloalkyl, nitro, cyano, sulfonyl, hydroxy, amino, alkylamino, formyl, alkylthio, polyhaloalkoxy, acyloxy, trialkylsilyl, alkylsulfonyl, arylsulfonyl, acyl, alkoxycarbonyl alkylsulfinyl; --OCONH 2 , --OCONH-alkyl, --OCON(alkyl) 2 , --NHCOO-alkyl, --NHCO-alkyl, phenyl, hydroxyalkyl, or morpholino;
each R 5 and R 6 is independently selected from the group consisting of H and alkyl, provided that when X is C(OR 5 ) 2 or C(SR 5 ) 2 , both R 5 groups cannot be H, and in addition, when X is C(OR 5 ) 2 or C(SR 5 ) 2 , the two R 5 groups in X may be joined to form --(CH 2 ) p -- wherein p is an integer of 2 to 4;
R 7 is independently selected from the group consisting of H, alkyl, arylalkyl, cycloalkyl, aryl and aryl substituted with R 3 and R 4 as defined herein;
each R 8 is independently selected from the group consisting of H, hydroxyalkyl, or alkyl or two R 8 groups may be joined to form an alkylene group;
R 9 is H, alkyl, or acyl:
R 20 is H, phenyl or alkyl; and
R 27 and R 28 are independently selected from the group consisting of H, alkyl, hydroxyalkyl, arylalkyl, aminoalkyl, haloalkyl, thioalkyl, alkylthioalkyl, carboxyalkyl, imidazolyalkyl, and indolyalkyl, additionally R 27 and R 28 may combine to form an alkylene group..
In a preferred group of compounds Y and Z are N
In another preferred group of compounds Y is CH and Z is N
In another preferred group of compounds R is ##STR13##
and X is O, SO or SO 2 .
In another preferred group of compounds R 3 and R 4 are H and either R 1 is cycloalkyl, alkyl, or CN and R 21 is H or R 1 and R 21 together form ═CH 2 or ═O.
In another preferred group of compounds R is ##STR14##
X is O, SO or SO 2 , R 3 and R 4 are H and either R 1 is cycloalkyl, alkyl, or CN and R 21 is H or R 1 and R 21 together form ═CH 2 or ═O.
In another preferred group of compounds Y and Z are N, R 1 is cycloalkyl, alkyl or CN, R 21 is H and R 2 is cycloalkyl or ##STR15##
In another preferred group of compounds Y is CH, Z is N, and R 2 is cycloalkyl or ##STR16##
In another preferred group of compounds at least one of R 27 and R 28 is alkyl.
In another preferred group of compound one of R 27 or R 28 is methyl and the other is hydrogen.
In another preferred group of compounds R is ##STR17##
Another preferred group of compounds is the group represented by the formula ##STR18##
wherein R, X, R 1 , R 27 , and R 21 are as defined in the following table
______________________________________# fromtable ofcom-pounds R X R.sup.1 R.sup.21 R.sup.27______________________________________169 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CN H H iso A227(-) 2-pyrimidinyl O cyclohexyl H H289 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CN CH.sub.3 H269 2-pyrimidinyl O CH.sub.3 H CH.sub.3244 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CO.sub.2 CH.sub.3 H H 2282 2-pyrimidinyl O i-propyl H H123 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CH.sub.3 H H286 4(CH.sub.3 O)C.sub.6 H.sub.4 SO ##STR19## H H296 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO CH.sub.3 CO.sub.2 Me H______________________________________
or having the structural formula ##STR20##
Another group of preferred compounds of formula I are:
(in the table that follows, when R 2 is substituted cyclohexyl, the substituent positions are numbered as follows: ##STR21##
__________________________________________________________________________compound # 600 601 602 603 604 605__________________________________________________________________________ CH.sub.3 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-CH.sub.3 O)C.sub.6 H.sub.4 ##STR22##R.sup.1 CH.sub.3 CH.sub.3 CH.sub.3 CH.sub.3 COOCH.sub.3 chexR.sup.2 cyclohexyl chex chex chex chex (chex)R.sup.3 H H 2-Cl H H HR.sup.4 H H H H H HR.sup.21 CH.sub.3 H H H H HR.sup.27 H H H H H HR.sup.28 H H H H H HX ##STR23## ##STR24## SO SO SO SY N N N CH N HZ N N N N N H__________________________________________________________________________comp. no. 606 607 608 609 610 611__________________________________________________________________________ ##STR25## ##STR26## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 *see below 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 CH.sub.3 CN CN CN CN CNR.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H H CH.sub.3 H CH.sub.3R.sup.27 H H H H H HR.sup.28 H H H H H HX SO.sub.2 SO SO.sub.2 SO S SO.sub.2Y N N CH N N CHZ N N N N N N__________________________________________________________________________comp. no. 612 613 614 615 616 617__________________________________________________________________________ ##STR27## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 C.sub.6 H.sub.5 *see belowR.sup.1 CH.sub.3 CN CN CN CN CNR.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H H CH.sub.3 H HR.sup.27 H (S)-3-CH.sub.3 H H H HR.sup.28 H H H H H HX SO.sub.2 SO SO SO ##STR28## SOY N N CH N N NZ N N N N N N__________________________________________________________________________comp. no. 618 619 620 621 622 623__________________________________________________________________________R C.sub.6 H.sub.5 *see below 2-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 ##STR29##R.sup.1 CH.sub.3 CH.sub.3 CN ##STR30## CN (R)CH.sub.3R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 CH.sub.3 H H H H HR.sup.27 H H H H (R)-2-CH.sub.3 2-CH.sub.3R.sup.28 H H H H H HX O SO.sub.2 O SO SO.sub.2 OY N N N N N NZ N N N N N N__________________________________________________________________________comp. no. 624 625 626 627 628 629__________________________________________________________________________R *see below 4-(CH.sub.3 O)C.sub.6 H.sub.4 *see below *see below 4-(CH.sub.3 O)C.sub.6 ##STR31##R.sup.1 CN CN CN CN CN CH.sub.3R.sup.2 chex ##STR32## chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H H H H HR.sup.27 H H H H (R)-2-CH.sub.3 (R)-2-CH.sub.3R.sup.28 H H H H H HX S S S SO SO OY N N N N N NZ N CH N N N N__________________________________________________________________________comp. no. 630 631 632 633 634 635__________________________________________________________________________R *see below *see below 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 CN CN with R.sup.21 forms O CN CN ##STR33##R.sup.2 chex chex chex ##STR34## chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H -- H H HR.sup.27 H H H H (R)-2-CH.sub.3 HR.sup.28 H H H H H HX SO SO S SO S SOY N N CH N N NZ N N N CH N N__________________________________________________________________________comp. no. 636 637 638 639 640 641__________________________________________________________________________ ##STR35## ##STR36## 4-(CH.sub.3 O)C.sub.6 H.sub.4 chex 4-(HO)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 with R.sup.21 forms O CN with R.sup.21 forms O CN CN with R.sup.21 forms NOCH.sub.3R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- H -- H H --R.sup.27 H (R)-2-CH.sub.3 H H H HR.sup.28 H H H H H HX S SO.sub.2 SO.sub.2 SO.sub.2 S SOY CH N CH N N CHZ N N N N N N__________________________________________________________________________comp. no. 642 643 644 645 646 647__________________________________________________________________________R C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 chex 4-(CH.sub.3 O)C.sub.6 4(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 (S)CH.sub.3 CN CN CN with R.sup.21 forms with R.sup.21 forms NOCH.sub.3R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H H H -- --R.sup.27 (R)-2-CH.sub.3 (S)-2-CH.sub.3 H H H HR.sup.28 H H H H H HX SO.sub.2 SO.sub.2 CO SO SO SOY N N CH N CH CHZ N N N N N N__________________________________________________________________________comp. no. 648 649 650 651 652 653__________________________________________________________________________R C.sub.6 H.sub.5 chex 4(CH.sub.3 O)C.sub.6 H.sub.4 C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 (R)CH.sub.3 CN CN with R.sup.21 forms O with R.sup.21 forms CH.sub.3R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H H -- -- --R.sup.27 (R)-2-CH.sub.3 H (R)-2-CH.sub.3 H H (R)-2-CH.sub.3R.sup.28 H H H H H HX SO.sub.2 S SO S SO SY N N N CH CH NZ N N N N N N__________________________________________________________________________comp.no. 654 655 656 657 658 659__________________________________________________________________________R C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 4-(F)C.sub.6 H.sub.4R.sup.1 with R.sup.21 forms CH.sub.2 CN (R)CH.sub.3 ##STR37## CN with R.sup.21 forms CH.sub.2R.sup.2 chex chex chex chex ##STR38## chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- CH.sub.3 H H H --R.sup.27 H H (R)-2-CH.sub.3 H H HR.sup.28 H H H H H HX SO SO SO.sub.2 SO SO SOY CH CH N CH N CHZ N N N N CH N__________________________________________________________________________comp. no. 660 661 662 663 664 665__________________________________________________________________________R C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(F)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 ##STR39##R.sup.1 with R.sup.21 forms O CONH.sub.2 with R.sup.21 forms O with R.sup.21 forms COOCH.sub.3 with R.sup.21 forms O CH.sub.2R.sup.2 chex chex chex chex ##STR40## chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- H -- -- H --R.sup.27 H H H H H HR.sup.28 H H H H H HX SO.sub.2 SO SO.sub.2 SO.sub.2 SO SY CH CH CH CH N CHZ N N N N CH N__________________________________________________________________________comp. no. 666 667 668 669 670 671__________________________________________________________________________R C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(F)-C.sub.6 H.sub.4 ##STR41##R.sup.1 with R.sup.21 forms (S)CH.sub.3 COOCH.sub.3 with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms O CH.sub.2 NOHR.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- H H -- -- --R.sup.27 H (R)-2CH.sub.3 H H H HR.sup.28 H H H H H HX SO.sub.2 SO.sub.2 SO SO SO SOY CH N CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 672 673 674 675 676 677__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR42## 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR43## 4-CH.sub.3 O)C.sub.6 H.sub.4 ##STR44##R.sup.1 CF.sub.3 with R.sup.21 forms see note with R.sup.21 forms with R.sup.21 forms CH.sub.2 with R.sup.21 forms CH.sub.2 CH.sub.2 CH.sub.2 NOCH.sub.3 Isomer AR.sup.2 chex chex chex chex ##STR45## chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H -- -- -- -- --R.sup.27 H H H H H HR.sup.28 H H H H H HX SO S SO SO SO SO Isomer 1Y N CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 678 679 680 681 682 683__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR46## ##STR47## ##STR48## 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR49##R.sup.1 F.sub.3 C with R.sup.21 forms with R.sup.21 forms O with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms O CH.sub.2 CH.sub.2 OR.sup.2 chex chex chex chex 4(C.sub.6 H.sub.5) chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H -- -- -- -- --R.sup.27 H H H H H HR.sup.28 H H H H H HX SO.sub.2 SO SO.sub.2 SO.sub.2 SO SY N CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 684 685 686 687 688 689__________________________________________________________________________R 4(F)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR50## 4-(CF.sub.3)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR51##R.sup.1 with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms with R.sup.21 with R.sup.21 forms CH.sub.2 CH.sub.2 O CH.sub.2 CH.sub.2 OR.sup.2 chex ##STR52## chex chex 4(C.sub.6 H.sub.5) chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- -- -- -- -- --R.sup.27 H H H H H HR.sup.28 H H H H H HX SO.sub.2 S SO SO SO.sub.2 SO.sub.2Y CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 690 691 692 693 694 695__________________________________________________________________________ ##STR53## 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR54## 3-(CH.sub.3 O)C.sub.6 H.sub.4 2-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 with R.sup.21 forms CN with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms CH.sub.3 CH.sub.2 CH.sub.2R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- H -- -- -- CH.sub.3R.sup.27 H H H H H HR.sup.28 H H H H H HX S SO SO SO.sub.2 SO.sub.2 SO.sub.2Y CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 696 697 698 699 700 701__________________________________________________________________________R 2-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR55## 4-benzyloxy phenyl 2-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 with R.sup.21 forms with R.sup.21 forms O with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms with R.sup.21 forms CH.sub.2 CH.sub.2 O OR.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 -- -- -- -- --R.sup.27 H H H H 2-(CH.sub.3) HR.sup.28 H H H H H HX O SO SO.sub.2 S SO.sub.2 SO.sub.2NHY CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 702 703 704 705 706 707__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.5 ##STR56## 3-(CH.sub.3 O)C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.5 4-(CH.sub.3 O)C.sub.6 H.sub.5R.sup.1 CN with R.sup.21 forms with R.sup.21 forms CH.sub.3 with R.sup.21 (S)C.sub.2 H.sub.5 CH.sub.2 O CH.sub.2R.sup.2 chex chex chex chex chex chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H -- -- CH.sub.3 -- HR.sup.27 H H H H 2(CH.sub.3) (R)-2-(CH.sub.3)R.sup.28 H H H H H HX SO SO.sub.2 SO SO SO.sub.2 SO.sub.2Y CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp.no.708 709 710 711 712 713__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 3-(Cl)C.sub.6 H.sub.4 4(CH.sub.3 O)C.sub.6 H.sub.4 see note 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1(R)C.sub.2 H.sub.5 with R.sup.21 forms CH.sub.3 with R.sup.21 forms CH.sub.2 with R.sup.21 CNrms O OR.sup.2chex chex ##STR57## ##STR58## chex chexR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H -- H -- -- CH.sub.3R.sup.27(R)-2-(CH.sub.3) H H H H HR.sup.28H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2Y N CH N CH CH CHZ N N N N N N__________________________________________________________________________comp. no.714 715 716 717 718 719__________________________________________________________________________R 4-CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(HO)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1(S)-2-propyl CH.sub.3 isomer 1 with R.sup.21 forms with R.sup.21 forms CH.sub.2 with R.sup.21 forms with R.sup.21 forms O OR.sup.2chex chex chex ##STR59## chex ##STR60##R.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H -- -- -- --R.sup.27(R)-2(CH.sub.3) (R)-2-n-C.sub.3 H.sub.7 H H H HR.sup.28H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 CONH SO.sub.2Y N N CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no.720 721 722 723 724 725__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CF.sub.3 O)C.sub.6 H.sub.4 ##STR61## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1(R)-2-propyl CH.sub.3 isomer 2 with R.sup.21 forms with R.sup.21 forms O CH.sub.3 with R.sup.21 forms O OR.sup.2chex chex chex chex chex ##STR62##R.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H -- -- CN --R.sup.27(R)-2(CH.sub.3) (R)-2-n-propyl H H H HR.sup.28H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SOY N N CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no.726 727 728 729 730 731__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1(S)CH.sub.3 (S)CH.sub.3 (S)CH.sub.3 CH.sub.3 with R.sup.21 forms (S)CH.sub.3R.sup.2cyclopentyl cycloheptyl cyclobutyl ##STR63## chex cyclopropylR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H H H -- HR.sup.27(R)-2-(CH.sub.3) 3-(CH.sub.3) (R)-2-(CH.sub.3) H (R)-2-(CH.sub.3) (R)-2-(CH.sub.3)R.sup.28H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO SO.sub.2 SO.sub.2Y N N N N N NZ N N N CH N N__________________________________________________________________________comp. no.732 733 734 735 736 737__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1(S)CH.sub.3 (S)CH.sub.3 (S)CH.sub.3 CH.sub.3 (S)CH.sub.3 (S)CH.sub.3R.sup.2cyclopentyl cyclooctyl cyclobutyl ##STR64## ##STR65## cyclopropylR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H H H H HR.sup.273(CH.sub.3) (R)-2(CH.sub.3) 3(CH.sub.3) H (R)-2(CH.sub.3) 3(CH.sub.3)R.sup.28H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2Y N N N N N NZ N N N CH N N__________________________________________________________________________comp. no.738 739 740 741 742 743__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 44-(CH.sub.3 O)C.sub.6 H.sub.4 See note 743R.sup.1(S)CH.sub.3 (S)CH.sub.3 with R.sup.21 forms (S)CH.sub.3 (S)CH.sub.3 CH.sub.3 CH.sub.2R.sup.2cycloheptyl cyclooctyl chex chex ##STR66## chexR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H -- H H HR.sup.27(R)-2(CH.sub.3) 3(CH.sub.3) with R.sup.28 forms 3-(CH.sub.3) 3-(CH.sub.3) H 3,5-(CH.sub.2).sub.2R.sup.28H H -- H H HX SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 SO.sub.2 CONHY N N CH N N NZ N N N N N N__________________________________________________________________________comp. no.744 745 746 747 748 749__________________________________________________________________________R See Note See Note See Note See Note 4(CH.sub.3 O)C.sub.6 H.sub.4 See NoteR.sup.1CH.sub.3 CH.sub.3 CN CH.sub.3 OH CH.sub.3R.sup.2chex chex chex chex chex chexR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H H H H HR.sup.27H H H H H HR.sup.28H H H H H HX CONH CONH S O SO CONHY N N N N CH NZ N N N N N N__________________________________________________________________________comp. no.750 751 752 753 754 755__________________________________________________________________________R See Note See Note See Note 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR67## 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1CH.sub.3 CH.sub.3 CN ##STR68## with R.sup.21 forms with R.sup.21 forms OR.sup.2chex chex chex chex chex chexR.sup.3H H H H H HR.sup.4H H H H H HR.sup.21H H H H -- --R.sup.27H H H H H 1-(CH.sub.3)R.sup.28H H H H H HX CONH CONH SO.sub.2 SO SO SOY N N N N CH CHZ N N N N N N__________________________________________________________________________comp. no.756 757 758 759 760 761__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR69## 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR70## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1OH with R.sup.21 forms O CH.sub.3 OH OH with R.sup.21 forms OH.sub.2R.sup.2chex chex chex chex ##STR71## chexR.sup.3H H H H H HR.sup.4H H H H H HR.sup.212-propyl -- H CH.sub.3 -- ethylR.sup.27H H H H H HR.sup.28H H H H H HX SO SO S SO SO.sub.2 SOY CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no. 762 763 764 765 766__________________________________________________________________________ ##STR72## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 with R.sup.21 forms CH.sub.2 with R.sup.21 forms CH.sub.2 ##STR73## with R.sup.21 forms CH.sub.2OHR.sup.2 chex ##STR74## chex ##STR75## chexR.sup.3 H H H H HR.sup.4 H H H H HR.sup.21 -- -- H -- HR.sup.27 H H H H HR.sup.28 H H H H HX SO SO S S SO.sub.2Y CH CH CH CH CHZ N N N N N__________________________________________________________________________comp.no. 767 768 769 770 771 772__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR76## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR77##R.sup.1 CH.sub.2OH with R.sup.21 forms CH.sub.2OCOCH.sub.3 with R.sup.21 forms CH.sub.3 with R.sup.21 forms NOCH.sub.3 CF.sub.2 NOCH.sub.3 Isomer B Isomer AR.sup.2 chex chex chex chex ##STR78## chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H -- H -- H --R.sup.27 H H H H H HR.sup.28 H H H H H HX SO SO Isomer 2 SO SO.sub.2 SO.sub.2 SO Isomer 2Y CH CH CH CH CH CHZ N N N N N N__________________________________________________________________________comp. no.773 774 775 776 777 778__________________________________________________________________________ ##STR79## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 omitR.sup.1with R.sup.21 forms CH.sub.3OCOCH.sub.3 with R.sup.21 forms with R.sup.21 forms CH.sub.2 CH.sub.3NOCH.sub.3 CF.sub.2Isomer BR.sup.2chex chex chex ##STR80## ##STR81##R.sup.3H H H H HR.sup.4H H H H HR.sup.21-- H -- -- HR.sup.27H H H H (R)-2(CH.sub.3)R.sup.28H H H H HX SO Isomer 1 SO.sub.2 SO SO.sub.2 SO.sub.2Y CH CH CH CH CHZ N N N N N__________________________________________________________________________comp. no. 779 780 781 782 783 784__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 n-butyl isomer 1 (CH.sub.3).sub.2C.sub.6 H.sub.4 with R.sup.21 forms with R.sup.21 forms (S)CH.sub.3 n-butyl isomer 2 isomer 1 CH.sub.2 CH.sub.2R.sup.2 chex chex ##STR82## ##STR83## ##STR84## chexR.sup.3 H H H H H HR.sup.4 H H H H H HR.sup.21 H H -- -- H HR.sup.27 (R)-2-(CH.sub.3) (R)-2-CH.sub.3 H H (R)-2-CH.sub.3 (R)-2-CH.sub.3R.sup.28 H H H H H HX SO.sub.2 SO.sub.2 SO.sub.2 S SO.sub.2 SO.sub.2Y N N CH CH N NZ N N N N N N__________________________________________________________________________comp. no. 785 786 787 788 789__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 (CH.sub.2).sub.3C.sub.6 H.sub.5 cyclopentyl with R.sup.21 forms CH.sub.2 (S)CH.sub.3 (S)CH.sub.3 isomer 2 isomer 1R.sup.2 chex chex ##STR85## ##STR86## ##STR87##R.sup.3 H H H H HR.sup.4 H H H H HR.sup.21 H H -- H HR.sup.27 (R)-2-CH.sub.3 (R)-2-CH.sub.3 H (R)-2-CH.sub.3 (R)-2-CH.sub.3R.sup.28 H H H H HX SO.sub.2 SO.sub.2 SO SO.sub.2 SY N N CH N NZ N N N N N__________________________________________________________________________comp. no. 790 791 792 793 794__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 (see note 792)- 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 (R)-2-CH.sub.3 (S)CH.sub.3 CN (S)CH.sub.3 (S)CH.sub.3R.sup.2 ##STR88## ##STR89## chex H ##STR90##R.sup.3 H H H H HR.sup.4 H H H H HR.sup.21 H H H H HR.sup.27 (R)-2-(CH.sub.3) (R)-2-CH.sub.3 H (R)-2-CH.sub.3 (R)-2-CH.sub.3R.sup.28 H H H H HX S SO.sub.2 SO SO.sub.2 SO.sub.2Y N N N N NZ N N N N N__________________________________________________________________________comp.no. 795 796 797 798 799__________________________________________________________________________##STR91## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-CH.sub.3 O)C.sub.6 H.sub.4R.sup.1 (R)CH.sub.3 (S)CH.sub.3 (S)CH.sub.3 CH.sub.3 (R)CH.sub.3R.sup.2 chex ##STR92## ##STR93## 1-CH.sub.3 -chex ##STR94##R.sup.3 H H H H HR.sup.4 H H H H HR.sup.21 H H H H HR.sup.27 (R)-2-(CH.sub.3) (R)-2-(CH.sub.3) (R)-2-(CH.sub.3) H (R)-2-(CH.sub.3)R.sup.28 H H H H HX SO.sub.2 S SO.sub.2 SO.sub.2 SO.sub.2Y N N N N NZ N N N N N__________________________________________________________________________comp. no.800 801 802 803 804 805__________________________________________________________________________R 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR95## 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 4-(CH.sub.3 O)C.sub.6 H.sub.4 ##STR96##R.sup.1CH.sub.3 (S)CH.sub.3 CH.sub.3 (S)CH.sub.3 (S)CH.sub.3 (S)CH.sub.3R.sup.2chex chex chex 4-(OH)-chex trans 4-(OH)-chex ##STR97##R.sup.3H H H H H HR.sup.4H H H H H HR.sup.21CH.sub.3 H CH.sub.3 H H HR.sup.272-CH.sub.3 (R)-2-CH.sub.3 2-CH.sub.3 3-CH.sub.3 (R)-2-(CH.sub.3) (R)-2-CH.sub.3R.sup.28H H H H H HX SO.sub.2 SO.sub.2 S SO.sub.2 SO.sub.2 SO.sub.2Y CH N CH N N NZ N N N N N N__________________________________________________________________________ ##STR98## ##STR99## ##STR100## ##STR101## ##STR102## ##STR103## ##STR104## 674. R.sup.1 and R.sup.21 together with the carbon atom to which they are attached form ##STR105## ##STR106## ##STR107## ##STR108## ##STR109## 746. R is 4 CH.sub.3N(CH.sub.3)COO!C.sub.6 H.sub.4 - ##STR110## ##STR111## ##STR112## ##STR113## 752. R is 4 (CH.sub.3).sub.2 NCOO!C.sub.6 H.sub.4- 792. R is 4 (CH.sub.3).sub.2 NCOO!C.sub.6 H.sub.4-
Another aspect of the invention is a pharmaceutical composition which comprises a compound having structural formula I as defined above in combination with a pharmaceutically acceptable carrier.
