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CROSS-REFERENCE TO RELATED APPLICATION
This Application is a Section 371 National Stage Application of International Application No. PCT/KR2012/011543, filed Dec. 27, 2012 and published, not in English, as WO 2013/100617 on Jul. 4, 2013.
FIELD OF THE DISCLOSURE
The present disclosure relates to an emergency stop method for hybrid construction equipment and a brake control device, and particularly, to an emergency stop method for hybrid construction equipment and a brake control device, which may stably stop a swing body in an emergency manner body by confirming a failure occurrence location of hybrid construction equipment, and absorbing inertial energy of the swing body using several functions for each generated failure location, and may smoothly stop the swing body by determining a brake pattern in a case in which an emergency stop needs to be performed, and controlling a hydraulic brake in accordance with the determined brake pattern.
BACKGROUND OF THE DISCLOSURE
Recently, researches on hybrid type construction equipment, which improves fuel efficiency by storing surplus power of an engine in a battery, and supplying power from the battery to the engine that does not have sufficient power so as to cope with a rapid increase in oil price, are being actively conducted.
A system, which uses the engine and an electric motor as a common power source as described above, and has an electrical energy storage device, is referred to as a hybrid system. For example, as the hybrid system, there is a hybrid system for heavy equipment such as a hybrid vehicle, and an excavator.
FIG. 1 is a configuration diagram of an electric power conversion device for general hybrid construction equipment.
As illustrated in FIG. 1 , an electric power conversion device for hybrid construction equipment includes an engine auxiliary motor 110 , an engine side inverter 111 , a swing motor 120 having a brake, a swing side inverter 121 , an ultracapacitor 130 , and a converter 131 .
The engine side inverter 111 operates the engine auxiliary motor 110 using a motor or an electric generator.
The swing motor 120 operates an upper swing body of a hybrid excavator. The swing side inverter 121 , which operates the swing motor 120 , performs an acceleration operation and a deceleration operation depending on lever control by a user who manipulates the hybrid excavator. The swing side inverter 121 operates the swing motor 120 using a motor at the time of an acceleration operation. In contrast, the swing side inverter 121 operates the swing motor 120 using an electric generator at the time of a deceleration operation. That is, the swing side inverter 121 converts rotational inertial energy of the upper swing body of the hybrid excavator into electrical energy.
The ultracapacitor 130 serves to store electrical energy, and is connected with the converter 131 that controls a charge operation and a discharge operation.
FIG. 2 is a flowchart of an exemplary embodiment regarding a failure occurrence process in an electric power conversion device for general hybrid construction equipment.
As illustrated in FIG. 2 , the electric power conversion device in the related art stops all operations when failure occurs in the electric power conversion device (S 202 ).
Specifically, the electric power conversion device turns off the engine side inverter 111 of the engine auxiliary motor 110 (S 202 ). In addition, the electric power conversion device turns off the swing side inverter 121 of the swing motor 120 (S 206 ). Next, the swing motor 120 undergoes a regeneration process of the swing motor 120 (S 208 ), and Vdc is in an overvoltage state (S 210 ). In addition, the electric power conversion device turns off the converter 131 at the ultracapacitor (UC) 130 side (S 212 ).
As described above, in the hybrid excavator, the upper swing body is freely rotated before a braking operation when the electric power conversion device is stopped, unlike a hydraulic excavator, and thus there is a problem in that a risk of an accident is greatly increased in this case. When the swing body is continuously rotated, there is a problem in that a peripheral area of the work environment may be damaged.
In order to reduce the aforementioned damage, the rotation of the swing body is blocked, and a swing brake is operated until inertial energy is exhausted. A brake control manner in the related art produces a brake off command when a swing speed is a predetermined value or less. The hydraulic brake is operated with a predetermined delay after the brake off command is generated. In this case, there is a problem in that when the braking operation is immediately performed using a mechanical swing brake in a case in which a large amount of inertial energy remains because a speed of the swing body is high immediately before failure occurs, impact may be applied to a user, and the excavator may be turned over on a slope.
The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter.
SUMMARY
This summary and the abstract are provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. The summary and the abstract are not intended to identify key features or essential features of the claimed subject matter, nor are they intended to be used as an aid in determining the scope of the claimed subject matter.
The present disclosure has been made in consideration of the aforementioned problem, and an object of the present disclosure is to provide an emergency stop method for hybrid construction equipment, which may absorb inertial energy of a swing body by confirming a failure occurrence location of hybrid construction equipment and using several functions for each generated failure location, thereby stably stopping the swing body in an emergency manner.
Meanwhile, the present disclosure has been made in consideration of the aforementioned problem, and another object of the present disclosure is to provide a brake control device for construction equipment, by which a user may smoothly stop a swing body in accordance with a desired stop speed profile by creating a brake pattern from a swing speed or front information when failure occurs in hybrid construction equipment, and by controlling a brake operation of the swing body by controlling a voltage control valve or a hydraulic valve in accordance with the created brake pattern.
To this end, a method according to the present disclosure includes: confirming a failure occurrence location at a swing side, an engine side, and an ultracapacitor side of the hybrid construction equipment; turning off an inverter or a converter connected with the confirmed failure occurrence location; and operating the inverter or the converter at a location that is not the confirmed failure occurrence location, and absorbing inertial energy of a swing body through an ultracapacitor or an engine auxiliary motor so as to perform an emergency stop.
To this end, a device according to the present disclosure includes: a brake for stopping a swing body when failure occurs in the construction equipment; a drive valve which is formed in a hydraulic manner or a voltage controlled manner, and controls pressure or an amount of fluid applied to the brake; and a control unit which determines a brake pattern using front information or a swing speed of the swing body, and controls the drive valve while creating a voltage control signal or a hydraulic pressure control signal so that the swing body is stopped depending on the determined brake pattern.
The present disclosure has an effect in that inertial energy of the swing body is absorbed by confirming a failure occurrence location of the hybrid construction equipment and using several functions for each generated failure location, thereby stably stopping the swing body in an emergency manner.
In addition, the present disclosure has an effect in that a user may quickly cope with a situation after the emergency stop by displaying the failure occurrence location and the emergency stop situation to the user.
In addition, the present disclosure has an effect in that impact to the user at the time of braking may be reduced because of a stable emergency stop of the swing body, and a risk of turning over the construction equipment when the construction equipment is located on a slope may be reduced.
Meanwhile, the present disclosure has an effect in that the user may smoothly stop the swing body in accordance with a desired stop speed profile by creating a brake pattern using a swing speed or front information when failure occurs in the hybrid construction equipment, and by controlling the brake operation of the swing body by controlling a voltage control valve or a hydraulic valve in accordance with the created brake pattern.
That is, the present disclosure has an effect in that the user may smoothly stop the swing body using the desired stop speed profile by controlling the hydraulic valve in a pulse width modulation manner. In addition, the present disclosure has an effect in that the user may select or calculate a desired brake pattern using the voltage control valve, and smoothly stop the swing body.
In addition, the present disclosure has an effect in that the brake control device may be simplified because the swing body may be stopped in an emergency manner without using an additional device such as an orifice in the related art, and the swing body may be stopped with various brake patterns by monitoring the front information or the swing speed.
Furthermore, the present disclosure has an effect in that impact to the user at the time of braking may be reduced because of a stable emergency stop of the swing body, and a risk of turning over the construction equipment when the construction equipment is located on a slope may be reduced.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a configuration diagram of an electric power conversion device of general hybrid construction equipment.
FIG. 2 is a flowchart of an exemplary embodiment regarding a failure occurrence process in the electric power conversion device of the general hybrid construction equipment.
FIG. 3 is an exemplified view of an exemplary embodiment regarding a deceleration graph for comparing swing speeds between the related art and the present disclosure.
FIGS. 4 and 5 are an explanatory view and a flowchart of a first exemplary embodiment regarding an emergency stop process at the time of swing side failure according to the present disclosure.
FIGS. 6 and 7 are an explanatory view and a flowchart of a second exemplary embodiment regarding an emergency stop process at the time of swing side failure according to the present disclosure.
FIG. 8 is a flowchart of the first exemplary embodiment regarding an emergency stop process at the time of engine side failure according to the present disclosure.
FIG. 9 is an exemplified view of the first exemplary embodiment regarding a swing speed at the time of engine side failure according to the present disclosure.
FIG. 10 is a flowchart of the second exemplary embodiment regarding an emergency stop process at the time of engine side failure according to the present disclosure.
FIG. 11 is an exemplified view of the second exemplary embodiment regarding a swing speed at the time of engine side failure according to the present disclosure.
FIG. 12 is a flowchart of the exemplary embodiment regarding an emergency stop process at the time of ultracapacitor side failure according to the present disclosure.
FIG. 13 is an exemplified view of the exemplary embodiment regarding a swing speed at the time of ultracapacitor side failure according to the present disclosure.
FIG. 14 is a configuration diagram of an exemplary embodiment of a brake control device according to the present disclosure.
FIG. 15 is a configuration diagram of a first exemplary embodiment of the brake control device according to the present disclosure.
FIG. 16 is a configuration diagram of a second exemplary embodiment of the brake control device according to the present disclosure.
FIG. 17 is an exemplified view of an exemplary embodiment of deceleration speed graphs of swing speeds in a case in which the brake control device according to the present disclosure is applied.
DESCRIPTION OF MAIN REFERENCE NUMERALS OF DRAWINGS
110 : Engine auxiliary motor
111 : Engine side inverter
120 : Swing motor
121 : Swing side inverter
130 : Ultracapacitor
131 : Ultracapacitor side converter
1400 : Brake control device
1410 : Brake
1420 : Drive valve
1421 : Hydraulic valve
1422 : Voltage control valve
1430 : Control unit
DETAILED DESCRIPTION
Hereinafter, an exemplary embodiment according to the present disclosure will be described in detail with reference to the accompanying drawings. A configuration of the present disclosure and an operation and an effect according to the configuration of the present disclosure will be clearly understood by the detailed description below. In the following detailed description, it should be noted that the same elements will be designated by the same reference numerals even though the elements are illustrated in different drawings, and a detailed explanation of publicly known related configurations may be omitted so as to avoid unnecessarily obscuring the subject matter of the present disclosure.
FIG. 3 is an exemplified view of an exemplary embodiment regarding a deceleration graph for comparing swing speeds between the related art and the present disclosure.
When failure occurs in an electric power conversion device in the related art, a swing body is rotated while inertial energy is consumed as frictional energy such that the swing body is not quickly stopped, as indicated by reference numeral 301 .
On the contrary, in the present disclosure, when failure occurs at an engine side of an electric power conversion device, the electric power conversion device charges an ultracapacitor 130 with inertial energy using a swing side inverter 121 and an ultracapacitor side converter 131 so as to absorb the inertial energy. A swing speed characteristic at this time is indicated by reference numeral 302 .
In addition, when failure occurs at the ultracapacitor side, the electric power conversion device consumes the inertial energy using the swing side inverter 121 and an inverter 111 of an engine auxiliary motor 110 side. A swing speed characteristic at this time is indicated by reference numeral 303 .
In addition, the electric power conversion device may allow the swing body to be stopped by further using a mechanical hydraulic brake in order to allow the swing body to be more quickly stopped while consuming the inertial energy using the swing side inverter 121 and the inverter 111 of the engine auxiliary motor 110 side. A swing speed characteristic region at this time is indicated by reference numeral 304 .
As such, the electric power conversion device of the present disclosure confirms a failure occurrence location at the swing side, the engine side, or the ultracapacitor side of the hybrid construction equipment. That is, the electric power conversion device confirms engine side failure (failure in the engine auxiliary motor 110 or the engine side inverter 111 ), swing side failure (failure in the swing motor 120 or the swing side inverter 121 ), and ultracapacitor side failure (failure in the ultracapacitor 130 or the ultracapacitor side converter 131 ). Further, the electric power conversion device turns off the inverter or the converter that is connected with the confirmed failure occurrence location. In addition, the electric power conversion device operates the inverter or the converter at a location that is not the confirmed failure occurrence location, and absorbs the inertial energy of the swing body so as to perform an emergency stop. That is, the electric power conversion device distinguishes the failure occurrence location, and may safely stop the swing body in an emergency situation using some of the inverters or the converters instead of turning off all of the operations.
Hereinafter, emergency stop processes at the time of the engine side failure, the swing side failure, and the ultracapacitor side failure will be described in detail.
FIGS. 4 and 5 are an explanatory view and a flowchart of a first exemplary embodiment regarding an emergency stop process at the time of the swing side failure according to the present disclosure.
As illustrated in FIGS. 4 and 5 , the electric power conversion device confirms that the swing side failure (failure in the swing motor 120 or the swing side inverter 121 ) occurs (S 502 ).
Further, the electric power conversion device turns off the swing side inverter 121 in which failure has occurred (S 504 ). In this case, the swing motor 120 is regenerated due to the inertial energy of the swing body (S 506 ).
In addition, in the first exemplary embodiment, the electric power conversion device turns off the engine side inverter 111 , and operates the ultracapacitor side converter 131 (S 508 ). Next, the electric power conversion device performs Vdc voltage control of the ultracapacitor side converter 131 (S 510 ), and stores the inertial energy of the swing body in the ultracapacitor 130 . Accordingly, the electric power conversion device absorbs the inertial energy of the swing body while stabilizing Vdc (S 512 ).
Meanwhile, in order to reduce time for deceleration of the swing body, the electric power conversion device may operate the mechanical hydraulic brake, which is provided in the swing motor 120 , so as to allow the swing body to be stopped (S 514 ).
FIGS. 6 and 7 are an explanatory view and a flowchart of a second exemplary embodiment regarding an emergency stop process at the time of the swing side failure according to the present disclosure.
As illustrated in FIGS. 6 and 7 , the electric power conversion device confirms that the swing side failure (failure in the swing motor 120 or the swing side inverter 121 ) occurs (S 702 ).
Further, the electric power conversion device turns off the swing side inverter 121 in which failure has occurred (S 704 ). In this case, the swing motor 120 is regenerated due to the inertial energy of the swing body (S 706 ).
In addition, in the second exemplary embodiment that is different from FIGS. 4 and 5 , the electric power conversion device turns off the ultracapacitor side converter 131 , and operates the engine side inverter 111 (S 708 ). Accordingly, the engine auxiliary motor 110 is operated as a motor that assists output of the engine.
Next, the electric power conversion device performs Vdc voltage control of the engine side inverter 111 (S 710 ), and absorbs the inertial energy of the swing body using the engine auxiliary motor 110 . Accordingly, the electric power conversion device stabilizes Vdc (S 712 ).
Meanwhile, in order to reduce time for deceleration of the swing body, the electric power conversion device may operate the mechanical hydraulic brake, which is provided in the swing motor 120 , so as to allow the swing body to be stopped (S 714 ).
FIG. 8 is a flowchart of the first exemplary embodiment regarding an emergency stop process at the time of the engine side failure according to the present disclosure, and FIG. 9 is an exemplified view of the first exemplary embodiment regarding a swing speed at the time of the engine side failure according to the present disclosure.
As illustrated FIG. 8 , the electric power conversion device confirms that the engine side failure (failure in the engine auxiliary motor 110 or the engine side inverter 111 ) occurs (S 802 ).
Further, the electric power conversion device turns off the engine side inverter 111 in which failure has occurred (S 804 ).
In addition, in the first exemplary embodiment, the electric power conversion device operates the swing side inverter 121 (S 806 ). Next, the electric power conversion device controls the swing speed to be ‘0’ (S 808 ).
Meanwhile, the electric power conversion device operates the ultracapacitor side converter 131 (S 810 ). Further, the electric power conversion device performs Vdc voltage control of the ultracapacitor side converter 131 (S 812 ).
Accordingly, the electric power conversion device absorbs the inertial energy of the swing body while stabilizing Vdc (S 814 ).
As illustrated in FIG. 9 , at a failure occurrence time point 902 , the inertial energy is stored in the ultracapacitor 130 through the ultracapacitor side converter 131 . Therefore, the swing speed of the swing body is slowed down with a gradient indicated by reference numeral 904 .
FIG. 10 is a flowchart of the second exemplary embodiment regarding an emergency stop process at the time of the engine side failure according to the present disclosure, and FIG. 11 is an exemplified view of the second exemplary embodiment regarding a swing speed at the time of the engine side failure according to the present disclosure.
As illustrated FIG. 10 , the electric power conversion device confirms that the engine side failure (failure in the engine auxiliary motor 110 or the engine side inverter 111 ) occurs (S 1002 ).
Further, the electric power conversion device turns off the engine side inverter 111 in which failure has occurred (S 1004 ).
In addition, the electric power conversion device operates the swing side inverter 121 (S 1006 ). Next, the electric power conversion device controls the swing speed to be ‘0’ (S 1008 ).
Meanwhile, the electric power conversion device operates the ultracapacitor side converter 131 (S 1010 ). Further, the electric power conversion device performs Vdc voltage control of the ultracapacitor side converter 131 (S 1012 ).
Accordingly, the electric power conversion device absorbs the inertial energy of the swing body while stabilizing Vdc (S 1014 ).
In the second exemplary embodiment, in order to reduce time for deceleration of the swing body, the electric power conversion device may operate the mechanical hydraulic brake, which is provided in the swing motor 120 , so as to allow the swing body to be stopped (S 1016 ).
As illustrated in FIG. 11 , at a failure occurrence time point 1102 , the inertial energy is stored in the ultracapacitor 130 through the ultracapacitor side converter 131 , and the swing speed is slowed down in a shape having a gradient 1104 . In this case, a time point 1112 at which the ultracapacitor 130 is fully charged may occur.
In a case in which the ultracapacitor 130 is fully charged, the inertial energy of the swing body is no longer stored in the ultracapacitor 130 , and thus the swing speed of the swing body may be slowed down in a shape having a more gradual gradient 1114 .
However, when the mechanical hydraulic brake, which is provided in the swing motor 120 , is operated in order to reduce time for deceleration of the swing body, in the electric power conversion device, the swing speed may be slowed down in a shape having a steeper gradient 1116 .
FIG. 12 is a flowchart of the exemplary embodiment regarding an emergency stop process at the time of the ultracapacitor side failure according to the present disclosure, and FIG. 13 is an exemplified view of the exemplary embodiment regarding a swing speed at the time of the ultracapacitor side failure according to the present disclosure.
As illustrated in FIG. 12 , the electric power conversion device confirms that the ultracapacitor side failure (failure in the ultracapacitor 130 or the ultracapacitor side converter 131 ) occurs (S 1202 ).
Further, the electric power conversion device turns off the ultracapacitor side converter 131 in which failure has occurred (S 1204 ).
In addition, the electric power conversion device operates the swing side inverter 121 (S 1206 ). Next, the electric power conversion device controls the swing speed to be ‘0’ (S 1208 ).
Meanwhile, the electric power conversion device operates the engine side inverter 111 (S 1210 ). Accordingly, the engine auxiliary motor 110 is operated as a motor that assists engine output of the engine. Further, the electric power conversion device performs Vdc voltage control of the engine side inverter 111 (S 1212 ).
Accordingly, the electric power conversion device absorbs the inertial energy of the swing body while stabilizing Vdc (S 1214 ).
Meanwhile, in order to reduce time for deceleration of the swing body, the electric power conversion device may operate the mechanical hydraulic brake, which is provided in the swing motor 120 , so as to allow the swing body to be stopped (S 1216 ).
As illustrated in FIG. 13 , at a failure occurrence time point 1302 , the inertial energy is consumed by the engine auxiliary motor 110 through the swing side inverter 121 and the engine side inverter 111 .
In general, the inertial energy of the swing body has larger capacity than the inverter 111 of the engine auxiliary motor 110 , and thus the electric power conversion device cannot quickly decelerate the swing body with a gradient indicated by reference numeral 1306 , but may stop the swing body in an emergency manner with a gradient indicated by reference numeral 1304 .
In order to supplement the aforementioned operations, when the electric power conversion device operates the mechanical hydraulic brake, which is provided in the swing motor 120 , in order to reduce time for deceleration of the swing body, the swing body may decelerate in a shape having a gradient in a steeper region 1308 .
Meanwhile, in the case of failure such as overvoltage, by which all electric power conversion devices cannot be operated, the electric power conversion device allows the swing body to be stopped by only using the mechanical hydraulic brake provided in the mechanical swing motor 120 .
Meanwhile, in a case in which the swing body is stopped in an emergency manner due to failure, the electric power conversion device may display a failure occurrence location and an emergency stop matter to a user through a monitoring device.
Meanwhile, a brake control device of construction equipment at the time of an emergency stop according to the present disclosure will be described with reference to FIGS. 14 to 17 .
FIG. 14 is a configuration diagram of an exemplary embodiment of a brake control device according to the present disclosure.
As illustrated in FIG. 14 , the brake control device includes a brake 1410 , a drive valve 1420 , and a control unit 1430 . The drive valve 1420 may be a hydraulic valve 1421 or a voltage control valve (electronic proportional pressure reducing (EPPR) valve) 1422 .
The brake control device 1400 controls the brake in two ways.
Firstly, in a case in which the drive valve 1420 is the hydraulic valve 1421 , the brake control device 1400 applies a control signal in a pulse width modulation (PWM) manner to the hydraulic valve 1421 so as to determine a brake pattern.
Secondly, in a case in which the drive valve 1420 is the voltage control valve 1422 , the brake control device 1400 determines the brake pattern depending on a predetermined stop speed profile.
The brake pattern is determined using a speed or front information of the swing motor 120 , and the brake control device 1400 controls the drive valve 1420 in accordance with the brake pattern.
Hereinafter, constituent elements of the brake control device of the construction equipment will be described, respectively.
The brake 1410 allows the swing body to be stopped. The brake 1410 is connected with the swing motor 120 .
The drive valve 1420 operates the brake 1410 in a hydraulic manner or a voltage controlled manner. The drive valve 1420 may be the hydraulic valve 1421 or the voltage control valve 1422 . The drive valve 1420 may adjust an amount or pressure of fluid discharged to the brake 1410 from a brake pump 1401 that is connected with the drive valve 1420 .
The control unit 1430 determines the brake pattern using the front information or the swing speed of the swing body. That is, the control unit 1430 needs to change the brake pattern depending on a size of inertial energy of the swing body. The control unit 1430 receives an input swing speed of the swing motor 120 , and selects or calculates the brake pattern using the swing speed and the front information of the swing body. Here, states of a boom, an arm, a bucket, and the like are included in the front information in a case in which the construction equipment is an excavator, but the front information is not limited to front information of specific construction equipment. The control unit 1430 may select any one brake pattern among a plurality of brake patterns that is precalculated. In addition, the control unit 1430 may calculate the brake pattern by reflecting the swing speed and the front information to a predefined brake function.
Further, the control unit 1430 creates a voltage control signal or a hydraulic pressure control signal of the drive valve 1420 depending on the determined brake pattern, and controls the drive valve 1420 so that the swing body is stopped.
FIG. 15 is a configuration diagram of the first exemplary embodiment of the brake control device according to the present disclosure.
As illustrated in FIG. 15 , in a case in which the drive valve 1420 is the hydraulic valve 1421 , the hydraulic valve 1421 adjusts an amount of fluid, which is discharged from the brake pump 1401 for operating the brake 1410 connected with the swing motor 120 , in a hydraulic manner.
In a case in which the drive valve 1420 is the hydraulic valve 1421 , the control unit 1430 creates the brake pattern in the pulse width modulation manner using the front information or the swing speed of the swing body. Here, the control unit 1430 may change a pressure period of the brake by adjusting a duty ratio per pulse that is turned on/off in the pulse width modulation manner.
Further, the control unit 1430 controls the drive valve 1420 , which is the hydraulic valve 1421 , depending on a hydraulic pressure control signal of the created pulse width modulation manner.
FIG. 16 is a configuration diagram of the second exemplary embodiment of the brake control device according to the present disclosure.
As illustrated in FIG. 16 , in a case in which the drive valve 1420 is the voltage control valve 1422 , the voltage control valve 1422 adjusts an amount of fluid, which is discharged from the brake pump 1401 for operating the brake 1410 connected with the swing motor 120 , in a voltage controlled manner.
In a case in which the drive valve 1420 is the voltage control valve 1422 , the control unit 1430 creates the brake pattern in the voltage controlled manner using the front information or the swing speed of the swing body. Here, the control unit 1430 may create the brake pattern using brake pattern characteristics that may be designated by the brake pressure with respect to brake input. The brake pattern characteristics may be preset by the user, and stored in the brake control device 1400 in advance.
Further, the control unit 1430 controls the drive valve 1420 , which is the voltage control valve 1422 , depending on a created hydraulic pressure control signal by the voltage control manner.
FIG. 17 is an exemplified view of the exemplary embodiment regarding a deceleration speed graph of the swing speed in a case in which the brake control device according to the present disclosure is applied.
As illustrated in FIG. 17 , the brake control device 1400 sets the brake patterns so that the brake patterns are varied depending on a size of the inertial energy of the swing body. The brake control device 1400 may select or calculate the brake pattern using the measured swing speed or the front information of the swing body.
A graph in which the swing body is changed to a stopped state on the basis of the failure occurrence time point 1700 is illustrated in FIG. 4 .
An upper end swing speed profile 1710 refers to a swing speed in a case in which the swing body is immediately stopped. A lower end swing speed profile 1720 refers to a swing speed that is slowed down depending on the brake pattern of the present disclosure.
The user may directly receive impact due to the hydraulic brake 1410 in the upper end swing speed profile 1710 . In addition, there is a risk that the construction equipment is turned over in a case in which the construction equipment is placed on a slope.
In the lower end swing speed profile 1720 , a swing speed after failure occurs in the construction equipment is illustrated. Here, area (integration) 1722 until the swing speed becomes ‘0’ is a movement distance of the swing body. In the lower end swing speed profile 1720 , a rotational distance of the swing body may be more increased than the upper end swing speed profile 1710 when the swing body is immediately stopped depending on a stop speed profile.
From the foregoing, it will be appreciated that the exemplary embodiments of the present disclosure have been described herein for purposes of illustration, and that various modifications may be made by those skilled in the art without departing from the scope and spirit of the present disclosure. The exemplary embodiments disclosed in the specification of the present disclosure will not limit the present disclosure. The scope of the present disclosure will be interpreted by the claims below, and it will be construed that all techniques within the scope equivalent thereto belong to the scope of the present disclosure.
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The present disclosure relates to an emergency stop method for hybrid construction equipment and a brake control device, and more particularly, to an emergency stop method for hybrid construction equipment and a brake control device, which may confirm a failure occurrence location of the hybrid construction equipment, absorb inertial energy of the swing body using several functions for each generated failure location so as to stably stop the swing body in an emergency manner, and when the failure occurs in the hybrid construction equipment, create the brake pattern by using the swing speed or the front information, control a brake of the swing body by controlling a voltage control valve or a hydraulic valve in accordance with the created brake pattern, such that a user may smoothly stop the swing body in accordance with a desired stop speed profile.
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FIELD OF THE INVENTION
The invention relates to a filter housing. Particularly, but not exclusively, the invention relates to a filter housing for use in a domestic appliance such as a vacuum cleaner.
BACKGROUND OF THE INVENTION
Vacuum cleaners are required to separate dirt and dust from an airflow. Dirt and dust-laden air is sucked into the appliance via either a floor-engaging cleaner head or a tool connected to the end of a hose and wand assembly. The dirty air passes to some kind of separating apparatus which attempts to separate dirt and dust from the airflow. Many vacuum cleaners suck or blow the dirty air through a porous bag so that the dirt and dust is retained in the bag whilst cleaned air is exhausted to the atmosphere. In other vacuum cleaners, cyclonic or centrifugal separators are used to spin dirt and dust from the airflow (see, for example, EP 0 042 723). Whichever type of separator is employed, there is commonly a risk of a small amount of dust passing through the separator and being carried to the fan and motor unit, which is used to create the flow of air through the vacuum cleaner whilst it is in operation. Also, with the majority of vacuum cleaner fans being driven by a motor with carbon brushes, such as an AC series motor, the motor emits carbon particles which are carried along with the exhaust flow of air.
In view of this, it is common for a filter to be positioned after the motor and before the point at which air is exhausted from the machine. Such a filter is often called a ‘post motor’ filter.
There is an increasing awareness among consumers of the problem of emissions, which can be particularly problematic for asthma sufferers. Thus, recent vacuum cleaner models are fitted with filters which have a large surface area of filter material, and the filters often comprise several types of filter material and a foam pad. Such filters are physically bulky and housing such filters in the cleaner is quite challenging. A vacuum cleaner called the Dyson DC05, manufactured and sold by Dyson Limited, houses a circular post motor filter beneath the dirt collection bin. Air flows towards a first face of the filter, passes through the filter and exhausts from the machine via a set of apertures in the cover above the filter.
U.S. Pat. No. 5,961,677 shows a vacuum cleaner exhaust filter in which air flows out of a central conduit, via a series of openings formed between angled vanes, before passing through an open space to a cylindrical filter which surrounds the central conduit.
SUMMARY OF THE INVENTION
The present invention seeks to provide an improved filter housing.
There is also a desire to increase the rate of flow of air through a vacuum cleaner. A higher rate of flow generally increases both the ability of the cleaner to pick up material from a surface and the ability of the cyclonic separator to separate material from the dirty airflow. However, an increased rate of airflow can cause the machine to be noisy in operation. It is possible to place acoustically absorbent material in the path of the exhaust air, but this increases the resistance of the path seen by the airflow. This has a detrimental effect on the overall rate of airflow through the machine in addition to adding both weight and cost to the machine.
Accordingly, the present invention provides a filter housing comprising an inlet for receiving an airflow, a cavity for receiving a filter, an airflow passage between the inlet and the cavity and at least one vane positioned in the airflow passage for partitioning the airflow passage into a plurality of ducts, wherein each vane has a non-linear shape in the direction of flow through the duct.
The non-linear vanes serve to reduce acoustic emissions from the machine since sound waves emitted by the fan and/or motor are caused to bounce off the vanes, which allows the vanes to absorb some of the sound energy. Thus, a reduction in noise is achieved without the use of dedicated noise reduction structures.
Although this invention is described in relation to a cylinder (canister) vacuum cleaner, it will be apparent that it can be applied to other kinds of vacuum cleaner, domestic appliances or machines which use a filter of some kind.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention will now be described with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a vacuum cleaner in which a filter housing according to the invention is embodied;
FIGS. 2 and 3 are side views of the vacuum cleaner of FIG. 1 , showing some of the internal components of the cleaner;
FIG. 4 shows the filter housing of the vacuum cleaner of FIGS. 1 to 3 ;
FIG. 5 shows the chassis of the vacuum cleaner and the conduit leading to the filter housing of FIG. 4 ;
FIG. 6 is a plan view of the lower part of the filter housing of FIG. 4 ;
FIGS. 7 and 8 illustrate the effect of vanes in reducing swirl in the airflow;
FIGS. 9 and 10 illustrate the effect of the shape of the vanes in the filter housing of FIG. 6 ; and
FIG. 11 is a plan view of an alternative embodiment of the lower part of the filter housing.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 3 show an example of a vacuum cleaner 10 in which the invention is embodied. The vacuum cleaner 10 is a cylinder or canister type of vacuum cleaner comprising a chassis 12 with wheels 13 , 15 for allowing the chassis 12 to be moved across a surface to be cleaned. The chassis 12 supports a chamber 20 which serves as a separator for separating dirt, dust and other debris from an airflow and also as a collector for the separated material. While a cyclonic separator is shown here, the separator can take any form and this is not important to the invention. Chamber 20 is removable from the chassis 12 such that a user can empty the chamber 20 . Although not shown for reasons of clarity, a hose connects to inlet 14 of the vacuum cleaner 10 and a user can fit a wand or tools to the distal end of the hose for use in cleaning various surfaces.
FIGS. 2 and 3 show some of the internal components of the vacuum cleaner 10 of FIG. 1 . The chamber 20 communicates with the inlet 14 through which an airflow can enter the chamber in a tangential manner. The chamber 20 has an apertured shroud 21 mounted centrally within it. The region 22 externally of the shroud 21 forms a first cyclonic separation stage. The apertures 23 in the shroud 21 communicate with a second cyclonic separation stage comprising a set of frusto-conical separators 25 arranged in parallel. The outlets of the second stage separators 25 are connected, via a duct 29 , to a housing for a pre-motor filter 30 . The pre-motor filter 30 serves to trap any fine dust or microscopic particles which have not been separated by the two cyclonic separation stages 22 , 25 . The downstream side of the pre-motor filter 30 communicates with a fan and motor housing 48 . This housing 48 accommodates an impeller 45 which is driven by a motor 40 . The outlet of the housing 48 communicates, via an aperture 50 , with a filter housing 60 . The filter housing 60 houses a post-motor filter 70 which serves to trap any particles remaining in the airflow, as well as carbon particles emanating from the motor 40 . The downstream side of the filter housing 60 communicates with an exhaust duct 90 having outlet apertures 95 at its furthest end.
The filter housing 60 will now be described in more detail with reference to FIG. 4 . The filter housing 60 comprises a lower part 61 , which in this embodiment forms part of the chassis 12 of the vacuum cleaner 10 , and an upper part 62 . The upper part 62 fits removably to the lower part 61 by means of lugs 64 and a snap fastener 67 . Other types of fastener could, of course, be used. The lower part 61 defines an airflow passage which communicates at its upstream end with the aperture 50 which forms the outlet from the housing 48 . The space between the lower part 61 and the upper part 62 defines a cavity for housing the filter 70 . The upper part 62 has an outlet branch 63 which mates, in an airtight manner, with the lower end of the exhaust duct 90 .
A plurality of vanes 65 a , 65 b , 65 c are located in the airflow passage. Two of the vanes 65 a , 65 b extend from the aperture 50 and into the area of the airflow passage which lies adjacent the cavity for receiving the filter 70 . In this area, the vanes 65 a , 65 b extend from the lower part 61 towards the upper part 62 so that they lie adjacent, or even contact, the filter 70 . A third vane 65 c extends from the aperture 50 towards the area of the airflow passage which lies adjacent the cavity for receiving the filter 70 but terminates immediately before the said area. Three separate ducts 51 , 52 , 53 are formed between the vanes 65 a , 65 b , 65 c.
The vanes 65 a , 65 b , 65 c serve to guide the airflow passing through the vacuum cleaner 10 to and from the filter 70 . The vanes 65 a , 65 b , 65 c extend from the outlet 50 of the motor housing 48 along the lower surface of part 61 . The vanes 65 a , 65 b continue beneath the area where filter 70 is located. The vanes 65 a , 65 b , 65 c have two uses: firstly they serve to distribute airflow across the surface of the filter 70 in a reasonably uniform manner, and secondly their non-linear shape serves to attenuate sound from the impeller 45 . Referring to FIG. 5 , the vanes 65 a , 65 b , 65 c divide outlet 50 into six apertures 51 a , 51 b , 52 a , 51 b , 53 a , 53 b . In use, this causes the flow of air from the impeller 45 to be divided into six separate flows. Each aperture 51 a , 51 b , 52 a , 52 b , 53 a , 53 b forms an inlet to one of the ducts 51 , 52 , 53 . Each duct 51 , 52 , 53 communicates with a distinct and separate portion of the surface area of the filter 70 . The height of each vane 65 a , 65 b is chosen such that the distal edges thereof lie adjacent, and preferably touch, the surface of the filter 70 when the filter is fitted in the filter housing 60 . Thus, each duct 51 , 52 , 53 communicates with a separate and distinct portion of the filter 70 so that air flowing along each duct 51 , 52 , 53 is constrained to flow through the respective portion of the filter 70 .
Referring again to FIG. 2 it can be seen that the upstream surface of the filter 70 lies, in use, at an acute angle (approximately 10°) with respect to the incoming airflow from the motor housing 48 . The division of the airflow into separate portions in the manner just described helps to distribute the airflow evenly across the surface of the filter 70 , even though the arrangement of the filter 70 with respect to the incoming airflow is not ideal for even distribution. It is particularly beneficial that each duct 51 , 52 , 53 serves a portion of the filter surface which is a different distance from the inlet 50 ; i.e. duct 51 serves the remote portion of the filter 70 , duct 52 the middle section, and duct 53 the nearest portion of the filter surface 70 .
FIG. 6 shows the lower part 61 of the filter housing 60 in plan view. The path taken by the airflow along part of the duct 52 is shown by arrow 85 while the path taken by sound waves is shown by arrow 86 . Due to the shape of the vanes 65 a , 65 b , it can be seen that the sound waves are forced to bounce between the vanes 65 a , 65 b on multiple occasions or at the very least provide an obstruction to sound waves emanating from the motor housing 48 . Vanes 65 a , 65 b , 65 c can be moulded or otherwise formed integrally with the lower part 61 of the filter housing 60 or they can be provided as a separate part or set of parts which locate within the lower part 61 of the filter housing 60 .
The provision of the vanes 65 a , 65 b , 65 c described above is also particularly beneficial where the airflow inlet 50 is off-centre with respect to the filter housing 60 . FIG. 7 shows the expected airflow without the presence of vanes of this sort. Air enters the filter housing 60 and swirls around the housing. This swirling airflow can cause added noise and can further reduce suction power. FIG. 8 shows the effect of positioning vanes 65 a , 65 b within the filter housing 60 . Air entering the filter housing 60 is now unable to swirl to any noticeable degree.
The shape of the vanes 65 a , 65 b , 65 c ensures a smooth transition between directions and section changes which helps to avoid ‘break away’ and turbulence which increase noise and back pressure. It is particularly desirable to minimise back pressure in a vacuum cleaner as it reduces suction power. FIGS. 9 and 10 show the effect of ‘break away’ airflow by contrasting a smoothly curved duct ( FIG. 9 ) with a duct which is curved too sharply ( FIG. 10 ).
The position of the vanes 65 a , 65 b , 65 c within the outlet aperture 50 of the motor housing 48 is chosen such that the cross sectional area of the inlet to each duct 51 , 52 , 53 is substantially proportional to the surface area of the filter portion served by that duct. This helps to ensure that the airflow is evenly distributed across the filter surface. The provision of two inlets to each duct (e.g. inlets 51 a , 51 b to duct 51 ) also helps to balance the airflow to the filter.
Filter 70 is shown here as a pleated filter, in which a cylindrical plastic case houses a pleated structure 72 . Other types of filter, e.g. a simple foam pad filter, could be used in place of what has been shown here. Preferably the post-motor filter is a HEPA (High Efficiency Particulate Air) filter.
FIG. 11 shows a plan view of an alternative embodiment of the lower part 61 of the filter housing 60 . In this embodiment, a set of vanes 165 a - 165 e are positioned in a different manner to that shown in FIG. 6 . Here, the vanes 165 a - 165 e extend outwardly from the outlet aperture 50 of the motor housing 48 towards the furthermost side of the lower part 61 of the filter housing 60 . As before, this arrangement of vanes divides the area beneath the filter 70 into a plurality of ducts 151 - 156 , each duct communicating with a different portion of the filter surface. Each vane has a non-linear, sinuous shape which enhances the likelihood of sound waves colliding with at least one of the vanes. In use, incoming airflow will be divided into a plurality of separate portions, each portion flowing along a respective duct. As before, the cross-section of each inlet is proportional to the filter area served by the inlet.
The operation of the vacuum cleaner will now be described. In use, air is drawn by the motor-driven impeller 45 , through any floor tool and hose into inlet 14 of the vacuum cleaner 10 . The dirty air passes through the cyclonic separation stages 22 , 25 , during which dirt and dust is removed from the airflow in a manner which is well documented elsewhere. Air flows from the outlet of cyclones 25 , along duct 29 , through pre motor filter 30 and into the motor housing 48 . Exhaust air is blown towards the aperture 50 and is there divided into six portions by the leading edges of the vanes 65 a , 65 b , 65 c . The divided portions of the airflow flow along the three ducts 51 , 52 , 53 . As described above, acoustic waves bounce along the ducts 51 , 52 , 53 between opposing vanes 65 a , 65 b . Airflow from the ducts 51 , 52 , 53 then passes through the portion of the post-motor filter 70 with which each respective duct 51 , 52 , 53 communicates. After passing through the filter 70 , air passes to the inlet to the exhaust duct 90 . Some of the air vents to atmosphere via apertures 80 in the upper face of the filter housing part 62 (see arrows 82 , FIG. 3 ). The remainder of the air flows along the exhaust duct 90 . As the air flows along the exhaust duct 90 , it slows down because the duct 90 widens in the direction of flow. This air vents to atmosphere via apertures 95 (see arrows 85 , FIG. 3 ).
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A filter housing includes an inlet for receiving airflow, a cavity for receiving a filter and an airflow passage between the inlet and the filter. At least one vane is positioned in the airflow passage for partitioning the airflow passage into a plurality of ducts. Each vane has a non-linear shape in the direction of flow through the airflow passage. This helps to reduce acoustic emissions from the machine since sound waves emitted by the fan and/or motor are caused to bounce off the vanes, which allows the vanes to absorb some of the sound energy. The filter housing can form part of a vacuum cleaner.
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The present invention relates generally to folders for web printing presses.
BACKGROUND OF THE INVENTION
Many folders used in web printing presses use driven belts or tapes to transport signatures from the cut cylinder to the next operation, such as signature deceleration or folding. These tapes contact the web or ribbons before the signature is created and have a velocity higher than that of the ribbon. The velocity difference causes relative motion (scrubbing) between the ribbons and tapes.
After a signature is created by the cut cylinder, the signature is accelerated by the tapes from ribbon or web speed, which generally matches the surface speed of the cut cylinder as well, to tape speed. The rate of signature acceleration depends on the mass of the signatures and on the normal force and coefficient of friction between the tapes and signatures. Variations in these factors cause position variations in the signatures when they reach the next device, such as a fan or jaw cylinder. Position variations include: signature-to-signature variation at a given press speed, variations due to press speed changes, and variations over time due to, for example, tape wear. Position variations cause the following problems: reduced maximum allowable press speed, increased need for manual phase adjustments, machine damage, and press downtime due to jammed signatures. Such problems are worse in variable cutoff applications and become worse as press speeds increase.
U.S. Pat. No. 4,919,027 shows a sheet diverting system and U.S. Pat. No. 6,612,213 shows a belt diverter. Both are hereby incorporated by reference herein.
SUMMARY OF THE INVENTION
The present invention provides a folder for a web printing press comprising: a cut cylinder cutting a web into signatures; a first transport belt having a first raised section; and a second transport belt having a second raised section, the signatures being received from the cut cylinder so as to be located between the first and second raised sections; and at least one variable speed motor driving the first and second transport belts so as to accelerate the signatures.
By providing raised belt sections and acceleration, head-to-tail spacing can be created while the signatures remain under positive control.
The present invention also provides a method for delivering signatures cut from a web comprising: receiving the signatures at a ribbon speed under positive control between two belts; and accelerating the two belts to create a spacing between the signatures.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the present invention is shown with respect to the drawings in which:
FIG. 1 shows a folder section including cut cylinders, a transport system, and slowdown fans;
FIG. 2 shows an enlarged view of the transport system; and
FIGS. 3A and 3B are plots of belt pad velocity as a function of time.
DETAILED DESCRIPTION
FIG. 1 describes a folder section 10 according to the present invention, having an incoming web or ribbon 12 , nip rollers 14 , a first cut cylinder 16 interacting with a first anvil cylinder, a second cut cylinder 18 interacting with a second anvil cylinder, a transport system 20 , and slowdown fans 22 , 24 . Transport system 20 includes tapes 26 , 28 driven by a motor 30 , and positive control transport belts 32 , 34 driven by motors 36 , 38 . First cut cylinder 16 creates first perforations in ribbon 12 , and second cut cylinder 18 creates signatures by cutting between the perforations. Transport system 20 delivers the signatures to slowdown fans 22 , 24 .
FIG. 2 shows transport system 20 schematically in more detail. Perforated ribbon 12 enters transport system 20 traveling at velocity V 1 . The lead edge of ribbon 12 is guided loosely by belts 26 , 28 traveling at a higher velocity V 2 , but is not positively gripped by the belts 26 , 28 .
Ribbon 12 then is contacted by belt pads 40 , 42 . Belt pads 40 , 42 are driven by motor 48 and, when belt pads first close on ribbon 12 , belt pads 40 , 42 are also traveling at velocity V 1 . Cut cylinder 18 then cuts a signature from ribbon 12 with a knife blade 50 . Motor 48 then accelerates the signature and pads 40 , 42 to velocity V 2 of tapes 26 , 28 . The signature is then transported from pads 40 , 42 to tapes 26 , 28 for continued transportation to fans 22 , 24 . Alternately, rather than being delivered to fans 22 , 24 , signatures could be delivered to a jaw cylinder, for example.
When a signature is first created by cut cylinder 18 , a trailing edge 52 of the new signature is contacting a leading edge 54 of ribbon 12 . By accelerating each signature in transport system 20 from V 1 to V 2 , a head-to-tail distance L between consecutive signatures is advantageously created for delivery of the signatures to fans 22 , 24 .
Pads 40 , 42 have positive control over the signature to prevent slipping between pads 40 , 42 and the signature. Positive control advantageously minimizes position variations in signatures at the exit of transport system 20 .
Transport belts 32 , 34 may contain two sets of pads 40 , 42 and 44 , 46 . Each set of pads 40 , 42 and 44 , 46 contacts every other signature and each belt 32 , 34 can be driven by separate motors 48 , 56 . The spacing of the pads is such that the pads 40 , 42 do not influence the signature contacted by the pads 44 , 46 (and visa versa).
After releasing a signature and prior to contacting a subsequent signature, each set of pads 40 , 42 and 44 , 46 is decelerated on return paths 58 , 60 to velocity V 1 by variable speed motors 48 , 56 . Then pads 40 , 42 and 44 , 46 contact ribbon 12 again, and the process is repeated.
FIGS. 3A and 3B contain plots of velocity versus time for belt pads 40 , 42 and belt pads 44 , 46 , respectively, during the creation of two consecutive signatures. In these figures, belt pads 40 , 42 contact and accelerate the first signature, and belt pads 44 , 46 contact and accelerate the second signature. The first signature is created by cut cylinder 18 at time t 1 and the second is created by cut cylinder 18 at time t 3 .
Variable speed motors, such as servo motors available from Siemens Corporation, can be used to provide such velocity variation.
As shown in both FIGS. 3A and 3B , the velocity of belt pads 40 , 42 and 44 , 46 oscillates between ribbon velocity V 1 and tape velocity V 2 . In FIG. 3A , at time t 1 , the velocity of belt pads 40 , 42 equals ribbon velocity V 1 . Belt pads 40 , 42 then accelerate the first signature and reach tape velocity V 2 at time t 2 . Belt pads 40 , 42 and signature A (SA) remain at velocity V 2 until time t 3 when belt pads 40 , 42 deliver the first signature to tapes 26 , 28 and begin to decelerate. Belt pads 40 , 42 reach ribbon velocity V 1 at time t 4 and remain at velocity V 1 until time t 5 when a new signature is created and the process repeats.
As shown in FIG. 3B , the velocity of belt pads 40 , 42 is the mirror image of the velocity of belt pads 44 , 46 . At time t 1 , belt pads 44 , 46 deliver a preceding signature to tapes 26 , 28 at velocity V 2 and begin to decelerate. Belt pads 44 , 46 reach velocity V 1 at time t 2 . When the second signature is created at time t 3 , belt pads 44 , 46 accelerate the second signature and reach velocity V 2 at time t 4 . Belt pads 44 , 46 and signature B (SB) remain at velocity V 2 until the second signature is delivered at time t 5 .
Belt pad velocity profiles are not limited to those shown in FIGS. 3A and 3B . Alternately, these velocity profiles could be sinusoidal or piece-wise linear, for example. Varying the velocity profiles can set the spacing between signatures.
A single variable motor and gearing could also be used for the belts 32 , 34 .
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A folder for a web printing press includes a cut cylinder cutting a web into signatures; a first transport belt having a first raised section; a second transport belt having a second raised section, the signatures being received from the cut cylinder so as to be located between the first and second raised sections; and at least one variable speed motor driving the first and second transport belts. A method is also provided.
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This application is a division of application Ser. No. 09/105,501, filed Jun. 26, 1998, now U.S. Pat. No. 5,878,736. This application discloses and claims subject matter that is disclosed in copending provisional application Ser. No. 60/051,060, filed Jun. 27, 1997.
BACKGROUND
This invention relates to gas-powered guns for firing projectiles of the paintball type.
Paintball guns, which typically are used for target practice and in mock war games, use a pressurized gas source, such as CO 2 , nitrogen or air, to propel projectiles (paintballs) out of the gun barrel. Paintballs typically comprise an admixture of approximately 92% ethylene glycol, 6% water and 2% titanium dioxide, encased in a fragile gelatin casing. The paintballs are designed to rupture upon impact to mark the target.
One typical problem with existing paintball guns is the tendency of balls to break while still in the gun, with its attendant mess and potential for clogging the gun. Ball breakage apparently is due to excessive bolt impact or gas pressure forces on the ball. Another problem is the difficulty of accessing the chamber, the barrel and the bolt of the gun in order to clean them. Yet another problem is inaccuracy due to inconsistent paintball velocity, apparently due to fluctuations in the pressure of the gas used to propel the balls.
SUMMARY OF THE INVENTION
This invention solves these problems by providing an electronically controlled paintball gun wherein two pressure regulators are used. One pressure regulator supplies a constant high-pressure source of gas for consistently and efficiently propelling paintballs out of the barrel. The other pressure regulator supplies a constant lower-pressure source of gas which allows for a fast cyclic rate for breech loading of paintballs without excessive, ball-crushing force. Further, an easily removable bolt cover is provided at the rear of the upper receiver. When the cover is removed, the bolt easily can be removed, giving easy access to the bolt, the breach and the barrel for cleaning purposes.
Thus, in accordance with one aspect of the invention, a gas-powered gun is provided for firing balls dispensed serially from a magazine into the gun, the gun adapted to be connected to a source of pressurized gas and having trigger-activated valving for controlling the flow of gas within the gun, a barrel with a chamber at the rear thereof, a breech behind the chamber for receiving one ball at a time through a ball feed port from the magazine, and a bolt slidable within the breech and the chamber to advance a ball from the breech into the chamber and close off the feed port so that gas pressure behind the ball forces the ball out of the front of the barrel. A high-pressure regulator supplies gas to the chamber at a substantially constant relatively high pressure to force the ball out of the barrel, while a low-pressure regulator supplies gas at a substantially constant relatively lower pressure for moving the bolt forwardly to advance a ball into the chamber.
In accordance with another aspect of the invention, a gas-powered gun is provided for firing balls dispensed serially from a magazine into the gun, the gun having a barrel with a chamber at the rear thereof, a breech behind the chamber for receiving one ball at a time through a ball feed port from the magazine, and a bolt slidable within the breech and the chamber to advance a ball from the breech into the chamber and close off the feed port so that gas pressure behind the ball forces the ball out of the front of the barrel. A bolt cover partially forms the breech and is removably secured to the rear of the gun behind the ball feed port. Removal of the bolt cover exposes the bolt and allows the bolt to be disengaged and removed from the gun, thereby facilitating cleaning of the bolt, the breech, the chamber and the barrel.
BRIEF DESCRIPTION OF THEE DRAWINGS
FIG. 1 is a side elevational view of a paintball gun according to the invention;
FIG. 2 is longitudinal cross-sectional view through the gun of FIG. 1, showing the gun in its "ready to fire" condition;
FIG. 2A is an enlarged view of the rear end of the gun as seen in FIG. 2;
FIG. 3 is a longitudinal cross-sectional view of the working parts of the gun, shown in the condition where a paintball has been loaded into the chamber and is ready to be propelled out of the barrel; and
FIG. 4 is an enlarged cross-sectional view of the same working parts of the gun, shown in the condition where high-pressure gas is being delivered to the chamber to drive the paintball out of the barrel.
DETAILED DESCRIPTION
Referring to FIG. 1, a paintball gun according to the invention has the following external features: a barrel 01; a grip 02; a trigger 03; a safety 04; a ball feed port 05; a foregrip 06 with a battery access door 06A; a regulator 07; an upper cover 08; a low-pressure regulator 09; an upper receiver 10; a constant gas adaptor 12; and an on/off switch 14.
A constant gas source is applied to the gun by means of a tank (usually CO 2 or nitrogen or compressed air) threaded into the opening of the constant gas adaptor 12. The pressurized gas is transported through opening 12A by means of a high pressure hose assembly (not shown) into opening 13 of regulator 07. Once the switch 14 is turned on and the safety 04 is moved to the "fire" (oft position, the gun is ready to fire by pulling rearwardly on trigger 03.
Paintballs B are loaded into the ball feed port 05 from a hopper (not shown) which can contain many paintballs, and which are gravity-fed into the breech at the rear of barrel 01. Paintball velocity can be adjusted by adjusting the gas pressure, i.e., by turning the regulator adjustment screw 07B by use of a "Allen" key tool (not shown). Gas pressure for propelling paintballs is regulated to 450-500 psi by regulator 07. This regulator (see FIG. 2A) has a spring pack 15 in a housing 07A, a disk 16, a piston 17 held in place by a retaining ring 18, and a shaft 19, which is biased rearwardly by a coil spring 20. Unregulated pressurized gas enters the chamber surrounding shaft 19 via opening 13 (not shown in these figures). Output pressure is governed by the position of adjustment screw 07B, which controls the degree of compression (and, hence, the spring constant) of spring pack 15. Gas flows outwardly from pressure regulator 07 through port 22A, and branches forwardly through bore 22B to a high pressure chamber 15A adjacent valve mechanism 43, 44, 45, and downwardly through bore 22C to low-pressure regulator 9.
When output pressure is stabilized (i.e., before the gun is fired), the conical part of shaft 19 seals against annular face seal 21, which is held in place by a threaded retainer 22. When the gun is fired, gas pressure in the region between retainer 22 and piston 17 drops, allowing spring pack 15 to push shaft 19 forwardly and out of engagement with seal 21. As gas flows again into the region between retainer 22 and piston 17, gas pressure moves the piston rearwardly against the force of spring pack 15, pulling shaft 19 with it until the conical part of the shaft again contacts seal 21.
Referring further to FIG. 2A, the low-pressure regulator 09 supplies lower-pressure gas via output 26 for actuation of the valve which quickly but gently cycles bolt 38 to push one paintball B at a time from the breech into the chamber at the rear of barrel 01. Low-pressure regulator 09 is comprised of a hollow piston 23, a coil spring 24 and a seal 25, all contained within a housing 9A. Gas entering low-pressure regulator 09 from regulator 07 via bore 22C flows around seal 25 and into the interior of piston 23 via cross-bores 23A. Under static downstream conditions (i.e., before the gun is fired), gas pressure within and forwardly of piston 23 overcomes the force of spring 24 to urge the piston rearwardly until seal 25 contacts the seat at the rear end of the regulator to close off gas flow. This arrangement provides a constant lower pressure at output port 26, preferably in the range of 150-200 psi.
Referring to FIG. 2, the output of low-pressure regulator 09 feeds into the input port 27 of a 4-way solenoid valve 28 via a hose or conduit (not shown). Solenoid valve 28 controls the flow of gas to double-acting pneumatic cylinder 33, which has a piston rod 33A. On the end of rod 33A is a carrier 34 which in the position shown is connected to a hammer 35 by means of a sear 36, which is pivoted at 36A on the hammer. A coil hammer spring 41 between carrier 34 and hammer 35 normally biases these two parts away from each other. Carrier 34 also holds a link 37 which attaches the carrier to bolt 38 which slides in upper receiver 08. The valve is in a normally-open condition such that the gas feeds into cylinder 33 through port 32, causing rod 33A of the cylinder to extend rearwardly. This rearmost position of the rod, carrier, hammer, link and bolt, illustrated in FIG. 2, is the "ready-to-fire" position.
The gun is controlled electronically by a circuit board 39 housed in grip 02. The circuit board is powered by batteries (4 "AA" size batteries in this case), which are housed in battery pack 40 in foregrip 06, and accessible through battery access door 06A. On/off-switch 14, located at the front of foregrip 06, controls the delivery of electrical power from the batteries to the circuit board.
With on/off switch in the "on" position, when trigger 03 is pulled it depresses and closes switch 34, which sends a signal to the circuit board 39. The circuit board, upon receiving the trigger signal, sends a signal to the 4-way valve 28 to close off 4-way output port 29 and open flow to 4-way output port 30 for a pre-set interval (approximately 70 ms) dictated by the circuit board. Flow of lower-pressure gas through output port 30, connected to cylinder port 31 via a hose or conduit (not shown), causes rod 33A to move forwardly quickly but gently, bringing with it carrier 34, link 37, bolt 38, hammer 35, hammer spring 41, and sear 36. This forward movement gently advances a paintball B ahead of the bolt from the breech into the chamber at the rear of barrel 01. The forward position of these components is illustrated in FIG. 3.
As these forwardly moving components near the end of their travel, the depending rear leg of sear 36 engages fixed roller pin 42. See FIG. 3. Further incremental forward movement of the components causes sear 36 to rotate about its pivot 36A (counterclockwise in FIG. 3) so that its front end moves downwardly and disengages from carrier 34. As carrier 34 continues to move forwardly, the hammer/sear assembly 35/36, being disconnected from the carrier, is thrust rearwardly by hammer spring 41. See FIG. 4. Hammer 35 strikes valve shaft 43, which is slidably retained in valve body 44 and biased forwardly by spring 43A. This causes valve shaft 43 to move rearwardly momentarily, dislodging seal 45 from its seat and allowing high pressure gas to flow from high pressure chamber 15A around the seal, into valve body 44, and up through the opening (inlet port) 45A in bolt 38. At this time, with the bolt forward and a paintball at the rear of the barrel 01, the bolt closes off feed port 05, preventing another ball from loading into the chamber and preventing the escape of gas. The high pressure gas flowing through bolt 38 pushes the ball through the barrel and out the muzzle end.
Once the 70 ms interval ends, circuit board 39 de-energizes the signal to 4-way valve 33, closing output port 30 and return gas flow to output port 29. This causes piston rod 33A to move rearwardly again until sear 36 again couples carrier 34 to hammer 35. Trigger 03 then is released, allowing it to move back to its initial position under the influence of trigger spring 46. The gun thus has returned to the "ready-to-fire" condition (FIG. 2), and will not fire until the trigger is pulled again. The gun will remain in this condition even if the on/off switch 14 is turned off and/or the gas source is removed from the gun.
For ease of cleaning bolt 38 and barrel 1, especially in the breech area, upper cover 8 is slidably secured to upper receiver 10, and easily can be removed by pulling it rearwardly. Removal of upper cover 8 exposes bolt 38, which then can be lifted out of the gun.
The trigger force can be adjusted (e.g., light pull or hard pull) either by changing trigger spring 46, or by changing the position of spring anchoring point 47.
It will be apparent to those skilled in the art that modifications may be made to the above-described preferred embodiment without departing from the true spirit and scope of the invention, which is defined by the appended claims.
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A gas-powered paintball gun has two pressure regulators which supply two different gas pressures for gun operation: a lower-pressure gas for quickly but gently loading balls into the chamber of the gun, and a high-pressure gas for consistently and efficiently propelling balls out of the barrel. A further aspect of the invention resides in the arrangement of the bolt under a removable cover, which gives easy access to the bolt, the breech and the barrel to enable these parts to be cleaned without major disassembly of other parts of the gun.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of controlling an easing roller included in a loom to execute selectively a position control operation or a tension control operation by an easing motion.
2. Description of the Related Art
An easing roller control method disclosed in JP-A No. 4-24244 controls the position of an easing roller by supporting each end of the easing roller for rotation on each free end of a pair of arms fixed to the output shaft of a drive motor, and controlling the turning angle of the output shaft of the drive motor. When a let-off tension control period is ended and an easing control period is started, the mode of control operation for controlling the drive motor is changed from a tension control mode to a position control mode. The easing roller is shifted by a desired distance set by operating a setting device toward the cloth fell at the beginning of the easing control period. The position of the easing roller thus determined at the beginning of the easing control period is dependent on the position of the easing roller determined for tension control in the tension control period preceding the easing control period. Thus, the position of the easing roller at the beginning of the easing control period varies for each weaving cycle of the loom; that is, the most advanced position of the easing roller, which, generally, is the position of the easing roller at a beating-up moment when the phase of the main shaft of the loom is 0°, varies for each weaving cycle of the loom. Thus, it is possible that the easing roller is required to move to an unexpected position depending on the condition of tension control and cannot be shifted to that required position, and satisfactory tension control cannot be achieved.
An easing motion disclosed in JP-A No. 7-238443 uses a cam mechanism to drive an easing roller for easing warp yarns for forming satin stripes. This prior art easing motion is free from disadvantages of the above-mentioned easing motions. Since the warp tension is dependent on the cam contour of a cam included in the cam mechanism, it is virtually impossible to adjust the actual warp tension to a desired warp tension because the operation of a control system is disturbed by disturbance and the warp tension varies.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an easing motion employing a servomotor, capable of positioning an easing roller always in a predetermined positional range and of easily achieving tension control and position control.
An easing roller control method according to the present invention moves an easing roller forward to a predetermined position in a position control period including a beating-up moment in one weaving cycle of a loom by driving a servomotor for position control to give warp yarns on the loom a predetermined first tension, and moves the easing roller backward in a tension control period including a moment when a maximum shed is formed by driving the servomotor for tension control to give the warp yarns a predetermined second tension higher than the first tension for the position control period.
According to a first aspect of the present invention, an easing roller control method comprises the steps of measuring the position of an easing roller included in a loom in a position control period, determining a correction according to a deviation of a measured position from a desired roller position, and correcting a controlled variable for position control by using the correction to make the actual position of the easing roller approach the desired roller position.
According to a second aspect of the present invention, an easing roller control method comprises the steps of measuring the position of an easing roller included in a loom in a tension control period, determining a correction according to the deviation of a measured position from a desired roller position, and correcting a controlled variable for tension control by using the correction to make the actual position of the easing roller approach the desired roller position.
According to a third aspect of the present invention, an easing roller control method comprises the steps of measuring the position of an easing roller included in a loom in a tension control period, determining a correction according to the deviation of a measured position from a desired roller position, and correcting a controlled variable for position control by using the correction upon transition from the tension control period to a position control period to make the actual position of the easing roller approach the desired roller position.
According to a fourth aspect of the present invention, an easing roller control method comprises the steps of measuring the position of an easing roller included in a loom in a position control period, determining a correction according to the deviation of a measured position from a desired roller position, and correcting a controlled variable for tension control by using the correction upon transition from the position control period to a tension control period to make the actual position of the easing roller approach the desired roller position.
In the position control period or the tension control period, the actual position of the easing roller is measured, and a control signal (a current) for position control or tension control is corrected according to the deviation of the measured position from the desired roller position. Thus, the servomotor is controlled properly to make the easing roller approach the desired roller position in the position control period, and the displacement of the easing roller to an unexpected position due to improper tension control in the tension control period can be prevented.
When the control period is altered from the tension control period to the position control period, a correction signal is corrected on the basis of a desired value for position control. Consequently, the position of the easing roller is adjusted accurately to the desired roller position by position control. When the control period is altered from the position control period to the tension control period, the correction for position control is used to correct a command value for tension control. Therefore, the easing roller is controlled so as to move moderately according to the correction when the control period is altered from the position control period to the tension control period to prevent the momentary tension rise by suppressing the inertial force of the easing roller.
The position of the easing roller can automatically be corrected by changing the position of a position transducer. For example, the foremost position can automatically be made to coincide with a sensor position if a sample signal is generated at a phase of 0°.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent from the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic side elevation of an easing motion for carrying out an easing roller control method according to the present invention;
FIG. 2 is a block diagram of a control unit;
FIG. 3 is a block diagram of a correcting unit; and
FIG. 4 is a diagram of assistance in explaining the variation of the position of an easing roller in a tension control period and a position control period included in one weaving cycle.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an easing motion 1 for carrying out an easing roller control method according to the present invention in easing warp yarns for satin stripes. Ground warp yarns 2 and satin stripe warp yarns 3 are wound on a warp beam 4. The ground warp yarns 2 and the satin stripe warp yarns 3 are wound round easing rollers 5 and 6, respectively. The ground warp yarns 2 and the satin stripe warp yarns 3 are passed through the eyes of heddles held on heddle frames 7. The heddle frames are moved vertically to form a shed 8. Weft yarns 9 are inserted into sheds 8, interlaced with the ground warp yarns 2 and the satin stripe warp yarns 3, and beaten up by a reed 10 to form a fabric 11. The fabric 11 is taken up through a breast beam 12 by a take-up beam 13.
The easing roller 6, i.e., a controlled member, has both ends supported for rotation on the free ends of a pair of arms 14. The pair of arms 14 are able to swing forward and backward to move the easing roller 6 forward and backward. Each of the arms 14 has a base end part fixed to an arm shaft coupled with the output shaft 16 of a servomotor 15 for controlling the position of the easing roller 6. The output shaft 16 of the servomotor 15 is turned either forward or backward through a predetermined angle in one weaving cycle, in which a main shaft 18 included in the loom makes one full turn, for position control in a position control period including a beating-up moment and for tension control in a tension control period including a moment when a maximum shed is formed.
A control unit 17 receives a phase signal provided by an encoder 19 associated with the main shaft 18 and a correction signal from a correcting unit 20, and controls the servomotor 15. The correcting unit 20 compares the position of the easing roller 6 measured by a position transducer 21 with a desired roller position, and gives a correction signal representing the deviation of the measured position from the desired roller position to the control unit 17.
Referring to FIG. 2 showing the control unit 17, a timing signal generator 22 receives a phase signal provided by the encoder 19, and gives a timing signal to a position control unit 23 and a tension control unit 24 at regular intervals of, for example, 5 in the turning angle of the main shaft 18. The timing signal generator 22 generates also a sampling signal at a predetermined phase of the main shaft 18, and gives the sampling signal to the correcting unit 20. The timing signal generator 22 actuates a position control unit 23 in a position control period including a beating-up moment, and actuates a tension control unit 24 in a tension control period including a moment when a maximum shed is formed.
In the position control period, the position control unit 23 generates a turning angle command signal on the basis of both input data on a desired roller position for the easing roller 6 corresponding to a phase set by a setting unit 25 and the timing signal given thereto to drive a servomotor controller 27. The servomotor controller 27 controls the servomotor 15 to turn the output shaft 16 of the servomotor 15 in a forward direction to shift the easing roller 6 to a front end position. The tension control unit 24 generates a tension control signal representing a current corresponding to a desired tension on the basis of both input data on the desired tension corresponding to a phase set by a setting unit 26 and the timing signal given thereto to drive the servomotor controller 27. The servomotor controller 27 controls the servomotor 15 to turn the output shaft 16 of the servomotor 15 in a backward direction by a torque corresponding to the desired tension to give the satin stripe warp yarns 3 the desired tension. A pulse generator 28 measures an angle through which the output shaft 16 of the servomotor 15 is turned and gives an angle signal representing the angle through which the output shaft 16 is turned as a feedback signal to the position control unit 23 and the servomotor controller 27.
Referring to FIG. 3 showing the correcting unit 20, a position signal generated by the position transducer 21 is amplified by an amplifier 29, and the amplified position signal is given to a roller position calculating unit 30. The roller position calculating unit 30 detects or calculates the position of the easing roller 6 every time a sampling signal is given thereto. The sampling signal is generated when the main shaft 18 is at a phase of, for example, 0° or 180°. The roller position calculating unit 30 gives data on a calculated roller position to a comparator 31. The comparator 31 compares the data on the calculated roller position with a desired roller position data corresponding to a sampling phase and given thereto by the setting unit 32, and gives a deviation signal representing the deviation of the calculated roller position from the desired roller position to a correction calculating unit 33. The correction calculating unit 33 gives a correction signal corresponding to the deviation at least to the position control unit 23 or the tension control unit 24.
Referring to FIG. 4, a weaving cycle, i.e., a period in which the main shaft 18 of the loom makes one full turn, has a position control period and a tension control period. The position control period corresponds to a phase range of, for example, 270° to 20° including a beating-up moment corresponding to a phase of 0°. The tension control period corresponds to a phase range of, for example, 20° to 270° including a phase angle of, for example, 180° when a maximum shed is formed. A position control operation is executed in the position control period to reduce the tension of the satin stripe warp yarns 3 by moving the easing roller 6 forward by the servomotor 15 to a level below a tension set by a tension control operation. The tension control operation is executed in the tension control period to increase the tension of the satin stripe warp yarns 3 to a level above the tension set by the position control operation. Thus, the easing roller 6 is moved forward and backward by the servomotor 15.
In the position control period, the position control unit 23 reads a position for the easing roller 6 corresponding to a timing signal given thereto on the basis of data on the position of the easing roller 6 when the main shaft 18 is at a phase set by the setting unit 25, gives a turning angle signal representing the position for the easing roller 6 to the servomotor controller 27. Then, the servomotor controller 27 drives the servomotor 15 to turn the output shaft 16 of the servomotor 15 in the predetermined direction to move the easing roller 6 forward.
In some cases the actual front end position of the easing roller 6 is dislocated from a desired position due to the malfunction of the control system of the loom caused by a disturbance or the undesired variation of warp tension. According to the invention as disclosed in claim 1, the correcting unit 20 generates a correction signal representing a correction on the basis of the comparison between a position signal provided by the position transducer 21 and a desired position signal and gives the correction signal to the position control unit 23. The position signal is provided by the position transducer 21 in response to the sampling signal generated every sampling period corresponding to one revolution or ten revolutions of the main shaft 18 of the loom. The desired position signal is set in advance by a setting device 32. Then, the position control unit 23 corrects the phase of the output shaft 16 of the servomotor 15 on the basis of the correction signal to shift the easing roller 6 to the desired position. Thus, the position control unit 23 executes the position control operation in the position control period to correct the position of the easing roller 6 at the sampling period.
In the tension control period, the tension control unit 24 generates a current signal representing a current corresponding to a timing signal given thereto on the basis of data on a desired tension corresponding to a phase of the main shaft 18 set by the setting unit 26, and gives the current signal to the servomotor controller 27. The servomotor controller 27 drives the output shaft 16 of the servomotor 15 for turning in a direction suitable for making the torque of the servomotor 15 and the tension of the satin stripe warp yarns 3 balance each other. Consequently, the easing roller is moved backward to adjust the tension of the satin stripe warp yarns 3 to the desired tension. Further, according to the invention as disclosed in claim 2, the correcting unit 20 generates the correction signal representing the correction on the basis of the comparison between the position signal provided by the position transducer 21 and the desired position signal and gives the correction signal to the tension control unit 24. The position signal is provided in response to the sampling signal generated every sampling period at a phase of 180° of the main shaft 18 in the tension control period, and gives the correction signal to the tension control unit 24. Accordingly, the tension control unit 24 corrects the current represented by the current signal given to the servomotor 15 and corresponding to the output torque of the servomotor 15 to reduce the tension when the easing roller 6 is moved excessively forward Thus, the easing roller 6 can always be moved to a fixed front end position, and the displacement of the easing roller 6 to an unexpected position in the tension control period can be avoided.
Although the correcting unit 20 gives a correction signal for the tension control period to the tension control unit 24 according to the invention disclosed in claim 2, it gives the same correction signal to the position control unit 23 when the tension control period is terminated and the position control period is started according to the invention as disclosed in claim 3. Accordingly, the position control unit 23 generates, for the position control period, a control signal representing a turning angle corresponding to the displacement of the easing roller 6 in the tension control period More specifically, correction is made so that the position is behind the desired position, when the easing roller 6 is moved excessively forward Accordingly, the position of the easing roller 6 in the initial stage of the position control period is not affected by the displacement of the easing roller 6 in the preceding tension control period, and the easing roller 6 is moved accurately to the desired position (front end position).
According to the invention as disclosed in claim 4, since the correcting unit 20 gives a correction signal for the position control period to the tension control unit 24 when the position control period is terminated and the tension control period is started, the tension control unit 24 regulates the rotating speed of the output shaft 16 of the servomotor 15, i.e., the speed of movement of the easing roller 6 from the front position to a back position so that the easing roller 6 moves at a moderate speed to suppress the effect of the inertia of the easing roller 6 on the variation of the warp tension so that the warp tension may not rise momentarily and to avoid the backward movement of the easing roller 6 beyond a desired position.
When weaving the satin stripe fabric on the loom, generally, the satin stripe warp yarns 3 are loosened, and ground warp yarns 2 are tightened due to the difference of the textile weave. But, when the position control and the tension control are executed alternately for the satin stripe warp yarns 3, the ground warp yarns 2 and the satin stripe warp yarns 3 are in the same tension. The present invention is applicable not only to the control of the easing roller 6 for easing the satin stripe warp yams, but also to the control of the easing roller 5 for easing the ground warp yarns 2 and to the control of the easing rollers of looms for weaving fabrics of ordinary weaves.
Although the invention has been described in its preferred form with a certain degree of particularity, obviously many changes and variations are possible therein. It is therefore to be understood that the present invention may be practiced otherwise than as specifically described herein without departing from the scope and spirit thereof.
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A method of controlling the easing motion (1) of a loom executes a position control operation and a tension control operation successively in one weaving cycle of the loom. The position of an easing roller (6) included in the easing motion (1) is measured in a position control period, a correction is determined according to the deviation of the measured position of the easing roller (6) from a desired roller position, and a controlled variable is corrected by using the correction to make the actual position of the easing roller (6) approach the desired roller position.
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[0001] This non-provisional application claims benefit to German priority document Application Serial No. 10215311.6-12 filed Apr. 8, 2002, which disclosure is hereby incorporated by reference herein.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] The present invention relates to a sealing device. More specifically, the present invention relates to a sealing device for sealing off a moving shaft or rod in a transition area between a high-pressure space, carrying, for example, a liquid medium, and a low-pressure area.
[0003] It is known to use seals made of thermoplastic or elastomeric materials which, on the one side, rest against the circumference of the shaft and, on the other side, against a housing or parts thereof.
[0004] As a result of high pressures, which in some systems are above 200 bar, as well as a pressure difference in comparison to the low-pressure area resulting therefrom, the rate of motion of the shaft, the temperature and type of the medium to be sealed off, a very high wear of the sealing rings will occur. That leads to a low durability and a correspondingly low service life of the system in which such a sealing device is used. On the whole, the durable reliability of the system is severely restricted.
[0005] Furthermore, operation-caused wear of the seals or sealing rings and the related frequent interruptions of the operation naturally result in high costs to which the repair costs are added, so that a sealing device of the above-mentioned type stands in the way of an optimized economic operation.
[0006] Other sealing solutions consist of providing a sealing ring which reaches around the shaft with a slight circumferential throttling gap. Along the length of this throttling gap, the pressure difference between the high-pressure space and the low-pressure area is reduced.
[0007] However, this is connected with a relatively high leakage flow which, also as a result of the flow rate, contributes to an erosion wear by which the throttling gap is enlarged. Finally, this results in unacceptable leakages which have to be eliminated by corresponding repairs.
[0008] For eliminating these problems, the throttling gap has to be kept very small which, however, because of the required precision, can be implemented only by means of very high manufacturing expenditures and correspondingly high manufacturing costs. Components of larger dimensions are therefore usually not produced.
[0009] The present invention is a sealing device for a movable shaft arranged between a high-pressure space and a low-pressure area of a pressure-resistant housing bounding the high-pressure space. The sealing device includes a deformable pressure ring, and a sealing ring that surrounds the shaft and is partially deformable by the deformable pressure ring. The pressure ring is supported under pressure at an outer circumference of the sealing ring with the sealing ring resting either against or almost against the shaft.
[0010] The sealing ring is formed as a sleeve, which preferably consists of hard metal or ceramics. It is formed in the manner of an elevation in the area of the partial deformation. The remaining area of the sealing ring encloses the shaft at a narrow gap distance.
[0011] Before a mounting, the sealing ring has a continuously smooth interior wall. After the deformable pressure ring is acted upon by a force, the partial deformation in the direction of the shaft will take place as a result of the transmitting deformation forces of the pressure ring. Depending on the applied force, a more or less extensive deformation will take place; that is, a more or less massive construction of a beaded ring occurs and it becomes precisely adjustable how closely this beaded ring rests against the shaft.
[0012] Even in the event of a wear of this closely contacting beaded ring, caused by the axial and/or rotational movement of the shaft, this wear can be compensated as a result of an adjustment and a further deformation of the pressure ring.
[0013] The pressure ring itself consists of metal or of a suitable plastic material. It is supported on the wall of the pressure-resistant housing which in this respect represents an abutment.
[0014] The force for deforming the pressure ring and thus for partially deforming the sealing ring can be transmitted by way of a thrust ring and can be generated by screws, threads or a hydraulic system. The force is applied to the low-pressure area and is greater than the counterforce resulting from the operating pressure existing in the high-pressure space, the force being freely adjustable.
[0015] The elastic transverse deformation, which results in the formation of the above-mentioned beaded ring, reduces the gap between the sealing ring and the shaft which originally existed in that area. The gap is reduced according to the desired demands with respect to the leakage amount, the manufacturing tolerances to be compensated and/or the compensation of the preceding wear. If required, leakage flows can even be reduced to zero.
[0016] Since the sealing ring or the entire sealing device operates almost without wear, these are considerable improvements particularly with respect to the operating costs. An exchange of the sealing ring is also not required after many hours of operation so that the service life of the system into which such a sealing device is installed will be significantly longer with resulting cost improvements.
[0017] Other objects or features of the present invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a cross-sectional view of an embodiment of a sealing device, according to the present invention.
[0019] [0019]FIG. 2 is a cross-sectional view of another embodiment of a sealing device, according to the present invention.
[0020] [0020]FIG. 3 is a cross-sectional view of another embodiment of a sealing device, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] FIGS. 1 - 3 each show an embodiment of a sealing device 100 , 200 , 300 respectively, for a rod or shaft 2 . The shaft 2 is movably disposed in a guide (not shown) arranged between a high-pressure space 10 and a low-pressure area 11 of a pressure-resistant housing 1 that bounds the high-pressure space 10 . The shaft 2 may be movable back and forth in axial direction A-A′ as well as rotating or swiveling in direction R or the reverse of direction R.
[0022] Each sealing device 100 , 200 , 300 has a sealing ring 3 which preferably consists of hard metal or ceramics and is constructed as a sleeve that surrounds the shaft 2 . The inside diameter of the sealing ring 3 is essentially slightly larger than the outside diameter of the shaft 2 , so that an interior gap 7 is formed.
[0023] A pressure ring 4 , forming a static seal, has one side resting against a portion of an outer jacket (not shown) of the scaling ring 3 . Pressure ring 4 is deformable and may be made of metal or of a plastic material or both. On another side, pressure ring 4 is supported on a wall of the pressure-resistant housing 1 , where it rests in a receiving device 22 , as shown in FIGS. 1 and 3.
[0024] By way of a spacer ring 6 , acting as the thrust ring, a force F originating from the low-pressure area 11 is applied in the axial direction A, so that the pressure ring 4 deforms. The pressure ring 4 is held in an expansion-resistant manner by sides of the receiving device 22 , which sides are formed, on the one hand, by a wall of the housing 1 and, on the other hand, by a step-shaped projection of the sealing ring 3 (see FIGS. 1 and 3). In the housing 1 and the spacer ring 6 , feeding bores 15 , 16 are provided so that liquid can be entered between the spacer ring 6 and the shaft 2 for cooling and lubrication.
[0025] For the embodiment shown in FIG. 2, there is a receiving space 22 which is comparable with the receiving device 22 shown in FIGS. 1 and 3. Pressure ring 4 is placed in receiving space 22 and is bounded by sealing ring 3 and a wall of the housing 1 , as well as by a front surface of a thrust piece 12 which is arranged between the sealing ring 3 and the spacer ring 6 and encloses the shaft 2 in a ring shape.
[0026] As shown in FIG. 2, when the force F is applied, deformation forces acting upon the pressure ring 4 are radially guided in the direction of the shaft 2 , causing a partial deformation and forming a beaded ring 5 on an interior wall of the sealing ring 3 . That partial deformation, depending on the applied force F, has the result that beaded ring 5 rests against shaft 2 or almost rests against shaft 2 .
[0027] In the case of the embodiment illustrated in FIG. 1, the sealing ring 3 is axially displaced by pressure onto the spacer ring 6 , in which case the sealing ring 3 experiences a pretensioning by the axial reduction of a chamber 9 adjacent to the housing 1 . In this case, the force F is greater than the product of the pressure of the medium in the high-pressure space 10 and the ring surface of the sealing ring 3 acted upon by pressure in the high-pressure space 10 minus the pressure in the low-pressure area 11 multiplied by the effective ring surface of the spacer ring 6 .
[0028] Depending on the adjustment of the force F by way of screws, threads or hydraulic devices (not shown), the beaded ring 5 moves more or less closer to the shaft 2 . In this case, the beaded ring 5 may even exercise a certain compressive stress upon the shaft 2 .
[0029] In the embodiments shown in FIGS. 1 and 3, the sealing ring 3 is disposed in an axially displaceable manner. In the embodiment shown in FIG. 2, the sealing ring 3 is fixedly positioned; that is, it is supported on a base of a shoulder 23 , while it carries the pressure ring 4 on an opposite end. In the embodiment of FIG. 2, the shaping-out toward the beaded ring 5 also takes place as described above by the spacer ring 6 , but it occurs indirectly, because the thrust piece 12 is arranged between the sealing ring 3 and the spacer ring 6 .
[0030] An expansion of the interior gap 7 of the sealing ring 3 , because of internal pressure and a resulting decrease of the sealing effect of the beaded ring 5 , is prevented by an exterior gap 8 . Gap 8 is formed such that the outside diameter of the sealing ring 3 , in a length region essentially projecting into the high-pressure space 10 , is smaller than the inside diameter of the high-pressure space 10 .
[0031] The exterior gap 8 is connected with the high-pressure space 10 , so that the same pressure that is in the high-pressure space 10 exists in the interior gap 7 , which gap 7 is also connected with the high-pressure space 10 and the exterior gap 8 .
[0032] In the embodiment illustrated in FIG. 2, the connection between the high-pressure space 10 and the exterior gap 8 may be established by radial grooves 14 which are provided in the sealing ring 3 on a front face or side, of the sealing ring 3 , which is supported on the shoulder 23 of the housing 1 .
[0033] In addition, as a result of the interior gap 7 , a throttling and thus a partial reduction of pressure takes place so that a lower pressure exists at a sealing area formed by the beaded ring 5 than in the high-pressure space 10 .
[0034] In the embodiment according to FIG. 2, the sealing ring 3 rests firmly against the shoulder 23 in the direction of the force F and the force F is applied by way of the thrust piece 12 to the pressure ring 4 . That provides adjustability, particularly in the case of greater lengths of sealing devices 3 . Furthermore, different materials, which may be optimal for their respective functions, can be used for the sealing ring 3 and the thrust piece 12 .
[0035] In the case of the sealing device 300 , shown in FIG. 3, the sealing ring 3 is relatively short in comparison with sealing device 100 , shown in FIG. 1. For sealing device 300 , the throttling of pressure takes place by way of a sleeve 17 . The sealing ring 3 rests against one side of the sleeve 17 and the sleeve 17 has a bevel 21 on the side facing the sealing ring 3 . There is a lengthening of interior gap 19 , in the form of a bevel 21 , which causes a related increase of the axial contact tension, which is higher than the pressure in the high-pressure space 10 . A sealing effect is thereby generated which prevents a pressure compensation between an exterior gap 18 , open in the direction of the high-pressure space 10 , and the interior gap 19 . The exterior gap 18 is shorter than interior gap 19 which extends along the entire length of the sleeve 17 .
[0036] In order to generate an initial pretensioning, a pressure spring 20 is provided which, on one side, is supported on the shoulder 23 of the housing 1 and, on the other side, is supported on the front side of the sleeve 17 facing away from the sealing ring 3 .
[0037] Although the present invention has been described and illustrated in detail, it is to be clearly understood that the same is by way of illustration and example only, and is not to be taken by way of limitation. The spirit and scope of the present invention are to be limited only by the terms of the appended claims.
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A sealing device for a movable shaft arranged between a high-pressure space and a low-pressure area of a pressure-resistant housing bounding the high pressure space. The sealing device includes a deformable pressure ring and a sealing ring that surrounds the shaft and is partially deformed by the deformable pressure ring. The pressure ring is supported under pressure at an outer circumference of the sealing ring, with the sealing ring resting either against or almost against the shaft.
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FIELD OF THE INVENTION
This invention relates to semiconductor devices, and more particularly relates to a package for a semiconductor device and the method of making the package.
THE PRIOR ART
An important aspect of fabricating semiconductor devices is the attachment of the semiconductor device to a mounting structure and the final packaging of the mounted device. With such semiconductor devices as SCR's, triacs and transistors, many previously developed packaging techniques have required mounting of the devices on a support member and then separately attaching two or more leads to the exposed upper face of the device.
It has thus been proposed that such multiterminal semiconductor devices be attached to their support housings by "flip-chip" mounting or face bonding. In this technique, the semiconductor device is mounted face down on its support substrate, thereby reducing fabrication costs since connection bonds between the device terminals and the substrate may be made simultaneously. Techniques of flip-chip mounting have included the use of solder coated balls between the semiconductor device and the substrate, and also included beam lead bonding, but these techniques have been costly and have increased surface area required for mounting. Still other flip-chip techniques have incorporated raised metallic bumps on the semiconductor device terminals, but bonding to the substrate with this technique requires alignment and bonding with thermo-compression or ultrasonic techniques.
It has thus been heretofore proposed to eliminate some of the problems of the prior art flip-chip mounting techniques by forming conductive patterns on the ceramic substrate and bonding a semiconductor device to the pattern. However, such prior attempts have not been successfully accomplished and have often resulted in the imposition of mechanical stresses on the semiconductor device through leads attached to the ceramic substrate and to the semiconductor device.
SUMMARY OF THE INVENTION
In accordance with the present invention, a technique has been provided for forming a semiconductor device package which incorporates ease of handling, simplicity of fabrication and proven reliability of the resulting package, without the imposition of mechanical stresses to the package through the attached leads.
In accordance with the present invention, a semiconductor device package includes a metal heat sink support member bonded to one side of a ceramic electrical insulating body. First and second spaced apart conductive patterns are formed on a second side of the ceramic body. A semiconductor switching device has first and second terminals on one side and a third terminal on the other side. The switching device is bonded on one side to the conductive patterns, with the first and second terminals bonded to the first and second conductive patterns. A first lead is bonded to the first conductive pattern and a second lead is bonded to the second conductive pattern. The first and second leads are located adjacent to, but spaced from, the switching device so as to isolate the switching device from mechanical stresses imposed on the leads.
In accordance with another aspect of the invention, a semiconductor device package includes a conductive heat sink support member. An electrically nonconductive body having two opposed planar faces is bonded to the support member on one of the planar faces. A conductive pattern is formed on the other of the planar faces of the body and includes at least two discrete pattern portions. A semiconductor device has at least first and second terminals on one side and a third terminal on the other side. The semiconductor device is bonded on the one side to the conductive pattern with the first and second terminals contacting the two discrete portions of the conductive pattern. First and second conductive leads are bonded to the two discrete portions of the conductive pattern adjacent to the semiconductor device and extend outwardly from the nonconductive body. A third conductive lead is bonded to the third terminal on the other side of the semiconductor device.
In accordance with another aspect of the invention, a method of packaging a semiconductor device includes forming at least two conductive patterns on a first planar face of a ceramic body. A metal heat sink member is then bonded to a second planar face of the ceramic body. Two terminals on one face of a semiconductor device are then bonded to areas of the conductive portions. Two leads are bonded to other areas of the conductive pattern such that two leads are spaced from the semiconductor device to isolate the device from mechanical stresses imposed upon the leads. A third lead is bonded on a third terminal on a second face of the semiconductor device. The ceramic body, semiconductor device and portions of the leads are encapsulated to form a semiconductor package with the leads extending therefrom.
DESCRIPTION OF THE DRAWINGS
For a more detailed description of the present invention and for other aspects and advantages thereof, reference is made to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a top view of a ceramic body having a plurality of conductive patterns formed thereon;
FIG. 2 is a view of the back side of a ceramic body shown in FIG. 1 illustrating the formation of additional conductive patterns thereon;
FIG. 3 is a top view of a tab frame with two ceramic bodies attached thereto;
FIG. 4 is a pictorial perspective view of the ceramic substrate about to be attached to a face of a semiconductor switching device;
FIG. 5 is a top view of the attached assembly shown in FIG. 4;
FIG. 6 is a top view of the assembly shown in FIG. 5 with the addition of three leads;
FIG. 7 is a sectional view taken through section lines 7--7 in FIG. 6;
FIG. 8 is a sectional view taken generally along the section lines 8--8 in FIG. 6;
FIG. 9 is a sectional view of an alternate embodiment of the present invention;
FIG. 10 is a top view of a ceramic body in accordance with another embodiment of the invention;
FIG. 11 is a top view of the structure shown in FIG. 10 with the addition of a semiconductor chip;
FIG. 12 is a top view of the structure shown in FIG. 11 with the addition of four leads thereto; and
FIG. 13 is a perspective view of a completed semiconductor package in accordance with the present invention attached to a heat sink member.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a ceramic body 10 having opposed planar sides and having a plurality of conductive patterns 12 formed thereon. Each of the conductive patterns 12 includes a first pattern portion 14 and a second spaced apart pattern portion 16. Pattern portions 14 and 16 are interdigitated, with an extension 18 extending from portion 16 into a cavity formed in portion 14. Pattern portions 14 and 16 are configured to correspond with the gate and cathode terminals of a semiconductor switching device such as an SCR. In construction, as many as eighty of the conductive patterns 12 will be symmetrically formed on one side of the ceramic body 10.
FIG. 2 illustrates a view of the back of the ceramic body 10, illustrating a plurality of rectangular conductive patterns 20 formed symmetrically thereon. Conductive patterns 20 correspond in placement with the position of a conductive pattern 12 on the opposite side.
The ceramic body 10 may be formed from any of the various ceramic materials which are commonly employed in the manufacture of electronic components, but preferably comprise a ceramic wafer formed from alumina (Al 2 O 3 ), beryllium oxide (BeO) or boron nitride (BN). Beryllium oxide in particular is useful in the fabrication of the ceramic body 10 due to its superior terminal conductivity characteristics.
The dimensions of the ceramic body 10 are not critical to the practice of the invention, but may comprise for example a thin rectangular wafer having dimensions of approximately 2×2×.02 inches.
The conductive patterns 12 and 20 are formed in accordance with the technique disclosed and claimed in U.S. Pat. No. 3,829,593 and entitled "COPPER HEAT SINKS FOR ELECTRONIC DEVICES AND METHOD OF MAKING SAME", issued Aug. 13, 1974. Specifically, molybdenum-manganese is applied on the base of the conductive patterns by means of silk screening or the like. The ceramic wafer and the molybdenum-manganese layers are then baked at about 1,300° C. in a hydrogen atmosphere. Subsequently, a layer of material containing copper is applied to each of the molybdenum-manganese bonding layers in accordance with the teachings of U.S. Pat. No. 3,829,598. The copper is then heated to fuse the copper or sinter the copper into a discrete conductive pattern comprising substantially elemental copper so as to provide maximum heat transfer, ductility and conductivity.
After the ceramic body 10 has been processed to form the conductive patterns 12 and 20 on opposite faces thereof, the ceramic body 10 is then severed into a plurality of components as by scribing or the like. Each resulting ceramic body is then bonded to a portion of a tab frame 22 as shown in FIG. 3. Tab frame 22 is preferably formed from a highly conductive metal and serves as a heat sink for the semiconductor package, as will be subsequently described. The tab frame 22 includes an elongated portion 24 with generally rectangular heat sink tabs 26 formed at spaced intervals therealong. The tab frame 22 is formed with a substantial length and may include ten or more tabs 26 along the length thereof. Apertures 28 are formed at spaced locations along the tab frame 22 in order to enable attachment of the package to a large heat sink as will be subsequently described.
As shown in FIG. 3, ones of the ceramic bodies 30 which are formed by severing the ceramic body 10 are bonded to the tabs 26 by soldering of the conductive patterns 20 to the tabs 26. Thus, the conductive patterns 14 and 16 are exposed on each tab 26 in the manner shown.
FIG. 4 illustrates the mounting of a semiconductor device 32 upon the ceramic body 30. While it will be understood that the semiconductor device 32 may comprise any of a plurality of various types of semiconductor devices, in the preferred embodiment, the device 32 comprises a switching device, with a SCR being illustrated. The semiconductor device 32 includes a main terminal 34 and a center gate 36 spaced apart from one another in the well known manner.
The pattern portions 14 and 16 are interdigitated, with the concave portion 38 receiving an extruding projection 40. The extending portion 40 is dimensioned to contact the center gate 36. A layer 42 of insulating material such as glass or the like is formed over a portion of the extending portion 40 in order to prevent contact with the main terminal 34. Main terminal 34 of the device 32 will then contact only pattern portions 14. In fabrication of the package, solder is placed on the pattern portions 14 and 16 and the semiconductor device 32 is placed face down as shown in FIG. 4.
FIG. 5 illustrates a top view of a semiconductor device 32 when properly positioned on the ceramic body 30. It will of course be understood that a plurality of semiconductor devices 32 are simultaneously placed on a plurality of ceramic bodies 30 extending along the tab frame 22. The semiconductor device 32 includes a second main terminal 44 which is exposed when the device is mounted on the ceramic body 30. The illustrated configuration of FIG. 5 is then heated in order to melt the solder between the semiconductor device 32 and the conductive portions 14 and 16 in order to firmly bond the semiconductor device 32 to the ceramic body 30. As will be subsequently described, the solder used to bond the device 32 to the body 30 has a relatively high melting point and may comprise for example 90% lead and 10% tin.
FIG. 6 illustrates the next step in assemblying the present package, with like numerals being utilized for like and corresponding parts shown in the previous drawings. At this stage, three metallic conductive leads 50, 52 and 54 are bonded to the assembly. Lead 50 is bonded to the pattern portion 14, while lead 54 is bonded to pattern portion 16. Lead 52 includes an enlarged pad portion 56 which is bonded to the second main terminal 44 of the semiconductor device 32.
FIG. 7 is a sectional view of the device shown in FIG. 6 taken generally along the section lines 7--7. FIG. 7 illustrates the layer of solder 57 which bonds the ceramic body 30 to the heat sink tab 26. The solder layer 58, previously described, bonds the semiconductor device 32 to the ceramic body 30. Solder layers 60, 62 and 64 bond the leads 50, 52 and 54 to the assembly.
In the preferred embodiment, the solder layers 60, 62 and 64 are provided with a lower melting point than the solder used for solder layer 58. Thus, when the leads 50, 52 and 54 are applied and heated to provide bonding, the previously soldered layer 58 will not remelt and cause shorting. Solder layers 60, 62 and 64 may comprise for example 60% tin and 40% lead or the like. If desired, the solder for layer 58 may comprise a hard solder comprised of gold-germanium or copper-silver bronze, or including the elements aluminum, platinum, gold, silver or cadmium.
FIG. 8 illustrates a sectional view of the device of FIG. 6 taken generally along the section lines 8--8. FIGS. 7 and 8 illustrate that the lead 52 is bonded to the top of the semiconductor device 32, while leads 50 and 54 are bonded directly to the ceramic body 30 on opposite sides of semiconductor device 32. Thus, mechanical stresses imposed upon leads 50 and 54 are not transmitted directly to the semiconductor device 32, and thus the semiconductor device 32 is isolated from such external mechanical forces. This creates a much stronger and long lasting semiconductor package. In addition, the package shown in FIGS. 1-8 provides less component parts than previously developed packages and correspondingly less numbers of fabrication steps. In addition, the present packaging devices may be accomplished simultaneously on a large number of devices to further facilitate economic fabrication.
Referring to FIG. 8, in an alternate embodiment of the invention, a small bend or "wrinkle" (not shown) may be provided in lead 52 a short distance away from the semiconductor device 32, in order to prevent mechanical stresses from being imposed through lead 52 to the semiconductor device 32. When such aa bend or wrinkle is utilized, lead 52 may be formed from a low expansion alloy such as Kovar or the like.
FIG. 9 illustrates an alternate packaging embodiment. A metallic heat sink member 70 is bonded by a solder layer 72 to a ceramic body 74 in the same manner previously disclosed. In this embodiment, metallic leads 76 and 78 are directly bonded to conductive patterns on the top of the ceramic body 74. The semiconductor device 80 is then bonded to the tops of the leads 76, and the third lead 82 bonded directly to the top of the semiconductor device 80. In this embodiment, the top lead 80 may be directly bonded to the semiconductor device without the requirement of a third conductive pattern on the ceramic body 74. However, the leads 76 and 78 will tend to impose mechanical stress on the semiconductor device 80, unlike the previously described embodiment.
FIGS. 10-12 illustrate yet another embodiment wherein a ceramic body 90 includes three conductive patterns 92, 94 and 96 formed thereon. Ceramic body 90 is bonded in the manner previously described to a metal tab 98 extending from a tab frame 100. Conductive pattern 94 includes a cutout portion 102 which receives an elongated projection 104 from pattern 96.
FIG. 11 illustrates the next stage of fabrication of the assembly as illustrated, with like numerals being utilized for like and corresponding parts. The elongated projection 104 is covered by glass or other insulation in the manner previously described. A semiconductor switching device 106 is placed face down into contact with patterns 94 and 96, and bonded thereto. The projection 104 is bonded to the center gate of the device 106, while the pattern 94 is bonded to the first main terminal. The second terminal 108 of the device is shown unconnected at this stage.
FIG. 12 illustrates the subsequent steps of fabrication of the assembly shown in FIGS. 10 and 11. In this embodiment, a metallic lead 110 is bonded at one end to the second main terminal 108 of the semiconductor device 106. The lead 110 is bonded at a reduced area end 112 to conductive pattern 92. Three external leads 114, 116 and 118 are bonded at the ends by soldering or the like to conductive patterns 92, 94 and 96 respectively. Thus, while the embodiment shown in FIGS. 10-12 does not impart mechanical stress from the external leads to the semiconductor device 106, this embodiment does require a fourth lead and requires subsequent additional parts, subsequent additional fabrication processing and utilizes a greater portion of the area of the ceramic member.
FIG. 13 illustrates the final packaging of a semiconductor device constructed in accordance with the invention. The tab 26 is trimmed to the desired dimension and the semiconductor device and associated lead circuitry is encapsulated within a housing 120. Housing 120 may comprise suitable epoxy or other fastening material and may include a plastic outer housing if desired. The device thus includes three external leads 122, 124 and 126. If the device is constructed in accordance with the preferred embodiment shown in FIGS. 1-8, mechanical stress imparted upon leads 122 and 126 will not be directly imparted to the semiconductor device within the housing 120. The heat sink tab 26 includes the aperture 28 which may receive a bolt 130 in order to attach the entire device into a heavy sink member 132. It will be seen that the present invention thus provides an economical technique for fabricating a semiconductor package which has a large number of economic and operational advantages.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims.
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The specification discloses a semiconductor device package which includes a conductive heat sink support member which is bonded to a planar face of a ceramic body. A conductive pattern is formed on a second planar face of the ceramic body and includes at least two discrete pattern portions. A semiconductor switching device has at least first and second terminals on one side and a third terminal on the other side. The semiconductor switching device is bonded on the one side to the conductive pattern, with the first and second terminals contacting the two discrete portions of the conductive pattern. First and second conductive leads are bonded to the two discrete portions of the conductive pattern adjacent to the semiconductor switching device and extend outwardly from the ceramic body. A third conductive lead is bonded to the third terminal on the other side of the semiconductor device.
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FIELD OF THE INVENTION
The present invention relates to a fuel injection device for an internal combustion engine according to the preamble of claim 1.
BACKGROUND OF THE INVENTION
Such a fuel injection device is generally known in the prior art. For example, an injection system for LPG is being marketed by Applicant under the name of LPI. The LPG in this case is in a liquid state during the injection and is not converted to vapour form until it is in the intake duct. Such a system has many advantages, such as negligible loss of power compared with petrol as the fuel, accurate metering possibilities and simple connection to electronics of electrically controlled petrol injection systems.
In order to ensure that the LPG used remains in the liquid state, a pump for increasing the pressure is used. Numerous measures are also taken to prevent heat transfer as much as possible from parts of the internal combustion engine to the supply/discharge pipes or injectors. The result of this is that liquid LPG can be guaranteed to be present in the injectors in all operating circumstances.
It has been found that injectors used inevitably show some leakage. This means that after the internal combustion engine has been switched off fuel goes into the intake manifold and makes starting more difficult. For the first part of the mixture which has been drawn in will contain excess fuel and ignite poorly, which gives rise to a risk of the spark plugs becoming fouled. This problem is particularly prevalent if the starting-up is on petrol. For during the first starting revolutions an excess of a mixture of vaporized LPG and petrol will be present, with the result that the petrol could well become deposited on the electrodes of the spark plugs.
This effect is a particular nuisance if the internal combustion engine is started up again a short time after being switched off. For if a longer period is allowed to elapse, the gaseous LPG will leak out of the system through the outlet or through other cylinders.
European Application 0,178,484 discloses an internal combustion engine which can run both on gas and on petrol. In this case LPG is introduced into the internal combustion engine in the liquid state.
U.S. Pat. No. 5,159,915 discloses an injector provided with a heating element. This injector is designed exclusively for running on petrol.
BRIEF SUMMARY OF THE INVENTION
It is the object of the present invention to provide a simple way of avoiding as far as possible the effect of leakage from the injectors for injecting liquid gas.
The invention is based on the idea that liquid will always leak on account of the fact that the injector always leaks slightly because of the optimum insulation and the increased pressure inside the injection system. This liquid (liquid LPG) expands by approximately a factor of 250. This means that the effect of the leakage is increased by a factor of 250. If the supply pipe is now heated during the switching-off, the liquid will pass into the vapour phase and most of it will be returned to the tank, and with the same leakage from the injector concerned 250 times less fuel will go into the cylinder. It has been found that starting problems then no longer occur.
Although the invention has been described above with reference to an LPG-driven engine, it should be understood that this principle can be used for any fuel which is relatively simple to convert from liquid phase to vapour phase. An example of the above is DME (dimethyl ether).
The supply pipes can be heated in any conceivable way. A particularly simple solution with the use of flexible pipes in particular is to have integrated therein an electric resistance heating coil. Its heating can be governed by a control mechanism. The injection system for the fuel such as LPG need not be changed any further.
With the design described above, only gaseous LPG will still be present in the pipes some time after the internal combustion engine has been switched off. It is not uncommon for such internal combustion engines to be started on petrol as indicated above. During this starting phase the injectors of the LPG injection system will remain closed, but the circulation pump present will still be functioning, in order to fill the system with liquid LPG and to discharge the heat in question which has been generated earlier. Obviously, at that stage the heating will no longer be in operation. The operating duration of the heating can be determined empirically in a simple manner, and in practice will last several minutes.
After the switch-over from petrol to LPG has been made, the pipes of the LPG system are flushed out, and the running can be continued in the usual way.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in greater detail below with reference to an exemplary embodiment illustrated in the drawing, in which:
FIG. 1 shows diagrammatically in side view a part of an internal combustion engine, and
FIG. 2 shows the diagram of the various components of the device according to the invention.
DETAILED DESCRIPTION
An internal combustion engine is indicated by 1 in FIG. 1. This engine is illustrated only very diagrammatically and, as emerges from FIG. 2, in this case it is a four-cylinder engine. The intake duct is indicated by 2, and an injector 3 for liquid LPG and an injector 23 for petrol are fitted therein. All this is explained further with reference to FIG. 2.
It can be seen that injector 3 is connected by way of a pipe 4 and a pressure regulator 8--with the interposition of a valve 7 and a pump 6--to a tank 5 containing liquid LPG. Injector 3 is provided with a valve 9 which is operated by a coil 10 connected by way of a line 11 to the control mechanism 14. Pipe 12 is connected to pipe 4 and serves to supply the next injector 3 and to discharge excess LPG from the first injector 3 (one furthest left). This injector is designed in the same way, and the last injector 3 (one furthest right) is connected by way of a return pipe 13, in which a pressure regulator 8 is accommodated, to tank 5.
The supply pipes 4, 12 are provided near the injectors with an electrical resistance heating element 16, which is connected to a control mechanism 15.
Apart from this LPG injection system, a conventional petrol injection system is present. The latter consists of injectors 23 which are fitted on a fuel rail 29 which is connected by way of a pressure regulator 25 to a pump 27 by connecting a supply pipe 24 between them. A return pipe 28 is present and the above are fitted in a tank 26. The system is controlled by means of device 30, which is connected in a manner generally known in the prior art to control mechanism 14.
The device described above functions as follows:
During normal running the petrol injection device is not in operation. The same applies to the heating element 16.
If the internal combustion engine is switched off, the heating element 16 is operated by means of control mechanism 15 for a predetermined period of time. A time of 1 to 6 minutes, and more particularly 3 minutes, is mentioned as an example. This causes the temperature inside pipe 4 or 12 to increase, and the liquid LPG present therein vaporizes to vaporous LPG.
The pressure in the pipe system consequently increases and pressure regulator 8 will become active, and in this way the system is flushed clean, so that in the end only vaporous LPG is present in the pipes 4, 12 and 13. The leakage from the injectors which inevitably occurs on a small scale will then result only in the introduction of small quantities of vapour, so that when the internal combustion engine is first started up on petrol no inadmissible enrichment occurs.
When the internal combustion engine is first started up on petrol, insofar as applicable, control mechanism 15 will switch off heating element 16. Injectors 3 remain closed, while injectors 23 are active. However, pump 6 is active in order to introduce liquid LPG into the system and to remove the vaporous material. After a few seconds the switch-over from petrol to LPG can then be made, and normal running as described above can be resumed.
With the device described above the negative effects of leaking of the injectors is prevented, without it being necessary to use very expensive and complex injectors.
The electric heating element described above can be integrated in the flexible pipe. Only part of the pipes 4, 12 of such a heating system is included in the drawing, but it must be understood that the entire pipe can be heated.
These and further variants are obvious to the person skilled in the art after reading this description, and are within the scope of the appended claims.
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The fuel used, such as LPG, evaporates at raised temperature. It is proposed that when the internal combustion engine is not running a part of the fuel supply pipes should be heated, so that the liquid fuel therein evaporates. When injectors leak only vaporous liquid will then enter the combustion chamber.
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TECHNICAL FIELD
The invention relates to insert plates for a workpiece support table, such as support table for a router.
BACKGROUND
Powered hand tools, such as, for example, routers, handsaws, drills, planers, and the like, are often mounted to a planar support structure, such as a support table, to allow simplified operation, for example, when operating on large workpieces. Precise operations, such as routing, cutting and/or sanding operations using a support table require that the powered hand tool is precisely positioned relative to the support table. Frequently, a powered hand tool is first fixed to an insert plate that is then mounted flush to the support table. To facilitate this mounting, a support table may include an approximately central through-hole to receive the powered hand tool mounted to the insert plate.
SUMMARY
In general, the invention relates to leveling an insert plate for a support table. Leveling is accomplished using a set of mounting and leveling apparatuses to attach the insert plate to the support table. The mounting and leveling apparatuses include at least one leveling device, such as a screw or bolt, which may be adjusted to change the distance between the insert plate and mounting bracket in order to mount the insert plate flush with the top surface of the support table. As the distance between the insert plate and mounting bracket is changed, the relative position of a surface of the insert plate changes with respect to the top surface of the support table.
In an embodiment, an assembly comprises a support table including a support table orifice; a insert plate within the support table orifice; and at least one mounting and leveling apparatus. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table.
Another embodiment is directed to a mounting and leveling apparatus, for mounting an insert plate to a support table. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table.
In another embodiment, a kit for mounting an insert plate to a support table comprises at least two mounting and leveling apparatuses and instructions for mounting the insert plate to the support table using the at least two mounting and leveling apparatuses. Each of the mounting and leveling apparatuses comprise a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table, and the at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table.
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 DRAWINGS
FIG. 1 illustrates a mounting and leveling apparatus for coupling a insert plate to a support table.
FIG. 2 illustrates a mounting and leveling apparatus coupled to a insert plate.
FIG. 3 illustrates a view of support table, four mounting and leveling apparatuses and a insert plate.
FIG. 4 illustrates a mounting bracket registered to a support table orifice.
DETAILED DESCRIPTION
FIGS. 1-3 generally illustrate a mounting and leveling apparatus 100 for coupling a insert plate 200 to support table 300 . As best seen in FIG. 1 , the mounting and leveling apparatus 100 includes mounting bracket 102 , clamp screw 104 , first leveling screw 106 a and second leveling screw 106 b (collectively “leveling screws 106 ”). Apparatus 100 further includes first mounting screw 108 a , second mounting screw 108 b and third mounting screw 108 c (collectively “mounting screws 108 ”).
As best seen in FIG. 2 , insert plate 200 includes top surface 202 and bottom surface 204 substantially opposite top surface 202 . Top and bottom surfaces 202 , 204 are joined by periphery wall 206 , which in the illustrated embodiment defines a generally rectangular shape of insert plate 200 . In other embodiments, insert plate 200 may be generally triangular, circular or elliptical, or may include any other desired geometry.
A hand tool (not shown) is generally fixed to insert plate 200 by screws or other suitable mechanism. Insert plate 200 further includes inner wall 208 that defines orifice 210 . Orifice 210 is sized to allow the cutting mechanism of a powered hand tool, such as, a router, saw, sander or the like, to extend above top surface 202 when the powered hand tool is mounted to insert plate 200 . Inner wall 208 forming orifice 210 includes ledge 212 extending radially inward from a lower section of inner wall 208 . Ledge 212 may be used to support a plate (not shown) with an orifice that more closely matches the size of the cutting mechanism of the hand tool mounted to insert plate 200 than orifice 210 . Such a plate may be fixed to insert plate 200 using screws or other suitable mechanism. Because different plates may be mounted within orifice 210 on ledge 212 , insert plate 200 is suitable for a variety hand tools and multiple size cutting mechanisms. For example, different plates may be used for different hand tools. As anther example, different plates may be used for routing bits of different sizes without removing the router from insert plate 200 .
Insert plate 200 supports a hand tool, and as well as work pieces that are worked on by the hand tool. Because of this, it is desirable for insert plate 200 to be formed from strong and durable materials. For example, insert plate 200 may be formed from suitable materials such as a metal, polymer, a filled resin, wood or the like.
As FIG. 3 illustrates, support table 300 includes a generally planar top surface 302 and a generally planar bottom surface 304 oriented substantially opposite top surface 302 . Top and bottom surfaces 302 , 304 are connected by peripheral wall 306 , which defines a generally rectangular perimeter of support table 300 . Support table 300 further includes inner wall 308 that defines orifice 310 sized to receive insert plate 200 . Orifice 310 is preferably sized such that inner wall 308 and periphery wall 206 form an intimate fit with each other. That is, it may be preferred that insert plate 200 is sized such that there is a minimal gap between periphery wall 206 and inner wall 308 once insert plate 200 is inserted in orifice 310 . This may facilitate the use of the hand tool on a work piece larger (e.g., in at least one dimension) than insert plate 200 by, for example, reducing the chances that the work piece catches on an edge of either insert plate 200 or support table 300 . Of course the leveling adjustment capability of mounting and leveling apparatus 100 also reduces the chances that the work piece catches on an edge of either insert plate 200 or support table 300 .
Support table 300 may be of any suitable size and may be supported by a support frame or other support structure. For example, support table 300 may be designed to rest on a work bench, and may thus include a relatively short support frame to suspend the support table 300 off of the work bench enough to provide clearance for a hand tool mounted to insert plate 200 . In other embodiments, support table 300 may include a frame which supports table 300 off of a floor at a desirable height. Support table 300 may include a durable and strong material, such as, for example, a metal such as aluminum or steel, wood, or the like.
It is generally desirable that top surface 302 of support table 300 and top surface 202 of insert plate 200 provide a substantially planar surface to support a work piece that is to be manipulated by the hand tool. Because insert plate 200 may experience wear during use of the hand tool, the thickness and/or thickness uniformity of insert plate 200 can change over the course of the lifetime of the insert plate. For example, insert plate 200 may wear substantially uniformly, and become thinner over substantially its entire area. As another example, a groove or depression corresponding to a common pattern of movement of a work piece across surface 202 of insert plate 200 may be formed over the course of time. Likewise, top surface 302 of support table 300 may also wear over time.
Regardless of the cause and/or evolution of any variation in the alignment of surface 202 of insert plate 200 with respect to surface 302 of support table 300 , it is desirable that this variation can be mitigated or fully corrected. Mounting and leveling apparatus 100 allows for straightforward and flexible adjustment of the position of surface 202 of insert plate 200 with respect to surface 302 of support table 300 .
For example, the combination of mounting bracket 102 , clamp screw 104 and leveling screws 106 allows precise adjustment of the distance between leveling plate 102 and surface 202 . Further, the use of at least two leveling screws 106 allows a user to adjust not only the distance between leveling plate 102 and surface 202 , but also the relative pitch of surface 202 of insert plate 200 with respect to leveling plate 102 (e.g., top surface 126 of leveling plate 102 ). As will be described in greater detail below, the configuration of mounting and leveling apparatus 100 allows precise positioning of leveling plate 102 relative to support table 300 . For example, mounting and leveling apparatus 100 may be used to align top surface 202 of insert plate 200 with surface 302 of support table 300 even if insert plate 200 becomes worn or warped over time.
As shown in FIG. 3 , in one embodiment, a system including a support table 300 defining a generally rectangular orifice 310 and a generally rectangular insert plate 200 may beneficially employ four mounting and leveling apparatuses 100 to allow adjustment of the position of surface 202 with respect to surface 302 at four locations. Employing more than one mounting and leveling apparatuses 100 may allow greater adjustment flexibility to facilitate adjustment of a position of surface 202 with respect surface 302 . For example, utilizing more than one mounting and leveling apparatus 100 may allow correction for any warp or thickness gradation of insert plate 200 . In other embodiments, more than four or fewer than four mounting and leveling apparatuses 100 may be employed.
Mounting plate 102 couples to support table 300 via mounting screws 108 a , 108 b , 108 c (collectively “mounting screws 108 ”), which extend through-holes 114 a , 114 b , 114 c (collectively “holes 114 ”), respectively. Holes 114 may include substantially smooth sidewalls. Mounting screws 108 then threadably engage with mounting holes 312 of support table 300 to couple mounting bracket 102 with support table 300 . In other embodiments, mounting screws 108 may be self tapping screws, such as wood screws, that do not require threaded holes or even holes in support table 300 . While three mounting screws 108 are illustrated in the figures, in other embodiments, any useful number of mounting screws 108 may be utilized. For example, in some embodiments, the mounting bracket 102 may be coupled to the support table using at least one mounting screw 108 .
Mounting plate 102 may be generally triangular in shape, as illustrated in the figures. However, it will be understood that the shape of the mounting bracket 102 is not thus limited, and may include other shapes, such as, for example, rectangular, circular, elliptical, or any other useful shape. Mounting plate may be formed of a wide range of materials, including, for example, metal, polymer, filled resin, or the like. In some embodiments, mounting bracket 102 includes a filled resin, such as, for example, a glass filled resin.
In the illustrated embodiment, mounting bracket 102 also includes a protrusion 116 , best seen in FIG. 1 . In the embodiment shown in the figures, protrusion 116 is shaped to register mounting bracket 102 with a corner 314 of the generally rectangular orifice 310 defined in support table 300 . To accomplish this, in the illustrated embodiment, the protrusion 116 includes edge 116 a that is curved with a radius of curvature approximately equal to the radius of curvature of the corner 314 of orifice 310 . More specifically the protrusion 116 is formed by a first straight side 116 b and a second straight side 116 c and an arched corner 116 d . The first straight side 116 b of the protrusion 116 is continuous with the arched corner 116 b of the protrusion and the arched corner 116 d of the protrusion 116 is continuous with the second straight side 116 c of the protrusion 116 . In other embodiments corner 314 may have a different shape such as a right-angle; in any embodiment protrusion 116 may be configured to match the shape of corner 314 . Registering mounting bracket 102 to corner may substantially align holes 312 of support table 300 with holes 114 of mounting bracket 102 to facilitate insertion and threading of mounting screws 108 .
Rectangular orifice 310 is a straight-cut through-hole in support table 300 . Rectangular orifice 310 may be created using a jigsaw or other suitable cutting instrument. The support table orifice 310 defines a first straight side 310 a and a second straight side 310 and an arched corner 310 c . The first straight side 310 a of the support table orifice 310 is continuous with the arched corner 310 c of the support table orifice 310 and the arched corner 310 c of the support table orifice 310 is continuous with the second straight side 310 b of the support table orifice 310 . Thus, the first and second straight sides 116 b and 116 c of the protrusion 116 and the arched corner 116 d of the protrusion 116 extends into the support table orifice 310 and continuously engages the first and second straight sides 310 a and 310 b of the support table orifice 310 and arched corner 310 c of the support table orifice 310 . In this manner, a kit including a set of mount and leveling apparatuses 100 and an insert plate 200 could be installed on any suitable table by cutting any suitable table to include orifice 310 . For example, such a kit may include a template for orifice 310 .
In other embodiments, mounting bracket 102 may not include a protrusion 116 to register the mounting bracket 102 to corner 314 of orifice 310 . In yet other embodiments, mounting bracket 102 may include a plurality of features which register mounting bracket 102 to corner 314 of orifice 310 . For example, mounting bracket 102 may include at least two smaller protrusions which together register mounting bracket 102 to corner 314 of orifice 310 . Further, in other embodiments, mounting bracket 102 may include protrusions or other features which register mounting bracket 102 to another location of orifice 310 , such as, for example, a location along an edge of orifice 310 .
As is best seen in FIG. 1 , leveling screws 106 are threaded into holes 110 a and 110 b (collectively “holes 110 ”) from the direction of bottom surface 128 of mounting bracket 102 . As shown in FIG. 1 , holes 110 and hole 112 , which is configured to receive clamp screw 104 , form a straight line. Furthermore, holes 110 are substantially equidistant from hole 112 . In other embodiments, holes 110 may not be substantially equidistant from hole 112 . Holes 110 may themselves be threaded, or may included a threaded inserts 124 a and 124 b molded into mounting bracket 102 . Threaded inserts 124 a and 124 b may include a highly durable and strong material, such as, for example, brass or steel.
Leveling screws 106 may be threaded through-holes 110 until each leveling screw 106 a and 106 b protrudes from top surface 126 of mounting bracket 102 . In this manner, leveling screws 106 are threaded through-holes 110 in the opposite direction that clamp screw 104 is threaded through-hole 112 . To accomplish the threading, leveling screws 106 may include suitable features to allow mating with a screw bit, such as a hex head bit, a Phillips bit, or the like.
Leveling screws 106 form contact sites on which insert plate 200 rests. Adjusting the length of each of leveling screws 106 that protrudes from surface 126 of mounting bracket 102 , then, likewise adjusts the distance between major surface 126 of mounting bracket 102 and bottom surface 204 of insert plate 200 at each point of contact.
Additionally, providing at least two leveling screws 106 in each mounting and leveling apparatus 100 allows a user to finely position insert plate 200 with respect to support table 300 . For example, utilizing two leveling screws 106 in each apparatus 100 may allow a user to correct the angle at which insert plate 200 is oriented at the location of each apparatus 100 . In contrast, use of a single leveling screw 106 at each apparatus 100 would not allow this fine adjustment or twisting of insert plate 200 to restore its flatness in the event it became warped. While FIG. 1 illustrates two holes 110 , in other embodiments, may include more than two holes 110 and a corresponding number of leveling screws 106 . The use of at least two leveling screws 106 may provide a more secure support of insert plate 200 than a single leveling screw 106 would allow. Likewise, in alternative embodiments, more than one hole 112 and corresponding clamp screw 104 may be utilized.
As is best seen in FIG. 2 , clamping screw 104 is inserted into hole 216 of insert plate 200 from the side of surface 202 . In the illustrated embodiment, hole 216 includes a countersunk opening in surface 202 , which may minimize the extent to which clamping screw 104 protrudes from surface 202 . Clamp screw 104 is then threaded through-hole 112 of mounting bracket 102 . Hole 112 may itself be threaded, or may included a threaded insert 122 molded into mounting bracket 102 . Threaded insert 122 may include a highly durable and strong material, such as, for example, brass or steel. Clamping screw 104 couples insert plate 200 to mounting bracket 102 and preferably firmly contacts insert plate 200 and leveling screws 106 . Once clamping screw 104 is sufficiently tightened, the mounting and leveling apparatus 100 substantially prevents movement of insert plate 200 with respect to support table 300 . While a single clamping screw 104 for each mounting and leveling apparatus 100 is illustrated in the figures, in other embodiments, more than one clamping screw 104 may be utilized.
The support table 300 may further incorporate a fence system. One exemplary fence system includes a universal machinery fence system, as described in further detail in U.S. Patent Application Publication No. 2006/0248998, which is incorporated herein by reference in its entirety. Generally, the universal machinery fence system has a rail for attachment to a support table 300 of a workpiece manipulation machine and the rail defines a track. A clamp block is releasably assembled to the rail with surfaces that mate with the track of the rail to guide the clamp block linearly along the rail. The clamp block includes a fastener for securing the position of the clamp block along the rail. The system includes a fence for guiding a workpiece into a workpiece manipulation tool, the fence being fixed to the clamp block. The clamp block and fence can be used on, for example, a band saw, a router, a table saw, a drill press, or the like, by substituting the rail for a rail of a different cross-sectional shape.
A kit may be useful to allow a craftsman to mount an insert plate to a homemade support table. A kit for mounting an insert plate to a support table may include at least two mounting and leveling apparatuses, such as mounting and leveling apparatus 100 ( FIG. 1 ). For example, a kit may include exactly four mounting and leveling apparatuses to facilitate mounting a rectangular insert plate to a support table. In some embodiments, as kit may include the insert plate itself. Such a kit may also include a template for forming an orifice for the insert plate in the homemade support table.
A kit may optionally include a screw driver for the screws in the mounting and leveling apparatuses. For example, the screw driver may be a Phillips screw driver, a flathead screw driver, an allen wrench, or a square drive. In embodiments having screws with different screw head configurations, a kit may include a screw driver for each screw head configuration. In one embodiment, a kit may include an alien wrench and a square drive.
Various embodiments of the invention have been described. These and other embodiments are within the scope of the following claims.
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An assembly comprises a support table including a support table orifice; a insert plate within the support table orifice; and at least one mounting and leveling apparatus. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards the mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table.
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BACKGROUND
There are a few “magic window” devices which permit the combining of an obscured printed image with a superimposed image printed on a transparent substrate. Such devices lack flexibility and versatility. A problem is that they are not particularly effective in engaging a user.
SUMMARY
What is needed is a “magic window” device that, by giving the user more freedom of operation, adds an interactive surprise effect such that it becomes puzzling for the user to understand how such an effect can be carried out under the interactive control of the user. By allowing the user to manipulate the device more fully, e.g., by allowing control of motion, orientation, and position of a viewfinder, the resultant interactivity and user control accompanied by surprise and puzzlement would exhibit a truly “magical” quality and lead to a more delightful user experience.
For example, according to teachings hereof, an apparatus is provided with a captive but free-floating wand with a viewfinder at an end of the wand, the viewfinder moveable over semi-transparently printed matter shown on a transparent top part of the apparatus, wherein inside the apparatus, a concealed part of the apparatus is tethered to the wand and travels with movement of the wand between the transparent top part and a hidden bottom part of the apparatus, wherein the tethered concealed part blocks the hidden bottom part from view except through an opening in the concealed part underlying the viewfinder so that movement of the wand shows both the semi-transparently printed matter and opaque printed matter on the bottom part superimposed in the viewfinder.
Such a device can be used as a premium item, a greeting card, a direct mailer, a point of sale display, a magazine insert, as part of a packaging application, or any number of similar printed applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front view of an embodiment of an apparatus, according to the present invention.
FIG. 2 shows a concealed component part in the form of a panel with an opening, according to the embodiment of FIG. 1 and tethered to the wand shown in FIG. 1 .
FIG. 3 shows a perspective view of a novelty device that includes an apparatus, according to an embodiment of the present invention.
FIG. 4 shows all but one of the parts that may be assembled into a device such as the novelty device of FIG. 3 .
FIG. 5 shows the concealed panel part that may be assembled along with the parts shown in FIG. 4 into a device such as the novelty device of FIG. 3 .
FIG. 6 shows how the tab of the wand is threaded through the slot of the front panel and attached to the concealed panel so that the concealed panel is tethered to the wand.
FIG. 7 is a stylized drawing (not to scale) that shows how a short base part of the inner tab of the concealed panel may be folded to form a stop that prevents over extension of the tethered wand.
FIG. 8 shows a die cut pattern for cutting one or more stacked sheets or, alternatively, outlines for hand-cutting parts of a hobby kit.
FIG. 9 shows a die with a die cut pattern such as shown in FIG. 8 in a press cutting one or more paper boards to produce parts for assembly into at least one apparatus or a novelty device that includes an apparatus, according to the present invention.
FIG. 10 (not to scale) shows the outlines of printed matter that corresponds to the printed matter of FIG. 1 , in this case, an x-ray profile corresponding to the head and shoulder profile shown in FIG. 1 .
DETAILED DESCRIPTION
FIG. 1 shows a front view of an embodiment of an apparatus 10 , according to the present invention. The apparatus 10 may be produced as a standalone “magic window” device or may be combined with other component parts, such as shown in FIG. 3 , to form various novelty devices that incorporate an apparatus such as disclosed herein.
In the embodiment of FIG. 1 , a front panel 12 of the apparatus 10 provides a frame or border 14 surrounding an opening 16 for presenting a printed transparent window 18 . For instance, a transparently clear, 4 mm sheet of Mylar material may be cut to size larger than the opening 16 and glued or otherwise fastened to the back of the front panel 12 as shown for instance at reference numeral 18 a in FIG. 6 . It then serves to function like a pane of glass though which the user may be provided a view into the apparatus. Printed matter on the transparent material 18 a may for instance be a head and shoulders profile 20 of an attractive young woman as shown (in outline) which may be provided in color, such as printed matter in the form of a reproduction of a color photograph. The photographic effect may for instance be carried out using a halftone reprographic technique that simulates continuous tone imagery through the use of dots that vary in one or more of size, shape, or spacing. Use of other reproduction methods to produce the printed matter is of course possible. The manner of printing of the printed transparent window 18 may be such that the printed matter is itself transparent or semi-transparent. Thus the printed matter, e.g., the exemplary colored profile 20 may be printed in such a way that it is not opaque to the transmission of light. When depositing a thin layer of various color inks onto a transparent Mylar sheet, for instance by use of a halftone printing process, the resultant printed matter is naturally transparent to the transmission of light. The various colors (for instance include yellow, magenta, cyan, and black) may be deposited as various sized, shaped, and spaced ink dots. The printed matter may also include line art.
Behind the front panel 12 is a back panel (not shown in FIG. 1 but see reference numeral 48 in FIG. 6 ) with printed matter on at least one side. The back panel may be made of high quality paper board such as Solid Bleached Sulfate (SBS) stock used for high end packaging where the quality of any printed image is required to be at a high level. The front panel 12 may also be made of the same high quality SBS stock. The at least one side of the back panel with printed matter faces the back of the front panel 12 . The printed matter on the back panel may be sized and positioned to match the size of the opening 16 in aligned registration therewith. Or it may be slightly larger to avoid showing any surrounding white coloration from the surrounding unprinted paper board near edges of the window. When depositing a thin layer of various color inks onto the back panel sheet, for instance by use of a halftone printing process onto the bleached white surface of SBS stock, the resultant printed matter is naturally opaque to the transmission of light. The various colors (for instance include yellow, magenta, cyan, and black) may be deposited as various sized, shaped, and spaced ink dots. The printed matter may also include line art. The back panel may itself be sized to match the size of the front panel so that they are in matching size alignment when folded over onto each other into a parallel, layered relationship. The front panel and the back panel may be foldable parts of a same piece of SBS stock such as shown by the respective reference numerals 12 a , 48 in FIG. 4 .
Importantly, the printed matter on the back panel “corresponds” to the printed matter on the printed transparent window 18 . Such correspondence may take many different forms. For instance, a boldly printed (halftone black & white) x-ray profile of the head and shoulders of a human skeleton may be provided underlying and in registration with the colored profile of the attractive young woman presented in the halftone printed transparent window. FIG. 10 (not to scale) shows the outlines of such an x-ray profile. In practice, as previously mentioned, it might be printed with a black and white halftone reprographic technique to simulate the continuous tone of an actual x-ray image with a range of greys. The “correspondence” is in this embodiment the more or less overall registration of the color profile with the x-ray profile. It should be realized that the x-ray illustration of FIG. 10 is sized to match the profile of FIG. 1 so the registration of the two profiles may be carried out so as to achieve the color profile of FIG. 1 in overlying alignment with the grey tone x-ray profile of FIG. 10 . In this way, the opaque black & white printed matter on the back panel may be seen through the transparent colored printed matter within the viewfinder. Another correspondence example will be shown below in connection with FIG. 6 but others are of course possible, limited only by artistic imagination.
A magic wand 23 is provided with a viewfinder attached to the end of a handle or tab 22 . The viewfinder may be square, rectangular, circular, or any other desired shape. The magic wand resembles a magnifying glass with a handle, and as such, the magic wand attracts the user's attention by in effect inviting the user to grab the handle 22 and move the viewfinder which, the user will discover, is free-floating in a plane parallel to the front panel. The tab or handle 22 of the magic wand 23 may be attached by an appendage (not shown) through a slot 25 in the front panel 12 to a concealed opaque panel 24 (see FIG. 2 ) lying under the printed transparent window and above the printed matter on the back panel 48 . The opaque panel 24 may be made of SBS stock without any printed matter, e.g., it may be bleached white in color with no printed matter thereon. Under the control of the user's movements 26 of the wand 23 , the concealed panel 24 may be made to likewise move in any planar direction 26 , i.e., by controlling movement of the handle or tab 22 . Thus the concealed opaque panel 24 is made to travel or slide in a narrow planar space between the printed matter on the printed transparent window 18 on front panel 12 and the printed matter on the bottom panel. If the opaque panel 24 is completely devoid of printed matter (e.g., completely white), its movement (tethered to the movements of the magic wand) under the profile 20 will not be visible to the user. Because the concealed panel 24 is smaller in size than the front and back panels, it may even be rotated to some degree depending on the relative size difference. Such rotation of the magic wand 23 is about an axis perpendicular to the plane of the front panel. The user may simply tilt the handle 22 slightly in an up or down lateral direction and thereby exert a twist force on the handle and appendage or tab 22 a , 22 b . A narrow field of view 28 of less than the totality of the field of view of the printed matter on the back panel may be provided through a viewfinder on the end of the wand 23 . That narrow field of view helps contribute to the illusion of a “magic window” frame or in the case of FIG. 1 , a “magic x-ray window” frame around an opening 30 in the concealed opaque panel 24 and through the semi-transparent printed matter on the printed transparent window 18 that overlies the concealed panel 24 . In moving the narrow field of view of the viewfinder about within the wider field of view of a scene represented by the printed matter on the back panel, the user gets to search with excitement and delight for possibly multiple hidden surprises awaiting. The term tab is also used to mean any appendage attached to the concealed panel 24 and the viewfinder so as to be useable for pulling, pushing, or otherwise maneuvering the concealed panel 24 in any planar direction parallel to the front and back panels. As shown in FIG. 4 below, the concealed panel 24 may itself provide a complementary tab extending from a side thereof for attachment to the tab 22 of the wand 23 . An appendage for passing through the slot 25 may instead be provided separately. Or, the tab 22 may include an appendage for passing through the slot 25 and attachment to the concealed panel or to a tab thereof. Any such appendage or tab or combination thereof should be sufficiently rigid to be able to move the concealed panel in concert with the user's movement of the handle or tab 22 , i.e., without undue slack so as to create a unified impression that the viewfinder on the end of the wand 23 and the opening 30 are one and the same even though they are not actually connected in the vicinity of the viewfinder (since they lie on opposite sides of the printed transparent window 18 ).
In various embodiments, the degree of transparency of the printed matter of the printed transparent window 18 may be controlled in relation to the degree of visibility required of the underlying printed matter on the back panel through the semi-transparently printed matter on the printed transparent window 18 . The correspondence between the printed matter on the back panel and the printed matter on the printed transparent window 18 may include printed matter on the back panel that is visible directly, i.e., not seen or to be viewed through parts of the semi-transparent printed matter but merely seen in some relation or correspondence thereto. See for instance the forest animals and cartoon character in FIG. 6 . In this way also, the printed matter on the back panel may graphically “correspond” to the printed matter on the printed transparent window in a way that perplexes the user as to how the hidden matter can be exposed by simple movement of the magic window about in a planar motion, under the user's random volitional control, to produce a surprising, humorous, or amusing effect for the user.
FIG. 3 shows a perspective view of a novelty device that includes an apparatus, according to an embodiment of the present invention. In the illustrated novelty device, a rectangular sheet of paper board (see FIG. 4 ) such as high quality SBS stock is folded to form a plurality of overlapping panels. The particular novelty device of FIG. 3 incorporates an apparatus such as shown in FIG. 1 by means of a sheet such as presented FIG. 4 . The novelty device is shown standing upright on a horizontal surface such as a tabletop. As shown, the novelty device has four overlapping panels, one of which is not visible in the illustration because it is folded within two other panels. The hidden panel corresponds to the back panel described above in connection with FIG. 1 . The front facing panel 12 a in FIG. 3 corresponds to the front panel 12 of FIG. 1 . An openable panel 32 (see panel 32 a in FIG. 4 ) is operable to be opened as shown unfolded from a folded state, i.e., swung open about a fold line 33 or axis defining a corner 34 so as to be made apart from the front panel 12 a and the back panel that are fastened together, e.g. glued together to form front and back panel parts of the illustrated apparatus (as in FIG. 1 ). It should be understood that the openable panel 32 , though useable in many products, is not necessarily present. Nevertheless, for novelty devices such as shown in FIG. 3 , a user may swing the openable panel 32 of the novelty device about the fold line 33 along the corner 34 to the open position as shown to allow the novelty device to be stood upright on the tabletop as shown or to allow for a reading of a greeting or the viewing of other graphic matter printed on the part of openable panel 32 facing the front and back panels when in the folded state. The surface of the openable panel 32 may for instance have printed matter thereon such as a greeting card type message, graphics, or both. For example, for the embodiment of the apparatus shown in FIG. 1 , a novelty device might be provided with the symbolic work of art as shown on the front panel of FIG. 1 as the front of a greeting card with a humorous message printed on the openable panel 32 intended for an epicurean friend.
FIGS. 4 and 5 together show parts that may be assembled into a device such as the novelty device of FIG. 3 .
FIG. 4 shows a rectangular sheet of paper board with four panel sections separated by vertically scribed fold lines that serve for ease in folding the panels into overlying relationship during assembly. A front panel 12 a has a central opening 16 a , a slot 25 a , and top and bottom folding tabs 40 , 42 that fold along respective scribed fold lines 44 , 46 . A back panel 48 is folded (downwardly into the plane of FIG. 4 ) and all the way around (one hundred and eighty degrees) so as to be aligned with the front panel 12 a with printed matter on its underside appearing within the opening 16 a and in registration therewith. In other words, if looking down over the top edge of the sheet, the panel 48 is rotated 180° clockwise about an axis defined by the scribed line 50 so as to lie in parallel facing the back of the front panel 12 a . The front panel 12 a is then parallel to the back panel 48 and the printed matter on the back panel 48 is visible through the front panel opening 16 a . As shown in FIG. 6 , the back panel 48 may have printed matter on at least one side as shown at reference numeral 28 a . In particular, when folded over, the at least one side with printed matter 28 a faces the front panel 12 a and is aligned with the opening 16 a in such a way that the printed matter on the transparent window panel is in the desired correspondence with the printed matter 28 a on the back panel 48 . For instance, the alignment may be such that the trees printed transparently or semi-transparently on the transparent window panel 18 a in FIG. 6 are aligned with and overlie the boldly printed trees in the printed matter 28 a on back panel 48 so that the transparent trees exactly match the underlying boldly printed trees. In this way, the user is presented with the two separate printed matters as a unified one printed matter. The woodland animals and the cartoon character appear on the printed matter on the back panel only but are nonetheless presented in this example in spatial, perspective, or at least positional “correspondence” with the printed tree matter on both the front panel and the back panel.
A clear, printed transparent window panel 18 a is shown in FIGS. 5 and 6 . It is glued or otherwise attached to the back of front panel 12 a so as to be affixed behind the opening 16 a . After assembly, it is thus situated between and parallel to the front panel and the back panel and is immobile with respect to the back panel and the front panel. The panel 18 a may be made slightly larger, e.g., 3.5 inch×4.5 inch (88.9 mm×114.3 mm) than the opening 16 a (e.g., 2 9/16 inch×3 7/16 inch (65.1 mm×87.33 mm)) to provide extra space for overlap of peripheral edges on the backside of panel 12 a for ease in gluing. As described previously and as shown in FIG. 6 , the transparent panel 18 a is provided with transparent or semi-transparent printed matter (trees shown printed faintly with transparency) on at least one side that corresponds to the printed matter (corresponding trees and woodland animals and cartoon/goblin character printed on the white stock so as to appear opaque on the at least one side of the back panel 48 and overlies same with exact registration so as to align at least parts (e.g. trees) of the two sets of printed matter. The printed matter 28 a may have overall dimensions greater than that of the opening 16 a as shown in FIG. 6 . Thus, when folded over, the at least one side with printed matter 28 a faces the front panel 14 and is aligned with the opening 16 a in such a way that the printed matter on the transparent window panel is in the desired correspondence with the printed matter 28 a on the back panel 48 . As shown in FIG. 6 , the alignment may be such that the trees printed transparently on the transparent window panel 18 a are aligned with and overlie the boldly printed trees in the printed matter 28 a on back panel 48 so that, from the perspective of a user viewing the front panel through the magic window 23 b , there is no perception of there being two sets of printed trees because the transparent trees match the underlying boldly printed trees and are seen as one set of printed trees.
FIG. 4 also shows a wand 23 a with a handle or wand tab 22 a attached to a wand viewfinder 23 b (“magic window”) at the end of the wand. A concealed panel 24 a is also shown with an opening 30 a and a tab 22 b extending therefrom. After the above-described 180° foldover of the back panel 48 onto the front panel 12 a so as to be in parallel alignment therewith, the concealed panel 24 a may be inserted in the planar space between the folded over back panel 48 aligned with the front panel 12 a.
The tab 22 b extending from the concealed panel 24 a may have two sections 22 c , 22 d separated by a foldline 22 f . Prior to insertion of the concealed panel 24 a between the front panel 12 a and the back panel 48 , a first section 22 c of tab 22 b may be attached directly to the concealed panel 24 a . This may be done by folding the first section 22 c over at a fold line 22 e and gluing it to a facing side of concealed panel 24 a shown in FIG. 4 . FIGS. 6 and 7 each show the first section 22 c folded over and glued to the concealed panel 24 a . As shown in stylized FIG. 7 (not to scale), tab 22 b will then be able to serve as a “stop” at the fold line 22 f against excessive extension of the wand in the direction of the arrow 70 in FIG. 7 , and prevent possible tearing damage to the connection between the outer tab 22 a and the underlying hidden inner tab 22 d , when the wand is fully extended. This “stop” acts to signal the user to stop trying to extend the wand any further and thereby prevents the connection between the outer tab 22 a and the inner tab 22 b from being damaged by the wand 23 a being pulled out too far with excessive force. During assembly, the second section 22 d of the inner or hidden tab 22 b is slipped through a slot 25 a and glued or otherwise attached at least at an end thereof to the outer or visible tab 22 a of wand 23 a as shown in FIG. 7 . After connection, the hidden inner tab 22 b and the outer visible tab 22 a become a unified tab or “tab assembly” or assembly of appendages that may be grasped by a user as a handle of the wand 23 a to move the visible viewfinder 23 b outside the apparatus and the intermediate panel 24 a hidden inside the apparatus as a unified whole. As shown, the first section 22 c of the inner hidden tab 22 b may be shorter than the longer second section 22 d.
In FIG. 6 the magic window and tab 22 a may be seen directly and in silhouette through the transparent or semi-transparent printed matter from the rear through the panel 18 a , as viewed from the backside of the front panel 12 a . During assembly, after the concealed panel 24 a is put in place between the front panel 12 a and the back panel 48 and is tethered to the magic wand 23 a , the panel 53 is folded over by a counterclockwise rotation about the fold lines 51 and the two tabs 40 , 42 may then be folded over and glued to the panel 53 to enclose the apparatus. The vertical pair of scribed lines 51 allow the panel 53 to be folded over without a sharp corner so as to provide a little extra space (depending on the distance between the scribed lines 51 ) on the corner edge and thereby avoid the panel 53 pressing down too hard on the facing front and back panels when the panel 53 is folded over and glued tight on the other side. This allows the panel 48 after it is folded over to face the rear of the panel 12 a (as described above) with sufficient space to allow the concealed part 24 a to move freely in the planar space between the two panels 12 a , 48 .
Upon assembly of the apparatus, the concealed panel 24 a thus serves as an intermediate panel parallel to the front panel 12 a , the back panel 48 , and the transparent panel 18 a . The concealed, intermediate panel 24 a is situated for lateral travel in a sliding motion between the transparent panel 18 a and the back panel 48 . The concealed, intermediate panel 24 a is smaller than the front panel but larger than the opening 16 a in the front panel. In an embodiment as shown in FIG. 6 , the concealed, intermediate panel may for instance be provided with dimensions of 4 inch×5¾ inch (101.6 mm×146.05 mm). The intermediate panel is visible through a 2 9/16 inch×3 7/16 inch (65.1 mm×87.33 mm) opening in the front panel, the intermediate panel blocking visibility of the printed matter on the at least one side of the back panel except that the intermediate panel has a 1⅜ inch×1⅜ inch (34.925 mm×34.925 mm) square opening that is smaller than the opening in the front panel and that exposes a part of the printed matter 28 a on the at least one side of the back panel 48 . The overall size of the assembly for the described embodiment, as measured from the front panel, may be 5 7/32 inch×7 27/32 inch (13.26 cm×19.92 cm).
The tab 22 a connected to the intermediate panel 24 a is moveable 26 by a user in moving the intermediate panel to expose different parts of the printed matter 28 a on the at least one side of the back panel 48 through the opening 30 a in the intermediate panel 24 a . The intermediate panel is moveable between the transparent panel 18 a and the back panel 48 in such a way that the opening 30 a in the intermediate panel 24 a is moveable within the boundaries of the opening 16 a of the front panel 12 a.
FIG. 8 shows a die cut pattern in solid lines for a die usable for cutting one or more preprinted sheets, e.g., 29×23 inch paper board sheets (73.66 cm×58.42 cm), e.g., one SBS stock sheet with a die cutting machine or press. Before or preferably simultaneous with the cutting operation, an impression die may be used to impress a plurality of fold lines 84 , 86 , 88 separating a plurality of foldable panels 90 , 92 , 94 , 96 on each sheet as well as other fold lines for the various tabs as shown in dotted lines and more fully described above in connection with FIG. 4 . Or, the fold lines may be scored with a scoring instrument. The die cut pattern may provide for cutting parts for only one or even more than the two devices shown in FIG. 8 . The illustrated die cut pattern is used to cut preprinted parts from one sheet for assembling two devices, such as described above for instance in connection with FIG. 4 , each device also including a separately preprinted clear transparent window 18 a as shown for instance in FIG. 5 made of a Mylar sheet. A die cut press 102 or top platen shown in FIG. 9 is able to cut the illustrated pattern from a sheet or a stack of sheets 104 set on a table, bottom platen, cutting surface, or area 106 by pressing for instance a steel rule cutting die 101 onto the sheet or sheets 104 to create a plurality of multiple panel parts 80 , 82 . The die 101 may be in the form of a flat base or substrate or block made for instance out of high-grade and high density plywood, e.g. a hardwood made out of maple that is free from voids and imperfections. A bandsaw or laser cutter may be used to cut precisely positioned slits into the substrate. A hardened steel in the form of an elongated razor blade (“steel rule”) is cut and bent by a die-maker and inserted into the slits in the substrate. The steel rule thus assembled in the slits forms thin metal walls held in place in the slits. The edges on one side of the steel rule may have a selected bevel that is sharpened for cutting the SBS stock on the press machine's bottom platen or table 106 . The other side faces the top platen or press 102 . An ejection rubber pad may be adhered to the substrate of the die to help eject the SBS stock after it is cut. Altogether the walls of the die 101 form a steel rule die that is pressed onto the paper board or boards to do the cutting operation. As suggested above, the die is attached to the top platen of the die cutting press that provides the force required to make the cut. The SBS stock is positioned below the die and then the press is actuated. The cutting edges of the steel rule penetrate through the SBS stock until they come in contact with the bottom platen or table which may be made of steel selected for cutting the SBS stock. The press then reverses and the cut part is exposed. As suggested above, foldlines, creases, perforations and the like may be made with a special rule that is positioned on the same die as the cutting rule. It is also possible to have a secondary foldline die positioned on the opposite side of the press and aligned with the primary foldline rule to create very crisp foldlines or creases. Windows and tabs similar to the window 16 a and tabs 40 , 42 are also provided for die cutting. Provision for cutting a slot similar to slot 25 a of FIG. 4 is also provided for in the die cut pattern for each multiple part panel 80 , 82 . As shown to the left of each multiple part panel 80 , 82 , there is a wand 98 and a concealed part 100 cut by the pattern. The die cut parts may be assembled into a plurality of devices, each device at least including an apparatus according to the teachings hereof. It should be realized that the pattern of FIG. 8 could itself be printed on a sheet of preprinted paper board and used as a cutting guide for hand cutting using scissors for an individual craft or hobby kit or school project. Such a paper board would be preprinted with at least the printed matter for the bottom/back panel, part, or component. In that event, the pattern of FIG. 8 instead represents a paper board sheet preprinted with at least printed matter such as shown at reference numeral 28 a in FIG. 6 on the panel 90 and actual line printing showing the outline of where to cut (solid lines) and where to fold (dotted lines). The dotted lines may be pre-impressed or pre-scored for easy folding.