Another aspect of the invention is the use of a compound formula I for the preparation of a pharmaceutical composition useful in the treatment of cognitive disorders and neurodegenerative diseases such as Alzheimer's disease.
Yet another aspect of the invention comprises a method for making a pharmaceutical composition comprising mixing a compound of formula I with a pharmaceutically acceptable carrier.
Another aspect of this invention is a method for treating a cognitive or neurodegenerative disease comprising administering to a patient suffering from said disease an effective amount of a compound of formula I.
Another aspect of this invention is a method for treating cognitive and neurodegenerative diseases, such as Alzheimer's disease with a compound of formula I in combination with an acetylcholinesterase inhibitor.
Another aspect of this invention is a method for treating a cognitive or neurodegenerative disease comprising administering to a patient suffering from said disease an effective amount of a combination of a compound capable of enhancing acetylcholine release (preferably an m2 or m4 selective muscarinic antagonist) with an acetycholinesterase inhibitor.
Another aspect of this invention is a kit comprising in separate containers in a single package pharmaceutical compounds for use in combination to treat cognitive disorders in one container a compound of formula I or a compound capable of enhancing acetylcholine release (preferably an m2 or m4 selective muscarinic antagonist) in a pharmaceutically acceptable carrier and in a second container an acetylcholinesterase inhibitor in a pharmaceutically acceptable carrier, the combined quantities being an effective amount.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the dose related effects of i.p. administration of a compound of this invention on acetylcholine (ACh) release from cortex of conscious rat.
FIG. 2 is a plot similar to FIG. 1 for ACh release from the striatum following i.p. administration.
FIG. 3 illustrates the effect of 3 mg/kg of Tacrine (i.p. administration) on ACh release from striatum of conscious rat.
FIG. 4 is a plot similar to FIG. 4 for 1 mg/kg of a compound of this invention (i.p. administration).
FIG. 5 is a plot similar to FIG. 4 for 1 mg/kg of a compound of this invention in combination with 3 mg/kg of Tacrine (both i.p. administration).
DETAILED DESCRIPTION
Except where stated otherwise the following definitions apply throughout the present specification and claims. These definitions apply regardless of whether a term is used by itself or in combination with other terms. Hence the definition of "alkyl" applies to "alkyl" as well as the "alkyl" portions of "alkoxy", "haloalkyl", etc.
Alkyl represents a straight or branched saturated hydrocarbon chain having 1 to 20 carbon atoms, more preferably 1 to 8 carbon atoms.
Alkenyl represents a straight or branched hydrocarbon chain of from 2 to 15 carbon atoms, more preferably 2 to 12 carbon atoms, having at least one carbon-to-carbon double bond.
Alkynyl represents a straight or branched hydrocarbon chain of from 2 to 10 carbon atoms, more preferably 2 to 8 carbon atoms, having at least one carbon-to-carbon triple bond.
Cycloalkyl represents a saturated carbocyclic ring having 3 to 12 carbon atoms.
Cycloalkenyl represents a carbocyclic ring having from 5 to 8 carbon atoms and at least one carbon-to-carbon double bond in the ring.
Bicycloalkyl represents a saturated bridged carbocyclic ring having 5 to 12 carbon atoms.
Acyl represents a radical of the formula ##STR114## wherein alkyl is as defined previously.
Halo represents fluoro, chloro, bromo or iodo.
Aryl represents phenyl or naphthyl.
Polyhalo represent substitution of at least 2 halo atoms to the group modified by the term "polyhalo".
Hydroxyguanidino represents a group having the formula ##STR115##
Azabicyclo represents a saturated bridged ring containing from 4 to 8 carbon atoms and at least one nitrogen atom.
Sulfonyl represents a group of the formula --SO 2 --.
Sulfinyl represents a group of the formula --SO--.
Alkylene represents a group having the formula --(CH 2 ) q , wherein q is an integer of from 1 to 20.
Naturally occurring amino acid (NOAA) means an acid selected from the group consisting of alanine(ala), arginine (arg), asparagine (asn), aspartic acid (asp), cysteine (cys), glutamine (gln), glutamic acid (glu), glycine (gly), histadine (his), isoleucine (ile), leucine (leu), lysine (lys), methionine (met), phenylalanine (phe), proline (pro), serine (ser), threonine (thr), tryptophan (trp), tyrosine (tyr), and valine (val).
Nitrogen protecting group (Prot) means a group capable of protecting a nitrogen on a naturally occurring amino acid (or an enantiomer thereof) from reaction. Preferred nitrogen protecting groups are carbobenzyloxy (CBZ), CH 3 OCO(CH 2 ) 9 CO, and t-butoxycarbonyl. Of course any operable nitrogen protecting group is included.
When a variable appears more than once in the structural formula, for example R 5 when X is --C(OR 5 ) 2 --, the identity of each variable appearing more than once may be independently selected from the definition for that variable.
Compounds of this invention may exist in at least two stereo configurations based on the asymmetric carbon to which R 1 is attached, provided that R 1 and R 21 are not identical. Further stereoisomerism is present when X is SO, or C(OR 5 ) 2 (when the two R 5 groups are not the same) or when R is --CR 5 ═C═CR 6 ,. Also within formula I there are numerous other possibilities for stereoisomerism. All possible stereoisomers of formula I are within the scope of the invention.
Compound of formula I can exist in unsolvated as well as solvated forms, including hydrated forms. In general, the solvated forms, with pharmaceutically acceptable solvents such as water, ethanol and the like, are equivalent to the unsolvated forms for purposes of this invention.
A compound of formula I may form pharmaceutically acceptable salts with organic and inorganic acids. Examples of suitable acids for salt formation are hydrochloric, sulfuric, phosphoric, acetic, citric, malonic, salicylic, malic, fumaric, succinic, ascorbic, maleic, methanesulfonic and other mineral and carboxylic acids well known to those skilled in the art. The salts are prepared by contacting the free base forms with a sufficient amount of the desired acid to produce a salt in the conventional manner. The free base forms may be regenerated by treating the salt with a suitable dilute aqueous base solution such as dilute aqueous sodium hydroxide, potassium carbonate, ammonia or sodium bicarbonate. The free base forms differ from their respective salt forms somewhat in certain physical properties, such as solubility in polar solvents, but the salts are otherwise equivalent to their respective free base forms for purposes of the invention.
Compound in accordance with formula I may be produced by processes known to those skilled in the art as shown by the following reaction steps:
Process A (for compounds of formula I where R 21 is H and X is O, SO, or SO 2 ) ##STR116##
wherein L 1 is a leaving group and L 2 is H or an alkali metal and Y, Z, R, R 1 , R 2 , R 3 , R 4 , R 27 and R 28 are as defined above for formula I, and X is O, SO or SO 2 .
Process A is preferably carried out neat or in a solvent such as DMF, DMSO, or acetonitrile, at temperatures ranging from 0° C. to 110° C. for a period of about 1-24 hours. It is preferable that L 1 be a chloride leaving group, but other leaving groups such as bromide, or mesylate, will suffice. It is preferable that L 2 be hydrogen.
Starting materials of formula II when X is O, SO, or SO 2 may be formed by the following reaction sequence ##STR117##
In step (a) the chloride compound is reacted with sodium hydroxide in presence of zinc in solvent such as water, at 50°-95° C. for 1-3 hours. Alternatively R--X--H is reacted with NaH in solvent such as THF or DMF at 0° to room temperature for 1-3 hours. In step (b) the substituted benzaldehyde is added to the reaction mixture from step (a) and the reaction carried out for 1-24 hours at 20°-70° C. In step (c) X 2 represents e.g. chloride or bromide. The reaction with R 1 MgX 2 is carried out in THF or diethyl ether solvent at 0° C.-70° C. for 1-24 hours. Reaction with SOCl 2 is preferably done in excess thionyl chloride as solvent at 25°-70° C. for 1-24 hours. Compounds of formula III are readily available. Some reaction schemes for making other compounds of formula II are shown below: ##STR118##
wherein L 4 is a leaving group and L 2 is H or alkali metal and X, Y, Z, R, R 1 , R 2 , R 3 , R 4 , R 21 , R 27 and R 28 are as defined above for formula I.
Process B is preferably carried out in solvent such as DMF at about 25° to 120° C. for about 1-24 hours. It is preferred that L 2 be Na or hydrogen and that L 4 be a chloride leaving group.
Compounds of formula IV may be produced by the following reaction scheme: ##STR119## In the above reactions scheme R 1A is preferably in accordance with the definition of R 7 for formula I.
Step (d) may be perfomed in acetone or DMF solvent at 20°-100° C., for 1-24 hours under basic conditions, e.g. with K 2 CO 3 .
Step (e) may be performed neat or in methylene chloride, at 20°-70° C., for 1-24 hours.
Step (f) may be performed in ethanol or methanol at 25°-70° C. for 1-24 hours.
Process C (for compounds of formula I where R 21 is H) ##STR120##
wherein L 6 is a leaving group and L 2 is H or alkali metal and X, Y, Z, R, R 1 , R 2 , R 3 , R 4 , R 27 and R 28 are as defined above for formula I.
Process C is preferably carried out in solvent such as DMF, DMSO or acetonitrile at about 0° to 110° C. for 1-24 hours. It is preferable that L 2 be hydrogen and that L 6 be a chloride leaving group.
Compounds of formula VI may be produced by the following reaction scheme: ##STR121##
Other compounds of formula VI may be produced by similar reactions.
Process D (for compounds of formula I where R 21 is H) ##STR122## werein Y 1 is H or alkyl, and compound X is (alkyl) 2 AlCN or a Grignard reagent.
Process D is preferably carried out by first treating a compound of formula VIII, titanium tetrachloride (TiCl 4 ) or titanium tetra isopropoxide, and a compound of formula IX neat or in solvent such as methylene chloride for about 1-24 hours at 20° to 70° C. Finally a compound of formula X is added and the mixture is stirred for 1-24 hours at 20°-70° C. Compounds of formula VIII may be produced by steps (a) and (b) of process A.
Process E (for compounds wherein R 21 is not H) ##STR123##
In the above reaction L is a leaving group. the reaction is performed insolvent, e.g. THF, at -70 C. to room temperature for 1/2 to 12 hours.
Process F (for compounds of structure XI or XII when Y and Z are both N, especially for non-racemic compounds where R 1 and R 27 are both CH 3 ) ##STR124## Reagents: a: (CF 3 CO) 2 O; b: dibromodimethylhydantoin, CH 3 SO 3 H; c: MeLi, then n-BuLi, then RSO 2 F; d: NaOH; e: R 27 CH(OSO 2 CF 3 )CO 2 Et, K 2 CO 3 ; f: ICH 2 CO 2 Et, Na 2 CO 3 ; g: LiAlH 4 ; h: AcOCH 2 COCl; i: BH 3 .Me 2 S.
Reaction of diol (8) with thionyl chloride gives a mixture of chlorides (10), which are in equilibrium with each other. This mixture is reacted with primary amines to afford compounds of the invention (11) and (12). ##STR125##
When the starting material 1 and reagent R 27 CH(OSO 2 CF 3 )CO 2 Et are optically pure or enriched, the products 11 and 12 are non-racemic.
Process G
For compounds of formula I where R 1 is alkyl, R 21 is H, and Y is N, especially compounds of this type when X is SO 2 and the carbon to which R 1 and R 21 are attached is not racemic. ##STR126##
The above reactions may be followed if necessary or desired by one or more of the following steps; (a) removing any protective groups from the compound so produced; (b) converting the compound so-produced to a pharmaceutically acceptable salt, ester and/or solvate; (c) converting a compound in accordance with formula I so produced to another compound in accordance with formula I, and (d) isolating a compound of formula I, including separating stereoisomers of formula I.
Based on the foregoing reaction sequence, those skilled in the art will be able to select starting materials needed to produce any compound in accordance with formula I.
In the above processes it is sometimes desirable and/or necessary to protect certain groups during the reactions. Conventional protecting groups, familiar to those skilled in the art, are operable. After the reaction or reactions, the protecting groups may be removed by standard procedures.
The compounds of formula I exhibit selective m2 and/or m4 muscarinic antagonizing activity, which has been correlated with pharmaceutical activity for treating cognitive disorders such as Alzheimers disease and senile dementia.
The compounds of formula I display pharmacological activity in test procedures designated to indicate m1 and m2 muscarinic antagonist activity. The compounds are non-toxic at pharmaceutically therapeutic doses. Following are descriptions of the test procedures.
MUSCARINIC BINDING ACTIVITY
The compound of interest is tested for its ability to inhibit binding to the cloned human m1, m2, m3, and m4 muscarinic receptor subtypes. The sources of receptors in these studies were membranes from stably transfected CHO cell lines which were expressing each of the receptor subtypes. Following growth, the cells were pelleted and subsequently homogenized using a Polytron in 50 volumes cold 10 mM Na/K phosphate buffer, pH 7.4 (Buffer B). The homgenates were centrifuged at 40,000×g for 20 minutes at 4° C. The resulting supernatants were discarded and the pellets were resuspended in Buffer B at a final concentration of 20 mg wet tissue/ml. These membranes were stored at -80° C. until utilized in the binding assays described below.
Binding to the cloned human muscarinic receptors was performed using 3 H-quinuclidinyl benzilate (QNB) (Watson et al., 1986). Briefly, membranes (approximately 8, 20, and 14 μg of protein assay for the m1, m2, and m4 containing membranes, respectively) were incubated with 3 H-QNB (final concentration of 100-200 pM) and increasing concentrations of unlabeled drug in a final volume of 2 ml at 25° C. for 90 minutes. Non-specific binding was assayed in the presence of 1 μM atropine. The incubations were terminated by vacuum filtration over GF/B glass fiber filters using a Skatron filtration apparatus and the filters were washed with cold 10 mM Na/K phosphate butter, pH 7.4. Scintillation cocktail was added to the filters and the vials were incubated overnight. The bound radioligand was quantified in a liquid scintillation counter (50% efficiency). The resulting data were analyzed for IC 50 values (i.e. the concentration of compound required to inhibit binding by 50%) using the EBDA computer program (McPherson, 1985). Affinity values (K i ) were then determined using the following formula (Cheng and Prusoff, 1973); ##EQU1##
Hence a lower value of K i indicates greater binding affinity.
The following publications, the entire contents of which are incorporated herein by reference, explain the procedure in more detail.
Cheng, Y.-C. and Prusoff, W. H., Relationship between the inhibitory constant (K i ) and the concentration of inhibitor which causes 50 per cent inhibition (IC 50 ) of an enzymatic reaction. Biochem. Pharmacol. 22: 3099-3108, 1973.
McPherson, G. A. Kinetic, EBDA, Ligand, Lowry: A Collection of Radioligand Binding Analysis Programs. Elsevier Science Publishers BV, Amsterdam, 1985.
Watson, M. J, Roeske, W. R. and Yamamura, H. I. 3 H! Pirenzepine and (-) 3 H)quinuclidinyl benzilate binding to rat cerebral cortical and cardiac muscarinic cholinergic sites. Characterization and regulation of antagonist binding to putative muscarinic subtypes. J. Pharmacol. Exp. Ther. 237: 411-418, 1986.
To determine the degree of selectivity of a compound for binding the m2 receptor, the K i value for m1 receptors was divided by the K i value for m2 receptors. A higher ratio indicates a greater selectivity for binding the m2 muscarinic receptor.
MICRODIALYSIS METHODOLOGY
The following procedure is used to show that a compound functions as an m2 antagonist.
Surgery: For these studies, male Sprague-Dawley Rats (250-350 g) were anesthetized with sodium pentobarbital (54 mg/kg, ip) and placed on a Kopf sterotaxic apparatus. The skull was exposed and drilled through to the dura at a point 0.2 mm anterior and 3.0 mm lateral to the bregma. At these coordinates, a guide cannula was positioned at the outer edge of the dura through the drilled opening, lowered perpendicularly to a depth of 2.5 mm, and permanently secured with dental cement to bone screws. Following the surgery, rats were given ampicillin (40 mg/kg, ip) and individually housed in modified cages. A recovery period of approximately 3 to 7 days was allowed before the microdialysis procedure was undertaken.
Microdialysis: All of the equipment and instrumentation used to conduct in vivo microdialysis was obtained from Bioanalytical Systems, Inc. (BAS). The microdialysis procedure involved the insertion through the guide cannula of a thin, needle-like perfusable probe (CMA/12,3 mm×0.5 mm) to a depth of 3 mm in striatum beyond the end of the guide. The probe was connected beforehand with tubing to a microinjection pump (CMA-/100). Rats were collared, tethered, and, following probe insertion, were placed in a large, clear, plexiglass bowl with litter material and access to food and water. The probe was perfused at 2 μl/min with Ringer's buffer (NaCl 147 mM; KCl 3.0 mM; CaCl 2 1.2 mM; MgCl 2 1.0 mM) containing 5.5 mM glucose, 0.2 mM L-ascorbate, and 1 μM neostigmine bromide at pH 7.4). To achieve stable baseline readings, microdialysis was allowed to proceed for 90 minutes prior to the collection of fractions. Fractions (20 μl) were obtained at 10 minute intervals over a 3 hour period using a refrigerated collector (CMA/170 or 200). Four to five baseline fractions were collected, following which the drug or combination of drugs to be tested was administered to the animal. Upon completion of the collection, each rat was autopsied to determine accuracy of probe placement.
Acetylcholine (ACh) analysis: The concentration of ACh in collected samples of microdialysate was determined using HPLC/electrochemical detection. Samples were auto-injected (Waters 712 Refrigerated Sample Processor) onto a polymeric analytical HPLC column (BAS, MF-6150) and eluted with 50 mM Na 2 HPO 4 , pH 8.5. To prevent bacterial growth, Kathon CG reagent (0.005%) (BAS) was included in the mobile phase. Eluent from the analytical column, containing separated ACh and choline, was then immediately passed through an immobilized enzyme reactor cartridge (BAS, MF-6151) coupled to the column outlet. The reactor contained both acetylcholinesterase and choline oxidase covalently bound to a polymeric backbone. The action of these enzymes on ACh and choline resulted in stoichiometric yields of hydrogen peroxide, which was electrochemically detected using a Waters 460 detector equipped with a platinum electrode at a working potential of 500 mvolts. Data acquisition was carried out using an IBM Model 70 computer equipped with a microchannel IEEE board. Integration and quantification of peaks were accomplished using "Maxima" chromatography software (Waters Corporation). Total run time per sample was 11 minutes at a flow rate of 1 m/min. Retention times for acetylcholine and choline were 6.5 and 7.8 minutes, respectively. To monitor and correct for possible changes in detector sensitivity during chromatography, ACh standards were included at the beginning, middle and end of each sample queue.
Increases in ACh levels are consistent with presynaptic m2 receptor antagonism.
RESULTS OF THE TESTS
For compoud numbers 169, 227(-), 289, 269, 214, 232, 123, 236, 296, 300, 301, 302, 304, and 305:
Ki, nM, m1: 2.1 to 224
Ki, nM, m2: 0.05 to 16.6
m2 selectivity ration (Ki, m1/Ki, m2)=9.3 to 42
Ki, nM, m4: 0.33 to 36
m4 selectivity ration (Ki, m1/Ki, m4): 3 to 12
For the persently preferred compounds, compound numbers 615, 633, 622, 650, 667, 656, 658, 757, 763, 760, 690, 711, 719, 726, 714, 777, 795, and 801:
Ki, nM, m2=0.03 to 0.48
Selectivity:
m1/m2=30 to 68
m3/m2=5 to 66
m4/m2=2 to 10.