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An apparatus, comprising a handle of a captive but freely-moveable wand, the handle useable to move an attached wand viewfinder over a clear front window of a front component to selectively reveal parts of printed matter on a hidden back component, wherein the clear front window has semi-transparently printed matter thereon, wherein inside the apparatus, a concealed component tethered to the wand is selectively moveable between the semi-transparently printed matter and the printed matter on the hidden back component, and wherein the tethered concealed component has an opening that lies in alignment with a matching opening in the wand viewfinder so that, with selective movement of the tethered concealed component: (a) both the printed matter on the clear front window is shown superimposed over the selectively revealed parts of the printed matter on the back component in the wand view finder and (b) solely the semi-transparently printed matter is shown on the clear front window outside the wand viewfinder.
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RELATED APPLICATIONS
[0001] This application is a division of U.S. patent application Ser. No. 11/321,557, entitled “COMPLEMENTARY METAL-OXIDE SEMICONDUCTOR (CMOS) IMAGE SENSOR,” filed Dec. 28, 2005, which, in turn, claims priority to Korean application 10-2004-0115887, filed Dec. 30, 2004, both of which are hereby incorporated by reference in their entireties.
FIELD OF THE INVENTION
[0002] The present invention relates to a semiconductor device; and, more particularly, to a CMOS image sensor having high voltage supply circuits.
DESCRIPTION OF RELATED ART
[0003] In general, an image sensor is one of semiconductor devices for converting an optical image into an electrical signal. The representative image sensor is mainly classified into a charge coupled device (CCD) and a complementary metal oxide semiconductor (CMOS) image sensor.
[0004] In the CCD, metal-oxide-silicon (MOS) capacitors are arranged such that they are very close to one another, and charge carriers are stored at the capacitors and they are transferred. On the contrary, in the CMOS image sensor, a plurality of MOS transistors, which are correspondent to number of unit pixels, are fabricated using a CMOS technology where a control circuit and a signal processing circuit are used as a peripheral circuit and thus, a processed data is outputted sequentially using the MOS transistors and the peripheral circuit. Herein, the CMOS image sensor employs four MOS transistors typically.
[0005] FIG. 1 is a circuit diagram setting forth a unit pixel of a conventional CMOS image sensor.
[0006] As shown, a unit pixel 100 includes one photodiode 10 and four NMOS transistors 11 , 12 , 13 and 14 . The four NMOS transistors are configured with a transfer MOS transistor 11 for transferring photocharges generated at the photodiode 10 to a charge sensing node N, a reset MOS transistor 12 for discharging the photocharges stored at the charge sensing node N for detecting a next signal, a drive MOS transistor 13 for acting as a source follower, and a select MOS transistor 14 for serving roles in switching and addressing.
[0007] In this manner, the four MOS transistors 11 , 12 , 13 and 14 and one photodiode 10 constitute one unit pixel. According to the number of the unit pixels included in the CMOS image sensor, the numbers of the photodiodes and the MOS transistors included in a pixel array of the CMOS image sensor is determined.
[0008] The image sensor receives a light through an optical lens and outputs an electrical digital code corresponding to each color.
[0009] According to a desired resolution, the number of the unit pixels is determined. Each unit pixel operates through one photodiode 10 and four transistors 11 , 12 , 13 and 14 as shown in FIG. 1 in general.
[0010] The photodiode 10 accumulates electrons corresponding to an incident light and the accumulated electrons are transferred to the sensing node FD, i.e., a floating diffusion node, through the transfer transistor 11 acting as a switch.
[0011] The drive transistor 13 acting as the source follower drives a source terminal according to the electrons applied to the sensing node FD. Thereafter, if the select transistor 14 is turned on, a predetermined signal, which is driven by the drive transistor 13 , is outputted to a correlated double sampling (CDS) circuit.
[0012] At this time, the predetermined signal outputted to the CDS circuit incorporates a noise component existing at the sensing node FD as well as a pure data signal transferred to the sensing node FD.
[0013] Therefore, there is a need for eliminating this noise component. To this end, the CMOS image sensor turns on the reset transistor 12 first to receive a reset signal from the sensing node FD. Afterwards, the CDS receives the data signal having the reset signal and calculates a voltage difference between a reset signal voltage and a data signal voltage after measuring the reset and data signal voltages, respectively. Thus, the voltage difference is used as an actual data signal.
[0014] However, in case that the reset transistor 12 is turned on for outputting the reset signal, a voltage reduced to a threshold voltage of the reset transistor 12 is transferred to the sensing node FD. Likewise, a voltage reduced to a threshold voltage of the drive transistor 13 from the voltage level of the sensing node FD is transferred to the source terminal of the drive transistor 13 . Therefore, a dynamic range decreases to the threshold voltage level of the reset transistor 12 .
[0015] In addition, the signal transferred by the photodiode 10 must be transferred in such a state that its voltage level is reduced to the threshold voltage levels of the transfer transistor 11 and the driving transistor 13 .
[0016] This is because all the transistors arranged in the unit pixel of the CMOS image sensor are configured to be NMOS transistors so that it is impossible to transfer the signal of which the voltage level is lower than the threshold voltage level.
[0017] In particular, all the photocharges accumulated at the photodiode 10 cannot be transferred to the sensing node FD under low light level condition so that an image becomes somewhat dark in whole, which results in degrading a total image quality.
SUMMARY OF THE INVENTION
[0018] It is, therefore, an object of the present invention to provide a CMOS image sensor of which a dynamic range does not decrease to threshold voltages of transistors in spite of configuring the transistors as NMOS transistors in each unit pixel.
[0019] In accordance with an aspect of the present invention, there is provided a CMOS image sensor including: a unit pixel including controlled by a high voltage; a reference high voltage generator for generating a reference high voltage; and a high voltage output unit for generating the high voltage by using the reference high voltage as an operating voltage to thereby output the high voltage to the unit pixel, wherein a level of the high voltage is stably maintained regardless of a variations of the reference high voltage level.
[0020] In accordance with another aspect of the present invention, there is provided a semiconductor device for converting an optical image into an electrical signal, the semiconductor device including: a unit pixel including controlled by a high voltage; and a high voltage output unit for generating the high voltage to thereby output the high voltage to the unit pixel, wherein the high voltage output unit includes: a reference voltage generator for amplifying a voltage divided from an operational voltage to generate the amplified voltage as a reference voltage; and a regulator for generating the high voltage by amplifying a voltage induced from an inputted reference voltage by an operational amplifier, to thereby output the high voltage to the unit pixel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The above and other objects and features of the present invention will become better understood with respect to the following description of the preferred embodiments given in conjunction with the accompanying drawings, in which:
[0022] FIG. 1 is a circuit diagram setting forth a unit pixel of a conventional CMOS image sensor;
[0023] FIG. 2 is a block diagram illustrating a CMOS image sensor in accordance with a preferred embodiment of the present invention;
[0024] FIG. 3 is a circuit diagram explaining a reference voltage generator of FIG. 2 ;
[0025] FIG. 4 is a circuit diagram representing a regulator of FIG. 2 ; and
[0026] FIGS. 5 and 6 are waveform diagrams showing an operation of the CMOS image sensor of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0027] A CMOS image sensor in accordance with exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
[0028] FIG. 2 is a block diagram illustrating a CMOS image sensor in accordance with a preferred embodiment of the present invention.
[0029] As shown, the CMOS image sensor of the present invention includes a unit pixel 100 and high voltage supply circuits 200 and 300 , wherein the unit pixel 100 is provided with a photodiode 10 for transferring a data signal accumulated corresponding to an incident light, a transfer transistor 11 for transferring the data signal from the photodiode 10 to a sensing node FD, and a drive transistor 13 of which one side is connected to a power voltage supply terminal VDDA for driving the other side thereof after receiving the data signal transferred from the sensing node FD through a gate thereof. Herein, one side and the other side of each transistor act as source and drain. Meanwhile, the high voltage supply circuits 200 and 300 play roles in supplying a high voltage VPX of which level is higher than a level of a power voltage applied from the power voltage supply terminal VDDA, as a transfer gate voltage VTX.
[0030] In addition, the CMOS image sensor of the present invention further includes a reset transistor 12 connected between the power voltage supply terminal VDDA and the sensing node FD, wherein the reset transistor 12 receives the high voltage VPX as a gate voltage VRX.
[0031] A distinct characteristic of the present invention is that the high voltage VPX of which the level is higher than the power voltage is generated and applied to the gates of the transfer transistor 11 and the reset transistor 12 in the unit pixel 100 of the CMOS image sensor.
[0032] At this time, the high voltage for the transfer transistor 11 and the high voltage for the reset transistor 12 may be separately generated and applied thereto. However, in the present invention, one high voltage VPX is commonly generated and is applied as the gate voltage VTX for the transfer for the transfer and the gate voltage VRX for the reset transistor 12 .
[0033] There is an advantageous merit that an optimum high voltage suitable for each operational characteristic can be generated and applied to the transfer and the reset transistors 11 and 12 if the high voltages for the transfer and the reset transistors 11 and 12 are separately generated, whereas there is a drawback that an additional circuit for generating another high voltage is inevitably needed.
[0034] Hereinafter, supposing that one high voltage be generated and applied to each gate of the transfer transistor 11 and the reset transistor 12 , detail descriptions will be set forth.
[0035] The high voltage supply circuits 200 and 300 is provided with a reference high voltage generator 200 for generating a reference high voltage VPP of which a level is higher than the level of the high voltage VPX, and a high voltage output unit 300 for outputting the high voltage VPX with a stable voltage level regardless of fluctuation of the reference high voltage VPP. The high voltage output unit 300 outputs the high voltage VPX after reducing the level of the reference high voltage VPP to the level of the high voltage VPX.
[0036] The reference high voltage generator 200 includes a detector 210 for detecting the level of the reference high voltage VPP inputted to the high voltage output unit 300 , an oscillator 220 for outputting an oscillated clock in response to the detection result of the detector 210 , and a charge pump 230 for applying the reference high voltage VPP to the high voltage output unit 300 by pumping charges to an output terminal in response to the oscillated clock of the oscillator 220 .
[0037] In addition, the reference high voltage generator 200 further includes a decoder 240 for transferring a set value to the detector 210 in order to adjust a level of the voltage detected at the detector 210 .
[0038] The high voltage output unit 300 includes a reference voltage generator 310 for outputting a reference voltage VPX_REF obtained by dividing the power voltage VDDA into a predetermined voltage level, and a regulator 320 for outputting the high voltage VPX after reducing the reference high voltage VPP to the high voltage VPX in response to the reference voltage VPX_REF.
[0039] The high voltage output unit 300 further includes a decoder 330 for transferring a set value to the reference voltage generator 310 in order to adjust a level of the reference voltage VPX_REF outputted from the reference voltage generator 310 .
[0040] FIG. 3 is a circuit diagram explaining the reference voltage generator 310 of FIG. 2 .
[0041] As shown, the reference voltage generator 310 is provided with a voltage divider 311 for outputting a division voltage VDDA/2 obtained by dividing the power voltage applied from the power voltage supply terminal VDDA, and a reference voltage supplier 312 for supplying the reference voltage VPX_REF. Herein, the reference voltage VPX_REF is obtained by summing the division voltage VDDA/2 with a voltage RXI with a predetermined level due to the set value.
[0042] The voltage divider 311 is provided with a first PMOS transistor MP 1 of which one side is connected to the power voltage supply terminal VDDA and a gate is connected to the other side thereof, and a second PMOS transistor MP 2 connected between the other side of the first PMOS transistor MP 1 and a ground voltage supply terminal. Meanwhile, the gate and the other side of the second PMOS transistor MP 2 are commonly connected to the ground voltage supply terminal.
[0043] Herein, though the voltage divider 311 is implemented using the PMOS transistors, it is possible to construct the voltage divider 311 such that NMOS transistors are diode-connected to each other.
[0044] The reference voltage generator 312 is provided with a first current source Is 1 connected to the power voltage supply terminal VDDA for applying a current after adjusting the current to have a predetermined amount corresponding to the set value, a second current source Is 2 connected to the ground voltage supply terminal, and a resistor R provided between the first and the second current sources Is 1 and Is 2 . Herein, the division voltage, which is represented as VX equal to VDDA/2, is applied to one end of the resistor R.
[0045] FIG. 4 is a circuit diagram representing the regulator 320 of FIG. 2 .
[0046] As shown, the regulator 320 is provided with operational amplifier A, a first PMOS transistor MP 3 , a second PMOS transistor MP 4 and a third PMOS transistor MP 5 . The operational amplifier A receives the reference high voltage VPP and the ground voltage VSSA as a driving voltage. Furthermore, the operational amplifier A receives a feedback voltage VPX_COMP through a positive terminal and the reference voltage VPX_REF through a negative terminal. The first PMOS transistor MP 3 receives the reference high voltage VPP through one side thereof to output the high voltage VPX through the other side thereof in response to the output of the operational amplifier A. In the second PMOS transistor MP 4 , one side and a bulk terminal are commonly connected to the other side of the first PMOS transistor MP 3 and its gate is connected to the other side thereof. The second PMOS transistor MP 4 applies the feedback voltage VPX_COMP through the other side thereof to the operational amplifier A. In the third PMOS transistor MP 5 , one side and a bulk terminal are commonly connected to the other side of the second PMOS transistor MP 4 and the gate and the other side are commonly connected to the ground voltage supply terminal.
[0047] FIGS. 5 and 6 are waveform diagrams showing an operation of the CMOS image sensor of FIG. 2 . In particular, FIG. 5 shows that the high voltage VPX is outputted with a constant level without any variation although the reference high voltage VPP is fluctuated, in which the high voltage VPX becomes the gate voltages VTX and VRX of the transfer and the reset transistors 11 and 12 , respectively. FIG. 6 shows that the high voltage VPX may be outputted with different constant levels according to the output of the decoder.
[0048] An operation of the CMOS image sensor in accordance with the embodiment will be set forth with reference to FIGS. 2 to 6 herebelow.
[0049] To begin with, an operation of the reference high voltage generator 200 , which generates the reference high voltage VPP, will be illustrated.
[0050] The detector 210 detects the level of the reference high voltage VPP transferred to the high voltage output unit 300 . When the detection level is lower than a predetermined level, the detector 210 outputs an enabling signal V LD enabling the oscillator 220 .
[0051] The oscillator 220 oscillates the clock in response to the enabling signal VLD transferred from the detector 210 . Thereafter, when the oscillated clock is inputted from the oscillator 220 , the charge pump 230 pumps charges to the output terminal. After pumping the charges, the reference high voltage VPP is transferred to the reference high voltage generator 200 while maintaining an original level. At this time, the decoder 240 plays a role in setting the level of the voltage detected at the detector 210 .
[0052] Considering the operation of the reference high voltage generator 300 , to begin with, the voltage divider 311 in the reference voltage generator 310 provides the division voltage VX, i.e., VDDA/2, obtained by dividing the power voltage by two. Then, the reference voltage supplier 312 in the reference voltage generator 310 outputs the reference voltage VPX_REF which is a summation of the division voltage VX with the predetermined voltage.
[0053] Assuming that the current passing through the resistor R of the reference voltage supplier 312 is I, the output, i.e., the reference voltage VPX_REF becomes VX+RI. At this time, by adjusting the currents passing through the current sources Is 1 and Is 2 , it is possible to control the reference voltage VPX_REF to have a desired voltage level. This may be achieved by modulating the set value through the decoder 330 .
[0054] The operational amplifier A of the regulator 320 compares the reference voltage VPX_REF and the feedback voltage VPX_COMP to equalize to each other. That is, when the feedback voltage VPX_COMP becomes equalized to the reference voltage VPX_REF, the high voltage VPX is outputted finally. Herein, the relationship between the high voltage VPX and the reference voltage satisfies a following equation, i.e., VPX=2×VPX_REF.
[0055] The high voltage VPX is supplied to the gate of the transfer transistor 11 or the reset transistor 12 in the unit pixel of the CMOS image sensor. Alternatively, the high voltage VPX may be applied to both the gates of the transfer transistor 11 and the reset transistor 12 .
[0056] When the high voltage VPX is supplied to the gate of the transfer transistor 11 in accordance with the present invention, it is possible to transfer more amount of electrons which cannot be transferred from the photodiode 10 to the sensing node FD due to the threshold voltage of the transfer transistor 11 in the conventional CMOS image sensor.
[0057] Therefore, since much more electrons may be transferred from the photodiode 10 , it is possible to increase the dynamic range of the unit pixel and enhance the image under low light level condition, which results in providing good image quality.
[0058] In addition, when the high voltage VPX is applied to the gate of the reset transistor 12 , it is possible to eliminate the electrons existing at the sensing node FD as much as the threshold voltage for turning on the reset transistor 12 .
[0059] Herein, the reason why the reference high voltage VPP generated at the reference high voltage generator 200 is not directly supplied to the unit pixel is that the level of the reference high voltage VPP is continuously varied because the reference high voltage VPP is achieved by the charge-pumping. At this time, the variation amount of the reference high voltage level ranges from about 100 mV to 200 mV. Thus, if the reference high voltage VPP with the variation is directly supplied to the unit pixel, the reset voltage of the unit pixel is also varied with the amount of about 10 mV to 20 mV, which results in decreasing resolution at an A/D converter so as to degrade the image quality of the image sensor in a large amount.
[0060] To address this problem, the reference high voltage VPP is made to have the voltage level higher than that of the high voltage VPX by about 0.3 V to 0.5 V, and then the reference high voltage VPP is used after reducing its voltage level to a predetermined level. At this time, the high voltage VPX outputted through the regulator 320 is insensitive to the operational voltage variation, the temperature variation, the variations of the process condition, or the like.
[0061] Although it is illustrated four transistors used for the unit pixel in the present invention, it is possible to configure the unit pixel with three transistors without employing the transfer transistor. In this case, the loss due to the threshold voltage of the reset transistor may also be eliminated by applying the high voltage VPX to the gate of the reset transistor.
[0062] As described above, in accordance with the present invention, because the high voltage of which the level is higher than the power voltage level is applied to the gate of the reset transistor and/or the transfer transistor among the transistors in the unit pixel of the CMOS image sensor, the voltage loss due to the threshold voltage of the reset transistor may be eliminated and further the transfer loss due to the threshold voltage of the transfer transistor may be compensated, to thereby increase the dynamic range of the unit pixel and improve the image under the low light level condition. Therefore, it is possible to maintain good image quality.
[0063] The present application contains subject matter related to Korean patent application No. 2004-115887, filed in the Korean Intellectual Property Office on Dec. 30, 2004, the entire contents of which is incorporated herein by reference. While the present invention has been described with respect to certain preferred embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.
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A CMOS image sensor includes a unit pixel including controlled by a high voltage; a reference high voltage generator for generating a reference high voltage; and a high voltage output unit for generating the high voltage by using the reference high voltage as an operating voltage to thereby output the high voltage to the unit pixel, wherein a level of the high voltage is stably maintained regardless of a variations of the reference high voltage level.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of Ser. No. 09/805,324 filed Mar. 13, 2001.
TECHNICAL FIELD
[0002] The present invention relates to an abrasion resistant conductive film and more particularly to such a film having utility as a component of a conductive gasket for electrical apparatus to block the entry or exit of electromagnetic interference (EMI) and radio frequency interference (RFI) through openings in the apparatus.
BACKGROUND OF THE INVENTION
[0003] Many modern electronic devices emit or are sensitive to electromagnetic interference (EMI) at high frequencies. Electromagnetic interference is understood to mean undesired conducted or radiated electrical disturbances from an electric or electronic apparatus, including transients, which can interfere with the operation of other electrical or electronic apparatus. Such disturbances can occur anywhere in the electromagnetic spectrum. Radio frequency interference (RFI) refers to disturbances in the radio frequency portion of the spectrum but often is used interchangeably with electromagnetic interference. Both electromagnetic and radio frequency interference are referred to hereafter as EMI.
[0004] Many electronic devices, for example, cell phones, computers, various radio frequency and microwave devices, among others, are sources of EMI. These devices not only are sources of EMI, but also the operation of such devices may be adversely affected by the emission of EMI from other sources. Consequently, electric or electronic apparatus susceptible to electromagnetic interference or apparatus likely to generate electromagnetic generally must be shielded in order to operate properly.
[0005] The shield generally is any metallic or electrically conductive configuration inserted between a source of EMI and a desired area of protection wherein the shield is capable of absorbing and/or reflecting the EMI. As a practical matter, such shields normally take the form of an electrically conductive housing or cabinet, which is electrically grounded. The shield, in any event, prevents both the radiation of EMI from a source and/or prevents such interference (either generated randomly or by design) from reaching a target within the shielded volume.
[0006] A shield comprising a metal cabinet often includes an opening for access to the electronics within the cabinet with a door or other removable cover closing the access opening. Any gap between the confronting, abutting or mating metal surfaces of the cabinet and closure afford an opportunity for the passage of electromagnetic interference. Gaps also interfere with electrical currents running along the surfaces of the cabinets from EMI energy which is absorbed and is being conducted to ground. The gaps reduce the efficiency of the ground conduction path and may even result in the shield becoming a secondary source of EMI leakage from gaps acting as slot antennae. Accordingly, it is common to use a conductive seal or gasket between such surfaces to block the passage of EMI.
[0007] Various configurations of gaskets have been developed to close the gaps between components of the shield. These gaskets establish as continuous a conductive path as possible across any gap that may exist, for example, between cabinet components. A common gasket employs a flexible core enclosed in a woven fabric made at least in part with conductive fibers. Examples of such fabrics are disclosed in U.S. Pat. No. 4,684,762. Another common gasket construction as disclosed, for example, in U.S. Pat. Nos. 4,857,668, and 5,597,979 has a flexible core enclosed in an electrically conductive sheath formed of a non-conducting woven or non-woven fabric. The fabric is rendered conductive by an electroless plating process wherein the fabric is dipped in a silver nitrate bath to impregnate the fabric with silver. In an alternative process, the conductive material including silver or copper may be applied by sputter deposition. After impregnation or coating with silver, the fabric is coated with a non-corrosive material to prevent the oxidation of the silver surface. Suitable coating materials applied either by electroplating or sputter deposition include a pure metal such a nickel or tin, a metal alloy such as Inconel® or Nichrome® or a carbon compound.
[0008] In addition to being conductive, the gasket also must have a degree of abrasion resistance. Resistance to abrasion is important as any wearing away of the conductive surface can result in loss of the EMI shield. Abrasion and erosion of the conductive surface occurs in response to the movement and flexing of the cabinet in which the electronic apparatus is contained and some abrasion occurs each time the door or closure is removed and replaced as may occur when the electronics are serviced.
[0009] While gaskets formed of a metalized fabric have been acceptable, the multiple steps required to manufacture such gaskets adds considerably to the cost of the gasket. Metalized films of a polymeric material also have been used as a sheathing material and in general, the manufacture of a conductive gasket from a metalized film involves fewer process steps. However, metalized films generally are not as abrasion resistant as a conductive fabric of a woven or non-woven material. In particular, when a metalized film is used as a conductive media for EMI gaskets, even low levels of abrasion that erodes the metal layer will adversely affect the surface conductivity and permit passage of EMI.
[0010] Accordingly, an object of the present invention is to provide an improved conductive gasket for use in sealing gaps between adjacent surfaces of a shielding housing for electric or electronic apparatus to isolate the electric or electronic device within the housing from EMI.
[0011] Another object of the invention is to provide an EMI gasket formed in part from a metalized polymeric film.
[0012] A further object of the present invention is to provide an abrasion resistant EMI gasket formed in part of a metalized polymeric film.
[0013] A still further object of the present invention is to provide an EMI gasket having a resilient core enclosed in an abrasion resistant metalized polymeric film.
SUMMARY OF THE INVENTION
[0014] In the present invention, a gasket having electromagnetic interference (EMI) shielding properties is provided for disposition between adjacent metal surfaces to block the entry or exit of electromagnetic radiation from between the adjacent metals surfaces. The gasket includes a resilient core member. The core may be composed of any suitable conductive or non-conductive material and preferably is formed of closed cell urethane foam. Surrounding the core is a polymeric film. The film has a reverse side in intimate contact with the core and an outward facing obverse side. The obverse side is embossed so as to form a plurality of peaks rising above the plane surface of the film. A conductive metal layer coats the obverse side and extends over both the peaks and plane surface.
[0015] In use, the gasket is disposed in the gap between adjacent metal surfaces of the shielded housing. At least one of these surfaces bears against the peaks on the gasket surface to form a conductive circuit across the gap. Over time, relative movement of the adjacent metal surfaces may abrade the metal coating from the peaks on the surface of the gasket. Abrasion wears metal from the summit of the peaks and exposes a thickness of coating on the sides of the peaks. The exposed thickness of coating remains in contact with the adjacent metal surfaces, which in turn maintains the conductivity of the gasket across the gap. The worn peaks inhibit further wear of the coating on the side surfaces.
[0016] Accordingly, the present invention may be characterized in one aspect thereof by a gasket having electromagnetic interference properties for disposition between adjacent metal components comprising:
[0017] a) a resilient core;
[0018] b) a conductive sheath surrounding the resilient core;
[0019] c) the conductive sheath being formed of a non conducting polymeric film having a reverse surface in contact with the resilient core and an obverse surface facing outward from the core, the obverse surface being embossed to provide a plurality of peaks standing above the plane surface of the film; and
[0020] d) a conductive metal coating overlying the peaks and the plane surface whereby the EMI shield provided by the gasket is unaffected by erosion of the metal coating from the tops of each peak.
DESCRIPTION OF THE DRAWINGS
[0021] [0021]FIG. 1 is a cross sectional view of the gasket of the present invention shown disposed between adjacent metal surfaces;
[0022] [0022]FIG. 2 is a perspective view of the sheath material for use in the gasket of FIG. 1;
[0023] [0023]FIG. 3 is a cross sectional view on an enlarged scale of the sheath material of FIG. 1;
[0024] [0024]FIG. 4 is a view on an enlarged scale of a portion of FIG. 1;
[0025] [0025]FIG. 5 is a view similar to FIG. 4 shown at a later time;
[0026] [0026]FIG. 6 is a view taken along lines 6 - 6 of FIG. 5; and
[0027] [0027]FIG. 7 is a view similar to FIG. 3 showing another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Referring to the drawings, FIG. 1 shows a conductive gasket of the present invention generally indicated at 10 . The gasket comprises a continuously molded foam core 12 , which is resilient and compliant over a range of temperatures and which preferably exhibits good compression set characteristics such that the material will “spring back” after repeated compression and decompression and even after long periods of compression. For example, a suitable material for core 12 is closed cell urethane foam.
[0029] Surrounding the core 12 is a sheath 14 . The sheath preferably is composed of a polymeric material, as set out herein below, that is metalized to render the sheath conductive. The gasket 10 , when positioned between adjacent metal surfaces 16 , 18 provides a conductive path between the surfaces to form an EMI shield.
[0030] As seen in FIG. 2, the sheath 14 is composed of a polymeric film 15 having a reverse side 20 and an obverse side 22 . The polymeric film may be formed of any suitable polymer including, but not limited to, nylon, low-density linear polyethylene or an oriented polypropylene. The thickness of the film may be as thin as 0.5 mils or as thick as 100 mils or more provided that the structure maintains its integrity as it is bent or shaped to conform to the core material. The polymeric film preferably contains a flame-retardant material and generally is non-conductive. However, films may be carbon filled or include metal fillers so the film is conductive.
[0031] The obverse side 22 of the film is embossed so as to form a plurality of peaks 24 upstanding from the plane surface 26 of the film obverse side 22 . In the case of a relatively thin film, the process of embossing the obverse side may also cause a pattern to form on the reverse side 20 . This is not the case with a thicker film or where the film is laid against a flat backing during the embossing process. A suitable film has been found to be an embossed film of linear low-density polyethylene identified as XEM-856.2-65 sold by Pliant Corporation. This film is a 4-mil film and is embossed on one side with a pattern of flat-topped four-sided pyramids. The height of the pyramids (peaks 24 ) is about one-fourth the film thickness or about 1 mil. The peaks are distributed across the film surface at a density of about 165 per square inch so as to create a pattern of peaks and valleys on the obverse side 22 of the film. This film as supplied by Pliant Corporation includes a flame-retardant so the film has flame resistance properties.
[0032] The polymeric film itself is non-conductive. To render the film conductive, the obverse side 22 is coated with a conductive metal. In this respect, FIG. 3 shows the film as including a coating 28 extending over the peaks 24 . The coating 28 includes one or more conductive metal layers applied, preferably, by vapor deposition. Vapor deposition is a process well known in the art. Given the thickness of the film and thickness of the coating 28 it should be appreciated that none of the Figures is to scale and the thickness of both the film and coating have been exaggerated for clarity. In particular, the coating thickness is from 100 Å to 5000 Å thick and preferably is about 3000 Å.
[0033] As best seen in FIG. 4, the coating 28 may comprise a single layer but preferably includes at least three metallic layers. A first adherence layer 30 is deposited directly onto the obverse side 22 of the film. This layer preferably is Nichrome but can be any other metal or alloy such as chrome, Inconel or titanium among others having the property of adhering both to the film substrate and to the second layer 32 . The second layer 32 is the conductive layer of the film and can be any highly conductive metal such as copper, gold, silver or platinum with silver being preferred. A third and surface layer 34 is deposited over the conductive layer for abrasion resistance and in the case of silver, to prevent oxidation of the silver layer.
[0034] Since the surfaces adjacent the gasket are very likely to be of a dissimilar metal, the accelerated oxidation of the silver layer on the gasket by galvanic action also is a concern. A surface layer 34 of a pure metal such as nickel, aluminum, iron, tin or zirconium or an alloy such as Nichrome or an Inconel will provide protection against galvanic action, be abrasion resistant and provide a conductive surface. An alloy such as Inconel 600 is preferred. All three metal layers may be deposited in sequence by vapor deposition which facilitates forming the conductive sheath as opposed to the multi step process of forming a metalized sheath of a woven or non woven fabric.
[0035] Abrasion resistance, corrosion resistance and galvanic compatibility also are provided by a thin outer coating of an organic material such as an acrylic, polyurethane, polyester or polycarbonate among others. Even though these materials are non-conductive, a thin layer will provide the desired protection without materially decreasing the conductivity of the metal layer beneath. It further is possible to improve the shielding effectiveness of the film by adding any of the organic materials noted above, among others, as a thin dielectric layer between additional metal layers to provide capacitance coupling. For example, a silver layer, a dielectric and a second silver layer may be applied to the film in a sequence of vapor deposition steps. Metalizing both sides of the polymeric film also will provide dielectric properties. Accordingly, it should be appreciated that the layer 28 also may include one or more layers of a non-metal to provide dielectric properties or to provide other desirable properties including adherence to the film. Any number of layers can be built up by vapor deposition provided the materials are selected so that adjacent layers adhere one to another.
[0036] The conductive sheath 14 is secured about the resilient core 12 by any suitable adhesive process. For example the surface of the core may be provided with an adhesive property so as to bond to the reverse side of the sheath. As an alternative a separate adhesive such as a layer of adhesive may be used or the sheath may be secured in position using an adhesive tape 36 (FIG. 1) to join abutting or overlapping edges of the sheath.
[0037] The gasket 10 of the present invention is disposed for use between adjacent metal surfaces 16 , 18 which may be, for example, a cabinet and a door or closure for an access opening into the cabinet. The gasket 10 , and particularly the outer metalized surface of the gasket, defines a conductive path between the adjacent surfaces 16 , 18 as shown in FIG. 4. The conductive path is established by direct contact of the adjacent surface 16 (and 18 ) with the metal layer 28 extending over the tops of the peaks 24 . In this fashion, EMI is prevented from passing between the surfaces 16 , 18 . No appreciable gap exists between the gasket and the adjacent surfaces to allow the passage of EMI. This is because of the disposition of the embossed peaks in a staggered pattern over the obverse side 22 of the polymeric film. Thus the spaces 38 between peaks as shown in FIG. 4 are blocked by peaks (not shown) both fore and aft of the vertical plane illustrated in FIG. 4.
[0038] Over time, there is relative movement between the metal surfaces 16 , 18 and the gasket 10 for several reasons such as for example temperature changes, flexing of the metal components during movement from one location to another or opening and closing of the closure. Such relative movement over time causes the erosion of the metal coating from the tops of the peaks 24 . Erosion of the metal layer from the plane surface of a smooth film would break the conductive path over the surface of the gasket and possibly compromise the EMI shielding. In the present invention however, erosion of the metal layer from the top of the peaks 24 does not compromise the EMI shield.
[0039] As shown in FIGS. 5 and 6 the erosion of metal to expose the non conductive surface 40 at the top of the peaks exposes a cross section 42 of thin layer of the metal coating on the sides of the peaks. This cross section continues to make a conductive contact around each peak with the adjacent metal surfaces 16 , 18 to maintain the integrity of the EMI shield even after the coating on the top surface is gone. Accordingly, abrasion of the metal surface of the gasket of the present invention does not compromise the EMI shield.
[0040] As noted above, embossing the film to provide peaks with sloped sides is preferred as this configuration presents a larger metal surface to contact as the conductive surface at the top of the peaks is worn away through abrasion. However, the shape of the peaks may be of any suitable configuration. For example the peaks could take the shape of a right-sided cylinder or a truncated cone or pyramid. A flat top, while preferred, is not essential and the peak may have a pointed top such as a true cone or pyramid.
[0041] Embossing the film should provide a pattern and distribution of peaks that avoids any line-of-sight path between the peaks from one side of the gasket to the other. Otherwise a gap could be created which may pass the EMI. As noted above a preferred arrangement is to have the peaks in the form of a four-sided pyramid having a flat truncated top distributed over the film surface wherein the density of the peaks is about 165/in 2 . Another embodiment as shown in FIG. 7 is to provide a coating 28 that completely covers the peaks 24 and fills the valleys 44 between the peaks. While this embodiment uses a greater quantity of metal, a greater cross section of metal is exposed and remains in contact with the adjacent surfaces when the coating is worn from the tops of the peaks. Filling the valleys with the metal containing coating also is another way of avoiding gaps between the peaks that might accommodate the passage of EMI and thus compromise the shield.
[0042] In yet another embodiment, it is possible to eliminate the resilient core 12 and have the metalized film itself comprise the gasket. This can be accomplished by folding the film so that the reverse faces are butted one against the other exposing the metalized obverse side around the entire outer periphery. In the case of a relatively thick film, embossing both sides of the film, cutting the film into thin strips and then metalizing all faces of the thin strip also can eliminate the core.
[0043] Thus, it should be appreciated that the present invention accomplishes its objects in providing an abrasion resistant conductive gasket for use in sealing gaps between adjacent surfaces of a shielding housing for electric or electronic apparatus to isolate the electric or electronic device within the housing from EMI. The gasket is formed in total or in part from a metalized polymeric film wherein the conducting surface of the film is embossed to provide a plurality of peaks standing above the plane surface of the film. With this arrangement, any abrasion that may wear conductive metal coating from the tops of the peaks does not compromise the conductive surface of the film in that such abrasion also will expose a cross section of the conductive metal at the sides of the peaks.
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A conductive gasket is disclosed for use in apparatus to block the exit or entry of electromagnetic interference (EMI) between adjacent metal surfaces of the apparatus. The gasket is formed at least in part by a polymeric film having an outward facing surface embossed so as to provide a plurality of peaks distributed over the surface. A metal is coated, by vapor deposition, onto the surface so as to over lie the peaks. This provides the film with a conductive surface. When located between adjacent metal surfaces, abrasion of the metal coating from the peaks over time does not adversely affect the conductive properties of the film surface. This is because the wearing away of the metal from the tops of the peaks exposes a cross section of the metal at the sides of the peaks, which remain in contact with the adjacent metal surfaces of the apparatus.
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PRIORITY CLAIM
[0001] The present non-provisional application claims the benefit of commonly owned provisional Application having Ser. No. 61/987,200, filed on May 1, 2014, which provisional application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Plants such as corn include a variety of constituents that can be used for many purposes. For example, starch obtained from corn plants can be used to make ethanol and plant fibers can be used as ingredients for a variety of products. Oftentimes it is desirable to separate the various plant constituents and purify them in an economical manner (e.g., energy efficient manner, environmentally friendly manner, and the like), while at the same time providing desired properties in the intermediate and/or final plant material products.
[0003] Accordingly, there is a continuing need to improve processes for treating plant materials such as plant fibers in an economical manner while at the same time providing desirable properties in the intermediate and/or final products.
SUMMARY
[0004] The present invention involves methods and systems that selectively adjust the amount of make-up aqueous stream(s) and recycled aqueous stream(s) that are used for washing plant fiber depending on the desired level of fiber purity so as to use water more efficiently.
[0005] According to one aspect of the present invention, a method of cleaning plant fiber includes: a) providing a first plant fiber component including plant fiber and one or more additional plant constituents; b) combining the first plant fiber component with at least a first aqueous component comprising water and at least a portion of the one or more additional plant constituents to form a first mixture including: i) a second plant fiber component including plant fiber and one or more additional plant constituents; and ii) a second aqueous component including water and one or more additional plant constituents; c) separating at least a portion of the second aqueous component from the first mixture; d) after step (c), combining the first mixture with at least a third aqueous component including water to form a second mixture including: i) a third plant fiber component including plant fiber; and ii) the first aqueous component; e) separating the first aqueous component from the second mixture; and f) recycling at least a portion of the first aqueous component so that it can be combined with the first plant fiber component, wherein the concentration of plant fiber on a dry matter basis in the third plant fiber component is greater than the concentration of plant fiber on a dry matter basis in the first plant fiber component.
[0006] According to another aspect of the present invention, a system for cleaning plant fiber includes: a) a first plant fiber component source including plant fiber and one or more additional plant constituents; b) a first aqueous component source including water and at least a portion of the one or more additional plant constituents; c) a first vessel in fluid communication with the first plant fiber component source and the first aqueous component source to combine the first plant fiber component with the first aqueous component to form a first mixture including: i) a second plant fiber component including plant fiber and one or more additional plant constituents; and ii) a second aqueous component including water and one or more additional plant constituents; d) a first separation apparatus in fluid communication with the first mixture to separate at least a portion of the second aqueous component from the first mixture; e) a second vessel in fluid communication with the first mixture from the first separation apparatus and a third aqueous component source including water to combine the first mixture with the third aqueous component to form a second mixture including: i) a third plant fiber component including plant fiber; and ii) the first aqueous component; f) a second separation apparatus in fluid communication with the second mixture to separate the first aqueous component from the second mixture; and g) a recycle line in fluid communication with the second separation apparatus and the first vessel to provide at least a portion of the first aqueous component to the first vessel, wherein the concentration of plant fiber on a dry matter basis in the third plant fiber component is greater than the concentration of plant fiber on a dry matter basis in the first plant fiber component.
[0007] The present invention also involves methods and systems that can process a plant fiber to produce a fiber product (e.g., ground corn bran fiber) having a desired moisture level using recycle and make-up air streams.
[0008] According to another aspect of the present invention, a method of processing a plant fiber includes: a) providing a plant fiber component including plant fiber, wherein the plant fiber component has an amount of moisture; b) processing the plant fiber component to provide a fiber product, wherein the plant fiber component is processed at a temperature that can reduce the amount of moisture in the plant fiber component; c) combining the plant fiber component with a first gas stream having a temperature and humidity value to control the moisture content of the fiber product; d) after said processing, separating at least a portion of gas from the fiber product to form a recycled gas stream; and e) using the recycled gas stream to form the first gas stream.
[0009] According to yet another aspect of the present invention, a system for processing a plant fiber includes: a) a plant fiber component source including plant fiber, wherein the plant fiber component has an amount of moisture; b) a grinding apparatus in fluid communication with the plant fiber component source to grind the plant fiber and produce a fiber product, wherein the plant fiber component is exposed to a temperature in the grinding apparatus that can reduce the amount of moisture in the plant fiber component; c) a first gas stream in fluid communication with the grinding apparatus, wherein the first gas stream can be combined with the plant fiber component, and wherein the first gas stream has a temperature and humidity value to control the moisture content of the fiber product; and d) a separation apparatus in fluid communication with the grinding apparatus, wherein the separation apparatus is configured to separate at least a portion of the first gas stream from the fiber product to form a recycled gas stream, wherein the recycled gas stream is in fluid communication with the first gas stream so that the recycled gas stream can be used to form the first gas stream.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1A is a process flow diagram illustrating an exemplary method and system for washing a corn bran fiber according to the present invention.
[0011] FIG. 1B is a process flow diagram illustrating an exemplary alternative of the method and system shown in FIG. 1A for washing a corn bran fiber according to the present invention.
[0012] FIG. 2 is a process flow diagram illustrating an exemplary method and system for grinding a corn bran fiber to produce a corn bran fiber product according to the present invention.
DETAILED DESCRIPTION
[0013] Methods and systems are described in detail herein below for processing plant fiber according to the present invention.
[0014] A wide variety of plant fibers can be processed according to the present invention. In some embodiments, plant fibers include grain fibers obtained from plants such as fibers from corn, sorghum, barley, oats, wheat, and the like. For example, a preferred plant fiber includes corn bran fiber obtained from one or more fractionation processes such as those used to make ethanol from corn grain. Fractionating corn grain to make ethanol is well-known and is described in, e.g., U.S. Pat. No. 8,454,802 (Redford); U.S. Pat. No. 8,449,728 (Redford); and U.S. Pat. No. 8,603,786 (Redford), wherein the entirety of each patent is incorporated herein by reference for all purposes. Corn bran fiber obtained from a fractionation process may include one or more additional materials such as additional plant constituents (e.g., starch). It may be desirable to remove such additional materials from corn bran fiber so as to purify and increase the content of the corn bran fiber.
[0015] One aspect of the present invention involves washing a plant fiber to clean the plant fiber and increase the purity of the plant fiber. For example, as discussed above, plant fiber can have other materials such as plant constituents (e.g., starch) bound to the fiber. A method of removing a plant constituent such as starch from plant fiber according to the present invention can selectively adjust the amount of make-up water and recycled water that are used for cleaning the plant fiber depending on the desired level of fiber purity so as to use water more efficiently.
[0016] An exemplary method and system 100 for washing a plant fiber according to the present invention will be described with respect to FIG. 1 in the context of removing starch from corn bran fiber to increase the level of fiber while using water in an efficient manner.
[0017] As shown in FIG. 1A , a crude corn bran fiber stream (i.e., a “fiber component”) 101 is provided to a vessel such as tank 110 . Crude stream 101 can be obtained from a corn fractionation process used to make ethanol. The crude corn bran fiber stream 101 includes at least residual starch from the corn fractionation process. Much of the starch is still bound to the corn bran fiber.
[0018] Aqueous steam 102 is also provided to tank 110 and combined with corn bran fiber stream 101 to form a mixture and help wet the corn bran fiber so that the starch can be more easily separated from the corn bran fiber. Aqueous stream 102 is preferably a recycle stream that includes water and one or more other materials separated from the corn bran fiber (e.g., soil, starch, and the like).
[0019] Tank 110 is maintained at appropriate conditions to facilitate wetting of the corn bran fiber and to help separate at least some of the starch from the bran fiber. For example, in some embodiments, tank 110 can use agitation (e.g., stirring) to help wet and wash the starch from the bran fiber. Also, the contents of tank 110 can be heated (e.g., via heating tank 110 and/or heating stream 102 ) to help remove starch from the corn bran fiber.
[0020] After processing the corn bran fiber in tank 110 for an appropriate amount of time, the mixture is pumped via line 103 so that at least a portion of the aqueous fraction of the mixture can be separated from the mixture. Because at least some washing occurs in tank 110 , the aqueous fraction of the mixture in line 103 tends to include relatively higher levels of washed materials (e.g., starch) as compared to aqueous stream 102 and the corn bran fiber tends to be relatively more clean as compared to the raw corn bran fiber in stream 101 . In some embodiments, an apparatus can be used to apply pressure to the mixture so as to separate at least a portion of the aqueous fraction from the mixture. Also, applying pressure can help abrade the corn bran fiber and separate material such as starch from the corn bran fiber. As shown, the mixture is pumped via pump 112 to screw press 114 . At least a portion of the aqueous fraction of the mixture that is separated via screw press 114 can be recycled to tank 110 via line 104 and another portion of the aqueous fraction of the mixture that is separated via screw press 114 can be removed from the washing process 100 via line 113 .
[0021] The aqueous fraction of the mixture that removed from the washing process 100 via line 113 can be handled in a variety of ways. In some embodiments, it can be discharged to waste or delivered to another process. For example, because the aqueous stream in line 113 can include starch separated from corn bran fiber, the starch in line 113 can be delivered to a fermentation process and fermented into ethanol.
[0022] After screw press 114 , the corn bran fiber is delivered to at least one additional vessel such as tank 120 so that an additional washing process can be performed with an aqueous stream that is different from stream 102 . As shown, aqueous stream 106 is delivered to tank 120 and is combined with the corn bran fiber from stream 105 to form a mixture and help wet the corn bran fiber so that at least some of the remaining starch can be more easily separated from the corn bran fiber. Preferably, aqueous stream 106 includes fresh clean water added to the system 100 (i.e., “make-up” water).
[0023] Tank 120 is maintained at appropriate conditions to facilitate wetting of the corn bran fiber and to help separate at least some of the remaining starch from the bran fiber. For example, in some embodiments, tank 120 can use agitation (e.g., stirring) to help wet and wash starch from the bran fiber. Also, the contents of tank 120 can be heated (e.g., via heating tank 120 and/or heating line 106 and/or heating line 105 ) to help remove starch from the corn bran fiber. Preferably, tank 120 is substantially the same as tank 110 .
[0024] After processing the corn bran fiber in tank 120 for an appropriate amount of time, the mixture is pumped via line 107 so that preferably as much of the aqueous fraction of the mixture can be separated from the mixture to create an aqueous stream 108 and a fiber stream 111 . Because at least some washing occurs in tank 120 , the aqueous fraction of the mixture in line 107 tends to include relatively higher levels of washed materials (e.g., starch) as compared to aqueous stream 106 and the corn bran fiber in line 111 tends to be relatively more clean as compared to the corn bran fiber in stream 105 . In some embodiments, an apparatus can be used to apply pressure to the mixture so as to help separate an aqueous fraction from the mixture. Also, applying pressure can help abrade the corn bran fiber and separate material such as starch from the corn bran fiber. As shown, the mixture is pumped via pump 122 to screw press 124 in a manner similar to screw press 114 (discussed above). At least a portion of the aqueous stream 108 that is separated via screw press 124 can be recycled to tank 120 via line 109 and another portion of the aqueous fraction of the mixture that is separated via screw press 124 can be recycled to tank 110 via line 102 .
[0025] The flow rates of the recycle streams and fresh/discharge streams in process 100 can be adjusted to impact the fiber purity level as desired in stream 111 , while at the same time taking into account the amount of fresh (“make-up”) water used. In some embodiments, the concentration of fiber in tanks 110 and 120 can be kept constant so as to provide a desired residence time for the fiber to be exposed to washing action. In such embodiments, as the flow rate of fresh water 106 is increased, the purity of fiber in stream 111 is increased. For example, if a relatively higher level of fiber purity is desired in stream 111 , then the flow rate of fresh water introduced into process 100 via line 106 can be increased, which corresponds to an increase in flow rate of lines 102 and 113 . As a result, the flow rates of the recycle streams such as streams 104 and 109 can be reduced to maintain the appropriate concentrations in each of tanks 110 and 120 . As another example, if a relatively lower fiber purity can be tolerated, the flow rate of fresh water introduced into process 100 via line 106 can be reduced, thereby saving on the amount of fresh water used as well as reducing the amount of water discharged via line 113 . In such a scenario, the flow rate of line 102 can also be reduced (and be almost the same as the flow rate of line 106 ) while the flow rates of the recycle streams 104 and 109 can be increased to accommodate the reduced flow rate in line 106 and maintain the appropriate concentrations in each of tanks 110 and 120 .
[0026] Fiber stream 111 can be further processed as desired. For example, fiber stream 111 can be ground as described below in connection with FIG. 2 . The fiber cleaning process 100 cleans the corn bran fiber delivered in stream 101 such that the purity or concentration of fiber on a dry matter basis in stream 111 is higher as compared to the concentration of fiber on a dry matter basis in stream 101 . In some embodiments, the concentration of fiber in stream 111 is 80 percent or greater on a dry matter basis, preferably 85 percent or greater on a dry matter basis, even 90 percent or greater on dry matter basis.
[0027] Optionally, the process 100 in FIG. 1A can be modified to include one or more additional washing vessels between tanks 110 and 120 . Such additional washing vessels could include recycle and/or fresh water streams to help wash the fiber in a manner as described above with respect to tanks 110 and 120 . Also optionally, such additional washing vessels could include one or more separating apparatuses (e.g., screw presses) between each washing vessel so as to separate an aqueous fraction from the fiber before delivering the fiber to the next washing vessel. In some embodiments, including additional washing vessels and maintaining similar concentrations as in the two tank system described in FIG. 1A (to provide appropriate residence times) can permit less fresh water to be used for a given fiber purity as compared to the two tank system in FIG. 1A . For example, an alternative process 150 is shown in FIG. 1B , where the same reference characters have been used for similar features as described in FIG. 1A (a discussion of those same reference characters is not repeated for FIG. 1B ). Process 150 includes an additional wash tank 160 . Process 150 is set up with recycle streams and a fresh water stream 106 such that the fresh water is used to wash the cleanest fiber in process 150 , which is in the last tank 120 , and the relatively most unclean recycle water in stream 162 is used to wash the incoming fiber from stream 101 , which is typically the most unclean fiber in process 150 . As mentioned above, because a third wash tank 160 is introduced and the same concentration is used for tanks 110 , 120 , and 160 as in FIG. 1A , a lower flow rate for fresh water stream 106 can be used while at the same time producing the same level of fiber purity as compared to the system in FIG. 1A , which would use a higher flow rate for fresh water line 106 . In a preferred embodiment, as shown in FIG. 1B , a screw press is used at least for the first and last wash tanks (i.e., tanks 110 and 120 ). Using a screw press 114 for the first wash tank helps abrade and scrap starch that may be bound to the fiber so as to loosen such starch and permit it to be washed in a subsequent wash tank such as tank 160 and/or tank 120 . Using a screw press after the last tank such as screw press 124 after tank 120 helps permit a relatively high amount of wash water to be separated from the fiber. Separating a relatively high amount of wash water from fiber after the last wash tank can be advantageous as it can lower the amount of water that needs to be removed in a downstream drying apparatus, which can save on energy costs. After washing in tank 160 , the mixture of at least fiber, starch, and water is pumped from tank 160 to a separation apparatus 174 via pump 172 and line 163 . Separation apparatus 174 permits an aqueous stream to be recovered for use as recycled wash water in lines 162 and 164 . In some embodiments, separation apparatus 174 can include a screw press, especially if fiber abrasion is desired. The fiber stream 165 can be delivered to tank 120 and treated as discussed above with respect to FIG. 1A .
[0028] Optionally, the processes 100 and 150 shown in FIGS. 1A and 1B can include processing steps and equipment known in the fiber processing art to facilitate cleaning and/or maintaining appropriate cleaning conditions such as filters, cyclone separators, heat exchangers, pumps, and the like.
[0029] Another aspect of the present invention involves processing a plant fiber to produce a fiber product (e.g., ground corn bran fiber) having a desired moisture level. For example, after washing corn bran fiber, it can be ground into a fiber product. Typically, the corn bran fiber is sufficiently dried before grinding so that the fiber can be handled in an efficient manner. If the corn bran fiber has too high of a moisture level, it can be difficult to handle and process. Oftentimes, the grinding process occurs at a temperature to inhibit bacterial growth in the grinding and related equipment as well as the final product. Such elevated temperatures can further dry the fiber to an undesirably low moisture level. A method of processing (e.g., grinding) a corn bran fiber according to the present invention can selectively adjust the flow rate of one or more recycled gas streams as well as the humidity, flow rate, and temperature of a fresh gas stream to create a combined gas stream that is exposed to the corn bran fiber during such processing so as to provide a desired moisture level in the final corn bran product.
[0030] An exemplary method and system 200 for processing a plant fiber according to the present invention is described with respect to FIG. 2 in the context of grinding corn bran fiber to produce a ground corn bran fiber product having a desired moisture level.
[0031] As shown in FIG. 2 , a stream of corn bran fiber 201 is delivered to a grinding apparatus 210 to reduce the size of the corn bran fiber to form a ground corn bran fiber stream 202 . After grinding the corn bran fiber in mill 210 , the ground corn bran fiber is transferred to separator 220 (e.g., a cyclone separator) to separate gas from the ground corn bran fiber. The gas is removed from the top of separator 220 via line 204 and the ground corn bran fiber leaves separator 220 through the bottom via line 203 . Gas stream 204 can be split into gas stream 205 (e.g., a gas exhaust) and recycled gas stream 206 , which are discussed in detail below. The ground corn bran fiber stream 203 can optionally be cooled via cooling apparatus 230 and packaged as a ground fiber product via line 209 . The process in FIG. 2 is controlled to produce a ground corn bran fiber product in stream 209 to have a desired moisture content, which is typically below 12 percent so that the fiber product can be stored without being susceptible to mold growth. In some embodiments, the ground corn bran fiber product in stream 209 has a moisture content in the range of from 2 to 10 percent.
[0032] The corn bran fiber in stream 201 typically has a moisture content before grinding. If the moisture level is too high, the fiber can become difficult to handle and process. In some embodiments, the stream of corn bran fiber 201 can be provided from a bran washing process, such as stream 111 discussed above with respect to FIG. 1A . Optionally, as shown in FIG. 2 , a corn bran fiber in stream 215 can be dried to the desired moisture content in dryer 240 prior to providing the stream 201 to grinding apparatus 210 . In some embodiments that include a dryer such as dryer 240 it can be desirable to dry the fiber so that it can at least be handled and processed. Removing more moisture than is necessary for the fiber to be handled and processed can add extra cost without necessarily providing a benefit. Accordingly, in some embodiments, the fiber in stream 201 can be as moist as possible as long as the fiber can be handled and is not prone to microbial growth. In some embodiments, the moisture content of the fiber in stream 201 is no more than 12 percent, preferably 10 percent or less.
[0033] Grinding apparatuses are well-known and include, e.g., mills, etc. Grinding apparatus 210 can be maintained at conditions to facilitate reducing the size of the corn bran fiber in stream 201 . In addition, the grinding apparatus 210 can be operated at a temperature that inhibits the growth of bacteria in the process equipment (e.g., grinding apparatus 210 and separator 220 ) as well as the ground fiber. Exemplary temperatures include at least 130° F., preferably at least 135° F. (e.g., from 130° F. to 170° F.). Such temperatures can reduce the moisture level of the corn fiber product 202 as compared to the corn bran fiber 201 entering the grinding apparatus 210 . Higher temperatures can be tolerated as long as the quality of the ground fiber and/or process equipment is not impacted to an undue degree. In some embodiments, the grinding process can operate at a temperature of 250° F. or less.
[0034] To help provide the ground fiber product in stream 209 with a desired moisture content (e.g., from 2-10 percent) the humidity and temperature of the incoming gas stream 208 are controlled. The humidity and temperature of gas stream 208 can be controlled using a combination of one or more of exhaust stream 205 , recycle gas stream 206 , and make-up (e.g., fresh) gas stream 207 . Controlling gas stream 208 in such a manner can advantageously produce a relatively quick response in moisture content of the ground fiber product in stream 209 . Also, controlling gas stream 208 in such a manner can provide desirable quality control of the moisture content in the ground fiber product. In embodiments that dry the fiber stream (e.g., via dryer 240 ) before it is provided to a grinding apparatus, the dryer can be used as a coarse adjustment for the moisture content of the fiber in stream 201 and gas stream 208 can be used as a fine adjustment to the moisture content of the fiber so as to provide the desired moisture content of the fiber in stream 209 .
[0035] In some embodiments, the humidity and temperature of gas stream 208 are such that moisture is transferred out of the fiber coming in from stream 201 (i.e., the fiber in stream 201 is dried) so as to provide the desired moisture content in the ground fiber in stream 209 . In other embodiments, the humidity and temperature of gas stream 208 are such that moisture content of the fiber coming in from stream 201 is maintained through to stream 209 so as to provide the desired moisture content in the ground fiber in stream 209 . In still other embodiments, the humidity and temperature of gas stream 208 are such that moisture is transferred into the fiber coming in from stream 201 (i.e., the fiber in stream 201 is moistened) so as to provide the desired moisture content in the ground fiber in stream 209 . If moisture is transferred into the fiber that is provided in stream 201 , the humidity and temperature of gas stream 208 are preferably selected so as to avoid condensation on process equipment (e.g., apparatus 210 and separator 220 ) and thereby reduce the chance for microbial growth.
[0036] The temperature and humidity of stream 208 can be controlled by selectively controlling at least the flow rates of gas streams 206 and 205 . Gas stream 206 is a recycled gas stream from the gas stream 204 leaving separator 220 . Gas stream 205 is an exhaust stream that can be used to throttle the flow of stream 206 as necessary to control the temperature and humidity of stream 208 . For example, if the moisture level of the fiber product in stream 209 is too high, then the flow rate of exhaust stream 205 can be increased. Optionally, make-up gas (e.g., air) stream 207 can be provided at a desired temperature and humidity and combined with recycled gas stream 206 . For example, if the fiber product in stream 209 is too dry and the temperature in grinding apparatus 210 is too high, then fresh humid air can be supplied via stream 207 and combined with recycled air stream 206 before being supplied to grinding apparatus 210 . As yet another example, if the moisture level of the fiber product in stream 209 is too high, then heated fresh air can be supplied via stream 207 and combined with recycled air stream 206 before being supplied to grinding apparatus 210 .
[0037] As mentioned, the temperature of gas stream 208 is controlled to a temperature depending on the desired moisture content of the ground fiber in stream 209 . Exemplary temperatures for gas stream 208 include a temperature in the range of from 130 F to 170° F. As also mentioned, the humidity of gas stream 208 is controlled to a humidity level depending on the desired moisture content of the ground fiber in stream 209
[0038] The temperature of make-up air stream 207 can be adjusted by techniques known in the art such using heating coils, cooling coils, combinations of these, and the like. The humidity of make-up air stream 207 can be adjusted using humidifying equipment and/or de-humidifying equipment, both of which are well known. Steam injection can also be used to adjust both temperature and humidity.
[0039] Exemplary corn bran fiber products in stream 209 can include at least 80 percent fiber on a dry matter basis, preferably at least 85 percent fiber on a dry matter basis, and even more preferably at least 90 percent fiber on a dry matter basis.
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The present invention relates to plant fiber processes (e.g., washing, drying, and/or grinding) that utilize recycle and/or make-up streams to use water resources efficiently and/or produce intermediate and/or final products with desired properties.
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This invention relates to high vacuum processing and particularly to the avoidance of particulate contamination in applications such as semiconductor device manufacturing by reducing contamination originating from the cycling of vacuum seals.
BACKGROUND OF THE INVENTION
High vacuum systems are widely used in technical and commercial applications such as semiconductor device manufacturing processes, which require the performance of the particular process in the absence of air and airborne contaminants. An example of such a process is the sputter deposition of thin films onto silicon wafer substrates in the manufacture of integrated circuit chips.
In such applications, the high vacuum sputtering system is typically composed of a metal processing chamber, which contains a variety of flanges or ports for the attachment of components such as vacuum producing pumps, sputtering cathodes, measurement instrumentation, access covers and observation windows. Additionally, specific ports are usually provided for the frequent insertion and removal of the wafer or other object being processed.
In order to provide a seal between members which is vacuum tight and yet removable for access or for component maintenance, the most commonly used device is a commercially available elastomeric gasket known as an O-ring. The material of choice for such seals is a rubber-like fluorocarbon material manufactured by E. I. Dupont de Nemours Inc. under the trademark VITON A. This material combines the desirable properties of low out-gassing, low permeability and good compressibility over a useful temperature range.
Most components attached with elastomeric seals are removed infrequently. However, seal ports used for the insertion and removal of objects being processed may be opened and closed as frequently as twice per minute, for 24 hours per day. This type of use generates microscopic particles of both seal material and of adjacent metal surfaces. Such particles are of extreme concern as they can destroy integrated circuits or other devices on the substrate being processed, thus causing a costly reduction in manufacturing yield.
For example, in the case of frequently cycled sealing ports, where a transfer chamber is provided and maintained at a high vacuum of 10 -7 torr, each time a substrate passes through a sealing port, that port is opened and then closed to isolate the environments between adjacent chambers, such as process chambers, a transfer chamber or load chambers.
The slit valve seal plate contains a sealing O-ring. The O-ring is totally compressed to provide a reliable vacuum seal against standard atmospheric pressure in the order of 14.7 pounds per square inch or 760 Torr, which is a pressure differential experienced between a transfer chamber and a loadlock chamber, or between a transfer chamber and a processing chamber when the processing chamber is occasionally opened to atmosphere for service. O-ring seals are also similarly compressed each time a wafer is transferred therethrough in the systems of the prior art when the pressure differential between adjacent chambers is significantly less than 760 Torr.
This compression of an O-ring produces microscopic particles which can be highly deleterious to the product being produced. These particles are produced in two ways. Firstly, repeated compression of the O-ring to the degree necessary to form a reliable standard atmospheric pressure tends to fatigue the elastomer material of which the O-ring is made, causing minute failures which generate elastomer particles. Secondly, as the O-ring is compressed into groove, sliding friction occurs along side faces of groove. This friction abrades both the surface of the O-ring and side surfaces of the groove, producing particles of both elastomer and metal. This abrasion also occurs during decompression of the O-ring.
The presence of such particles in processes such as the manufacture of semiconductor devices results in a substantial loss of value and productivity. This is increasingly the case with the trend toward device miniaturization in which the presence of a sub-micron size particle on the surface of a substrate can result in the production of a totally defective device.
Accordingly, there is an increased need to reduce the quantity of contaminating particles in high vacuum processes, particularly in the manufacture of semiconductor devices.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a high vacuum processing apparatus with the frequently cycled ports thereof seated in a way that reduces the levels of particle generation. It is a further object to provide a seat and sealing method that produces reduced levels of particulate contamination.
It is a more particular objective of the present invention to provide a sealing method for high vacuum processes in which O-ring compression is such as to effectively seal as well as reduce the production of particles thereby, particularly in accordance with the requirements of the system.
According to principles of the present invention, seal compression is provided to an extent that is sufficient to effectively provide the sealing function required, while excess compression that could increase the amount of particle generation is avoided. According to the preferred embodiment of the invention, different degrees of seal compression are brought about in accordance with system conditions that require different degrees of compression for an effective seal.
Further in accordance with the preferred embodiment of the invention, it is appreciated that there are two different conditions under which a port must seal in high vacuum processes. In the first condition, one or more of the various process chambers, the transfer chamber or loading chamber may be opened to atmosphere for purposes of maintenance or for the loading or unloading of substrate cassettes, while adjacent chambers are maintained at high vacuum. This is a relatively infrequent event, especially with respect to a transfer chamber and the process chambers where such maintenance may only occur, for example, once per week. In this condition, with full atmospheric pressure of 760 Torr on the port seal that isolates the process chamber from the transfer chamber, full compression of O-ring is provided to enable the port to hold the high vacuum against the standard atmospheric pressure and thereby prevent leakage. The second condition, occurs with every substrate processing cycle. In this condition, compression of the aperture O-ring is limited to only partial compression, providing effective sealing where the vacuum level in transfer chamber is, for example, about 10 -7 torr and the pressure in processing chambers is, for example, 10 -2 torr, which creates a pressure differential across the O-ring of, for example, about 1/76,000 of atmospheric pressure, which does not require full O-ring compression to provide a reliable seal.
Further in accordance with the preferred embodiments of the invention, actuation of valves between chambers in a high vacuum processing apparatus is controlled to limit compression of valve seals, particularly by compressing the seals less than the full amount of compression of which the seal is capable. Preferably, the compression of the seal is selectively controlled so that the seal can compress only the amount needed to be effective under conditions where less than the maximum possible pressure differential occur, and can compress a greater amount when higher pressure differentials require more seal compression to effectively provide a seal.
In one embodiment of the invention, the position of the valve closure is controlled so that the amount of valve compression can be maintained at a predetermined amount. In another embodiment, the force applied to the valve closure is controlled so that the force which deforms the valve seal is controlled so as to limit seal compression to the predetermined amount.
The present invention provides the capability of compressing valve seals only to the extent required to effectively provide a seal. This limits the amount of fatigue and abrasion to which the seal is subjected, thereby substantially reducing the amount of particle generation of elastomeric seal material and cooperating surfaces, thus reducing the production of defective devices and other processed products and increasing the overall productivity of the vacuum process.
These and other objectives of the present invention will be more readily apparent from the following detailed description of the invention, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan diagram of a semiconductor wafer processing machine.
FIG. 2 is a cross-sectional diagram of a seal in an aperture and valve of the machine of FIG. 1.
FIG. 3 is a cross-sectional diagram of a seal of the valve of FIG. 2 with the seal in an uncompressed condition.
FIG. 4 is a cross-sectional diagram of a seal of the valve of FIG. 2 with a seal in a fully compressed condition.
FIG. 5 is a cross-sectional diagram of a seal of the valve of FIG. 2 with a seal in a controlled partially compressed, particularly in accordance with principles of the present invention.
FIG. 6 is a diagrammatic illustration of a valve actuator for the valve of FIG. 2, according to the present invention, for operating the valve in a controlled manner among the conditions of FIGS. 3-5.
FIG. 7 is a diagrammatic illustration, similar to FIG. 6, showing an altertive actuator for operating the valve in a controlled manner among the conditions of FIGS. 3-5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An apparatus in which the present invention is particularly useful is apparatus 10, which is diagrammatically illustrated in FIG. 1. The apparatus 10 may include all of the typical elements of a semiconductor wafer processing cluster tool. In the apparatus 10, for example, a central transfer chamber II is provided, which is typically maintained at a high vacuum of 10 -7 torr. The transfer chamber 11 contains a robot mechanism 12 such as an extendable transfer arm having a wafer chuck or holder (not shown) at an end thereof for holding thereto a wafer or other substrate 13. The system 10 also includes loading chamber 14 capable of enclosing a cassette (not shown) of substrates 13, and is connected to the transfer chamber 11 through a sealing port 15. One or more processing chambers 16 are also provided, which are similarly connected to the transfer chamber 11 through other sealing ports 15.
In operation, the robot arm 12 removes substrates 13 one-by-one from the loading chamber 14 and delivers them to, and transfers them among, any of one or more of the process chambers 16, and then returns them to loading chamber 14, according to the steps of the particular process. Each time a substrate 13 passes through a sealing port 15, that port 15 is opened and then closed to isolate the environments of process chambers 16, transfer chamber 11 and load chamber 14 from each other.
FIG. 2 shows the construction of such a typical sealing port 15. Transfer chamber 11 is separated from process chambers 16 by wall 21, which contains an aperture or slit 22 through which a substrate 13 may pass. A seal plate 23 is provided, which is driven by a plate actuator mechanism such as a pneumatic cylinder (not shown) in the direction of arrow 24. When seal plate 23 engages surface 25 of wall 21 surrounding the slit 22, the process chamber 16 is isolated from transfer chamber 11. When seal plate 23 is momentarily retracted to the position illustrated in phantom lines in FIG. 2, out of the plane of the aperture 22 and the substrate 13, the substrate 13 may be passed through aperture 22.
Seal plate 23 will typically contain a sealing O-ring 26, shown in circled FIG. 2 and is illustrated in more detail in the enlarged view of FIG. 3., which shows the O-ring 26 in an uncompressed or relaxed position.
Referring to FIG. 3, O-ring 26 is shown installed in a groove 27 formed in seal plate 23. The groove 27 has sidewalls 28, one or both of which are angled inwards, typically at about 15°, in order to retain the O-ring 26 in the groove 27 during motion of plate 23. The depth D of groove 27 is about 75% of the relaxed section diameter or thickness T of the O-ring 26, leaving a projection P of about 25% of T above surface 30 of the plate 23. This dimension P represents the amount of compression of O-ring 26 that is available to form a seal, that is, to perform a sealing function between the plate 23 and the surface 25 surrounding the slit 22. For a typical sealing the O-ring 26, the dimension T may typically be 0.210 inches, the groove depth D may typically be 0.157 inches and the projection P may typically be 0.053 inches.
FIG. 4 shows the same O-ring 26 with sealing surfaces engaged, that is, with surface 30 of plate 23 in contact with the surface 25. In this position, O-ring 26 is fully compressed within groove 27. For the typical O-ring dimensions given above, the width W of contact area between seal surface 25 and the compressed O-ring 26 is generally about 0.190 inches. This width of seal contact in conjunction with the force applied to compress the O-ring 26 provides a reliable vacuum seal against standard atmospheric pressure in the order of 760 Torr.
In accordance with principles of the present invention, apparatus 10 also includes a valve for closing sealing port 15 in which seal 26 can be partially compressed, as illustrated in FIG. 5, which shows the O-ring seal 26 compressed, but to a lesser degree than in FIG. 4. With O-ring 26 of 0.210 inches in cross-section and the groove depth D of 0.157 inches, but a compression of only 10% instead of 25% of the O-ring thickness T. a gap G of about 0.032 inches is provided between surface 30 of plate 23 and sealing surface 25. The width X of O-ring contact area with the surface 25 is about 0.060 inches. With a differential pressure of, for example, about 8 torr or less, this contact area width X and the force effective to achieve it are sufficient to for seal against such a reduced pressure differential. This limited compression of O-ring 26 produces less fatigue of the elastomer material than does the complete compression of FIG. 4, thereby reducing particle generation. Additionally, the reduced compression also reduces the sliding of O-ring 26 against groove side faces 28, thus reducing abrasion and the generation of both elastomer and metal particles.
Depending on the durometer (hardness) of the elastomer used, an O-ring of the dimensions referred to above generally requires about 35 pounds of force per linear inch to achieve a 25% compression, but only about 10 pounds of force per linear inch to achieve a 10% compression.
According to certain embodiments of the invention, valve actuation is controlled so that the limited seal compression in a predetermined amount is specifically provided. According to one preferred embodiment of the invention, a mechanical motion device 40 is employed move seal plate 23 to a pre-determined distance G from seal surface 25, thus allowing a pre-determined degree of compression, for example 10%, of O-ring 26. For full compression of the seal 26, surface 30 may be moved into engagement with surface 25. One embodiment of such a device is shown in FIG. 6.
Referring to FIG. 6, seal plate 23, containing O-ring 26 is mounted to a drive shaft 45, which is flexibly sealed to opposing chamber wall 46 by a bellows 47. A drive gear 48 is provided with a threaded bore therethrough which engages a threaded portion 49 of shaft 45 so that rotation of gear 48 by a motor gear 50 on the shaft of a drive motor 51 fixed relative to the wall 46 causes linear motion of seal plate 23 in the direction of arrow 24 in FIG. 6. A position sensor 53 is provided, connected between the shaft 45 and a stationary reference such as the wall 46 is provided to measure and feedback to a controller 54 the actual position of the plate 23, so that, in response to the feedback from the sensor 53 and the predetermined position that corresponds to the gap G programmed in the controller 54, activates the motor 51 to move the plate 23 to bring its surface 30 to the distance G from the surface 25. In this manner, seal plate 23 may selectively be fully withdrawn to permit passage of a substrate through aperture 22, may be brought into engagement with surface 25 for a full compression seal, or may be positioned with a predetermined gap G to provide a low compression seal. The selection is made in accordance with the condition of the system, under the control of the controller 54, which may operate either in accordance with a predetermined sequence, or in response to sensors that sense machine condition or both.
Other control arrangements may also be utilized to achieve the objective of controlling the compression of seal 26 and the position of plate 23 with respect to surface 25 over the range of motion required to selectively provide the various degrees of compression of O-ring 26. For example, the compression of O-ring 26 may be controlled by controlling the force exerted on plate 23 rather than sensing and controlling its distance from surface 25. Using, for example, O-ring 26 described above, wherein a force of 35 pounds per linear inch of seal 26 produces a 25% compression and a force of 10 pounds per linear inch produces a 10% compression, with an O-ring having a total length of 20 inches, a total force of 700 pounds will provide 25% compression and a total force of 200 pounds will provide 10% compression.
The embodiment illustrated in FIG. 7 is one embodiment of a variable force controlled system, wherein seal plate 23 is connected by shaft 45 a to sliding piston 60 of a pneumatic cylinder 61. The cylinder 61 is connected to compressed air supply 62 through high pressure regulator 63 and valve 64 and through low pressure regulator 65 and valve 66. High pressure regulator 63 is adjusted to a pressure that produces a force of at least 700 pounds on piston 60 when valve 64 is opened, admitting air from regulator 63 into chamber 67 of cylinder 61. This produces full 25% compression of O-ring 26. If piston 60 has an active area of 10 square inches, then regulator 63 is adjusted to approximately 70 PSI. Low pressure regulator 65 is adjusted to a pressure that will produces a force of 200 pounds on piston 60 when valve 66 is opened, admitting air from regulator 65 into chamber 67. Adjustment of regulator 65 to about 20 PSI produces this force, which results in a 10% compression of O-ring 26.
Valve 68 is used to admit air to chamber 69 of cylinder 61 in order to retract seal plate 23 and permit passage of a substrate through aperture 22. The selection of valves 64, 66 or 68 is made though controller 70 which provides control functions equivalent to controller 54 of FIG. 6. It will be recognized that the objective of selectively controlling the force applied to seal plate 23 and thus the degree of compression of O-ring 26 can be achieved in other ways.
A sputtering system 10 according to principles of the present invention is preferably equipped to automatically determine and provide the required degree of seal compression for each individual port seal. For example, referring to FIG. 2, transfer chamber 11 can be provided with a vacuum sensing switch 76 and each of process chambers 16 or the loading chambers 14 can contain a vacuum sensing switch 75. Each of switches 75 or 76 is set to actuate at an absolute pressure level above any process pressure but below atmospheric pressure. A typical setting threshold is I Torr. Switches 75 and 76 preferrably provide signals to controllers 54 or 70 to control port seals 15 in the following manner:
If transfer chamber switch 76 is actuated, indicating a high pressure, all port seals 15 will operate in high (25%) compression mode.
If any of process or load chamber switches 75 is actuated, indicating a high pressure, the port seal 15 for that chamber will operate in high (25%) compression mode while the remaining port seals for chambers whose switches 75 are not actuated, indicating that those chambers are at low pressure, operate in low (10%) compression mode.
If none of switches 75 or 76 is actuated by high pressure, then all port seals operate in low (10%) compression mode.
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A wafer processing apparatus is provided with sealing ports between adjacent evacuatable chambers that are actuated to compress elastomeric seals carried by the valve sealing elements to differing degrees of compression, based on the amount of pressure differential between the chambers when sealed. The degree of compression is controlled so that less compression of the seal takes place when less is required to seal, such as with lower pressure differentials, thereby avoiding unnecessary fatigue and wear of and around the seals that would otherwise increase the generation of particulate contamination.
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FIELD OF THE INVENTION
Acylglutamates are a type of mild surfactant and are notable for very good biodegradability, low aquatic toxicity and mild, good to excellent skin and mucosa tolerability. Acylglutamates are used widely as care components, particularly sodium cocoylglutamate in cosmetic cleansing preparations.
The synthesis of acylglutamates is based on the known Schotten-Baumann reaction, i.e. the reaction of fatty acid chlorides with the amino group of sodium glutamate.
In order to react the lipophilic fatty acid chloride with the hydrophilic amino acid or the parent salt in an aqueous medium, the earlier procedures require the addition of an organic solvent, such as, for example, acetone, methyl ethyl ketone, dioxane, tetrahydrofuran, tert-butanol or cyclohexane (U.S. Pat. No. 3,758,525). A disadvantage of this process is the fact that the organic solvent must be removed from the reaction mixture in processes that are very time-consuming and costly.
The object of the present invention is to find a process for the preparation of acylglutamates which does not require solvents.
SUMMARY OF THE INVENTION
Surprisingly, it has been found that by adding surfactants to the aqueous reaction mixture, it is possible to dispense with an organic solvent. The presence of a surfactant enables the concentration of the acylglutamate reaction product in the finished aqueous solution to be increased to from 25 to 40% by weight, in particular from 25 to 35% by weight.
The invention thus provides a process for the preparation of acylglutamates of the formula ##STR1## in which R is C 6 -C 36 -alkyl, preferably C 10 -C 18 -alkyl or C 6 -C 36 -alkenyl, preferably C 10 -C 18 -alkenyl and X is an alkali metal ion or ammonium ion, by reaction of a glutamic acid salt of the formula ##STR2## with an acid chloride of the formula
RCOCI
in water and in the presence of an anionic or zwitterionic surfactant.
The process is preferably carried out by firstly preparing an approximately 10 to 30% strength aqueous glutamate solution and adding the surfactant and alkali metal hydroxide. The amount of surfactant is such that the finished acylglutamate solution generally comprises from 2 to 50% by weight, preferably from 3 to 30% by weight, in particular from 5 to 25% by weight, of surfactant. The amount of alkali is from 1.0 to 1.03 mol of alkali per mole of glutamic acid salt. This solution is cooled to from about 10 to 20° C., and then the equimolar amount of fatty acid chloride is slowly added thereto. At the same time, enough alkali metal hydroxide is added in order to keep the reaction mixture at a pH of from about 12.2 to 12.6. In the process, the temperature should not exceed 10 to 20° C. After the fatty acid chloride has been added, the reaction mixture is then stirred for about a further 2 hours without cooling and its pH is then adjusted to from 9 to 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Suitable surfactants are all anionic and zwitterionic surfactants which do not react with the acid chloride and which are resistant to alkali.
In very general terms, anionic surfactants which may be used are alkyl-sulfates, alkylsulfonates, alkylcarboxylates, alkylphosphates, and mixtures thereof. The anionic surfactants which are suitable for the present invention are water-soluble or can be dispersed in water. These anionic surfactants comprise, as cation, sodium, potassium, calcium, magnesium, ammonium or substituted ammonium cations, including mono-, di- or triethanolammonium cations.
Particularly suitable surfactants are alkylsulfates of the formula ROSO 3 M, in which R is C 10 -C 14 -alkyl, preferably C 10 -C 20 -alkyl, in particular C 12 -C 18 -alkyl and M is hydrogen or a cation, for example an alkali metal cation (e.g. sodium, potassium or lithium) or ammonium or substituted ammonium, for example methyl-, dimethyl- and trimethylammonium cations and quaternary ammonium cations, such as tetramethylammonium and dimethylpiperidinium cations.
Surfactants which are particularly suitable for the novel process are water-soluble alkyl ether sulfates c)f the formula RO(A) m SO 3 M, in which R is a C 10 -C 24 -alkyl, preferably C 12 -C 20 -alkyl, particularly preferably C 12 -C 18 -alkyl. A is an ethoxy or propoxy unit, m is greater than 0, typically a number between about 0.5 and about 6, particularly preferably between about 0.5 and about 3 and M is hydrogen or a cation, such as, for example, a metal cation (e.g. sodium, potassium, lithium, calcium, magnesium, etc.), ammonium or a substituted ammonium cation. Specific examples of substituted ammonium cations are methyl-, dimethyl-, trimethylammonium and quaternary ammonium cations, such as tetramethylammonium and dimethylpiperidinium cations. Examples which may be mentioned are C 12 -C 18 -alkylpolyethoxysulfates containing in each case 1, 2.25, 3 or 4 moles of ethylene oxide and sodium or potassium as the cation.
Another suitable anionic surfactant which may be used according to the invention is alkylbenzenesulfonate. The alkyl group can be either saturated or unsaturated, and branched or linear. Preferred alkylbenzenesulfonates contain linear alkyl chains having from 9 to 25 carbon atoms, preferably from 10 to 13 carbon atoms; the cation is sodium, potassium, ammonium, mono-, di- or triethanolammonium, calcium or magnesium and mixtures thereof.
It is likewise possible to use secondary alkanesulfonates, in which case the alkyl group can be either saturated or unsaturated, branched or linear. The sulfo group is randomly distributed over the whole carbon chain, the primary methyl groups at the start of the chain and at the end of the chain having no sulfonate group. Preferred secondary alkanesulfonates contain linear alkyl chains having from 9 to 25 carbon atoms, preferably having from 10 to 20 carbon atoms and particularly preferably having from 13 to 17 carbon atoms. The cation is sodium, potassium, ammonium, mono-, di- or triethanolammonium, calcium or magnesium and mixtures thereof. For the sake of simplicity, sodium is the preferred cation.
Other surfactants which can be used are carboxylates, for example fatty acid soaps. The soaps can be saturated or unsaturated and can contain various substituents, for example alpha-sulfonate groups. They preferably contain linear saturated or unsaturated hydrocarbon radicals as the hydrophobic component. The hydrophobic components usually contain from 6 to 30 carbon atoms, preferably from 10 to 18 carbon atoms. The cation is an alkali metal cation, for example sodium or potassium, an alkaline earth metal cation, for example calcium or magnesium, or ammonium or substituted ammonium including mono-, di- and triethanolammonium.
Other anionic surfactants are salts of acylaminocarboxylic acids which are formed in the reaction of fatty acid chlorides with sodium sarcosinate in an alkaline medium (acyl sarcosinates), and the salts of alkylsulfamidocarboxylic acids and the salts of alkyl and alkylaryl ether carboxylic acids. It is likewise possible to use the acylglutamates themselves as surfactants in the novel process.
Other anionic surfactants which may be used are C 8 -C 24 -olefinsulfonates, sulfonated polycarboxylic acids prepared by sulfonation of the pyrrolysis products of alkaline earth metal citrates, as is described, for example, in GB-A-1 082 179, alkyl glycerol sulfates, fatty acyl glycerol sulfates, oleyl glycerol sulfates, alkylphenol ether sulfates, primary paraffinsulfonates, alkylphosphates, alkyl ether phosphates, isethionates, such as acylisethionates, N-acyltaurides, alkylsuccinamates, sulfosuccinates, monoesters of sulfosuccinates (particularly saturated and unsaturated C 12 -C 18 monoesters) and diesters of sulfosuccinates (particularly saturated and unsaturated C 12 -C 18 -diesters), sulfates of alkylpolysaccharides and alkylpolyethoxycarboxylates, such as those of the formula RO(CH 2 CH 2 ) k CH 2 COO--M + in which R is a C 8 -C 22 -alkyl, k is a number from 0 to 10 and M is a cation which forms a soluble salt. Resin acids or hydrogenated resin acids, such as rosin or tall oil resins and tall oil resin acids can also be used.
Zwitterionic surfactants which can be used in the novel process are, in quite general terms, aliphatic secondary or tertiary amines having a linear or branched C 8 -C 18 -alkyl radical and which contain an anionic, water-soluble group, such as, for example, a carboxyl, sulfonate, sulfate, phosphate or phosphonate group.
Typical examples of zwitterionic surfactants are alkylbetaines, alkylamidobetaines, aminopropionates, aminoglycinates or amphoteric compounds of the formula
R.sup.1 CONR.sup.4 (CH.sub.2).sub.n N.sup.⊕ R.sup.2 R.sup.3 CH.sub.2 ZX.sup.⊖
in which R 1 is C 8 -C 22 -alkyl or -alkenyl, R 2 is hydrogen or CH 2 CO 2 M, R 3 is CH 2 CH 2 OH or CH 2 CH 2 OCH 2 COOM, R 4 is hydrogen, CH 2 CH 2 OH or CH 2 CH 2 COOM, Z is CO 2 M or CH 2 CO 2 M, n is 2 or 3, preferably 2, M is hydrogen or a cation, such as alkali metal, alkaline earth metal, ammonia or alkanolammonium.
Preferred zwitterionic surfactants of this formula are monocarboxylates and dicarboxylates. Examples thereof are cocoamphocarboxypropionate, cocoamidocarboxypropionic acid, cocoamphocarboxyglycinate (also referred to as cocoamphodiacetate) and cocoamphoacetate.
Further preferred zwitterionic surfactants are alkyldimethylbetaines and alkyldipolyethoxybetaines containing an alkyl radical which may be linear or branched having from about 8 to about 22 carbon atoms, preferably having from 8 to 18 carbon atoms and particularly preferably having from about 12 to about 18 carbon atoms. These compounds are marketed, for example by Clariant AG under the trade name ®Genagen LAB.
Of all the abovementioned surfactants, the acylglutamates, in particular cocoylglutamate, alkyl ether sulfate, in particular lauryl ether sulfate, and alkylamidopropylbetaines, in particular cocoamidopropylbetaine, are preferred. It is also preferable to use a mixture of different surfactants.
EXAMPLE 1
Preparation of Disodium C 12 -acylglutamate
440 g of water, 196.7 g of monosodium glutamate, 128.5 g of 33% strength sodium hydroxide solution and 102.5 g of ®Genapol LRO (liquid) are cooled to from 10 to 20° C. in a reactor which has been rendered inert using N 2 . In the course of 8 hours, 245.9 g of lauryl fatty acid chloride and simultaneously from 120 g to 130 g of 33% strength sodium hydroxide solution are added dropwise using a metering pump. Throughout the reaction period, the pH must be maintained at from 12.2 to 12.6. In addition, the temperature of the reaction mixture during the metering phase must be between 10 and 20° C. In the subsequent stirring period (about 2 h) NaOH is added to adjust the pH to a value between 11.0 and 12.0. Cooling to from 10 to 20° C. is no longer necessary in the subsequent stirring period. At the end of the subsequent stirring period, the reaction product is heated to 60° C. and adjusted to a pH of from 9 to 10 using hydrochloric acid.
EXAMPLE 2
Preparation of Disodium C 12 -C 18 -cocoylglutamate
440 g of water, 196.7 g of monosodium glutamate, 128.5 g of 33% strength sodium hydroxide solution and 102.5 g of ®Genapol LRO (liquid) are cooled to from 10 to 20° C. in a reactor which has been rendered inert using N 2 . In the course of 8 hours, 252.3 g of coconut fatty acid chloride and simultaneously from 120 g to 130 g of 33% strength sodium hydroxide solution are added dropwise using a metering pump. Throughout the reaction period, the pH must be maintained at from 12.2 to 12.6. In addition, the temperature of the reaction mixture during the metering phase must be between 10 and 20° C. In the subsequent stirring period (about 2 h) NaOH is added to adjust the pH to a value between 11.0 and 12.0. At the end of the subsequent stirring period, the reaction product is heated to 60° C. and adjusted to a pH of from 9 to 10 using hydrochloric acid.
EXAMPLE 3
Preparation of Disodium C 12 -C 18 -cocoylglutamate
440 g of water, 196.7 g of monosodium glutamate, 128.5 g of 33% strength sodium hydroxide solution and 120.4 g of ®Hostapon KCG are cooled to from 10 to 20° C. in a reactor which has been rendered inert using N 2 . In the course of 8 hours, 252.3 g of C 12 -C 18 -coconut fatty acid chloride and simultaneously from 120 g to 130 g of 33% strength sodium hydroxide solution are added dropwise using a metering pump. Throughout the reaction period, the pH must be maintained at from 12.2 to 12.6. In addition, the temperature of the reaction mixture during the metering phase must be between 10 and 20° C. In the subsequent stirring period (about 2 h) NaOH is added to adjust the pH to a value between 11.0 and 12.0. At the end of the subsequent stirring period, the reaction product is heated to 60° C. and adjusted to a pH of from 9 to 10 using hydrochloric acid.
EXAMPLE 4
Preparation of Disodium C 10 -acylglutamate
440 g of water, 196.7 g of monosodium glutamate, 128.5 g of 33% strength sodium hydroxide solution and 115.5 g of ®Genagen CAB are cooled to from 10 to 20° C. in a reactor which has been rendered inert using N 2 . In the course of 8 hours, 216.3 g of decanoyl chloride and simultaneously from 120 g to 130 g of 33% strength sodium hydroxide solution are added dropwise using a metering pump. Throughout the reaction period, the pH must be maintained at from 12.2 to 12.6. In addition, the temperature of the reaction mixture during the metering phase must be between 10 and 20° C. In the subsequent stirring period (about 2 h) NaOH is added to adjust the pH to a value between 11.0 and 12.0. At the end of the subsequent stirring period, the reaction product is heated to 60° C. and adjusted to a pH of from 9 to 10 using hydrochloric acid.
EXAMPLE 5
Preparation of Disodium C 12 -C 14 -cocoylglutamate
440 g of water, 196.7 g of monosodium glutamate, 128.5 g of 33% strength sodium hydroxide solution and 102.5 g of Genapol LRO, liquid are cooled to from 10 to 20° C. in a reactor which has been rendered inert using N 2 . In the course of 8 hours, 249.5 g of C 12 -C 14 -coconut fatty acid chloride and simultaneously from 120 g to 130 g of 33% strength sodium hydroxide solution are added dropwise using a metering pump. Throughout the reaction period, the pH must be maintained at from 12.2 to 12.6. In addition, the temperature of the reaction mixture during the metering phase must be between 10 and 20° C. In the subsequent stirring period (about 2 h) NaOH is added to set a pH between 11.0 and 12.0. At the end of the subsequent stirring period, the reaction product is heated to 60° C. and adjusted to a pH of from 9 to 10 using hydrochloric acid.
Chemical names of the tradenames
______________________________________Genapol LRO, liquid 27.0% of a sodium C.sub.12 -C.sub.14 -alkyldiglycol ether sulfate in water, Clariant GmbH Hostapon KCG 25% of monosodium acylglutamate in water, Clariant GmbH Genagen CAB 30% of cocoamidopropylbetaine, Clariant GmbH______________________________________
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Process for the preparation of acylglutamate solutions by reaction of a glutamic acid salt with an acid chloride in water and in the presence of an anionic or zwitterionic surfactant.
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FIELD OF THE INVENTION
[0001] The invention relates to a roll shade that is configured to be converted between motorized and manual operation. Specifically, the invention relates to a roll shade that is configured to be easily converted between motorized and manual operation including conversion after installation.
BACKGROUND OF THE INVENTION
[0002] A roller shade is a rectangular panel of fabric, or other material, that is attached to a cylindrical, rotating tube. The shade tube is mounted near a header of a window or door such that the shade rolls up upon itself as the shade tube rotates in one direction, and rolls down to cover a desired portion of the window or door when the shade tube is rotated in the opposite direction. Typically roller shades are either manual roller shades or motorized roller shades.
[0003] When the roller shade is a manual roller shade, a counter-balance mechanism, clutch type manual operation system and/or the like is used to operate the roller shade. This system allows a user to roll the shade down and be able to maintain the shade down to cover a desired portion of the window or door when the shade is pulled down by a user. The system further allows the user to operate the shade such that it rotates in the opposite direction by the manual system so that the shade rolls up upon itself.
[0004] When the roller shade is a motorized system, rotation of the roller shade is accomplished with an electric motor that is coupled to the shade tube. The roller shade may be battery-powered to provide installation flexibility by removing the requirement to connect the motor and control electronics to facility power. The batteries for these roller shades are typically mounted within, above, or adjacent to the shade mounting bracket, headrail or fascia. The motor may be located inside or outside the shade tube, may be fixed to the roller shade support and may be connected to a simple switch. In more sophisticated applications a radio frequency (RF) based system controls the activation of the motor and the rotation of the shade tube. The roller shade typically may include a counter-balance mechanism, such as counter-balance springs, that counter-balance the weight of the shade.
[0005] The typical housing for the roller shade is designed either for a manual operation system or a motorized system. The typical manual system cannot be easily removed and replaced with a motor assembly and power source and vice versa without the use of tools, fasteners, controller, wiring, structural modifications, extensive labor and/or the like.
[0006] Accordingly, there is a need for a shade that can be configured to be easily converted between motorized and manual operation, including conversion after installation, and does not greatly increase manufacturing complexity and maintenance.
SUMMARY OF THE INVENTION
[0007] Aspects of the invention advantageously provide a motorized roller shade that includes a roller shade tube including an outer surface, an inner surface defining an inner cavity, and two end portions, a shade attached to the outer surface of the roller shade tube, a counterbalancing unit configured to provide a counterbalancing force to the shade, and the roller shade tube further comprising substitution configurations to allow the roller shade tube to receive and operate with either a motor assembly or a manual operation assembly.
[0008] Further aspects of the invention advantageously provide a motorized roller shade that includes a roller shade tube including an outer surface, an inner surface defining an inner cavity, and two end portions, a shade attached to the outer surface of the roller shade tube, a counterbalancing unit configured to provide a counterbalancing force to the shade, and substitution configurations associated with the roller shade in order to allow either a motor assembly or a manual operation assembly to move the shade.
[0009] Additional aspects of the invention advantageously provide a motorized roller shade that includes a roller shade tube including an outer surface, an inner surface defining an inner cavity, and two end portions, a shade attached to the outer surface of the roller shade tube, a counterbalancing unit configured to provide a counterbalancing force to the shade, the roller shade tube further comprising substitution configurations to allow the roller shade tube to receive and operate with either a motor assembly or a manual operation assembly, wherein the substitution configurations comprise a roller shade tube feature associated with the roller shade tube and at least one of a motor assembly feature and a manual operation assembly feature are configured to interact with one another to form a mechanical connection, and wherein the substitution configurations further comprise at least one of the motor assembly configured to be self-contained and the manual operation assembly configured to be self-contained.
[0010] There has thus been outlined, rather broadly, certain aspects of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the invention that will be described below and which will form the subject matter of the claims appended hereto.
[0011] In this respect, before explaining at least one aspect 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 aspects in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0012] 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 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 invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an aspect of a roll shade assembly constructed in accordance with aspects of the invention.
[0014] FIG. 2 is a perspective view of FIG. 1 showing the roll shade separated from the storage roll assembly and the mounting brackets.
[0015] FIG. 3 is a perspective view of the storage roll implemented with a manual configuration with the counterbalance spring and manual control assemblies removed in accordance with aspects of the invention.
[0016] FIG. 4 is a perspective view of the storage roll with the manual control assembly replaced by the motorized control assembly constructed in accordance with aspects of the invention.
[0017] FIG. 5 is an exploded perspective view of the manual control assembly constructed in accordance with aspects of the invention.
[0018] FIG. 6 is an exploded perspective view of the motorized control assembly constructed in accordance with aspects of the invention.
DETAILED DESCRIPTION
[0019] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. The term “shade” as used herein describes any flexible material, such as a shade, a curtain, a screen, etc., that can be deployed from, and retrieved onto, a storage tube or similar structure.
[0020] Generally, the invention relates to a roll type window or door covering system where the coverings are designed to be deployed and stored as part of a manually operated roll shade system having a counterbalanced suspension system. More importantly the window or door covering system is configured to receive a motorized actuator and a power source that can be added or removed at any time after the initial purchase and/or installation to allow motorized operation to control the roller shade. The housing for the window or door covering system is designed such that clutch type manual operation system can be removed and replaced with a motor assembly and power source without the need for tools or fasteners and the power source may be connected to the controller without the need for additional wiring.
[0021] There are a number of different approaches to motorized window or door coverings where the coverings, such as a blind or shade, have one or more of an actuator within a housing that holds a gear-reduced motor, a control signal receiver and generator, a counterbalance system, and at least one DC battery where a rotor of the motor is coupled to at least one shaft for raising and lowering the blind or shade to control the amount of solar gain or privacy. In some applications, a control signal generator may generate a control signal for completing the electrical circuit between the battery and the motor. The control signal can be generated in response to a predetermined amount of daylight or in response to a user-generated remote command signal. The actuator can be used to open or close the shade or blind.
[0022] In the majority of these cases, the motor and power supply, whether battery or line voltage, is designed into the construction of the unit such that one would need to decide whether to purchase a motorized unit or a manual. Further, not all products have motorized capability. One may have to choose a motorized unit from one manufacturer and a manual unit from another manufacturer if they want both types of products. This is less than desirable as many times the products from different manufacturers do not match in appearance.
[0023] The invention is a window or door covering system that may be purchased and installed as a manually operated cordless system and has the capability to easily add a motorized actuator and power supply at a later date; or may be purchased and installed as a motorized system and has the capability to easily modified to be a manual system at a later date. The invention has many benefits including: allowing the window covering unit to be motorized at the factory or any time after installation by installing a motor assembly and power supply; the window covering system can be purchased as a manually operated system and can be easily and quickly upgraded to a motorized system by inserting a motor unit and batteries; the motor unit and power supply can be quickly and easily moved from one window covering system to another window covering system as desired; the motor unit contains the motor controls and an RF receiver for remote control of the window covering system to which it is attached; a motorized shade may be easily converted to a manual shade; and so on.
[0024] The advantages of the invention over the prior art may include one or more of: a user can purchase either manually operated or motorized covering systems as needed or can afford and can add or change the system's operational features as needed; a motor and power supply may be removed from one unit and placed into another unit in the field quickly and easily; a user can motorize a unit with RF controls; the invention may not require wiring the unit internally or externally; the invention does not require modifications to the components or additional fasteners to convert from manual to motorized operation; and with the shade being counterbalanced one motor size can be used for multiple size shades.
[0025] FIG. 1 is a perspective view of an aspect of a roll shade assembly constructed in accordance with aspects of the invention; and FIG. 2 is a perspective view of FIG. 1 showing the roll shade separated from the storage roll assembly and the mounting brackets. In particular, the roller shade assembly 1 may include a storage roll assembly 5 having a roll shade 4 attached to and wound around the storage roll assembly 5 . The storage roll assembly 5 may include a shaft 3 on each end thereof (only one is shown). The storage roll assembly 5 and the roll shade 4 may be supported adjacent a window or door by the shafts 3 held in end brackets 2 . The end brackets 2 may be attached to structure associated with the window or door. There can also be valances and other coverings as known in the art (not shown) but associated with the roller shade assembly 1 . The roller shade assembly 1 may be implemented with a manual control configuration or a motorized control configuration. Moreover, the roller shade assembly 1 may be implemented with a configuration to allow conversion between manual control and motorized control as described in greater detail below.
[0026] FIG. 3 is a perspective view of the storage roll implemented with a manual configuration with the counterbalance spring and manual control assemblies removed in accordance with aspects of the invention. In the manual control configuration, the storage roll assembly 5 may include a roll tube 32 , a manual control system 6 , and a counterbalance system 7 . The manual control system 6 may include a clutch that may be mechanically coupled to the shaft 3 . The counterbalance system 7 may include one or more springs that may be mechanically coupled to the shaft 3 (not shown).
[0027] FIG. 4 is a perspective view of the storage roll with the manual control assembly replaced by the motorized control assembly constructed in accordance with aspects of the invention. With respect to FIG. 4 , the manual control assembly 6 may be replaced with a motorized control assembly 8 if motorized control of the roll shade assembly 1 is desired.
[0028] One or more of the roll tube 32 , the manual control system 6 , the counterbalance system 7 , and the motorized control assembly 8 may include assembly configurations to allow the roll tube 32 to firmly hold the manual control system 6 , the counterbalance system 7 , and the motorized control assembly 8 in at least one of an axial direction along the roll tube 32 and a radial direction with respect to the roll tube 32 . Furthermore, the assembly configurations allow the roll tube 32 to release at least the manual control system 6 for replacement with the motorized control assembly 8 without the use of tools, fasteners, controller, wiring, structural modifications, extensive labor and/or the like.
[0029] As shown in FIG. 3 and FIG. 4 , the assembly configurations on the roll tube 32 may include at least one groove 10 extending along the inner surface of the roll tube 32 . The assembly configurations on the manual control system 6 , the counterbalance system 7 , and the motorized control assembly 8 may include at least one protrusion 11 mated to fit in the groove 10 of the roll tube 32 . The assembly configurations may include any type of component to hold the components together including a slot, a groove, a ring, a lip, an edge, a hole, a slit, a fastener, a clasp, a clip, a catch, a hook, a protrusion, and the like. These assembly constructions prevent the manual control system 6 , the counterbalance system 7 , and the motorized control assembly 8 from rotating within the roll tube 32 . In this regard, the assembly configurations may allow for the construction of these components of the roller shade assembly 1 or the removal of these components of the roller shade assembly 1 without the use of tools, fasteners, wiring, structural modifications, extensive labor and/or the like.
[0030] End caps 34 of the manual control system 6 , the counterbalance system 7 , and the motorized control assembly 8 may also have assembly configurations to hold end caps 34 with respect to the roll tube 32 . In this regard, the assembly configurations of the end caps 34 may have a raised ring 31 to limit the depth the assemblies 6 , 7 and 8 can be inserted into the roll tube 32 . Although specific implementations of the assembly configurations are shown in FIG. 3 and FIG. 4 described above, it is within the scope and spirit of the invention to have other possible assembly configurations. For example, the assembly configurations may include any type of component to hold the components including a slot, a groove, a ring, a lip, an edge, a hole, a slit, a fastener, a clasp, a clip, a catch, a hook, a protrusion and the like.
[0031] The output shaft 3 of the manual control system 6 may have a configuration 33 such that when the configuration 33 is mated with the slot 34 in the end bracket 2 it may be prevented from turning. The output shaft 3 may be round and allowed to turn in the end bracket 2 . Further, there may be a similar arrangement for the output shaft 3 (not shown) of the counterbalance spring assembly 7 .
[0032] Each of the manual control system 6 , the counterbalance system 7 , and motorized control assembly 8 may also include a self-containment configuration. The self-containment configuration allows the entire system (manual control system 6 , the counterbalance system 7 , or motorized control assembly 8 ) to be removed from the roller shade assembly 1 as a complete unit. This unit may have all the components to operate. The self-containment configuration with the assembly configurations further simplifies conversion between motorized and manual operation.
[0033] In this regard, the manual control assembly 6 may removed by lifting the roll shade 4 and storage roll 5 out of the brackets 2 and sliding the manual control assembly 6 out of the roll shade assembly 1 . The assembly configurations and/or self-containment configuration described above make the removal process straightforward in that moving the manual control assembly 6 in a direction parallel with the groove 10 and at least one protrusion 11 allows the manual control assembly 6 and the roll tube 32 to be separated.
[0034] Once the manual control assembly 6 is out of the roll tube 32 , the motorized control assembly 8 and the power source 9 can then be inserted into the roll tube 32 . In a similar manner, the assembly configurations and/or self-containment configuration described above make the insertion and assembly process straightforward in that moving the motor control assembly 8 in a direction parallel with the groove 10 and at least one protrusion 11 allows the motor control assembly 8 and the roll tube 32 to be assembled.
[0035] After the motor control assembly 8 and the roll tube 32 are assembled, the storage roll 5 with the roll shade 5 can be placed back in the brackets 2 and the roller shade assembly is now motorized. This process may be reversed to change from motorized operation to manual operation.
[0036] The motorized control assembly 8 may also contain motor controls and a RF receiver on a control board assembly 30 (shown in FIG. 6 ). With the shade being counterbalanced, the motorizing of the shade assembly 1 may not be greatly affected by the weight or size of the shade therefore one motor size can be used interchangeably for all size shades.
[0037] FIG. 5 is an exploded perspective view of the manual control assembly constructed in accordance with aspects of the invention. In particular, as shown in FIG. 5 , the manual control assembly 6 may include a counter-counterbalanced spring 17 arranged in a spring case 35 , bearing housings 13 and shaft housings 12 . The spring case 35 may have protrusions 11 that fit into the grooves 10 of the roll tube 32 . Similar protrusions 11 may be arranged on the bearing housings 13 and the shaft housings 12 .
[0038] Another end of the spring 17 may be secured to a shaft 21 . The shaft 21 may be arranged on a spindle 22 and located by the lock collar 20 . A connector 14 may connect the shaft 21 to the drive shaft 3 . The spring case 35 may include an end portion 19 and a spacer portion 18 . A dampener 15 may also be implemented to regulate the movement of the tube 32 allowing a smooth operation and will hold the shade in any position.
[0039] FIG. 6 is an exploded perspective view of the motorized control assembly constructed in accordance with aspects of the invention. In particular, the shade or blind can become motorized as noted above. FIG. 6 shows an implementation of the motorized control assembly 8 that may include a bearing housing 23 with bearings 18 and a spacer 24 . A clip 25 may be arranged to mechanically hold various components.
[0040] The drive shaft 3 may extend through a housing 26 and be attached to the motor 27 . Adjacent the motor 27 may be motor controls 30 and the motor control cover 29 . The connection between the motor 27 and the motor controls 30 is shown at 28 . The power source 9 that may include batteries in a separate tube. Portions of the motorized control assembly 8 may include protrusions 11 that fit into the grooves 10 of the roll tube 32 .
[0041] Although the above is a specific implementation of the manual control assembly 6 and the motorized control assembly 8 , it is within the scope and spirit to have other implementations.
[0042] Accordingly, the shade of the invention as described above in the various exemplary aspects associated with the drawings and broader applications described above can address many size applications without greatly increasing costs and parts inventory and not greatly increasing manufacturing complexity and maintenance.
[0043] The motorized roller shade assembly may include other components such as an electrical power connector that includes a terminal that couples to a power supply unit, and power cables that may connect to the circuit board(s) located within the circuit board housing.
[0044] In some aspects, two circuit boards may be mounted within the circuit board housing in an orthogonal relationship. Circuit boards generally include all of the supporting circuitry and electronic components necessary to sense and control the operation of the motor, manage and/or condition the power provided by the power supply unit, etc., including, for example, a controller or microcontroller, memory, a wireless receiver, etc. In one aspect, the microcontroller is a Microchip 8-bit microcontroller, such as the PIC18F25K20, while the wireless receiver is a Micrel QwikRadio® receiver, such as the MICRF219. The microcontroller may be coupled to the wireless receiver using a local processor bus, a serial bus, a serial peripheral interface, etc. In another aspect, the wireless receiver and microcontroller may be integrated into a single chip, such as, for example, the Zensys ZW0201 Z-Wave Single Chip, etc. In another aspect, a wireless transmitter is also provided, and information relating to the status, performance, etc., of the motorized roller shade may be transmitted periodically to a wireless diagnostic device, or, preferably, in response to a specific query from the wireless diagnostic device.
[0045] The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.
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There is provided a motorized roller shade that includes a roller shade tube including an outer surface, an inner surface defining an inner cavity, and two end portions. The motorized shade further includes a shade attached to the outer surface of the roller shade tube, a counterbalancing unit configured to provide a counterbalancing force to the shade, and the roller shade tube further comprising substitution configurations to allow the roller shade tube to receive and operate with either a motor assembly or a manual operation assembly.
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RELATED U.S. APPLICATION DATA
[0001] This application claims priority from U.S. Provisional Patent Application No. 60/422,330 filed Oct. 30, 2002, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to surgical tools and procedures generally and relates more particularly to the use of electrosurgical ablation to treat atrial fibrillation.
[0003] In patients with chronic atrial fibrillation or having atrial tachycardia that is resistant to medical treatment, the Maze III procedure has been employed. This procedure controls propagation of the depolarization wavefronts in the right and left atria by means of surgical incisions through the walls of the right and left atria. The incisions create blind or dead end conduction pathways, which prevent re-entrant atrial tachycardias from occurring. While the Maze procedure is successful in treating atrial fibrillation, the procedure is quite complex and is currently practiced by only a few very skilled cardiac physicians in conjunction with other open-heart procedures. The procedure also is quite traumatic to the heart, as in essence the right and left atria are cut into pieces and sewed back together, to define lines of lesion across which the depolarization wavefronts will not propagate.
[0004] It has been suggested that procedures similar to the Maze procedure could be instead performed by means of electrosurgical ablation, for example, by applying radiofrequency (RF) energy to internal or external surfaces of the atria to create lesions across which the depolarization wavefronts will not propagate. Such procedures are disclosed in U.S. Pat. No. 5,895,417, issued to Pomeranz, et al., U.S. Pat. No. 5,575,766, issued to Swartz, et al., U.S. Pat. No. 6,032,077, issued to Pomeranz, U.S. Pat. No. 6,142,944, issued to Swanson, et al., U.S. Pat. No. 5,871,523, issued to Fleischman, et al. and U.S. Pat. No. 6,502,575, issued to Jacobs et al., all incorporated herein by reference in their entireties. Hemostat type, electrosurgical or cryo-ablation devices for use in performing such procedures are described in U.S. Pat. No. 5,733,280 issued to Avitall, U.S. Pat. No. 6,237,605 issued to Vaska, et al, U.S. Pat. No. 6,161,543, issued to Cox, et al., PCT published Application No. WO99/59486, by Wang and in pending U.S. patent application Ser. No. 09/747,609 filed Dec. 22, 2000 by Hooven, et al., all incorporated herein by reference in their entireties. In order for such procedures to be effective it is desirable that the electrosurgically created lesions are continuous along their length and extend completely through the tissue of the heart (i.e. transmural lesions). These goals may be difficult to accomplish employing dry ablation electrodes or electrodes applied only to the interior or exterior surfaces of the heart tissue. Electrosurgical hemostats configured to allow fluid—assisted tissue ablation are generally described in U.S. Pat. No. 6,096,037, issued to Mulier, also incorporated by reference in its entirety.
SUMMARY OF THE INVENTION
[0005] The present invention provides an ablation hemostat, particularly useful in performing a maze type procedure by applying ablation energy (e.g. RF energy) across the walls of the left and right atria by means of delivery means located on either side of the atrial walls. In a preferred embodiment of the invention, the hemostat is provided with elongated RF electrodes malleable to assume various straight and curved configurations to produce lesions that approximate the incisions that would occur during the Maze III procedure as described in the book ‘ Cardiac Surgery Operative Technique’ by Donald B. Doty, M. D. at pages 410-419, incorporated herein by reference in its entirety, or to allow creation of lines of lesion corresponding to the incisions that would be provided by other forms of the Maze procedure. The hemostat may be useful in conjunction with other procedures as well.
[0006] The hemostat of the present invention is provided with a number of useful features, particularly adapted to ease its use in conjunction with creating elongated lines of lesion. While the disclosed and most preferred embodiments of the invention employ all of the improved features, each of the improved features discussed below is believed valuable in and of itself to improve the performance and ease of use of prior art electrosurgical hemostats.
[0007] In order to allow the hemostat to produce straight and curved elongated lesions, the jaws of the hemostat are malleable to allow the physician to set the specific jaw configuration. The jaws are fabricated of a flexible plastic sheath enclosing elongated bendable or malleable backbones and electrodes to achieve this result. The backbones and electrodes may be shaped by the physicians' fingers into a desired curvature and serve to retain the curvature imparted to them until reshaped for creation of a subsequent lesion. The backbones take the form of elongated plates having thicknesses substantially less than their widths to encourage bending of the jaws within a single plane so that the opposed electrodes can more readily be maintained in alignment along their lengths. The backbones are also preferably tapered along their length such that the width of the backbones diminishes as they approach the tips of the jaws, in turn making it easier to provide the jaws with the curvature extending over the entire length of the jaws.
[0008] The hemostat includes an elongated handle portion or handle and a jaw assembly mounted at the distal end of the handle. The jaw assembly preferably includes two elongated jaws carrying RF electrodes or other ablation elements, extending along the lengths of the jaws and arranged so that they are located on opposite sides of tissue compressed between the jaws. In preferred embodiments, the electrodes take the form of fluid irrigated RF electrodes, however, other ablation mechanisms such as cyroablation, direct current ablation, microwave ablation, and the like may be substituted for RF ablation electrodes.
[0009] The jaw assembly preferably includes a swiveling head assembly adapted to allow the jaws to be rotated relative to the axis of the handle (roll) and allowing the jaws to pivot around an axis perpendicular to the axis of the handle (pitch). Adjustment of the jaws relative to the handle (pitch and roll) is made manually by the physician, and the jaws are retained in their desired orientation relative to the handle by means of detent mechanisms.
[0010] The jaws are mounted to one another at a pivot point and are opened and closed by means of a trigger, mounted to the handle, which applies tensile force to a cable or other tension member extending along the handle. The cable, when pulled, pulls the jaws toward one another to compress tissue between them. In the particular embodiments disclosed, the cable is anchored offset from the pivot point to a first one of the jaws. The first jaw is fixed, i.e. retains its location during jaw closure regardless of the pitch and roll adjustment made to the jaw assembly. The second, pivoting jaw, is mounted to the fixed jaw at a pivot point and the cable passes around an internal boss within the pivoting jaw, also offset from the pivot point. Application of tension to the tension member pulls the internal boss in the pivoting jaw toward the cable mounting point in the fixed jaw and thereby causes movement of the jaws toward one another. Tissue placed between the jaws can thus be engaged by the jaws and compressed between the jaws as the jaws close.
[0011] The cable enters the jaw assembly along its rotational (roll) axis, so that rotation of the jaw assembly about the roll axis does not alter the operation of the cable. The cable extends around a shoulder internal to the fixed jaw, which shoulder remains essentially in the same location regardless of the pitch adjustment of the jaw assembly, so that pitch adjustment of the jaw assembly does not significantly effect operation of the cable to close the jaws.
[0012] In preferred embodiments, the trigger mechanism is provided with a locking detent mechanism which may be engaged or disengaged and which, when engaged, retains the trigger in its position, in turn maintaining compression of the jaws against tissue located there between. The detent mechanism in a preferred embodiment is activated or deactivated by means of a sliding button, mounted to the handle.
[0013] In preferred embodiments, irrigation fluid is provided to the electrodes by means of plastic tubing that is provided with in-line flow limiters, controlling the delivery rate of irrigation fluid to the electrodes. This feature allows the use of a simplified fluid pumping mechanism and also provides balanced, even fluid flow to the electrodes. In its preferred embodiment, the trigger, when released, also serves to block fluid flow to the electrodes, preventing irrigation while the hemostat is not in use.
[0014] In one embodiment, the RF electrode assembly can take the form of an elongated porous material coupled to the fluid delivery lines and carrying elongated electrode wires on their inner, facing services. The electrode wires may be coupled to the porous material by means of a series of spikes extending from the electrode wires into the porous material. Other alternative electrode designs may of course be substituted, including electrodes comprised of elongated coil electrodes or perforated tubular electrodes with porous material located either inside of or surrounding the electrodes. For example, a perforated tubular electrode can be seated inside a porous polymeric support such the electrode is entirely within the support. In this embodiment, conductive fluid flows through the interior of the electrode, out of perforations in the electrode and through the porous support to facilitate ablation such that the polymeric support, not the electrode, is on the facing surfaces of the jaws to contact the tissue to be ablated.
[0015] The hemostat may optionally also include a thermocouple, located along the jaws allowing for temperature controlled feedback of power provided to the RF electrodes and may also preferably includes an indicator LED mounted to the handle, activated to indicate that delivery of RF energy is underway. The hemostat is usable useable with conventional RF generators. Alternatively, the hemostat may be used in conjunction with an RF generator system, which incorporates a transmurality measurement and automatic shut off of ablation energy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a plan view of an assembled hemostat according to one embodiment of the present invention.
[0017] [0017]FIG. 2 is an exploded view of the jaw assembly of the hemostat of FIG. 1.
[0018] [0018]FIG. 3A is a cross-section view through the jaw assembly of the hemostat of FIG. 1.
[0019] [0019]FIG. 3B is a cross-section view through lines 3 B- 3 B of FIG. 3A.
[0020] [0020]FIG. 4 is an end view in partial cross-section of the proximal end of the knuckle portion of the jaw assembly of the hemostat of FIG. 1.
[0021] [0021]FIG. 5A is a plan view of an elongated tubular electrode used in the hemostat of FIG. 1.
[0022] [0022]FIG. 5B is an enlarged cross-section view taken along lines 5 B- 5 B of the electrode illustrated in FIG. 5A.
[0023] [0023]FIG. 6A is an end view of an electrode support as used in the jaw assembly of the hemostat of FIG. 1.
[0024] [0024]FIG. 6B is a cross-section view taken along lines 6 A- 6 A of FIG. 6A illustrating the electrode support.
[0025] [0025]FIG. 7A is an end view of an electrode sheath as included in the jaw assembly of the hemostat of FIG. 1.
[0026] [0026]FIG. 7B is a cross-section view taken along lines 7 B- 7 B of FIG. 7A illustrating the electrode sheath.
[0027] [0027]FIG. 8A is a plan view of the right half of the handle employed in the hemostat of FIG. 1.
[0028] [0028]FIG. 8B is an enlarged plan view of the distal portion of the right handle half illustrated in FIG. 8A.
[0029] [0029]FIG. 8C is a cross-section view taken along lines 8 C- 8 C through the right handle half of the hemostat of FIG. 1.
[0030] [0030]FIG. 9A is a plan view of the left half of the handle employed in the hemostat of FIG. 1.
[0031] [0031]FIG. 9B is an enlarged plan view of the distal portion of the left handle half illustrated in FIG. 9A.
[0032] [0032]FIG. 9C is a cross-section view taken along lines 9 C- 9 C through the left handle half of the hemostat of FIG. 1.
[0033] [0033]FIG. 10 is an enlarged view of the trigger portion of a hemostat as in FIG. 1 with the left handle half removed.
[0034] [0034]FIG. 11A is a perspective view of a trigger lock as employed in the trigger assembly of the hemostat as in FIG. 1.
[0035] [0035]FIG. 11B is a plan view of the trigger lock of FIG. 11A.
[0036] [0036]FIG. 12A is a top plan view of a link arm as employed in the trigger assembly of an assembled hemostat as in FIG. 1.
[0037] [0037]FIG. 12B is a side plan view of the link arm of FIG. 12A.
[0038] [0038]FIG. 13A is a side plan view from the distal end of the trigger employed in the trigger assembly of the hemostat of FIG. 1.
[0039] [0039]FIG. 13B is a cross-section view taken along lines 13 B- 13 B through the trigger of FIG. 13A.
[0040] [0040]FIG. 14 is a cut-away view of the proximal portion of the hemostat of FIG. 1 with the left handle half removed.
[0041] [0041]FIG. 15A is a sectional view through an alternative embodiment of an upper and lower jaw for use with a hemostat otherwise as in FIG. 1.
[0042] [0042]FIG. 15B is a cross-sectional view taken along lines 15 B- 15 B of FIG. 15A.
[0043] [0043]FIG. 16A is a plan view of an electrode extension employed in the alternative embodiment of the upper and lower jaw depicted in FIGS. 15A and 15B.
[0044] [0044]FIG. 16B is an expanded view of a barb of the electrode extension depicted in FIG. 16A.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] In reference to FIG. 1, a preferred embodiment of the hemostat of the present invention generally comprises an elongated handle assembly or handle 10 having a jaw assembly 90 mounted at handle distal end 15 , a trigger 20 intermediate the handle proximal and distal ends 95 and 15 , and a strain relief 60 located at handle proximal end 95 . An elongated cable is coupled to the strain relief 60 and comprises a fluid conduit 70 extending to a proximal fluid fitting 75 adapted to be coupled to a source of conductive fluid and a multi-conductor electrical cable 80 extending to a proximal electrical connector 85 adapted to be coupled to an electrosurgical unit. The trigger 20 is employed to move the jaws of the first or lower jaw assembly 40 with respect to the second or upper jaw assembly 30 of the jaw assembly 90 together to compress tissue therebetween to allow for creation of a linear RF ablation by electrically conductive fluid emitted from electrodes and contacting tissue or direct contact of the electrodes located along the upper and lower jaws 35 and 45 .
[0046] The jaw assembly 90 includes the upper jaw assembly 30 , the lower jaw assembly 40 , and a swivel assembly 50 , discussed in more detail below. The upper jaw and lower jaw assemblies 30 and 40 have opposed upper and lower jaws 35 and 45 , respectively, each comprising a fluid assisted elongated electrode assembly. The upper and lower jaw assemblies 30 and 40 support elongated electrodes, discussed in more detail below, each coupled to one of the insulated conductors within conduit 70 extending proximately through the strain relief 60 to electrical connector 85 . Each of the jaws 35 and 40 of respective upper and lower jaw assemblies 30 and 40 are also coupled to fluid conduit 80 enabling delivery of saline or other conductive fluid from a source coupled to fitting 75 along the lengths of the opposed jaws 35 and 45 .
[0047] The swivel assembly 50 , provides the physician with the opportunity to position the jaw assembly 90 in a variety of orientations relative to the handle 10 , to facilitate placing the 35 and 45 jaws against tissue to form desired lines of lesions, e.g., the heart wall in performance of the above-described Maze procedure. The physician can manually grasp and rotate the swivel assembly 50 and the jaw assembly 90 to provide a roll adjustment R, preferably through an arc of at least 300 degrees, relative to the axis of the distal end 15 of the handle 10 through interaction of components of the handle and swivel assembly described further below. In addition, the physician can grasp the jaw assembly 90 and adjust it in pitch P relative to the swivel assembly 50 through the interaction of components of the jaw assembly 90 and the swivel assembly 50 described further below. Preferably, the available arc of pitch P adjustment extends over at least 90 degrees. Moreover, the upper and lower jaws 35 and 45 are malleable as described further below. The combination of these features and the S-shape handle 10 make the hemostat highly versatile in use.
[0048] The trigger 20 is employed to open (separate apart) and close (draw together) the jaws 35 and 45 and to compress tissue between the jaws 35 and 45 prior to application of RF energy to create an elongated lesion. A thumb slide 25 is provided in conjunction with an internal trigger lock, allowing the position of the trigger 20 and the jaws 35 , 45 to be locked. After the trigger 20 is drawn toward the handle 10 to close the jaws 35 and 45 , the thumb slide 25 is moved distally relative to the handle 10 to cause an internal trigger lock to engage one of a series of ratcheting-lock points that define a set of locking locations for the jaws 35 , 45 , as described further below. Movement of the thumb slide 25 proximally relative to the handle 10 releases the trigger 20 and the jaw assembly 90 , allowing the jaws 35 , 45 to return to a fully open position. The interaction of the trigger 20 , thumb slide 25 and the associated trigger lock mechanism frees the physician from the need to maintain pressure on the trigger 20 to compress tissue between the jaws 35 , 45 during the ablation, simplifying operation of the hemostat.
[0049] Referring to FIG. 2, the upper jaw assembly 30 includes a pivotable, relatively rigid, upper jaw mount 300 , an elongated backbone 310 , an elongated insulated electrode sheath 320 , an elongated conductive electrode 330 , and an elongated electrode support 340 . Upper jaw mount 300 may be fabricated of plastic or other insulated material, and in preferred embodiments may be fabricated of Teflon filled polycarbonate plastic. Backbone 310 is preferably fabricated of malleable stainless steel or other malleable metal and is attached at a proximal end to upper jaw mount 300 . An insulated electrode sheath 320 is fitted over spine 310 with its proximal end located adjacent upper jaw mount 300 . The elongated conductive electrode 330 comprises a length of malleable conductive metal tubing as shown in FIGS. 5A and 5B is fitted into a lumen of the elongated electrode support 340 . The insulated electrode sheath 320 is formed with a channel that receives the sub-assembly of the elongated conductive electrode 330 and electrode support 340 disposed along the jaw 35 . Electrode sheath 320 may be fabricated of a flexible, electrically insulating, material, for example, silicone rubber. Elongated electrode support 340 is preferably fabricated of a porous material, such as Porex™ plastic, allowing for conductive fluid infiltration through its sidewall along its length and correspondingly delivery of conductive fluid along the length of jaw 35 . The jaw 35 can therefore be bent laterally with respect to the upper jaw mount 300 to form a curve along the length thereof.
[0050] The lower jaw assembly 40 also includes a relatively rigid, lower jaw mount 400 , an elongated backbone 410 , an elongated insulated electrode sheath 420 , an elongated conductive electrode 430 , and an elongated electrode support 440 that are all formed of the same materials as the corresponding elements of the upper jaw assembly 30 . The assembly of the elongated backbone 410 , elongated insulated electrode sheath 420 , elongated conductive electrode 430 , and elongated electrode support 440 is also shown in FIG. 3B.
[0051] The jaw 45 can therefore also be bent laterally with respect to the lower jaw mount 400 to form a curve along the length thereof. In use, the physician manually forms a lateral curve in both the upper and lower jaws 35 and 45 to fit the contour of the tissue, e.g., the heart wall.
[0052] The lower jaw mount 400 is formed with a pair of spaced apart, parallel, plates or flanges 401 and 403 each bearing a series of notches 402 and 404 , respectively, along the edges thereof. When assembled, a proximal portion of the upper jaw mount 300 is fitted between the flanges 401 and 403 . A pin 480 extends through aligned holes through the proximal portion of upper jaw mount 300 and the flanges 401 and 403 . The ends of pin 480 are fixed to the flanges 401 and 403 allowing the proximal portion of the upper jaw mount 300 to be rotated about the pin 480 , thereby allowing jaws 35 and 45 to open and close. The upper and lower jaws 35 and 45 are separated apart a predetermined distance in the fully closed positions although the electrically insulated distal ends of the insulated electrode sheaths 320 and 420 may contact one another. A spring 450 urges the upper and lower jaws 35 and 45 apart from one another, facilitating opening of the jaws 35 and 45 upon release of the trigger 20 after application of RF energy.
[0053] As shown in FIGS. 2 and 3A, the swivel assembly 50 includes a swivel 500 that may also be fabricated of Teflon filled polycarbonate plastic to have a tubular proximal swivel portion 506 , a pair of parallel plates or flanges 502 and 504 extending distally from swivel proximal portion 506 and a extending detent 501 extending laterally between flanges 502 and 504 . The jaw assembly 90 is mounted to the swivel assembly 50 by outwardly and laterally extending bosses 405 on the outer surfaces of flanges 401 and 403 that are fitted into bores 503 through swivel flanges 502 and 504 . The upper jaw mount 300 is mounted to the lower jaw mount 400 by pin 480 as described above, and the lower jaw mount is 400 pivotably mounted relative to the swivel 500 . Therefore, the upper and lower jaw assemblies 30 and 40 may be pivoted together relative to the swivel 500 , allowing for movement of the jaws 35 and 45 together through the range of pitch P adjustment. The selected pitch P adjustment is maintained by the engagement of the detent 501 into an opposed pair of notches 402 and 404 , stabilizing the upper and lower jaws 35 and 45 in a desired orientation relative to the swivel assembly 50 . In use, the physician adjusts the relative positions of the jaws 35 and 45 relative to the swivel assembly 50 by simply manually moving the jaw assemblies 30 and 40 in the pitch P direction around the pivot axis defined by bosses 405 within the corresponding bores 505 in swivel flanges 502 and 504 . The detent 501 simply rides over the ridges separating adjacent notches 402 and 404 .
[0054] As noted above, the swivel assembly 50 and the upper and lower jaw assemblies 30 and 40 can be rotated around the axis of the distal end 15 of the handle 10 to a desired roll adjustment R to facilitate positioning the jaws 35 and 45 for creation of elongated lesions. The proximal portion 506 of swivel 500 is rotatably mounted within a collar 550 that is mounted fixedly to the distal end 15 of the handle 10 as shown in FIG. 3A. The collar 550 has a wavy or sinusoidal distally facing surface 551 of collar 550 . A washer-shaped insert 510 having a wavy or sinusoidal proximally facing surface 511 is fitted over the elongated proximal portion 506 of swivel 500 and attached to the swivel 500 through notches 514 , engaging corresponding bosses 557 and 567 (shown in FIG. 4) formed on swivel 500 . A C-clip 524 mounted in a circumferential groove formed in the proximal portion 506 of swivel 500 maintains the proximal portion 506 within the lumen of collar 550 . A spring washer 522 and a flat washer 520 are interposed between the C-clip 524 and the proximal end of collar 550 . Spring washer 522 urges the wavy or sinusoidal surfaces of collar 550 and insert 510 against one another, whereby a plurality of detent locations are defined that maintain a selected roll R adjustment relative to the distal end 15 of the handle 10 . In use, the physician adjusts the roll R of the jaw assembly 90 by simply turning the swivel assembly 50 relative to the handle 10 . The detent mechanism maintains the swivel assembly 50 in the selected desired roll R adjustment prior to and during closure of the jaws 35 , 45 to compress tissue during application of RF energy.
[0055] A cable 390 is also shown in FIGS. 3A and 4 that extends from the trigger 20 and that is employed to open and close the jaws 35 and 45 . Cable 390 passes through the internal lumen of proximal swivel portion 502 , through cable bore 565 , around shoulder 404 of lower jaw mount 400 , around boss 303 in upper jaw mount 300 and then upward into bore 408 in lower jaw mount 400 . The distal end of the cable 390 is maintained within bore 408 by ball 350 . When the cable 390 is pulled proximally by squeezing trigger 25 , boss 303 of upper jaw 300 is pulled toward bore 408 in lower jaw 400 , thereby pulling upper jaw 35 toward lower jaw 45 , allowing for compression of tissue there between. It should be noted that during this operation, the lower jaw mount 400 remains fixed relative to the swivel assembly 50 and only upper jaw mount 300 moves relative to the swivel assembly 50 or the handle 10 . Proximal movement of cable 380 does not affect the position of the lower jaw 45 relative to the handle 10 , nor does it affect the selected roll R adjustment of swivel 500 . Rotation of the jaw assembly 90 and swivel 500 about the roll axis does not affect the operation of the cable 390 because the cable 390 passes through the swivel 500 and enters the jaw assembly 90 along the roll axis. Pitch P adjustment of the jaw assembly 90 does not significantly effect operation of the cable 390 in opening or closing the jaws 35 , 45 because shoulder 404 is at the center of rotation of lower jaw mount 400 relative to swivel 500 and remains essentially in the same location regardless of the pitch P adjustment.
[0056] [0056]FIGS. 3A and 4 also internal electrical wiring and fluid delivery conduits of this embodiment of the invention including, insulated conductors 360 and 460 and fluid conduits 370 and 470 that both terminate at connections with the proximal ends of the upper and lower electrodes 330 and 430 , respectively. The fluid conduits 370 and 470 deliver conductive fluid into the lumens of the tubular upper and lower electrodes 330 and 430 , respectively. As shown in FIG. 4, the upper insulated conductor 360 and the upper fluid conduit 370 are routed to one side of the cable 390 , and the lower insulated conductor 460 and the lower fluid conduit 470 are routed to the other side of the cable 390 while passing through the lumen 534 .
[0057] The elongated tubular electrodes 330 and 430 are illustrated in FIGS. 5A and 5B. The tubular electrodes 330 and 430 are preferably formed of thin-walled, malleable stainless steel tubing extending between a proximal open end 331 , 431 and a distal closed end 333 , 433 . A series of fluid ports 335 , 435 are formed, e.g., by laser drilling, through the sidewall of the tubing from the lumen 339 , 439 and extending in a single line, although the fluid ports could be formed in any selected array extending around the circumference of the sidewall of the tubing. The proximal ends 331 , 431 are notched in alignment with the series of fluid ports 335 , 435 to assist in assembly so that the fluid ports 335 , 435 are directed in a particular alignment with the porous electrode support 340 , 440 .
[0058] The porous electrode support 340 , 440 , depicted in FIGS. 6A and 6B, comprises a length of non-conductive, porous, malleable tubing having a channeled side 343 , 443 adapted to fit within an elongated channel 323 , 423 of the insulated electrode sheath 320 , 420 , depicted in FIGS. 7A and 7B. The porous electrode support 340 , 440 is conically shaped at the support distal end 347 , 447 to fit within a conically shaped terminus 327 , 427 of the elongated channel 323 , 423 of the insulated electrode sheath 320 , 420 . During assembly, the elongated tubular electrode 330 , 430 is inserted into the elongated lumen 341 , 441 of the porous electrode support 340 , 440 . Preferably, the series of fluid ports 335 , 435 are oriented toward the channeled side 343 , 443 so that the conductive fluid emitted from the lumen through the series of fluid ports 335 , 435 then migrates laterally through the pores of the porous electrode support 340 , 440 and around its circumference to thoroughly and uniformly wet the porous electrode support 340 , 440 along the upper and lower jaws 35 and 45 .
[0059] The sub-assembly so formed is fitted into the shaped terminus 327 , 427 and the elongated channel 323 , 423 of the insulated electrode sheath 320 , 420 as also shown in FIGS. 3A and 3B. Adhesive is applied to the contacting surfaces 323 , 343 and 423 , 443 to maintain the sub-assembly of the elongated tubular electrode 330 , 430 inserted into the elongated lumen 341 , 441 of the porous electrode support 340 , 440 affixed to the insulated electrode sheath 320 , 420 . The adhesive does not block migration of conductive fluid around the porous electrode support 340 , 440 . Electrode sheathe 320 , 420 is also formed having an elongated tapered internal recess 421 441 that receives the malleable backbone 310 , 410 as shown in FIGS. 2 and 3. Again, adhesive may be applied to the contacting surfaces of the backbone 310 , 410 and the elongated tapered internal recess 421 441 .
[0060] The handle 10 is formed of a right handle half 600 depicted in FIGS. 8 A- 8 C and a left handle half 700 depicted in FIGS. 9 A- 9 C. Trigger sections 620 and 720 of the respective right and left handle halves 600 and 700 include downwardly opening recesses 621 and 721 in which trigger 20 is mounted (as shown in FIGS. 1 and 10) to pivot inward to apply tension on cable 390 or outward to release tension on cable 390 . Upward openings 627 and 727 in respective right and left handle halves 600 and 700 receive the thumb slide 25 . Inwardly extending projections 630 and 730 are also formed in respective right and left handle halves 600 and 700 that function to constrict the fluid conduits 370 and 470 to prevent conductive fluid flow therethrough when the trigger 20 is released as described further below.
[0061] A set of circular matching, laterally opposed, sockets 623 and 723 are formed in the interior surfaces of the respective right and left handle halves 600 and 700 . The set of sockets 623 , 723 , receive a pair of pivot bosses 206 , 206 ′ of trigger 20 (shown in FIG. 13A) about which the trigger 20 pivots as described further below. A set of matching, laterally opposed, and slightly elongated or oblong, sockets 624 and 724 are formed in the interior surfaces of the respective right and left handle halves 600 and 700 . The set of sockets 624 , 724 receive and guide a trigger lock 27 (shown in FIGS. 11A and 11B) that interacts with trigger 20 as described further below. The oblong shape of the set of sockets 624 , 724 assists in allowing the trigger 20 to ratchet along the trigger lock 27 when trigger is drawn inward to tension the cable 390 during closing of the jaws 35 , 45 as described further below.
[0062] A further set of matching, laterally opposed, elongated sockets 625 and 725 are also formed in the interior surfaces of the respective right and left handle halves 600 and 700 . The set of sockets 625 , 725 receive and guide a link arm 26 (shown in FIGS. 12A and 12B) that interacts with trigger 20 as described further below.
[0063] As shown in FIGS. 8B and 9B, the distal portions of right and left handle halves 600 and 700 are formed with internal cylindrical recesses or sockets 612 and 712 that receive the laterally extending bosses 552 of collar 550 (FIG. 2). Internal grooves 611 and 711 are also formed within the distal portions of right and left handle halves 600 and 700 in which the c-clip 524 , flat washer 520 and spring washer 522 (FIGS. 2 and 3A) are fitted.
[0064] As shown in FIGS. 8C and 9C, the right and left handle halves 600 and 700 are also provided with a series of laterally extending, perpendicular internal walls 628 and 728 that include slots and recesses for routing the fluid conduits or tubes 370 and 470 , the cable 390 and the insulated wire conductors 360 and 460 that extend through the length of handle 10 .
[0065] The trigger 20 , thumb slide 25 , and the associated link arm 26 and trigger lock 27 are shown assembled to the right handle half 600 in FIG. 10 with the trigger 20 in the released position and the thumb slide 25 in the unlocked distal or retracted position. The trigger lock 27 is shown in greater detail in FIGS. 11 A- 11 B, the link arm 26 is shown in greater detail in FIGS. 12 A- 12 B, and the trigger 20 is shown in isolation in FIGS. 13 A- 13 B.
[0066] Trigger 20 is provided with laterally extending cylindrical pivot bosses 206 , 206 ′ that are mounted into sockets 723 and 623 , respectively. When released, trigger 20 extends outward through downwardly opening recesses 621 and 721 . When pulled, trigger 20 is pivoted inwardly into the handle recesses 621 and 721 about pivot bosses 206 , 206 ′ to apply tension to the cable 390 that draws the upper and lower jaws 35 and 45 together. Cable 390 is mounted within a lubricious tube 391 , extending from the proximal wall 628 to the distal end 15 of the handle 10 , to allow the cable 390 to move freely within the handle 10 when trigger 20 is pulled or released.
[0067] Trigger 20 is coupled to the proximal end of cable 390 through link arm 26 , illustrated in isolation in FIGS. 12A and 12B. Link arm 26 is provided at a distal end with two laterally extending bosses 262 and 262 ′ that are received in circular sockets 204 (one of which is shown in FIG. 13B) formed on the interior walls of the internal chamber 202 of trigger 20 to thereby pivotally mount the distal end of the link arm 26 to the trigger 20 . Link arm 26 is formed with a longitudinally extending slot 266 , allowing compression of the distal end of the link arm 26 to facilitate positioning of cylindrical bosses 262 and 262 ′ within the corresponding sockets 204 within the trigger 20 . As also shown in FIG. 13B, longitudinal slots 215 are provided in the interior 202 to assist insertion of the bosses 262 , 262 ′ on link arm 26 into sockets 204 in trigger 20 during assembly. Link arm 26 is provided at its proximal end with two laterally extending, circular bosses 264 and 264 ′ that are received within the elongated slots 625 and 725 , respectively, in the respective right and left handle halves 600 and 700 . When trigger 20 is released, the circular bosses 264 and 264 ′ are disposed at the distal ends of the opposed elongated slots 625 and 725 , respectively. When trigger 20 is pulled inward, the proximal end of the link arm 26 is moved proximally within the opposed slots 625 and 725 , applying tension to cable 390 .
[0068] Cable 390 is coupled to the link arm 26 by means of a swaged retainer 24 , mounted within a coil spring 28 . Coil spring 28 is fitted within a generally cylindrical chamber 266 formed extending at 90 degrees to the proximal end of link arm 26 . Cable 390 passes through an upwardly facing slot 270 in link arm 26 and through the interior of spring 28 to retainer 24 . Spring 28 is normally extended within chamber 266 but is compressed to provide protection against over tensioning of the cable 390 , if the upper and lower jaws 35 and 45 encounter significant resistance to further movement toward one another. The configuration of the trigger 20 , link arm 26 and slots 625 and 725 provide a mechanism whereby, the cable 390 is pulled proximally relatively quickly during initial upward movement of the trigger 20 to facilitate initial rapid closing of the jaws 35 and 45 . The cable 390 is pulled relatively more slowly during further upward movement of the trigger 20 to provide increased control to the physician during final compression of the jaws 35 and 45 against the tissue to be ablated.
[0069] Trigger 20 is also provided with a distally extending projection 208 terminating with a laterally extending, generally cylindrical, boss 210 shown best in FIG. 13B. As illustrated in FIG. 10, when the trigger 20 is released and in its most downward position (corresponding to the point of maximum jaw opening), the fluid conduits or tubes 370 and 470 are disposed side by side and compressed between cylindrical boss 210 and the inwardly extending projections 630 and 730 . This compression of the fluid conduits or tubes 370 and 470 prevents flow of conductive fluid from the fluid source and out of the electrodes 330 and 430 and the electrode mounts 340 and 440 when the hemostat is not in use.
[0070] The trigger 20 is also formed with a laterally extending slot 212 having an array of teeth 214 formed along one side of the slot 212 . A trigger lock mechanism is provided involving the interaction of the thumb slide 25 with the trigger 20 through a trigger lock 27 that is coupled at one end with the thumb slide 25 and selectively engages the teeth 214 to retain the upper and lower jaws 35 and 45 at a fixed position adjacent tissue to be ablated without requiring the physician to continually apply pressure to trigger 20 . Distal or forward movement of the thumb slide 25 causes the trigger lock 27 to engage the teeth 214 , and proximal or rearward movement of the thumb slide 25 releases the engagement. The trigger 20 can be operated freely by the physician to open or close the upper and lower jaws 35 and 45 when the thumb slide 25 is in the rearward position. With the thumb slide 25 in the forward position, the trigger 20 can be moved inward ratcheting over the teeth 214 to close the upper and lower jaws 35 and 45 , but the trigger 20 will not move outward upon release by the physician.
[0071] The trigger lock 27 depicted in isolation in FIGS. 11A and 11B comprises an elongated link arm 275 having rods 272 and 278 laterally extending parallel to one another from opposed ends of the link arm 275 . As shown in FIG. 10, the rod 272 is inserted through the slot 202 so that the link arm 275 extends alongside the trigger 20 within the recess 721 . The rod 278 extends into a generally centrally located notch 252 of a resilient beam section 250 of the thumb slide 25 . Cylindrical pivot bosses 276 and 276 ′ extend laterally on either side of the link arm 275 in alignment with rod 272 and are inserted into sockets 724 and 624 , respectively.
[0072] The rod 272 inserted through the slot 212 extending through the trigger 20 is formed with a laterally extending ramped tooth 274 that is selectively engagable with one of the ramped teeth 214 formed along the proximal edge of slot 212 , when the trigger lock 27 is pivoted forward from the position illustrated in FIG. 10 by distal or forward movement of the thumb slide 25 by the physician. Movement of the trigger 20 inwardly into the handle recess with the trigger lock 27 advanced forward from the position illustrated in FIG. 10 causes the interaction of the tooth 274 on the trigger lock 27 with the teeth 214 to retain the trigger 20 in position when pressure is released. The oblong configuration of sockets 624 and 724 that receive bosses 276 ′ and 276 of the trigger lock 27 allow the trigger lock 27 to move slightly forward during inward movement of the trigger 20 so that the tooth 276 on trigger lock 27 may ratchet along the ramped teeth 214 of trigger 20 . Interaction of the teeth 214 with the ramped tooth 274 on the trigger lock 27 prevents outward movement of the trigger 20 as long as the thumb slide 25 remains in the forward position in the slot formed by openings 627 and 727 .
[0073] Release of the trigger 20 is accomplished by proximal or rearward movement of thumb slide 25 , pivoting the ramped tooth 274 out of engagement with a tooth of the teeth 214 along slot 212 which allows the upper and lower jaws 35 and 45 to open unless the physician holds the trigger 20 in position. The trigger 20 is urged outwardly out of the recess in handle 10 by spring 23 upon release of the trigger 20 and rearward movement of the thumb slide 25 . When the trigger 20 reaches its full outward position, flow of conductive fluid through fluid conduits 370 and 470 is terminated as the tubing is compressed between the laterally extending boss 210 and the inwardly extending projections 630 and 730 , as discussed above.
[0074] The thumb slide 25 is provided with a resilient beam section 250 , having a generally centrally located notch 252 which engages the laterally extending rod 278 on trigger lock 27 , coupling the thumb slide 25 to the trigger lock 27 . The thumb slide 25 is preferentially retained at either the proximal, rearward or distal, forward point of its travel, without the necessity of the physician manually maintaining pressure on the thumb slide 25 due to the resilience of the beam 250 and the arcuate path of travel of the rod 278 .
[0075] [0075]FIG. 14 illustrates a proximal portion of the assembled hemostat of FIG. 1 with the left handle half 700 removed to show the multi-conductor cable 80 and fluid conduit 70 extending through the strain relief 60 and their joinder to the wire conductors 360 , 460 and the fluid conduits 370 , 470 .
[0076] The distal end of the fluid conduit 80 is coupled through a fitting 802 to proximal end of flexible tubing 804 . The distal end of flexible tubing 804 is coupled to the trunk of a Y-connector 806 , and the distal legs of the Y connector 806 are coupled to arms of a D-connector 810 . The D connector 810 is formed of a flexible plastic, e.g., silicone rubber, providing spaced apart fluid channels that are coupled to the proximal ends of the fluid conduits 370 and 470 .
[0077] The fitting 804 supports a proximal flow controller or regulator 820 that has a precisely sized orifice that limits conductive fluid flow into the Y-connector 806 . The flow regulator 820 establishes a fixed flow rate and pressure within the Y-connector 806 regardless of the pressure of the fluid source that is available in the surgical theatre. The flow rate is established depending upon the upper and lower electrode area and design.
[0078] The D connector 810 supports a pair of downstream flow regulators 822 and 824 that have equal, precisely sized orifices that further reduce the fluid flow rate and pressure of the conductive fluid entering the fluid conduits 370 and 470 . The downstream flow regulators 822 and 824 ensure that an even flow of conductive fluid is provided from within the Y connector 806 into the fluid conduits 370 and 470 . By this mechanism, the hemostat may be operated without the necessity of an associated pressurized fluid source and still provide controlled and even fluid flow to the upper and lower jaws 35 and 45 that contact the tissue to be ablated.
[0079] An optional light emitter, e.g., an LED 830 , is depicted in FIG. 14 located within the strain relief 60 and coupled through an electrical junction 832 with the insulated wire conductors 360 and 460 . The wire conductors 360 and 460 can take the form of a twisted wire cable that extends distally from the electrical junction 832 through the length of the handle to the swivel assembly 50 where they are separated as shown in FIGS. 3A and 4. Separate wire conductors within a cable 834 extend from the electrical junction 832 to the LED 830 . In use, the LED 830 is illuminated in response to activation of an associated RF electrosurgical generator, and the LED illumination illuminates the strain relief 60 , which is preferably fabricated of a translucent flexible material, such as silicone rubber or the like. The physician will typically hold the handle 10 in orientations that make the strain relief 60 visible, and illumination of the LED 830 indicates to the physician that RF energy is being applied to the electrodes
[0080] The proximal portion of the handle 10 may also optionally carry other electronic components including circuitry containing calibration information, for example calibrating a thermocouple if provided to sense electrode or tissue temperature. Circuitry containing identification information or providing re-use prevention may also be included, however such features are not believed to be essential to or a part of the present invention.
[0081] [0081]FIGS. 15A and 15B illustrate an alternative embodiment of the electrode described above that can be employed in modified upper and lower jaw assemblies 30 A and 40 A corresponding generally to upper and lower jaw assemblies 30 and 40 . The upper and lower jaw assemblies 30 A, 40 A have a malleable backbone 310 , 410 and a sheath 320 , 420 as described above that are attached to the respective upper and lower jaw mounts 300 and 400 as shown in FIGS. 2 and 3. However, electrode 330 A, 430 A incorporates an exposed elongated electrode extension 350 A, 450 A extending to the outer surface of porous electrode support 340 A, 440 A and along the jaw 35 , 45 that is intended to directly contact the tissue to be ablated. In this embodiment, conductive fluid is delivered as described above into the lumen of the internal tubular electrode 330 A, 430 A, which may be substantially the same as the tubular electrodes 330 , 430 . An elongated electrode surface 352 A, 452 A of the electrode extension 350 A, 450 A and the contacted tissue are irrigated by conductive fluid emitted through the fluid ports of the internal tubular electrode 330 A, 430 A and conducted through the pores of the electrode support 340 A, 440 A.