Presently the most preferred compounds are numbers 667, 760, 801. and 805.
Numerous other compounds in accordance with formula I were tested with the following range of results:
K i binding to m1 receptor, nM: 0.01 to 4770 with undetermined values up to >4200. An undetermined value occurred when a K i was not completely determined, but was found to be above some value of up to 4200 nM.
K i binding to m2 receptor, nM: 0.01 to 1525 with undetermined values up to >4600. An undetermined value occurred when a K i was not completely determined, but was found to be above some value of up to 4600 nM.
m2 Selectivity Ratio K i for m1/K i for m2!
0.3 to 41.5 without regard to any undetermined K i values.
When compound No. 169 from the table of compounds was administered following increases in ACh release above baseline levels were measured.
______________________________________Dosage mg/kg Peak ACh release(Compound 169) as % increase over Baseline______________________________________From Cortex of Conscious Rat (i.p. administration)(FIG. 1)30 150010 4001 75From Striatum of Conscious Rat (i.p. Administration)(FIG. 2)30 27010 1503 1251 300.1 10______________________________________
Oral administration of compound 169 also caused a significant increase in ACh release.
We have made the surprising discovery that compounds of formula I in combination with an acetylcholinesterase (ACh'ase) inhibitor have a synergistic effect on ACh release, as shown below. Here Tacrine was used as the ACh'ase inhibitor.
______________________________________From Striatum of Conscious Rat Peak ACh release as % increase over BaselineDose (FIGS. 3 to 5)______________________________________Tacrine 3 mg/kg (i.p.) 30 (FIG. 3)Compound 169 1 mg/kg (i.p.) 40 (FIG. 4)Tacrine 3 mg/kg and 130 (FIG. 5)Compound 169 1 mg/kg (i.p.)______________________________________
As shown immediately above, when administered in combination, compound 169 and tacrine produce a synergistic increase in ACh release.
The present invention also relates to achieving similar synergistic results by administering a compound of formula I in combination with any other ACh'ase inhibitor including, but not limited to, E-2020 (available from Eisai Pharmaceutical) and heptylphysostigmine.
The present invention also relates to achieving similar synergistic results by administering any compound capable of enhancing ACh release, such as scopolamine or QNB in combination with an ACh'ase inhibitor. Preferably the ACh release enhancing compound is an m2 selective muscarinic antagonist, i.e. one having a (K i for m1/K i for m2) ratio greater than 1 or an m4 selective muscarinic antagonist (Ki for m1/Ki for m4 greater than 1). The m2 or m4 selective muscarinic antagonists for practicing this aspect of the invention include without limitation 3-α-chloroimperialine, AF-DX 116, AF-DX 384, BIBN 99 (these three compounds being available from Boehringer-Ingleheim), tripitramine, and himbacine.
For preparing pharmaceutical compositions from the compounds of formula I, compounds capable of enhancing ACh release, and ACh'ase inhibitors, pharmaceutically acceptable, inert carriers are admixed with the active compounds. The pharmaceutically acceptable carriers may be either solid or liquid. Solid form preparations include powders, tablets, dispersible granules, capsules, cachets and suppositories. A solid carrier can be one or more substances which may also act as dilutents, flavoring agents, solubilizers, lubricants, suspending agents, binders or tablet disintegrating agents; it may also be an encapsulating material.
Liquid form preparations include solutions, suspensions and emulsions. As an example may be mentioned water or water-propylene glycol solutions for parenteral injection.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for either oral or parentertal administration. Such liquid forms include solutions, suspensions and emulsions. These particular solid form preparations are most conveniently provided in unit dose form and as such are used to provide a single liquid dosage unit.
The invention also contemplates alternative delivery systems including, but not necessarily limited to, transdermal delivery. The transdermal compositions can take the form of creams, lotions and/or emulsions and can be included in a transdermal patch of the matrix or reservoir type as are conventional in the art for this purpose.
Preferably, the pharmaceutical preparation is in unit dosage form. In such form, the preparation is subdivided into unit doses containing appropriate quantities of the active components. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation such as packeted tablets, capsules and powders in vials or ampules. The unit dosage form can also be a capsule, cachet or tablet itself, or it may be the appropriate number of any of these in a packaged form.
The quantity of active compound in a unit dose preparation may be varied or adjusted from 1 mg to 100 mg according to the particular application and the potency of the active ingredient and the intended treatment. This would correspond to a dose of about 0.001 to about 20 mg/kg which may be divided over 1 to 3 administrations per day. The composition may, if desired, also contain other therapeutic agents.
The dosages may be varied depending on the requirement of the patient, the severity of the condition being treating and the particular compound being employed. Determination of the proper dosage for a particular situation is within the skill of those in the medical art. For convenience, the total daily dosage may be divided and administered in portions throughout the day or by means providing continuous delivery.
When a compound of formula I or a compound capable of enhancing ACh release is used in combination with an acetylcholinesterase inhibitor to treat cognitive disorders these two active components may be co-administered simultaneously or sequentially, or a single pharmaceutical composition comprising a compound of formula I or a compound capable of enhancing ACh release and an acetylcholinesterase inhibitor in a pharmaceutically acceptable carrier can be administered. The components of the combination can be administered individually or together in any conventional oral or parenteral dosage form such as capsule, tablet, powder, cachet, suspension, solution, suppository, nasal spray, etc. The dosage of the acetylcholinesterase inhibitor may range from 0.001 to 100 mg/kg body weight.
The invention disclosed herein is exemplified by the following preparation and examples which should not be construed to limit the scope of the disclosure. Alternative mechanistic pathways and analogous structures may be apparent to those skilled in the art.
PREPARATIONS ##STR127##
21.4 g (130 mmol) of 1 and 15.0 g (108.6 mmol) of 2 were placed in a round bottom flask. DMSO (100 ml) was added and the mixture was warmed to 130° C. where it was stirred for 70 hours. The reaction was cooled and poured into 400 g of ice and stirred thoroughly. The mixture was filtered and a white precipitate was collected which was washed with water. The solid was recrystallized from ethanol. ##STR128##
Compound 3 (13.72 g, 52.7 mmol) was dissolved in methanol (100 ml) and cooled to 0° C. where NaBH 4 (1.2 g, 31.6 mmol) was added in small portions. The mixture was stirred for one half hour, then warmed to reflux, stirred for 4 hours, and cooled to room temperature. The solvent was removed on a rotary evaporator. The residue was dissolved in ethyl acetate (400 ml) and washed with water and brine, dried over Na 2 SO 4 and then filtered. The solvent was removed with a rotary evaporator. ##STR129##
A CH 2 Cl 2 (120 ml) solution of 4 (14 g, 53 mmol) was cooled to 0° C. and SOCl 2 (7.8 ml, 107 mmol), in 20 ml CH 2 Cl 2 was added over a 30 minute period. The mixture was warmed to room temperature and stirred overnight. The volatiles were removed on a rotary evaporator and the residue dissolved in 500 ml ethyl acetate. The organic solution was washed with water, saturated with NaHCO 3 , and brine. The mixture was dried over Na 2 SO 4 , filtered and the solvent was removed on a rotary evaporator. ##STR130##
Compound 6 (25 g, 180 mmol) was dissolved in 80 ml DMF and cooled to 0° C. Sodium hydride (7.2 g 60% dispersion in mineral oil) was added under nitrogen. Stirring was continued for 20 minutes then the reaction mixture was warmed to room temperature when compound 5 (20 g, 180 mmol), dissolved in 40 ml DMF, was added with syringe. The solution was heated to 100° C. and stirred for 3 hours, then cooled to room temperature. DMF was removed with a rotary evaporator, then 250 ml water was added and the pH adjusted with NaOH to 12. The solution was extracted with ethyl acetate, dried over Na 2 SO 4 and filtered. The solvent was then removed with a rotary evaporator. ##STR131##
Compound 7 (22 g, 100 mmol) was dissolved in 450 ml EtOH, and cooled to 0° C. NaBH 4 (1.9 g, 51 mmol) was added in portions. The mixture was warmed to room temperature and stirred overnight. Water (300 ml) was added and then removed on a rotary evaporator. Ethyl acetate was added to the residue which was then washed with water. The organic layer was dried over Na 2 SO 4 , filtered, and removed with a rotary evaporator. ##STR132##
Compound 8 (22 g, 100 mmol) was dissolved in 400 ml CH 2 Cl 2 and cooled to 0° C. SOCl 2 (9 ml, 120 mmol) was dissolved in CH 2 Cl 2 (50 ml) and added to compound 8 with a dropping funnel, under nitrogen. After addition was complete, the mixture was stirred at 0° C. for 1/2 an hour, then at room temperature for 2 hours. The solution was decanted into an Erlenmeyer flask to remove the precipitate. 10% NaHCO 3 was added until the pH of the aqueous layer was 8. The layers were separated and the CH 2 Cl 2 layer was dried with MgSO 4 . The layer was then filtered and the solvent was removed on a rotary evaporator. ##STR133##
Compound 10 (54 g, 400 mmol) was dissolved in 500 ml DMF and cooled to 0° C. NaOCH 3 (20.5 g) was added in portions with stirring. The ice bath was removed and compound 11 (68.4 g, 400 mmol) was added with stirring. The mixture stirred at room temperature for 3 hours, then at 80° C. for 1 hour, and cooled to room temperature. The DMF solution was concentrated to 200 ml, then 400 ml water and 300 ml ethyl acetate was added with stirring by a mechanical stirrer. The pH was made basic with NaOH, and the organic layer was separated, and dried over MgSO 4 . The solution was filtered and the solvent was then removed by a rotary evaporator. ##STR134##
Compound 12 (33.4 g, 147 mmol) was dissolved in 1 L CH 2 Cl 2 . Compound 13 (25 g, 148 mmol) and triethylamine (21 ml) were added next. To this solution was added TiCl 4 (75 ml of a 1M CH 2 Cl 2 solution). Stirring was continued at room temperature overnight (18 h). The reaction was quenched with a solution of NaCNBH 3 (27 g, 440 mmol, in 150 ml MeOH). After stirring for 2-3 hours, water was added and the pH adjusted to 13 with NaOH. The organic layer was separated and dried over MgSO 4 , followed filtration and removal of the solvent. The residue was dissolved in ethyl acetate and extracted with 3N HCl. The layers were separated and the aqueous layer was basified with NaOH (pH=13). CH 2 Cl 2 was used to extract the aqueous layer. The CH 2 Cl 2 layer was then dried over MgSO 4 , filtered and evaporated to give compound 14. ##STR135##
Ethanol (300 ml) was added to compound 14 (17 g, 45 mmol), followed by 2.5 g Pd(OH) 2 /C. The mixture was placed on a Parr shaker for 1 to 8 hours monitored by TLC at 60 psi of hydrogen then filtered through Celite and the EtOH was removed. The residue was dissolved in ethyl acetate and washed in NaOH. The pH of the aqueous layer was then adjusted to 7, then the aqueous layer was extracted with CH 2 Cl 2 , dried with Na 2 SO 4 , then evaporated to produce compound IV'. This was then recrystalized from CH 3 CN to produce pure IV'. ##STR136##
4.3 g (1 equivalent) of 60% sodium hydride dispersion in mineral oil was weighed into a flame-dried 250 ml flask under nitrogen. The mineral oil was removed by washing with hexane, and 100 ml of dry N,N-dimethylformamide was added by syringe. The suspension was cooled in an ice water bath while 15 g (1 equiv.) of 4-methoxythiophenol was added in portions. The mixture was stirred for 1 hour at room temperature after addition was complete, and 14.6 g (12.6 mL, 1.1 equiv.) of 4-fluorobenzaldehyde was added in one portion. The mixture was stirred for 3 days at room temperature, then poured slowly into 600 mL of ice water with vigorous stirring. The yellow solid was separated by filtration, then triturated twice with 150 mL portions of hexane by vigorous stirring. The product obtained is a light yellow powder, 23 g (88% yield), sufficiently pure for further reaction. ##STR137##
6.75 grams of bis(paramethoxyphenyl)disulfide were stirred with 3.6 mL of glacial acetic acid, and the mixture was cooled to -40° C. Sulfuryl chloride (7.5 mL) was added in portions, and the solution was maintained at -40° C. while the solid dissolved. The brown solution was warmed gradually to -20° C. and stirred for five hours, then warmed to 0° C. Gas was evolved during this period, and the solution darkened to green. The volatiles were removed in vacuo, and the crude material was used in the next reaction without delay. ##STR138##
6.9 grams (39.1 mm) of (1R,2S)-2-phenylcyclohexanol (prepared in accordance with J. K. Whitesell, M-S Wong, J. Org. Chem, 56(14), p. 4552, 1991) were dissolved in 150 mL dry THF with 6 mL dry pyridine. The solution was cooled to -78° C., and para-methoxyphenyl sulfinyl chloride (derived from 6.75 g of the corresponding disulfide) was added slowly. The solution developed a white precipitate as it was stirred at -78° C. for one hour. The reaction was quenched with saturated sodium bicarbonate, diluted with ethyl acetate, and extracted with bicarbonate solution and brine. The organic layers were dried over sodium sulfate, concentrated, and purified by column chromatography in a gradient of 10% ethyl acetate/hexane to 25% ethyl acetate/hexane, yielding 10 grams (78%) of the desired sulfinate, slightly contaminated with the minor diastereomer. This diastereomer was purified by crystallization from hexane/ethyl acetate, a procedure also applicable to the crude product. ##STR139##
1.25 grams of magnesium turnings (52 mm, 2.3 equivalents) were stirred in 5 mL of dry THF. One drop of 1,2-dibromoethane was added, followed by a small portion (roughly one gram) of 4-bromobenzaldehyde diethyl acetal. The solution was heated to initiate formation of the Grignard reagent, and the remaining acetal (to a total of 11.2 grams, 45 mm, 2 equivalents) was added in portions, along with THF (to a total of 25 mL.) The mixture was heated to reflux for 45 minutes, then cooled to room temperature. The Grignard solution thus obtained was added in portions to a solution of the starting sulfinate ester (7.5 grams, 22.6 mm) in 150 mL dry toluene at 0° C. After one hour, the reaction was quenched with saturated sodium bicarbonate solution, diluted with ethyl acetate, and extracted with brine. The organic layers were dried over sodium sulfate, concentrated, and purified by brief column chomatography in 25% ethyl acetate/hexane to give recovered chiral alcohol and the desired acetal, which was used directly in the next reaction. ##STR140##
The acetal obtained from the reaction of 7.5 grams of sulfinate ester was taken up in 60 mL of THF with 10 mL distilled water. A catalytic amount of paratoluene sulfonic acid was added, and the solution was warmed to 60°. After three hours, the mixture was cooled to room temperature, diluted with ethyl acetate, and extracted with saturated sodium bicarbonate solution. The organic layers were dried over sodium sulfate and concentrated to give the desired aldehyde as a crystalline solid, 5.42 grams (97% over two steps). ##STR141##
2 grams (8.17 mm) of the starting 4-(4-methoxyphenyl)thiobenzaldeyde and 1.75 g (1 equivalent of 80%) meta-chloroperbenzoic acid were taken up in 40 mL of dichloromethane at 0°. After 30 minutes, 300 mg of additional MCPBA was added, and the reaction stirred 30 minutes more. The solution was diluted with ethyl acetate and extracted with saturated sodium bicarbonate. The organic layers were dried over sodium sulfate, concentrated, and the product was crystallized from ethyl acetate/hexane to give a first crop of 1.65 grams.
EXAMPLE 1 ##STR142##
Compound II' (1.0 g, 3.5 mmol) was dissovled in DMF (10 ml), followed by addition of K 2 CO 3 (1.5 g). Compound III' (0.66 g, 3.9 mmol) was next added. The mixture was warmed to 50° C. and maintained for 18 hours with stirring. The mixture was cooled to room temperature and ethyl acetate (EtOAc) (150 ml) was added. The organic layer was washed with water (5×50 ml) and saturated NaCl (1×25 ml). The organic layer was dried over Na 2 SO 4 , filtered, and the volatiles removed with a rotary evaporator. The resulting oil was purified by column chromatography, on silica gel, with ethyl acetate as solvent.
EXAMPLE 2 ##STR143##
To the solid chloride (770 mg) was added a solution of 2 equivalents of cyclohexylpiperazine in 5 mL CH 3 CN. The mixture was heated with stirring at reflux for 2 hours then allowed to stand for 18 hours. The resulting solid was suspended in 1:1 EtOAc:water. The aqueous layer was basified with solid K 2 CO 3 . The organic layer was washed several times with water, dried with MgSO 4 and evaporated to obtain the crude product. This was purified by chromatography on a column of silica gel, (TLC grade), and 50:3:1 CH 2 Cl 2 :EtOH:NH 4 OH as the eluant.
EXAMPLE 3 ##STR144##
To an ice cold solution of compound IV' (1 equivalent) in dry DMF under nitrogen was added 0.9 equivalents of NaH, (60% dispersion in mineral oil). After 20 minutes 2-chloropyrimidine was added (0.9 equivalents). The solution was heated at 100° C. for 4 hours. After cooling to room temperature water was added (10 mls per 1 ml DMF) and the solution extracted with ethyl acetate. The organic extracts were dried with MgSO 4 and evaporated to obtain the crude product which was then purified by column chromatography, (Silica gel, TLC grade and 50:3:1 CH 2 Cl 2 :EtOH:NH 4 OH as eluant).
EXAMPLE 4 ##STR145##
To a solution of VI' (0.25 g, 0.73 mmol) in 5 ml acetonitrile was added a solution of VII' (0.12 g, 0.73 mmol, dissolved in 3 ml acetonitrile). The mixture was stirred at room temperature (20° C.) for 0.5 hours, then warmed to 45° C. and stirred for 6 hours. The mixture was cooled to room temperature and ethyl acetate (150 ml) was added and the organic layer was washed with saturated NaCl (1×50 ml). The organic layer was dried over Na 2 SO 4 . The organic layer was filtered and the volatiles removed with a rotary evaporator. The resulting oil was purified by flash chromatography using 50 g silica gel and 9:1 CH 2 Cl 2 /MeOH (saturated with NH 4 OH) as solvent. 0.19 g of a syrup was collected.
EXAMPLE 5 ##STR146##
2 grams (8.17 mmol) of the starting 4-(4-methoxyphenyl)thiobenzaldehyde, VIII', and 1.65 g (10 ml, 1.2 equivalents) of N-cyclohexylpiperazine, X', were taken up under a nitrogen atmosphere in 1 mL of dry dichloromethane at room temperature. 2.9 mL (10 mmol, 1.2 equivalents) of titanium tetraisopropoxide were added by syringe, and the resulting solution was stirred at room temperature for 18 hours. The reaction developed a white precipitate during this period. The reaction was cooled in an ice water bath while 16.3 mL of a 1 molar toluene solution (2 equivalents) of diethylaluminum cyanide were added in portions by syringe. The resulting homogeneous red/brown solution was stirred for 30 minutes at room temperature. The reaction was diluted by the addition of 100 mL ethyl acetate, and quenched by the slow addition of 25 mL water, with vigorous stirring. After 1 hour, the inorganic solids were removed by filtration through Celite, and the filtrate was washed with a saturated brine solution and dried by anhydrous sodium sulfate. The product was concentrated, then purified by column chromatography in a gradient of acetate/hexane, yielding 3.29 grams of the desired product (95% yield.)
EXAMPLE 6 ##STR147##
2 grams (4.6 mm) of the starting nitrile were stirred in 25 mL of tertiary butanol with 1.2 grams (21 mm) of powdered potassium hydroxide. The mixture was heated to reflux for 30 minutes, cooled to room temperature, and diluted with 250 mL of water. The solution was extracted twice with ethyl acetate, and the organic layers were dried over sodium sulfate. Evaporation gave the amide (2 grams, 96%) as an amorphous solid which can be used in subsequent reactions without further purification.
EXAMPLE 7 ##STR148##
0.95 grams of starting amide (2.1 mm) were taken up in 20 mL of 4N hydrochloric acid. The reaction was heated to reflux for 16 hours. The volume of the solution was reduced in vacuo, whereupon the dihydrochloride salt of the desired product precipitated. The solid was isolated by filtration and washed with dry ethyl ether to give 0.85 grams of product, 77% yield. This solid was suitable for use without further purification.
EXAMPLE 8 ##STR149##
A solution of methanolic HCl was prepared by the addition of 3 mL of acetyl chloride to 50 mL of dry methanol. To this solution was added 400 milligrams (0.88 mm) of the starting acid. The flask was fitted with a Soxhlet extraction thimble containing freshly activated molecular sieves (3 Å), and the solution was heated to reflux for 16 hours. The reaction was cooled to room temperature, and the acid was neutralized with solid sodium carbonate. The solution was diluted with 300 mL of dichloromethane and washed with distilled water. The organic layers were dried over magnesium sulfate and purified by column chromatography in 3% methanol/dichloromethane to give 310 milligrams (76%) of the desired product.
EXAMPLE 9 ##STR150##
250 milligrams (0.57 mm) of the starting nitrile were taken up under a nitrogen atmosphere in 4 mL of dry toluene with 0.15 mL trimethylsilyl azide (2 equivalents) and 14 milligrams of dibutyltin oxide (1 equivalent). The solution was heated at 100° for 48 hours, whereupon additional equivalents of the azide and tin reagents were added and the solution was heated an additional 24 hours. The reaction was cooled to room temperature and evaporated to a brown solid, which was purified by preparative thin-layer chromatography in 20% methanol/dichloromethane. 27 milligrams of the desired tetrazole were isolated.