[0082] The electrode extension 350 A, 450 A is depicted prior to assembly with the electrode support 340 A, 440 A and the elongated tubular electrode 330 A, 430 A in FIGS. 16A and 16B. As formed, the electrode extension 350 A, 450 A includes an elongated straight portion 352 A, 452 A that is mounted against the exposed to the exterior of the electrode support 340 A, 440 A. A distally extending portion 360 A, 460 A is adapted to be inserted into the lumen of the electrode support 340 A, 440 A to extend alongside the elongated tubular electrode 330 A 430 A as shown in FIG. 15B.
[0083] A series of barbed projections 354 A, 454 A extend laterally away from the elongated straight portion 352 A, 452 A. The electrode extension 350 A, 450 A is adapted to be bent back at junction 356 A, 456 A to enable insertion of the series of barbed projections 358 A, 458 A into the electrode support 340 A, 440 A. The proximal end 362 A, 462 A is electrically connected to the proximal ends of the tubular electrodes 330 A, 430 A and the distal ends of the wire conductors 360 , 460 .
[0084] This alternative exposed electrode embodiment can be formed by modifying the tubular electrode 330 , 430 to have a conductive electrode band extending from the tubular electrode along the surface of the electrode support 340 , 440 . Alternatively, this alternative electrode design can be accomplished without use of the tubular electrode 330 , 430 , whereby conductive fluid is delivered to a lumen of the electrode support 340 , 440 or to a fluid channel between the electrode support 340 , 440 and the sheath 320 , 420 , and the exposed electrode band is supported by the electrode support 340 , 440 .
[0085] The embodiments of the electrosurgical hemostat described above contain a number of valuable features and components, all of which contribute to provide a hemostat, which is convenient to use while providing substantial flexibility in use. However, many of the features of the hemostat could be employed in hemostats of other designs. For example, the trigger mechanism and/or the trigger lock mechanism of the above-described hemostat would certainly be of use in conjunction with cable activated hemostats having jaws of alternative designs to that described above. Similarly, the jaw assembly of the present hemostat might well be employed in conjunction with alternative trigger mechanisms. And/or in conjunction with alternative electrode designs, including electrodes which might not include provision for fluid irrigation and/or in the context of the hemostat having jaws that are rigid and not malleable by the physician to assume desired configurations. Further the specific electrode design employed in the hemostat design described above would be of significant use in conjunction with other hemostat types, including hemostats having jaws which are moved toward one another by alternative mechanisms. Similarly, a strain relief of the type described above including an LED indicator is believed to be of value in conjunction with any number of electrosurgical tools, particularly those in which the strain relief is within the physician's field of view, during normal operation of the hemostat. As such, the above description should be taken as exemplary, rather than limiting, with regard to the claims which follow.
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A hemostat-type device for ablative treatment of tissue, particularly for treatment of atrial fibrillation, is constructed with features that provide easy and effective treatment. A swiveling head assembly can allow the jaws to be adjusted in pitch and roll. Malleable jaws can permit curved lesion shapes. A locking detent can secure the jaws in a closed position during the procedure. An illuminated indicator provides confirmation that the device is operating. A fluid delivery system simplifies irrigated ablation procedures.
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RELATED APPLICATION
[0001] This application claims the benefit of provisional application Serial No. 60/177,520, filed Jan. 21, 2000 entitled “IN-VIVO TISSUE INSPECTION AND COLLECTION DEVICE”, which application is incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention relates generally to tissue inspection and more specifically to in vivo tissue inspection. More particularly, the invention relates to in-vivo tissue inspection using extrinsic fluorescence. In a particular embodiment, the invention relates to in-vivo tissue inspection using extrinsic fluorescence measured using noncoherent light gathering optics.
BACKGROUND
[0003] The Pap test is widely regarded as one of the most effective screening tests for cervical cancer and displasia, as evidenced by the major mortality rate reductions that occur wherever Pap screening is widely deployed and readily available. Although sample collection and processing for Pap testing can be performed by persons having relatively little specialized training, sample evaluation requires a substantial and highly skilled supporting infrastructure. This limits the deployment of Pap screening to those areas where such an infrastructure is available. Furthermore, it can require days to weeks to process and evaluate a Pap sample.
[0004] Thus, the physician must locate and contact the patient to inform the patient of the results and, if abnormalities were detected, to arrange for a follow-up visit. Contacting the patient is a time consuming process that is not always successful. Even if contact is made, only a fraction of those informed of abnormal results return for follow-up and treatment. This is particularly true in public health screening situations where the patient population is generally transient and where logistics frequently preclude a return visit.
[0005] A screening test for cervical displasia and cancer that can be performed and evaluated within the time frame of a typical single gynecological examination is needed to increase the availability of this type of testing. Particularly in the public health sector, it is highly desirable that the test be simple enough that it can be performed by paramedical personnel; that the instrumentation, if any, be compact, rugged and reliable; and that the cost per result be minimized.
[0006] Most tissues, including cervical tissues, can be made to fluoresce when illuminated with the appropriate wavelengths of light. The characteristics of this fluorescence can indicate the presence of cellular abnormalities including displasia and cancer. The measurement and characterization of tissue autofluorescence is the basis of many devices and methods that have been proposed as alternatives to or replacements for the traditional Pap procedure.
[0007] Autofluorescence measurements are made by illuminating the cervix with light of particular spectral characteristics and collecting and analyzing the resulting fluorescent emissions. These emissions arise from many different cellular constituents such as, but not limited to, collagen, elastin, flavins and heme-containing proteins. The fluorescence emissions from these various species are broad and overlap each other, resulting in what amounts to a continuum of emissions.
[0008] Furthermore, the fluorescence emissions from one such specie can couple to, and thus excite, fluorescence in another specie, resulting in a tissue autofluorescence spectrum that is very complex. Tissue autofluorescence also tends to be of low intensity, largely because many of the fluorescent species are weak or inefficient emitters that are present at low concentrations. The reported changes in tissue fluorescent emissions that are associated with the presence of cellular abnormalities are subtle, consisting primarily of small changes in emission intensity or emission wavelength distribution.
[0009] Thus, measuring tissue autofluorescence is a difficult undertaking, particularly when performed in-situ, as it involves quantitatively detecting small changes in small signals in the presence of many interferences.
[0010] These difficulties are typically addressed in several ways. The level of the desired fluorescent emission is maximized by careful selection of the exciting wavelengths and by increasing the excitation intensity to the point where all of the target fluorophores are saturated, i.e., being excited at the maximum possible rate. Highly sensitive detectors coupled to highly discriminating wavelength selection means are used to capture the desired signals while complex signal processing algorithms are used to extract the desired information.
[0011] Lasers are the most commonly used light sources for tissue autofluorescence measurements due to their narrow spectral bandwidths and the high power densities that can be achieved. High intensity arc lamps coupled to an appropriate wavelength selection means are also used for this purpose. These light sources tend to be large, delicate and expensive units that require considerable operator attention during use. Tissue auto fluorescence is typically excited using light in the violet and ultraviolet spectral regions. Light in these spectral regions is known to have the potential to cause tissue damage, especially at the high power densities required in order to obtain the maximum possible signal level, and can pose a hazard to both the operator and the patient.
[0012] Autofluorescence measurements generally use photomultiplier tubes, avalanche diodes or intensified array-type imaging detectors (such as a CCD) as the light detection means. Detector selection is based upon the number of wavelengths at which measurements are to be made as well as the spatial and spectral resolution requirements of the particular embodiment. Interference filters are commonly used as the wavelength selection means in cases where only a few wavelengths are of interest while diffraction gratings are typically used when it is desired to acquire data at a large number of wavelengths. As is the case of the light source, these detection assemblies tend to be large, delicate and expensive.
[0013] The large number of complex calculations required to extract the desired information from the acquired data dictates that substantial computational power be provided. Suitable computers, yet again, tend to be large and expensive.
[0014] Because the light source, detector and signal processing means in a tissue autofluorescence measuring system are large and the cervix to be examined is located in a confined space, the system elements are generally located remotely from the cervix and an endoscope or similar device is used to deliver the exciting light to, and collect the fluorescent emissions from the cervix.
[0015] Several limitations of the present art derive from the endoscope that typically is used to transport light from the light source to the cervix and from the cervix to the detector. These endoscopes are constructed as bundles having thousands of individual optical fibers. Lenses and other optical components are attached to each end of the bundle to provide for imaging and other functions. The fiber bundles used in these endoscopes are “coherent”, meaning that the position of a particular fiber within the array of fibers at one end of the bundle being identical to the position of this same fiber within the array of fibers at the opposite end of the bundle. This spatial coherence allows the bundle to transmit a recognizable image from one end of the bundle to the other. Building a coherent fiber bundle is a painstaking task that greatly contributes to the high cost of an endoscope.
[0016] Each fiber within the bundle consists of a core (through which light is transmitted) that is surrounded by a cladding that serves to contain the light within the core and to provide some measure of physical protection for the core. Although the manufacturers of optical fibers and endoscopes go to great lengths to minimize the thickness of the cladding relative to the diameter of the core, some portion of the cross sectional area of a fiber, and therefore of a fiber bundle, will be occupied by cladding and will therefore not be available to transmit light. In addition, light is also lost due to absorption and scattering of light within the fiber and reflective losses at the end faces. Some fiber bundles used in endoscopes use the same fibers to transport light in both directions.
[0017] A more common design, however, dedicates specific fibers within the bundle for illumination and others for light collection. This split design can significantly simplify the optics required at the proximal end of the bundle. Split fiber bundles have a significantly smaller effective fill factor than do those employing a common path and thus are less efficient in transmitting light between two locations.
[0018] The optics at the distal end of an endoscope (the end that is presented to the tissue being examined) are designed to image the tissue onto the end of the fiber bundle. The focal depth of these imaging optics dictates that the positioning and alignment of the distal end of the bundle relative to the tissue being examined be controlled within tight limits in order to ensure that the image presented at the proximal (or viewing) end of the bundle is in focus and is useable for measurement or imaging purposes. Quantitative measurements are particularly sensitive to the quality of focus.
[0019] Due to positional sensitivity, using an endoscope to make quantitative measurements requires considerable skill and excellent technique on the part of the operator. The alternative, forgoing the use of imaging optics at the distal end of the bundle and pressing the end of the bundle directly against the tissue, eliminates the depth of focus issue, but again requires considerable skill on the part of the operator to prevent the distal end of the fiber bundle from becoming contaminated by accidental tissue contact before it is abutted against the target area of the cervix. Such contamination can substantially interfere with the quality of the measurement.
[0020] Conflicting design requirements limit present endoscopes to sampling either the endo- or ecto-cervical region, but not both simultaneously. This limitation necessitates making two separate measurements using two separate devices in order to provide a complete cervical examination. The use of two devices does not, however, ensure adequate sampling of the transition region between the endo- and ecto-cervical tissues.
[0021] The cost of the fiber bundle used in an endoscope suitable for quantitative applications is sufficiently high that the fiber bundle must be reused in order to keep the cost per test within acceptable limits. This means that the bundle must be decontaminated before reuse to control infection and to ensure that adhering materials do not interfere with subsequent measurements. As decontamination is a time consuming procedure, a significant number of fiber bundles must be kept on hand to support the workflow of a screening site. The decontamination process can also cause both progressive and catastrophic damage to the fiber bundle leading to a relatively short useful lifetime before it must be replaced or repaired. In some cases, a disposable sheath is placed over the end of the bundle to prevent the bundle from coming into contact with the patient. Such a sheath can largely eliminate the need for frequent decontamination, but it can interfere with measurements made using the fiber bundle.
[0022] As is the case with all of the other major or system elements, endoscopes are large, expensive, delicate units that require considerable operator skill and attention. The net effect is that while tissue autofluorescence has been demonstrated to be capable of relatively rapidly detecting cervical abnormalities, the current embodiments of such systems are far too large, complex, delicate and expensive for widespread deployment as a routine screening tool.
[0023] Thus, a need remains for an efficient, economical system for in-vivo screening of cervical tissues. A need remains for a suitable replacement for the endoscope. A need remains for a screening system that employs exogeneous reagents to enhance cellular fluorescence.
SUMMARY
[0024] The present invention utilizes an exogenous detection reagent to increase the signal level and suppress the background against which signal measurements are made. This, in turn, allows considerable simplification of the measurement instrumentation with concomitant reductions in size and cost.
[0025] Accordingly, the invention is found in an in-vivo tissue inspection device that includes an first non-imaging light collector that has an entrance and an exit and a second non-imaging light collector that has an entrance and an exit. The second non-imaging light collector is arranged so that its entrance is in light communication with the exit of the first non-imaging light collector. The device further includes a light guide and an optical element. The light guide is positioned between the second non-imaging light collector and the optical element.
[0026] The invention is also found in an in-vivo cervical tissue inspection system that includes a light source, a light detector, and the in-vivo tissue inspection device described hereinabove.
[0027] The invention is also found in a method of inspecting cervical tissue for abnormalities. The method includes contacting the cervical tissue with an exogenous fluorescent reagent that is preferentially taken up by abnormal cells, subsequently contacting the cervical tissue with light of a first wavelength, and detecting and measuring fluorescent light of a second wavelength. The light of a first wavelength and the fluorescent light of a second wavelength are both transmitted in a non spatially-resolved manner.
[0028] The invention is also found in a cervical screening method for screening cervical tissue that includes steps of applying an exogenous reagent to the cervical tissue, where the exogenous reagent is configured to cause abnormal cells to provide a discemable response to incident light, contacting the cervical tissue with an incident light sufficient to cause the discemable response to the incident light, where the discemable response includes emitted light of a particular wavelength, using a non-imaging light collector to gather and concentrate the emitted light, and impinging a detector with the gathered and concentrated light.
[0029] Other features and advantages of the present invention will be apparent from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0030] [0030]FIG. 1 is an illustration of a tissue inspection device according to a particular embodiment of the present invention.
[0031] [0031]FIG. 2 is an illustration of a tissue inspection and sampling device according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0032] The present invention replaces the fiber bundle used in present endoscopes with a simpler, less costly device that addresses the limitations of present technology. In particular, these limitations can be addressed by replacing the imaging fiber bundle and appurtenances with a device based upon the principles of non-imaging optics.
[0033] Optics
[0034] Non-imaging optics are optical devices that manipulate light in a non-spatially resolved manner. Such devices are distinguished by their simple structures and their exceptional efficiency in collecting light from one location and delivering that light to another location. The technology underlying such devices is extensively described in the open literature, most notably in the works of Winston. See, for example, U.S. Pat. Nos. 3,957,031; 4,002,499; 4,003,638; 4,230,095; 4,387,961; 4,359,265; 5,289,356; and 5,971,551, each of which are incorporated by reference herein.
[0035] The forms of non-imaging optical elements preferred in the present invention are known as compound parabolic and compound elliptical concentrators (CPC, CEC). These designations refer to the mathematical functions (parabolic and elliptical, respectively) that describe the shapes of these devices. The specific form selected for a particular embodiment of the present invention is primarily a matter of preference and convenience, and has minimal, if any, effect on the function or performance of the device. As such, these two base forms and their derivatives may be used interchangeably in the present invention. For simplicity, all following references will be to the CPC form with the recognition that alternative forms are equally suitable.
[0036] Mathematically, a CPC is a shape derived from the equation of a parabola having larger and smaller ends connected by a parabolic profile. The smaller end is usually called the throat of the device. Light enters the device through one end and exits through the other. Each end is characterized by an acceptance angle. Any light entering one end within the corresponding acceptance angle (less minimal reflectance and absorbance losses) is delivered to and exits from the other end. Light exiting the device is distributed over the entire acceptance angle of the exit end.
[0037] Since all light transiting the device passes through both end faces, the illumination density at the smaller end is greater than that at the larger end by an amount equal to the ratio between the areas of the two ends. The acceptance angle at each end of the device is determined by the relationship existing between the diameters of the ends of the device and the distance between these ends. Qualitatively, the smaller the axial ratio (length to diameter), the larger the acceptance angle. The present invention preferably utilizes each of these characteristics of a CPC.
[0038] In a preferred embodiment, the present invention is constructed around two CPC elements joined at the throat. The entry face of the device is intended to contact the cervical area to be examined. The diameter of the entry face of this composite device is defined by the diameter of the area on the cervix that is to be sampled while the length and throat diameter of the CPC comprising this portion of the device is largely a matter of design convenience. An axial ratio of about 3:1 and an area ratio of between 3:1 and 5:1 are preferred for this section.
[0039] Preferably, the throat diameter of the second CPC section is identical to that of the first section. It is desirable that the light exiting this second CPC section have a narrow angular distribution that matches the acceptance angle of the means used to deliver this light to the proximal end of the overall optical system. This is accomplished by selecting an axial ratio of between 5:1 and 10:1 in conjunction with a area ratio of approximately 2:1. The design particulars are illustrated in the Figures, which are described in detail hereinafter.
[0040] As the area of the exit face of this compound device is smaller than the entrance face, the optical power density at the exit face is greater than that at the entrance face by the ratio of the areas. This concentration effectively facilitates detection by increasing the signal levels.
[0041] The light exiting the second CPC section is delivered to optics at the proximal end of the system via a free space connection, a hollow core light guide, or an optical fiber. In these latter two cases, the diameter of the core of the light guide or fiber is selected to match that of the exit face of the second CPC. Note that the optical system as described is reversible in that light entering the system at the proximal end of the light delivery means will exactly retrace the path taken by light entering the system at the distal end of the device. This allows illumination and collection to be performed using the same optical path through the device.
[0042] The composite CPC used in this device can be fabricated by any of a number of established methods, selection between which is largely determined by whether the device is to be of the filled (immersed) or unfilled type. This, in turn, is largely determined by the overall length allocated to the CPC element during system design. A filled CPC generally has a lower axial ratio and, therefore, a shorter length than does an equivalent unfilled CPC.
[0043] Filled CPC's are most conveniently fabricated by casting or injection molding while unfilled devices are more conveniently fabricated by electroforming, casting or injection molding. Stamping, diamond turning and assembly from separately fabricated components are among the other methods that can be employed. Hollow core light guides are most conveniently fabricated by electroforming or by extrusion or tube drawing followed, in the case of a metallic guide, by electropolishing.
[0044] The present invention can, if desired, be configured to provide a limited degree of spatial resolution over the sampled area should this be desirable in a particular application. This is accomplished by assembling multiple CPC pairs, each of which has its own means of delivering light to the proximal optics. In this configuration, each CPC pair in the assembly contributes one spatially resolved point to a final measurement.
[0045] Such assemblies of CPC pairs are most conveniently fabricated as electroformed elements that may, if desired, be subsequently filled by a casting process. This level of spatial resolution is beneficial to the user in that it permits localizing a lesion to within a particular region of the cervix. This information facilitates follow-up procedures such as colposcopy, biopsy and therapy. In all cases, a compliant sleeve or collar projecting beyond the distal end of the CPC assembly facilitates alignment of the device with the cervix and serves as a shield to minimize the effects of stray light on the measurement.
[0046] The design of the CPC assembly can also be extended to accomplish simultaneous sampling of both the ecto-and endo-cervical regions. In this configuration, the distal end of the CPC is shaped to conform to the shape of the cervix with an extension that projects into the cervical canal. Preferably, the CPC is of the filled type and is designed to provide spatial resolution, preferably with one resolution element being dedicated to the canal and multiple elements being dedicated to the ectocervix. Filling the CPC allows for evanescent wave coupling into the canal and provides rigidity that assists in the insertion of the device into the canal.
[0047] Design details of the proximal optics are largely determined by the selection of the exogenous reagent. In particular, selection of the source of illumination, the wavelength selection means and, to a lesser extent, the detection means will be determined by the spectral properties of the particular reagent employed. In a preferred embodiment, a reagent such as BPD(Tm) having an excitation maximum in the vicinity of 630 nm and an emission maximum in the vicinity of 660 mn can be employed. Preferably, the fluorophore concentration will be determined from the ratio of emission intensities at 660 nm and 690 mn. In a preferred embodiment, tissue reflectance in the approximately 830-860 nm range can be used as a reference to correct for the hemoglobin concentration (hemoglobin absorbs light in the 630 nm range) and degree of oxygenation in the tissue being sampled.
[0048] Such an optical system could be constructed using the traditional epifluorescence/reflectance optical geometry. Such a geometry, which consists of an assembly of interference filters and dichroic reflectors is widely used in the prior art in those cases where excitation and emission share the same fibers in the fiber bundle. Alternative designs incorporating filter changers or Accousto-optic Tunable Filters, monochrometer or similar tunable wavelength selection means are also known in the prior art and are used in those instances where sequential rather than simultaneous measurements are acceptable. An “imaging spectrograph” geometry is also known and can be used. However, the limiting factor in each of these prior art embodiments is that they are large, complex and expensive, and in many cases suffer from low optical efficiency.
[0049] The present invention uses diffractive or holographic optical elements to accomplish these same ends. The differentiation between diffractive and holographic optics lies largely in the manner in which they are fabricated rather than in function or performance. For all practical purposes, a diffractive optical element is one that is fabricated using a largely digital process while a holographic optical element is fabricated using a largely analog process. Either type of optical element can be envisioned as combining the functions of a diffraction grating and a lens into a single structure.
[0050] In addition to combining wavelength selection and optical power (focusing) into a single integrated structure, diffractive and holographic optical elements also provide a means of precisely and selectively manipulating optical wavefronts. Specifically, diffractive and holographic elements can be made to transform any arbitrary wavefront incident on the entry aperture of the device into any other arbitrary wavefront at the exit aperture of the device. The specific wave front transformation(s) performed by a given device are determined by the details of its construction. One unique feature of such devices is that they can be constructed to perform multiple simultaneous independent transformations on the same incident wavefront.
[0051] In a preferred embodiment, solid state laser diodes emitting at 635 and 850 mn can be used as illumination sources. Moreover, it is preferred that fluorescence emissions from the cervix can be detected at 660 and 690 nm with bandwidths of 10 nm (Full Width Half Maximum) and that reflectance from the cervix at 850 nm can also be monitored. The 660 nm and 690 nm detectors are most conveniently blue enhanced silicon photodiodes or avalanche diodes while the 850 nm detector is most conveniently a gallium arsenide photodiode. Miniature photomultiplier tubes such as those available from Hamamatsu of Bridgewater, N.J., can also be used as detectors.
[0052] The diffractive/holographic optical element preferably performs several independent wavefront transformations. Specifically, the optical element should transform the wavefront associated with the light delivery means that connects the CPC to the proximal optics into narrowband wavefronts that match those of the two laser diodes and band limited wavefronts that can be efficiently coupled to each of the three detection elements. Furthermore, the optical element should spatially separate these various wavefronts in a manner that allows physical disposition of the light delivery means, lasers and detectors in the overall optical assembly.
[0053] The wavefront associated with the light delivery means can be described and modeled as that of light diverging from an extended, approximately circular source and illuminating the entire area of the optical element. The wavefronts associated with the lasers can be modeled as diverging elliptical beams from virtual point sources. As the divergence of such a beam is relatively small, they will illuminate only a portion of the optical element.
[0054] For convenience, the centroids of these beams will intersect the center of the element with the major axis of the two ellipses being at right angles to each other. The major constraint placed on the wavefronts incident on the detectors is that the shapes and sizes of the beams at the detectors match the shapes (square) and sizes (approximately 3 mm) of the respective detection elements. Dispersion in these beams also needs to be controlled in order to achieve the desired bandwidths. Ancillary interference filters may be placed at the entries to the detectors to further control the detection bandwidths.
[0055] In addition to these transformations, the optical element should rotate the plane of polarization of the 850 nm light by 45 degrees on each pass through the element, but should not affect the polarization of the light at the other wavelengths. Manipulating the polarization of the 850 nm light is preferable since excitation and detection of reflection is done at the same wavelength. Introducing the quarter wave rotation into the polarization of this light means that the plane of polarization of the reflected light will be rotated by 90 degrees relative to that of the light from the laser. Since the planes of polarization of the laser and reflected light are now orthogonal, the optical element can process each independently. This allows the 850 nm source and detector to be at physically separate locations.
[0056] A similar effect can be obtained by appropriate manipulations of the object and reference beams during the design and fabrication of the optical element. In those instances where a spatially resolved CPC is used, a separate optical element can be employed for each spatial channel or a single optical element can be constructed to process all of the channels. The use of a separate element per channel is preferred both to minimize interchannel crosstalk and due to the fact that the optical efficiency of such an element decreases and the cost increases as an increasing number of functions are integrated into a single structure.
[0057] Fabrication of a diffractive or holographic optical element that performs the functions described is accomplished by established means and methods that are well known to those skilled in the art. Fabrication services for such elements are available from a number of commercial sources. Implementing the proximal optics as a diffractive or holographic element allows the size, cost and complexity of these optics to be substantially reduced relative to what is possible using conventional optics.
[0058] The data reduction algorithms required in the present invention are rudimentary compared to those required by the prior art. In particular, the present invention requires one (or a small number of) ratiometric intensity determinations that have been corrected for tissue reflectance as determined using an third data channel. The prior art requires doing a very large number of spatially resolved measurements at high spectral resolution; deconvoluting the composite data to extract the signal changes of interest; and employing image analysis methods to localize the source(s) of the detected emissions.
[0059] The net effect is that the present invention requires substantially less computational power than is required by the prior art. This computing power can be provided using any of a rapidly increasing number of commercially available single board or “system on a chip” computers. Selecting such a computer that is packaged in a “credit card” or similar miniaturized format in conjunction with a miniature display and an embedded realtime operating system such as QNX a system offered by QNX Software Systems, Inc., Kanata, Ontario, Toronto, Canada allows the computer to be embedded in the hand held measuring device.
[0060] The Figures provide an illustration of several preferred embodiments of the present invention. FIG. 1 shows an in-vivo tissue inspection device 100 while FIG. 2 shows a particular embodiment of the present invention wherein in-vivo tissue inspection and sampling device 200 includes means to sample the tissue being examined.
[0061] In FIG. 1, the inspection device 100 is formed from a housing 128 that includes an entrance CPC 102 and an exit CPC 108 . The first, or entrance, CPC 102 includes a first end 104 that is configured to contact the particular tissue to be sampled. While the first end 104 is illustrated as having essentially a flat or planar configuration, the invention is not limited to such. Indeed, the first end 104 can also be configured to match more closely with the profile of the tissue being examined. In a preferred embodiment, the tissue being examined is cervical tissue and the first end 104 can thus be configured to match a typical cervical profile.
[0062] The entrance CPC 102 also has a second end 106 , which is also referred to as the throat of the CPC 102 . The second end 106 of the entrance CPC 102 is preferably the same diameter as the first end 110 of the second, or exit CPC 108 . The exit CPC 108 has a second end 112 that is preferably the same configuration and diameter as the first end 116 of the light guide 114 . The second end 118 of the light guide 114 preferably contacts an optical guide 120 .
[0063] [0063]FIG. 2 is quite similar, with the exception that the housing 228 further includes an elongate rod 230 that is attached to a biopsy apparatus 232 . The biopsy apparatus 232 can be any suitable biopsy means known in the art, provided that it can obtain a tissue sample when desired. In a preferred embodiment, the biopsy apparatus 232 is a sampling brush 232 (as illustrated). In this embodiment, the physician or other health professional administering the screening test can, if desired, rotate and extend the elongate rod 230 so that the sampling brush 232 contacts the tissue being examined. Movement of the sampling brush 232 relative to the tissue causes tissue cells to be exfoliated and collected on the surface of the sampling brush 232 . The sampling brush itself is described in greater detail in U.S. Pat. Nos. 5,999,844 and 6,081,740; each of which are incorporated in their entirety by reference herein.
[0064] The inspection device 200 includes an entrance CPC 202 having a first end 204 and a second end 206 . As with FIG. 1, the entrance CPC 202 has a first end diameter that is significantly greater than the second end diameter. In contrast, the exit CPC 208 has a first end diameter (first end 210 ) that is not much smaller than its second end diameter (second end 212 ). As described in detail previously, the ratio between the first end diameter and the second end diameter defines the area ratio of the CPC while the axial ratio is a length to diameter indication.
[0065] In either embodiment, the inspection device 100 , 200 has an optical element 120 , 220 present at the proximal end 118 , 218 , respectively, of the light guide 114 , 214 . Preferably, the optical element 120 , 220 is a diffractive optical element that can include only one diffractive or holographic element or can include a plurality of different elements. An aperture mask 122 , 222 is used to direct and tighten the beams of light coming from the light sources 226 and to the detectors 224 .
[0066] Reagents
[0067] One class of exogenous reagent preferably employed in the present invention is selected or derived from among the large number of chemical compounds that have been developed or evaluated as sensitizing agents for photodynamic therapy (PDT). These are fluorescent or fluorogenic compounds that are selectively and preferentially taken up, accumulated, and in the case of fluorogenic compounds, metabolized to form a fluorescent specie by abnormal cells.
[0068] In the intended therapeutic use of these compounds, exposing the target tissue to light of the appropriate spectral region will cause the compound that has been preferentially accumulated in abnormal cells to fluoresce. PDT therapeutic agents are designed such that the excited state produced upon exposure to light is highly reactive. This excited state reacts with water or other cellular constituents to produce “reactive oxygen” species such as singlet oxygen, hydroxyl radical or superoxide with a high quantum efficiency. These reactive oxygen species, in turn, react with other cellular constituents, thus damaging the cell to the point where it dies. As the PDT agent is selectively accumulated in abnormal cells, this provides a means of selectively killing abnormal cells in the presence of normal cells.
[0069] The present invention utilizes these PDT agents as detection, rather than therapeutic, reagents. As is the case of a therapeutic agent, a detection agent is selectively and preferentially taken up only by abnormal cells and is rapidly accumulated to high concentrations within these cells. Unlike the PDT therapeutic agents, the PDT detection agents are selected to efficiently produce high levels of fluorescence when optically excited at the appropriate wavelengths.
[0070] Where the excited state of a therapeutic agent is highly reactive and reacts with cellular constituents to form reactive oxygen species, the excited state of a detection agent is relatively unreactive and returns to its ground state via the emission of a photon. These detection agents are sometimes described as defective therapeutic agents because their output upon excitation is light rather than toxic chemicals.
[0071] Immunohistochemical and molecular probe reagents are another class of detection reagents that can be used in the present invention. These reagents incorporate a moiety such as an antibody (in the immunohistochemical reagents) or a molecule such as a lectin or a nucleic acid (in the molecular probe agents) that binds selectively to a preselected epitope or other molecular feature of a cell. These target features are selected from among those such as transferrin receptor, epidermal growth factor receptor or any of a wide variety of other cellular constituents whose presence or concentration has been correlated with the presence of the type(s) of cellular abnormalities of interest.
[0072] One or more “reporter” groups can directly or indirectly be coupled to the binding moiety to facilitate visualization. In the present invention, these reporter groups are most conveniently fluorescent species such as allophycocyanin, phycoerythrin, CY5 or the like, although fluorogenic, colored or chromogenic species may also be used. These reporter species can be selected so as to minimize the potential for interference with the measurements by tissue autofluorescence. To this end, the reporter species is preferably illuminated and quantitated at wavelengths greater than 550 nm. In addition to maximizing contrast, factors such as toxicity, photometric efficiency and speed of uptake are also considered during the selection process. Reagents of the types included in this class are well known to those skilled in the art.
[0073] Selecting a detection reagent according to these criteria results in abnormal cells having fluorescent emissions that are many times greater than those of normal cells and many times greater than tissue autofluorescence. Thus both the signal level and the signal to noise ratio are strongly enhanced over those observed with respect to tissue autofluorescence.
[0074] Additional benefits can be obtained by selecting the detection reagent such that the excitation and emission wavelengths do not significantly overlap those of tissue autofluorescence. For this reason, preference is given to reagents that excite and emit in the yellow, orange, red and near infrared spectral regions. Some of the PDT agents that have been found to be suitable for detection purposes include, but are not limited to: delta-aminolevulinic acid (ALA); Photofrin(Tm); BPD(Tm); Rhodamine 123; and a derivative of Nile Blue A developed by The Roland Institute for Science, Cambridge, Mass. Some suitable reporter moieties were identified above.
[0075] The means by which the exogenous reagent is administered to the patient depends upon the characteristics of the reagent and the intended application. Most PDT reagents are designed for injection because many of the target sites are not accessible for topical application. However, many PDT reagents including most of those listed above can be taken up by cells when applied topically. The immunohistochemical and molecular probe reagents are utilized in topical form. Some reagents are taken up rapidly upon topical application, but most require several hours to be absorbed or bound. Similarly, reagents such as ALA that must be metabolized in order to become active must be administered several hours before the measurements are to be made.
[0076] In the present invention, the reagent is preferably administered topically by applying a tampon or sponge containing the reagent to the cervix. Aspiration or spraying of the reagent onto the cervix can also be employed. In the instance of the tampon or sponge, one form of the applicator may be essentially as described in the U.S. patent application Ser. No. 09/603,625, which is hereby incorporated by reference herein; except that the face of the sampling element is made of a porous sponge material that serves as a reagent reservoir.
[0077] In the case of a slower acting reagent, the patient preferably inserts the device into her vagina several hours before a scheduled gynecological examination. Preferably, the sampling element rests against the cervix. This allows sufficient time for the reagent to diffuse from the sampling element and be taken up by any abnormal cervical cells that are present.
[0078] In those cases where a fast acting reagent is employed or where it was not practical or possible for the patient to apply the reagent to her cervix; where the patient did not comply with instructions to do so; or where the patient applied the reagent improperly, the reagent application can be performed by the clinician shortly before the examination. In this case, either a fast acting reagent is selected or the reagent is formulated to include an ingredient such as dimethyl sulfoxide that rapidly transports the reagent into the cells.
[0079] One limitation to the use of such transport agents to speed reagent uptake is that the ability of the reagent to discriminate between normal and abnormal cells is reduced. This approach is also not applicable to reagents that must be metabolized in order to become active. It is generally desirable for the clinician to remove any excess topical reagent from the cervix by washing or wiping before initiating the measurement procedure.
[0080] The uptake or binding of these detection reagents by cervical cells can be quantitated using the same instrumentation that is used to quantitate tissue autofluorescence. However, the substantially higher signal level and the selective concentration of the reagent in abnormal cells allows the performance requirements placed on the instrumentation to be relaxed somewhat relative to that needed for autofluorescence measurements. This can, in turn, somewhat reduce the cost and complexity of the instrumentation, but not to the level where it is practical for widespread deployment as a screening tool.
[0081] The present invention has been described with respect to using a single reagent or marker. However, the invention is not limited to such. Indeed, the present invention includes the use of a plurality of different markers that can be administered sequentially or simultaneously. In a preferred embodiment, the reagent actually includes a mixture of three different reagents or markers that are administered simultaneously.
[0082] While the invention has been described with reference to specific embodiments, it will be apparent to those skilled in the art that many alternatives, modifications and variations may be made. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variations that may fall within the spirit and scope of the appended claims.
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An in-vivo tissue inspection device provides for increased signal levels and the ability to discriminate between normal and abnormal tissues through the use of an exogenous fluorescent or fluorogenic reagent. The device reduces the costs of in-situ fluorescent measurements for screening and diagnostic purposes by eliminating the need for an imaging endoscope; simplifying the illuminating and detection means used in the device; and reducing the computing power needed for data reduction; reducing the operator skill level required to make quantitative measurements of in-situ fluorescence, and enabling simultaneous sampling of the ectocervix and the endocervical canal.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority of Japanese Patent Applications No. 2003-290445 filed on Aug. 8, 2003 and No. 2004-223466 filed on Jul. 30, 2004 the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1) Field of the Invention
[0003] The present invention relates to a fluorescence lifetime measurement apparatus that calculates a fluorescence lifetime by measuring the number of fluorescence photons emitted from a specimen which is irradiated with excitation light.
[0004] 2) Description of the Related Art
[0005] There is known a method of calculating a fluorescence lifetime by irradiating a specimen with excitation light to excite the specimen, and by measuring the number of fluorescence photons emitted from the specimen. In particular, in a field of biochemistry, attention is paid to a fluorescence lifetime measurement apparatus using pulse excitation light because a microstructure of a living body can be clarified by creating a fluorescence lifetime distribution image. As a method of calculating the fluorescence lifetime, there is known a time correlated single photon counting (TCSPC) in which a specimen is irradiated with pulse excitation light and a time until fluorescence photons are received is measured (see Japanese Patent Application Laid-Open No. 2002-107300).
[0006] There is also known a time gate method in which (1) a specimen is irradiated with pulse excitation light, (2) the number of fluorescence photons emitted from the specimen in a plurality of time windows each referred to as “a time gate” is measured, and then (3) the fluorescence lifetime is calculated from the number of fluorescence photons measured.
[0007] The TCSPC requires that the number of fluorescence photons emitted by the irradiation of one pulse excitation light be a very small number of about 0.01 piece. Accordingly, the specimen must be irradiated with pulse excitation light at least several tens of thousands of times to calculate the fluorescence lifetime once, and thus it takes a very long time to calculate of the fluorescence lifetime.
[0008] On the other hand, the time gate method can effectively use pulse excitation light. However, setting a plurality of time gates inappropriately makes a large error in a calculated fluorescence lifetime. Therefore, the time gates must be appropriately set to reduce the error of the fluorescence lifetime. Thus, when a fluorescence lifetime of an unknown specimen is measured in the time gates fixed, if the time gates fixed. are inappropriate, it is difficult to reduce the error of the fluorescence lifetime.
SUMMARY OF THE INVENTION
[0009] A fluorescence lifetime measurement apparatus according to one aspect of the present invention includes a light source irradiating a specimen with excitation light, a first controller, a second controller, a measurer, a processor, and a third controller. The first controller controls a total gate length that is a total time window during which a number of fluorescence photons emitted from the specimen excited by the excitation light is measured. The second controller controls a start gate length of a plurality of gate lengths into which the total gate length is divided. The start gate length is a time window whose start time is when measurement of the number of fluorescence photons starts. The measurer measures the number of fluorescence photons for each of the gate lengths. The processor calculates a fluorescence lifetime the specimen based on the start gate length and the number of fluorescence photons measured by the measurer. The third controller causes, when the fluorescence lifetime does not satisfy a predetermined condition, the first controller and the second controller to change the start gate length and the total gate length.
[0010] The other objects, features, and advantages of the present invention are specifically set forth in or will become apparent from the following detailed description of the invention when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram of a fluorescence lifetime measurement apparatus according to a first embodiment of the present invention;
[0012] FIG. 2 is a block diagram of a measurer of the fluorescence lifetime measurement apparatus according to the first embodiment;
[0013] FIG. 3 is a time chart of a laser control signal S and gate control signals S 1 and S 2 which are used in the fluorescence lifetime measurement apparatus according to the first embodiment;
[0014] FIG. 4 is a graph indicating an attenuation characteristic of the number of fluorescence photons in the first embodiment;
[0015] FIG. 5 is a graph indicating a characteristic of a standard deviation of a gate delay time normalized;
[0016] FIG. 6 is a graph indicating a region R satisfying ((t1+t2)/τ)≧4 and 1≦t1/τ≦2;
[0017] FIG. 7 is a flowchart of an operation of the fluorescence lifetime measurement apparatus according to the first embodiment until a fluorescence lifetime τ is determined;
[0018] FIG. 8 is a graph indicating a relation of the standard deviation and the number of fluorescence photons measured by the measurer;
[0019] FIG. 9 is another time chart of the laser control signal S and the gate control signals S 1 and S 2 ,
[0020] FIG. 10 is a block diagram of another measurer of the fluorescence lifetime measurement apparatus according to the first embodiment;
[0021] FIG. 11 is a block diagram of still another measurer of the fluorescence lifetime measurement apparatus according to the first embodiment;
[0022] FIG. 12 is a block diagram of a fluorescence lifetime measurement apparatus being a modification of the first embodiment;
[0023] FIG. 13 is a block diagram of a fluorescence lifetime measurement apparatus according to a second embodiment of the present invention;
[0024] FIG. 14 is a graph indicating an attenuation characteristic of the number of fluorescence photons in the second embodiment;
[0025] FIG. 15 is a time chart of a laser control signal S and gate control signals S 1 and S 2 which are used in the fluorescence lifetime measurement apparatus according to the second embodiment;
[0026] FIG. 16 is a block diagram of a fluorescence lifetime measurement apparatus according to a third embodiment of the present invention;
[0027] FIG. 17 is a time chart of a laser control signal S and gate control signals S 1 and S 2 which are used in the fluorescence lifetime measurement apparatus according to the third embodiment; and
[0028] FIG. 18 is a flowchart of an operation of the fluorescence lifetime measurement apparatus according to the third embodiment until a fluorescence lifetime τ is determined.
DETAILED DESCRIPTION
[0029] Exemplary embodiments of a fluorescence lifetime measurement apparatus according to the present invention is explained below in detail with reference to the accompanying drawings.
[0030] FIG. 1 is a block diagram of a fluorescence lifetime measurement apparatus 100 according to a first embodiment of the present invention. The fluorescence lifetime measurement apparatus 100 includes a controller 1 , an optical system 2 , a measurer 3 , and a processor 4 .
[0031] The controller 1 includes a total gate length control unit 1 a , a gate length control unit 1 b , and a determination unit 1 c . The total gate length control unit 1 a controls a total gate length that is a total time window from a start to an end of measurement of the number of fluorescence photons. The gate length control unit 1 b controls each gate length obtained by dividing the total gate length into a plurality of gate lengths. The determination section 1 c determines whether a calculated value of a fluorescence lifetime satisfies a predetermined condition and settles the fluorescence lifetime.
[0032] The optical system 2 includes a laser oscillator 2 a , lenses 2 b and 2 c , and a photo multiplier tube (PMT) 2 d acting as a photoelectric converter. The laser oscillator 2 a emits pulse excitation light, the lens 2 b focuses the pulse excitation light onto a specimen 5 , and the lens 2 c guides fluorescence photons emitted from the specimen 5 to the PMT 2 d.
[0033] The controller 1 outputs a laser control signal S to the optical system 2 . The laser control signal S input to the optical system 2 causes the laser oscillator 2 a to emit pulse excitation light. The pulse excitation light is focused onto the specimen 5 through the lens 2 b , and excites the specimen 5 . Fluorescence photons are emitted from the excited specimen 5 and condensed to the PMT 2 d through the lens 2 c . The PMT 2 d converts the fluorescence photons incident thereon into an electric signal E, and outputs the electric signal E to the measurer 3 . The measurer 3 controls the respective gate lengths in response to gate control signals S 1 and S 2 received from the controller 1 , and measures the numbers of fluorescence photons in the respective gate lengths. The measurer 3 outputs to a processor 4 measured-value signals Ct 1 and Ct 2 corresponding to the numbers of fluorescence photons measured in the respective gate lengths. The processor 4 calculates a fluorescence lifetime τ based on the measured-value signals Ct 1 and Ct 2 , and outputs a signal indicating the fluorescence lifetime τ to the controller 1 .
[0034] FIG. 2 is a block diagram of the measurer 3 . The measurer 3 includes an amplifier 3 a , switches SW 1 and SW 2 , pulse height discriminators H 1 and H 2 , and digital counters C 1 and C 2 . The amplifier 3 a amplifies the electric signal E input from the PMT 2 d . The amplified electric signal E is transmitted to the switches SW 1 and SW 2 . The switches SW 1 and SW 2 are controlled by gate control signals S 1 and S 2 . When the gate control signals S 1 and S 2 are in an “ON” state, the switches SW 1 and SW 2 are closed, and the amplified electric signal E is transmitted to the pulse height discriminators H 1 and H 2 . The pulse height discriminators H 1 and H 2 converts with a predetermined value the input signal into a binarized signal represented by “0” and “1”, and output the binarized signal to the counters C 1 and C 2 respectively. The counters C 1 and C 2 count the number of signals “1” input thereto and outputs to the processor 4 measured-value signals Ct 1 and Ct 2 which indicate the numbers of fluorescence photons.
[0035] FIG. 3 shows a time chart of the laser control signal S and the gate control signals S 1 and S 2 . Let T0 be a time at which the laser control signal S changes from “ON” to “OFF”. As shown in FIG. 3 , the gate control signal S 1 is in an “ON” state during a period of time t1 (time T0 to T1), and the gate control signal S 2 is in an “ON” state during a period of time t2 (time T1 to T2). This means that a first gate length is t1, a second gate length is t2, and a total gate length is (t1+t2). Here, let the first gate length t1 be a gate delay time t1.
[0036] Since an emission probability of the fluorescence photons emitted from the specimen 5 follows Poisson distribution, the number of fluorescence photons attenuates based on characteristics of natural logarithm during emission of the fluorescence photons. FIG. 4 is a characteristic graph which indicates that the number of fluorescence photons attenuates based on a predetermined attenuation constant.
[0037] The fluorescence lifetime τ is defined as a reciprocal of the attenuation constant of the number of fluorescence photons. Accordingly, the number of fluorescence photons I is given as a function of a period of time t by the following equation (1):
I = I 0 exp ( - t τ ) ( 1 )
where I 0 is the number of fluorescence photons at time T0.
[0039] Let I 1 be the number of fluorescence photons measured during the first gate length t1, and let I 2 be the number of fluorescence photons measured during the second gate length t2. A ratio I 2 /I 1 of I 2 to I 1 is represented by the following equation (2):
I 2 I 1 = ∫ T1 T2 exp ( - t τ ) ⅆ t ∫ T0 T1 exp ( - t τ ) ⅆ t ( 2 )
[0040] Let a ratio R be the ratio of I 1 and I 2 as shown by the following equation (3):
R=I 2 /I 1 (3)
[0041] If the ratio R is substituted for equation (2), the fluorescence lifetime τ is approximated by the following equation (4):
τ = t1 ln + 1 + R R ( 4 )
where T2 is sufficiently large.
[0043] Accordingly, the processor 4 calculates the fluorescence lifetime X by calculating equation (4) based on the gate delay time t1 set by the controller 1 and the number of fluorescence photons I 1 and I 2 measured by the measurer 3 , and outputs a signal indicating the fluorescence lifetime τ to the controller 1 .
[0044] The controller 1 determines whether the fluorescence lifetime τ received from the processor 4 is within an appropriate error range, based on the gate delay time t1 and the total gate length (t1+t2). If the fluorescence lifetime τ is not within the appropriate error range, the controller 1 sets the gate delay time t1 and the total gate length (t1+t2) again, and recalculates the fluorescence lifetime τ.
[0045] Determination criteria by the controller 1 is explained below. FIG. 5 is a characteristic graph indicating a standard deviation σ/τ with respect to the gate delay time t1 normalized by the fluorescence lifetime τ. A characteristic for each total gate length (t1+t2)/τ is shown in FIG. 5 . Note that the characteristic is a result of calculation of the fluorescence lifetime τ repeated 5000 times by a Monte Carlo method with 250 photons. An error a is defined by the following equation (5):
σ = ∑ i = 1 k ( τ i - τ _ ) 2 ( k - 1 ) ( 5 )
[0046] If the standard deviation σ/τ is used as indication of the error σ, a fluorescence lifetime τ satisfying a standard deviation σ/τ of 0.1 or less is generally acknowledged as high accuracy. As shown in FIG. 5 , If the standard deviation σ/τ is 0.1 or less, a normalized gate delay time t1/τ satisfies 1≦t1/τ≦2, and a normalized total gate length (t1+t2)/τ satisfies 4≦(t1+t2)/τ. Thus, the controller 1 uses as decision criteria the following conditional inequalities (6) and (7):
(( t 1+ t 2)/τ)≧4 (6)
1 ≦t 1/τ≦2 (7)
[0047] FIG. 6 shows a region R satisfying conditional inequalities (6) and (7). As shown in FIG. 6 , t2/τ is expressed by a function L (t2/τ=4−t1/τ) of t1/τ. Further, the region R satisfying the two conditional inequalities (1≦t1/τ≦2 and 4≦(t1+t2)/τ) is indicated by a shaded area in FIG. 6 .
[0048] Accordingly, if t2/τ and t1/τ are within the region R, the determination unit 1 c determines the fluorescence lifetime τ and finishes the calculation. If t2/τ and t1/τ are not within the region R, the determination unit 1 c sets the gate delay time t1 and the total gate length (t1+t2) again.
[0049] FIG. 7 is a flowchart which depicts an operation of the fluorescence lifetime measurement apparatus 100 until the fluorescence lifetime τ is determined. The gate length control unit 1 b sets the gate delay time t1, and the total gate length control unit 1 a sets the total gate length (t1+t2) (step S 101 ). The controller 1 outputs the laser control signal S to the optical system 2 as well as outputs the control signals S 1 and S 2 to the measurer 3 , and measures the number of fluorescence photons I 1 and I 2 (step S 102 ). The measurer 3 outputs the measured-value signals Ct 1 and Ct 2 corresponding to the number of measured fluorescence photons, to the processor 4 . The processor 4 calculates the fluorescence lifetime τ based on the measured-value signals Ct 1 and Ct 2 (step S 103 ). The fluorescence lifetime τ calculated is transmitted to the determination unit 1 c . The determination unit 1 c determines whether the input fluorescence lifetime τ is within the region R (step S 104 ). If the fluorescence lifetime τ is within the region R (step S 104 , YES), the determination unit 1 c determines the fluorescence lifetime τ (step S 105 ). If the fluorescence lifetime τ is not within the region R (step S 104 , NO), the gate length control unit 1 b sets the gate delay time t1 which satisfies τ≦t1≦2τ (step S 106 ). The total gate length control unit 1 a sets the total gate length (t1+t2) which satisfies t1+t2≧4τ, based on the gate delay time t1 (step S 107 ). Note that, set of the gate delay time t1 (step S 106 ) and set of the total gate length (t1+t2) (step S 107 ) may be executed at the same time.
[0050] FIG. 8 is a characteristic graph indicating a relation of the standard deviation σ/τ and the number of fluorescence photons measured by the measurer 3 . As shown in FIG. 8 , the standard deviation σ/τ is 0.1 or less for 185 fluorescence photons. Conventionally, 250 or more of fluorescence photons are required for a standard deviation σ/τ of 0.1 or less. Accordingly, the fluorescence lifetime τ with approximately the same level of error can be calculated using about three fourth of the conventional number of measured fluorescence photons or less.
[0051] In the first embodiment, whether the t1/τ and t2/τ are within the region R is determined after the fluorescence lifetime τ is calculated, and thus either the fluorescence lifetime τ is determined or the gate delay time t1 and the total gate length (t1+t2) are set again. As a result, the fluorescence lifetime τ of high accuracy can be calculated in a short time.
[0052] Note that, in the first embodiment, the gate control signals S 1 and S 2 of the measurer 3 individually control the gate delay time t1 and the second gate length t2. As shown in a time chart of FIG. 9 , the gate delay time t1 may be controlled based on the gate control signal S 1 , and the total gate length (t1+t2) may be controlled based on the gate control signal S 2 .
[0053] A measurer 3 A shown in FIG. 10 in place of the measurer 3 may be used if the specimen 5 has a high emission probability of fluorescence photons. The measurer 3 A includes amplifiers 3 a , 3 b , and 3 c , switches SW 1 and SW 2 , integrators 11 and 12 , and A/D converters AD 1 and AD 2 . The electric signal E input to the measurer 3 A is transmitted to the integrators 11 and 12 through the amplifier 3 a , the switches SW 1 and SW 2 , and further the amplifiers 3 b and 3 c . The electric signal E is integrated by the integrators 11 and 12 , and sampled and converted into digital signals by the A/D converters AD 1 and AD 2 . The measurer 3 A uses the digital signals output from the A/D converters AD 1 and AD 2 as the measured-value signals Ct 1 and Ct 2 indicating the number of fluorescence photons Thus, even if the specimen 5 has a high emission probability of fluorescence photons and the electric signal E is not formed in a pulse shape, the number of fluorescence photons can be accurately measured because the A/D converters AD 1 and AD 2 make sampling in correspondence to one photon.
[0054] A measurer 3 B shown in FIG. 11 in place of the measurer 3 may be used. The measurer 3 B can measure the number of fluorescence photons, regardless of an emission probability of fluorescence photons of the specimen 5 . The measurer 3 B shown in FIG. 11 is arranged by combining the configuration of the measurer 3 shown in FIG. 2 with that of the measurer 3 A shown in FIG. 10 . Thus, the processor 4 can select the measured-value signals Ct 1 and Ct 2 of the number of fluorescence photons based on a emission ratio of fluorescence photons emitted from the specimen 5 . Further, the processor 4 can calculate two kinds of fluorescence lifetime τ, and select and output a more appropriate fluorescence lifetime τ.
[0055] FIG. 12 is a block diagram of a fluorescence lifetime measurement apparatus 100 A being a modification of the first embodiment. As shown in FIG. 12 , the fluorescence lifetime measurement apparatus 100 A includes a storage 6 connected to a controller 1 A. The storage 6 stores the characteristic graph shown in FIG. 5 as a table. When the processor 4 outputs a signal indicating the fluorescence lifetime τ, appropriate t1/τ and appropriate (t1+t2)/τ are input from the table stored in the storage 6 to the controller 1 A, which determines whether the input fluorescence lifetime τ is appropriate. Thus, a time for calculating t1/τ and (t1+t2)/τ can be saved, thereby the fluorescence lifetime τ of high accuracy can be determined in a shorter time.
[0056] A second embodiment is explained below. In the first embodiment, the number of fluorescence photons is measured just after the specimen 5 is irradiated with the pulse excitation light. In the second embodiment, however, a delay time is set before measurement of the number of fluorescence photons starts so that the number can be calculated accurately.
[0057] FIG. 13 is a block diagram a fluorescence lifetime measurement apparatus 100 B according to the second embodiment of the present invention. As shown in FIG. 13 , a controller 1 B includes a time delay control unit 1 d . The time delay control unit 1 d sets gate control signals S 1 and S 2 such that measurement of fluorescence photons is delayed until emission of fluorescence photons becomes equal to or less than a light sensitivity of the PMT 2 d.
[0058] Since an emission probability of fluorescence photons emitted from an excited specimen follows Poisson distribution, the number of fluorescence photons is maximized just after emission of the excitation light, and thus may exceed the light sensitivity of the PMT 2 d . In this case, the number of fluorescence photons cannot be correctly measured, and thus a calculated fluorescence lifetime τ has a large error a. Thus, the time delay control unit 1 d sets an appropriate delay time so that the number of fluorescence photons can be accurately calculated.
[0059] FIG. 14 is an attenuation characteristic graph indicating that a limit of the light sensitivity of the PTM 2 d corresponds to the number of fluorescence photons no. Accordingly, the time delay control unit 1 d sets a delay time t0 (time T0 to T0′) so that the number of fluorescence photons is measured after it attenuates to no. FIG. 15 shows a time chart of a laser control signal S and gate control signals S 1 and S 2 .
[0060] As shown in FIG. 15 , a gate delay time t1 is set from a time T0′ to a time T1, a second gate length t2 is set from the time T1 to a time T2, and a total gate length (t1+t2) is set from the time T0′ to the time T2. Accordingly, if the number of fluorescence photons measured during the gate delay time t1 is shown by I 1 and the number of fluorescence photons measured during the second gate length t2 is shown by I 2 , a ratio I 2 /I 1 of I 2 to I 1 is expressed by the following equation (2)′:
I 2 I 1 = ∫ T1 T2 exp ( - t τ ) ⅆ t ∫ T0 ′ T1 exp ( - t τ ) ⅆ t ( 2 ) ′
[0061] Accordingly, the fluorescence lifetime τ can be calculated by the equation (2)′ in place of equation (2) explained in the first embodiment.
[0062] In the second embodiment, provision of the delay time after fluorescence photons are emitted enables the number of fluorescence photons to be measured accurately and the fluorescence lifetime τ to converge in a short time. Note that, in the second embodiment, the delay time is set based on the lightsensitivity of the PMT 2 d . However, it may be set in conformity with an emission probability of fluorescence photons discharged from the specimen 5 and with resolution of the apparatus in its entirety to the number of fluorescence photons.
[0063] A third embodiment is explained below. In the first and second embodiments, the processor 4 calculates and outputs the fluorescence lifetime τ, and the determination unit 1 c determines whether the gate delay time t1 and the total gate length (t1+t2) are appropriate based on the fluorescence lifetime τ. In the third embodiment, however, a first gate length and a second gate length are set to the same time length, and a time difference between a time at which the first gate length starts and a time at which the second gate length starts is set as a gate delay time. Whether the gate delay time t1 and the total gate length (t1+t2) are appropriate depends on measured value signals Ct 1 and Ct 2 output from the measurer 3 so that unnecessary calculation of the fluorescence lifetime τ can be omitted.
[0064] FIG. 16 is a block diagram of a fluorescence lifetime measurement apparatus 100 C according to the third embodiment. As shown in FIG. 16 , the measurer 3 measures the number of fluorescence photons 1 i and 12 by inputting an electric signal E and outputs measured-value signals Ct 1 and Ct 2 to a controller 1 C and the processor 4 . The controller 1 C determines whether a gate delay time t1 and a total gate length (t1+t2) are appropriate based on the measured-value signals Ct 1 and Ct 2 input thereto. When the gate delay time t1 and the total gate length (t1+t2) are not appropriate, the digital counter C 1 set them again, and as long as they are appropriate, the controller 1 C calculates a fluorescence lifetime τ through the processor 4 .
[0065] FIG. 17 shows a time chart of a laser control signal S and gate control signals S 1 and S 2 . As shown in FIG. 17 , “ON” period of times of the gate control signals S 1 , S 2 are set to the same period of time t2, and a time difference between the time at which the first gate length t2 starts and the time at which the, second gate length starts is set as a gate delay time t1. Accordingly, a total gate length is expressed by (t1+t2).
[0066] When the first gate length t2 and the second gate length t2 have the same gate length t2 and the numbers of fluorescence photons measured by the respective gate lengths are expressed by I 1 and I 2 , the fluorescence lifetime τ is expressed by the following equation (4)′:
τ = t1 ln I 1 I 2 ( 4 ) ′
[0067] The total gate length (t1+t2) is expressed by the following inequality (6)′ which is a modification of inequality (6) explained in the first embodiment:
t 1 +t 2≧4τ (6)′
[0068] On the other hand, a ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 and I 2 is expressed by the following inequality (7)′ which is a modification of inequality (7) explained in the first embodiment likewise:
e≦I 1 /I 2 ≦e 2 (7)′
[0069] When an approximate value (e≈2.72) is substituted for a base “e” of natural logarithm shown in the inequality (7)′, inequality (7)′ is approximated by the following inequality (7)″:
2.72≦( I 1 /I 2 )≦ e 2 (7)″
[0070] Accordingly, a determination unit 1 e determines whether the ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 and I 2 satisfies inequality (7)″ from the measured-value signals Ct 1 and Ct 2 corresponding to the number of fluorescence photons I 1 and I 2 . When the ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 , and I 2 satisfies inequality (7)″, a calculation instruction unit 1 f causes the processor 4 to calculate the fluorescence lifetime τ. When the ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 and I 2 does not satisfy inequality (7)″, the determination unit 1 e sets the first gate length t2 and the total gate length (t1+t2) again.
[0071] FIG. 18 is a flowchart of an operation of the fluorescence lifetime measurement apparatus 100 C until the fluorescence lifetime τ is settled. The gate length control unit 1 b sets the first gate length t2, the total gate length control unit 1 a sets the total gate length (t1+t2) (step S 201 ). Next, the measurer 3 measures the numbers of fluorescence photons I 1 and I 2 (step S 202 ). The measurer 3 outputs the measured-value signals Ct 1 and Ct 2 corresponding to the numbers of fluorescence photons I 1 and I 2 to the controller 1 C. A determination unit 1 e in the controller 1 C determines whether the ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 and I 2 satisfies 2.72≦I 1 /I 2 ≦7.39 based on the measured-value signals Ct 1 and Ct 2 (step S 203 ). When the ratio (I 1 /I 2 ) satisfies 2.72≦I 1 /I 2 ≦7.39 (step S 203 , YES), the calculation instruction unit if causes the processor 4 to calculate the fluorescence lifetime τ (step S 204 ). When the ratio (I 1 /I 2 ) does not satisfy 2.72≦I 1 /I 2 ≦7.39 (step S 203 , NO), the determination unit 1 e sets the first gate length t2 and the total gate length (t1+t2) again.
[0072] When the first gate length t2 and the total gate length (t1+t2) are set again, the first gate length t2 may be set appropriately and only the gate delay period of time t1 may be changed based on inequality (7)′ without changing the first gate length t2 and the second gate length t2. In this case, since portions to be changed are small in number, the first gate length t2 and the total gate length (t1+t2) can be set appropriately in a shorter time.
[0073] In the third embodiment, whether the first gate length t2 and the total gate length (t1+t2) are appropriate can be easily determined by setting the first gate length t2 and the second gate length t2 to the same length and determining whether the ratio (I 1 /I 2 ) between the numbers of fluorescence photons I 1 and I 2 , which are measured by the first gate length t2 and the second gate length t2, satisfies a conditional equation employing specific values. Accordingly, when the fluorescence lifetime τ is calculated only when the first gate length t2 and the total gate length (t1+t2) are determined appropriate, the fluorescence lifetime τ of high accuracy can be settled at a high speed by omitting unnecessary calculation of the fluorescence lifetime τ.
[0074] Note that, in the first to three embodiments although a plurality of gate lengths are set as the two gate lengths, that is the first and second gate lengths t1 and t2, they may be set as three or more gate lengths.
[0075] Thus, the fluorescence lifetime of high accuracy can be calculated in a short time by a simple method.
[0076] Although the invention has been described with respect to a specific embodiment for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art which fairly fall within the basic teaching herein set forth.
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A fluorescence lifetime measurement apparatus includes a first controller controlling a total gate length and a second controller controlling a start gate length of a plurality of gate lengths into which the total gate length is divided. The start gate length is a time window whose start time is when measurement of the number of fluorescence photons of a specimen starts. The apparatus also includes a measurer measuring the number of fluorescence photons for each of the gate lengths; a processor calculating a fluorescence lifetime the specimen based on the start gate length and the number of fluorescence photons; and a third controller causing, when the fluorescence lifetime does not satisfy a predetermined condition, the first and second controllers to change the start gate length and the total gate length.
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BACKGROUND OF THE INVENTION
It is well known that the weaving process necessarily involves the use of loom apparatuses and processes whereby the warp yarns are controlled to form sheds through which the weft is inserted, beat up by the loom reed and then locked into position by warp reversal. The warp yarns are controlled by means of heddles mounted within harness frames, the frames being moved between upper and lower positions by suitable driving means. In the most simple weaving arrangement there are only two harness frames, each frame controlling a preselected number, usually half, of the warp yarns. To produce more intricate weaving patterns, larger numbers of harness frames are used so that the number of warp yarns controlled by any given frame is less than the number that would usually be controlled in the simple two harness construction.
It is also known that loom harnesses may be moved between upper and lower positions by either positive or negative drive means. The positive driving method means that the harnesses are actively moved in two directions by a positive driving mechanism whereas in the negative method the harnesses are driven positively in one direction and then returned to the original position by means of biasing springs, or equivalent motivating elements. Most commonly, in loom negative dobby applications, the frames are moved to the upper position by means of a loom dobby that is connected to the upper rail of each frame. The return biasing means is appropriately connected to the bottom rail of each frame. Thus, when the dobby moves a frame to the upper position, the lower biasing means is tensioned so that it can return the frame to its lower position upon relaxation of the dobby pull.
Although various loom negative dobby systems generally have been used widely and found useful for many applications, there exist inherent limitations. Specifically as loom speed has been increased to achieve greater loom productivity it has been necessary to increase the strength of the biasing means. This increase in strength has, in turn, caused the harness frames to be placed in extreme tension and the result has been bowing of the frame, with the consequent undesirable side effects. Strengthening of all of the interrelated parts has meant increases in the sizes of the parts and these increases in sizes have restricted the number of loom harnesses that could be used on any given loom. Also, change or repair of a loom harness has caused excessive down time of the loom because the connections to the harnesses were not capable of being easily disconnected.
OBJECTS OF THE INVENTION
It is therefore a principal object of this invention to provide an improved support for harness frames in loom negative dobby applications such that the harnesses are not subjected to damaging tensile stresses.
Another object of this invention is to provide an improved loom harness support in which the support members for the harness are of no greater thickness than the harness frame, thus permitting a greater number of loom harnesses in a given space than has heretofore been possible.
An additional object of this invention is to provide an improved loom harness support in which the harnesses are operated from only one of the two horizontal harness frame members.
These and other objects of this invention will be in part obvious and in part explained by reference to the accompanying specification and drawings in which:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the improved support of this invention showing a portion of the dobby pull cable and a portion of the top rail of the harness frame;
FIG. 2 is a perspective view of the pivot pin that is used to connect the two operative links shown in FIG. 1;
FIG. 3 is a perspective view of a retaining clip that is used to attach the vertical link of FIG. 1 to the base member that is attached to the harness frame;
FIG. 4 is a perspective view of the pivot pin used in conjunction with the same connection as the clip FIG. 3;
FIG. 5 is a perspective view of the mounting base that is used to connect the connecting link to the harness frame; and
FIG. 6 is a view taken along the line 6--6 of FIG. 6.
DESCRIPTION OF THE INVENTION
It has herein, previously been stated that the present invention makes possible the mounting of a greater number of loom harnesses within a more compact area than has been possible with previous harness supports. Additionally, since the operating forces to move the harnesses between their upper and lower positions are effected from one side only the tensile stresses to which harnesses were formerly subjected has also been eliminated. For a better understanding of the invention reference is made to FIG. 1 of the drawings in which the numeral 10 indicates a portion of the upper, horizontal rail of a harness frame. It can be seen that there is a mounting base 11 that has been attached to the upper rail by means of a pair of threaded fasteners 12 that thread directly into the upper portion of the rail 10. Mounting base 11 includes an upwardly extending flange 13, which in this case is actually constituted of a pair of upstanding members. Through the flange 13 there is a circular opening 14, best seen in FIG. 5 of the drawings, which receives the pivot pin 15 shown in FIG. 2 of the drawings. It will be noted that, referring to FIG. 4 of the drawing, the pivot pin 15 is substantially cylindrical in shape and has a pair of slotted openings 16 on each side thereof which receive the pin clip 17 shown in FIG. 3 of the drawings. It is the function of the pin clip to hold the clip extends completely around the bottom of base 11 through an opening formed by removing a small portion of the base which would normally contact the upper rail 10 of the harness frame.
The next element in the improved support of this invention is the connecting link 20 having means at one end to mate with the flange 13 of mounting base 11. This means comprises an end 20' that interfits with the flange 13 of base 11. The end 20' includes a circular opening which extends therethrough and which can be brought into registry with the opening 14 of flange 13.
The other end of connecting link 20 includes means for connecting the link to the dobby. In this case the means comprises a hook like portion 21 that defines a recess 22 for receiving the connecting link 23 of the dobby pull cable 24.
To effect upward and downward movement of the connecting link 20 and thereby the harness frame 10, the improved support also includes a harness return bar 30 that is disposed substantially horizontally and which is mounted for pivot movement about a shaft 31 that is connected directly to the frame of the loom. The inner end of harness return bar 30, i.e. that end adjacent to the connecting link 20 has means providing for a simple, easily disassembled connection with the connecting link 20. This means comprises an upwardly and rearwardly directed slot of lesser diameter than the diameter of the opening that is present in the connecting link 20. The numeral 32 identifies this upwardly and rearwardly extending slot which is formed by the hook like overhand portion 33 on the end of harness return bar 30.
The connecting link 20 has an opening extending therethrough, in the vicinity of slot 22, to receive a pivot pin 34 that enables connection between the connecting link and harness return bar 30. The pivot pin 34 has extensions 35 protruding outwardly from each side thereof which are of approximately the same thickness as that of the slot 32 formed by overhang 33. This combination provides a simple yet effective means for connecting members 20 and 30, and one which can be readily disconnected.
The other end of harness return bar 30 is provided with a plurality of openings 40 into which can be hooked a spring or other suitable biasing means 41 that is to be used to return the harness and the remainder of the dependent support mechanism to the lower position when the dobby pull cable 24 no longer is overcoming the return pull of spring 41.
It can be seen by referring to the drawings that the only connections made to the harness frame 10 are those which operate through the support base 11 that is secured to the frame 10 by means of threaded fasteners 12. When it is desired to form a shed with certain of the warp yarns the appropriate dobby pull cable 24 will be actuated upwardly and the harness return bar 30 pivoted in a clockwise direction about shaft 31. This action of course stretches the coil spring 41 causing it to exert a greater pull against the outer end of bar 30. When the dobby pull cable returns to its original position then the action of coil spring 41 will result in counterclockwise movement of bar 30 about the axis of shaft 31, permitting the connecting link 20 and the frame 10 to return to its lowermost position.
In the event that it is desired to completely remove a harness frame it is necessary only to move the outwardly extending ears of pin 34 down and out of the slot 32 so that the spring 41 no longer exerts its biasing influence. Once this constraining influence is removed, then the entire harness frame assembly can be moved upwardly so that the hook portion 21 clears the connector 23 and the harness is easily removed from the loom.
Although the present invention has been described in connection with preferred embodiments, 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.
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An improved support for loom harness frames comprising a mounting base for attachment to the frame, a connecting link to engage the loom dobby, a harness return bar, and separate means joining the base, the connecting link and the return bar which are of lengths substantially no greater than the combined thicknesses of the elements being joined.
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BACKGROUND OF THE INVENTION
The invention concerns a device for determining the influence of dispersion on a distance measurement by the principles of phase or pulse modulation according to the preamble of claim 1 , as well as a use of the device for correcting distance measurements for the influence of dispersion according to claim 1 and a geodetical instrument according to claim 12 .
In almost all electronic distance mesauring (EDM) devices, the influence of atmospheric parameters is added after the distance measurement properly speaking, in terms of a distance correction obtained in a calculation step. The pertinent atmospheric parameters are measured, not with the distance meter itself but with other, separate instruments such as thermometers, barometers, and hygrometers.
The rate of propagation of an optical pulse emitted in electro-optic distance measurements, or of a signal train modulated in whatever way, is determined by the group refractive index n. Here the refractive index and the group refractive index depend primarily on wavelength, temperature, atmospheric pressure, the gas mixture and humidity of the prevalent atmosphere, rather than being constant quantities.
A direct range reading D 0 as measured and displayed by the electronic distance meter (EDM) (the raw measurement) refers to a particular group refractive index n 0 . The true group index n=(T, p, RH, . . . ) can be calculated with the aid of the meteorological parameters of temperature T, atmospheric pressure p, and relative humidity RH. Using a so-called atmospheric correction Δ D = D 0 · ( n 0 - n n ) ( 1 )
the true distance D can be determined:
D=D 0 +ΔD. (2)
Using this atmospheric “post processing” procedure one can attain distance measuring precisions attaining 1 ppm, but the raw distance D 0 that is read can easily deviate from the true value by 30 ppm or more when temperature T and atmospheric pressure p are not known or not representative over the full optical path.
When the distances are longer and then often cover a nonuniform topography, then it becomes doubtful that the effective group refractive indices can be determined reliably from meteorological data applicable at the two extreme points of the range. Attempts to determine such data along the way have not been successful so far.
In geodesy an economic distance meter is desirable which can automatically and rapidly correct for the influence of the atmospheric refractive index. At distances in the range between 100 m and several km this index has a decisive influence on the results of electro-optical distance measurements. This is true, both for electro-optical distance meters based on phase measurements and for distance meters based on travel time measurements. Correcting automatically for the influence of atmospheric refraction one could considerably reduce the time and instrumental requirements in precision measurements involving long distances.
One of the basic ideas is that of utilizing the spectroscopically wide-band dispersion, by measuring the distance with light or electromagnetic radiation having two different wavelengths. This two-color or multicolor procedure has been known since about 1975. When measuring the distance simultaneously with at least two different electromagnetic wavelengths, either optical or in the microwave range, and accounting for the known, spectroscopically wide-band dispersive behavior of the atmosphere, one can determine the most important atmospheric interference parameter(s), and thus substantially correct the distance value for the influence of the group refractive index, which as a rule is not precisely known.
Pertinent theories rely on the spectroscopically wide-band formulas of Edlen and of Barrel & Sears. (Ref. Rainer Joeckel, Manfred Stober: Elektronische Entfernungs-und Richtungsmessung [Electronic distance and direction measurements], Konrad Wittwer Publishers).
The resulting distance values from the two carrier wave-lengths are D r and D b , the corresponding refractive indices are n, und n b . The true distance is obtained from the following relation for distance correction: D = D r - ( D b - D r ) · ( n r - 1 n b - n r ) . ( 3 )
The actual difficulty of this two-color method, which relies on the model of the spectrocopically wide-band formula, is related to the resolution and precision needed in determining the difference of distances (D b −D r ).
The model parameter Q = ( n r - 1 ( n b - n r ) ) ( 4 )
becomes smaller and more favorable the further apart the two carrier wavelengths. The model parameter is very large, and with it the error of distance correction, when the two carrier wavelengths are not sufficiently far apart.
The current limit of precision that can be attained in measurements of optical signals is known to be around 1%, the main factor influencing the signal measuring errors being the atmospheric turbulence. Since the influence of resolution is independent of the distance, this kind of two-color instrument will be potentially superior to single-color instruments at distances well beyond 2 km.