EXAMPLE 10 ##STR151##
20 milligrams (0.57 mm) of the starting tetrazole were treated with an ethereal solution of diazomethane (excess) at 0°. The solution became homogeneous after ten minutes, and after an additional thirty minutes the solution was evaporated and purified by preparative thin-layer chromatograpy in 7.5% methanol/dichloromethane. 10 milligrams of product were isolated.
EXAMPLE 11 ##STR152##
100 milligrams (0.2 mm) of the starting ester were taken up under a nitrogen atmosphere in 4 mL of dry tetrahydrofuran at 0°. 0.53 mL (0.26 mm, 1.3 equivalents) of potassium hexamethyldisilazide solution (0.5M in toluene) were added by syringe, and the resulting solution was stirred for ten minutes. 0.02 mL of iodomethane (1.3 equivalents) were then added by syringe The reaction was stirred for 20 minutes while warming to room temperature, then diluted by the addition of 50 mL ethyl acetate, and extracted with saturated sodium bicarbonate solution and brine. The organic layers were dried by anhydrous sodium sulfate, concentrated, and purified by preparative thin-layer chromotagraphy in 5% methanol/dichloromethane, giving 24 milligrams of the desired product.
EXAMPLE 12 ##STR153##
200 milligrams (0.46 mm) of the starting nitrile were taken up under a nitrogen atmosphere in 10 mL of dry tetrahydrofuran at 0°. 1.2 mL (0.6 mm, 1.3 equivalents) of potassium hexamethyldisilazide solution (0.5M in toluene) were added by syringe, and the resulting orange solution was stirred for ten minutes. 0.05 mL of iodomethane (1.3 equivalents) were added by syringe, which decolorized the solution. The reaction was stirred for 20 minutes while warming to room temperature, then diluted by the addition of 100 mL ethyl acetate, and extracted with saturated sodium bicarbonate solution and brine. The organic layers were dried by anhydrous sodium sulfate, concentrated, and purified by column chromatography in a gradient of hexane/ethyl acetate, giving 190 milligrams of the desired product (92% yield) as an oil that slowly solidified.
EXAMPLE 13 ##STR154##
1.82 grams of the starting sulfide (4.4 mm) were dissolved in 20 mL of dichloromethane and 17 mL of a 0.5N solution of methanesulfonic acid in dichloromethane. 1.15 grams of commercial MCPBA (60-80% pure) were added at 0°, and the solution was stirred for thirty minutes. The reaction mixture was diluted with ethyl acetate and extracted with saturated sodium bicarbonate. The organic layers were dried over sodium sulfate, concentrated, and purified by column chromatography in a gradient of 75% ethyl acetate/hexane to 5% methanol/ethyl acetate to give 1.22 grams of the desired sulfoxide and 0.4 grams of the corresponding sulfone.
EXAMPLE 14 ##STR155## Step 1
To a stirred mixture of 501 (5.0 g) in 50 ml of aqueous NaOH (20% w/w) was added, at 0° C., Di-tert-butyloxy dicarbonate (3.4 g, 1.2 eq.) dissovled in 50 ml of diethyl ether. The cooling bath was removed and the mixture was stirred at room temperature for 2 hours. Two phases were separated and the aqueous phase was extracted with 2×50 ml of ethyl acetate. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a crude product. Purification by flash chromatography on silica gel (10% EtOAc-Hex.) afforded 3.5 g (89%) of 502 as a white solid (m.p.=89°-90° C.).
Step 2
NaH (460 mg, 60% in mineral oil) was washed with dry hexanes and was stirred with 8 ml of dry DMF. To this mixtue was added 4-methoxythiophenol by syringe. The mixture was stirred at RT for 20 min. while the slurry became a clear solution. Compound 502 dissolved in 8 ml of DMF was added dropwise and the mixture was stirred at room temperature over night. Water (80 ml) was added and the mixture was extracted with 3×100 ml of EtOAc. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a crude. Purification by flash chromatography on silica gel (20% EtOAc-Hex.) afforded 3.6 g (74%) of 503 as a white solid (m.p.=105°-107° C.).
Step 3
To a solution of 503 (1.5 g) in 40 ml of dry THF at 0° C., was added MeMgBr (1.15 ml, 3.0M in ether). The mixture was stirred at 0° C. for 1 h. and was quenched with 20 ml of a 10% KHSO 4 . The aqueous phase was extracted with 2×50 ml of ethyl acetate. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a crude. Purification by flash chromatography on silica gel (30% EtOAc-Hex.) afforded 1.3 g (96%) of 504 as a solid, mp 129°-130°.
Step 4
At 0° C., 1.3 g of 504 was dissolved in a mixture of 5 ml TFA and 15 ml CH 2 Cl 2 . The cooling bath was removed and the mixture was stirred at RT for 2 h, quenched with saturated bicarbonate at 0° C., and the aqueous layer extracted with EtOAc. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a white solid compound 505 which was used in the next step without further purification.
Step 5
The white solid from step 4 was dissolved in 10 ml methylene chloride and to this solution was added 350 mg of cyclohexanone followed by 1.3 g of titanium (IV) isopropoxide. The mixture was stirred at RT over night. At 0° C., 440 mg of NaCNBH 3 , dissolved in 2 ml of methanol was added and the mixture was stirred at RT for an additional 3 h. The mixture was quenched with water and extracted with EtOAc. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a crude product. Purification by flash chromatography on silica gel (100% EtOAc) afforded 0.5 g (40%) of Compound 302 as a white solid. The solid was dissolved in ethyl acetate, and treated with 2-3 equivalents of ethereal dry HCl. The mixture was evaporated to dryness in vacuo to give the hydrochloride, m.p. 227°-30°.
Step 6
To a stirred solution of 350 mg of compound 302 in 60 ml EtOAc and 60 ml CH 2 Cl 2 were added 1.7 ml of MeSO 3 H (0.5M in CH 2 Cl 2 ), followed by 262 mg of mCPBA (50-60%) at -40° C. The mixture was allowed to reach 0° C. and was quenched with saturated bicarbonate solution (100 ml). The mixture was extracted with 3×100 ml of EtOAc. The combined organic phases were dried over Na 2 SO 4 , filtered and concentrated to give a crude product. Purification by flash chromatography on silica gel (15% EtOH-EtOAc) afforded 0.2 g (55%) of compound 304 as a white solid.
HPLC Separation of compound 304 on a Chiralcel OJ column; (Chiral Technologies, Inc., Exton, Pa.):
Compound 304 was separated on a 100-200 mg scale under the following conditions:
Solvent system: 0.1% diethyl amine/3% ethanol/hexane
Flow rate: 160 ml/min
Retention Time: 70 min for enantiomer A (compound 300, mp=141-142) 90 min for enantiomer B (compound 301, mp=141) ##STR156##
Compound 505 (0.375 g, 1.15 mmol) and 4-carboethoxycyclohexanonone (0.294 g, 1.72 mmol) were dissolved in 6 mL of CH 2 Cl 2 . The reaction mixture was then cooled to 0° C. followed by addition of Ti(i-PrO) 4 (1.3 mL, 4.42 mmol). The reaction mixture was stirred at room temperature overnight, when TLC indicated there was no starting material. To the reaction mixture was slowly added a solution of NaCNBH 3 (0.364 g, 5.8 mmol) in MeOH (2 mL). The reaction mixture was then stirred at room temperature for 2 h. The reaction was quenched by addition of 50 mL of 1N NaOH followed by 50 mL of ethyl acetate. The reaction mixture was stirred at room temperature for 1 h then was extracted with ethyl acetate (50 mL×3). The organic layer was dried with NaHCO 3 . Solvent was removed and the residue was separated on a silica gel column (5% methanol/CH 2 Cl 2 ) to afford the sulfide (0.46 g, 83% yield) as an oil.
The sulfide (0.038 g, 0.08 mmol) was dissolved in 2 mL of HOAc followed by addition of NaBO 3 /4H 2 O (0.037 g, 0.24 mmol). The reaction mixture was stirred at room temperature overnight, when TLC indicated there was no starting material. To the reaction mixture was then added 1N NaOH until basic. The reaction mixture was extracted with ethyl acetate (20 mL×3). The organic layer was dried with NaHCO 3 . Solvent was removed and the residue was separated on a silica gel column (5% methanol/CH 2 Cl 2 ) to afford Sch 65546 (0.007 mg, 17% yield) as an oil.
EXAMPLE 15 ##STR157## Preparation of 511
To a solution of 25 mmol of cyclohexanone in 20 ml of acetic acid is added 62.5 mmol of cyclohexylpiperazine. The system is blanketed with N 2 and 31.3 mmol of TMS-cyanide, is added. The solution is then heated at 60° C. under N 2 for approximately 20 hours. Acetic acid is removed on a rotary evaporator and the residue treated with 100 ml of water. This is extracted with EtOAc, (3×, 50 ml). Organic layers are washed with 100 ml. of water, dried with Na 2 SO 4 and evaporated to give the crude product as an oil which is purified by column chromatograpy using 100:3:1 CH 2 Cl 2 :EtOH:NH 4 OH as eluant. An oil was obtained, 10 g of which was dissolved in 100 ml CH 2 Cl 2 and 50 ml water, then basified to pH 8 with K 2 CO 3 . The organic layer was dried with Na 2 SO 4 and evaporated to obtain a light yellow powder, 6.6 g. ##STR158## Preparation of Compound 306
In a three necked round bottomed flask is placed 5.4 mmol of Mg and the flask is fitted with a condenser, dropping funnel and nitrogen inlet. The system is flame dried under nitrogen. Bromodiphenyylether (5.4 mmol), is dissolved in anhydrous THF, (10 ml), and added drop-wise. Addition of a drop of ethylene dibromide, iodine and occasional warming may be necessary to initiate Grignard formation. Once initiated the mixture is heated at reflux until all the Mg dissolves. Next, 1.8 mmol of cyanoamine 511 as a solution in 5 ml of dry THF is added, reflux is continued, and the reaction monitored by TLC.
The reaction mixture is cooled to room temperature and quenched by addition of a saturated NH 4 Cl solution, (10 ml ). This is diluted with 10ml of water and extracted with 15 ml EtOAc, (3×). The organic extracts are dried with Na 2 SO 4 and evaporated to give the crude product as an oil which is purified by column chromatography using ether/EtOAc as eluant. 370 ml of clear colorless oil was obtained.
The dimaleate salt was prepared by dissolving the oil in 10 ml of EtOAc and treating with 200 mg of maleic acid. A white powder was obtained (510 mg, mp=144-146).
EXAMPLE 16
Synthesis of Compound 303
Example 15 is repeated except in place of cyclohexanone there is used a compound of the formula ##STR159## Compound 303 is obtained as a di-maleate: ##STR160##
EXAMPLE 17 ##STR161##
NaH (334 mg,, 60% oil suspension) was washed with 15 ml of hexane, then stirred with 5 ml of DMF. Compound 522 (1.03 ml) was added without solvent, the mixture stirred at room temperature for 20 min, a solution of 521 (2.42 g obtained by reductive alkylation) in 1.7 ml of hot DMF added, and the resulting mixture stirred at room termperature for two days. The mixture was quenched with water, and extracted with ethyl acetate. The extracts were purified by flash chromoatography over SiO 2 to give 3.0 g of product 523, mp 128°-9°. ##STR162## m-Chloroperbenzoic acid (MCPBA, 81 mg) was added to a solution of 523 (105 mg) and MeSO 3 H (0.5M in CH 2 Cl 2 , 1.0 ml) in 50 ml of ethyl acetate at -40°. Sufficient CH 2 Cl 2 was added at this temperature to effect dissolution of solids, and the mixture allowed to warm to room temperature. The mixture was quenched with excess NaHCO 3 solution, and extracted with ethyl acetate. The extracts were concentrated and purified by preparative thin-layer chromatography, developing with 20% ethanol-ethyl acetate to give Compound 305 N-oxide. This material was dissolved in CH 2 Cl 2 , CS 2 added, and the resulting mixture stirred for 3 hrs. at room temperature. Evaporation of volatiles and purification of the residue by preparative TLC as above gave Compound 305, mp 125°.
EXAMPLE 18 (Process F)
Preparation of compounds 3-10 shown in Process F, where R is 4-methoxyphenyl, R3 and R4 are H, R1 is (S)--CH 3 , and R27 is (R)--CH 3 and
Preparation of Compound (3)
To an ice cooled solution of trifluoroacetic anhydride (19 mL) in CH 2 Cl 2 (100 mL) add over 15 min (S)-(-)-α-methylbenzylamine (12.2 g) in CH 2 Cl 2 (25 mL) with stirring, then stir at RT for 1 h. Cool in ice and add methanesulfonic acid (40 mL) then powdered dibromodimethyl hydantoin (15 g). Stir till dissolved, then store for 20 h at RT, protected from light. Add to a stirred solution of NaHSO 3 (5 g) in ice-H 2 O (100 mL), stir 5 min., separate, extract with CH 2 Cl 2 , wash the combined organics with H 2 O and dry (MgSO 4 ). Filter on 30 g flash silica and elute with CH 2 Cl 2 (300 mL). Evaporate the total eluates to dryness, add Et 2 O (100 mL), stir 10 min. and add hexanes (500 mL). Stir 0.5 h, filter, wash with hexanes and dry to obtain the 4-bromocompound (12.3 g) as white crystals.
Mp: 153°-155°. Mass spectrum: MH + =296/298.
Preparation of Compound (4)
Cool a solution of compound (3) (11.95 g) in dry THF (160 mL) to -70° under N 2 and add methyllithium (1.4M in Et 2 O, 28.8 mL). Stir 5 min. then add n-butyllithium (2.5M in hexanes, 17 mL). Stir 5 min. then add 4-methoxybenzenesulfonyl fluoride (16 g). remove the cooling bath, stir for 0.5 h, add 1N-HCl aq. (200 mL) and exteract with CH 2 Cl 2 . Wash with H 2 O, dry (MgSO 4 ) and filter on a 15 g pad of flash silica gel, wash with 5% Et 2 O--CH 2 Cl 2 and evaporate. Recrystallise with Et 2 O-hexanes and dry to give the sulfone (13.4 g) as off-white crystals.
Mp: 97°-100°. Mass specrtum: MH + =388.
Preparation of Compound (5)
Reflux on a steam bath for 2 h a mixture of compound (4) (17.5 g) and NaOH (6 g) in H 2 O (15 mL) and ethanol (120 mL). Cool, add H 2 O and extract with CH 2 Cl 2 . Dry over K 2 CO 3 , filter and evaporate. Triturate with Et 2 O-hexanes till solid, filter and dry to afford the amine (10.4 g), as a white solid.
Mp: 113°-115°. Mass spectrum: MH+=292
Preparation of Compound (6)
To solution of compound (5) (1.46 g) in CH 2 Cl 2 (20 mL) and potassium carbonate (2 g) in H 2 O (10 mL) add ethyl (S)-lactate trifluoromethanesulfonate (1.1 g) and stir at RT for 5 h. Wash with water, dry (MgSO 4 ), evaporate and chromatograph on flash silica gel, eluting with a 0-15% gradient of Et 2 O in CH 2 Cl 2 . Evaporate the pure fractions and triturate in hexanes to obtain the crystalline ester (1.90 g)
Mp: 56°-58°. Mass spectrum: MH+=392.
Preparation of Compound (7)
Reflux a mixture of compound (6) (1.73 g), acetonitrile (15 mL), anhydrous sodium carbonate (1.5 g) and ethyl iodoacetate (1.4 mL) for 48 h., work up in H 2 O--CH 2 Cl 2 , dry (MgSO 4 ) and evaporate. Chromatograph on silica, using a 0 to 10% gradient of Et 2 O in CH 2 Cl 2 and evaporate appropriate pure fractions to separately obtain the solid product (1.46 g) and recovered starting aminoester (0.53 g).
Mp: 69°-71°. Mass spectrum: MH+=478.
Preparation of Compound (8)
Stir lithium aluminum hydride (0.45 g) in THF (15 mL) under N 2 with ice cooling and add over 2-3 min. a solution of diester (7) (1.30 g) in THF (25 mL). Stir in ice for 0.5 h., add EtOAc (5 mL) dropwise, then add the solution to stirred, ice cooled 2N-NaOH solution (50 mL). Separate, extract the aq. with 3:1 Et 2 O--CH 2 Cl 2 , combine, dry and evaporate the organics and triturate with a little Et 2 O to obtain the diol as a white powder (0.88 g).
Mp: 123°-125°. Mass spectrum: MH+=394.
Preparation of Mixture (10)
Reflux a mixture of compound (8) (0.125 g), thionyl chloride (0.25 mL) and 1,2-dichloroethane (5 mL) for 1.5 h., evaporate, co-evaporate with 3 mL dichloroethane and dry at high vacuum to obtain the mixture of dichlorocompounds as a pale yellow foam, suitable for use in the next step.
Preparation of Compound Numbers 730 and 803
These compounds are examples of compounds 11 and 12 as shown for process f.
Convert diol (0.125 g) to the dichlorides as described above, then reflux this product for 2 h. in acetonitrile (2.5 mL) with trans-4-aminocyclohexanol hydrochloride (0.32 g), sodium iodide (0.5 g) and diisopropylethylamine (0.6 mL). Cool, and partition in H 2 O--CH 2 Cl 2 . Dry and evaprorate the organic phase, and subject the residue to preparative TLC, eluting with acetone. Extract the separated bands with 1:1 CH 2 Cl 2 --MeOH, evaporate and dry at high vacuum to obtain the free bases as foams.
The less polar band (0.056 g) is compound no.730. Dissolve this in CH 2 Cl 2 (2 mL) and add to stirred Et 2 O (15 mL) containing 4M HCl-dioxan (0.4 mL). Centrifuge, wash by suspension-centrifugation in ether (2×15 mL) and dry under N 2 to obtain the dihydrochloride as a white powder.
Mp: 195°-205°, with decomposition. Mass spectrum: MH+=473.
The more polar band (0.076 g) is compound 803. Convert this to the hydrochloride as above.
Mp: 215-225 C., with decomposition. Mass Spectrum MH+=473
EXAMPLE 19 (Process G) ##STR163##
A solution of the aldehyde (Compound VII' of preparation 4, Process C, 4.9 g, 0.02 mol) in 50 mL THF was cooled in an ice water bath and methylmagnesium bromide (8.5 mL, 3.0M) was slowly added. After 0.5 h the temperature was warmed to room temperature where stirring was continued for 16 h. After dilution with ethyl acetate and addition of water the organic layer was washed with water, brine, and concentrated. Drying under vacuum produced a yellow oil (5.1 g ) which was used without further purification.
A dichloromethane (150 mL) solution of the sulfide was cooled in an ice water bath where MCPBA (11.7 g, 60%) was added. After stirring for 1 h the temperature was warmed to room temperature and stirred for 16 h. After diluting with ethyl acetate the reaction was washed with 10% sodium carbonate, water, and brine. The solution was concentrated and purified by chromatography with ethyl acetate to the sulfone alcohol. ##STR164##
To a clear pale yellow solution of the p-anisylthioacetophenone 1 (0.8 g; 3.1 mmol) in anhydrous tetrahydrofuran (5 mL) was added (S)-oxaborolidine catalyst 2 (0.168 g; 0.6 mmol) and stirred at room temperature for 15 minutes. A solution of borane-methyl sulfide in tetrahydrofuran (2M from Aldrich Chemicals; 1.86 mmol; 0.93 mL) was added dropwise over 6 minutes to the solution of ketone 1 and catalyst 2 at room temperature. After 10 minutes of stirring, thin layer chromatography (TLC) showed absence of starting material and formation of a new, slightly more polar spot. The reaction was quenched by adding methanol (5 mL) and stirring for 15 minutes. Volatiles were removed on the rotary evaporator and the residue was dissolved in methylene chloride (50 mL). The organic extract was washed with water, 1N.HCl, water, 10% NaHCO 3 , brine and dried over magnesium sulfate. Concentration of the organic extract gave the carbinol 3 as a clear pale yellow oil (0.76 g; yield=94%).
HPLC: AS-Column (5% i-PrOH in Hexanes); R t ˜19 min; R:S=97:3 (94% ee/R-Alcohol)
α!D =+26.1 (c=0.1; CHCl 3 )
A clear pale yellow solution of 3 (0.76 g; 2.92 mmol) in anhydrous dichloroethane (8 mL) at room temperature was treated sequentially with solid NaHCO 3 (0.6 g; 7 mmol) and solid meta-chloroperoxybenzoic acid (1.1 g; 6.43 mmol). The flask was fitted with a reflux condensor and the reaction mixture was heated to reflux. TLC at the end of 8 hours showed absence of 3 and formation of a more polar spot. Reaction mixture was allowed to cool to room teperature. The organic layer was decanted away from the white precipitate of sodium salts, washing the solid residue with methylene chloride (2×20 mL). The combined organic extract was washed with water, 10% Na 2 S 2 O 3 solution, water, 10% NaHCO 3 solution and brine. Dried the organic layer over magnesium sulfate and concentrated to obtain ˜0.8 g of a pale yellow solid. Flash silicagel chromatography (20% EtOAc--CH 2 Cl 2 ) gave 0.75 g (88% from 1) of sulfone as a white solid, mp: 125°-126° C. α!D=+22.1 (C=0.095; CHCl 3 ) ##STR165##
To a suspension of the alcohol (4.0 g, 13.6 mmol) in dichloromethane (30 mL) was added triethylamine (2.75 g, 27.2 mmol). The mixture was cooled in an ice/water bath and methanesulfonyl chloride (1.87 g, 16.3 mmol) was added dropwise. After 1 h the mixture was diluted with dichloromethane and washed with water, 2% HCl, water, 10% NaHCO 3 and brine. After drying over sodium sulfate the solvent was evaporated to afford the crude product as a gum. It was used without further purification. ##STR166##
2-(R)-Methylpiperazine (30 g, 0.3 mol) and cyclohexanone (32 g, 0.33 mol) were dissolved in methylene chloride (60 mL) and cooled in an ice/water bath where titanium (IV) isopropoxide (93 g, 0.33 mol) was added dropwise. Stirring was continued for 1 h at 0° C. then at room temperature for 16 h. A solution of sodium cyanoborohydride (21 g, 0.33 mol) in methanol (200 mL) was added with stirring continued for 24 h. The mixture was diluted with 1 L ethyl acetate and stirred with 400 mL 10% NaOH for 1 h. The aqueous solution containing a white precipitate was discarded. The organic layer was washed with water and brine, followed by concentration on a rotary evaporator. The residue purified by flash chromatography with 25:1 CH 2 Cl 2 /MeOH (saturated with aqueous ammonia), yield=50%. ##STR167##
The mesylate from step 2 (4.8 g, 13 mmol) and 1 -cyclohexyl-3(R)-methylpiperazine (3.5 g, 19.4 mmol) were dissolved in 40 mL CH 3 CN and heated to 60 C. where stirring was continued for 24 h, then refluxed for 8 h. The solvent was removed and the residue dissolved in ethyl acetate. The organic layer was washed with 10% sodium carbonate and brine. The solvent was evaporated and the residue chromatographed with 4:1 dichloromethane/acetone. When step 1a is used, two diastereomers (compounds 656 and 667) were collected in a 1:1 ratio (656: R f 0.40, ethyl acetate: Anal. calc. C 68.39, H 7.95, N 6.13, S 7.02; found C 68.01, H 8.02, N 6.09, S 7.05. 667: R f 0.30, ethyl acetate: found C 68.06, H 8.08, N 6.18, S 6.84). When step 1b is used starting with the (S)-oxaborolidine shown, then the product is 656 while (R)-oxaborolidine catalyst gives 667. ##STR168##
By appropriate choice of starting materials, the following compounds were prepared. In these tables the following notes apply.
t-BOC means t-butloxycarbonyl. The compound numbering is not consecutive. A (+) or (-) after a compound number indicates the optical rotation of the stereoisomer for which data is given. "IsoA" or "IsoB" after a compound number indicates an assignment of A or B to different stereoisomers of a compound having the same structural formulas without regard to optical rotation. When the chiral atom has been identified, "isoA" or "isoB" is listed after a substituent for that atom. NBA is nitrobenzyl alcohol, G/TG is glycerol/thioglycerol. Chex means cyclohexyl.
__________________________________________________________________________Compounds having the formula ##STR169### R X R.sup.1 R.sup.2 Mass Spectrum or__________________________________________________________________________ MP1 C.sub.6 H.sub.5 S CH.sub.3 CH.sub.3 MP = 254-256 (di-HCl)2 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 CH.sub.3 MP = 226-230 (di-HCl)3 C.sub.6 H.sub.5 SO CH.sub.3 CH.sub.3 MP = 240-242 (di-HCl)4 C.sub.6 H.sub.5 SO CH.sub.3 H MP = 80-85 (dimaleate)5 C.sub.6 H.sub.5 S CH.sub.3 H MP = 227-229 (di-HCl)6 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 H MP = 180-220 (di-HCl hydrate)7 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 OH MP = 236-238 (di-HCl)8 4-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 OH MP = 242-244 (di-HCl)9 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.2 OH CI (CH.sub.4): 327(M + 1), 309, 19710(+) C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 OH FAB-NBA-G/TG-DMSO: 375 (M + 1)11(-) C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 OH FAB-NBA-G/TG-DMSO: 375 (M + 1)12 2-pyridyl O CH.sub.3 CH.sub.3 MP = 172-175 (Dimaleate)13 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.2 O(CH.sub.2).sub.2 OH EI: 370 (M+), 197, 9914 C.sub.6 H.sub.5 SO.sub.2 i-Pr (CH.sub.2).sub.2 OH EI: (M + 1) 402, 359, 329, 128,15 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 2-CH.sub.3 OC.sub.6 H.sub.4 FAB-NBA-G/TG-DMSO: 437 (M + 1)16 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): (m + 1) 41317 C.sub.6 H.sub.5 SO.sub.2 i-Pr cyclohexyl CI (CH.sub.4): (M + 1) 441, 397, 29918 4-CH.sub..sub.3 C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl EI: 427 (M + 1), 383, 16719 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 C.sub.6 H.sub.5 SIMS-NBA-G/TG-DMSO: 407 (M + 1) 23220 3-pyridyl O CH.sub.3 (CH.sub.2).sub.2 OH MP = 165-168 (Dimaleate)21 3-pyridyl O CH.sub.3 cyclohexyl MP = 219-222 (Dimaleate)22 3-pyridyl S CH.sub.3 (CH.sub.2).sub.2 OH MP = 155-158 (Dimaleate)23 3-pyridyl S CH.sub.3 cyclohexyl MP = 157-159 (Dimaleate)24 2-CH.sub.3 -4-pyridyl O CH.sub.3 (CH.sub.2).sub.2 OH MP = 165-166 (Dimaleate)25 2-CH.sub.4 -pyridyl O CH.sub.3 cyclohexyl MP = 90-9126 C.sub.6 H.sub.5 O CH.sub.3 cyclohexyl EI: 364 (M+), 349, 197, 16727 C.sub.6 H.sub.5 SO.sub.2 C.sub.6 H.sub.5 cyclohexyl FAB-NBA-G/TG-DMSO: (M + 1) 475, 335, 307, 25728 C.sub.6 H.sub.5 SO.sub.2 i-Pr (CH.sub.2).sub.3 OH FAB-G/TG-DMSO: (M + 1) 417, 373, 315, 27329 C.sub.6 H.sub.5 SO.sub.2 i-Pr (CH.sub.2).sub.2 O(CH.sub.2).sub.2 OH FAB-NBA-G/TG-DMSO: (M + 1) 447, 404, 329, 31530 C.sub.6 H.sub.5 SO.sub.2 n-Bu cyclohexyl MP = 217-22031 4-ClC.sub.6 H.sub.4 SO.sub.2 i-Pr cyclohexyl MP = 134-137 (dec)32 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 i-Pr cyclohexyl MP = 208-21033 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 4-NO.sub.2C.sub.6 H.sub.4 FAB-NBA-G/TG-DMSO: 452 (M + 1)34 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 (CH.sub.2).sub.3 OH FAB-NBA-G/TG-DMSO: 389 (M + 1)35 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 2,3-(CH.sub.3).sub.2C.sub.6 H.sub.3 CI (CH.sub.4): 449 (M + 1), 191, 14836 4-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl FAB-NBA-G/TG-DMSO: 447 (M + 1)37 3-pyridyl O i-Pr cyclohexyl MP = 150-153 (Difumarate)38 4(CH.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 i-Pr cyclohexyl CI (CH.sub.4): (M + 1) 471, 427, 305, 289, 144,39 4-ClC.sub.6 H.sub.4 SO.sub.2 C.sub.6 H.sub.5 cyclohexyl FAB-NBA-G/TG-DMSO: 510 (M + 1), 399, 34140 4-ClC.sub.6 H.sub.4 SO.sub.2 n-Bu cyclohexyl FAB-NBA-G/TG-DMSO: 489 (M + 1): 349, 31441 4-(t-Bu)C.sub.6 H.sub.4 SO.sub.2 i-Pr cyclohexyl FAB-NBA-G/TG-DMSO: 497 (M + 1), 453, 371, 329, 301, 22342 3-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 447 (M + 1)43 C.sub.6 H.sub.5 SO.sub.2 cyclohexyl cyclohexyl CI (CH.sub.4): 481 (M + 1), 341, 315, 219, 169, 167, 111, 7944 C.sub.6 H.sub.5 SO.sub.2 CN cyclohexyl CI (CH.sub.4): 424 (M + 1), 397, 328, 286, 258, 233, 197, 169, 167, 111, 7945 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.2 -O-t-BOC FAB-SIMS-NBA-G/TG-DMSO: 411 (M + 1), 308, 19746(+) 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl EI: 427 (m + 1), 388, 16747(-) 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl EI: 427 (m + 1), 388, 16748 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.3O-t-BOC CI (Isobutane): 425 (M + 1)49 4-t-Bu-C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 469, 45650 4(CH.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 443, 399, 167, 12551 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CN cyclohexyl CI (Isobutane): 438 (M + 1), 411, 272, 261, 16952 2,4-(Cl).sub.2C.sub.6 H.sub.3 O CH.sub.3 cyclohexyl CI (Isobutane): 435 (M + 2), 434, 433, 314, 312, 267, 265, 195, 169, 16753 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 NHCOCH.sub.3 CI (CH.sub.4): 430 (M + 1), 35754 4-t-Bu-C.sub.6 H.sub.4 O CH.sub.3 cyclohexyl CI (Isobutane): 421 (M + 1) 349, 335, 261, 259, 9155 n-Bu O CH.sub.3 cyclohexyl CI (Isobutane): 345 (M + 1), 177, 16956 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 CH.sub.2 CONH.sub.2 CI (CH.sub.4): 402 (M + 1)57 2-pyrimidyl O CH.sub.3 cyclohexyl MP = 191-193 (Dimaleate)58 4-CH.sub.3 -3-pyridyl O CH.sub.3 cyclohexyl MP = 168-170 (Dimaleate)59 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 CH.sub.2 -cyclohexyl CI (CH.sub.4): 441 (M + 1)60 3-pyridyl O CH.sub.3 CH.sub.2 -cyclohexyl MP = 187-189 (Dimaleate)61 2-benzoxazolyl O CH.sub.3 cyclohexyl MP = 165-168 (Maleate)62 3-pyridyl O CH.sub.3 CH.sub.2 CH(OH)C.sub.6 H.sub.5 MP = 162-164 (Dimaleate)63 3-pyridyl O CH.sub.3 bicyclo 2.2.1!hept-2-yl MP = 168-175 (Dimaleate)64 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.2 OCOCH.sub.2 -tBu CI (CH.sub.4): 425 (M + 1), 309, 19765 1-Me-2-imidazolyl S CH.sub.3 cyclohexyl MP = 155-158 (Dimaleate)66 2-pyrimidyl O CH.sub.3 cyclopentyl MP = 178-181 (Dimaleate)67 2-pyrimidyl O CH.sub.3 cycloheptyl MP = 167-171 (Dimaleate)68 2-pyrimidyl O CH.sub.3 tetrahydrothiapyran-4-yl MP = 157-160 (Dimaleate)69 2-pyrimidyl O CH.sub.3 3-Me-2-butenyl MP = 180-182 (Dimaleate)70 2-pyrimidyl O CH.sub.3 2-cyclohexenyl MP = 171-174 (Dimaleate)71 2,4-(MeO).sub.2 -6- O CH.sub.3 cyclohexyl MP = 196-199 (Dimaleate) pyrimidyl72 4-CF.sub.3 -2-pyridyl O CH.sub.3 cyclohexyl MP = 178-182 (Dimaleate)73 3-Me-2-butenyl O CH.sub.3 cyclohexyl MP = 194-197 Dimaleate)74 2-pyrimidyl S CH.sub.3 cyclohexyl MP = 182-184 (Dimaleate)75 4-Me-2-pyrimidyl S CH.sub.3 cyclohexyl MP = 163-165 (Dimaleate)76 3-pyridyl O CH.sub.3 1-azabicyclo 2.2.2!-oct-3-yl MP = 182-18477 3,4-(MeO).sub.2C.sub.6 H.sub.3 SO.sub.2 CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 473 (M + 1), 399, 337, 305, 273, 21478 4-Me-2-pyrimidyl O CH.sub.3 cyclohexyl MP = 179-181 (Dimaleate)79 4-HOC.sub.6 H.sub.4 O CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 381, 287, 241, 213, 195, 167,80 4-EtC.sub.6 H.sub.4 O CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 393, 377, 253, 225, 195, 169,81 1-piperidyl CH.sub.2 CH.sub.3 cyclohexyl CI (Isobutane): (M + 1) 370,83 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 2-ketocyclohexyl CI (CH.sub.4): 441 (M + 1), 345, 26184 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 (CH.sub.2).sub.2 OH SIMS-NBA-G/TG-DMSO: 389 (M + 1)85 3,5-(CH.sub.3).sub.2C.sub.6 H.sub.3 O CH.sub.3 cyclohexyl EI: (M + 1) 392, 377, 343, 327, 225, 155,86 4-CH.sub.3 OC.sub.6 H.sub.4 O CH.sub.3 cyclohexyl CI (Isobutane): 395 (M + 1), 269, 227, 181, 16987 2-cyclohexenyl O CH.sub.3 cyclohexyl CI (Isobutane): 369 (M + 1), 28888 4-Cl-2-pyrimidyl O CH.sub.3 cyclohexyl MP = 160-161 (Dimaleate)89 4,6-(Cl).sub.2 -2- O CH.sub.3 cyclohexyl MP = 180-182.5 (Dimaleate) pyrimidyl90 2,4-(MeO).sub.2 -1,3,5- O CH.sub.3 cyclohexyl MP = 198-200 (Dimaleate) triazin-6-yl91(-) 2-pyrimidyl O CH.sub.3 cyclohexyl CI (CH.sub.4): 367 (M + 1), 199, 14292(+) 3-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 449, 447 (M + 1),93(-) 3-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 449, 447 (M + 1),94(+) 2-pyrimidyl O CH.sub.3 cyclohexyl CI (CH.sub.4): 367 (M + 1), 199, 14295 tetrahydropyran-4- O CH.sub.3 cyclohexyl MP = 218-220 (diHCl) yl96 2,3,5-(Me).sub.3C.sub.6 H.sub.2 O CH.sub.3 cyclohexyl EI (M + 1): 406, 266, 239, 16797 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 1-methylbutyl SIMS-NBA-G/TG-DMSO: 415 (M + 1)98 C.sub.6 H.sub.5 S CH.sub.3 cyclohexyl CI (CH.sub.4): 381 (M + 1)99 6-Cl-3-pyridazinyl O CH.sub.3 cyclohexyl MP = 115-117100 6-MeO-3- O CH.sub.3 cyclohexyl MP = 123-127 pyridazinyl101 3-pyridazinyl O CH.sub.3 cyclohexyl MP = 113-115102 2-MeS-4- O CH.sub.3 cyclohexyl MP = 185-187 (Dimaleate) pyrimidinyl103 2-thiazolyl O CH.sub.3 cyclohexyl MP = 184-186 (Dimaleate)104 pivaloyl O CH.sub.3 cyclohexyl CI (CH.sub.4): 373 (M + 1), 205, 169, 167, 121106 4-CH.sub.3 OC.sub.6 H.sub.4 S CH.sub.3 cyclohexyl CI (Isobutane): (M + 1) 411, 243, 169,107 3,4-(MeO).sub.2 C.sub.6 H.sub.3 S CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 441, 273, 164,108 C.sub.6 H.sub.5 C(CH.sub.3) CH.sub.3 cyclohexyl MP = 185-18 Dimaleate (OH)109 N-morpholinyl CH.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 372 (M + 1), 285, 249, 204, 191, 169, 167, 119110 4-Me-piperazin-1-yl CH.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 385 (M + 1), 217, 195, 169, 113, 89111 C.sub.6 H.sub.5 CCH.sub.2 CH.sub.3 cyclohexyl MP = 189-191 (Dimaleate)112 C.sub.6 H.sub.5 CHOH CH.sub.3 cyclohexyl CI (CH.sub.4): 379 (M + 1), 362, 301, 273, 211, 195, 169, 166113 pyrazinyl O CH.sub.3 cyclohexyl MP = 110-111114 2-propynyl O CH.sub.3 cyclohexyl MP = 173-175 (Dimaleate)115 2-hydroxyethyl O CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 333, 317, 205, 165, 121116 benzyl O CH.sub.3 cyclohexyl EI: (M + 1) 470, 455, 330, 303, 167117 H CO CH.sub.3 cyclohexyl CI (CH.sub.4): 301 (M + 1), 385, 195, 169, 135, 119118 CH.sub.3 CO CH.sub.3 cyclohexyl MP = 158-161 (dimaleate)119 4-CH.sub.3 OC.sub.6 H.sub.4 CHOH CH.sub.3 cyclohexyl EI: 408, 279, 268, 241, 167, 135, 126.120 (Me).sub.2 NCO O CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 360, 273, 220, 192, 108121 4-NO.sub.2C.sub.6 H.sub.4 O CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 409 (M + 1), 393, 366, 338, 283, 270, 242, 196, 167122 4-HOC.sub.6 H.sub.4 S CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 397, 257, 229, 195, 167123 4-CH.sub.3 OC.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 427.2 (M + 1), 343124 C.sub.6 H.sub.5 CHCH CH.sub.3 cyclohexyl MP= 108-111125 4-CH.sub.3 OC.sub.6 H.sub.4 CO CH.sub.3 cyclohexyl CI (CH.sub.4): 407 (M + 1), 299, 269, 241, 197, 169, 167, 135.126 3-CH.sub.3 OC.sub.6 H.sub.4 S CH.sub.3 cyclohexyl CI (CH.sub.4): 411, (M + 1), 271, 245, 243, 195, 169, 166.127 4-Br-2,3,5,6- O CH.sub.3 cyclohexyl CI (CH.sub.4): 515 (M + 1), 437, 435, 271, 269, 191, 167. tetrafluoro-phenyl128 3-CH.sub.3 OC.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl MP = 231-234129 4-CHOC.sub.6 H.sub.5 O CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 393 (M + 1), 365, 307, 289, 273, 262, 257, 246, 225130 4-HOC.sub.6 H.sub.5 SO CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 413, 397, 271, 229, 167131 3,4-(CH.sub.3 O).sub.2 C.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl CI (Isobutane): (M + 1) 457, 441,132 3-phenyl-2- O CH.sub.3 cyclohexyl MP = 191-194 (Dimaleate) propynyl133 3-phenyl-2- O CH.sub.3 cyclohexyl MP = 145-148 (HCl) propenyl134 2-butynyl O CH.sub.3 cyclohexyl MP = 190-192 (dimaleate)135 4-CH.sub.3 OC.sub.6 H.sub.4 SO.sub.2 CN cyclohexyl SIMS-NBA-G/TG DMSO 454: (M + 1), 427, 399, 346, 299, 274, 257, 238, 215136 2-pyrimidinyl SO.sub.2 CH.sub.3 cyclohexyl MP = 194-195 (dimaleate)137 2-pyrimidinyl SO CH.sub.3 cyclohexyl MP = 165-167 (dimaleate)138 3-pyridyl SO CH.sub.3 cyclohexyl MP = 123-125139 3-pyridyl SO.sub.2 CH.sub.3 cyclohexyl MP = 142-145140 3-CH.sub.3 OC.sub.6 H.sub.4 O CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 395.4 (M + 1), 258, 238, 227,142 4-CH.sub.3 OC.sub.6 H.sub.4 CNOH CH.sub.3 cyclohexyl EI: (M + 1) 421, 405, 378, 265, 239, ISO 1143 4-CH.sub.3 OC.sub.6 H.sub.4 CNOH CH.sub.3 cyclohexyl EI: (M + 1) 421, 405, 377, 265, 254 ISO 2144 4-CH.sub.3 OC.sub.6 H.sub.4 S CN cyclohexyl SIMS-NBA-G/TG-DMSO: 422 (M + 1), 395, 300, 273, 257, 254, 238145 4-CH.sub.3 OC.sub.6 H.sub.4 SO CN cyclohexyl CI (CH.sub.4): 438.2 (M + 1), 411.3, 331, 254.2146 benzyl C C CH.sub.3 cyclohexyl MP = 180-183 (dimaleate)147 1-Me-1-propynyl O CH.sub.3 cyclohexyl MP = 174-176 (dimaleate)148 4-CH.sub.3 OC.sub.6 H.sub.4 CNOCH.sub.3 CH.sub.3 cyclohexyl CI (Isobutane): (M + 1) 436, 404,150 2-(CH.sub.3 O)C.sub.6 H.sub.4 CHOH CH.sub.3 cyclohexyl EI: (M + 1) 408, 393, 282, 241, 167151 2-thienyl C(CH.sub.3) CH.sub.3 cyclohexyl MP = 147-149 (OH)152 4(CF.