Known two-color instruments are for instance the Goran I from National Physical Laboratory (Teddington/UK) with λ b =458nm and λ g =514 nm and the large value of Q=57. For a distance error of 1 mm, the resolution needed is then 0.02 mm. This can only be realized, if at all, with very substantial input, hence this method has so far not become accepted. So far no commercial instruments are in use, and installations built up to now are very expensive and occupy the surface area of a lab bench.
From the patent document U.S. Pat. No. 5,233,176, a device using the two-color method is known which compensates the results for the influence of atmospheric effects by evaluating the departure of two laser beams having different wavelengths from corresponding reference beam pathways. Laser light is emitted in short pulses with two different carrier wave-lengths. From the dispersive shift of the two pathways from a straight line, the dispersive influence is deduced and the results corrected.
It is a considerable drawback of known devices with two or three carrier wavelengths that they utilize the small variations in wide-band optical dispersion resulting from two closely spaced carrier wavelengths. In doing so they follow the wide-band models of Barrel & Sears or the relations of Edlen. The main drawback is the small size of the quantity measured, which provides an inaccurate distance correction inferior in its quality to the classical atmospheric correction involving a determination of the meteorological parameters T, p, and RH. According to the models of Barrel & Sears or the relations of Edlen, the difference in group refraction of the atmosphere between red (e.g., 635 =m) and near infrared (e.g., 820 nm) is very small (about 5 ppm).
One thus can summarize the essential drawbacks of all hitherton existing instruments with two or three carrier wavelengths, as follows:
(i) Using carrier wavelengths having little separation leads to a very small difference in optical dispersion.
(ii) This leads to the need for an extremely high resolution which in the prior art cannot be realized under field conditions.
(iii) The alternative of using carrier wavelengths that are widely spaced, according to the prior art requires a high instrumental effort inasmuch as the requirements for controls, switching, etc. are different between the two wave-length regions.
(iv) The instruments to be realized when using carrier wavelengths that are widely spaced do not meet the requirements of surveying technology, especially so with respect to their weight and ruggedness.
SUMMARY OF THE INVENTION
It is a technical object of the present invention to provide a geodetic device, fit for field measurements of dispersion over a visible range of distances using a multi-color method requiring lower resolution for a given distance error or yielding a smaller distance error for a given, attainable resolution than devices of the prior art.
It is a further object to provide a device based on phase measurements yielding distance values corrected for the dispersive influence.
It is a further task to simplify the technical prerequisites for the emission of electromagnetic radiation for multicolor measurements involving a larger wavelength difference.
It is a further task to provide a device for multicolor measurements involving a large wavelength difference utilizing optics in common with a visual telescope.
These objects are attained according to the invention by the characterizing features of claim 1 or the dependent claims. A use of the device follows from claim 11 , a theodolite follows from claim 12 . Advantageous and alternative embodiments and extensions become evident from the features of the dependent claims.
The basic idea of the invention is that of supplementing the measurements in the infrared or red region (850 nm or 780 nm) with measurements in the blue-violet or violet region (440 nm or 405 nm). Light in the blue-violet or violet region is subject to a strong effect of atmospheric refraction, hence an improved atmospheric correction becomes possible. The difference in atmospheric group refraction index is about 25 ppm in the violet region, for instance, while factor Q is about 10, so that the demands on the accuracy of single-color measurements are much lower than in methods of the prior art.
Power-saving, economic semiconductor lasers to be used as sources of radiation in the blue-violet and violet region of the spectrum provide the basis for implementing instruments for a compact solution suitable for practical geodesic uses. Lasers emitting in this region of the spectrum, or the semiconductor materials on which they are based, are known for instance from the patent documents U.S. Pat. No. 5,306,662, U.S. Pat. No. 5,578,839, U.S. Pat. No. 5,747,832, and U.S. Pat. No. 5,767,581.
Blue-violet or violet laser diodes have an accuracy superior to that of blue laser diodes. A potential use of UV laser diodes (<400 nm) is no longer advantageous, since their radiation is strongly attenuated by increasing atmospheric scattering. Because of Rayleigh scattering, the scattering coefficient of air increases with the fourth power with decreasing wavelength.
For the region at the long-wave end of the visible spectrum, laser diodes are commercially available and sensitive semiconductor detectors exist, thus economic solutions can be realized.
For instance, a distance meter can be fitted with an infrared semiconductor laser having a wavelength of λ IR =850 nm as well as with a violet semiconductor laser having a wavelength of λ v =405 nm, where suffixes IR and V signify infrared and violet, respectively. The required measurement of distance can occur with both lasers at the same time, or consecutively.
The difference between the two distance readings is about 25 ppm, that is, for a distance of 1 km the violet laser yields a value about 25 mm farther than the infrared laser. However, the range difference D V −D IR will vary depending on the current group refractive index of air (as a function of temperature, atmospheric pressure, humidity, C02 content etc.).
The true distance can be calculated while allowing for (3), according to D = D IR - ( D V - D IR ) · ( n IR - 1 n V - n IR ) . ( 5 )
Using wavelengths of λ v =405 n und λ IR =850 nm one finds D = D IR - ( D V - D IR ) · ( 1.002945 - 1 1.000320 - 1.0002945 ) = D IR - ( D V - D IR ) · 11.54902 . ( 6 )
Thus, for making the correction one multiplies the distance difference with the factor of 11.549, which implies that the individual distances must be determined more accurately by a factor of 11.549·{square root over (2)} than the accuracy desired for the final result. For instance, for a desired absolute acuracy of 3 mm the single-color distances must be determined relative to each other with an accuracy of −0.2 mm.
A very precise, known measuring procedure based on the so-called Fizeau principle is that of the Mekometer (J. M. Rüeger: Electronic Distance Measurement, 4th edition, Springer Publishers, 1996), where the laser beam to be emitted is modulated with an electro-optic modulator (a Kerr cell) in the MHz to GHz range, while the received beam is demodulated with the same modulator in a phase-coherent way. Particularly because of the high frequencies involved, this method of external modulation yields an extremely high accuracy in distance measurements, but is rather less suitable for ergonomic instruments of small volume fit for field measurements.
The objective of distance measurements with laser diodes which are to be accurate to <0.2 mm calls for another technical solution. That of directly modulating the current with a high frequency is not appropriate in the case of laser diodes, since it does not yield the required measuring acuracy.
The required accuracies in the sub-millimeter range can be attained, to the contrary, when the intensity of laser diodes is modulated directly by electronic control circuits, so that the optical rise and decay times are if possible comparable to 1 nanosecond or less.
The accuracy of an individual distance reading then depends on the wave front of the signal or phase fluctuation during emission. A modulation of intensity of the carrier wave-length or an excitation of the laser diodes for the emission of pulses having a pulse width of less than 2 nano-seconds offers the advantage of smaller phase fluctuations, since the radiative modes of the laser diode are forced to emit in phase, while interference from coherent radiation characteristics are suppressed as well. A device having this characteristic is known from patent documents EP-0,701,702 and EP-0,738,899.
The use of carrier wavelengths in the blue-violet or violet region requires pulse widths or rise times preferably in the picosecond range, since the energy differences between the levels of the lasers are larger than in lasers of longer wavelengths, while the lifetime of states in a laser level is negatively correlated, for instance with the energy difference of the levels and of the radiation to be emitted in the transition. In such short pulses a higher power and a homogeneous emission can be attained.
The exclusive use of wavelenghts in the visible region (ca. 700 nm to 400 nm) or of wavelengths in the border regions of the visible spectrum is advantageous in terms of laser safety, since such lasers are in the laser class 2 authorizing higher power levels. Moreover, a visible light spot produced by the laser on the object to be surveyed provides a simple way of positioning the light spot.
With wavelengths in the border region rather than in the middle of the visible part of the spectrum, it is then possible to use optics in common with a visual telescope, and the theodolite telescope will not provide a tinted image, while if a green laser was used, for instance, the image in the telescope would appear tinted to the eye.
Common optics have the further advantage to economize volume, particularly in the case of radiometric optical systems having a receiver aperture as large as possible. Moreover, the two coaxially arranged carrier waves travel through precisely the same air volume, so the distance difference comes about through dispersion exclusively, while other interferences cannot occur.
An advantage on the receiver side arises when using common optics, and the same receiver (photodiode, rf amplifier, demodulator), so that possible drifts will mutually cancel. In devices existing up to now, which because of the different laser systems employ different modulation procedures, separate receiver systems are required. Moreover, because of the smaller wavelength difference present in these devices, the individual distances must be measured rather more accurately, which may lead to either a long measuring time or a smaller range of action.
The use according to the invention, of wavelengths wide apart by comparison, not only has the advantage that the more strongly dispersive behavior of the atmosphere can be used in a better way to determine the refractive index but also, that the visual telescope channel is not adversely affected.
Using a common objective for both the visual telescope and the two carrier wavelengths in the border region of the visible spectrum, is associated with special optical requirements. On one hand the optical imaging quality and particularly so the sharpness of the image must be secured, on the other hand the image intercepts must be identical for the two wavelengths if both carrier waves are imaged on the same receiver diode. This difficult task can be tackled with an objective consisting of a mere three lenses when an optimum selection is made for the glass qualities of the lenses.
For identical dimensions of the image intercepts at 400 nm and 780 nm, for instance, one uses suitable glass qualities in order to move the curve of chromatic focal shift which is parabolic as a function of wavelength to the correct spectroscopic position. The image intercepts for the two carrier wavelengths are now identical without a deterioration of image quality in the visual part of the spectrum.
Using optics having reflective elements which exhibit an achromatic behavior, one has the possibility of receiving and imaging beams having different wavelengths with the same opticts, but systems with mirror elements generally are more expensive and more demanding as to the surface quality of the optically active surfaces.
Using two semiconductor lasers as the radiation sources one can attain a small structural size of the device for dispersion correction, which thus can be integrated without difficulties into a theodolite, and be used there for an automatic elimination of dispersive errors in distance measurements. For their use in a theodolite, the low power consumption of the semiconductor lasers is an advantage, since the normal power supply is by batteries. The use of the device according to the invention in a theodolite is described here, merely as an example for a geodetic instrument. Basically, this device can be utilized in any appropriate geodetic instrument.
Further design advantages arise for the device according to the invention. In the device according to the invention, the second light source is also a laser diode or LED which in its response to the electronic controls corresponds to the distance meter's first light source. Thus, technically simple realizations of the two-color process become possible, since merely a duplication is required, in particular, for the pathway of the emitted beam and for the electronic controls. The common pathway for the emitted beams implies that an approximately identical volume of the atmosphere is probed by the two coaxial wavelengths.
When using an infrared and a violet semiconductor laser, the same type of modulation (amplitude modulation) can be used for both lasers. This leads to a simpler adjustment of luminous power and a simpler electronic controller, since direct current modulation can be employed. In view of this direct modulation an external modulator which has drawbacks both with respect to its price and complexity and with respect to its space requirements, is not needed.
The semiconductor lasers that can be used according to the invention have dimensions which are orders of magnitude smaller than those of the gas or solid-state lasers used up to now in two-color range finders, which in most cases were operated with an external polarization modulator. The energy or power consumption is lower by a factor of 10 to 100, and expensive and complicated modulator controls are no longer required. Moreover, in view of the direct emission of laser light having different carrier wave-lengths, a frequency doubling or tripling of the laser light with a nonlinear crystal is not necessary.
In view of the stronger dependence of the refractive index on wavelenght in the region of short wavelengths, it will be advantagous to stabilize the blue-violet or violet radiation source with respect to its wavelength. This can be achieved with generally known procedures, such as distributed feedback, distributed Bragg reflection, fibre Bragg grating, or Fabry-Perot etalon locking.
Possiblities to account for temperature-dependent drift of the laser exist in terms of its simulation and subsequent correction by calculation, or by its direct suppression with cooling or heating of the laser. The possibility of correction by calculation is based on the unique dependence of wavelength on laser temperature which exists in the blue-violet and violet region of wavelengths. Violet laser diodes, for instance, have a thermal wavelength drift of typically 0.05 nm/° C., which is distinctly smaller than that of longer wavelength laser diodes, hence the need for a compensation or correction is smaller than with other laser types. Using a temperature sensor placed directly on the laser diode one can determine the wavelength to 0.05 nm accuracy, and eliminate the influence on the dispersive effect with the needed precision by calculation.
The drift can also be avoided directly or reduced, as an alternative or in addition, by using cooling or heating of the laser, for instance with a Peltier element.
In view of the advantages that were described, with respect to the optics and electronics used, the mechanical dimensions attainable, and the energy or current consumption, the device according to the invention will allow two-color distance measurements to be integrated into a geodetic instrument such as for instance a tachymat.
BRIEF DESCRIPTION OF THE DRAWINGS
The device according to the invention and, in the instance of a theodolite, an instrument according to the invention will in the following be described purely as examples in greater detail with the aid of embodiments presented schematically in the drawing. Individually,
FIG. 1 shows the physical conditions for a two-color method in a device of the prior art;
FIG. 2 shows the physical conditions for a two-color method in a device according to the invention;
FIG. 3 shows in a schematic way the advantage of stabilizing the shorter-wavelength source of radiation;
FIG. 4 shows in a schematic way the use of a device according to the invention in a theodolite telescope;
FIG. 5 shows the chromatic focal shift of optics for a device according to the invention, and
FIG. 6 shows the wave front error of optics for a device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a utilization of dispersion for a two-color method of the prior art where two carrier wavelengths λ 1 and λ 2 are used which probe volumes of the atmosphere in the red region of the spectrum at 700 nm and in the infrared region of the spectrum at 850 =m. Wavelength λ is plotted on the horizontal axis, while the refractive index n is plotted on the vertical axis. As the precision of the dispersive correction demands a difference between the refractive indices covered by the measurements that is as large as possible, two carrier wavelengths must be selected in view of the wavelength dependence of the refractive index which are far apart, i.e., the difference Δλ of the carrier wavelengths λ 1 and λ 2 is maximized. According to the prior art, this is done by shifting one of the wavelengths into the infrared region.
FIG. 2 shows the physical conditions for a two-color method in a device according to the invention. Wavelength λ is again plotted on the horizontal axis while the refractive index n is plotted on the vertical axis. The wave lengths used, of λ 1 and λ 2 , are now in the violet region at 405 nm and in the red region at 700 nm. This implies that while there is a larger wavelength difference, both wavelengths can be located in the visible region. Moreover, the difference Δn of the refractive indices is reinforced by the steep rise of the refractive index at the short-wave end of the spectrum. Curve A schematically shows the brightness sensitivity of the human eye.
FIG. 3 shows the physical facts leading to advantages of a stabilization of the short-wave radiation. Again the wavelength λ is plotted on the horizontal axis, while the refractive index n is plotted on the vertical axis. The radiation emitted with a wavelength of 405 nm may on account of a number of effects, such as thermal effects, fluctuate around its nominal value within a range of Δλ or drift away from it. The resulting variation Δn of the refractive index attains values which, in view of the steep curve of the refractive index in the short-wave region, may attain the order of magnitude of the total difference found in a procedure of the prior art, and hence has a negative effect on the accuracy of the device. Therefore, a stabilization of the short-wave radiation will under certain conditions be a necessary prerequisite.
FIG. 4 shows as an example the realization of the device according to the invention in a theodolite telescope. A transmitter unit 1 controls a short-wave source of radiation 2 and a long-wave source of radiation 3 , which thus emit electromagnetic radiation of two different carrier wavelengths. A beam splitter 4 brings the two carrier wavelenghts together, and the beams are then sent through the volume of atmosphere 5 to be probed, to a reflector 6 . After their reflection, the radiation is sent via a splitting cube 7 to a receiver 8 , is received there, and is electronically processed in a receiver unit 9 . In the distance measuring unit 10 that follows, the distance being measured is calculated and corrected for the dispersive influence in a calculating unit 11 . A visual telescope 12 is optionally used to align the theodolite.
FIG. 5 shows the curve of the chromatic focal shift for a common optics consisting of three lenses which by selection of the glass qualities have been spectroscopically optimized with respect to the two wavelengths used. The vertical axis indicates the wavelength of the electromagnetic radiation in micrometers, the horizontal axis indicates the focal shift in micrometers. Line B indicates the situation for two semiconductor lasers having their wavelengths in the violet region at 400 nm and in the red region at 780 nm. An identical focal shift occurs for these wave-lengths, so that a common imaging optics can be used. If instead of the violet semiconductor laser a blue-violet one was used, or instead of the red semiconductor laser, a green one was used, as shown for comparison by line C, then different focal shifts would arise for the two wavelengths, and different optics optimized for this new wavelength combination would have to be used. In view of similar shifts occurring at red and violet wavelengths, which are due to the typical shape of the curve of focal shifts, it is easier to produce common optics for these two wave-lengths.
The optical quality attainable with corresponding optics, that is, the image quality, is shown in FIG. 6 . Plotted is the RMS (root-mean-square) wave front error against wavelength of the electromagnetic radiation for the three lenses. The horizontal axis indicates the wavelength in micrometers, while the vertical axis indicates the wave front error in units of wavelength. The RMS wave front error is a measure of quality of the corresponding lens.
The curves for the refractive index and for the brightness sensitivity of the human eye shown in FIGS. 1 to 3 should be understood to be merely qualitative. The differences such as Δn and Δλ, explain the effects that appear in a qualitative way but cannot be used as a basis of quantitatively exact considerations.
It is to be understood that the figures presented represent one of many embodiments, and one skilled in the art will be able to derive alternative embodiments, for instance by using other means for emission or reception of the electro-magnetic radiation or signal uptake or signal processing.
Listing of Reference Symbols
1 Emitter unit
2 Short-wave source of radiation
3 Long-wave source of radiation
4 Beam splitter
5 Volume of atmosphere
6 Reflector
7 Splitting cube
8 Receiver
9 Receiver unit
10 Distance measuring unit
11 Calculating unit
12 Visual telescope
A Brightness sensitivity
B Line
C Line
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A device determines and subsequently corrects the dispersive influence on a measurement made according to the principles of phase or pulse modulation along a visible range. The device has an element for emission of electro-magnetic radiation with two carrier wavelengths in the border regions of the visible spectrum. After passing through a volume of atmosphere to be probed, and reflection, the radiation is received and the dispersive influence, for instance, on the distance measurements, is calculated and corrected.
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FIELD OF THE INVENTION
The invention described herein relates to modified biotins useful for the preparation of conjugates with radionuclides for use in human and animal diagnostics and therapy, particularly for the diagnosis and treatment of pathological conditions such as tumours.
BACKGROUND OF THE INVENTION
Tumour therapy is mostly implemented through the use of substances targeted at destroying cancer cells. This can be achieved with cytotoxic substances, which have to penetrate into the tumour cells in order to exert their full effect, or by means of treatment of the tumour cells with radiation of sufficient energy to kill the cells. In both cases the main problem is to deliver the substance in a selective manner to the target cells, so as to avoid possible damage to the surrounding healthy cells. In the case of radiopharmaceuticals, i.e. substances carrying radioactive portions, the problem of selectively delivering the active part (that is, the radioactive portion) to the tumour target, avoiding as far as possible diffusion of the radionuclide in the body or interaction with healthy cells surrounding the tumour, is perceived as being particularly important.
For a discussion of all the issues involved and the solutions proposed to date, the reader is referred to U.S. Pat. Nos. 5,283,342, 5,608,060 and 5,955,605, assigned to NeoRx Corporation.
In these documents, the problem, amongst others, of the resistance of the molecule carrying the radionuclide to the metabolic attacks of the body is discussed. Specifically, the case most carefully studied is the molecule of biotin, which is one of the first choices for delivering the radionuclide to the tumour cells, thanks to its well-known interaction with avidins. Biotin is bound to the radionuclide-chelating portion, e.g. a molecule of tetra-azacyclododecanetetra-acetic acid [DOTA], via a linker. One of the main problems related to the use of biotin-DOTA conjugates is the resistance of the complex containing the biotin molecule, as connected to the radionuclide via the linker, to biotinidases, enzymes that break the peptide bond present in the complex. This peptide bond stems from the union of the chelating agent and biotin.
Among its much desired characteristics, this complex must be eliminated from the body rapidly and efficiently and must be sufficiently small (M.W.<1000) to allow easy distribution into the extracellular fluid where it will bind the tumour cells. In addition, it must show proven stability in vivo with only minimal uptake by non-tumour cells and rapid (renal) clearance and must not be metabolised.
Moreover, the chelating moiety must be such that it is not released in vivo, thus delivering potentially toxic compounds within the body. Experts in the field are clearly familiar with the problem of the release of radionuclide by the chelating portion, including metal ions which are entirely foreign to the body, which may be endowed with radioactivity of various types and even high-energy radiation, which is therefore highly damaging.
In a previous patent application from the same Applicant (WO 02/066075) our group reported the synthesis of a new biotin-DOTA conjugate together with binding, stability and affinity studies performed on this new derivative. The novelty of the new conjugate was that the amide carboxylic group was reduced to a methylene one thus generating the N-aminohexyl biotinamido derivative (r-BHD) in which the amide was transformed into a secondary amine without affecting the length of the biotin side-arm involved in Av/Sav binding. The DOTA ligand, in this compound, was directly linked to the amino group of the reduced biotin-hexamethylenediamine derivative through one of the four N-acetic side arms.
Moreover, the synthetic flexibility of r-BHD allows to generate a variety of new biotin derivatives for example with two DOTA chelators conjugated to the side-chain of biotin with the purpose to increase the efficacy of targeted radionuclide therapy by delivering higher radiation dose to the tumor.
US Patent application 2004/0241172, by Axworthy Donald B. et al., discloses biotin derivatives incorporating two DOTA groups, through specific linkers, which are directly bonded, through a benzyl group, to the core of DOTA molecules. This modification of the DOTA group could reduce the binding ability of the chelating moiety.
In order to improve the radiation/dose ratio we have designed and synthesized a new class of biotin derivatives.
DESCRIPTION OF THE INVENTION
The main object of the present invention is to provide new biotin derivatives that fulfill the requirement of an high ratio radiation/dose.
In particular the invention resides in a new class of biotin derivatives carrying two chelating groups per biotin molecule.
In this way using the same molar amount of biotin derivative, the radioactvity reaching the tumour cells is doubled.
One of the objects of the invention described herein is therefore a formula (I) compound as follows:
where:
A is CH 2 or CO;
B is H, CHO or COOH; with the proviso that:
when A is CH 2 , Q is a —(CH 2 ) n — group, in which n is an integer from 4 to 12, in which case R is absent; when A is CO, Q is selected from the group consisting of —(CH 2 ) a —CH(R—)—(CH 2 ) b —, where a and b are, independently, integers from 0 to n−1 and R is defined as below;
W is a C 1 -C 12 alkylene or C 2 -C 12 alkenylene linear chain or a functionalized polyethylene glycol; or a C 6 -C 10 aromatic residue; or a glycofuranose residue; or
W, alone or together with the nitrogen atom supporting the —(CH 2 ) c —NHR′ and —(CH 2 ) d —NHR″ chains, is a heterocyclic group with 5 or 6 members containing one or more heteroatoms selected from O, N, S;
when W is an aromatic residue, an heterocyclic group or a sugar moiety, the nitrogen atom supporting the —(CH 2 ) c —NHR′ and —(CH 2 ) d —NHR″ chains is optionally absent and the —(CH 2 ) c —NHR′ and —(CH 2 ) d —NHR″ chains are directly and independently bonded to the carbon or nitrogen atoms of the aromatic and heterocyclic rings or to oxygen atoms of the glycofuranose residue;
c and d independently are integers from 3 to 10;
R′ and R″ are, independently, -Λ, where −Λ is a formula (II) macrocycle:
where Y are the same or different and are selected from the group consisting of hydrogen, linear or branched C 1 -C 4 alkyl —(CH 2 ) m —COOH, where m is an integer from 1 to 3;
X is hydrogen, or the —CH 2 —U group, where U is selected from methyl, ethyl, p-aminophenyl, or X is the —(CHJ) o -Z group, where o is an integer from 1 to 5, J is hydrogen, methyl or ethyl, Z is a heterocyclic group with 5 or 6 members containing one or more heteroatoms selected from O, N—R 1 , R 1 being a hydrogen atom or a linear or branched C 1 -C 4 alkyl group, and S; or Z is selected from —NH 2 , —NH—C(═NH—)—NH 2 , or —S—R 2 where R 2 is a linear or branched C 1 -C 4 alkyl group;
p is the integer 2 or 3;
R is selected from the group consisting of linear or branched C 1 -C 4 alkyl, cycloalkyl, heterocycle or —(CH 2 ) q -T, where T is selected from the group consisting of S—CH 3 , —OH, or —COOH, and q is 0, 1 or 2.
Linear or branched C 1 -C 4 alkyl group means methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, iso-butyl or ter-butyl.
Heterocycle with 5 or 6 members is an aromatic or non-aromatic heterocycle having in the ring at least a heteroatom selected from O, N—R 1 , or S, such as, for example, 2-, 3- or 4-pyridyl, or 2-, 4-, or 5-imidazolyl.
reduce the binding ability of the chelating moietyA first group of preferred compounds according to the invention consists in the formula (I) compounds where A is CH 2 , B is H, Q is —(CH 2 ) n —, where n is an integer from 4 to 8, preferably 6, c and d are both 3 or 6, R′ and R″ are −Λ where Y is always —CH 2 —COOH; X is hydrogen, and p is 2.
A further object of the invention described herein consists in formula (I) compounds with radioisotopes for diagnostic and/or therapeutic use. Examples of these isotopes are: Fe-52, Mn-52m, Co-55, Cu-64, Ga-67, Ga-68, Tc-99m, In-111, I-123, I-125, I-131, P-32, Sc-47, Cu-67, Y-90, Pd-109, Ag-111, Pm-149, Re-186, Re-188, At-211, Bi-212, Bi-213, Rh-105, Sm-153, Lu-177, and Au-198.
A first group of preferred complexes according to the invention are those where, in the formula (I) compounds, A is CH 2 , B is H, Q is —(CH 2 ) n —, where n is an integer from 4 to 8, preferably 6, c and d are together 3 or 6, R′ and R″ are −Λ where Y is always —CH 2 —COOH; X is hydrogen, p is 2 and the radioisotope is Y-90.
Further objects of the invention described herein are processes for the preparation of formula (I) compounds and their complexes with radiopharmaceuticals.
Further objects of the invention described herein are pharmaceutical and/or diagnostic compositions containing formula (I) compounds and their complexes as indicated above.
Other objects of the invention described herein are the use of formula (I) compounds and their complexes with radioisotopes as medicaments or diagnostic tools, particularly for the preparation of medicaments which are useful in tumour therapy or diagnosis.
These and other objects relating to the invention described herein will be illustrated in detail in the part that follows here below, also by means of experimental examples.
The compounds according to the invention described herein may be prepared according to the following scheme, including the steps of:
a) formation of an amide bond between the carboxyl group of biotin and a primary amine group of H 2 N-Q-NH 2 diamine, the other primary amine group being suitably protected, for example, with a Boc group, if necessary; or, alternatively, the coupling could be performed with the α-α-NH 2 group of an α,ω-diamino acid (i.e. Lys), being the ω-amino group suitably protected. b) deprotection of the primary amine group; c) reduction of the amide group to an amine, if A is CH 2 group; d) coupling of the amine with the N-protected N,N-bis-substituted glycine amines of formula (III) which can be
prepared by methods known to the operators skilled in the art;
where V and L are suitable protecting groups and c and range independently from 3 to 10;
e) conjugation with the desired formula (II) chelating agent −Λ.
Biotin is a commercial product, so as the amino acid Lys is. H 2 N-Q-NH 2 diamines are available on the market and can in any event be prepared in several steps by using known methods.
The protection of the primary amine groups is easily achieved using suitable protective groups, such as, for example, Boc or Fmoc, and which in any event can be found from among those reported in the literature (see for instance: T. W. Greene, P. G. M. Wuts, “Protective groups in organic synthesis”, 3rd Ed., J. Wiley & Sons, Inc., New York, 1999; Handbook of Reagents for Organic Synthesis, “Oxidizing and Reducing Agents”, Edited by S. D. Burke and R. L. Danheiser, J. Wiley & Sons, Inc., New York, 1999).
Alternatively, the formula (I) compound, if A is CO group, can be prepared according to the above reported scheme devoid of the step c.
Activation of the —COOH group of biotin could be accomplished according to the known methods of peptide synthesis (P. Lloyd-Williams, F. Albericio, E. Giralt, “Chemical Approaches to the Synthesis of Peptides and Proteins”, CRC Press, Boca Raton, New York, 1997); if the coupling is performed with an α,ω-diamino acid (i.e. Lys), the reaction can be carried out by anchoring the amino acid on a suitable resin, following the methods known in the solid phase peptide synthesis technique.
The conjugation of the compound according to the invention with the radioisotope to produce the complexes envisaged in the context of the invention described herein is carried out using the known traditional methods in the field, as described, for example, in Paganelli, Chinol et al. European Journal of Nuclear Medicine Vol. 26, No 4; April 1999; 348-357.
One of the preferred compounds of the invention is the one in which A is CH 2 group, Q is —(CH 2 ) n —, where n is preferably 6, c=d are 3 or 6, R′=R″ are −Λ where m is 1, Y is always —CH 2 —COOH; X is hydrogen, p is 2 (DOTA chelating agent).
The process for preparing this preferred compound comprises the following steps:
a) formation of an amide bond between the carboxyl group of biotin and the primary amine group of hexamethylenediamine, suitably protected, for example with a Boc group, if necessary; b) deprotection of the amine group of hexamethylenediamine; c) reduction of the amide group to an amine group; d) conjugation with the formula (III) amine where c=d=3 or 6, V=L are Fmoc protecting groups. e) deprotection of the obtained amine; f) conjugation with the chelator -Λ.
Step a) in the process according to the invention described herein consists in the formation of an amide bond between the biotin carboxyl group and the primary amine group of hexamethylenediamine-Boc. The biotin was treated with HATU to form an extremely active ester in situ that reacts with the amine group of hexamethylenediamine-Boc to form the relevant amide. This activation mechanism, which is used above all for peptide synthesis in the solid phase, requires a basic medium. To prevent the base from reacting with the active ester, tertiary organic bases such as di-isopropylethylamine (DIPEA) or N-methylmorpholin (NMM) are used. Protection of one of the two amine groups of hexamethylenediamine with Boc (ter-butyloxycarbonyl) is necessary to prevent the biotin binding to both ends of the diamine chain. The end product is isolated from the reaction medium after evaporation of the solvent (DMF) and precipitation with water. The product, recrystallised with propanol, was characterised by 1 H-NMR, elemental analysis and ESI-MS. The reaction yield is around 88%.
In step b), biotinyl-hexamethylenediamine-Boc is solubilised in a mixture of AcOEt/HCl, approximately 3 M, to detach the Boc group. After removing the solvent mixture the product was lyophilised to completely eliminate HCl. The sample was purified by means of recrystallalisation with an aqueous solution at basic pH and characterised by 1 H-NMR and TLC.
In step c), the reduction of the amide group was done with BH 3 THF. Since the reducing agent is extremely reactive, the process must be carried out in anhydrous conditions. The starting product was held under vacuum prior to the reaction and then solubilised in anhydrous THF (distilled with sodium and benzophenone). The reaction mixture was refluxed in a nitrogen atmosphere until complete reduction of the amide group (as monitored by 1 H-NMR spectra) had taken place. After evaporating the solvent under reduced pressure, the reaction mixture was treated with an aqueous solution of HCl. After lyophilising the acid solution, the product was purified by recrystallisation from an aqueous solution at basic pH and then by reverse-phase column chromatography. Analysis of the product was done by analytical TLC which revealed its purity. The reaction yield is approximately 55%.
Step d) provided the conjugation reaction of the reduced biotinyl-hexamethylenediamine with the protected amine (III) by activation with the HATU/NMM system in NMP as solvent.
In step e) the Fmoc groups were removed by using the base piperidine.
Step f) provided the coupling of two DOTA groups, performed with the specific reagents for the formation of amide bonds in an aqueous medium: 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydrochloride (EDC), and sulpho-NHS. DOTA (4 mole equiv respect to the biotin derivative) was dissolved in water and adjusted to a pH value suitable for activating mostly one of four carboxylic groups (G. Sabatino, M. Chinol, G. Paganelli, S. Papi, M. Chelli, G. Leone, A. M. Papini, A. DeLuca and M. Ginanneschi, J. Med. Chem. 2003, 46, 3170-3173). In this way, we can reduce the likelihood of obtaining side products. To the basic solution were added sulpho-NHS and lastly EDC. After the formation of the active ester in situ, the N,N-bis-alkylamino glycine derivative of the reduced biotinyl-hexamethylenediamine was added, checking that the pH of the solution remained around 7.5. Pre-purification of the crude product was done by SPE (Solid Phase Extraction) and the purification was performed by means of semi-preparative RP-HPLC.
The objects of the invention described herein are pharmaceutical or diagnostic compositions containing as their active ingredient at least one formula (I) compound, also in the form of a complex with a radioisotope or, in the case of said formula (I) compound, in association with other active ingredients useful in the treatment of the diseases indicated in the invention described herein, e.g. other products possessing anticancer activity; also in separate dosage forms or in forms suitable for combined therapy. The active ingredient according to the invention will be in the form of a mixture along with suitable vehicles and/or excipients commonly used in pharmaceutical technology, such as, for example, those described in “Remington's Pharmaceutical Sciences Handbook”, latest edition. The compositions according to the invention shall contain a therapeutically effective amount of the active ingredient. The dosages will be determined by the expert in the field, e.g. the clinician or primary care physician, according to the type of disease to be treated and the patient's condition, or concomitantly with the administration of other active ingredients.
Examples of pharmaceutical compositions are those that allow parenteral or loco-regional administration. Pharmaceutical compositions suitable for the purpose are solutions, suspensions, or lyophilised forms to be reconstituted at the time of use.
Forms suitable for the industrial application of the invention are kits for cancer radiotherapy, as, for example, described in European Patent 0 496 074, in the paper by Paganelli, Chinol et al. published in the European Journal of Nuclear Medicine Vol. 26, No 4; April 1999; 348-357, in U.S. Pat. No. 5,968,405 and in the relevant literature.
A further object of the invention described herein is a kit for the therapy or diagnosis of tumours by means of radioactivity. characterised in that at least one of the components of said kit contains a formula (I) compound or one of its complexes with a suitable radioisotope.
The compounds according to the invention are useful for the preparation of therapeutic and/or diagnostic agents for the treatment and diagnosis of tumours.
The compounds according to the invention, following the binding with radioisotopes for diagnostic and/or therapeutic use (as explained before), are useful to radiolabel preparations of avidin colloids for different medical applications.
For example, they can be used in tumour treatment methods with anticancer radiopharmaceuticals, such as, for example, those described in European Patent 0 496 074, in the paper by Paganelli, Chinol et al. published in the European Journal of Nuclear Medicine Vol. 26, No 4; April 1999; 348-357, in U.S. Pat. No. 5,968,405 and in the relevant literature.
The following example further illustrates the invention.
EXAMPLE
Preparation of the BisDOTA-C 3 —Compound 4
The preparation of Compound 4 was carried out following the steps herewith reported.
Synthesis of the Reduced Biotinamidohexylamine (r-BHD)—Compound 1
The detailed synthetic procedure and physico-chemical properties of Compound 1 were reported in the article by G. Sabatino, M. Chinol, G. Paganelli, S. Papi, M. Chelli, G. Leone, A. M. Papini, A. De Luca, and M. Ginanneschi, J. Med. Chem., 2003, 46, 3170-3173. The NMR spectra of the products herewith reported were recorded in DMSO-d 6 solution on Varian 400. The N,N-bis[3-(Fmoc-amino)propyl]glycine of the example was purchased from Fluka (Switzerland) as potassium sulphate salt.
Synthesis of the r-BHD Conjugate with the N,N-bis[(3-amino)propyl]glycine—Compound 2
HATU (66.5 mg, 0.175 mmol, 0.7 mole eq.) in NMP (0.5 mL) were added to a solution of N,N-bis[3-(Fmoc-amino)propyl]glycine potassium sulphate (115.5 mg, 0.15 mmol, 0.6 mole eq.) and NMM (33.05 μL, 0.3 mmol, 1.2 mole eq.) in NMP (1 mL). This solution was dropwise added in 5 min to a suspension of r-BHD (Compound 1) (100 mg, 0.25 mmol) in NMP (5 mL) containing NMM (27.5 μL, 0.25 mmol, 1 mole eq.). The reaction mixture was stirred at room temp. monitoring the reaction by RP-HPLC (eluent: from 30% to 100% of B in 20 mim; t R =13.4 min). After 2.5 h, Compound 1 (57.7 mg, 0.08 mmol, 0.3 mole eq.) was added again to the reaction mixture. After 2.5 h the reaction was stopped and the solvent evaporated under reduced pressure. The yellow-orange oil was suspended in water at 0° C. under stirring obtaining a white precipitate that was purified by RP-CC (LiChroprep RP-8, 40-63 μm; 170×20 mm; eluent: CH 3 CN/H 2 O/HCl=50:50:0.1, 1 mL/min) giving Compound 2 (130 mg; 55% yield). The Fmoc-protected bis-amino derivative (Compound 2) appeared to be pure by T.L.C. inspection (CH 3 CN/H 2 O/HCl=50:50:0.1). 1 HNMR (200 MHz, DMSO): δ 9.63 (br s, 1H), 8.64 (br s, 3H), 7.87 (d, 4H), 7.65 (d, 4H), 7.43-7.27 (m, 8H), 6.41 (d, 2H), 4.31-4.14 (m, 8H), 3.85 (s, 2H), 3.14-3.03 (m, 11H), 2.82-2.76 (m, 4H), 2.6 (d, 2H), 1.76-1.25 (m, 20H) ESI-MS (m/e): calculated [M+H] + 944.5, found 944.5.
The Fmoc-protected bis-amine derivative (Compound 2) (88 mg, 0.09 mmol) was dissolved in DMF containing 25% of piperidine (5 mL). The solution was kept under stirring at room temp. for 6 h monitoring the reaction via RP-HPLC (from 30 to 100% B in 20 min; t R =16.7 min). The reaction mixture was then evaporated under reduced pressure and the crude oil dissolved in the minimum amount of MeOH and precipitated with Et 2 O. The collected solid was twice washed with ether, dissolved in water and lyophilised, affording a white product which was purified by SPE (Solid Phase Extraction; LiChroprep RP-18, 25-40 μm; 170×20 mm; eluent: H 2 O 100%-MeOH from 4 to 100%). The eluted fractions were collected and lyophilised giving de-protected bis-amine (Compound 3) (30 mg, 75% yield). 1 HNMR (200 MHz, CDCl 3 ): δ 8.12 (br s, 2H), 6.45 (s, 2H), 4.26 (m, 1H), 4.12 (m, 1H), 3.59-2.95 (m, 7H), 2.95-2.70 (m, 12H), 2.50 (d, 2H), 1.80-1.20 (m, 20H) ESI-MS (m/e): calculated [M+H] + 443.6, found 443.1.
Conjugation of Compound 3 with the Activated DOTA for Obtaining BisDOTA-C 3 Compound 4
Sulpho-NHS (26 mg, 0.12 mmol) was added to a solution of DOTA-0.31H 2 O (49.2 mg, 0.12 mmol) in H 2 O (0.750 mL). The pH was then adjusted to 6.5 with 0.1 M NaOH and a solution of EDC (23 mg, 0.12 mmol) in H 2 O (0.5 mL) was added dropwise at 0° C.
The reaction mixture was stirred at 0° C. for 30 min and then a solution of Compound 3 (15 mg, 0.03 mmol) in H 2 O (0.750 mL), at pH 7.8, was added dropwise during 5 min.
The reaction was checked via RP-HPLC (from 5 to 100% of B in 30 min; t R =16.4 min).
After 2 h the reaction mixture was lyophilized and the crude compound was pre-purified by SPE (Solid Phase Extraction; LiChroprep RP-18, 25-40 μm; 15×65 mm; eluents: a) H 2 O; b) 4% MeOH in H 2 O; c) 100% MeOH. HPLC test of the extracted fractions demonstrated that the Compound 4 was mainly in the fraction c. The methanolic solution was evaporated and the product purified by RP-HPLC (from 5 to 30% of B in 30 min: t R =16.4 min) obtaining the pure Bis-DOTA (Compound 4) (15 mg, 24% yield) as a white solid.
ESI-MS: m/e calculated [M+H] + 1272.7, found 1272.7; [M−H] + 1270.7, found 1270.9. Anal. (C 56 H 101 N 15 O 16 S.6TFA.5H 2 O) C, H, N.
Labelling tests, radiochemical purity, and serum stability tests were carried out with the compound illustrated in the foregoing example.
Labelling tests were carried out using 2 mg/mL MilliQ water solutions of BisDOTA-C 3 . 1.0 mM sodium acetate buffer (pH 5.0) was added to BisDOTA-C 3 , that were subsequently added with the radioisotope chloride solution (MCl 3 , M= 111 In, 90 Y, 177 Lu) at a specific activity of 1 mCi/7.2 μg. Finally these solutions were incubated at 95° C. for 30 min.
In order to determine Radiochemical Purity (RCP), Silica Gel Instant Thin Chromatography (ITLC-SG) was used. An aliquot of the radiolabelled mixture was added to a molar excess of Avidin and DTPA, then a drop was spotted on ITLC strips and developed with saline. The strip was analysed by a Radio-TLC apparatus; in this system, the complex formed by BisDOTA-C 3 and Avidin remains at the origin, while the unbound radiometal is complexed by DTPA and migrates with solvent front. RCP values typically obtained were >96%.
Stability assays were performed with and without ascorbic acid (AA) as radical scavenger. Aliquots from the labelled molecules were incubated at 37° C. with a 4-fold volume of saline or AA solution (4 mg/mL in 1.0 M sodium acetate buffer, pH 5.0). Stability studies were carried out at 24 and 48 hours and RCPs were calculated using ITLC-SG method as described before. Results showed that, in the presence of AA, the radiolabelled M-BisDOTA-C 3 were stable to radiolysis up to 48 hours.
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Formula (I) compounds are described: Formula (I) where the radicals are as defined in the description, processes for their preparation, and their uses for the preparation of conjugates with radionuclides for use in human and animal therapy and diagnostics, particularly for the diagnosis and therapy of pathological conditions such as tumors.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a movable work support, also referred to as a scaffold, which is particularly adapted to use within a cylindrical structure, and which includes means for vertical and rotational movement of the support within the structure.
2. Description of the Prior Art
A large variety of scaffolding structures are known in the prior art for particular applications. Scaffolds provide a work surface upon which a workman or apparatus may be positioned adjacent a structure to permit work to be done on the structure. Typically, scaffolds may be classified as either those which are fixed structures which require disassembly and reassembly in order to move their location, and those which incorporate means for changing the location or orientation of the scaffold.
The closest prior art to the present invention is believed to be shown in U.S. Pat. No. 3,420,332, issued to Textor on Jan. 7, 1969. The Textor patent discloses a work support which is adapted for use within a cylindrical structure and which includes means for vertical and rotational movement of the scaffold. The Textor device includes a rigid suspension unit which is connected to the center of the top of a silo or similar structure. At one end of this rigid suspension unit is located a yoke which supports a pair of rollers positioned to bear against the inner surface of the top of the enclosure. A work platform is suspended from the suspension unit by a pair of chains which attach to opposite ends of the work platform. One of the chains extends from the suspension unit at the end of the suspension unit opposite the location of the yoke and bearing rollers. The other chain extends from the suspension unit at a point intermediate the ends of the suspension unit. The chains are thereby positioned such that the center of gravity of the work platform is located to have the point of attachment of the suspension unit to the top of the structure between the bearing rollers and the center of gravity. The center of gravity therefore applies a force which causes the bearing rollers to bear against the top of the structure within which the scaffold is being employed. The work platform of the Textor device also includes wheels which are positioned to bear against the interior of the side wall of the silo or other structure. These wheels are positioned to move the work platform further from the side wall than would otherwise be the case, and therefore causes frictional engagement of the wheels to the side wall. However, the center of gravity of the platform remains located as previously described with respect to the point of attachment of the suspension unit to the top of the structure. In operation, a workman is positioned on the work platform and is thereby located near the portion of the side wall against which bear the wheels located on the platform. The Textor device is suitable for certain structures. However, the Textor device is not operable if a structure has a top which is not smooth on the inside for the bearing rollers to move over or which has a top which is not sufficiently strong at required locations for the rollers to bear against. Some farm structures, for example, have only a tripod at the top with either a thin sheet metal covering, or no covering at all, and the Textor device could not be used therewith for both of the reasons heretofore enumerated.
A hanging scaffold for use within a cylindrical structure is also disclosed in U.S. Pat. No. 1,090,856, issued to Johnson on Mar. 24, 1914. The Johnson scaffold comprises a circular structure including wheels for centering the scaffold within the cylindrical structure. A similar device is disclosed in U.S. Pat. No. 1,284,699, issued to Johnson on Nov. 12, 1918. In U.S. Pat. Nos. 3,187,838, issued to Stewart et al. on June 8, 1965, and 3,241,634, issued to Prosser on Mar. 22, 1966, there are disclosed scaffolding structures which are positionable about the outside of a cylindrical structure.
SUMMARY OF THE INVENTION
A movable work support, particularly adapted for use within a silo or similar structure having a cylindrical side wall and a top, which comprises a frame having first and second ends, the frame including a work support surface at the first end, attachment means for securing a load including the frame to the top of a cylindrical structure, the attachment means including an elongated member having a first end portion connected at a first location on the top of the structure and a second end portion connected to the frame, the load secured by the elongated member having a center of gravity, vertical movement means for moving the frame vertically with respect to the cylindrical structure, horizontal movement means for moving the frame in a horizontal plane relative the cylindrical structure, and bearing means connected with the frame at the second end of the frame for bearing against the side wall of the cylindrical structure at a second location, and locating means for causing the distance between the center of gravity of the load and the second location to be greater than the perpendicular distance from the second location to a vertical line extending through the first location on the top of the cylindrical structure.
It is an object of the present invention to provide a movable work support particularly adapted for use within a silo or similar structure having a cylindrical side wall.
Another object of the present invention is to provide a movable work support which includes means for vertical and rotational movement while suspended within a cylindrical structure.
A further object of the present invention is to provide a movable work support of the described type which is simple and lightweight in construction, and which is easily disassembled and reassembled.
It is another object of the present invention to provide a movable work support as previously described which may be dismantled sufficiently to be passed through a relatively small door and may be readily reassembled within a structure for use.
It is a further object of the present invention to provide a movable work support which may be suspended from a single point within a cylindrical structure, and yet is stable during use.
Another object of the present invention is to provide a movable work support which may be remotely controlled to be moved throughout the interior surface of a cylindrical structure.
It is another object of the present invention to provide a movable work support which obtains its stability and rotational movement ability by bearing against the side wall of a cylindrical structure, rather than bearing against the top of the structure.
It is a further object of the present invention to provide a movable work support of the described type which is adaptable to be used with cylindrical structures of varying internal diameters.
Further objects and advantages of the present invention will become apparent from the description of the preferred embodiments which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of the movable work support of the present invention.
FIG. 2 is a side, diagrammatic view of the movable work support of FIG. 1, showing the vertical-movement wheels engaging the wall of a cylindrical structure.
FIG. 3 is a side, diagrammatic view of the movable work support of FIG. 1, showing the horizontal-movement wheels engaging the side wall of a cylindrical structure.
FIG. 4 is a top, partial view of the movable work support of FIG. 1, showing the configuration of the wheel assemblies in correspondence with the position shown in FIG. 3.
FIG. 5 is a top, partial view of the movable work support of FIG. 1, showing the configuration of the wheel assemblies in correspondence with the position shown in FIG. 2.
FIG. 6 is a side view of an alternate embodiment of the movable work support of the present invention.
FIG. 7 is a top view of the alternate embodiment shown in FIG. 6.
FIG. 8 is a partial, top view of the movable work support of FIG. 1, showing an alternate embodiment for the wheel assemblies thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.
The movable work support of the present invention is particularly adapted for use within a silo or similar structure having a cylindrical side wall and a top. The movable work support of the present invention is a relatively simple and inexpensive device which permits both vertical and horizontal movement of the support to be readily obtained by simple manipulation of appropriate controls. The support has horizontal stability, and is readily adapted for use in conjunction with a variety of existing cylindrical structures. In particular, the scaffold is of such simple construction that it may be readily disassembled and passed through a comparatively-small opening in a structure, and thereafter reassembled for use.
Referring in particular to the figures, there is shown a movable work support 10 constructed in accordance with the present invention. Support 10 includes a frame 11 comprising side rails 12 and 13 and end rails 14 and 15. A work platform 16, including a surrounding fencework 17, is connected to and supported at one end of the frame 11. Work platform 16 is intended to support a person who would operate the movable work support 10, and who could also perform work on the interior walls of the silo or other structure within which the support 10 is being employed. Alternatively, a piece of work apparatus could be mounted in the general location of platform 16 and the movable work support 10 could be remotely controlled to cause the apparatus to operate appropriately.
Frame 11 includes a cross beam 18 upon which motor 19 is mounted. Winch assembly 20 is also mounted upon cross beam 18 and is driven by motor 19. A cable 21 is secured at the top 22 of silo 23 or another similar structure at a location 24. Cable 21 extends from location 24 to winch assembly 20, winch assembly 20 being operable to extend or retract cable 21 to move frame 11 down or up relative the location 24, and therefore relative silo 23. Winch assemblies of the type employed by the movable work support 10 are known in the art, and will therefore not be described in detail in the present text. A variety of winch assemblies could be incorporated in the movable work support 10, and cable 21 could correspondingly be changed to suit the particular winch assembly being used. For example, a winch assembly which operates with a chain could be employed, if a chain were used to suspend frame 11, rather than the cable 21.
A quadripod is formed by support members 25-28. Each of the support members 25-28 is secured at one end to the frame 11, and at the other end to housing 29. Pulleys 30 and 31 are mounted within housing 29 and cable 21 extends therebetween. Pulleys 30 and 31 facilitate vertical movement of the movable work support 10 by rolling against the cable 21 as it is drawn into or extended from winch assembly 20. Pulleys 30 and 31 also provide an elevated bearing point, and increases the distance between the center of gravity of the support 10 and the point along cable 21 at which a tilting force is applied. As a result, the effect of any unbalance of the frame 11 and any supported elements is reduced, and the movable work support 10 has excellent horizontal stability.
Mounted to frame 11 adjacent end rail 14 are two pairs of wheel assemblies. Wheels 32 and 33 are mounted to frame 11 to rotate about a common horizontal axis 34. Referring in particular to FIGS. 2 and 5, it is shown that wheels 32 and 33 are positioned to engage the interior 35 of side wall 36. Because wheels 32 and 33 are rotatable about a horizontal axis, the wheels 32 and 33 will roll along the interior 35 of side wall 36 as frame 11 is raised and lowered relative the wall 36.
Wheels 37 and 38 are mounted upon arms 39 and 40 which are rotatably attached to frame 11 by pivot pins 41 and 42, respectively. Arms 39 and 40 include extensions 43 and 44. Hydraulic cylinders 45 and 46 include piston rods 47 and 48 which are attached, respectively, to extensions 43 and 44. Cylinders 45 and 46 are connected to end rail 14 and are operable to extend or retract piston rods 47 and 48. Referring in particular to FIGS. 4 and 5, it is shown that wheels 37 and 38 have a first position adjacent the interior 35 of wall 36 when piston rods 47 and 48 are extended from hydraulic cylinders 45 and 46, respectively. Wheels 37 and 38 are rotatable about vertical axles 49 and 50, and are thereby operable to roll along interior 35 in correspondence to horizontal, rotational movement of frame 11 within structure 23. Withdrawal of piston rods 47 and 48 within hydraulic cylinders 45 and 46, respectively, rotates arms 39 and 40 about pins 41 and 42, respectively, and thereby retracts wheels 37 and 38 from the interior 35 of side wall 36.
Hydraulic cylinders 45 and 46 include hydraulic hoses 51 and 52 which extend to and connect with a suitable source of hydraulic pressure. A hydraulic-type drive motor 53 is mounted upon arm 39 and a belt 54 drivably connects motor 53 with wheel 38. Hydraulic hoses 55 and 56 connect with motor 53 and extend to and connect with a suitable source of hydraulic pressure. Movable work support 10 includes a control box 57 (FIG. 1) including suitable controls for regulating the hydraulic pressure within hoses 51, 52, 55 and 56, and thereby provide control of the extension and retraction of wheels 37 and 38, and also of the driving of wheel 38. As previously mentioned, control box 57 may be located remote from frame 11 to permit remote control of the movement of the movable work support 10.
At all times during use of the movable work support 10 of the present invention, either wheels 37 and 38, or wheels 32 and 33 bear against the interior 35 of wall 36. This is ensured by the fact that the distance from the bearing point of the wheels to the center of gravity 58 of support 10 is greater than the distance from the bearing point of the wheels to a vertical line extending through location 24 (FIG. 2). The positioning of the center of gravity 58 is accomplished as a result of several factors. Primarily, frame 11 is constructed such that the center of gravity will be so positioned when wheels 32 and 33 rest adjacent interior 35 of wall 36, and the center of gravity 58 will then be even further displaced upon engagement of wheels 37 and 38 with wall 36 (FIG. 3). If the support 10 is intended for use with a person standing upon work platform 16, then this will further shift the center of gravity of the suspended support 10 and person further from the bearing point of the wheels.
Support 10 could alternatively be constructed such that the center of gravity of the support 10 without a person located on platform 16 would not be displaced from the center of the silo 23 in a direction away from the bearing point of wheels 32 and 33. Support 10 could then still be operable since the positioning of a person on platform 16 could sufficiently shift the center of gravity to fulfill this requirement. It is preferable, however, to construct the frame and position the wheels such that the center of gravity of the support 10 alone is displaced from the center of the cylindrical structure in a direction away from the bearing point of the wheels. The effective force against the side wall 36 is then enhanced by a person being positioned on platform 16. The center of gravity would have to be appropriately positioned when a work apparatus is mounted on support 10 if the support and apparatus are to be operated by remote control.
The purpose in displacing the center of gravity away from the bearing point of the wheels and beyond the center of the structure is that the normal state of a suspended structure, such as support 10, is to have the center of gravity of the suspended load located directly beneath the single point of attachment 24 of the supporting cable 21. Displacement of the center of gravity 58 in the manner previously described will therefore cause the frame 11 to be urged toward the bearing point of wheels 32 and 33 or of wheels 37 and 38 against side wall 36. This force of the wheels against side wall 36 causes frictional engagement between the wheels and the side wall, and provides added horizontal stability to the support 10. In particular, the support will have greater stability when being raised or lowered with the wheels 32 and 33 resting adjacent side wall 36. Moreover, the frictional engagement is increased when wheels 37 and 38 further displace the center of gravity away from side wall 36, and this frictional engagement permits rotation of wheel 37 to move frame 11 in rotation about the interior of cylindrical structure 23.
In FIGS. 6 and 7 there is shown an alternate embodiment of the movable work support of the present invention. Support 59 includes a frame 60 including two pairs of wheel assemblies mounted to one end. The wheel assemblies are identical to those described above with respect to wheels 32, 33, 37 and 38, and therefore will not be described with respect to this alternate embodiment of the invention. A tubular member 61 is mounted to a work platform 62 and telescopingly receives frame 60 therein. Tube 61 includes several pairs of horizontally and diametrically aligned apertures, such as 63. Frame 60 includes tube portion 64 which is received within tube 61, tube portion 64 including at least one pair of horizontally and diametrically aligned apertures. A rod 65 extends between a selected pair of apertures in tube 61 and also through the pair of apertures in tube portion 64, thereby securing tube portion 64 with tube 61. Any of a number of apertures defined by tube 61 may be aligned with and secured to the apertures in tube portion 64 to vary the overall length of movable work support 59. In this manner, support 59 is readily adaptable to use with a variety of silos or other cylindrical structures having different internal diameters. This or another system could be incorporated in the construction of support 10 to similarly provide for adjustability of the support length.
A vertical support 66 is mounted to work platform 62. Angle brace 67 is secured to vertical support 66 and cylindrical sleeve 68 is secured to the end of angle brace 67. Adjustment rod 69 is received within cylindrical sleeve 68, and also within a suitable aperture defined by the top end of vertical support 66. Adjustment rod 69 includes several diametrically aligned pairs of apertures, such as 70. Pins 71 and 72 extend through aligned apertures defined by cylindrical sleeve 68 and vertical support 66, respectively, and also extend within pairs of aligned apertures in adjustment rod 69 to secure the position of rod 69.
Pulley 73 is rotatably mounted to the end of adjustment rod 69, and pulley 74 is similarly mounted within yoke 75 which is secured to vertical support 66. Cable 21' is secured at the top of structure 23' and extends about pulleys 73 and 74 to winch assembly 20'. Winch assembly 20' operates in the same manner as previously described with respect to winch assembly 20 to extend or retract cable 21'. Pulley 74 is fixed relative winch assembly 20', and therefore maintains proper alignment of cable 21' with winch assembly 20'. Pulley 73, however, is movable with respect to winch assembly 20'. This permits the position of pulley 73 relative the point of attachment of cable 21' at the top of structure 23' to be maintained when the relative position of tube portion 64 and tube 61 is varied. Thus, as the overall length of the movable work support 59 is increased, the pulley 73 may be positioned further from vertical support 66 by appropriate movement of adjustment rod 69.
Referring now to FIG. 8, there is shown an alternate embodiment of the wheel assemblies utilized in accordance with the present invention. Wheels 32 and 33 remain mounted upon frame 11 in the manner previously described with respect to the support 10 of FIG. 1. Wheels 37 and 38 are also similarly mounted upon arms 39 and 40 as previously described. Arms 39 and 40 include extensions 43 and 44. A hydraulic cylinder 76 is mounted to end rail 14 through a bracket 77 connected to flange 78. Hydraulic cylinder 76 includes a piston rod 79 which is extendable from and retractable into cylinder 76. Piston rod 79 is pivotally attached through pivot pin 80 to bar 81, bar 81 being pivotally attached to end rail 14 by pivot pin 82. Rods 83 and 84 each have one end attached to an end of bar 81, and the other end attached to extensions 43 and 44, respectively. As shown in FIG. 8, piston rod 79 has a first position extended from hydraulic cylinder 76 and corresponding to bar 81 being rotated about pivot pin 82 to extend wheels 37 and 38 against wall 36. Retraction of piston rod 79 within hydraulic cylinder 76 pulls rods 83 and 84 inwardly and pivots arms 39 and 40 to retract wheels 37 and 38 from wall 36. Hydraulic hose 85 extends to and is connected with hydraulic cylinder 76 and also a suitable source of hydraulic pressure to provide the described operation of hydraulic cylinder 76.
In a particular embodiment of the present invention, the movable work support has been employed to provide access to the interior walls of grain elevators and farm silos. A typical silo has an internal diameter of about twenty feet and a typical elevator has an internal diameter of between about thirty and forty feet. The movable work support of the present invention has been easily constructed with an appropriately-sized frame 11 to operate within structures of these sizes. In addition, the access door at the bottom of these types of structures is typically relatively small, in the order of twenty inches square. The movable work support 10, as shown in FIG. 1, is readily dismantled to pieces which will fit through a door which is twenty inches square, and can be quickly and surely reassembled within the structure for use.
In one application of the support 10 of the present invention, the support has been used during cleaning and resurfacing the interior walls of silos. The inside concrete in silos is worn away by the action of the acid associated with the silage stored in the silos. An operator positioned on the movable work support 10 of the present invention may readily manipulate the support to provide access to the full interior of the silo. A washing apparatus using 2,000 pounds of water pressure to scour the interior of the silos has been used to clean the silo walls initially. The support 10 provides excellent stability during use of the high pressure scouring apparatus. The vertical and horizontal position of the support is readily controlled by appropriate regulation of the hydraulic systems connected with the wheels and the winch assembly.
The winch assembly used in one embodiment of the present invention was one marketed under the trademark "Sky Climber," and the winch easily moved the support up and down under full control. A "Char Lynn" orbit motor has been used for driving the wheel 37 with good success. It has been found to be preferable to periodically alter the direction in which the frame 11 is rotated relative the structure 23 to prevent undue twisting or tangling of the various control lines, and also any safety lines which may be employed for the operator of the support.
The movable work support 10 of the present invention is a very simple yet sturdy device. In part because of the simplicity of construction, the support 10 may be used with cables already existing in many silos and similar structures which are otherwise used for different purposes. Certain structures include cables which normally extend from the center of the top and are operable through a crank or winch to be lowered and raised. For these structures, the support 10 is easily used by lowering the cable present in the structure and attaching cable 21 thereto. The existing cable is then raised to the top by the means already existing with the structure, and the winch cable 21 is thereby positioned for use. The movable work support of the present invention is relatively light due to the simplicity of construction, and is therefore easily transported. At the same time, the support is sturdy and is well balanced by having a low center of gravity relative the point on cable 21 at which any tilting forces are applied.
The movable work support 10 of FIG. 1 includes a quadripod comprising support members 25-28, connected to housing 29. The points of attachment of members 25-28 to the side rails 12 and 13 of frame 11 may be made adjustable, such as by providing a plurality of holes in the side rails and corresponding holes in the support members. The quadripod, and therefore the position of housing 29, can thereby be adjusted with respect to the length of frame 11 to compensate for varying amounts of weight to be supported upon work platform 16. Other modifications of the disclosed device could similarly be made to adapt the support to various applications. For example, the two pairs of wheels employed for vertical and rotational movement of the support 10 could be replaced by a single pair of wheels operable to swivel to change orientation from vertical to horizontal planes of rotation. The disclosed embodiments of the present invention are preferred, however, since they provide a support which is inexpensively constructed, and which performs excellently.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
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A movable work support particularly adapted for use within a silo or similar cylindrical structure is disclosed herein. The work support comprises a frame supporting a work platform and a winch mechanism. A cable extends from the winch to a point of securement at the top of the cylindrical structure, and extension or retraction of the cable from the winch mechanism will cause the framework to lower or raise, respectively. A first pair of wheels is located at an end of the frame opposite the location of the work platform. The first pair of wheels is positioned to engage the side wall of the structure and to roll along the side wall as the frame is moved vertically. A second pair of wheels is mounted near the first pair of wheels on the frame and is oriented to roll along the side wall as the frame is rotated in a horizontal plane within the structure. The first and second pairs of wheels are located such that the center of gravity of the work support is displaced from the point of attachment of the cable at the top of the structure in a direction away from the pairs of wheels. The frame is thereby urged in the direction of the pairs of wheels to ensure frictional engagement of the wheels with the side wall of the structure.
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CROSS-REFERENCE TO RELATED APPLICATIONS
Priority is claimed from provisional patent application U.S. Ser. No. 61/038,321 filed on Mar. 20, 2008 and incorporated by reference herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
In general, this invention relates to a device, system and method for concealing a bodily protrusion. More particularly, the present invention relates to an article of apparel and method for obfuscating, hiding or concealing an erect nipple through the clothing covering the breast.
2. Description of the Known Prior Art
Throughout recorded history, women have used a variety of garments and devices to cover, restrain, or elevate their breasts. Women tend to rely on their brassier to support and enhance their breasts during everyday activities. Today, however, many modern woman desire to have a brassier, or bra, that not only provides functionality, but also flatters their natural beauty in a way that is tasteful, yet not excessively provocative.
An often embarrassing problem exists, one in which a variety of apparatus and methods have attempted to address, that certain women experience when they wish to wear clothing that is flattering, but may otherwise allow a protrusion, profile image, or “tenting” of the garment over the nipple. Not only is this tenting effect considered highly personal for a woman, but may also portray an undesired image of a woman in such circumstances like the workplace, professional and business meeting and in many social settings.
For years now, women have fought to overcome gender discrimination in all facets of life, and especially in the workplace and higher education. Recognizing that significant efforts have been made to eradicate gender discrimination, a struggle still stands to ensure that women are placed on an equal footing with men. The last thing that a talented female attorney or articulate businesswoman needs is to not be taken seriously simply because the temperature is cold, or perhaps a simple brush of the skin, has caused this tenting effect.
Numerous U.S. design patents and U.S. utility patents describe devices and apparel for women that are intended to provide women with more modesty protection by either covering the entire breast, or only covering the nipple and areola of a woman's breast. For example, U.S. Pat. No. 5,782,672 issued to Woodley on Jul. 21, 1998, discloses a nipple pad made of a pliable elastic material, such as latex or other polymeric material, with an adhesive strip affixed to the material for covering the nipple of a female breast. Likewise, U.S. Pat. No. 6,350,175 issued to Johnson, et al. on Feb. 26, 2002, discloses a method and device for concealing an erect nipple wherein an adhesive is coated over a major portion of one side of the device in order to adhere directly to the nipple.
Although such devices can provide modesty coverage for the wearer, the requirement that wearers use relatively large areas of adhesive to attach the devices can be quite uncomfortable. Special precautions are recommended by the manufacturers, such as using a special skin-preparation lotion before applying the adhesive coverings, wearing them for a very limited amount of time before removing them, and taking special precautions to remove the coverings carefully and by pre-lubrication with baby oil, for example, so as not to provide excessive damage to the skin. Nonetheless, the skin can be irritated and made to become very sore by the use of such devices.
Another disadvantage of such adhesive covers is that they can be used only once and then must be thrown away. This adds expense and waste.
Padded concealment “solutions” include padded or foam devices that surround the nipple or protrusion at a distance away from the skin such that the nipple has enough room to erect into the pad. A common drawback of these padded solutions is the creation of an unnatural curve around the breast. Furthermore, a tenting effect can still occur in pads that have lost their thickness due to repeated washing and wearing.
Several U.S. design patents and U.S. utility patents also disclose various articles of apparel that cover the entire breast. For example, U.S. Pat. No. 6,419,548 issued to Wittes et al. on Jul. 16, 2002, discloses a concave shield member made of soft, flexible material. In use, the soft, flexible material is in direct contact with the skin of the wearer. Such direct contact is known to cause irritation and/or perspiration. Furthermore, the soft, flexible material may also slip from the nipple and areola portion of the breast, thereby negating its purpose.
It is therefore desirable to provide a device, system and method for concealing a bodily protrusion in which the foregoing disadvantages are alleviated or eliminated. The above discussed limitations in the prior art is not exhaustive. The current invention provides an inexpensive, less irritating, more reliable and less wasteful apparatus, system and method where the prior art fails or is deficient. Other noteworthy problems may also exist; however, those mentioned here are sufficient to demonstrate that methodology appearing in the art has not been altogether satisfactory and that a significant need exists for the invention described and claimed here.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of apparatus, systems and methods now present in the prior art, the present invention provides a new and improved device, system and method which allows a user to obfuscate, hide or conceal an erect nipple, or protrusion, in a flattering, natural way. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide an article of apparel that alleviates the often embarrassing problem that women experience when a nipple can be seen as protruding into the garment overlying the nipple.
To attain this, the present invention essentially comprises a pad constructed in accordance with the present invention that cooperates with a brassiere to provide a device, system, and method that may be utilized either on a daily basis or periodically to conceal an erect nipple, or protrusion. It is contemplated that the pad of the present invention may comprise a variety of materials arranged in separate layers.
For the sake of brevity, the present invention is generally described herein as relating primarily to nipple concealment; however, it should be understood that the current invention is not limited to just nipples, and has application to any type of skin protrusion, like raised moles, warts, and growths. In a similar manner, it is understood that the present invention may be useful for men, as well as women, and should not be regarded as limited to only one specific gender. Furthermore, it should be understood that the present invention may be used in conjunction with a specific brassiere designed to accommodate the present invention, with a conventional brassiere well known in the art, or independent of a brassiere. It is contemplated the current invention may be built into a brassiere, slipped into a conventional brassiere, slipped into a modified brassiere having a receptor portion for an insert, and combinations thereof.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in this 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. 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 devices, methods, and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing Background and Brief Summary of the Invention is to enable the U.S. Patent and Trademark Office and the public generally, and especially the engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. As such, the Background and Brief Summary is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
Therefore, it is an object of the present invention to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion.
It is a further object of the present invention to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that is susceptible to a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible to low prices of sale to the consuming industry, thereby making such device, system, and method economically available to all potential users.
Still another object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that provides all of the advantages of the prior art, while simultaneously overcoming the disadvantages normally associated therewith.
Another object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that may be easily and efficiently manufactured and marketed.
Yet another object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that provides a less irritating and painful method of concealment than the prior art.
An even further object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that is of a durable and reliable construction and may be used time and time again.
Still another object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that is comfortable to the wearer, and provides a natural, flattering look.
Yet another object of the present invention is to provide a new and improved device, system, and method for concealing an erect nipple, or protrusion, that may be adapted for use with a specially designed brassiere, a conventional brassiere, or independently worn.
These, together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages, and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed pictorial illustrations, graphs, drawings, and appendices.
FIG. 1 portrays a front view of a nipple concealment device constructed in accordance with the present invention.
FIG. 2 shows a front view of an alternative embodiment of a nipple concealment device constructed in accordance with the present invention.
FIG. 3 displays a cross-sectional view of the nipple concealment device shown in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, illustrations, pictures and attachments, and more particularly to FIG. 1 , reference numeral 10 designates a device, system and method, which allows a user to obfuscate, hide or conceal an erect nipple, or protrusion, in a flattering, natural way, constructed in accordance with the present invention.
In a preferred embodiment, the invention 10 may be constructed in a manner that essentially provides two materials for concealment purposes: a foam pad 20 and a soft rubber pad 30 . The foam pad 20 and the soft rubber pad 30 are shown to be shaped in a substantially similar manner such that the foam pad 20 and the soft rubber pad 30 can be in direct contact with one another. The soft rubber pad 30 is shown to be on top of the foam pad 20 such that the foam pad 20 is in direct contact with the skin of the wearer. It is understood that the word “pad” should not be consider to limit the invention as such.
It is contemplated that foam pad 20 would generally cushion against the users nipple or other body protrusion and rubber pad would 30 provide a surface against the brassiere interior wherein the rubber or like material would generally provide a slip free or reduced slip contact between invention 10 and the brassiere. It is understood that invention 10 use of the rubber or rubber like material would allow placement such that an adhesive is not required to either stick invention 10 to the brasserie and or invention 10 to the user.
It is understood that brassieres are available in many variations, styles, and types. As such, the foam pad 20 and soft rubber pad 30 , either independently or together, may be of different sizes, shapes, styles, and so forth. It is further contemplated that invention 10 may be constructed of a variety of materials to achieve the purpose of concealing an erect nipple, or protrusion. For example, the material for the foam pad 20 may include, but is not limited to, polyurethane, polyethylene, cotton, polyester, polypropylene foam, and the like. Furthermore, it is preferred that the material for the soft rubber pad 30 be relatively soft and semi-rigid. As such, it is contemplated that the material for the soft rubber pad 30 may include, but is not limited to, rubber, foam-rubber, vinyl, silicone rubber, styrene based thermoplastic elastomer, Acrylonitrile Butadiene Styrene, and the like. It is understood that the term “rubber” may also include natural rubber and man made rubber.
It is also contemplated that rubber or other like material may be applied to foam pad 20 in general. The rubber or like material may be sprayed, dipped, brushed, or otherwise applied. It is understood that numerous means of applying the rubber or rubber like material may be utilized and the above discussion should not be considered to limit the invention as such. It is also understood that foam pad 20 may be bonded to rubber pad 30 by known conventional means such as but not limited to an adhesive layer, glue, press fit and so forth.
In a preferred embodiment, the invention 10 may be used in conjunction with a brassiere (not shown) by inserting the invention 10 inside an opening of the brassiere. The invention 10 may then be secured inside the brassiere by any fastening means feasible (sewing, buttons, slide seal, zipper, etc). It is understood that such arrangement may not require the two types of materials explained above to achieve the stated purpose, and may only require the use of the soft rubber pad 30 .
Referring now to FIGS. 2 and 3 , reference numeral 10 a designates a device, system and method, which allows a user to obfuscate, hide or conceal an erect nipple, or protrusion, in a flattering, natural way, constructed in accordance with the present invention. In another preferred embodiment, the invention 10 a may be constructed in a manner that essentially provides three materials for concealment purposes: a foam pad 20 a , a soft rubber pad 30 a , and a fabric 40 . The foam pad 20 a , the soft rubber pad 30 a , and the fabric 40 are shown to be shaped in a substantially similar manner such that the foam pad 20 a , the soft rubber pad 30 a , and the fabric 40 can be in direct contact with one another. However, it should be understood that the foam pad 20 a and soft rubber pad 30 a , either independently or together, may be of different sizes, shapes, styles, and so forth.
In a preferred embodiment, the invention 10 a may be used in cooperation with a brassiere (not shown) by inserting the invention 10 a between the skin and the brassiere. Likewise, it is contemplated that the fabric 40 of the invention 10 a may have an adhesive quality such that the invention 10 a may be used independently and attach to the overlying garment.
It is further contemplated that the invention may be used in other applications besides pads to conceal nipple protrusion, such as rubber or other non-slip material push-up pads to prevent slippage of the pad. Furthermore, the invention may be generally used as a prosthesis device to enhance size for breast cancer survivors or others in need of cosmetics enhancements. It is contemplated the current invention my be of a construction such that on a ½ inch to 2 inch pad is utilized to prevent slippage and add enhancement. It is understood that the enhancement may be less than a ½ inch or greater than 2 inches.
From the above description, it is clear that the present invention is well adapted to carry out the objects and to attain the advantages mentioned herein. While presently preferred embodiments of the invention have been described for purposes of disclosure, it will be understood that numerous changes may be made which readily suggest themselves to those skilled in the art and which are accomplished within the spirit of the invention disclosed.
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An apparatus for concealing a bodily protrusion such as a human nipple comprising a foam pad for placing against the protrusion and a rubber pad for placing against a garment interior like the inside of a brassiere cup wherein the foam pad and the rubber pad are attached together.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation in part of U.S. application Ser. No. 10/621,982 filed on Jul. 17, 2003, which is currently pending and which is hereby incorporated by reference in its entirety, and which is a continuation of international application number PCT/EP02/00384 filed on Jan. 16, 2002, now abandoned and which is hereby incorporated by reference in its entirety, and which claims priority to and is a continuation of German application DE 101 02 292.1 filed Jan. 19, 2001.
FIELD OF THE INVENTION
[0002] The invention relates to a headlight unit for single-track two-wheeled vehicles, especially motorcycles, motor scooters or the like, which experience an inclination around their longitudinal axis while negotiating curves, the unit being provided with a sensor-controlled correction device for the light pattern generated by the dipped low beam.
BACKGROUND OF THE INVENTION
[0003] While a motorcycle is negotiating a curve, the inclination of the vehicle causes the light pattern of the dipped beam to deviate considerably from the form required by traffic regulations for the upright vehicle. As a result, the driver's visibility distance in the curve is greatly reduced, and the oncoming traffic is blinded.
[0004] In order to counteract such impairment of traffic safety, it is provided according to a known proposal (German Patent 19817594 A1) that the light cone of the dipped beam of a motorcycle negotiating a curve be stabilized by pivoting the headlight around its optical axis, in such a way that the light pattern is maintained substantially constant relative to the roadway centerline for each inclination on the curve.
[0005] For this purpose there is provided a control unit that cooperates with two sensors that do not operate on the ground-sensing principle. One measures the yaw of the vehicle around the vertical axis while the other measures the inclination of the vehicle around the longitudinal axis. Because of the pivoting of the headlight, the known headlight-stabilization system does not operate without wear; moreover, it necessitates a complex movement mechanism.
[0006] Finally, from German Patent 19639526 A1, there is known, for adaptation of the light distribution of a headlight system during negotiation of a curve, a method in which the light distribution for straight-ahead driving is supplemented by a light distribution with broader horizontal dispersion during negotiation of a curve, by the fact that a plurality of headlights is combined as appropriate.
[0007] In another known headlight unit on a motorcycle (Japanese Patent A 01127466), a main headlight is provided on each side with an auxiliary headlight, which is turned on in response to the inclination of the motorcycle during negotiation of a curve. Even though the light beam of the respective auxiliary headlight is directed outward and upward, it fails to illuminate the respective inside of the curve adequately.
[0008] U.S. Pat. No. 4,024,388 to Skoff discloses a cornering light system comprising single headlight and two auxiliary cornering lights, which are not comparable with the light system of the present application. In the present application, three equal lights are disposed, a central headlight and two laterally mounted headlights. Advantageously, as will be discussed further herein, this means that one light is functioning at full illumination, whereas the two other lights are either dark or dimmed.
[0009] In U.S. Pat. No. 5,727,864 to Stelling appears to disclose three horizontally arranged lights. These lateral headlights are not turned about their optical axis by a predetermined angle.
SUMMARY OF THE INVENTION
[0010] In contrast, the object of the present invention is to reduce the system costs significantly compared with the known art by providing a simply constructed headlight unit without wearing parts, thus ensuring trouble-free operation with high operating safety. As regards illumination of the driving lane while negotiating a curve, the headlight unit is designed to achieve improved illumination, corresponding substantially to that of straight-ahead driving; the purpose is to prevent, even if the vehicle is extremely inclined on the curve, an upwardly directed light cone that blinds the oncoming traffic.
[0011] In an advantageous embodiment, the inventive headlight unit, which is designed as a kind of multi-faceted headlight, comprises three or more headlights mounted in fixed condition inside a common lamp housing. Each of these headlights may be identical individual headlights commonly available on the market. At least one headlight is disposed in the middle and the others are disposed at the sides thereof, with at least one on the right side and one on the left side respectively.
[0012] To achieve better illumination, especially while negotiating a curve, it is expedient to mount the laterally disposed headlights lower than the middle headlight relative to the upright orientation of the vehicle, in such a way that a bow-shaped headlight bar bent downward on both sides is formed. Alternatively, however, other headlight arrangements are also conceivable within the inventive headlight unit, such as an arrangement of all headlights at the same height, an inversely bowed arrangement thereof or even an asymmetric arrangement of headlights. For example, it may be expedient, depending on whether the vehicle will be operated in traffic driving on the right or left, to increase the number of headlights on the right or left side compared with the respective other side, in order to achieve better illumination across the driving lane.
[0013] By means of the inventive headlight unit there is achieved significantly improved illumination during negotiation of a curve, not only in the stretch of driving lane immediately ahead of the vehicle but also on the inside of the respective curve. A particular additional advantage is prevention of the blinding effect, not only because only one of the lateral headlights or only the headlights on one side relative to the central headlight are turned on during negotiation of a curve, while the headlights on the opposite side as well as the middle headlight are turned off, but also—and in particular—because the lateral headlight or lateral headlights are mounted in such a way that they are turned around their optical axis, thus causing them to be out of horizontal orientation and, in fact, to be directed toward the inside of the respective curve. Thereby the headlight cone on both sides of the vehicle is directed toward the surface of the driving lane while the said vehicle is inclined during negotiation of a curve, thus substantially maintaining the intended light-beam pattern. This is of particular importance during driving with dipped low beam, because thereby the elongated lateral light branch on the right side remains substantially unchanged, while the blinding effect on the left side—which is otherwise unavoidable with the use of a standard headlight, which shines upward because of the greatly inclined orientation of the vehicle—is prevented.
[0014] A suitable angle by which the lateral headlight can be turned to compensate for inclination ranges between 25 and 35°, preferably 30°. In the scope of the inventive configuration, it is provided that a lateral headlight will be turned on only after a roll angle of 10 to 20°, preferably 15°, has been exceeded. This means that changeover from the central headlight to a lateral headlight, especially to the right lateral headlight during negotiation of a left-hand curve and to the left lateral headlight during negotiation of a right-hand curve, takes place only when the vehicle inclination corresponding to this roll angle is reached. In this connection it is self-evident that the changeover from the central headlight to a lateral headlight takes place on entering the curve and the inverse changeover takes place on exiting the curve, or in other words when, at the end of negotiation of a curve, the driver returns his vehicle to upright orientation to the extent that the roll angle becomes smaller than the minimum value during the upward movement.
[0015] In order to improve illumination of the driving lane ahead of the driver during negotiation of a curve, it is provided in a further inventive proposal that the headlights laterally adjoining the middle headlight are each mounted in such a way that they are skewed toward the middle headlight, around their axis parallel to the vertical axis of the vehicle, so that their optical axes form, together with a middle plane of the vehicle defined by the longitudinal and vertical axes, a skew angle ranging preferably from 4 to 8°. Expediently, this skew angle can have a different value for the right and left headlights, such that the right headlight in the case of traffic driving on the right and the left headlight in the case of traffic driving on the left is skewed slightly more toward the inside than the respective other headlight; suitable skew angles are, for example, 5 and 7° respectively.
[0016] By means of the inventive headlight unit, it is possible, during negotiation of a curve with two-wheeled vehicles, to achieve the same illumination as in straight-ahead driving. Thus, instead of the usually distorted, greatly diminished, poorly illuminated light pattern, a light-beam pattern corresponding substantially to the requirements for straight-ahead driving is achieved even during negotiation of a curve, by virtue of the changeover between the headlights.
[0017] In this connection, simultaneous changeover of the headlight lamps is sufficient for continuous illumination of the driving lane without darkness interruptions during the changeover, because the delayed buildup of light output of the headlight being turned on is bridged by the inertia of the incandescent lamp of the headlight being turned off. Alternatively, however, operation of the two headlights can be synchronized in such a way that, when the stabilization device is activated, the headlights are actuated in such a way by the control unit that the lateral headlights are gradually turned on or off before the central headlight is gradually turned off or on respectively. By such synchronized operation during the changeover from one headlight to the other, the headlights can be actuated in a manner that is particularly gentle for the lamps.
[0018] In the lamp housing containing the three or more headlights, there are also installed a sensor unit and the control unit. Within the interior of the lamp housing, the individual headlights are each fixed in individually adjustable manner on a mounting plate. The individual headlight lamps are equipped with multiple reflectors for high and low beam, as is customary in the industry. The headlight housing is provided with a common front lens containing dispersion sections adapted to the individual headlights.
[0019] The stabilization device comprises, in a manner known in itself, a sensor unit having two sensors, one being a longitudinal-axis sensor that measures the vehicle inclination around the longitudinal axis of the vehicle, and the other being a vertical-axis sensor that measures the vehicle motion around the vertical axis during negotiation of a curve. Each sensor sends signals proportional to the angular velocity to the control unit.
[0020] In this connection, the vertical-axis sensor is used to improve the accuracy of measurement of the degree of lean of the vehicle; it contributes to improvement of the operating safety to the extent that its measured values are analyzed in a computer of the control unit as part of a plausibility test, in which the degree of lean determined by the longitudinal-axis sensor is compared with the variation of vehicle movement during negotiation of a curve. As explained, the said computer analyzes the signals of both sensors and determines therefrom the transition between driving in substantially upright orientation and negotiation of a curve, by comparing the respective inclination of the vehicle with the minimum roll angle. In the process, the sensor signals are corrected by filtering, linearization and temperature compensation. The switching instants calculated at the beginning and end of negotiation of a curve are appropriately converted to switching processes of a power circuit for actuation of the headlights.
[0021] Advantageously, the control unit contains a safety circuit, which turns on the lateral headlights with appropriate power distribution if the central headlight fails, and which turns on the central headlight with full power if the lateral headlights fail.
[0022] By the fact that the inventive headlight unit is composed of individual commercially available headlights, low system costs are achieved. With the exception of the incandescent lamps themselves, the inventive headlight unit is able to operate without wearing parts, thus also contributing to a concomitant increase in its functional safety and useful life. By the fact that the blinding effect is largely prevented, it is also possible to use headlights with greater light outputs. The inventive headlight unit can be provided as a retrofit kit, to be mounted in place of a conventional headlight, on the cable connection thereof.
[0023] The sensors used do not rely on ground or speed sensing, but instead operate on the principle of piezoelectric vibration-dependent gyroscopes, which are available on the market.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] A practical example of the invention will be explained hereinafter with reference to the drawing, wherein:
[0025] FIG. 1 shows a light-beam pattern of standard type required by traffic regulations for a motorcycle being driven straight ahead;
[0026] FIG. 2 shows the light-beam pattern according to FIG. 1 in a left-hand curve;
[0027] FIG. 3 shows the light-beam pattern according to FIG. 1 in a right-hand curve;
[0028] FIG. 4 shows the inventive headlight unit in front view of a motorcycle negotiating a right-hand curve;
[0029] FIG. 5 shows the light-beam pattern of the inventive headlight unit in a right-hand curve;
[0030] FIG. 6 shows the light-beam pattern of the inventive headlight unit in a left-hand curve;
[0031] FIG. 7 shows the inventive headlight unit in schematic front view;
[0032] FIG. 8 shows a section according to VIII-VIII of FIG. 7 , and
[0033] FIG. 9 shows a section according to IX-IX of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 shows a light-beam pattern in the form required by traffic regulations, for the case of a dipped beam, adapted for traffic driving on the right, of a motorcycle 1 provided with a commercially available headlight, wherein the illuminated area 4 during straight-ahead driving is defined by a left and a right boundary beam 3 and 2 respectively, extending in driving direction.
[0035] FIG. 2 shows motorcycle 1 in a left-hand curve. Because of its inclination by angle a on the curve, the resulting illuminated area 5 is smaller than that in FIG. 1 . A fraction of area 4 on the inside of the curve is no longer illuminated. Right boundary beam 2 no longer reaches the ground and thus becomes blinding beam 10 . For the driver of motorcycle 1 equipped with a standard headlight, therefore, the asymmetric branch of the dipped beam no longer contributes to improvement of the view of the road along the right boundary of the driving lane.
[0036] FIG. 3 shows motorcycle 1 during negotiation of a curve bending to the right. Because of the degree of lean of motorcycle 1 by inclination angle a, there is obtained an illuminated area 6 spread across the driving lane. Right boundary beam 2 no longer illuminates the right side of the road, and left boundary beam 3 no longer reaches the ground and thus becomes blinding beam 12 . As in FIG. 2 , the light pattern deviates considerably from the traffic regulations developed on the basis of safety considerations.
[0037] FIG. 4 shows an enlarged diagram of motorcycle 1 in front view with the inventive “multi-faceted” headlight unit 13 during negotiation of a right-hand curve. The headlight unit comprises three individual headlights mounted close to each other in a common headlight housing 20 , namely a central headlight 23 , a right headlight 22 and a left headlight 24 . In the illustrated right-hand curve, only left headlight 24 is turned on. Compared with central headlight 23 , it is mounted in such a way that it is turned by an angle β toward the outside of the curve, in order to compensate for inclination. The motorcycle itself is inclined by the angle a, which is larger than a minimum roll angle α, which corresponds approximately to an inclination of 15° around longitudinal axis X-X relative to a plane defined thereby together with vertical axis Z-Z. When roll angle α is reached, a control unit turns on left headlight 24 . Boundary beams 2 and 3 shown for central headlight 23 in FIGS. 1 to 3 are not a factor in this situation. Instead, left headlight 24 generates boundary beams 2 f , 3 f , which are directed toward the ground and, because left headlight 24 , in order to compensate for inclination, is turned by angle β, which is equal to about 30°, create a light pattern that corresponds approximately to the required pattern even during negotiation of a curve, as shown in the following FIGS. 5 and 6 .
[0038] In a right-hand curve being negotiated by motorcycle 1 , as illustrated in FIG. 4 , there is obtained according to FIG. 5 an illuminated area 8 with boundary beams 2 f and 3 f . This light-beam pattern, which corresponds to illuminated area 8 , is skewed slightly by an angle δ toward the inside of the curve. The skew angle δ of left headlight 24 is indicated in FIG. 8 and has a value of about 5°. Thereby the asymmetric branch of the light-beam pattern is made to travel along the inside boundary of the driving lane, in conformity with the regulations.
[0039] To avoid the situation in which the light pattern of headlight unit ( 13 ) perceived by oncoming traffic varies whenever individual headlights are turned on and off during negotiation of a curve, two inactive light sources, or in other words ( 22 ) and ( 24 ) during straight-ahead driving, ( 22 ) and ( 23 ) on the right-hand curve or ( 23 ) and ( 24 ) on the left-hand curve, can be operated with lower illuminating power than the remaining third light source in each case. In other words, all three light sources are turned on at all times. In the right-hand curve, the two right headlights ( 22 ) and ( 23 ) are operated with non-blinding illuminating power, while left headlight ( 24 ) is operated with full illuminating power. In the left-hand curve, the two left headlights ( 23 ) and ( 24 ) are operated with non-blinding illuminating power, while right headlight ( 22 ) is operated with full illuminating power. During straight-ahead driving, the two outside headlights ( 22 ) and ( 24 ) are operated with relatively low illuminating power, while center headlight ( 23 ) is operated with full illuminating power. With this control circuit, the overall contour of activated headlight unit ( 13 ) is constantly perceived as a complete light pattern by oncoming traffic.
[0040] As a result, depending on degree of lean, only the headlight projecting its beam pattern onto the driving lane in the manner most favorable for the respective degree of lean is operated with full illuminating power. Thus the overall light contour of activated headlight unit ( 13 ) is always constantly perceived as a uniform signal pattern by oncoming traffic.
[0041] FIG. 6 shows the diagram corresponding to FIG. 5 for a left-hand curve. In this case right headlight 22 is used. It is also skewed by an angle δ toward the central headlight, as is evident once again from FIG. 8 . Right headlight 22 is skewed by a slightly larger amount than left headlight 24 , namely by about δ=7°. Thereby illuminated area 7 is deflected more toward the inside of the left-hand curve. In both this case and that of negotiation of a right-hand curve according to FIG. 5 , the production of a blinding beam is effectively prevented.
[0042] For the purpose of illustration, the light-beam patterns corresponding to the prior art in FIGS. 1 to 3 and to the condition achieved with the inventive headlight unit in FIGS. 5 and 6 are accompanied by additional diagrams of the motorcycle driver in side view and in front view respectively, the beam profile being illustrated in the direction of a vertical plane. The additional diagrams and reference symbols are understandable in themselves, and so each of the said figures can be considered as a complete diagram.
[0043] FIGS. 7 to 9 schematically show the construction of the inventive headlight unit, which in the present case has the form of a triple-faceted headlight unit, in which the two lateral headlights 22 , 24 are mounted lower than central headlight 23 . Three commercially available headlights 22 , 23 , 24 with high and low beams are installed close beside each other in a housing 20 . The three individual headlights can be fixed individually and adjustably on a mounting plate 25 . They are disposed rearward of a front lens 21 , which seals headlight housing 20 and protects the internals of housing 20 from environmental influences.
[0044] During straight-ahead driving, only central headlight 23 is turned on. This is also the case for gentle curves, which are negotiated with relatively low degrees of lean up to a roll angle α of 10 to 20°, preferably 15°. Right headlight 22 and left headlight 24 are expediently turned off during straight-ahead driving with dipped beam.
[0045] On a left-hand curve, right headlight 22 is turned on as soon as minimum roll angle α is exceeded, and the other two headlights are then turned off. Right headlight 22 is mounted in such a way that, when viewed from the front, it is turned around its optical longitudinal axis by an angle of β=30° in counterclockwise sense to compensate for inclination; in addition, it is mounted in such a way that it is skewed toward central headlight 23 by a skew angle of δ=7°, around an axis parallel to the Z axis, so that the driver's visibility range in the direction of the inside of the curve is improved.
[0046] Left headlight 24 is turned on for illumination during negotiation of right-hand curves upon passage through a minimum roll angle of α=15°. During negotiation of such curves, the other two headlights are turned off. The left headlight is mounted in such a way that it is also turned by an angle of β=30° in clockwise direction to compensate for inclination. It is also positioned in such a way that it is skewed around the Z axis toward central headlight 23 by the skew angle of δ=5°. Thereby the driver's visibility range in the direction of the inside of the curve is considerably improved.
[0047] Besides the three headlights, electronic unit 26 for switching the power circuit is also installed inside headlight housing 20 , as is a computer 27 together with longitudinal-axis sensor and vertical-axis sensor, which are not illustrated in detail.
[0048] The power circuit contains solid-state switches for the headlight lamps and an integrated failure-detection circuit for the individual lamps.
[0049] The longitudinal-axis sensor is oriented in the direction of the X axis, and it measures the angular velocity of the roll motion of the vehicle as it begins and ends negotiation of the curve.
[0050] The vertical-axis sensor is oriented in the direction of the Z axis, and it measures the angular velocity of the vehicle around the center of the curve being negotiated. Computer 27 calculates the inclination of the vehicle around the X axis from the sensor signals, and controls actuation of the power circuit during passage through the minimum roll angle α.
[0051] As a result, the angular error in recreating the light-beam pattern during negotiation of a curve is now at most plus or minus 15°, whereas, by comparison, the angular error in motorcycles with standard headlights is as large as 45°, thus illustrating the great contribution of the inventive proposal toward improvement of traffic safety.
[0052] In a further embodiment, a dimming feature is utilized wherein one or more of the headlights are operated at a reduced illumination relative to a full illumination, i.e. normal illumination. Therein, a dimming feature is utilized wherein all three headlights 22 , 23 , 24 are illuminated at all times. Thus, if the motorcycle is traversing a straight-away segment, the central headlight 23 is at full illumination and the lateral headlights 22 , 24 are at a reduced illumination. It is envisioned, that the illumination is reduced to 25% of the full illumination, i.e. ¼ of the full illumination.
[0053] When the motorcycle exits a straight-away and makes a left-hand turn, for example, the right headlight 22 is then switched to full illumination while the illumination of the central headlight 23 is reduced and the left headlight 24 maintains its reduced illumination.
[0054] Similarly, when the motorcycle exits a straight-away and negotiates a right-hand turn the left headlight 24 is then switched to full illumination while the illumination of the central headlight 23 is reduced, to for example 25% of full illumination, and the right headlight 22 maintains its reduced illumination.
[0055] In yet a further embodiment, if the motorcycle is traversing a straight-away segment, the central headlight 23 is at full illumination. When the motorcycle exits a straight-away and makes a left-hand turn, for example, the right headlight 22 is then switched to full illumination while the illumination of the central headlight 23 is reduced relative to the full illumination, of for example 25% relative to the full illumination.
[0056] Similarly, when the motorcycle exits a straight-away and negotiates a right-hand turn the left headlight 24 is then switched to full illumination while the illumination of the central headlight 23 is reduced to, for example, 25% of full illumination.
[0057] It should be appreciated that the reduction of illumination is relative to the full illumination and a reduced illumination at high-beam may be more or less than full-illumination as measured by lumens and/or foot-candles. Thus, in one embodiment the dimming feature may be utilized during both high and low beam operation of the headlight units. That is, the dimming feature may be utilized when the operator selects low beam headlights as well as when he selects high beam operation and need not require operator intervention to engage or reengage the dimming feature when the operator selects between low and high beams during the course of the same drive.
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A vehicle headlight unit comprising a sensor-controlled corrective device for the light beam pattern generated by the dipped low beam, at least one central headlight for driving in a straight line and one respective lateral headlight positioned to the right and left thereof, with right-hand headlight for illuminating left-hand bends and the left-hand headlight for illuminating right-hand bends. Each headlight is rotated away from the horizontal position about its optical axis through an incline-compensation angle, so that the outer edge that lies at a distance from the central headlight is in a lower position than the latter. The corrective device comprises an electronic control unit, which activates at least the central headlight within a driving range for a substantially upright driving position and when bends are negotiated and a minimal tilting angle is exceeded, deactivates the central headlight and activates either the left-hand or right-hand headlight.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a device for transporting freight, in particular freight containers in freight compartments of aircraft, in particular power drive unit (PDU) having a drive cylinder which is mounted in a frame.
[0002] Conventional devices for transporting freight are conventionally referred to as power drive units (PDU) and serve for actively and/or passively transporting freight containers in freight compartments of aircraft.
[0003] Such devices are not only subjected to intense demands during flight, since they must absorb very high loads, but rather must also operate reliably.
[0004] In particular, the drive roller of such device, in the case of an actively driven design, is subjected to a very high degree of wear, since said drive roller is provided on its outer surface and lateral surface with a coating, rubber lining or the like in order to transport the freight, in particular the freight containers, in a frictionally engaging manner.
[0005] Conventional PDUs have drive rollers, the drives of which must be dismounted in order to be able to remove the drive roller itself, which is undesirable.
[0006] Furthermore, no installation space is available for the drive unit, since the lateral bearing arrangements prevent simple disassembly.
[0007] It is an object of the present invention to provide a device of the type specified in the introduction which eliminates the stated disadvantages and in which the drive roller can be exchanged very quickly in a simple and cost-effective manner. Furthermore, the design should be cost-effective to produce. Furthermore, an integration of the drive into the drive roller should be possible while simultaneously enabling a fast change or exchange of the drive roller.
SUMMARY OF THE INVENTION
[0008] The object is achieved by providing a device wherein the drive roller is readily exchangeable.
[0009] In the present invention, it has proven to be particularly advantageous for the drive cylinder itself to be mounted so as to be pivotable, in particular swivelable or in an articulated fashion, with respect to a frame, in particular a lateral frame part.
[0010] A drive, in particular an electric motor, and/or a gearing unit is integrated in the drive cylinder itself.
[0011] Here, it is a particular advantage of the present invention that the drive roller can be plugged coaxially and in the manner of a sleeve onto the drive cylinder itself.
[0012] A bearing element is seated on the end of the drive roller which has the outer coating, casing, rubber lining or the like in order to transport the freight container in a frictionally engaging manner, which bearing element engages into a corresponding bearing depression or support of the opposite lateral frame part.
[0013] By correspondingly swiveling the unit composed of the drive cylinder and drive roller upward and outward, it is then possible for the drive roller to be pulled axially from the drive cylinder in order to exchange said drive roller for the purpose of repair or replacement.
[0014] In this way, it is necessary merely for the drive cylinder with the attached drive roller to be pivoted upward about a bearing arrangement of the lateral frame part. The corresponding drive roller can then be pulled off axially.
[0015] A repaired or new drive roller with a corresponding, possibly exchanged bearing element is then correspondingly pushed on in the reverse sequence in a very fast, time-saving and cost-saving manner, since this can even be carried out during operation of the aircraft.
[0016] This is likewise to be encompassed by the present invention.
[0017] In a further exemplary embodiment of the invention, it is possible for lateral auxiliary frames to be pivoted upward with respect to the frame itself, with a drive cylinder being fixedly connected at the end side to an auxiliary frame and being mounted there and with it being possible for a drive roller to be plugged on or pushed on coaxially in the manner of a sleeve at the other end at the end side in the above-described manner. Said drive roller is then mounted by means of corresponding auxiliary frames, with it being possible for a bearing receptacle with attached bearing element to be swiveled about a joint, in particular pivoted out of the end-side region, in order to axially pull the drive roller from the drive cylinder or push the drive roller onto the drive cylinder for the purpose of exchange and disassembly or assembly. It is possible here too for the drive roller to be removed from the drive cylinder or exchanged in a very fast, cost-effective and simple manner.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further advantages, features and details of the invention can be gathered from the following description of preferred exemplary embodiments and on the basis of the drawing; in which:
[0019] FIG. 1 a shows a perspective view of a device for transporting freight, in particular PDU;
[0020] FIG. 1 b shows a perspective view of the device according to FIG. 1 a in a possible assembly position;
[0021] FIG. 1 c shows a perspective view of the device according to FIGS. 1 a and 1 b in another assembly position;
[0022] FIG. 2 a shows a perspective side view of a further exemplary embodiment of a device for transporting freight, in particular PDU, in a deployed position;
[0023] FIG. 2 b shows a perspective view of the device according to FIG. 2 a in a further assembly position;
[0024] FIG. 2 c shows a perspective view of the device according to FIGS. 2 a and 2 b in a further assembly position.
DETAILED DESCRIPTION
[0025] According to FIG. 1 a , a device R 1 according to the invention for transporting freight, in particular freight containers in freight compartments of aircraft, which device is referred to in particular as a power drive unit (PDU), has a frame 1 which is formed in the manner of a housing.
[0026] A controller 2 for activating a drive cylinder 3 is integrated in the frame 1 , as can be seen in more detail in FIG. 1 c.
[0027] Drives, motor units and/or gearing units (not illustrated here in any more detail) are integrated in the drive cylinder 3 and drive a drive roller 4 , which is seated coaxially on the drive cylinder 3 , in rotation.
[0028] The drive roller 4 is of sleeve-like design and is provided on the outside with a coating, rubber lining or the like.
[0029] Here, the drive roller 4 can be connected in a rotationally fixed manner to the drive cylinder 3 , such that a rotational drive movement of the drive cylinder 3 can be directly transmitted to the drive roller 4 .
[0030] Lateral frame parts 5 . 1 , 5 . 2 adjoin the frame 1 , between which lateral frame parts 5 . 1 , 5 . 2 the drive cylinder 3 with coaxially attached drive roller 4 is mounted.
[0031] Furthermore, a lifting unit 6 with an integrated drive (not illustrated here) adjoins the lateral frame parts 5 . 1 , 5 . 2 at the ends, in order, by means of corresponding, in each case laterally projecting eccentrics 7 , to deploy the frame 1 , in particular the drive cylinder 3 and drive roller 4 , upward in a known way in order to convey and transport an item of freight, in particular a freight container, by means of the driven drive roller 4 .
[0032] The drive roller 4 and also the bearing element 9 thereof are subjected to a certain degree of wear, such that these must often be exchanged.
[0033] In order that the entire device R 1 need not be dismounted entirely from the aircraft, it has proven to be particularly advantageous in the present invention for the drive cylinder 3 with coaxially attached drive roller 4 to be mounted so as to be pivotable, in particular swivelable, with respect to the frame part 5 . 1 .
[0034] Here, in the present invention, it is possible for the drive cylinder 3 with attached drive roller 4 to be pivoted upward and outward about a longitudinal axis of the frame part 5 . 1 by means of a bearing arrangement 8 , as illustrated in FIGS. 1 b and 1 c by the double arrow X. The bearing element 9 adjoins the end of the drive roller 4 , which bearing element 9 can be pivoted out of an upwardly-open bearing depression 10 of the frame part 5 . 2 , which forms a half-shell-like support 11 .
[0035] When acted on with pressure, for example by means of a freight container, the drive roller 4 as illustrated in FIG. 1 a is mounted and held at one end by means of the bearing element 9 in the support 11 of the bearing depression 10 of the lateral frame part 5 . 2 .
[0036] To exchange the drive roller 4 , the latter can be pulled from the drive cylinder 3 , after the latter has been swiveled out, in the illustrated Y direction as indicated in FIG. 1 c , with an anti-twist device being released or removed if appropriate.
[0037] It is then possible, for example, to push a new drive roller 4 coaxially onto the drive cylinder 3 , if appropriate with a new bearing element 9 , in the axial direction. After the drive cylinder 3 and the drive roller 4 with bearing element 9 are correspondingly swiveled and placed into the bearing depression 10 , the device R 1 is once again ready for use.
[0038] An exchange of the drive roller 4 takes place very quickly and may be carried out without dismounting the entire device R 1 .
[0039] In the exemplary embodiment of the present invention according to FIG. 2 a , a device R 2 is shown in which the frame is formed from lateral frame parts 5 . 1 , 5 . 2 , wherein in each case within a lateral frame part 5 . 1 , 5 . 2 , a lateral auxiliary frame 12 . 1 , 12 . 2 can be pivoted upward and outward in an illustrated X direction.
[0040] Here, in particular as is the design in the exemplary embodiment of the present invention according to FIG. 2 c , the drive cylinder 3 with integrated electric drive, as a motor and/or gearing unit, is seated at the end side on the auxiliary frame 12 . 1 .
[0041] The drive roller 4 is seated coaxially on the drive cylinder 3 in the above-described manner, and is preferably rotationally fixedly connected to the drive cylinder 3 .
[0042] At the outside, the drive roller 4 is provided with a coating, rubber lining or the like, which comes into direct contact with an item of freight to be transported, in particular freight container.
[0043] The drive roller 4 is supported and mounted on the auxiliary frame 12 . 2 by means of a bearing element 14 .
[0044] Here, in the present invention, it has proven to be particularly advantageous for a bearing receptacle 15 to be pivotable, in particular swivelable about a joint 16 , out of the end-side region of the drive roller 4 after the removal of a retaining shaft 17 .
[0045] As illustrated in FIG. 2 c , it is possible, after the auxiliary frame 12 . 1 , 12 . 2 has been swiveled out of the frame, for the retaining shaft 17 to be removed from the drive roller 4 and the bearing receptacle 15 or from the bearing element 14 , after which it is possible for the bearing receptacle 15 with inserted bearing 14 to be subsequently swiveled away or pivoted out, as illustrated in FIG. 2 b , in order to subsequently pull the drive roller 4 coaxially from the drive cylinder 3 in the direction of the auxiliary frame 12 . 2 , in the illustrated double arrow direction Y, as per the exemplary embodiment according to FIG. 2 c , for the purpose of exchange.
[0046] A new drive roller 4 can then be pushed coaxially onto the drive cylinder 3 again in the reverse sequence, after which merely the bearing receptacle 15 is subsequently pivoted back in front of the drive roller 4 at the end side and the drive roller 4 and/or the drive cylinder 3 are/is connected by means of the retaining shaft 17 to the auxiliary frame 12 . 2 and therefore to the bearing element 14 and the bearing receptacle 15 thereof.
[0047] Here, too, a very fast exchange of the drive roller 4 from the drive cylinder 3 takes place without it being necessary to completely exchange or dismount the device R 2 .
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A device for transporting freight, especially freight containers in the cargo compartments of aircraft, especially to a power drive unit (PDU) having a drive roller ( 3 ) received in a frame ( 1 ) wherein the at least one drive roller ( 3 ) carrying the drive roll ( 4 ) placed thereon is mounted so as to be pivoted relative to the frame for the purpose of replacing the drive roll ( 4 ).
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TECHNICAL FIELD
[0001] The present invention relates to a method for preparing nanofibrillated cellulose capable of producing high-quality cellulose nanofibrils by a simple process without using conventional enzymatic treatment, in which a cellulose aqueous dispersion is homogenized by adding an aqueous alkaline solution having a pH between 8 and 14 thereto so that the aqueous alkaline solution aids the swell of an amorphous region of cellulose, thereby promoting the nanofibrillation of cellulose during the homogenizing process.
BACKGROUND ART
[0002] Cellulose is the most general natural polymer having a basic unit of β-1,4-glucose, which is the most abundant and renewable resource among all organic compounds present in nature, and is used in the form of pulp, building materials, energy sources, etc. Recently, with a growing demand on the environment-friendly polymer materials, study has been focused on highly-purified cellulose from the bacterial cellulose or wood to replace various kinds of functional polymers from petrochemicals (G. Siqueira et al., Polymer, 2010, 2, 728-765).
[0003] In particular, intensive studies have been performed on the separation of cellulose microfibrils from plants to use the cellulose microfibrils as a reinforcing material for nanofiber composite materials (M. Paakko et al., Biomacromolecules, 2007, 8, 1934-1941).
[0004] Nanofibrillated cellulose is known to have high elasticity of 150 GPa to 200 GPa and high strength of 5 GPa or higher, and these physical properties of nanofibrillated cellulose are excellent compared to those of general carbon fiber and glass fiber. Additionally, nanofibrillated cellulose has the merits of a low mean size, low expansion coefficient, environment-friendliness, recyclability, etc., and there is a large possibility that nanofibrillated cellulose can replace glass fiber in the composite material industry if the nanofibrillation of cellulose can be achieved by optimization of its preparation process (T. Zimmermann et al., Advanced Engineering Materials, 2004, 6, 754-761).
[0005] In this regard, intensive studies have been performed on natural fiber materials in England, Germany, USA, Japan, etc., and in particular, Innventia (Sweden) had previously reported their research result on the preparation of cellulose nanofibers by hydrolytic decomposition comprising enzymatic treatment and mechanical treatment (M. Paakko et al., Biomacromolecules, 2007, 8, 1934-1941). However, research and development on the nanofibrillation of cellulose and its application on composite materials is still in its early stages.
[0006] Microfibrils with a mean size of 100 nm or less are mainly prepared by mechanical homogenization such as refining or homogenizing in an aqueous dispersion. Homogenization is a method to make a mixture homogeneous by dispersing each component in a non-homogeneous mixture into fine particles, and methods of homogenization can be classified into mechanical treatments and chemical treatments. The structure and shape of cellulose fibers can vary according to the method of homogenization, i.e., mechanical or chemical treatment. In particular, cellulose may be fibrillated by impact force, shearing force, and cavitation which occur when an aqueous dispersion of cellulose is passed through a micro nozzle under high pressure, and repetition of the process (J. Floury et al., Innovative Food Science and Emerging Technologies, 2000, 1, 127 -134). The level of fibrillation can be partially controlled by the regulation of the number of passes through a high pressure homogenizer.
[0007] However, the nanofibrillation of cellulose does not progress continuously with the increase in the number of passes of the homogenizer, and there is a disadvantage such as a decrease in crystallinity after repeated mechanical treatment, thus requiring the optimization of the preparation process to minimize this disadvantage.
[0008] Alkali treatment of cellulose is mainly processed using aqueous ammonia solution and sodium hydroxide (A. N. Nakagaito et al., Cellulose, 2008, 15, 323-331). When cellulose is immersed into an aqueous alkaline solution, cellulose becomes constricted in a width direction and swollen in a height direction. Such aqueous ammonia solution have been mainly used as a swelling agent of cellulose in the conventional biomass conversion process (T. T. T. Ho et al., Journal of Polymer Science Part B: Polymer Physics, 2013, 51, 638-648). The ammonia molecules used as a swelling agent penetrate into the inside of cellulose and replace the hydrogen bond (O—H . . . O) between cellulose molecules, which are interconnected between cellulose and ammonia, with the hydrogen bond (O—H . . . N) between cellulose and ammonia molecules. The bond (O—H . . . N) is disassembled during the washing process. Natural cellulose has the structure of cellulose I, but, after ammonia treatment, the structure of cellulose changes into the structure of cellulose III. In the basic structure, the cellulose III has larger volume, longer molecular chain distance, and lower density compared to cellulose I.
[0009] Accordingly, the present inventors have developed a technology to promote nanofibrillation through a simple process by inducing the swelling of the cellulose molecular chains in the high pressure homogenizer utilizing the conventional biomass conversion process by adding an aqueous alkaline solution having a pH between 8 and 14, and confirmed that an aqueous alkaline solution can help the nanofibrillation of cellulose, by comparing the crystalline properties, mean size, specific surface area, and morphological structure with those of the cellulose nanofibrils prepared in the conventional aqueous dispersion state, thereby completing the present invention.
SUMMARY OF THE INVENTION
[0010] An object of the present invention is to provide a method for preparing high-quality cellulose nanofibrils by a simple process without going through with enzymatic treatment.
[0011] In order to achieve the above object, the present invention provides a method for preparing nanofibrillated cellulose, including:
[0012] dispersing pulp in water to obtain an aqueous dispersion of pulp (Step 1);
[0013] adding an aqueous alkaline solution having a pH between 8 and 14 to the aqueous dispersion of pulp to obtain a dispersed aqueous alkaline solution of pulp (Step 2); and
[0014] homogenizing the dispersed aqueous alkaline solution of pulp to obtain a homogenized material (Step 3).
[0015] Preferably, the method for preparing nanofibrillated cellulose may further include mechanically refining the aqueous dispersion of pulp after Step 1.
[0016] Preferably, the method for preparing nanofibrillated cellulose may further include stirring the dispersed aqueous alkaline solution of pulp after Step 2 (Step 2-1).
[0017] Preferably, the method for preparing nanofibrillated cellulose may further include drying the homogenized material after Step 3 (Step 3-1).
[0018] Cellulose fibrillation has been conventionally prepared by a mechanical method such as refining or homogenizing in a state of an aqueous dispersion. Additionally, the structure and shape of cellulose fibers could have been controlled by a chemical method such as an enzymatic treatment accompanying the mechanical method. In particular, in the case of using a high pressure homogenizer, the cellulose can be fibrillated by repeating the process of passing the cellulose through a micro nozzle under high pressure, and the level of fibrillation can be controlled partially by repeating the passes through the high pressure homogenizer and adjusting the size of the micro nozzle. However, the above mechanical method has problems in that the method cannot achieve a satisfiable degree of cellulose fibrillation, and also is not efficient with respect to the obtainment of fibrillated cellulose with a mean size of a certain level which requires an increasing number of passes through the homogenizer under high pressure. The enzymatic treatment method also has disadvantages of long processing time and high cost.
[0019] The present invention provides a method for preparing fibrillated cellulose at a nano level via homogenization after adding an aqueous alkaline solution to a cellulose aqueous dispersion.
[0020] The method for nanofibrillation of the present invention is a method for preparing high-quality cellulose nanofibrils by a simple process without using the conventional enzymatic treatment, in which an aqueous alkaline solution aids the swell of an amorphous region of cellulose, thereby promoting the nanofibrillation of cellulose during the homogenizing process.
[0021] The present invention will be explained in detail herein below.
[0022] Step 1 relates to preparing an aqueous dispersion of pulp by dispersing pulp in water.
[0023] In the present invention, the pulp in Step 1 may be wood pulp such as hardwood pulp, softwood pulp, etc., but is not limited thereto.
[0024] Step 1-1 relates to mechanical refining of the aqueous dispersion of pulp obtained in Step 1, thereby further dispersing and dissociating the pulp in water.
[0025] In the present invention, the mechanical refining may be performed using the pulper for the wet-laid nonwoven equipment. Additionally, the mechanical refining may be preferably performed for 20 minutes to 1 hour. By performing the mechanical refining, pulp can be sufficiently dissociated in an efficient manner during the period of the mechanical refining.
[0026] Step 2 relates to adding an aqueous alkaline solution having a pH between 8 and 14 to the aqueous dispersion of pulp to obtain a dispersed aqueous alkaline solution of pulp, in which pulp is dispersed in the aqueous alkaline solution. Preferably, the aqueous alkaline solution having a pH between 8 and 14 is aqueous ammonia solution.
[0027] The preparation method of the present invention has an effect of promoting nanofibrillation via homogenization by adding an aqueous alkaline solution having a pH between 8 and 14 to an aqueous dispersion of pulp as described above.
[0028] Specifically, in an exemplary embodiment of the present invention, nanofibrillated cellulose was prepared via homogenization in the state of an aqueous dispersion of pulp or dispersed aqueous ammonia solution of pulp, respectively, and the mean size of the as-prepared nanofibrillated cellulose was examined. As a result, when an aqueous ammonia solution dispersion was used, nanofibrillated cellulose with a smaller mean size was obtained compared to the case of aqueous dispersion, thus confirming that the use of aqueous ammonia solution can promote nanofibrillation (Experimental Example 2).
[0029] In the present invention, the aqueous dispersion of pulp in Step 2 may preferably contain pulp solid in a concentration of from 0.01 wt % to 1 wt %. In Step 2, the use of a low-concentration aqueous dispersion, which contains the pulp solid in a low concentration of from 0.01 wt % to 1 wt %, can facilitate the dissociation of pulp.
[0030] In the present invention, the amount of the aqueous alkaline solution having a pH between 8 and 14 in Step 2 may be in an amount of 0.1 vol % to 20 vol % relative to that of the aqueous dispersion of pulp. When the addition of the aqueous alkaline solution is less than 0.1 vol %, the degree of nanofibrillation becomes low, thus increasing the mean size of the nanofibrils of cellulose, whereas when the addition of the aqueous alkaline solution exceeds 20 vol %, excessive nanofibrillation can occur and the cellulose nanofibrils become aggregated with adjacent nanofibrils, thereby increasing the mean size of the cellulose nanofibrils.
[0031] Step 2-1 relates to stirring the dispersed aqueous alkaline solution of pulp after Step 2 thereby further homogenously dispersing the pulp in the aqueous alkaline solution.
[0032] In the present invention, the stirring may be preferably performed for from 20 minutes to 1 hour. By stirring for the described time period, sufficient stirring can be advantageously performed in an efficient manner.
[0033] Step 3 relates to homogenizing the dispersed aqueous alkaline solution of pulp to obtain nanofibrillated cellulose.
[0034] In the present invention, the homogenization of Step 3 may be performed by passing the dispersed aqueous alkaline solution of pulp through a homogenizer. In particular, a high pressure homogenizer such as a microfluidizer may be used for the homogenization. Specifically, the use of a z-shaped chamber can maximize the fibrillation efficiency and thus it is preferable to use the z-shaped chamber.
[0035] In the present invention, the internal pressure of the homogenizer may be in the range from 70 MPa to 310 MPa. When the internal pressure of the homogenizer is within the above range, the fibrillation can be advantageously performed in an easy and efficient manner.
[0036] In the present invention, the diameter of the nozzle may be in the range from 50 μm to 250 μm. When the nozzle diameter is smaller than 50 μm, the pressure becomes too great when the dispersed aqueous ammonia solution of pulp passes through the nozzle, and thus the process efficiency becomes low, whereas when the nozzle diameter is larger than 250 μm, the level of fibrillation may decrease.
[0037] The nozzle to be used may be one attached to a homogenizer.
[0038] In the present invention, the number of passes through the homogenizer may be in the range from 3 to 20. When the number of passes is less than 3, the level of fibrillation may decrease, whereas when the level of fibrillation is greater than 20, the energy consumption becomes high.
[0039] In the present invention, the mean size of the nanofibrillated cellulose prepared after Step 3 may be 100 nm or less.
[0040] In an exemplary embodiment of the present invention, it was confirmed that the mean size of nanofibrillated cellulose can be 100 nm or less when homogenization is performed according to the preparation method of nanofibrillated cellulose, namely, homogenization by an aqueous ammonia dispersion instead of an aqueous dispersion (Experimental Example 2 and Experimental Example 4).
ADVANTAGEOUS EFFECTS OF THE INVENTION
[0041] In the method for preparing nanofibrillated cellulose of the present invention, a cellulose aqueous dispersion is homogenized by adding an aqueous alkaline solution and thus ammonia can aid the swell of an amorphous region of cellulose, thereby promoting the nanofibrillation of cellulose during the homogenizing process. Accordingly, the present invention provides a method for preparing high-quality cellulose nanofibrils by a simple process without using the conventional enzymatic treatment.
BRIEF DESCRIPTION OF DRAWINGS
[0042] FIG. 1 shows the results of XRD analysis of cellulose nanofibrils according to the homogenizing process and the kinds of dispersions.
[0043] FIG. 2 shows the analysis results of the mean size and the specific surface area of cellulose nanofibrils according to the homogenizing process and the kinds of dispersions.
[0044] FIG. 3 shows the analysis results of morphological structures of cellulose nanofibrils according to the homogenizing process and the kinds of dispersions.
[0045] FIG. 4 shows the analysis results of the mean size of cellulose nanofibrils according to the amount of addition and the presence of washing.
[0046] FIG. 5 shows the analysis results of morphological structures of cellulose nanofibrils according to the homogenizing process and the kinds of dispersions.
[0047] FIG. 6 shows the results of XRD analysis of cellulose nanofibrils.
[0048] FIG. 7 shows the analysis results of specific surface area of cellulose nanofibrils.
[0049] FIG. 8 shows the morphological structures of cellulose nanofibrils.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Hereinafter, the present invention will be described in detail with reference to the following Examples. However, the Examples of the present invention may be embodied in many different forms and these Examples should not be construed as limiting the scope of the present invention.
EXAMPLE 1
Nanofibrillation of Cellulose in Aqueous Ammonia Solution
[0051] Before being passed through a homogenizer, pulps from hardwoods and softwoods were dispersed in water, respectively, and subjected to a mechanical refining process with the pulper of wet-laid non-woven equipment for 30 minutes, thereby completing dispersion and dissociation. A dispersion with a low solid concentration of 0.2 wt % was prepared and then a 0.3 vol % aqueous ammonia solution was added thereto. The aqueous dispersion and aqueous ammonia dispersion were stirred for 30 minutes, respectively, and passed through the homogenizer. In particular, the internal pressure of the homogenizer was in the range from 70 MPa to 310 MPa and the diameter of the nozzles used was 250 μm, 200 μm, and 150 μm, respectively. The pulp dispersions were sequentially passed 5 times through each nozzles from the nozzle with the largest diameter to nozzle with the smallest diameter in this order for maximizing the fibrillation efficiency of cellulose. The names of samples prepared are shown in Table 1 below.
[0000]
TABLE 1
Nozzle Size of Homogenizer 5) -Number of Passes 6)
Pulp
Dispersion
0
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
C 1)
W 3)
CW0
CW
CW
CW
CW
CW
CW
CW
CW
CW
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
A 4)
CA0
CA
CA
CA
CA
CA
CA
CA
CA
CA
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
I 2)
W
IW0
IW
IW
IW
IW
IW
IW
IW
IW
IW
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
A
IA0
IA
IA
IA
IA
IA
IA
IA
IA
IA
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
[Note]
1) Softwood pulp,
2) Hardwood pulp,
3) water,
4) aqueous ammonia solution,
5) nozzle size × 10 μm,
6) number
EXPERIMENTAL EXAMPLE 1
Evaluation of Crystalline Properties of Nanofibrillated Cellulose in Aqueous Ammonia Solution
[0052] The crystalline properties of cellulose nanofibrils prepared in Example 1 were evaluated by wide angle X-ray diffraction (XRD), and the crystalline index (CI) was determined by Equation 1 below (L. Y. Mwaikambo et al., Journal of Applied Polymer Science, 2002, 84, 2222-2234).
[0000]
CI
=
(
I
(
002
)
-
I
(
am
)
)
I
(
0002
)
[
Equation
1
]
[0053] The I (002) peak, which represents the crystalline region of the cellulose used, and the I (am) peak, which represents amorphous region, appeared at 2θ=28° and 16°, respectively.
[0054] The results of XRD analysis of the cellulose nanofibrils prepared by the above process are illustrated in FIG. 1 . From FIG. 1 , it was confirmed that, as the number of passes in the homogenizer increased, the 2θ of the crystalline peak moved to small angle and the peak intensity also decreased.
[0055] Additionally, XRD peak intensities (of the crystalline region and the amorphous region) and the crystalline index calculated by XRD analysis according to the homogenizing process and dispersions are shown in Table 2 below.
[0000]
TABLE 2
Items
I (002)
I (am)
Crystalline Index
General Pulp 1)
—
—
1.26 to 1.13
CW
0
1259
367
0.71
25-1
1196
379
0.68
25-3
815
261
0.68
25-5
890
290
0.67
20-1
764
270
0.65
20-3
840
346
0.59
20-5
707
335
0.53
15-1
553
273
0.51
15-3
493
274
0.44
15-5
336
230
0.32
CA
0
1047
329
0.69
25-1
820
286
0.65
25-3
906
317
0.65
25-5
888
326
0.63
20-1
775
305
0.61
20-3
704
335
0.52
20-5
568
295
0.48
15-1
443
273
0.38
15-3
499
309
0.38
15-5
263
199
0.24
IW
0
1156
306
0.74
25-1
876
248
0.72
25-3
1307
442
0.66
25-5
1028
370
0.64
20-1
653
261
0.60
20-3
692
277
0.60
20-5
611
248
0.59
15-1
533
220
0.59
15-3
520
253
0.51
15-5
425
257
0.40
IA
0
1460
362
0.75
25-1
1333
332
0.75
25-3
1340
351
0.74
25-5
1356
384
0.72
20-1
1377
391
0.72
20-3
1294
386
0.70
20-5
1043
319
0.69
15-1
6576
2064
0.69
15-3
1338
435
0.68
15-5
272
204
0.25
[Note]
1) A. E. S. I. Ahmed et al., Pigment & Resin Technology, 2013, 42, 68-78
[0056] From Table 2 above, it was confirmed that, while the crystalline index of pulp was generally in the range of 1.26 to 1.13, the crystalline index of pulp mechanically dissociated after dispersing in water or aqueous ammonia solution was in the range of 0.69 to 0.75. In contrast, the crystalline index of cellulose after 15 passes in the homogenizer was decreased to the range of 0.24 to 0.40. These results confirm that the destruction of the crystalline region of the cellulose can be induced by the mechanical dissociation process and the repeated homogenizing process. For the pulp mechanically dissociated after dispersing in aqueous ammonia solution, there was a greater decrease in crystalline index compared to the pulp mechanically dissociated after dispersing in the aqueous dispersion, and this result confirmed that ammonia molecules penetrated into the cellulose molecular chains, caused more effective swelling of the cellulose molecular chains than water molecules, and then helped the fibrillation during the mechanical dissociation and homogenizing process. Additionally, hardwood pulp had a higher crystalline index and a lower decrease in crystalline index caused by the homogenizing process than softwood pulp, and these results appear to be due to intrinsic properties wherein hardwood pulp has a more well-developed crystalline region than softwood pulp.
EXPERIMENTAL EXAMPLE 2
Analysis of Specific Surface Area of Nanofibrillated Cellulose in Aqueous Ammonia Solution
[0057] The specific surface area (SSA) of cellulose fibrils was analyzed by the Congo red dye adsorption method (M. Ksibi et al., Materials Letters, 2008, 62, 4204-4206). For the calculation of specific surface area, the solutions, prepared by varying the concentration of the Congo red dye at 0.01 mg/mL to 0.16 mg/mL on the phosphate solution (pH 6.0), were treated with 5 mg of cellulose solid, respectively, and dyed in an oven at 50° C. for 24 hours. The as-prepared dispersions were measured for their respective dye adsorption concentration in the UV-VIS wavelength at 500 nm, and the amount of dye adsorption was calculated by Equation 2 below.
[0000]
1
A
=
(
1
K
ads
[
A
]
max
)
(
1
C
)
+
(
1
[
A
]
max
)
[
Equation
2
]
[0058] In Equation 2 above, A represents the amount of dye adsorption (amount of dye (mg)/cellulose solid (g)), [A] max represents the maximum value of dye adsorbed to cellulose (amount of dye (mg)/cellulose solid (g)), C represents the amount of unadsorbed dye (mg/mL), and K ads represents the Langmuir constant.
[0059] The specific surface area was calculated by Equation 3 below using the [A] max calculated by Equation 2 (S. H. Lee, Bioresource Technology, 2010, 101, 769-774).
[0000]
SSA
substrate
=
[
A
]
max
×
N
A
×
SA
CR
CR
[
Equation
3
]
[0060] In Equation 3 above, N A represents the Avogadro constant (6.022×10 23 mol −1 ), SA CR represents the surface area of Congo red dye molecules (1.73 nm 2 ), and CR represents the molecular weight of Congo red dye (696.7 g/mol).
[0061] In particular, the mean size of cellulose fibrils was analyzed by scanning electron microscope.
[0062] The analysis results of the mean size and the specific surface area of the cellulose nanofibrils prepared by the method described above are illustrated in FIG. 2 .
[0063] The mean size of the cellulose fibrils of hardwood pulp before and after the homogenizing process was shown to be smaller than that of softwood pulp. This result confirms that the hardwood pulp is more effective than softwood pulp in preparing the cellulose nanofibrils by the homogenizing process in aqueous ammonia solution. Additionally, the mean size of the aqueous dispersion of hardwood pulp before the homogenizing process was 24.6 μm, and the mean size of the cellulose fibrils after 15 times of the homogenizing process was decreased to 74.9 nm, whereas the mean size of the cellulose fibrils when aqueous ammonia solution was used was decreased from 22.4 μm to 53.1 nm. From the results, it was confirmed that cellulose nanofibrillation was promoted when aqueous ammonia solution was used as a dispersion compared to when water was used.
[0064] Additionally, as the number of passes in the homogenizer increased, the specific surface area of cellulose fibrils increased. In particular, the specific surface area of the sample, which was prepared by dispersing hardwood pulp in aqueous ammonia solution and subjected to the homogenizing process, was most significantly increased from 22.14 m 2 /g to 482.4 m 2 /g. This phenomenon showed the same trend as in the decrease of the mean size. As a result, it was confirmed that the mean size of the cellulose fibrils at the micron level was decreased to a nano-size level via the homogenizing process, and the specific surface area finally increased to about 500% to 2,000%. Additionally, it was confirmed that when aqueous ammonia solution was used as the dispersion solution in the homogenizing process, the mean size was further decreased and the specific surface area increased.
EXPERIMENTAL EXAMPLE 3
Analysis of Morphological Structures of Nanofibrillated Cellulose in Aqueous Ammonia Solution
[0065] The morphological structures of cellulose fibrils were analyzed by a scanning electron microscope.
[0066] The morphological structures of cellulose fibrils prepared are illustrated in FIG. 3 .
[0067] From FIG. 3 , it was confirmed that as the number of passes in the homogenizer increased, cellulose became more effectively fibrillated in aqueous ammonia solution than in an aqueous dispersion. From the result, it was confirmed that the homogenizing process is more effective for nanofibrillation of hardwood pulp than softwood pulp and that the addition of aqueous ammonia solution improved the nanofibrillation process more rapidly and efficiently.
EXAMPLE 2
Nanofibrillation of Cellulose According to the Amount of Aqueous Ammonia Solution Added and the Presence of Washing
[0068] In order to examine the effect of the amount of aqueous ammonia solution added and the presence of washing, hardwood pulp was dissociated with pulper according to the mechanical dissociation method of Example 1 and thereby 0.2 wt % aqueous dispersion of pulp was prepared. To an aqueous dispersion of pulp was added aqueous ammonia solution in a vol % of 0, 0.6, 2.0, 4.0, and 20.0, respectively, and each was passed through a homogenizer before and after washing. The internal pressure of the homogenizer, the nozzle diameter, the number of passes, and the experimental method were the same as in Example 1 and the names of the samples prepared are shown in Table 3 below.
[0000]
TABLE 3
Added
Amount of
Presence of
Ammonia
Nozzle Size in Homogenizer 6) -Number of Passes 7)
Pulp
Dispersion
Washing
(%)
0
25-5
20-5
15-5
I 1)
W 2)
U 4)
0
IWU0
IWU0-25-5
IWU0-20-5
IWU0-15-5
A 3)
U
0.6
IAU0.6-0
IAU0.6-25-5
IAU0.6-20-5
IAU0.6-15-5
2
IAU2-0
IAU2-25-5
IAU2-20-5
IAU2-15-5
4
IAU4-0
IAU4-25-5
IAU4-20-5
IAU4-15-5
20
IAU20-0
IAU20-25-5
IAU20-20-5
IAU20-15-5
S 5)
0.6
IAS0.6-0
IAS0.6-25-5
IAS0.6-20-5
IAS0.6-15-5
2
IAS2-0
IAS2-25-5
IAS2-20-5
IAS2-15-5
4
IAS4-0
IAS4-25-5
IAS4-20-5
IAS4-15-5
20
IAS20-0
IAS20-25-5
IAS20-20-5
IAS20-15-5
[Note]
1) hardwood pulp,
2) water,
3) aqueous ammonia solution,
4) no washing,
5) washing,
6) nozzle size × 10 μm,
7) number
EXPERIMENTAL EXAMPLE 4
Analysis of the Mean Size of Nanofibrillated Cellulose According to the Amount of Aqueous Ammonia Solution Added and the Presence of Washing
[0069] The mean size of the cellulose nanofibrils prepared according to the process in Example 2 was analyzed according to the amount of aqueous ammonia solution added by a scanning electron microscope. The analysis results are illustrated in FIG. 4 .
[0070] From FIG. 4 , it was confirmed that the nanofibrillation of cellulose was promoted and the deviation of mean size became smaller, when aqueous ammonia solution was used as the dispersion solution compared to when an aqueous dispersion was used. Additionally, the most significant decrease of the mean size was shown when cellulose was passed 5 times through a nozzle with a diameter of 250 μm. The cellulose nanofibrils with the smallest mean size were prepared when 2 vol % of aqueous ammonia solution was used as the dispersion solution and washing was not performed, and in this case, the mean size was decreased to the minimum 10 nm level, whereas, on the contrary, the mean size of the cellulose nanofibrils increased when 4 vol % and 20 vol % of aqueous ammonia solution were used, compared to when 0.6 vol % and 2 vol % of aqueous ammonia solution were used, respectively. The results suggest that the excess amount of ammonia added prevented the maintenance of the shape of nanofibrils, thus causing the aggregation of the nanofibrils with the adjacent nanofibrils. It was confirmed that, after the dispersion in ammonia, the unwashed samples had a larger mean size than that of the samples washed before the homogenizing process. Regarding this phenomenon, it is speculated that ammonia molecules effectively swell the space between the cellulose molecular chains under the high pressure and high temperature conditions during the homogenizing process. Accordingly, the cellulose nanofibrils with a small mean size but with uniformity could be obtained when cellulose was subjected to the homogenizing process without washing after the treatment with 2 vol % of ammonia.
EXPERIMENTAL EXAMPLE 5
Analysis of Morphological Structures of Nanofibrillated Cellulose According to the Amount of Aqueous Ammonia Solution Added and the Presence of Washing
[0071] The morphological structures of the cellulose nanofibrils prepared according to the process in Example 2 were analyzed according to the amount of aqueous ammonia solution added and the presence of washing by a scanning electron microscope. The analysis results are illustrated in FIG. 5 .
[0072] From FIG. 5 , it was confirmed that the mean size of the samples, which were washed before the homogenizing process after the dispersion in aqueous ammonia solution, was slightly larger than that of the samples unwashed before the homogenizing process after the dispersion in aqueous ammonia solution. However, it was confirmed that the washed samples had a smooth surface on the nanofibrils and generated less aggregation, and that as the number of passes in the homogenizer increased, the size of aggregation on the surface of the nanofibrils became smaller. Additionally, the nanofibrillation proceeded more effectively when 0.6 vol % and 2 vol % of aqueous ammonia solution were used, compared to when 4 vol % and 20 vol % of aqueous ammonia solution were used, respectively. Regarding the result, it is speculated that the addition of an excess amount of aqueous ammonia solution prevents the fibrillation of cellulose to the contrary, and causes an aggregation phenomenon wherein the cellulose nanofibrils prepared by the homogenizing process become aggregated with each other. From the result, it was confirmed that the nanofibrillation of cellulose can be promoted by the addition of an appropriately controlled amount of ammonia.
EXAMPLE 3
Nanofibrillation of Cellulose in Aqueous Sodium Hydroxide Solution
[0073] A 0.2 wt % dispersion based on the weight of the pulp solid was prepared by dispersing hardwood pulp in water and dispersion/dissociation by subjecting the resultant to the mechanical refining process in the same manner as in Example 1. The as-prepared pulp dispersion was treated with 1,000 wt % of 25% aqueous sodium hydroxide solution relative to the weight of the pulp solid, stirred for 30 minutes, and then passed through a homogenizer. The internal pressure of the homogenizer, the diameter of the nozzle used, and the experimental method were the same as in Example 1. The names of the samples used are shown in Table 4 below.
[0000]
TABLE 4
Nozzle Size in Homogenizer 6) -Number of Passes 7)
Pulp
Dispersion
0
25 3) -1 4)
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
I 1)
N 2)
IN0
IN
IN
IN
IN
IN
IN
IN
IN
IN
25-1
25-3
25-5
20-1
20-3
20-5
15-1
15-3
15-5
[Note]
1) hardwood pulp,
2) aqueous NaOH,
3) nozzle size (×10 μm),
4) number of passes (no.)
EXPERIMENTAL EXAMPLE 5
Evaluation of Crystalline Properties of Nanofibrillated Cellulose in Aqueous Sodium Hydroxide Solution
[0074] The evaluation of the crystalline properties of the cellulose fibrils prepared by the process of Example 3 was performed in the same manner as in Experimental Example 1.
[0075] The XRD analysis results of the cellulose nanofibrils prepared by the above process are illustrated in FIG. 6 . From FIG. 6 , it was confirmed that the 2θ of the crystalline peak moved with a lesser angle as the number of passes in the homogenizer increased.
[0076] Additionally, the crystalline index calculated based on the XRD peak intensities (crystalline and amorphous regions) according to the homogenizing process and the use of aqueous sodium hydroxide solution and XRD analysis is shown in Table 5 below.
[0000]
TABLE 5
Items
I (002)
I (am)
Crystalline Index
General Pulp 1)
—
—
1.26 to 1.13
IN
0
263
991
0.73
25-5
369
1341
0.72
20-5
246
734
0.66
15-5
230
519
0.56
[Note]
1) A. E. S. I. Ahmed et al., Pigment & Resin Technology, 2013, 42, 68-78
[0077] From Table 5 above, it was confirmed that, while the crystalline index of general pulp was in the range of 1.26 to 1.13, the crystalline index of pulp mechanically dissociated after dispersing in aqueous sodium hydroxide solution was 0.73, and the crystalline index of cellulose after 15 repetitions of the homogenizing process was decreased to 0.56. These results confirm the destruction of the crystalline region of the cellulose caused by the mechanical dissociation process and the repeated homogenizing process. While the crystalline index of the samples (IW) and (IA), which are prepared by dispersing the same hardwood pulp in water and in aqueous ammonia solution, was decreased to 0.40 and 0.25, respectively, the crystalline index of the sample dispersed in aqueous sodium hydroxide solution was decreased less than the above.
[0078] It is speculated that this phenomenon occurs because the aqueous sodium hydroxide solution, which is prepared by dissolving sodium hydroxide in water, remained in a solid phase due to high temperature and high pressure during the homogenizing process and thus could not effectively penetrate into the cellulose molecules, thereby being unable to effectively induce the swelling.
EXPERIMENTAL EXAMPLE 6
Analysis of Specific Surface Area of Nanofibrillated Cellulose Prepared in Aqueous Sodium Hydroxide Solution
[0079] The specific surface area of the cellulose fibrils prepared in aqueous sodium hydroxide solution was analyzed in the same manner as in Experimental Example 2.
[0080] The analysis results of the specific surface area of the cellulose fibrils prepared in aqueous sodium hydroxide solution by the above process are illustrated in FIG. 7 .
[0081] As the number of passes in the homogenizer increased, the specific surface area of the cellulose fibrils prepared in aqueous sodium hydroxide solution increased. While the specific surface area of the hardwood pulp prepared in aqueous sodium hydroxide solution before the homogenizing process was about 20 m 2 /g, the specific surface area of the sample after the homogenizing process increased to about 270 m 2 /g.
[0082] The above specific surface area is lower than the values of specific surface area, 282.1 m 2 /g and 482.4 m 2 /g, obtained by treating the samples IW and IA, which were prepared by dispersing hardwood pulp in water and aqueous ammonia solution.
[0083] Accordingly, it was confirmed that the specific surface area of the nanofibrillated cellulose significantly increased when aqueous ammonia solution was used as a dispersion solution during the homogenizing process, compared to when a water dispersion or aqueous sodium hydroxide solution was used as the dispersion solution.
EXPERIMENTAL EXAMPLE 7
Analysis of Morphological Structures of Nanofibrillated Cellulose Prepared in Aqueous Sodium Hydroxide Solution
[0084] The morphological structures of cellulose fibrils prepared in aqueous sodium hydroxide solution were analyzed in the same manner as in Experimental Example 3 and the morphological structures of the prepared cellulose fibrils are illustrated in FIG. 8 .
[0085] From FIG. 8 , it was confirmed that although cellulose became fibrillated as the number of passes in the homogenizer increased, the solidified sodium hydroxide remained on the surface of the fibers. From the results of Experimental Examples 3 and 7, it was confirmed that the nanofibrillation process through the homogenizing process could be more rapidly and efficiently improved when the nanofibrillation proceeded in aqueous ammonia solution rather than in water or aqueous sodium hydroxide solution.
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The present invention relates to a method for preparing nanofibrillated cellulose capable of producing high-quality cellulose nanofibrils by a simple process without using the conventional enzymatic treatment, in which a cellulose aqueous dispersion is homogenized by adding an aqueous alkaline solution having a pH between 8 and 14 thereto so that the aqueous alkaline solution aids the swell of an amorphous region of cellulose, thereby promoting the nanofibrillation of cellulose during the homogenizing process.
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RELATED APPLICATIONS
[0001] This patent application is related to the following co-pending and commonly assigned applications: U.S. patent application Ser. No. ______, entitled “Tachyarrhythmia Therapy Selection Based On Patient Response Information,” filed on Nov. 23, 2004 (Attorney Docket No. GUID.198PA); and U.S. patent application Ser. No. ______, entitled “Template Generation Based On Patient Response Information”, filed on Nov. 23, 2004 (Attorney Docket No. GUID.203PA), both of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This patent document pertains generally to administration of antitachyarrhythmia therapy, and more particularly, but not by way of limitation, to arrhythmia memory for tachyarrhythmia discrimination.
BACKGROUND
[0003] Arrhythmia is an abnormal rhythm of the heart. A tachyarrhythmia is an abnormally fast heart rhythm. A tachyarrhythmia originating in the ventricular region of the heart is called a ventricular tachyarrhythmia (VT). Ventricular tachyarrhythmia can produce symptoms of fainting, dizziness, weakness, blind spots, and potentially, unconsciousness and cardiac arrest. A tachyarrhythmia that does not originate from the ventricular region of the heart is called a supraventricular tachyarrhythmia (SVT). An SVT episode typically originates from an impulse arising in the atrium, the atrioventricular node (AV node), or the bundle of His. SVT episodes tend to be much less lethal than VT episodes.
[0004] Treatment for cardiac tachyarrhythmia can be administered by a medical device, such as a pacemaker or a defibrillator, which can be implanted in the human body. These devices can be configured to sense an intrinsic electrical heart signal and analyze the signal to determine whether a tachyarrhythmia is occurring. Such devices can also be configured to deliver antitachyarrhythmia therapy, such as electric stimulation. Improved cardiac rhythm management methods and systems are needed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] In the drawings, which are not necessarily drawn to scale, like numerals describe substantially similar components throughout the several views. Like numerals having different letter suffixes represent different instances of substantially similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.
[0006] FIG. 1 is a schematic illustration of medical device and a heart.
[0007] FIG. 2A is a flow chart that illustrates a process in which a degree of similarity is determined between a SVT template and a heart signal.
[0008] FIG. 2B is a flow chart that illustrates a process in which a degree of similarity is determined between a SVT template and a heart signal.
[0009] FIG. 2C is a flow chart that illustrates a process in which a template is generated for an arrhythmia morphology that does not require antitachyarrhythmia therapy.
[0010] FIG. 3 is a flow chart that illustrates a method in which a degree of similarity is determined between a monitored heart signal and a SVT template selected from a group of candidate SVT templates.
[0011] FIG. 4 is a flow chart that illustrates a method in which a heart signal is compared to a normal sinus rhythm and a SVT template.
[0012] FIG. 5 is a flow chart that illustrates methods by which a SVT template is discarded from a storage medium and a new SVT template is added.
[0013] FIG. 6 is a flow chart that illustrates an embodiment of a process in which a heart signal from a tachyarrhythmia episode is compared to a normal sinus rhythm (NSR) template and then compared to a supraventricular tachyarrhythmia (SVT) template.
[0014] FIG. 7 is a block diagram of an implantable device.
[0015] FIG. 8 shows an example of a normal sinus rhythm morphology.
[0016] FIG. 9 shows an example of a SVT morphology.
DETAILED DESCRIPTION
[0017] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments, which are also referred to herein as “examples,” are described in enough detail to enable those skilled in the art to practice the invention. The embodiments may be combined, other embodiments may be utilized, or structural, logical and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
[0018] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive or, unless otherwise indicated. Furthermore, all publications, patents, and patent documents referred to in this document are incorporated by reference herein in their entirety, as though individually incorporated by reference. In the event of inconsistent usages between this document and those documents so incorporated by reference, the usage in the incorporated reference(s) should be considered supplementary to that of this document; for irreconcilable inconsistencies, the usage in this document controls.
[0019] In varying examples, a morphological template can be generated from a tachyarrhythmia episode and used to identify a later episode. For example, a tachyarrhythmia episode can be detected by an implantable medical device and analyzed to determine whether the episode is a type that necessitates antitachyarrhythmia therapy. In one example, a morphological graph of a tachyarrhythmia episode is presented to a human analyst, such as a physician, and an assessment of the tachyarrhythmia episode is received from the human analyst. The assessment can, for example, include an input that indicates whether the human analyst deems the tachyarrhythmia episode is a VT episode or a SVT episode. In another example, the tachyarrhythmia episode can be analyzed by a computer to determine whether it is a VT or SVT episode. The computer can be in an implanted medical device, or external to the patient. A morphological template can be generated from the tachyarrhythmia episode and later used to identify a similar episode as it is occurring. For example, if a tachyarrhythmia episode correlates with an SVT template, an SVT can be declared, i.e. the episode can be identified as an SVT and treated accordingly. Templates can be selected or discarded based a variety of factors including conditions in the patient or characteristics of arrhythmias.
[0020] In an example, a template is a sampled data representation of a heart depolarization. In another example, a template is a set of selected features from a sampled data representation of a heart depolarization. In another example a template is generated from multiple SVT beats, for example by taking an average of several beats.
[0021] FIG. 1 shows a schematic illustration of an exemplary medical device 10 and a heart 20 . A processing circuit 30 communicates with a sensing circuit 40 and an antitachyarrhythmia therapy circuit 50 . The sensing circuit 40 detects an intrinsic electrical signal from a heart. The antitachyarrhythmia therapy circuit 50 delivers defibrillation or other antitachyarrhythmia therapy to the heart 20 . The processing circuit 30 analyzes input from the sensing circuit 40 and directs the antitachyarrhythmia therapy circuit 50 to administer antitachyarrhythmia therapy as necessary. The processing circuit 30 also sends information to a memory circuit 60 .
[0022] The memory circuit 60 includes a storage medium, such as solid state RAM. In an exemplary configuration, the processing circuit 30 sends data received from the sensing circuit 40 during a tachyarrhythmia episode to the memory circuit 60 and the memory circuit 60 stores the data for later reference. The processing circuit 30 also communicates with a wireless communication system 70 . The wireless communication system 70 sends data to or receives data from an external system 80 , which typically includes a display system on which a user can view a graphical representation of the data. The medical device 10 can be configured as an implantable device, but is not necessarily implantable. While one processing circuit is shown, examples of the medical device including multiple processors are also possible. In varying examples, the processor is in a device implanted in the patient, or in a device such that is external to the patient, such as a programmer or a remote computer system.