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 497 (M + 1), 481, 413, 329, 257, 238153 2(CH.sub.3 O)C.sub.6 H.sub.4 CO CH.sub.3 cyclohexyl FAB(+ve)-HMR: (M + 1) 407, 397, 329, 307, 260, 237,154 CH.sub.3 COOC.sub.6 H.sub.4 S CH.sub.3 cyclohexyl EI: (M + 1) 438, 395, 298, 271, 229, 167,155 4-CH.sub.3 SO.sub.2C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 cyclohexyl FAB(+ve)-HMR: (M + 1) 491, 475, 391, 365, 273, 257156 C.sub.6 H.sub.5 SO iso A CH.sub.3 cyclohexyl CI (CH.sub.4): 397 (M + 1), 382, 213, 167158 C.sub.6 H.sub.5 SO iso B CH.sub.3 cyclohexyl CI (CH.sub.4): 397 (M + 1), 382, 213, 167159 2-pentynyl O CH.sub.3 cyclohexyl 191-193 (dimaleate)160 2-thienyl CCH.sub.2 CH.sub.3 cyclohexyl MP = 173-176 (dimaleate)161 C.sub.6 H.sub.5 O CH.sub.3 (CH.sub.2).sub.2 OCOC(Me).sub.2 CI (CH.sub.4): 439 (M + 1) n-C.sub.3 H.sub.7162 3-butenoyl NH CH.sub.3 cyclohexyl MP = 155-156163 4(CH.sub.3 O)C.sub.6 H.sub.4 CH.sub.2 CH.sub.3 cyclohexyl CI (Isobutane): 393 (M + 1), 379, 285, 225, 169164 3-(3,4- NH CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 462 (M + 1), methylenedioxy 294, 174, 169, 120 phenyl)-2-propenoyl165 trifluoroacetyl NH CH.sub.3 cyclohexyl MP = 127-130166 CH.sub.3 CNO-2 CH.sub.3 cyclohexyl MP = 173-174 (dimaleate) pyrimidyl167 4(CH.sub.3 S)C.sub.6 H.sub.4 S CH.sub.3 cyclohexyl CI (CH.sub.4): (M + 1) 427, 303, 259, 195, 167,168 4(CH.sub.3)C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 (CH.sub.2).sub.3 N(Et)COC(Me).sub.2 CI (CH.sub.4): 514 (M + 1) n-C.sub.3 H.sub.7169 4(CH.sub.3 O)C.sub.6 H.sub.4 SO Iso A CN cyclohexyl SIMS-NBA-G/TG-DMSO: 438 (M + 1), 411, 395, 331, 254, 246, 214170 4-CH.sub.3 SO.sub.2C.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl CI (Isobutane): (M + 1) 475, 459171 4-CH.sub.3 SOC.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl FAB(+ve)-HMR: (M + 1) 458, 443, 365, 307, 273, 257172 p-toluenesulfonyl NH CH.sub.3 cyclohexyl EI: 441, 301, 273, 167, 118173 methanesulfonyl NH CH.sub.3 cyclohexyl CI (CH.sub.4): 399 (M + 1), 260, 169174 2-propynyl NH CH.sub.3 cyclohexyl CI (CH.sub.4): 326 (M + 1), 195, 158175 2-pyrimidinyl S CN cyclohexyl CI (CH.sub.4): 394 (M + 1), 367, 257, 217, 167.176 4-Me-1-piperazinyl SO.sub.2 CH.sub.3 cyclohexyl CI (CH.sub.4): 435 (M + 1), 269, 217, 183, 170, 167.177 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CN cyclohexyl SIMS-NBA-G/TG-DMSO: 438 (M + 1), 411, Iso B Iso B 395, 331, 254, 246, 214178 C.sub.6 H.sub.4 SO CN cyclohexyl CI (Isobutane): (M + 1) 408, 381, 233, 169 ISO B179 2-pyrimidinyl SO CN cyclohexyl SIMS-NBA-G/TG-DMSO) 410 (M + 1), 383, 331, 307180 1-piperidyl SO.sub.2 CH.sub.3 cyclohexyl CI (Isobutane): 420 (M + 1), 376, 188, 167, 140, 125, 112, 85181 N-morpholino SO.sub.2 CH.sub.3 cyclohexyl CI (Isobutane): 372, (m + 1) 370, 285, 249, 204, 191, 170, 167, 119, 100, 88182 2-thiazolyl S CH.sub.3 cyclohexyl 178-180 (dimaleate)183 2-thiazolyl SO CH.sub.3 cyclohexyl MP = 179-180 (dimaleate)184 6-Cl-3-pyridazinyl S CH.sub.3 cyclohexyl MP = 123-125185 6-Cl-3-pyridazinyl SO.sub.2 CH.sub.3 cyclohexyl MP = 154-156186 6-Cl-3-pyridazinyl SO CH.sub.3 cyclohexyl MP = 135-137187 4-(CH.sub.3 SO)C.sub.6 H.sub.4 S CH.sub.3 cyclohexyl FAB(+ve)-HMR: (M + 1) 433, 427, 275, 259, 169,188 t-BOCNH(CH.sub.2).sub.7 CO NH CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 529 (M + 1), 261189 4(CH.sub.3 O)C.sub.6 H.sub.4 S CH.sub.2 NH.sub.2 cyclohexyl CI (Isobutane): (M + 1) 426, 395,190 propadienyl S CH.sub.3 cyclohexyl MP = 175-177 (dimaleate)191 propadienyl SO.sub.2 CH.sub.3 cyclohexyl MP = 143-145 (dimaleate)192 propadienyl SO.sub. CH.sub.3 cyclohexyl MP = 159-161 (dimaleate)193 2-propynyl SO CH.sub.3 cyclohexyl M.P = 153-156 (dimaleate)194 1-propynyl S CH.sub.3 cyclohexyl MP = 180-183 (dimaleate)195 2-pyrimidinyl O C.sub.6 H.sub.5 cyclohexyl SIMS-NBA-G/TG-DMSO: 429 (M + 1), 308, 261196 propadienyl O CH.sub.3 cyclohexyl MP = 149-152 (dimaleate)197 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CN Isomer B cyclohexyl SIMS-NBA-G/TG-DMSO: 438 (M + 1), 411, 395, Isomer A 331, 254, 246, 214198 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 427 (M + 1), 343 Isomer A200 4(CH.sub.3 O)C.sub.6 H.sub.4 SO iso B CN iso A cyclohexyl SIMS-NBA-G/TG-DMSO: 438 (M + 1), 411, 395, 331, 254, 246, 214201 C.sub.6 H.sub.5 O H cyclohexyl CI (CH.sub.4): 351 (M + 1)202 C.sub.6 H.sub.5 O CN cyclohexyl SIMS-NBA-G/TG-DMSO: 375 (M + 1)203 6-(MeNH)- SO.sub.2 CH.sub.3 cyclohexyl MP = 177-179 3-pyridazinyl204 6-(MeNH)- SO CH.sub.3 cyclohexyl MP = 113-135 3-pyridazinyl205 2-propynyl S CH.sub.3 cyclohexyl 170-173 (dimaleate)207 4-(CH.sub.3 O)C.sub.6 H.sub.4 S H cyclohexyl CI (Isobutane): (M + 1) 397,208 2-propynyl NMe CH.sub.3 cyclohexyl MP = 73-76209 2-propynyl O CN cyclohexyl MP = 128-130 (maleate)210 6-(MeO)-3- SO.sub.2 CH.sub.3 cyclohexyl MP = 165-167 (dimaleate) pyridazinyl211 4(CH.sub.3 O)C.sub.6 H.sub.4 SO iso A CN iso A) cyclohexyl SIMS-NBA-G/TG-DMSO: 438 (M + 1), 411, 395, 331, 254, 246, 214212 2-pyrimidinyl O cyclohexyl cyclohexyl CI (Isobutane): 435 (M + 1), 351213 2-pyrimidinyl O CN cyclohexyl FAB-NBA-G/TG-DMSO: 378 (M + 1), 351214 4(CH.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 CO.sub.2 CH.sub.3 cyclohexyl FAB-NBA-G/TG-DMSO: (m + 1) 487, 455, 429, 391, 232215 C.sub.6 H.sub.5 O CN cyclohexyl CI (CH.sub.4): 376 (M + 1), 349216 4-HOC.sub.6 H.sub.4 SO CN cyclohexyl SIMS-G/TG-DMSO-30% TFA: (M + 1) 424, 408, 397, 381217 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 cyclohexyl cyclohexyl EI: 510, 427218 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO cyclohexyl cyclohexyl EI: 494, 411219 4-(CH.sub.3 O)C.sub.6 H.sub.4 S cyclohexyl cyclohexyl EI: 478, 395, 328, 245, 229220 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO.sub.2 CONH.sub.2 cyclohexyl SIMS-NBA-G/TG-DMSO (M + 1) 472, 456, 427, 345, 232221 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO C(NH.sub.2)NOH cyclohexyl FAB-NBA-G/TG-DMSO: (m + 1) 471, 411, 391, 293, 257, 232,222 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO CONH.sub.2 cyclohexyl FAB-NBA-G/TG-DMSO: 456 (M + 1), 411, 349, 272223 1-propynyl S CN cyclohexyl MP = 173-175 (maleate)224 4-(CH.sub.3 O)C.sub.6 H.sub.4 SO CO.sub.2 CH.sub.3 cyclohexyl FAB-NBA-G/TG-DMSO: 471 (M + 1), 455, 411, 364, 287, 273225 cyclopropylmethyl O CH.sub.3 cyclohexyl MP = 197-198 (dimaleate)226 2-propynyl S CN cyclohexyl 123-125 (maleate)227(-) 2-pyrimidinyl O cyclohexyl cyclohexyl CI (CH.sub.4): 435 (M + 1), 267228(+) 2-pyrimidinyl O cyclohexyl cyclohexyl CI (CH.sub.4): 435 (M + 1), 267229 1-propynyl S cyclohexyl cyclohexyl MP = 159-162 (dimaleate)230 2-butynyl O CN cyclohexyl MP = 137-140 (maleate)231 2-pyrimidinyl O 1-Me-4- cyclohexyl EI: 449, 351, 282, 185. piperidynyl232 2-pyrimidinyl O i-Pr cyclohexyl SIMS-NBA-G/TG-DMSO: 395 (M + 1), 227233 4(CH.sub.3 O)C.sub.6 H.sub.4 S CO.sub.2 CH.sub.3 cyclohexyl SIMS-NBA-G/TG-DMSO: 455 (M + 1), 395, 287, 246234 4(CH.sub.3 O)C.sub.6 H.sub.4 SO 5-tetrazolyl cyclohexyl SIMS-NBA-G/TG-DMSO: (M + 1), 481, 465, 456, 411, 395235 2-pyrimidinyl O cyclopentyl cyclohexyl M.P. = 165-8 (HCl)236 4(CH.sub.3 O)C.sub.6 H.sub.4 SO 2-Me-5- cyclohexyl FAB-NBA-G/TG-DMSO: 495 (M + 1), 471, 438, tetrazolyl 411, 283, 273, 246, 232237 4(CH.sub.3 O)C.sub.6 H.sub.4 S allyl cyclohexy FAB-NBA-G/TG-DMSO: 437 (M + 1), 395, 313, 264, 246, 242238 2-propynyl O CN cyclohexyl M.P. = 115-117239 2-propynyl O CH.sub.3 cyclohexyl M.P. = 178-180 (Dimaleate)240 4(CH.sub.3 O)C.sub.6 H.sub.4 SO 3-TMS-4-(1,2,3)- cyclohexyl FAB-NBA-G/TG-DMSO: 552 (M + 1), 536, 368, triazolyl 356, 214241 2-pyrimidinyl O allyl cyclohexyl M.P. = 225-7 (HCL)199 4-(CH.sub.3)C.sub.6 H.sub.4 SO CON(Me).sub.2 cyclohexyl FAB-NBA-G/TG-DMSO: 468 (M + 1), 431, 395, 304, 300__________________________________________________________________________
__________________________________________________________________________Compounds having the formula ##STR170### R X R.sup.1 R.sup.2 Mass Spectrum or MP__________________________________________________________________________242 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 CH.sub.3 EI: 343 (M), 125243 2-pyrimidinyl O CN chex SIMS-NBA-G/TG-DMSO: 377 (M + 1)141 C.sub.6 H.sub.5 O H chex FAB-NBA-G/TG-DMSO: 350 (M + 1)149 3-ClC.sub.6 H.sub.5 SO.sub.2 CH.sub.2 CH.sub.3 FAB-NBA-G/TG-DMSO: 376 (M + 1)__________________________________________________________________________
__________________________________________________________________________Compounds having the formula ##STR171### R X R.sup.1 R.sup.2 Mass Spectrum or MP__________________________________________________________________________244 C.sub.6 H.sub.5 SO.sub.2 i-Pr N(CH.sub.3).sub.2 FAB-NBA-G/TG-DMSO: (M + 1) 401, 356, 312, 273245 C.sub.6 H.sub.5 SO.sub.2 C.sub.6 H.sub.5 1-piperidyl CI (CH.sub.4): (M + 1) 475, 307246 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 i-Pr 1-piperidyl247 2-pyrimidinyl O CH.sub.3 CH.sub.3 CI (CH.sub.4): 298 (M + 1), 282, 199, 126. CI (City)248 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 CH.sub.3 EI: 358 (M + 1), 342249 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 CO.sub.2 Et SIMS-NBA-G/TG-DMSO: 416 (M + 1)250 4-CH.sub.3C.sub.6 H.sub.4 SO.sub.2 CH.sub.3 benzyl SIMS-NBA-G/TG-DMSO: 434 (M + 1)251 2-pyrimidinyl O CH.sub.3 1-piperidyl CI (CH.sub.4): 367 (M + 1) 281, 199, 167252 2-pyrimidinyl O CH.sub.3 chex SIMS-NBA-G/TG-DMSO: 366 (M + 1), 350253 C.sub.6 H.sub.5 SO.sub.2 H (CH.sub.2).sub.3 N(Et)COC SIMS-NBA-G/TG-DMSO: 513 (M + 1) (Me).sub.2 n-C.sub.3 H.sub.7254 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 CH.sub.3 CI (CH.sub.4): 344 (M + 1)255 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 chex CI (CH.sub.4): 412 (M + 1)256 C.sub.6 H.sub.5 O CH.sub.3 CH.sub.3 CI (CH.sub.4): 296 (M + 1) 82 4-CH.sub.3C.sub.6 H.sub.6 SO.sub.2 CH.sub.3 chex CI (CH.sub.4): 426 (M + 1) 342, 270,__________________________________________________________________________ 166
__________________________________________________________________________Compounds having the formula ##STR172### R X R.sup.1 R.sup.2 * Mass Spectrum or MP__________________________________________________________________________257 C.sub.6 H.sub.5 SO.sub.2 H chex SIMS-G/TG-DMSO: 413 (M + 1)258 C.sub.6 H.sub.5 SO.sub.2 H chex Isomer A SIMS-NBA-G/TG-DMSO: 413 (M + 1)259 C.sub.6 H.sub.5 SO.sub.2 H chex Isomer B CI (CH.sub.4): 413 (M + 1)260 3-ClC.sub.6 H.sub.4 SO.sub.2 CH.sub.3 chex Isomer B SIMS-NBA-G/TG-DMSO: 463, 461 (M + 1)261 2-pyrimidinyl O CH.sub.3 chex Isomer A CI (CH.sub.4): 381 (M + 1), 199.262 2-pyrimidinyl O CH.sub.3 chex Isomer B SIMS-NBA-G/TG-DMSO: 381 (M + 1)263 4(CH.sub.3 O)C.sub.6 H.sub.4 SO CN chex Isomer A SIMS-NBA-G/TG-DMSO: 452 (M + 1)iso A206 4-CH.sub.3 OC.sub.6 H.sub.4 SO CN chex Isomer B CI (Isobutane): 452 (M + 1), 425iso B SO__________________________________________________________________________
__________________________________________________________________________Compounds having the formula ##STR173### R X R.sup.1 R.sup.2 * Mass Spectrum or MP =__________________________________________________________________________265 C.sub.6 H.sub.5 SO.sub.2 H chex EI: 412, 369, 181, 126.266 C.sub.6 H.sub.5 SO.sub.2 H chex Isomer A SIMS-NBA-G/TG-DMSO: 413 (M + 1)267 C.sub.6 H.sub.5 SO.sub.2 H chex Isomer B CI (CH.sub.4): 413 (M + 1)268 C.sub.6 H.sub.5 SO.sub.2 CH.sub.3 chex CI (CH.sub.4): 427 (M + 1)269 2-pyrimidinyl O CH.sub.3 chex SIMS-NBA-G/TG-DMSO: 381 (M + 1), 199270 2-pyrimidinyl O 1-Me-4- chex CI (CH.sub.4): 464 (M + 1), 462, 282 piperidinyl271 2-pyrimidinyl O i-Pr chex SIMS-NBA-G/TG-DMSO: 409 (M + 1), 227272 2-pyrimidinyl O H chex CI (CH.sub.4): 367 (M + 1)273 2-pyrimidinyl O n-hexyl chex SIMS-NBA-G/TG-DMSO: 451 (M + 1), 269274 2-pyrimidinyl O chex chex CI (CH.sub.4): 449 (M + 1), 365, 267Iso. A275 2-pyrimidinyl O chex chex CI (CH.sub.4): 449 (M + 1), 365, 267Iso. B157 C.sub.6 H.sub.5 SO.sub.2 H 2- SIMS-NBA-G/TG-DMSO: 411 (M + 1) cyclohexenyl__________________________________________________________________________
______________________________________Compounds having the formula ##STR174### Mass Spectrum or MP______________________________________280 R is 4-CH.sub.3C.sub.6 H.sub.4 : X is SO.sub.2: ##STR175##R.sup.3, R.sup.4, R.sup.8, R.sup.9, and R.sup.21 are H;Y and Z are Nmass spec CI(CH.sub.4): 429 (M + 1)281 R is 4-CH.sub.3C.sub.6 H.sub.4 ; X is SO.sub.2 ; R.sup.1 is CH.sub.3; R.sup.2 is chex; R.sup.3 is OCH.sub.3 ;R.sup.4, R.sup.8, R.sup.9, and R.sup.21 are H; and Y and Z are Nmass spec CI(CH.sub.4): 457 (M + 1)282 R is 4-CH.sub.3C.sub.6 H.sub.4 ; X is SO.sub.2 ; R.sup.1 is CH.sub.3; R.sup.2 is chex; R.sup.3 is H;R.sup.4 is F; R.sup.8, R.sup.9, and R.sup.21 are H; Y and Z are Nmass spec CI(CH.sub.4): (M + 1) 445, 289, 277, 195, 167283 R is C.sub.6 H.sub.5 ; X is SO.sub.2 ; R.sup.1 is CH.sub.3 ; R.sup.2is chex; R.sup.3 is Cl; R.sup.4, R.sup.8, R.sup.9,and R.sup.21 are H; Y and Z are N; mass spec CI(CH.sub.4): 449,447,(M + 1)284 R is 4-CH.sub.3C.sub.6 H.sub.4 ; X is SO.sub.2 ; R.sup.1 is CH.sub.3; R.sup.2, R.sup.3 and R.sup.4 are H; R.sup.9 isCH.sub.2 OH; R.sup.4 and R.sup.21 are H; Y is N; Z is CH.sub.2 ;mass spectrum CI(CH.sub.4); 374 (M + 1), 261.285 ##STR176##R.sup.1 is CH.sub.3 ; R.sup.2 is chex; R.sup.3, R.sup.4, R.sup.8,R.sup.9, and R.sup.21 are H,Y and Z are Nmass spectrum EI: (M + 1) 482, 467, 439, 343, 255, 211, 167286 R is CH.sub.3 ; ##STR177##R.sup.1 is CH.sub.3 ; R.sup.2 is chex; R.sup.3, R.sup.4, R.sup.8,R.sup.9 and R.sup.21 are H;Y and Z are NMP = 173-175 dimaleate287 R is C.sub.6 H.sub.5 ; X is SO.sub.2 ; R.sup.1 is H, R.sup.2 ischex; R.sup.3 is Cl; R.sup.4 and R.sup.5 are H;R.sup.9 is (R)CH.sub.3, R.sup.21 is H; Y and Z are N;mass spec Cl(CH.sub.4): 447 (M + 1)288 R is 4-(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CN; R.sup.2is chex; R.sup.3, R.sup.4, R.sup.8,and R.sup.9 are H; R.sup.21 is CH.sub.2 CO.sub.2 CH.sub.3 ; Y and Zare N;mass spec SIMS-NBA-G/TG-DMSO) 510.2 (M + 1) 483.2,307.1, 273.1, 246.1, 214289 R is 4-(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CN; R.sup.2is chex; R.sup.3, R.sup.4, R.sup.8,and R.sup.9 are H; R.sup.21 is CH.sub.3 ; Y and Z are Nmass spec SIMS-NBA-G/TG-DMSO: 452.2 (M + 1),425.2, 293.1, 268.1, 257.1290 R is 4-(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CN; R.sup.2is chex; R.sup.3, R.sup.4, R.sup.8,and R.sup.9 are H; R.sup.21 is CO.sub.2 Me; Y and Z are Nmass spec FAB-NBA-G/TG-DMSO: 496 (M + 1), 480,469, 454, 389, 312291 R is 2-pyrimidinyl; X is O; R.sup.1 is CH.sub.3 ; R.sup.2 is chex;R.sup.3 and R.sup.4 are H;R.sup.8 is (S)CH.sub.3 ; R.sup.9 and R.sup.21 are H; Y and Z are N;mass specFAB-NBA-G/TG-DMSO: 381 (M + 1), 199.292 R is 2-pyrimidinyl; X is O; R.sup.1 is H; R.sup.2 is chex; R.sup.3and R.sup.4 are H;R.sup.8 is (S)CH.sub.3 ; R.sup.9 and R.sup.21 are H; Y and Z are N;mass specFAB-NBA-G/TG-DMSO: 267 (M + 1)293 R is 2-pyrimidinyl; X is O; R.sup.1 is H; R.sup.2 is chex; R.sup.3and R.sup.4 are H;R.sup.8 is (R)CH.sub.3 ; R.sup.9 and R.sup.21 are H; Y and Z are N;mass specFAB-NBA-G/TG-DMSO: 367 (M + 1)294 R is 2-pyrimidinyl; X is O; R.sup.1 is CH.sub.3 ; R.sup.2 is chex;R.sup.3 andR.sup.4 are H; R.sup.8 is (R)CH.sub.3 ; R.sup.9 and R.sup.21 are H;Y and Z are N; M.P. = 170-173 (HCL)295 R is 4-(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CN; R.sup.2is chex; R.sup.3, R.sup.4,R.sup.8 and R.sup.9 are H; R.sup.21 is CN; Y and Z are N; mass specFAB-NBA-G/TG-DMSO: 463 (M + 1); 436, 356, 307, 273296 R is 4(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CH.sub.3 ;R.sup.2 is chex; R.sup.3, R.sup.4,R.sup.8, and R.sup.9 are H; R.sup.21 is CO.sub.2 Me; Y and Z are N;mass specFAB-NBA-G/TG-DMSO: 485 (M + 1),471, 425, 381, 365, 338, 320297 R is 2-propynyl; X is O; R.sup.1 is CH.sub.3 ; R.sup.2 is chex;R.sup.4 is Cl; R.sup.3,R.sup.8, R.sup.9, and R.sup.21 are H; Y and Z are NM.P. = 172-174 (dimaleate)298 R is 4-(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 is CN; R.sup.2is chex; R.sup.3, R.sup.4,R.sup.8 and R.sup.9 are H; R.sup.21 is allyl; Y and Z are N; massspecFAB-NBA-G/TG-DMSO: 478 (M + 1), 451, 354, 294, 246299 R is 2-propynyl; X is O; R.sup.1 is CN; R.sup.2 is chex; R.sup.4 isCl; R.sup.3, R.sup.8,R.sup.9 are R.sup.21 are H; Y and Z are NM.P. = 132-134 (maleate)300 R is 4(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 and R.sup.21togehter formCH.sub.2 ; R.sup.2 is cyclohexxyl, y is CH, Z is N, R.sup.3,R.sup.4, R.sup.8 andR.sup.9 are H - sulfoxide isomer A301 R is 4(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 and R.sup.21togehter form CH.sub.2 ;R.sup.2 is cyclohexyl, y is CH, Z i N, R.sup.3, R.sup.4, R.sup.8 andR.sup.9are H - sulfoxide isomer B; mp = 141-142302 R is 4(CH.sub.3 O)C.sub.6 H.sub.4 ; X is S; R.sup.1 and R.sup.21together formCH.sub.2 ; R.sup.2 is cyclohexyl, Y is CH, Z is N, R.sup.3, R.sup.4,R.sup.8and R.sup.9 are H; mp = 227-230 (HCl)303 ##STR178##Y and Z are N; R.sup.2 is cyclohexyl; R.sup.3, R.sup.4, R.sup.8 andR.sup.9 are H;mp = 137-139304 R is 4(CH.sub.3 O)C.sub.6 H.sub.4 ; X is SO; R.sup.1 and R.sup.21togehter form CH.sub.2 ;R.sup.2 is cyclohexyl, y is CH, Z is N, R.sup.3, R.sup.4, R.sup.8and R.sup.9 areH - racemic mixture; mp = 122305 R is 4(H.sub.3 CO)C.sub.6 H.sub.4 ; X is SO; R.sup.1 and R.sup.21together form O;R.sup.2 is cyclohexyl; Y is CH; Z is N; R.sup.3, R.sup.4, R.sup.8and R.sup.9 are H.306 ##STR179##and Y and Z are N, R.sup.3, R.sup.4, R.sup.8 and R.sup.9 are H; mp =144-146(dimaleate)______________________________________
In like manner compounds 600 to 804 from the previous table were produced with the following physical data:
__________________________________________________________________________CompoundNumber Melting Point of Mass Spectral Data__________________________________________________________________________600 FAB (NBA-G/TG-DMSO): 435(M + 1), 391, 338, 324601 mp = 164-167602 MS CALC'D 461.2030 FOUND 461.2040603 MS CALC'D 425 FOUND 425604 FAB (NBA-G/TG-DMSO): 471 (M + 1), 455, 411, 364, 287605 mp = 64-68606 mp = 194-195607 Mass Spec CI (ISOB): 408 (M + 1), 381, 365, 231, 169608 MS CALC'D 453 FOUND 453609 Mass Spec SIMS (NBA-G/T-DMSO): 452 (M + 1), 425, 409, 293, 232610 Mass Spec FAB(NBA-G/TG-DMSO): 544 (M + 1), 543, 516, 232611 MS CALC'D 467 FOUND 467612 mp = 142-145613 Mass Spec CI: 452 (M + 1)614 MS CALC'D 437 FOUND 437615 Mass Spec SIMS (NBA-G/TH-DMSO): 452 (M + 1), 425, 409, 293, 232616 MS CALC'D 389 FOUND 390617 Mass Spec FAB(NBA-G/TG-DMSO): 560 (M + 1), 559, 532, 433, 363618 mp = 143-145619620 mp = 123-124621 Mass Spec FAB (NBA-G/TG-DMSO): 495 (M + 1), 411, 299, 283622 mp = 205623 mp = 212624 Mass Spec FAB (NBA-G/TG-DMSO): 544 (M + 1), 543, 516625 mp = 132-134626 Mass Spec FAB (NBA-G/TG-DMSO): 514 (M + 1), 513, 486, 240627 Mass Spec FAB (SIMS9CAL): 530 (M + 1), 425, 398628 mp = 141-145629 mp = 151-154630 Mass Spec FAB (NBA-G/TG-DMSO): 560 (M + 1), 559, 532631 Mass Spec FAB (SIMS4CAL): 5l5 (M + 1), 514, 487, 307, 289, 238632 mp = 121-124 MS CALC'D 410 FOUND 410633 MS CALC'D 438.2200 FOUND 438.2215634 Mass Spec CI: 436 (M + 1), 409635 mp = 190 (dec)636 MS CALC'D 381 FOUND 382637 mp = 225638 MS CALC'D 441 FOUND 442639 mp = 253-255640 Mass Spec FAB (NBA-G/TG-DMSO): 409 (M + 1), 381641 MS CALC'D 454 FOUND 455642 mp = 245643 mp = 209644 MS CALC'D 419.2698 FOUND 419.2706645 mp = 248-250646 mp = 132-133 MS CALC'D 439 FOUND 439647 MS CALC'D 454 FOUND 455648 mp = 210-211649 mp = 250650 mp = 200-203651 MS CALC'D 380.2048 FOUND 380.2047652 mp = 129-131 MS CALC'D 439 FOUND 439653 mp = 188-189654 MS CALC'D 394.2205 FOUND 394.2199655 MS CALC'D 451.2419 FOUND 451.2404656 mp = 227-230657 MS CALC'D 452 FOUND 452658 mp = 53-55659 MS CALC'D 412.2110 FOUND 412.2111660 MS CALC'D 412.1946 FOUND 412.1950661 HRMS Calcd 455.2368 Found 455.2370662 MS CALC'D 430.1852 FOUND 430.1856663 mp = 159-163 MS CALC'D 439 FOUND 440664 MS CALC'D 471.2318 FOUND 471.2327665 MS CALC'D 381.2001 FOUND 381.2000666 MS CALC'D 410.2154 FOUND 410.2158667 mp = 241-242668 MS CALC'D 470.2367 FOUND 470.2367669 mp = 168-170 MS CALC'D 440 FOUND 441670 MS CALC'D 414.1903 FOUND 414.1899671 mp = 130.5-131.5672 Mass Spec CI (CH4): 481 (M + 1), 465, 445, 357, 297, 249, 167673 MS CALC'D 379.2208 FOUND 379.2210674 MS: calcd for C28H35NSO4: 481 found 481.7.675 MS CALC'D 395.2157 FOUND 395.2161676 MS: calcd for C29R37NSO4: 495; found 494 (M + 1).677 mp = 150-151678 Mass Spec CI (CH4): 497 (M + 1), 477, 325, 167679 MS CALC'D 387 FOUND 388680 MS CALC'D 413.1899 FOUND 413.1892681 MS CALC'D 411.2106 FOUND 411.2100682 MS: calcd for C32H37NSO2: 499; found 500 (M + 1).683 MS CALC'D 381.2001 FOUND 381.1996684 MS CALC'D 478.2028 FOUND 478.2014685 MS: calcd for C29H37NSO3: 479; found 480.4 (M + 1).686 MS CALC'D 397.1950 FOUND 397.1954687 MS CALC'D 462.2078 FOUND 462.2078688 MS: calcd for C32H37NSO3: 515; found 516 (M + 1).689 MS CALC'D 413.1899 FOUND 483.1892690 MS CALC'D 379.2208 FOUND 379.2203691 MS CALC'D 437.2263 FOUND 437.2264692 MS CALC'D 395.2157 FOUND 395.2169693 MS CALC'D 442.2052 FOUND 442.2057694 MS CALC'D 442.2052 FOUND 442.2057695 MS CALC'D 456.2572 FOUND 456.2580696 MS CALC'D 391 FOUND 391697 MS CALC'D 397.1950 FOUND 397.1954698 MS CALC'D 516.2572 FOUND 516.2572699 MS CALC'D 410.2154 FOUND 410.2154700 mp = 215-218701 MS CALC'D 456 FOUND 457702 MS CALC'D 437.2263 FOUND 437.2269703 MS CALC'D 411.2106 FOUND 411.2104704 MS CALC'D 426.2103 FOUND 426.2117705 MS CALC'D 440.2623 FOUND 440.2632706 mp = 215-218707 m.p. = 165.0-170.0° C. (·2HCl)708 m.p. = 155.0-160.0° C. (·2HCl)709 MS CALC'D 470.2001 FOUND 470.2007710 mp = 248-250711 MS: calcd for C30H40N2SO5: 540; found 541 (M + 1).712 MS CALC'D 510.2790 FOUND 510.2787713 MS CALC'D 466 FOUND 467714 m.p. = 141.0-142.0° C. (free base)715 Mass Spec FAB: 485 (M + 1), 441, 253, 209716 MS CALC'D 428.1896 FOUND 428.1904717 MS: calcd for C25H32N2SO3: 440; found 441.2 (M + 1).718 MS CALC'D 420 FOUND 421719 MS CALC'D 514 FOUND 515720 m.p. = 90.0-95.0° C. (free base)721 Mass Spec FAB: 485 (M + 1), 391, 273, 232722 MS CALC'D 496.1769 FOUND 496.1765723 MS CALC'D 497.2474 FOUND 497.2460724 MS CALC'D 466 FOUND 467725 MS CALC'D 498 FOUND 499726 mp = 200-210 (dec) , Mass Spec MH+ = 433727 mp = 210 (dec)728 mp = 22o deg (dec)729 MS CALC'D 427.2419 FOUND 427.2427730731 mp = 180 (dec)732 mp = 200 (dec), Mass Spec MH+ = 433733 mp = 180 deg (dec)734 mp = 215 deg (dec)735 MS CALC'D 443.2368 FOUND 443.2367736 mp = 210 deg (dec)737 mp = 200 deg (dec)738 mp = 205 deg (dec)739 mp = 210 deg (dec)740741 mp = 205 deg (dec)742 mp = 185 deg (dec)743 mp = 120-123744 mp = 125-128745 mp = 130-133746 Mass Spec FAB (NBA-G/TG-DMSO): 480 (M + 1), 479, 452, 311747 mp = 208-211748 MS CALC'D 427 FOUND 428749 mp = 131-134750 161-163751 FAB MS 648 (MH+)752 Mass Spec FAB (NBA-G/TG-DMSO): 511 (M + 1), 484753 FAB: 495 (M + 1), 479, 411, 311754 MS CALC'D 439 FOUND 440755 MS CALC'D 440.2259 FOUND 440.2255756 MS CALC'D 470 FOUND 470757 mp = 131-132.5758 MS: calcd for C26H35NSO2: 425; found 426.3 (M + 1).759 MS CALC'D 455 FOUND 456760 MS: calcd for C28H36N2SO5: 512; found 513.2 (M + 1).761 MS CALC'D 456 FOUND 456762 mp = 165-166 MS CALC'D 437 FOUND 438763 MS: calcd for C28H36N2SO4: 496; found 497.3 (M + 1).764 MS: calcd for C26H33NSO2: 423; found 424.3 (M + 1).765 MS: calcd for C28H36N2SO3: 480; found 481.6 (M + 1).766 MS: calcd for C26H35NSO4: 457; found 458 (M + 1).767 MS: calcd for C26H35NSO3: 441; found 442 (M + 1).768 mp = 149-150769 MS: calcd for C28H37NSO4: 483; found 484 (M + 1).770 MS CALC'D 476.2071 FOUND 476.2066771 MS: calcd for C28H38N2SO5: 514; found 515.3 (M + 1).772 mp = 142-143773 mp = 143-144774 MS: calcd for C28H37NSO5: 499; found 500 (M + 1).775 MS CALC'D 460 FOUND 460776 MS: calcd for C29H37NSO5: 511; found 512 (M + 1).777 MS: calcd for C28H41N3S2O5: 563; found 564.1 (M + 1).779 m.p. = 150.0-152.0° C. (·2HCl)780 m.p. = 187.0-189.0° C. (·2HCl)781 MS: calcd for C25H31NSO4: 441; found 442 (M + 1).782 MS: calcd for C25H31NSO2: 409; found 410 (M + 1).783 MS: calcd for C28H39N3SO5: 529; found 530.7 (M + 1).784 m.p. = 155.0-157.0° C. (·2HCl)785 m.p. = 135.0-137.0° C. (·2HCl)786 MS calc'd 511.2994 found: 511.3000787 MS: calcd for C25H31NSO3: 425; found 426 (M + 1).788 MS: calcd for C28H39N3SO5: 529; found 530.3 (M + 1).789 MS: calcd for C28H39N3SO3: 497; found 498.4 (M + 1).790 MS: calcd for C28H39N3SO3: 497; found 498.3 (M + 1).791 MS: calcd for C29H41N3SO4: 527; found 528.1 (M + 1).792 mp = 205-210793 Mass Spec CI: 375 (M + 1)794 mp = 150-152795 mp = 224-227796 MS: calcd for C30H43N3SO3: 525; found 526 (M + 1).797 MS: calcd for C28H40N4SO4: 528; found 529.1 (M + 1).798 Mass Spec CI: 441 (M + 1)799 mp = 138-140800 mp = 143-146801 mp = 259802 mp = 120-122803 mp = 215-225 (dec) Mass Spec MH+ = 473804 mp = 195-205 (dec) Mass Spec MH+ = 473805 mp = 228-230 (dec)__________________________________________________________________________ | Di-N-substituted piperazine or 1,4 di-substituted piperadine compounds of formula I ##STR1## wherein one of Y and Z is N and the other is N, CH, or C-alkyl;
X is --O--, --SO 0-2 --, amino, substituted amino, --CO--, --CH 2 --, mono or di-substituted methylene, --CS--, --CONR 20 --, --NR 20 --SO 2 --, --NR 20 CO--, --SO 2 NR 20 --, --CH═CH--, --C.tbd.C-- or --NHC(O)NH--;
R is optionally substituted phenyl, aryl or cycloalkyl, or other substituents as defined in the specification;
R 1 and R 21 are H, CN or optionally substituted alkyl, or other substituents as defined in the specification;
R 2 is optionally substituted cycloalkyl or piperidyl, or other substituents as defined in the specification; and
R 3 , R 4 , R 5 , R 20 , R 27 and R 28 are as defined in the specification; are muscarinic antagonists useful for treating cognitive disorders such as Alzheimer's disease; pharmaceutical compositions and methods of preparation are also disclosed, as well as synergistic combinations of compounds of the above formula or other compounds capable of enhancing acetylcholine release with acetylcholinesterase inhibitors. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a pulse-width modulation circuit for the amplification of analog signals such as an audio signal, and more particularly to a self-oscillation type pulse-width modulation circuit requiring no carrier signal source.
2. Description of the Prior Art
FIG. 1 shows a conventional direct feedback type pulse-width modulation circuit in which a pulse-width modulated signal is directly fed back to an input thereof. This pulse-width modulation circuit comprises an operational amplifier 1 whose non-inverting input terminal is supplied with an input signal Vi. An inverting input terminal of the operational amplifier 1 is connected to ground through a resistor 2 (value Ra), and a capacitor 3 (value C) for integration is connected between the inverting input terminal and output terminal of the operational amplifier 1. This pulse-width modulation circuit further comprises a hysteresis comparator circuit 4 and a feedback resistor 5 (value Rb) connected between an output terminal of the hysteresis comparator circuit 4 and the inverting input terminal of the operational amplifier 1. The hysteresis comparator circuit 4 comprises an operational amplifier 6, resistor 7 (value R1) and 8 (value R2) and is supplied with an output voltage V1 of the operational amplifier 1 as an input signal. An output signal V0 of this hysteresis comparator circuit 4 appears at an output terminal of the operational amplifier 6.
With this construction, during a period when the output signal V0 is +E (See FIG. 2) the voltage V1 is decreased at a constant slope of -K1 since the capacitor 3 is charged with a current determined by the following formula.
(E-Vi)/Rb-Vi/Ra
And at the time when the voltage V1 drops beyond a negative threshold -(R1/R2)E of the hysteresis comparator circuit 4, the output signal V0 goes to low (-E). Then when the output signal V0 is -E, the voltage V1 is increased at a constant slope of +K2 since the capacitor 3 is discharged with a current determined by the following formula.
(Vi+E)/Rb+Vi/Ra
And at the time when the voltage V1 rises beyond a positive threshold +(R1/R2)E of the comparator circuit 4, the output signal V0 goes high (+E). And thereafter, the above-mentioned operation is repeated.
With this pulse-width modulation circuit, the inclinations -K1 and +K2 of the voltage V1 vary in accordance with the voltage of the input signal Vi, so that a duty factor D of the output signal V0 linearly varies with the voltage of the input signal Vi while a frequency F of the output signal V0 quadratically decreases with the increase of absolute voltage of the input signal Vi. This pulse-width modulation circuit is therefore suitable for an audio amplifier.
However, it is essential that the output voltage V1 of the operational amplifier 1 should have enough amplitude to exceed both positive and negative threshold levels of the hysteresis comparator circuit 4, since this pulse-width modulation circuit employs hysteresis characteristics of the comparator circuit 4 to obtain self-oscillation conditions. This means that a part of gain of the operational amplifier 1 necessary to obtain a voltage corresponding to the voltage between the thresholds, that is to say, a hysteresis width of the comparator circuit 4, does not contribute to the effective amplification. It will be appreciated that the hysteresis comparator circuit 4 has a dead band correspondind to the hysteresis width. An open-loop gain of this pulse-width modulation circuit is decreased by an amount equal to the gain loss of the operational amplifier 1, so that the distortion reduction effected by the negative feedback is also decreased by the gain loss. Further it is impossible for this pulse-width modulation circuit to lessen solely the hysteresis width to overcome the above-mentioned drawbacks, because the self-oscillation conditions are determined by the hysteresis width.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a pulse-width modulation circuit capable of producing a high open-loop gain.
Another object of this invention is to provide a pulse-width modulation circuit having a low distortion by virtue of distortion reduction effected by a negative feedback.
According to the present invention, there is provided a pulse-width modulation circuit which comprises amplifier means for amplifying an input signal inputted thereto to develop an amplified output signal from an output terminal thereof, the amplifier means having capacitor means connected between the inverting input and output terminals of the amplifier means; delayed pulse generating means for producing an output pulse signal in delayed relation to a resulted signal by comparing the output signal of the amplifier means with a reference voltage, the output pulse signal being outputted from the output terminal thereof; and feedback circuit means for feeding the output pulse signal of the delayed pulse generating means back to the inverting input terminal of the amplifier means; whereby a pulse-width modulated signal having a pulse width corresponding to an amplitude of the input signal appears at the output terminal of the delayed pulse generating means.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a conventional pulse-width modulation circuit;
FIG. 2 is a time chart for explaining the operation of the conventional pulse-width modulation circuit of FIG. 1;
FIG. 3 is a block diagram of a pulse-width modulation circuit according to the present invention;
FIGS. 4 and 5 are time charts for explaining the operation of the pulse-width modulation circuit of FIG. 3;
FIG. 6 is a detailed circuit diagram of the pulse-width modulation circuit of FIG. 3;
FIG. 7 is a time chart for explaining the operation of the pulse-width modulation circuit of FIG. 6
FIG. 8 is a block diagram of a modified pulse-width modulation circuit according to the present invention; and
FIG. 9 is a block diagram of a further modified pulse-width modulation circuit according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 3 shows a block diagram of a pulse-width modulation circuit according to the present invention. In FIG. 3, an input signal Vi is applied between an input terminal 10a and a ground terminal 10b. The input terminal 10a is connected to a noninverting input terminal of an operational amplifier 11. A capacitor 12 (value C) for integration is connected between inverting input and output terminals of the operational amplifier 11, the inverting input terminal being connected to the ground terminal 10b through a resistor 13 (value Ra). The output terminal thereof is connected to a non-inverting input terminal of a comparator 14. This comparator 14 is provided for comparing an output voltage V1 of the operational amplifier 11 with ground level, an inverting input terminal thereof being connected to the ground terminal 10b while an output terminal thereof is connected to an input terminal 15a of a phase shifter 15. This phase shifter 15 is so constructed that the output voltage V3 derived from an output terminal 15b is delayed with respect to the input voltage V2 by a period of time φ, an output terminal thereof being connected to an input terminal of a buffer amplifier 16. The buffer amplifier 16 is supplied with power voltages +E and -E at its positive and negative power input terminals, respectively, and an output terminal thereof is connected to an output terminal 17a of this pulse-width modulation circuit and also to the inverting input terminal of the operational amplifier 11 through a feedback resistor 18 (value Rb). In this case, the phase shifter 15 cooperates with the buffer amplifier 16 to form a pulse amplification circuit 19. A terminal 17b serves as a ground terminal.
Firstly, conditions of self-oscillation of this pulse-width modulation circuit will be described. A voltage at the inverting input terminal of the operational amplifier 11 is always equal to the input signal Vi by virtue of the provision of an operational amplifier with a feedback loop. It is assumed that an output signal Vo in the form of rectangular waves shown in FIG. 4 is obtained as a result of the operation of this pulse-width modulation circuit. In this case, during a period when the output signal V0 is high (voltage +E), a current determined by the following formula (1) passes through the capacitor 12 in the direction indicated by an arrow in FIG. 3, so that the voltage V1 at the output terminal of the operational amplifier 11 drops at a constant slope -K1 as shown in FIG. 4.
(E-Vi)/Rb-Vi/Ra (1)
Next, during a period when the output signal V0 is low (voltage -E), a current determined by the following formula (2) passes through the capacitor 12 in the direction opposite to the arrow, so that the voltage V1 rises at a constant inclination +K2.
(E+Vi)/Rb+Vi/Ra (2)
The voltage V1 thus forms continuous triangular waveshapes as shown in FIG. 4. The voltage V1 is compared with the ground level by the comparator 14, and as a result, the voltage V2 in the form of rectangular waves shown in FIG. 4 is obtained at the output terminal thereof. This voltage V2 has the same duty factor D and frequency F as the output signal V0 but differs in phase from the output signal V0 by φ. Therefore, if the phase of the voltage V2 is shifted or delayed through the phase shifter 15 by φ, the resultant voltage V3 obtained at the output terminal of the phase shifter 15 coincides in phase with the output signal V0, so that the self-oscillation conditions of this pulse-width modulation circuit are perfectly met.
Now, the duty factor D of the output signal V0 in this embodiment will be described in more detail. When the pulse-width modulation circuit is in a stationary state in which the self-oscillation is maintained, the voltage V1 should vary continuously. Therefore, the amount of charge flowing into the capacitor 12 should be equal to the amount of charge flowing therefrom. The amount of charge Q+ flowing into the capacitor 12 during a time period T1 (See FIG. 5) when the output signal V0 is +E can be calculated by the following formula (3) derived from the formula (1).
Q+=((E-Vi)/Rb-Vi/Ra).T1 (3)
In the same manner, the amount of charge Q-flowing from the capacitor 12 during a time period T2 when the output signal V0 is -E can be calculated by the following formula (4) derived from the aforementioned formula (2).
Q-=((E+Vi)/Rb+Vi/Ra).T2 (4)
The charges Q+ and Q- should be equal to each other in amount, and ((E-Vi)/Rb-Vi/Ra) and ((E+Vi)/Rb+Vi/Ra) can be substituted by K1 and K2, respectively. Therefore, the following formulas (5) and (6) are obtained.
((E-Vi)/Rb-Vi/Ra).T1=((E+Vi)/Rb+Vi/Ra).T2 (5)
K1.T1=K2.T2 (6)
Therefore, the duty factor D can be expressed as follows: ##EQU1##
It will be readily understood from the formula (8) that the duty factor D varies linearly with the variation of the input signal Vi and that the modulation gain G is determined by the ratio of the value Ra to the value Rb.
Next, the frequency F or the frequency of oscillation of this pulse-width modulation circuit will be described. Reference is first made to the variation of voltage V1 around the negative peak P1 thereof. The following formula (9) can be obtained since the voltage V1 should vary continuously:
K1.φ=K2.(T2-φ) (9)
And the frequency F is represented by the following formula (10):
F=1/(T1+T2)=(1-D)/T2 (10)
And then the following formula (11) is obtained by substituting the formula (9) for the formula (10).
F=(1-D)/(K1+K2).φ/K2) (11)
Further, the following formula (12) is obtained by substituting the formula (7) for the formula (11).
F=(K1.K2)/(K1+K2).sup.2.φ) (12)
Consequently, the frequency F is represented by the following formula: ##EQU2##
It is seen from the above formula (13) that the frequency F varies in such a manner that the frequency F quadratically decreases with the increase of absolute voltage of the input signal Vi.
With the construction of this pulse-width modulation circuit, it is not essential for the comparator 14 to have hysteresis characteristics since the self-oscillation conditions can be determined by the phase shift effected by the phase shifter 15. The gain of the operation amplifier 11 is therefore utilized with less loss, so that open-loop gain of the pulse-width modulation circuit becomes greatly high. In addition, the distortion reduction effected by the negative feedback through the resistor 18 is increased. Further with this construction, the duty factor D of the output signal V0 varies linearly with the variation of voltage of the input signal Vi. In addition, the frequency F varies in such a manner that it decreases with the increase of absolute voltage of the input signal Vi, so that the respective circuit portions of this pulse-width modulation circuit including the pulse amplification circuit 19 need less width of band than the conventional pulse-width modulation circuit. This pulse-width modulation circuit is therefore quite suitable for amplification of audio signals.
In the case of the pulse-width modulation circuit described above, the phase shifter 15 is provided in the pulse amplification circuit 19 as an essential circuit. However, an output of a common pulse amplification circuit is delayed by delay factors of its switching control circuit or a delay of switching elements or a delay of the comparator 14. It is therefore possible to obbtain stable self-oscillation conditions by utilizing such delay without providing any particular phase shifters.
There is shown in FIG. 6 a circuit diagram of the abovedescribed pulse-width modulation circuit in which an on-off timing control circuit 20 and the inverter 14a function as a phase shifter. The on-off timing control circuit 20 serves to render output-stage switching elements of this pulse-width modulation circuit non-conductive for a certain period of time when the switching elements are in their transit states so as to prevent both switching elements from simultaneously being rendered conductive. Accordingly, no current flows through both switching elements at the same time, so that the power efficiency at the output-stage is improved
An operational amplifier 11 in FIG. 6 is provided with two capacitors 12a and 12b serially connected between the inverting input and output terminals thereof, the junction point of these capacitors 12a and 12b being grounded through a resistor 21. The capacitors 12a and 12b and the resistor 21 form a negative feedback network for the operational amplifier 11 which network functions as a secondary lead factor. The integrator comprised of the operational amplifier 11 and the negative feedback network eventually has amplitude transfer characteristics by which the output signal thereof decreases sharply, i.e., at a rate of 12 dB/oct, over the range of higher frequencies than the cutoff frequency of the integrator. Consequently, the passage of the carrier signals through the integrator is more efficiently prevented. The upper cutoff frequency of the integrator can therefore be set higher than that of the integrator with a single capacitor shown in FIG. 3 to improve the frequency characteristics of the overall circuit of this pulse-width modulation circuit.
In operation, the output voltage V1 of the operational amplifier 11 is supplied to an inverter 14a. The inverter 14a is composed of a CMOS gate and functions as a comparator. The output voltage V2 of the inverter 14a is fed to the on-off timing control circuit 20 with a delay of φ1 based on a delay function of the CMOS gate. This delay of φ1 shares in the delay time which determines the conditions of self-oscillation. The on-off timing control circuit 20 operates so as to prevent a current from passing serially through field-effect power transistors 22a and 22b, which are the output-stage switching elements of this pulse-width modulation circuit. It is seen from the time chart shown in FIG. 7 that when the output voltage V2 of the inverter 14a falls from a high level (positive voltage) to a low level (negative voltage), the low level signal is immediately supplied to an input terminal of an inverter 23 through a diode 24, so that the output voltage V3 of the inverter 23 rises from the low level to the high level immediately. On the other hand a signal level at an input terminal of an inverter 25 falls gradually from the high level to the low level in accordance with a time constant determined by a resistor 26 and a capacitor 27, since a diode 28 is turned off. As a result, an output voltage V4 of the inverter 25 rises instantaneously from the low level to the high level a certain period of time (delay time of φ2) after the voltage V2 falled.
At the moment when the voltage V2 rises from the low level to the high level, the high level signal is immediately supplied to the input terminal of the inverter 25, so that the voltage V4 also falls immediately from the high level to the low level. On the other hand, the signal level at the input terminal of the inverter 23 rises gradually from the low level to the high level in accordance with a time constant determined by a resistor 29 and a capacitor 30. As a result, the voltage V3 falls instantaneously from the high level to the low level a certain period of time (delay time of φ2) after the voltage V2 rose. The delay times of φ2 in the switching operations of the voltages V3 and V4 are set by the time constants determined by the respective resistor 29 and capacitor 30, and resistor 26 and capacitor 27, and the same delay times φ2 are obtained by setting such time constants at same values. The delay time of φ2 shares in the delay time which determines the conditions of self-oscillation. The low-level signal portions of the voltage V3 and the high-level signal portions of the voltage V4 are added together through diodes 31 and 32, and the resultant signal is fed to an input terminal of an inverter-type pulse amplifier 33. The voltage V5 at the input terminal of the pulse amplifier 33 varies as shown in FIG. 7.
The complementarily-connected field effect power transistors 22a and 22b are driven by the output voltage V6 of the pulse amplifier 33, so that the output signal V0 shown in FIG. 7 is obtained at the common-drain of the field effect power transistors 22a and 22b. The output signal V0 is demodulated through a low-pass filter 34, and the resultant audio signal is then supplied to a loudspeaker 35. In the case where this pulse-width modulation circuit is required to have an overall gain of 1, the resistor 13 (value Ra) should be omitted from the circuitry shown in FIG. 3 or 6.
FIG. 8 shows a block diagram of a modified embodiment of the present invention in which like reference characters denote corresponding parts of the above-mentioned embodiment. This pulse-width modulation circuit is constructed so as to operate inversely with respect to the pulse-width modulation circuit shown in FIG. 3. An input impedance of this pulse-width modulation circuit is defined by the value Ra of the resistor 13.
FIG. 9 shows a block diagram of a further modified embodiment of the present invention in which CMOS gates are employed in order to make the structure thereof simpler. In this case, an inverter 41 composed of a CMOS gate substitutes the operational amplifier 11 and another inverter 44 composed of a CMOS gate substitutes the comparator 14 while an inverter-type pulse amplifier 16a is employed as the pulse amplifier 16. | A pulse-width modulation circuit of self-oscillation type produces a pulse-width modulated signal having a pulse width corresponding to an amplitude of an analog input signal. An integrator having an amplifier and at least one capacitor produces a triangle-wave signal. A comparator compares the triangle-wave signal with a reference voltage to generate a pulse signal. A delay circuit produces a delayed pulse signal in response to the pulse signal generated by the comparator. A feedback circuit feeds the delayed pulse signal back to an input terminal of the amplifier so that the self-oscillation is effected. The pulse-width modulated signal is derived from an output terminal of the delay circuit. | 7 |
RELATED APPLICATIONS
This application claims the benefit of U.S. provisional patent application 61/978,566 filed Apr. 11, 2014 to the same inventor, the contents of which are included herein by reference.
FIELD OF ART
The present invention relates to an aileron system that causes an aircraft to safely respond to a pilot's habitual actions in situations where the pilot's habitual actions would normally be hazardous. The present invention relates to an aileron system that uses unsynchronized ailerons to simultaneously cause yaw and roll and which can recover an aircraft from a dropped-wing stall by intuitive or habitual use of the yoke.
BACKGROUND OF THE INVENTION
Conventional aircraft execute turns using ailerons, which are aerodynamic devices that work as a synchronized opposing pair along the trailing edges of opposing wings. A first aileron rotates upward to give a first wing a downward aerodynamic force and the second aileron simultaneously rotates downward to give the second wing an upward force to roll the aircraft, thereby rotating the lift vector and so creating a horizontal component of lift that moves the aircraft horizontally to execute the turn. Synchronized ailerons produce differential profile drag, producing a reverse yaw effect that must be compensated for with a rudder.
Many crashes with loss of life have resulted from low speed stalls on final approach to landing, because only a highly-skilled pilot can resist the normal reaction to a wing dropping. The normal reaction is to turn the yoke in the direction opposite the low wing, which would normally (at higher speeds and altitudes) be the correct response. In response to the reaction, the low wing gains additional lift from the increase in camber caused by the drooping aileron, and the raised aileron on the opposite wing reduces lift on that wing. These combined forces cause the wings to become level. However, when the aircraft has slowed to minimum approach speed, and a wing drops, the normal reaction of turning the yoke in the opposite direction increases the camber of the low, slow wing and so increases drag on that wing, which is likely to cause the wing to stall and induce a tailspin from which even a skilled pilot could not recover at final-approach altitude. The correct procedure in this case is to lower the nose and increase power to avoid the stall. The skilled pilot must recognize that only increasing speed will allow the aircraft to maintain level flight and normal glide path to escape a low-altitude dropped wing stall using conventional ailerons.
Thus, there is a need for an aileron system that will cause the aircraft to avoid a low-speed dropped-wing stall in response to the intuitive reaction of a relatively unskilled pilot rather than require the reasoned reaction of a skilled pilot.
SUMMARY OF THE INVENTION
The present invention provides an aileron system that causes the aircraft to avoid a low-speed dropped-wing stall in response to the intuitive reaction of a relatively unskilled pilot. With the safety aileron system of the present invention, only one aileron operates at any time. The safety aileron pivots further back than conventional ailerons and so never droops like a conventional aileron. Rather the safety aileron rotates to position its leading edge below the bottom surface of the wing and position the trailing edge of the aileron above the surface of the wing. Turning the yoke in the intuitive direction (opposite the turn) works without inducing a stall, since the aileron on the low side doesn't move at all. The opposite (high side) safety aileron activates, reducing the lift of that wing to level the aircraft, instead of increasing lift (and drag) on the low side and risking a stall. The safety aileron on the high side lowers its leading edge below the wing, causing drag that produces a yawing moment toward that wing. This also increases the speed of the low wing, creating more lift and assisting in leveling the aircraft.
In addition to the low-speed safety features described herein, the safety aileron system is also superior to conventional ailerons at cruising speeds. First, because the safety aileron system provides both roll and yaw inputs in the same direction to effect a change in the aircraft's heading, little or no rudder input is required for normal turns. Rudder input will continue to be necessary for aerobatic maneuvers and cross-wind landings, in the same manner as the rudder is used in conjunction with conventional ailerons. Second, the safety aileron system is of particular benefit in canard, flying-wing and other unconventional aircraft configurations where a rudder is not effective. Third, because the safety aileron system reduces overall drag, a fuel savings is also realized
The safety aileron system has been successfully tested with unmanned aerial vehicles (UAVs) of both conventional and canard layouts.
DESCRIPTION OF THE FIGURES OF THE DRAWINGS
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, the hundreds digits of reference numerals indicate the drawing number in which the feature is first referenced, and
FIG. 1 is a side cross-sectional view illustrating an exemplary embodiment of the safety aileron system in a wings level flight configuration, according to a preferred embodiment of the present invention;
FIG. 2 is a side cross-sectional view illustrating the exemplary embodiment of the safety aileron system of FIG. 1 in a turning flight configuration, according to a preferred embodiment of the present invention;
FIG. 3 is a photographic view illustrating an exemplary embodiment of the safety aileron system of FIG. 1 in a left turn configuration, according to a preferred embodiment of the present invention;
FIG. 4 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system of FIG. 3 , according to a preferred embodiment of the present invention;
FIG. 5 is a photographic view illustrating an exemplary embodiment of the safety aileron system of FIG. 1 in a right turn configuration, according to a preferred embodiment of the present invention;
FIG. 6 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system of FIG. 5 , according to a preferred embodiment of the present invention;
FIG. 7 is a second photographic view illustrating an exemplary embodiment of the safety aileron system of FIG. 1 in a right turn configuration of FIG. 5 , according to a preferred embodiment of the present invention; and
FIG. 8 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system of FIG. 7 , according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a side cross-sectional view illustrating an exemplary embodiment of the safety aileron system 100 in a wings level flight configuration, according to a preferred embodiment of the present invention. Wing section 104 is pivotably connected to safety aileron 102 by means known in the art for installing ailerons. However, the pivot axis 106 for the safety aileron is positioned further aft than with conventional ailerons. Likewise, the safety aileron 102 is larger, for a given aircraft 302 (see FIG. 3 ), than conventional ailerons. In some embodiments, particularly for high-speed aircraft, the pivot axis 106 may be moveable, in the manner of pivots for flaps, as is known in the art.
Wing section 104 has top surface 122 , a bottom surface 120 , and a rear surface 124 . The shape of the safety aileron 102 preferably completes the shape of the wing section 104 for the airfoil type of the particular wing. Gap 116 between rear surface 124 and safety aileron 102 should be sized to permit operational rotation of the safety aileron 102 about pivot axis 106 . Safety aileron 102 has a front portion 110 that is forward of the pivot axis 106 and a rear portion 108 that is aft of the pivot axis 106 . Safety aileron 102 forms part of the trailing edge of the wing 104 during wings level flight, as shown in relation to forward direction 118 . In some particular embodiments, gap covers 114 and 112 may be used to make continuous the top surface 122 and the bottom surface 120 of the wing, respectively, during wings level flight. Gap covers 114 and 112 may be flexible and resilient gap covers 114 and 112 such as, for non-limiting example, rubber gap covers 114 and 112 . In a high speed aircraft, gap covers 114 and 112 may be more rigid retractable devices that are extendable from wing section 104 .
FIG. 2 is a side cross-sectional view illustrating the exemplary embodiment of the safety aileron system 100 of FIG. 1 in a turning flight configuration, according to a preferred embodiment of the present invention. Safety aileron 102 is shown pivoted by pivot angle α into an operational position. Front portion 110 extends below the bottom surface 120 of the wing 104 , thereby creating drag that induces yaw in the desired turning direction. The rear portion 108 extends above the top surface of the wing 104 to reduce lift on the wing 104 , causing the wing 104 to lower in further execution of the turn. In normal operation, the turning direction wing will have the configuration of FIG. 2 and the other wing will concurrently have the configuration of FIG. 1 . Only one wing's safety aileron 102 rotates at any given time. Pivot angle α is preferably controllably variable for varying rates of turn.
Gap 116 opens into slot 216 with safety aileron 102 rotated into active position. In various embodiments, slot 216 may be open to channel air flow or may be closed with further extended gap covers 114 and 112 . In a particular embodiment, gap covers 114 and 112 may incompletely cover slot 216 .
In dropping-wing stall avoidance operation, the safety aileron 102 is activated on the high wing 104 in response to intuitive or habitual yoke inputs to level the aircraft. The drag-induced yaw increases lift on the low wing, while the lift reduction on the high wing 104 assists in bringing the aircraft 302 (see FIG. 3 ) level and so avoids the stall.
FIG. 3 is a photographic view illustrating an exemplary embodiment of the safety aileron system 100 of FIG. 1 in a left turn configuration, according to a preferred embodiment of the present invention. Unmanned Aerial Vehicle (UAV) test aircraft 302 has two safety ailerons 102 with actuators 304 . The type of actuators 304 is not a limitation of the invention. The safety aileron 102 on the left wing 104 is shown in a left turn configuration for normal flight and in a configuration to avoid a right-dropped-wing stall in a dropped-wing stall avoidance flight regime. Right-wing safety aileron 102 is not activated in either case.
Safety aileron system 100 includes controls, actuators, and associated hardware and, in some embodiments, software. The actuators 304 are illustrated as a screw-type electro-mechanical actuator, but this is not a limitation of the invention. Actuators may include, for non-limiting examples, direct mechanical linkages from the yoke (manual operation), electro-mechanical (solenoid), hydraulic torsion, and pneumatic torsion actuators. Likewise, control systems may be, for non-limiting examples, analog mechanical, electrical (ON/OFF), electronic, and computer-controlled (fly-by-wire or wireless). Similarly, aircraft 302 may be any type of aircraft, including, for non-limiting examples, conventional two-winged aircraft, canard aircraft, and flying-wing aircraft.
FIG. 4 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system 100 of FIG. 3 , according to a preferred embodiment of the present invention. The rear portion 108 of safety aileron 102 can be seen positioned above the top surface 122 of wing 104 . This reduces the lift on the wing 104 , thereby assisting in turning the aircraft. If the aircraft 302 were in a dropped-wing stall, safety aileron 102 would turn the aircraft 302 to the left, increasing the wind speed over the right wing to cause the right wing to rise, while the drag and the air flow pattern change from the safety aileron 102 on the left wing will cause that wing to drop. Thus, the aircraft 302 can be brought back from a dropped wing stall at low altitude.
FIG. 5 is a photographic view illustrating an exemplary embodiment of the safety aileron system 100 of FIG. 1 in a right turn configuration, according to a preferred embodiment of the present invention. UAV test aircraft 302 has two safety ailerons 102 with actuators 304 . The safety aileron 102 on the right wing 104 is shown in a right turn configuration for normal flight and in a configuration to avoid a left-dropped-wing stall in a dropped-wing stall avoidance flight regime. Left-wing safety aileron 102 is not activated. If the aircraft 302 were in a dropped-wing stall, safety aileron 102 would turn the aircraft 302 to the right, increasing the wind speed over the dropped left wing to cause the left wing to rise, while the drag and the air flow pattern change from the safety aileron 102 on the right wing will cause that wing to drop. Thus, the aircraft 302 can be brought back from a dropped wing stall at low altitude.
FIG. 6 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system 100 of FIG. 5 , according to a preferred embodiment of the present invention. The rear portion 108 of safety aileron 102 can be seen positioned above the top surface 122 of wing 104 . The forward portion 110 of safety aileron 102 extends below the bottom surface 120 (see FIG. 2 )
FIG. 7 is a second photographic view illustrating an exemplary embodiment of the safety aileron system 100 of FIG. 1 in a right turn configuration of FIG. 5 , according to a preferred embodiment of the present invention. The forward portion 110 of safety aileron 102 can be seen positioned below the wing 104 to induce drag to generate yaw to assist with turning the aircraft 302 . The rear portion 108 of safety aileron 102 is positioned above the wing 104 to reduce lift and so bank the turn in normal operation or correct a dropped-wing stall condition using the normal pilot responsive movement of the yoke.
FIG. 8 is a photographic close-up view illustrating the exemplary embodiment of the safety aileron system 100 of FIG. 7 , according to a preferred embodiment of the present invention. Forward portion 110 is below the bottom surface 120 of the wing 104 .
Safety aileron system 100 will meet FAA Part 23 regulations for stall resistant aircraft and aircraft equipped with safety aileron system 100 will not require special training for dealing with low altitude stall warnings, as the habitual or intuitive pilot response will be the correct response.
Location of the pivot axis 106 and the best pivot angle α must be determined for each aircraft design and can be accomplished by a person of ordinary skill in that art (an aerospace engineer with aircraft design experience) without undue experimentation. | Individually operable ailerons pivotable to extend a forward end below a bottom wing surface and a rearward end above a top wing surface. The extended aileron forward end increases drag and subsumes the rudder function in the turn, while the aileron rear end produces drag and airflow redirection to reduce lift on the wing. The advantage of the safety ailerons is that habitual or instinctive pilot inputs to the yoke will recover from a dropped-wing stall at low speed and altitude, while conventional ailerons require counter-intuitive pilot actions to avoid crashing in such conditions. | 8 |
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