[0023] FIG. 2A is a flow chart that illustrates a process in which a SVT episode is identified and declared. At 210 , an implantable medical device senses an intrinsic heart signal. At 220 , the medical device stores a portion of the intrinsic electrical heart signal that was sensed during a tachyarrhythmia episode. At 230 , a user indicates whether the portion of the intrinsic electrical heart signal is considered to be indicative of a SVT. In an alternative embodiment, a processor analyzes the portion of the signal to determine whether it is indicative of a SVT. If the portion of the intrinsic electrical heart signal is determined to be indicative of a SVT, a SVT template is generated at 240 . In an example, a processor in the implanted medical device generates the template. In another example, the template is generated on an external computer system and downloaded to the implanted medical device. Various techniques can be used to generate the template. In an example, the template consists of one heart beat from the SVT episode. Alternatively, the template includes more than one heart beat. In an example, the template consists of the actual data from the intrinsic electrical heart signal as the template. Alternatively, a processor converts the intrinsic electrical heart signal data into a file that requires less storage space than the original data.
[0024] Returning to FIG. 2A , at 250 , a processor determines at least one degree of similarity between a second portion of the heart signal from a later tachyarrhythmia episode and at least one SVT template. The degree of similarity is a quantity that is computed through an algorithm that uses the sensed intrinsic electrical heart signal (or a derivative thereof) as an input. In varying examples, determining the degree of similarity includes computing a feature correlation coefficient, a wavelet coefficient, or areas or integrals of a heart signal waveform or an approximation thereof. In varying examples, determining the degree of similarity involves computation of data in the time domain, wavelet domain, frequency domain, or other domains.
[0025] At 260 , the device declares the second portion of the heart signal to represent a SVT episode if the degree of similarity exceeds a threshold valued. In one example, a processor in the medical device declares a SVT episode if a feature correlation coefficient for a heart beat exceeds a threshold. In another example, a processor declares a SVT if multiple feature correlation coefficients for respective multiple beats exceed a threshold value. In one scenario, a SVT is declared if a specified fraction of heart beats in a sequence of beats (e.g. 3 out of 10 beats) exhibit a feature correlation coefficient that exceeds a threshold. In another example, a SVT is declared if an average feature correlation coefficient for a number of beats exceeds a threshold (e.g. the average for 10 beats≧0.94).
[0026] In an example, the processor determines a degree of similarity between the second portion and multiple SVT templates. In one example, the processor begins determining degrees of similarity for the second portion for a sequence of templates and stops determining the degree of similarity if the degree of similarity for one of the templates exceeds a threshold. In other words, the processor compares the heart signal to a sequence of templates until a template match is found or all the templates are used. In another example, the portion of the heart signal is compared to all of the templates regardless of whether a match is found, and an SVT is declared if the degree of similarity for any one of the templates exceeds a threshold.
[0027] In addition to supraventricular tachyarrhythmia (SVT) episodes, a heart can exhibit other types of tachyarrhythmia that do not warrant antitachyarrhythmia therapy, including some instances ventricular tachyarrhythmia (VT). Such other non-lethal VT episodes can also be identified and used to generate templates.
[0028] FIG. 2B is another flow chart that illustrates a process in which a degree of similarity is determined between a SVT template and a heart signal. At 212 , an implantable medical device senses an intrinsic heart signal. At 222 , the medical device stores a tachyarrhythmia portion of the intrinsic electrical heart signal that was sensed during a tachyarrhythmia episode. At 232 , a processor determines at least one degree of similarity between the tachyarrhythmia portion of the heart signal and at least one SVT template. At 242 , the processor determines whether the at least one degree of similarity exceeds at least one threshold value. In an example, the processor determines degrees of similarity for multiple beats and determines whether the degree of similarity exceeds a threshold for at least a predetermined fraction of the beats (e.g. 3 out of 8 beats). If the at least one degree of similarity exceeds at least one threshold value, the portion of the heart signal is declared to represent a SVT episode and antitachyarrhythmia therapy is suppressed, at 252 . If the at least one degree of similarity does not exceed at least one threshold value (e.g. fewer than 3 out of 10 beats exhibit a degree of similarity in excess of a threshold), the portion of the heart signal is declared to represent a VT episode and antitachyarrhythmia therapy is delivered, at 262 . The portion of the heart signal is stored and later presented to a user. If, at 272 , an input from the user indicates that the portion is indicative of SVT, an SVT template is generated at 282 . If another tachyarrhythmia event occurs, the process returns to box 232 and determines at least one degree of similarity between the tachyarrhythmia portion of the heart signal from the next tachyarrhythmia event and at least one SVT template, which can be the template generated at 282 . If the user input does not indicate that the portion is indicative of SVT, a template is not generated, at 292 .
[0029] FIG. 2C is a flow chart that illustrates a process in which a template is generated for an arrhythmia morphology that does not require antitachyarrhythmia therapy. At 205 , an implantable medical device senses an intrinsic heart signal. At 215 , the medical device stores one or more portions of the intrinsic electrical heart signal that were sensed during a tachyarrhythmia episode. At 225 , a graphical representation of one or more stored portions of the intrinsic electrical heart signal is presented to a user. At 235 , the user provides input that identifies at least one tachyarrhythmic portion of the intrinsic electrical heart signal that did not require antitachyarrhythmia therapy. The portion of the intrinsic electrical heart signal that did not require antitachyarrhythmia therapy can be, but is not necessarily, indicative of SVT. At 245 , input is received from a user designating at least one portion of the intrinsic electrical heart signal that should be used to generate a template. At 255 , a template is generated from a portion of the heart signal designated by the user. In an embodiment, an external computer system receives the input from the user to generate the template, which is downloaded to the implantable medical device. In another example, the user communicates directly with the implantable medical device, which generates the template. In an example, the user designates multiple portions of the heart signal, and multiple templates are generated.
[0030] Referring again to FIG. 2C , At 265 , a processor in the medical device determines one or more degrees of similarity between a second portion of the intrinsic electrical heart signal from a later tachyarrhythmia episode and the template. At 275 , the processor determines whether the one or more degrees of similarity exceed a threshold value. If the one or more degrees of similarity exceed a threshold value, the processor suppresses an antitachyarrhythmia therapy at 285 .
[0031] In an alternative embodiment, in lieu of presenting a graphical representation to a user and receiving an input, a portion of the heart signal is analyzed automatically by a processor to determine whether antitachyarrhythmia therapy is appropriate.
[0032] FIG. 3 is a flow chart that illustrates a method in which a degree of similarity is determined between a monitored heart signal and a SVT template selected from a group of candidate SVT templates. At 305 , a medical device monitors a heart signal. At 310 , portions of the heart signal that are indicative of SVT are identified. In varying examples, the portions that are indicative of SVT can be identified by a physician, for example, or identified by an automated computerized analysis. At 315 , portions of the heart signal that are indicative of SVT are stored as candidate SVT templates. The candidate template can be stored with a corresponding heart rate at which the template was observed. One or more selection protocols can be used to select a SVT template from a group of candidate SVT templates when analyzing a later tachyarrhythmia episode. For example, at 320 , a SVT template is selected from a group of candidate templates based upon the heart rate associated with the candidate templates. The processor selects a template having a heart rate that is closest to the heart rate of the later tachyarrhythmia episode. Alternatively, at 325 , a candidate SVT template is selected based other information about the patient. In an example, the drug treatment regimen of a patient is considered in the selection of a SVT template. The morphology of SVT episodes in a patient can vary depending upon the drug treatment regimen of the patient. In one example, the medical device stores information about drug treatment regimens associated with the tachyarrhythmia episodes used to generate the candidate templates. The current drug regimen is also stored in the device. The processor selects a SVT template based upon a similarity between the drug treatment associated with the selected template and the current drug treatment. In another example, the medical device detects one or more of neural activity, patient activity, sleep state, hemodynamic status, transthoracic impedance, or cardiac impedance. In further examples, the device detects REM (random eye movement) status, sympathetic/parasympathetic tone, intercardiac blood pressure including right ventricular pressure, left atrial pressure, or pulmonary artery pressure, oxygen saturation, heart size and contractability, blood flow, or edema. In varying examples, the medical device considers one or more of these parameters in selecting an SVT template. In another example, the processor identifies one or more characteristics of the patient, and selects a SVT template using statistics from other patients having similar characteristics. In varying examples, the characteristics include (but are not limited to) as height, weight, age, disease history, medication, and patient status (such as neural activity, blood pressure, etc.) In another alternative, at 330 , a candidate SVT template is selected based upon multiple factors. In an example, both the heart rate and the drug treatment regimen are taken into consideration.
[0033] At 335 , the processor determines a degree of similarity between the heart signal from the later tachyarrhythmia episode and the selected SVT template. The processor compares the degree of similarity to at least one threshold, at 340 . If the degree of similarity falls below a threshold, a SVT episode is not declared. In an example, if a SVT episode is not declared, the medical device declares a VT episode at 341 and delivers a ventricular antitachyarrhythmia therapy at 342 . Alternatively, other determinations can be made before the medical device administers ventricular antitachyarrhythmia therapy.
[0034] If the degree of similarity does exceed a threshold, the medical device declares the heart signal from the later tachyarrhythmia episode to represent a SVT episode at 345 . The medical device then suppresses ventricular antitachyarrhythmia therapy at 350 .
[0035] FIG. 4 is a flow chart that illustrates a method in which a heart signal from a tachyarrhythmia episode is compared to a normal sinus rhythm and to a SVT template. At 405 , a medical device senses an intrinsic electrical heart signal. The medical device monitors the heart rate at 410 . At 415 , the medical device compares the heart rate to a threshold. If the heart rate does not exceed the threshold, the medical device continues sensing the heart signal but does not perform a tachyarrhythmia discrimination algorithm. If the heart rate does exceed a threshold, the medical device declares a tachyarrhythmia episode at 420 . At 425 , the medical device compares the tachyarrhythmia portion of the heart signal to the normal sinus rhythm (NSR) template for the patient. In an example, the medical device computes a feature correlation coefficient between the tachyarrhythmia portion of the heart signal and the NSR template. If the tachyarrhythmia portion of the heart signal sufficiently correlates with the NSR template (e.g. the feature correlation coefficient exceeds a threshold), the medical device declares the tachyarrhythmia portion of the heart signal to represent a SVT episode at 430 and suppresses a ventricular antitachyarrhythmia therapy during the episode, at 435 .
[0036] If the tachyarrhythmia portion of the heart signal is not similar to the NSR template, at 440 the medical device determines a degree of similarity between a portion of the heart signal and a SVT template. At 445 , the medical device determines whether the degree of similarity exceeds a threshold. If the degree of similarity exceeds a threshold, the medical device declares the portion of the heart signal to represent a SVT episode at 450 . In an example, declaring the portion of the heart signal to represent a SVT episode merely means making a determination to executing a response that is consistent with a SVT, such as suppressing a ventricular antitachyarrhythmia episode at 455 .
[0037] If, at 445 , the degree of similarity does not exceed a threshold, the medical device stores the tachyarrhythmia portion of the heart signal at 460 . The stored portion is displayed to a user at 465 and an input is received from the user at 470 . At 475 , if the user indicates that the heart signal is indicative of SVT, a template is generated from the tachyarrhythmia portion of the heart signal, at 480 .
[0038] FIG. 5 is a flow chart that illustrates examples of methods by which a SVT template is added and an old SVT template is discarded. A medical device monitors a heart signal at 510 . Portions of the heart signal that are indicative of SVT are identified at 520 through computer analysis or input from a user. The medical device stores the portions of the heart signal that are indicative of SVT as SVT candidate templates at 530 . At 540 , the medical device discards the oldest SVT template. Alternatively, the medical device tracks the frequency of similarity of a portion of the heart signal from a tachyarrhythmia episode to one of a plurality of SVT templates at 550 and discards the SVT template exhibiting the least frequent similarity with the heart signal and saves a new template at 560 . In another alternative example, the medical device discards a SVT template with a heart rate similar to heart rates of other SVT templates at 570 . In the example at 580 , the medical device discards a SVT template that is associated with a discontinued drug therapy regimen. In the example at 590 , the medical device discards a SVT template that is most correlated to other SVT templates. In varying examples, a decision of which template to discard is made by a computer system, the medical device, or a user who inputs a direction to discard a template.
[0039] FIG. 6 is a flow chart that illustrates an example of a process in which a heart signal from a tachyarrhythmia episode is compared against a normal sinus rhythm (NSR) template 630 and then a supraventricular tachyarrhythmia (SVT) template 660 . At 610 , a tachyarrhythmia episode is detected. A NSR correlation module 620 computes a NSR feature correlation coefficient (FCC) for 10 heart beats. If the NSR feature correlation coefficient is equal to or greater than 0.94 for 3 out of 10 beats, the correlation module 620 declares a SVT and a SVT protocol 640 is followed. If the fewer than 3 out of 10 beats have a NSR feature correlation coefficient greater than or equal to 0.94, a SVT correlation module 650 computes a SVT feature correlation coefficient for the 10 heart beats. If the SVT feature correlation coefficient is equal to or greater than 0.95 for 3 out of 10 beats, the SVT correlation module 650 declares a SVT. If fewer than 3 out of 10 beats have a SVT feature correlation coefficient equal or greater than 0.95, the episode is treated as a ventricular tachyarrhythmia (VT) and a VT protocol is followed. For example, VT protocol 670 can include administration of antitachyarrhythmia therapy.
[0040] FIG. 7 is a block diagram of an exemplary implantable device 700 incorporating a processor 710 and that runs software modules to analyze a signal from a heart 720 through a lead 770 . A sensor 720 detects an intrinsic electrical heart signal. The processor 710 receives the signal from the sensor 720 and interprets the signal to determine whether an antitachyarrhythmia therapy should be delivered. A similarity module 740 determines a degree of similarity between portion of the heart signal from a tachyarrhythmia episode and a SVT template representative of a previous SVT episode. A suppress therapy module 750 suppresses a ventricular antitachyarrhythmia therapy if the degree of similarity exceeds a threshold value. SVT templates are stored in a memory circuit 760 . A lead 770 delivers ventricular antitachyarrhythmia therapy as directed by the processor.
[0041] While the present examples have generally been described in terms of an implanted or implantable device, the presently described examples can also be implemented in non-implantable devices and systems.
[0042] FIG. 8 shows an example of a normal sinus rhythm morphology. FIG. 9 shows an example of a SVT morphology. In an example, a template includes a morphology for a single beat, as shown in FIG. 8 . In another example, a template includes multiple beats, as shown if FIG. 9 . In another example, a template for an atrial tachyarrhythmia can be created. The atrial tachyarrhythmia template can be used to declare a future episode of atrial tachyarrhythmia and suppress antitachyarrhythmia therapy as appropriate.
[0043] Varying algorithms can be used to generate a template and determine the degree of similarity between a heart signal and a template. In one example, a set of pre-determined rules are used to locate a number of points on a waveform, and those points are used as the template for comparison against a heart signal. In an example, eight pre-determined points can be located. In one example, the maxima, minima, and inflection points are located. The located points are stored as the template. Features are extracted from a portion of the heart signal by aligning the portion of the heart signal with the template. In an example, a peak on the template is aligned with a peak on the portion of the heart signal from one beat of a tachyarrhythmia episode. The amplitude of the points on the portion of the heart signal is measured at times corresponding to the points in the template. To determine the degree of similarity, a feature correlation coefficient (FCC) is computed using the amplitudes measured from the signal and the amplitude in the template. Computation of the feature correlation coefficient is further described in U.S. Pat. No. 6,708,058, which is incorporated herein by reference in its entirety.
[0044] In an example, a cardiac rate channel signal and a shock channel signal are sensed. The rate channel signal is measured from a sensing tip to a distal coil on a lead. The shock channel is measured from a distal coil to a proximal coil of the RV lead. A fiducial point is determined from the cardiac rate channel signals. A shock channel signal is aligned using the fiducial point. A template is generated using the aligned shock channel signal. Use of signals from rate and shock channels is further described in U.S. Pat. No. 6,708,058, which is incorporated by reference in its entirety. In other examples, a signal is sensed and then aligned using the same channel from which it was sensed.
[0045] In another example, a processor computes a wavelet transform or Fourier transform of the signal from which a template is to be generated. A predetermined number of largest wavelet coefficients are saved as a template. Features are extracted from a heart signal by aligning the peak of the signal with the peak of the template and computing the wavelet transform of the aligned tachy beat waveform. A predetermined number of largest wavelet coefficients are saved. The sum of the absolute value of the differences between the saved wavelet coefficients and the wavelet coefficients in the template is determined and divided by the sum of absolute value of the wavelet coefficients in the template. The resulting value is subtracted from 1 and multiplied by 100 to provide a “percent match score”, which is compared to a threshold. In an example, the threshold is 70%, and beats having a percent match score greater than or equal to 70% are considered SVT in origin. In an example, if 3 out of 8 beats are SVT, an SVT episode is declared. Wavelet-based algorithms are further discussed in U.S. Pat. Nos. 6,393,316 and 5,782,888, which are incorporated herein by reference in their entirety.
[0046] In another example, a heart signal waveform is approximated as three consecutive triangles. The areas of each of the triangles is calculated and saved in a template. To extract features from a portion of a heart signal, peaks in the heart signal are aligned with the template, and the heart signal is approximated as three triangles. The area of each of the three triangles is calculated. To determine the degree of similarity to the template, a “similarity score” is determined based on the sum of the differences in the areas of the signal triangles and the template triangle. The similarity score is inversely proportional to this sum. If the similarity score is greater than a threshold, the beat is considered SVT in origin. If a predetermined number of beats exceed a threshold, an SVT episode is declared.
[0047] The preceding descriptions of techniques for determining a degree of similarity are considered exemplary. Other techniques, or variations of the described techniques, can be employed with the methods described in this application.
[0048] It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.
[0049] The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.
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This document discusses, among other things, a method of identifying a non-fatal tachyarrhythmia episode by determining a degree of similarity between the episode and a template generated from a previous tachyarrhythmia episode.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending and co-owned U.S. patent application Ser. No. 10/245,611 entitled “Panel and Locking System for Panels”, now U.S. Pat. No. 7,146,772, filed with the U.S. Patent and Trademark Office on Sep. 17, 2002, by the inventor herein, the specification of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a locking system for panels with edge profiles provided on at least two opposite edges of the panels for the positive connection of similar panels, including an edge profile designed as a groove profile, with an upper groove wall and a lower groove wall, and an edge profile designed as a tongue profile, with a notch projection on the underside of the tongue that engages a notch recess in the lower groove wall of an adjacent panel in the assembled state, where the engaged edge profiles form an articulated joint that acts to restore the panels to their installation plane when deflected either up or down. The invention also relates to a panel with the locking system according to the invention.
[0004] 2. Background of the Prior Art
[0005] Locking systems of this kind are used for floor panels, for example, such as parquet panels with a natural wood surface or laminated panels. The latter have a core made of MDF, HDF, or particle board and are provided with a reproduced surface made of a decorative laminate.
[0006] 299 11 462 U1 discloses a generic locking system, whose connection has the function of an articulated joint. Locking systems of this kind are used for floor coverings, which, for example, lie on uneven bases or must bear deflection in the connection area due to the presence a soft backing, such as impact sound insulation. Deflection of the connection causes high stresses in the region of the tongue-and-groove profiles of two locked panels, because the connection bends under the load. The panel material cannot withstand the high stresses in the region of the edge profiles and fails in the connection area.
[0007] The ease of installation of the known jointed locking system leaves much to be desired. Its resistance to being pulled apart in the installation plane does not meet expected, future quality standards for floor coverings with mechanical locking systems. Furthermore, the known joint connection can be installed in two ways, where the second installation method described is associated with the undesirable side effect that the connection displays particularly low resistance to being pulled apart.
[0008] According to the first installation method, a new panel, preferably tongue-first, is placed at an angle against a laid panel and then folded or rotated downwards until it lies in the common installation plane of the panels and locks automatically.
[0009] In the second installation method, locking occurs when both panels are in the installation plane, namely by sliding the panels laterally towards one another. The panels can only be joined together in this way because the undercut between the notch projection of the tongue and the notch recess in the lower groove wall is designed to be correspondingly small. The notch connection achieved in this way is of such low strength that gaps can form between abutting surfaces of adjacent panels due to normal changes in length of the floor. This is the case, for example, when the temperature of the floor fluctuates. This method of jointing also results in immediate damage to the edge profiles, because they must be subjected to strong deformation in order for the undercut of the tongue and the lower groove wall to engage.
[0010] Furthermore, the tongue of the known locking system has a long, tapered shape. The top of the tongue has an inclined surface that is intended to facilitate insertion of the tongue tip into the groove. In reality, however, the tongue proves to be very easily damaged due to its tapered shape. This has a disadvantageous effect on the product's ease of installation, service life, and utility.
SUMMARY OF THE INVENTION
[0011] The object of the invention is to design a locking system for an articulated panel connection, which is easier to handle, displays greater resistance to being pulled apart, and has a longer service life than the known locking system.
[0012] According to the invention, the object is solved in that the upper groove wall has a flank on the inside that opens towards the free end of the groove wall.
[0013] Providing a flank on the upper groove wall creates a wide groove opening on the groove side of a panel, into which the tongue profile of an adjacent panel can be inserted more easily than the known, tapered tongue profile into the narrower groove opening of the known locking system.
[0014] The flank preferably transitions into a levelling surface extending towards the groove base, which ensures exact vertical positioning without vertical offset between locked panels. In other words, the segment of the inside of the upper groove wall running from the flank to the base of the groove forms the levelling surface, the distance of which to the surface of the panel is precisely equal to the distance of the top side of the tongue to the surface of the panel, meaning that no vertical offset occurs between locked panels.
[0015] The flank can be of curved or plane design, where a straight shape is expedient for manufacturing purposes and a curved shape is somewhat more favourable for the panel joining procedure in terms of stress. When the tongue profile comes into contact with the curved flank of the groove profile, the surface pressure is somewhat lower than in the case of contact between the tongue profile and the edge on the end of the plane flank.
[0016] A levelling surface is also provided on the top side of the tongue, which interacts with the levelling surface of the upper groove wall when the panels are joined. Since the upper groove wall has a flank on the free, front end, the levelling surface of the tongue is only in partial contact with the levelling surface of the upper groove wall, namely in the region of the free end of the tongue. If the levelling surface of the tongue were in contact with the upper groove wall along the entire length of the top tongue surface, a rigid connection would result. The flank lends the connection a degree of flexibility that favours the joint function of the connection and reduces stress in the material of the edge profiles.
[0017] In the event of deflection of the connection towards the installation base, in particular, the flank creates room for movement, so that the top side of the tongue can be moved towards the flank without coming up against it prematurely. The flexibility of the connection achieved in this way enables articulated movement without rupturing the tongue or damaging the groove walls due to excessive stress.
[0018] The handling and service life of the locking system are improved if the tongue length, meaning the distance by which the tongue protrudes beyond the upper edge of the panel, is less than or equal to the thickness of the upper groove wall of the groove profile. A tongue of this length is short compared to the prior art. The short tongue has the advantage that only a relatively short insertion path has to be traveled when the tongue is inserted at an angle into a groove profile. Consequently, the proposed locking system is particularly easy to handle during installation and can be installed much more quickly than the known locking system.
[0019] The tongue has a blunt surface on its free end, which is more robust and durable compared to the tapered shape of the tongue of the known locking system.
[0020] The groove depth of the groove profile, meaning the distance the groove recedes beyond the upper edge of the panel, is favourably greater than the tongue length described above by roughly half. In other words, if the groove depth starting from the upper edge of the panel is 3/3, the tongue protrudes into the groove by a tongue length of ⅔ when two panels are assembled, leaving a space with a residual depth of ⅓ the groove depth between the free end of the tongue and the groove base. Such a large groove depth would not be necessary to simply accommodate the tongue in the groove. However, the large groove depth influences the flexible length of the lower groove wall protruding freely from the edge of the one panel. This makes the connection flexible, reduces stress in the material, and thus increases the service life of the connection.
[0021] The flexible length of the lower groove wall preferably roughly corresponds to the thickness of the panel. This is because the spring travel required on the free end of the lower groove wall is then relatively short referred to the length of the tongue, and the elastic expansion occurring during joining of the panels causes only little stress in the material, which can be withstood without difficulty.
[0022] The depth of the recess in the lower groove wall expediently amounts to roughly one-third the thickness of the tongue. This results in a degree of undercut in the assembled state that prevents the panels from being pulled apart in installed state under normal conditions of use. Compared to conventional mechanical locking systems according to the prior art, which are locked by means of horizontal sliding in the installation plane, the degree of undercut of the locking system according to the invention is roughly doubled and, as a result, the resistance of panels against being pulled apart in the installation plane dramatically increased.
[0023] For the purpose of material-saving manufacture, the offcut dimensions on the edges of the panels are relatively small. They preferably differ on the groove side and the tongue side.
[0024] On the groove side of a panel, the resulting offcut of the decorated surface is favourably less than half the panel thickness.
[0025] On the tongue side of a panel, the resulting offcut of the decorated surface is preferably roughly between ⅓ and ¼ the thickness of the panel. It essentially corresponds to the length the tongue protrudes beyond the upper edge of the panel.
[0026] A panel, particularly a floor panel, is expediently equipped with a locking system according to the invention. The locking profile is preferably used for laminated flooring panels, which comprise a core material made of HDF, MDF, or particle board, where the edge profiles of the locking system are milled into the edges of the panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] An example of the invention is illustrated in a drawing and described in detail below on the basis of figures. The figures show the following:
[0028] FIG. 1 : A locking system consisting of a tongue profile and a groove profile of two joined panels.
[0029] FIG. 2 : The locking system according to FIG. 1 during joining.
[0030] FIG. 3 : The locking system according to FIG. 1 , where the articulated connection is lifted off the base and deflected upwards.
[0031] FIG. 4 : Locking system according to FIG. 1 with a joint deflected downwards towards the installation base.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] According to the drawing, locking system 1 consists of two positively engaging edge profiles provided on the edges of panels 2 and 3 . The edge profiles are largely designed to be complementary to one another as groove profile 4 and tongue profile 5 . Groove profile 4 on one edge of a panel 2 or 3 is always opposite a tongue profile 5 on the opposite edge of the same panel 2 or 3 . In this way, identically profiled panels 2 and 3 can be connected to one another. Locking system 1 is expediently provided on all opposing sides of a panel 2 or 3 .
[0033] The configuration described relates to floor panels equipped with the locking system according to the invention. Of course, the locking system can also be used for wall and ceiling panels, or for panels for fence or house construction, where the problem of deflection occurs to a lesser degree.
[0034] FIG. 1 shows that the locking system according to the invention involves a modified tongue-and-groove profile. Groove walls 6 and 7 of groove profile 4 protrude different distances beyond the edge of panel 3 . Segments 8 and 9 adjacent to tongue 10 of tongue profile 5 recede different distances beyond the edge of panel 2 . Protruding groove walls 6 , 7 and receding areas 8 , 9 of groove profile 4 and tongue profile 5 are adapted to one another such that they can be joined. In order to secure the lock against panels 2 and 3 being pulled apart in the installation plane, a concave notch recess 11 is incorporated on the inside of lower groove wall 7 that is engaged by a convex notch projection 12 in the assembled state according to FIG. 1 . Convex notch projection 12 is provided on the underside of tongue 10 facing installation base U. On the free, protruding end of lower groove wall 7 , a shoulder 13 provides resistance to tongue 10 of panel 2 being pulled out of groove profile 4 of adjacent panel 3 in the horizontal plane.
[0035] FIG. 1 further shows that the edges of the edge profiles only contact one another in three areas. The first is the upper edge of the two panels 2 and 3 facing away from installation base U, where a tight, gapless joint is located. Abutting surfaces 14 and 15 are in contact here. The second contact area is the one between the top side of the tongue and the inside of the upper groove wall no more than 25 percent of the upper surface of the upper tongue surface contact the upper groove wall. Here, levelling surfaces 16 and 17 of the two edge profiles are in contact with one another, where both levelling surface 16 of tongue 10 and levelling surface 17 of upper groove wall 6 are at exactly the same distance from the top side of the respective panel 2 or 3 . A vertical offset between joined panels 2 and 3 is avoided in this way. The third contact area is the contact between concave notch recess 11 of lower groove wall 7 and convex notch projection 12 of tongue 10 . This contact area is located on the part of notch recess 11 facing the free end of lower groove wall 7 . Generously dimensioned spaces 18 , 19 and 20 are provided between these contact areas, meaning that contact really only ever occurs at the desired contact areas, a gapless, tight joint is ensured on the top side of the floor covering, and no vertical offset occurs.
[0036] In the present practical example, plane flank 21 is provided on the inside of upper groove wall 6 , the result being that only in the region of its free end does the top side of the tongue act as levelling surface 16 , which is in contact with levelling surface 17 of upper groove wall 6 . FIG. 1 shows tongue length f, by which tongue 10 protrudes beyond the upper edge of panel 2 . This tongue length f is less than or equal to thickness n of upper groove wall 6 . In this case, the protrusion of tongue 10 is relatively small. Inclined flank 21 on upper groove wall 6 results in the formation of mouth-like opening 22 , into which short tongue 10 can be inserted very easily. Moreover, short tongue 10 results in a very short insertion path until tongue 10 is completely inserted in the groove. The manual assembly of panels equipped with this locking system is very simple and substantially faster than with panels provided with the known locking system.
[0037] Groove depth t, by which the groove recedes beyond the upper edge of panel 3 , is greater than tongue length f by roughly half. A groove depth t of this kind would not be necessary to accommodate tongue 10 . However, it promotes the flexibility of groove walls 6 and 7 , particularly of lower groove wall 7 , which must be slightly elastically expanded in order to join panels 2 and 3 . The elasticity of the material results in a restoring action. Panels 2 and 3 spring back into the initial position shown in FIG. 1 , in which both panels are located in a common plane. Resulting space 19 further serves to accommodate dirt particles that can get into the joint during installation of panels 2 and 3 . In addition, the joint can be improved by adding glue in space 19 , in which case, however, the joint characteristics of the connection change, depending on the glue selected.
[0038] FIG. 2 shows the positioning of panel 2 with tongue profile 5 against groove profile 4 of panel 3 , which is already located on installation base U.
[0039] Blunt, free end 23 of tongue 10 can be inserted very easily at an angle and over a short insertion path into groove profile 4 of laid panel 3 , which has wide, mouth-like opening 22 due to the flank. Three contact points result in the initial position of the joining motion, as shown in FIG. 2 . A first edge contact 24 is formed on the upper edge of panels 2 and 3 . A second edge contact 25 is formed between the top side of the tongue and upper groove wall 6 , and a third contact 26 between convex notch projection 12 of tongue 10 and concave notch recess 11 of lower groove wall 7 . Starting in the position shown in FIG. 2 , continuation of the joining procedure causes minimal expansion, essentially due to the elastic deflection of lower groove wall 7 towards installation base U. In this way, convex notch projection 12 of tongue 10 is moved into notch recess 11 of lower groove wall 7 and the final position of panels 2 and 3 reached, as shown in FIG. 1 . In this position, notch projection 12 of tongue 10 engages the shoulder of lower groove wall 7 and ensures a secure hold against pulling apart in the horizontal plane.
[0040] FIGS. 3 and 4 show locking system 1 in such a way that the joint function of the connection is apparent.
[0041] Locking system 1 is used, for example, for floor coverings lying on uneven installation bases U. With uneven installation bases U of this kind, it can occur that panels 2 and 3 have no contact with the ground in the region of a joint and a space exists. When a load is applied in the region of the joint, it bends. Consequently, deflection of the edge profiles must be tolerable in the joint region. The joint may also bend on a level installation base U. This can happen when panels 2 and 3 are laid on a soft backing, such as impact sound insulation.
[0042] In order to withstand such loads, design measures are provided that lend the joint the articulated flexibility it needs. This flexibility prevents deflection of the joint from causing such high stresses in the region of groove profile 4 and tongue profile 5 that the material of panels 2 and 3 fails under the high stress. The positions shown in FIGS. 3 and 4 are arbitrary positions of movement and do not represent limit positions of the joint motion.
[0043] FIG. 3 shows the joint deflected upwards, i.e. away from installation base U. In this position, slight elastic deflection again occurs essentially on lower groove wall 7 . Due to its elasticity, lower groove wall 7 has a restoring effect on panels 2 and 3 , as soon as the load is removed. The movement of the joint reduces space 20 between the root of tongue 10 and shoulder 13 of lower groove wall 7 . In this way, existing space 20 permits articulated flexibility of the joint. In contrast, space 18 becomes larger.
[0044] FIG. 4 shows deflection of the locking system in the opposite direction, towards installation base U. Elastic expansion, essentially of lower groove wall 7 , is again evident in this case, which likewise has a restoring effect on panels 2 and 3 when the load is removed. The movement of the joint reduces space 18 between tongue 10 and flank 21 of upper groove wall 6 .
[0045] In this case, space 18 permits the articulated flexibility of the joint. In contrast, space 20 becomes larger.
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The invention relates to a panel and a locking system for panels with edge profiles provided on at least two opposite edges of the panels for the positive connection of similar panels, including an edge profile designed as a groove profile, with an upper groove wall and a lower groove wall, and an edge profile designed as a tongue profile, with a notch projection on the underside of the tongue that engages a notch recess in a the lower groove wall on an adjacent panel in the assembled state, where the engaged edge profiles form an articulated joint that acts to restore the panels to their installation plane when deflected either up or down, where the upper groove wall has a flank on the inside that opens towards the free end of the groove wall.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] (Not Applicable)
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] (Not applicable)
BACKGROUND OF THE INVENTION
[0003] An enclosure for containing an electrical meter or other instrument, module or device in an explosion-proof manner is disclosed.
[0004] Explosion-proof enclosures or housings are generally known for containing electrical and electronic equipment which is used in hazardous environments in which a spark or flame could ignite flammable gasses or other constituents in the operating environment. Explosion-proof housings are designed and constructed to meet industry standards such as the explosion-proof standards contained in the National Electrical Code (NEC). Such explosion-proof housings generally comprise a first housing portion which contains the associated meter or other instrument or device, and a second housing portion threadably attached to the first housing portion to fully enclose the device. Housing of known construction have deficiencies which limit their applicability and which limit their ease of use. Conventional housings usually require internal electrical fittings which must be carefully aligned to properly seat and install the electrical device being contained in the housing. Often such fittings must be preassembled in the housing before installation of the device. Examples of known explosion-proof housings are shown in U.S. Pat. Nos. 6,882,523 and 7,233,154.
BRIEF SUMMARY OF THE INVENTION
[0005] In accordance with the invention, an explosion-proof enclosure is provided for containing an electrical meter or other instrument, module or device. The enclosure includes a lower housing portion adapted to be mounted on a mounting surface or structure, an inner mounting assembly to which the meter or other device can be attached, and an upper housing portion which is threadably attachable to the lower housing portion to fully enclose the meter or other device. The upper housing portion has a transparent window for viewing the visual display of the meter or other device. The lower portion has a plurality of bosses that are spaced about the periphery of the interior chamber of the lower housing portion. The inner mounting assembly contains a plurality of recesses about the periphery thereof that cooperate with the bosses of the lower housing portion and which allow the mounting assembly and device attached thereto to be oriented in different rotational positions. The mounting and the device attached thereto can be oriented to readily read the display of the mounted device irrespective of the orientation of the mounted lower housing portion.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0007] FIG. 1 shows an isometric view of a lower housing portion in accordance with the present invention;
[0008] FIG. 2 shows a cross section of a lower housing portion with an inner mounting assembly attached thereto in accordance with the present invention;
[0009] FIG. 3 shows an isometric view of an upper housing portion in accordance with the present invention;
[0010] FIG. 4 shows an exploded view of the lower housing portion, inner mounting assembly and upper housing portion in accordance with the present invention; and
[0011] FIG. 5 shows a cross-sectional view of the upper housing portion in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Referring to FIGS. 1-5 , there are shown various views of an explosion-proof enclosure. The enclosure 10 includes an upper housing portion 12 , a lower housing portion 14 , and an inner mounting assembly or module 16 . The upper and lower housing portions 12 and 14 are fabricated of a material, e.g., steel, cast iron, and the like, that is capable of preventing a spark or flame from within the housing from reaching the environment external to the enclosure. Preferably the upper and lower housing portions are each cast as a single integral unit. The inner mounting assembly or module 16 is fabricated from a durable and preferably non-conductive material such as plastic.
[0013] The lower housing portion 14 ( FIG. 1 ) includes a sidewall portion 20 , a bottom portion 22 , and a threaded attachment portion 24 , which are structured and arranged to provide an open chamber 26 therein. The chamber 26 accommodates the device and associated wiring, fittings, and the like.
[0014] The sidewall portion 20 is substantially cylindrical and includes a substantially planar rim portion 28 and first and second ports 21 and 23 into each of which a conduit (not shown) for cables, wires, and the like can be threaded or otherwise affixed. Although the sidewall portion 20 shown in FIG. 1 is substantially cylindrical and two ports 21 and 23 are also shown, this is for illustrative purposes only. The sidewall portion 20 can have a shape other than cylindrical and the number of ports can be more than or less than two. In addition, the ports may be differently disposed than the illustrated embodiment in which the ports are in line with each other.
[0015] The attachment portion 24 is substantially cylindrical and further structured to include threads 25 for releasably attaching the lower housing portion 14 and the upper housing portion 12 . Preferably, a sealing element, such as an O-ring 15 , is disposed in a groove 29 adjacent to the rim 28 for providing an air- and water-tight seal between the upper and lower housing portions 12 and 14 when the upper and lower housing portions 12 and 14 are in threaded attachment.
[0016] Within the chamber 26 of the lower housing portion 14 and along the inner face 30 of the sidewall portion 20 is a plurality of bosses or ribs 32 . The bosses 32 are spaced about the periphery of the chamber and preferably are integrally formed with the lower housing portion 14 . Alternatively, the bosses 32 can be separate elements which are attached to the lower housing portion 14 . Although four bosses 32 are shown in FIG. 1 , the invention is not to be construed as being limited to four as the number of bosses 32 can be greater than or fewer than four.
[0017] The bosses 32 serve two primary purposes. First, they provide structural support and reinforcement to the lower housing portion 14 . Second, the bosses 32 provide guides for orienting and supporting the inner mounting assembly or module 16 . As will be further described below, the mounting assembly has recesses which are cooperative with the bosses to orient and mount the mounting assembly 16 in the chamber 26 . After installation of the mounting assembly 16 in an intended position in chamber 26 , the mounting assembly can be secured by an appropriate fastener. For example, as shown in FIG. 1 and FIG. 2 , each boss 32 can include a threaded opening 47 for receiving a fastener 46 , such as a thumbscrew, machine screw or bolt.
[0018] For mounting the enclosure 10 to an external surface or structure, the lower housing portion 14 includes mounting flanges 49 that each include an opening 48 through which a fastener or other mounting element (not shown) can be accommodated. The flanges 49 and openings 48 are adapted to attach the enclosure 10 to a supporting structure, e.g., wall, beam, column, and so forth, in any orientation so that the first and second ports 21 and 23 are oriented horizontally, vertically or at any angle therebetween.
[0019] As mentioned above, the plural bosses 32 also provide multiple guides for supporting and/or securing the mounting assembly or module 16 . Advantageously, the plural bosses 32 enable mounting the mounting assembly or module 16 to the lower housing portion 14 independently of the orientation of the mounted lower housing portion 14 . Consequently, the mounting assembly or module 16 can be disposed against and attached to the plural bosses 32 so that the device contained in the chamber 26 is always right-side up or otherwise oriented to facilitate observing the display of the device regardless of how the lower housing portion 14 is externally mounted. In the illustrated embodiment, four bosses 32 are provided in the lower housing portion 14 and cooperate with four recesses in the mounting assembly 16 to provide four different mounting positions for the mounting assembly and device attached thereto.
[0020] The upper housing portion 12 ( FIG. 3 through FIG. 5 ) includes a sidewall portion 34 and a top portion 36 that are structured and arranged to provide a chamber 38 that provides space for the portion of the mounting assembly 16 and device attached thereto which extends outwardly of the lower housing portion 14 .
[0021] The top portion 36 of the upper housing portion 12 includes a transparent window 31 for viewing a readout or display of the meter, instrument or other device contained within the chambers of the housing. The window 31 can be made, for example, of glass, acrylic, polycarbonate, and the like, and is in sealing engagement with the surrounding portion of the housing 12 .
[0022] The upper housing portion 12 includes a circular groove 71 in which a first O-ring 75 or other sealing element is disposed. The first O-ring 75 is seated in the circular groove 71 and is structured and arranged to abut the confronting surface of the window 31 , to provide an air- and water-tight seal. The window 31 is retained in place by a retaining ring 73 that is adapted to exert pressure against the window 31 to form the seal with the first O-ring 75 .
[0023] The retaining ring 73 also includes a circular groove 72 in which a second O-ring 79 or other sealing element is disposed. The second O-ring 79 is structured and arranged to abut the reverse surface of the window 31 , so that when the retaining ring 73 is inserted in the housing portion and tightened, the second O-ring 79 provides another air- and water-tight seal.
[0024] The retaining ring 73 is operatively disposed within the chamber 38 of the upper housing portion 12 . In one embodiment, the retaining ring 73 is threaded about its outer periphery. The threads in the retaining ring 73 mate with threadings 70 within the chamber 38 of the upper housing portion 12 . By threading the retaining ring 73 within the chamber 38 of the upper housing portion 12 , the retaining ring 73 will exert pressure against the second O-ring 79 and against the window 31 . The window is retained in sealing engagement with the upper housing portion 12 to provide an air- and water-tight seal. Although FIG. 5 shows that the retaining ring 73 is threaded into a threaded portion 74 of the chamber 38 that is separate from the internal threaded attachment portion 33 for attaching the upper housing portion 12 to the lower housing portion 14 , this is done for illustrative purposes only. The internal threaded attachment portion 33 for attaching the upper housing portion 12 to the lower housing portion 14 , could, instead, be continuous so that the outer periphery of the retaining ring 73 mates with continuous internal threaded attachment portion 33 , rather than a separate set of threadings 70 .
[0025] For applications in which the meter or other device contained in the enclosure has no display to be read by a user, the window 31 can be eliminated and in its place, a blind cover can be provided. Alternatively, the upper housing portion can be integrally formed with a solid cover portion.
[0026] The sidewall portion 34 shown in FIGS. 3 through 5 is substantially cylindrical and includes a threaded attachment portion 33 and a beveled portion 37 . Grooves 40 for accommodating human fingers can be provided on the exterior surface 42 of the sidewall portion 34 , to facilitate rotation and threading of the upper housing portion 12 to the lower housing portion 14 . The internal threaded attachment portion 33 mates with the external threaded portion 25 of the lower housing portion 14 .
[0027] The beveled portion 37 is disposed at the bottom portion of the sidewall portion 34 . The beveled portion 37 is adapted to accommodate an O-ring 15 that has been fitted onto the rim portion 28 of the lower housing portion 14 , to provide an air- and water-tight seal when the upper and lower housing portions 12 and 14 are in threaded attachment. Also, disposed on the exterior surface 42 of the sidewall portion 34 of the upper housing portion 12 is a locking device 45 , such as a locking screw, for releasably locking the upper and lower housing portions 12 and 14 .
[0028] The inner mounting assembly or module 16 is structured and arranged to accommodate and support at least one meter, instrument, or other electrical device. Referring to FIG. 2 and FIG. 4 , the inner mounting assembly or module 16 includes a first cylindrical portion 65 , a second cylindrical portion 60 , and a planar portion 51 that is orthogonal or substantially orthogonal to each of the cylindrical portions 65 and 60 and that connects the first cylindrical portion 65 to the second cylindrical portion 60 .
[0029] The first cylindrical portion 65 of the inner mounting assembly or module 16 includes a plurality of recesses 58 that are configured to be cooperative with the bosses 32 of the lower housing portion 14 and one or more attachment studs 52 that is disposed on the planar portion 51 . The second cylindrical portion 60 is stepped inwardly from the first portion 65 and has openings 57 and 61 and threaded studs (not shown) for receiving a meter or other device mounted thereto. The mounting assembly 16 can be configured with openings and mounting elements to accommodate a particular type of device or a range of device types.
[0030] The mounting assembly 16 and the device attached thereto is positioned in the lower housing portion 14 with the recesses 58 of the mounting assembly in cooperative engagement with the bosses 32 . The mounting assembly 16 is secured in position by one or more fasteners 46 which extend through associated mounting studs 52 into threaded attachment with threaded holes 47 on the outer surface of respective bosses 32 .
[0031] In the illustrated embodiment, the mounting assembly 16 is secured in the lower housing portion 14 by two diametrically positioned fasteners 46 . It will be appreciated that in some instance a single fastener 46 can suffice to secure the mounting assembly 16 , while in other instances, a fastener 46 may be employed for attachment to each of the bosses 32 of the lower housing portion 14 .
[0032] It will be further appreciated that the configuration of the inner mounting assembly 16 can vary to suit the particular meter or other device to be attached thereto. In use, the meter or other device is attached to the mounting assembly 16 by suitable fasteners or other attachment elements, and electrical connection is made to the device by wires which extend into the housing chamber via the one or more conduits.
[0033] Internal wiring within the explosion-proof is highly variable being determined, in large part, by the particular internal device and the end-user application. Wiring can include—for purposes of illustration and not limitation—analog and/or digital input signals and/or serial communication lines that represent an industrial process variable or that are used for process control and/or transmission or retransmission of the input; contact closure, i.e. relay, or transistor output that are used for alarm indication and/or process control; DC voltage output supply for powering an external device; and DC or AC voltage input supply for powering an internal device.
[0034] Many changes in the details, materials, and arrangement of parts and steps, herein described and illustrated, can be made by those skilled in the art in light of teachings contained hereinabove. Accordingly, it will be understood that the following claims are not to be limited to the embodiments disclosed herein and can include practices other than those specifically described, and are to be interpreted as broadly as allowed under the law.
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A system for enclosing an instrument, module or other assembly in an explosion-proof housing. The system includes an upper housing portion that includes a first threaded portion and, optionally, a transparent window portion; a lower housing portion that has a second threaded portion that is structured and arranged to cooperate with the first threaded portion to provide a tight, air- and water-tight fit; and an inner mounting assembly for supporting an instrument, module, electrical circuit, electrical device, display device, or other assembly. In pertinent part, the lower housing portion includes integrated bosses that provide horizontal surfaces for supporting the inner mounting assembly and for releasably attaching the inner mounting assembly to the lower housing portion. The number of positioning of the bosses and the number and positioning of mounting studs on the inner mounting assembly are designed to mount the inner mounting assembly within the lower housing portion in a manner that is independent of the mounting orientation of the lower housing portion.
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TECHNICAL FIELD
The invention relates generally to an ink cartridge and related methods of manufacture or use and related assemblies or combinations.
BACKGROUND ART
As used herein the term “ink cartridge” includes a cartridge which of itself may incorporate or may be adapted to connect to inkjet printing apparatus or part thereof. The term also includes an ink cartridge, the sole function of which is, to refill a printer cartridge and therefore the term “ink cartridge”, except where otherwise specified, is generic to both applications plus any other application of an ink cartridge.
FIG. 1 of the accompanying drawing illustrates a conventional ink cartridge 100 for an inkjet printer comprising two sections i.e. an ink supply section 110 containing an ink bag 111 and a waste ink recovery section 120 having absorbent material 121 to hold waste ink return from the printing process. Sections 110 and 120 are partitioned by an inner wall 101 forming separated housing chambers. The ink bag 112 in section 110 is coupled to an outlet port 113 and the absorbent material 121 is in contact with an inlet port 123 forming a close fluid communication circuit when inserted into the inkjet printer.
The problem encountered in connect ion with the two sections of ink cartridge 100 in FIG. 1 is that it is necessary to have a sufficiently large waste ink recovery section 110 to contain an absorbent material having a capability of recovering the entire volume of ink supply contained in the ink bag 111 . This capability is provided to cover the unlikely event of its being required to recover all ink that could be dispensed from ink bag 111 . This means the volume of waste ink recovery section 120 has to be substantially the same as the volume of ink supply section 110 . As a result, the volume of the entire cartridge 100 is large in order to accommodate the entire ink supply volume in either section of the cartridge.
U.S. Pat. No. 5,157,421 addresses a reduction in the overall size of the ink cartridge. FIG. 2 illustrates the cartridge of this U.S. patent where the design of the ink cartridge 200 allows a smaller overall size. The ink cartridge 200 has ink supply means (in a form of an ink bag 210 ) and a waste ink recovery means for recovering waste ink, which are both housed within the same cartridge chamber 201 . The waste ink recovery means has a waste ink bag 220 including a polymeric absorber 221 therein. The polymeric absorber 221 has great absorption capabilities with a volume requirement of about one-half to one-tenth of that compared to conventional absorbent material used in the conventional ink cartridge. Therefore, a smaller volume of polymer absorber 221 can be used in the waste ink bag 220 . Further, in employing a single chamber 201 for both the ink bag 210 and the waste ink bag 220 , the volume increase in the waste ink bag 220 upon recovery of waste ink can be offset by the volume decrease in the ink supply bag 210 in supplying ink to a printer jet printing mechanism. This enables a remarkable reduction in the size and volume of the ink cartridge as compared to the conventional ink cartridge.
The improved design of cartridge as in U.S. Pat. No. 5,157,421 may achieve overall small cartridge size, however, it is more difficult to manufacture and increases the cartridge cost. Particularly, the cartridge uses two ink bags: one for supplying ink and one for recovering waste ink. There is the cost of the two ink bag rather than one. High capacity polymer absorbent material is also of higher cost as compared to conventional absorbent material. Further, the ink bag and waste recovery bag are made of multi-layer material such as nylon film, polyethylene film and thin metal film laminated together. This costly multi-layer laminated material is then sealed at all sides and welded to the inlet port 230 and outlet port 240 (commonly made of hard plastic e.g. high density polyethylene if the contact layer of the laminated material is polyethylene film) respectively using technology such as heat welding. Welding a laminated film material onto a bard plastic is both difficult and risky as the rejection rate for quality assure purposes is high if leakage between laminated film and hard plastic is to be avoided. Further, depending on the inkjet printer mechanism, some of the waste ink may be returned into the ink supply bag and can contaminate the unused ink in the ink cartridge.
The problems that exist in ink cartridge as illustrated in U.S. Pat. No. 5,157,421 translate into extremely high product cost.
A object of the present invention is to provide an ink cartridge wherein the size of the cartridge is reduced using less costly components and using simpler and less costly manufacturing processes.
A further or alternative object to provide an ink cartridge less likely to allow waste ink contamination of unused ink.
SUMMARY OF THE INVENTION
The ink cartridge of the present invention is of a kind having both an ink supply and recovery system. It will have application with printer cartridge filling apparatus as disclosed in the patent specification being filed simultaneously herewith.
In a first aspect the present invention consists in an ink cartridge comprising or including
a housing defining an interior space and having two ports to that space,
a collapsable reservoir containing ink positioned within the interior space within the housing and having its outlet (“ink supply outlet”) at or adjacent one of said ports (“the ink supply port”),
optionally, a one way valve at or adjacent said outlet to allow only ink egress from the reservoir,
(whether forming part of the optional one way valve or distinct therefrom) a needle or cannula penetratable resilient seal sealing the optional one way valve and/or the ink supply outlet,
optionally, a dip tube from said optional one way valve or said ink supply outlet, said dip tube having its inlet at or adjacent that internal periphery of the collapsible reservoir that will be lowermost when the ink cartridge is orientated to its in use condition, and
a needle or cannula penetratable seal sealing the second part (the “waste ink recovery port”) of the housing,
wherein said housing about the collapsible reservoir, and more so as the reservoir collapses as ink is taken therefrom, defines an ink receiver capable progressively as the reservoir collapses of taking into the space outside of the collapsible reservoir but wholly within the housing at least substantially all of the ink content of the collapsible reservoir.
Preferably said housing is formed at least essentially from two moulded parts, a first moulded part being able to receive and locate at least the collapsible reservoir containing ink and any optional one way valve prior to assembly of the two moulded parts together.
Preferably a said one way valve and a dip tube is present.
Preferably an assembly of the collapsible reservoir containing ink, the one way valve and the dip tube has been located in one part of the housing prior to the other component of the housing being sealed thereto.
Preferably one or both of the seals is or are inserted in the polls after the otherwise sealing together of the components of the housing.
Preferably the collapsible reservoir containing ink is a blow moulded plastics container having a neck or a head at or adjacent the ink supply outlet, such neck or head being less disposed to collapse than much of the remainder of the collapsible reservoir.
Preferably the collapsible reservoir containing ink is of a kind having a body with the ink supply outlet offset from any central access of the body and where there is a truncation or chamfer of part of the reservoir periphery to improve uptake of ink by a said dip tube inlet from within the collapsible reservoir.
The ink cartridge of the present invention supply means in the form of thin wall plastic bottle housed in a cartridge, and, a waste recovery chamber in the same cartridge. Preferably the cartridge housing is of two moulded sealed together using any suitable jointing technology, such as ultrasonic welding, adhesion, etc.
The ink supply bottle preferably is blow moulded to a thin wall form from a preform or parison in low density polyethylene. The preform can have, if desired, only a momentary existence without ever having been cooled to ambient temperatures.
A blow moulded bottle is perhaps the most perfect means to store liquid material such as ink. Unlike the ink bag which is heat sealed at all sides thereby increasing the risk of leakage of ink, a blow moulded bottle, despite its low cost, has a homogeneous wall all round and allows only a small opening in the form of an injection moulded bottle neck that provides communication of ink in an out of the bottle. The homogeneous wall of the bottle means no leakage is possible the wall of the bottle is thin and relatively soft. In the event any ink is dispensed out of the bottle with a cannula through a properly seal bottle neck (e.g. seal with a bottle plug), the wall of the bottle collapses as the amount of ink dispensed out reduces the internal pressure in the bottle. The choice of the material and wall thickness of the bottle preferably enables it to filly collapse when ink is completely depleted.
Therefore, as the bottle is preferably housed in a welded together two moulded component housing, the collapse of the bottle wall translates into space for the waste ink in the same chamber. The peripherally welded cartridge includes a supply port and a waste ink return pore. The supply port and waste ink return port are each plug sealed with a rubber seal plug capable of being pierced to enable a fluid tight communication to and from both (i) the ink cartridge and the inkjet printer, printer cartridge or the like requiring ink.
In the ink cartridge the internal chamber of the cartridge housing is able to contain all the waste ink recovered. In the unlikely worst case scenario where all ink from the ink bottle is recovered into the waste ink recovery chamber, the bottle would have been fully collapsed and waste ink chamber space correspondingly increased to be able to fully contain the full amount of waste ink. Effectively, the size of the cartridge in this invention can be smaller has been conventional and preferably can be smaller than that of the cartridge illustrated in U.S. Pat. No. 5,157,421 as neither ink bag nor absorber material is needed in the cartridge.
It is a well known problem in the inkjet industries that the ink quality is very important in ensuring both good print functionality as well as printout quality. The waste ink may contain dirt particles and excessive air bubbles, both are, effectively, the biggest enemy to high quality inkjet printing. Therefore, preferably a one-way valve within the ink supply port allows ink to flow only in an outwards direction thereby precluding the possibility of waste ink flowing back into the ink bottle and contaminating the unused ink.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional illustration of a conventional ink cartridge known in the prior art.
FIG. 2 is a cross sectional illustration of an improved ink cartridge known in the prior art.
FIG. 3 is a cross sectional illustration of the ink cartridge of this invention.
FIG. 4 a and FIG. 4 b are diagrammatic views illustrating the collapsible bottle used in the cartridge of FIG. 3 .
FIG. 5 a to FIG. 5 d are diagrammatic views illustrating various design considerations given to ensure a minimum amount of unused ink will be left in the ink cartridge in this invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 3 wherein there is described the first embodiment of this invention.
Ink cartridge 10 has a housing component 11 closeable with a complementary housing component to define a single chamber 12 containing ink supply means (in the form of plastic ink bottle 20 ) and ink recovery means built-in in the same chamber 12 of cartridge 10 .
The ink bottle 20 which contains ink has a plastic needle or tube (ie; dip tube) 30 that is assembled onto the offset bottle neck area. The plastic tube 30 allows ink to be dispensed out of the ink bottle and thus the cartridge effectively. A one-way valve 50 is associated with (eg; inserted onto) the bottle neck as well. A rubber seal plug 40 is plug on to the bottle neck 21 to seal up the bottle, preventing ink leakage and forming the supply port 14 of the ink cartridge.
The pre-assembled ink bottle assembly is then assembled onto one half of the ink cartridge housing 11 as shown. At the waste ink return port 15 , another rubber seal plug 41 is plugged onto the ink cartridge housing 11 .
The other half or complementary housing component of the ink cartridge housing is then closed and sealed using for example, ultrasonic welding.
In use the ink cartridge is associated by insertion into a device (whether or the inkjet printer itself or otherwise) so that two cannulas will penetrate through the rubber seal plugs 40 and 41 of both the supply port 14 and waste ink return port 15 respectively. Upon full penetration, the rubber seal plug 40 and 41 is capable of self-sealing on the penetrating cannula thus closing fluid communication between the cartridge 10 and the device (eg; printer cartridge that requires ink filling or the inkjet printer itself) that is using it. The device has normally a suction mechanism that draw ink from the supply port 14 and any waste ink resulted from the device is returned into the waste ink recovery chamber 12 through the waste ink return ink port 15 .
The built in one-way valve 50 is able to ensure better print functionality and printout quality by restricting waste ink from contaminating the ink in the ink supply bottle of the ink cartridge.
The plastic ink bottle 20 is a thin wall bottle made by a blow moulding process. It is of a plastic material such as low density polyethylene or other similar flexible material. The bottle wall, being flexible with a careful choice of material and wall thickness, is capable of collapsing when ink is drawn out from the ink bottle 20 . When the ink amount reduces in the ink bottle 20 , as a result of being dispensed out by a suction mechanism from the device that is using it, the internal pressure will drop, thus causing the bottle wall to collapse.
Now, reference is made to FIG. 4 a and FIG. 4 b . When the ink bottle 20 is full of ink, it occupies almost the entire volume of the ink cartridge 10 , leaving a small amount of empty space to serve as waste ink recovery chamber 12 . When ink is dispensed out through the cannula 60 that penetrates through the rubber seal plug 40 , ink bottle 20 collapses. In the normal working scenario, where all the ink is being depleted and the majority of the ink is being used by the device, the ink bottle 20 will filly collapse as shown in FIG. 4 b . Nevertheless some amount of ink will return to the waste ink recovery chamber 12 which is now increased in size due to the collapse of ink bottle 20 . In the unlikely event of the worst case scenario where all ink supplied is returned as waste ink, the waste ink recovery chamber is also sufficient to contain all the waste ink within the now fully increased in space waste ink recovery chamber 12 .
Reference is now back to FIG. 3 .
As opposed to normal blow bottle where the bottle neck is normally at the center of the bottle body, ink bottle 20 preferably has a bottle neck 21 offset to one side of the bottle body. The body of the ink bottle preferably also has a chamfer or truncation 22 at the bottom corner on the same side as the bottle neck 21 .
The ink cartridge housing 11 preferably has a corresponding chamfered or truncated corner 13 .
The chamfers allows the ink cartridge 10 and thus the ink bottle 20 to be seated at an angle, at around 45°. The plastic needle 30 is also specifically designed to have a chamfered end 31 facing towards the chamfer 22 area of the ink bottle 20 . The purpose of this arrangement is to reduce amount of unused ink as illustrated in FIG. 5 a to FIG. 5 d.
Before examining the amount of ink that will remain in the bottle (i.e. ink that is unable to be fully dispensed out), it is required to note that there needs to be sufficient clearance H between the end of the plastic needle 30 and the wall, specifically the chamfer area 22 of the ink bottle 20 , for proper ink flow Too little clearance H is undesirable as it will slow down the ink flow rate.
FIG. 5 a and FIG. 5 b show that if the plastic needle is either located at the center or one side of the bottle, but the bottle is made without a chamfer, the amount of unused ink is L1×H×T. In FIG. 5 c , if the chamber if added to allow the cartridge to be seated in an angle, but the plastic needle has a flat end, the amount of ink left is approximately (L2)(H+Y)×T. FIG. 5 d shows that if the chamber is added to allow the cartridge to be seated in an angle, and the end of the plastic needle is also chamfered to the same angle, the amount of unused ink is approximately L2×H×T. Since L1 is greater than L2 (L1>L2), the least amount of unused ink will result from the design as shown in FIG. 5 d which is preferably employed in the design of the preferred embodiment of the present invention.
Thus, the invention described herein is capable of achieving smaller overall cartridge size and lower product cost.
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An ink cartridge where, in a two part housing, there are two cannula or needle penetrable resiliently sealed ports, one port providing access to an ink supply in a collapsible reservoir defined by a blow moulded container fitted with a one way valve and the second port providing, as a waste ink recover zone, space sealed within the housing that will grow as the ink supply is drawn off in use and the ink supply reservoir collapses. Preferably the one way valve is from a dip tube in the reservoir.
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RELATED CASES
[0001] This application is a Continuation-in-Part of our copeding patent application Ser. No. 11/112,996 filed on Apr. 21, 2005 and now pending.
FIELD OF THE INVENTION
[0002] This invention relates to medical apparatuses and methods for treatment of dermatological pathological conditions, such as the edematous-fibrosclerotic panniculopathy, commonly known as cellulite, acne scars or even physiological conditions such as deep wrinkles.
BACKGROUND—DESCRIPTION OF THE PRIOR ART
[0003] Numerous treatments have been devised for the dermatological condition edematous-fibrosclerotic panniculopathy, commonly known as cellulite.
[0004] Some of these treatments have a scientific base, some have a pseudo-scientific, empiric base.
[0005] The edematous-fibrosclerotic panniculopathy commonly named cellulite, a non medical term coined in Europe, is a disorder of the skin and subcutaneous tissue. The edematous-fibrosclerotic panniculopathy is due to the formation of an abnormal fibrous network in the hypoderm. The abnormal fibrous network encapsulates conglomerates of fat cells causing a subcutaneous architectural disruption which results in a dimples and nodules appearance of the skin, known as orange peel skin. Strands of fibrous tissue connect the skin to deeper tissue layers and also separate compartments that contain conglomerates of fat cells. Cellulite affects more commonly the hips, thighs, glutei, abdominal wall and upper arms. Women are commonly more affected than men. Researchers agree that most of cellulite “cures” have been ineffective. Recent researches have confirmed that cellulite is product of faulty anatomy, genes and hormones.
[0006] Anticellulite products with unsubstantiated claims of successful treatment of the condition include creams and gels, brushes, rollers, body wraps toning lotions, electrical stimulation devices, vibrating machines, inflatable hip-high pressurized boots, hormone or enzymes injections and many others.
[0007] More recently, radio frequency and laser devices, cold-laser massage devices, combined radio frequency/infrared devices, fat melting injections, targeted liposuction, tissue fillers have been used for the treatment of cellulite with minimal or marginal success, eventually with only transitory improvements.
[0008] A more recently devised surgical procedure called skin subcision has shown some promising results. The procedure consists of cutting the cellulitic fibrous bands, the tethers which cause the depression in the skin with a special needle having surgical scalpel-like tip. The dimples, freed from their fibrous attachments, pop up and the skin is able to regain the even, pre-cellulitic aspect. Regretfully, the procedure is not void of complications. Pain, bruises, hemosiderosis have been associated with the procedure as reported in the International Journal of Dermatology, Volume 39 Issue 7, Page 539, July 2000.
BRIEF SUMMARY OF THE INVENTION
[0009] With the present invention, applicants propose a simple medical-surgical device having the scientific prerequisites of being capable of detaching the fibrous attachments that connect the skin to the deeper layers and cause the typical dimples of a cellulitic skin, via blunt dissection, rather than via sharp dissection as currently in use. Detachment of such fibrous attachments resolves the skin dimples, restituting normal appearance to the skin, minimizing complications more likely to develop with the current technique of sharp dissection.
[0010] The device is composed of a needle having an expandable balloon in proximity of the tip, connected to a syringe provided with a handle. The operator inserts the needle into the skin, inflates the balloon, grossly shaped as a donut. The balloon once inflated has the double finction of dissecting by outward radial expansion the fibrous bands network and of serving as anchoring device for skin traction purposes. The operator gently pulls up the needle acting upon the syringe handle connected to the needle carrying the expanded balloon. In doing so the operator elevates the skin, stretching it to the point of rupture the cellulitic fibrous bands which cause the dimpling of the skin.
[0011] The detachment of the fibrous bands occur by blunt dissection. It is expected that the extensible surrounding blood vessels are just stretched and not severed as in the above mentioned sharp subcision technique. Surrounding structures will be less traumatized being not sharply cut as in the sharp subcision technique. It is reasonable to say that less trauma to the tissue is expected to occur with greater patient comfort and with expectation of lesser complications. In the instances that blunt dissection results insufficient to detach such fibrous bands the device will be able to place the fibrous bands under sufficient tensile traction to be easily detectable at touch by a blindly exploring sharp cutting tool, with consequent economical and efficient severing of such fibrous bands by such cutting tool, or to enable a cutting tool mounted on the skin traction apparatus to economically and efficiently sever such fibrous bands, in both cases with minimal damage to surrounding tissues in a fashion comparable to blunt dissection technique.
OBJECT OF THE PRESENT INVENTION
[0012] It is an object of the present invention to provide a simple, rapidly deployable medical device for the treatment of cellulite, the treatment being based on solid anatomic-pathological foundations.
[0013] It is an object of the present invention to provide the consumer with a simple minimally invasive effective, rapidly deployable means and method for improving cosmetic appearance of the skin affected by cellulite.
[0014] It is an object of the present invention to provide a safe, simple and effective apparatus and method to target and to induce mechanical lysis of the fibrous bands which are at the core of the formation and persistence of the cellulite in body areas of patient's concern.
[0015] It is an object of the present invention to provide the operator with an alternative improved apparatus and method of an already proven effective method of cellulite treatment, i.e. skin subcision: the dissection of the cellulitic fibrous bands. The proposed device dissects the fibrous tissue by blunt, not sharp, dissection, causing less trauma, less bleeding, ultimately less inflammatory reaction in the subcutaneous tissue.
[0016] It is an objective of the present invention to provide the operator with a device which by minimal, needle-like skin invasion ensues an adequate traction on the skin from below without any further puncturing or cutting of the skin.
[0017] It is an objective of this invention to provide the operator with an adequate skin traction device requiring a single skin hole of a diameter comparable to a needle-like element capable of exerting traction pressure to the skin from below without any further puncturing or cutting of the skin.
[0018] It is further objective of this invention to provide the operator with a minimally invasive device for traction of the skin from below to ensue enough tensile traction on fibrous bands responsible of the skin dimpling characterizing the cellulite to cause detachment of such fibrous bands from their attachments to the skin or to deeper layers, and/or to cause easy detection at touch by a blindly exploring sharp cutting tool as a result of the tensile traction applied to them, with consequent economical and efficient severing of such fibrous bands by such cutting tool, or to enable a cutting tool mounted on the skin traction apparatus to economically and efficiently sever such fibrous bands, in both cases with minimal damage to surrounding tissues in a fashion comparable to the blunt dissection technique.
DRAWING FIGURES
[0019] FIG. 1 is a side view of device with the balloon deflated at rest prior to use.
[0020] FIG. 2 is a side view of the device with the balloon inflated.
[0021] FIG. 3 is as side view of the same device with a larger balloon fully inflated.
[0022] FIG. 4 is across sectional view of a detail of the device of FIG. 2 to 3 specifically the inflatable member or balloon or bluntly dissecting member or anchoring member inflated.
[0023] FIG. 5 shows a detail of the device specifically the locking mechanism for the plunger of device prior to actuation of the locking mechanism.
[0024] FIG. 6 shows a cross sectional view of the skin of a patient with the device in action with the balloon deployed pulled upward by the operator resulting in blunt dissection/disruption of the cellulitic fibrous bands at the skin attachment and or at the deeper layer attachment.
[0025] FIG. 7 is a side view of another embodiment of the device illustrated in FIG. 1-6
[0026] FIG. 7A is side view of an enlargement of a detail of the device of FIG. 7
[0027] FIG. 7B is an enlarged cross section view of a detail of the device of FIG. 7 .
[0028] FIG. 7C is an enlarged cross section view of a detail of the device of FIG. 7
[0029] FIG. 8 is side view of another embodiment of the device illustrated in FIG. 1-6
[0030] FIG. 8A is side view of an enlargement of a detail of the device of FIG. 8
[0031] FIG. 9 is a side view of another embodiment of the device of FIG. 1-6 .
[0032] FIG. 9 A is side view of an enlargement of a detail of the device of FIG. 9
[0033] FIG. 10 is a side view of another embodiment of the device of FIG. 1-6 .
[0034] FIG. 10A is a side view of another embodiment of the device of FIG. 10
[0035] FIG. 11 is a side view of another embodiment of the device of FIG. 1-6 .
[0036] FIG. 12 is side view of another embodiment of the device of FIG. 1-6
[0037] FIG. 12A is side view of an enlargement of a detail of the device of FIG. 12
[0038] FIG. 13 is a side view of another embodiment of the device of FIG. 1-6 .
[0039] FIG. 13A is side view of an enlargement of a detail of the device of FIG. 13
[0040] FIG. 13B is side view of an enlargement of a detail of the device of FIG. 13
[0041] FIG. 14 is a perspective view of another embodiment the device illustrated in FIG. 11 .
[0042] FIG. 15 is a perspective view of a component of embodiment of FIG. 14
[0043] FIG. 16 is a perspective view of another component of embodiment of FIG. 14 .
[0044] FIG. 17 is a perspective view of the embodiment of FIG. 14 in a stage of deployment.
DETAILED DESCRIPTION OF THE INVENTION
[0045] As shown in FIG. 1 , Infra-epidermic Subcision Device for Blunt Dissection of Sub-epidermic Tissues or Skin blunt Dissector/Elevator 1 consists of hollow hypodermic needle or skin penetrating means 2 sufficiently rigid to allow skin perforation connected to and in flow communication with syringe or inflating means 4 . Needle 2 is in tight sealing connection with syringe 4 via detachable hub 3 . Needle tip segment 3 ′ of needle 2 is imperforated as better shown in FIG. 4 , while the remaining segment 3 ″ of the needle is hollow. Syringe 4 is formed with barrel 8 , slideable piston or plunger 10 and handle or handling means or traction or pulling means 6 . Syringe is formed at its proximal end with plunger locking mechanism 9 formed with flanges 9 ′ for the release of locking mechanism 9 .
[0046] As shown in FIG. 1 , balloon or expandable member or bluntly dissecting member or anchoring member 14 , grossly donut shaped once inflated as shown in FIGS. 2 and 3 , 4 and 6 is mounted on needle shaft 12 of needle 2 .
[0047] As better shown in shown in FIG. 4 which is a blown up cross sectional view of needle 2 distal segment, balloon 14 , shown inflated, is in flow communication with hollow needle 2 via needle holes or needle perforations 20 . Needles holes 20 are proximal to imperforated needle tip 3 ′. Balloon 14 of FIG. 1 , 2 , 4 , 6 or balloon 14 ′ of FIG. 3 , made of extensible material up to a maximum point of expansion, is sealingly attached to needle shaft 12 via cylindrically shaped balloon extensions or sleeve 22 and 22 ′ as better shown in FIGS. 1 and 4 .
[0048] Needle 2 can be formed with different sizes balloons allowing variable radial balloon expansions.
[0049] FIG. 3 shows device 1 with larger diameter balloon 14 ′ for radial-lateral blunt dissection/disruption of cellulitic fibrous bands.
[0050] As better shown in FIG. 5 , plunger locking members or mechanism 9 of plunger 10 is releasable upon pressing down on flanges 9 ′ which disengage locking members 9 from plunger 10 .
[0051] As shown in FIG. 1 , plunger 10 , at rest prior to use, is withdrawn to a degree just sufficient to fully inflate balloon 14 once plunger 10 is fully downwardly displaced.
[0052] As it can be better understood from FIG. 6 , which shows the device in use, the operator advances needle 2 with imperforated tip 3 ′ into the patient skin 30 . Local anesthetic can be administered prior to skin insertion of needle tip 3 ′ for pain relief. Needle 2 is preferably inserted in the depressed center of a skin dimple 21 ′ of the cellulitic skin 30 . Dimple 21 ′ is shown before skin traction, while dimple 21 is shown in FIG. 6 during skin traction, as it will be described below. Once needle tip 3 ′ and distal segment of needle shaft 12 with balloon 14 is at sufficient depth underneath the epidermis, balloon 14 is inflated by the operator by advancement of plunger 10 . Upon full advancement, plunger 10 is locked by locking mechanism 9 in its fully advanced position, as shown in FIGS. 2, 3 and 6 . Upon full advancement of plunger 10 , balloon 14 inflates and expands radially-laterally. Radial-lateral expansion of balloon 14 and to a larger degree of balloon 14 ′ of larger diameter, will stretch cellulitic fibrous bands 24 to a point of rupture, via blunt dissection or disruption. Cellulitic fibrous bands are shown in FIG. 6 before blunt disruption 24 ′ and after disruption at 24 . When fully expanded, balloons 14 or 14 ′ act as sub-epidermic anchoring device for skin traction. The operator pulls the device away from the skin surface via handle or traction means 6 . Balloon or expandable member or bluntly dissecting member or anchoring member 14 or 14 ′ grossly donut shaped, sub-epidernically placed indeed act as anchoring member allowing elevation/traction of the skin. By elevating the skin, fibrous bands 24 are bluntly disrupted and dissected from attachments to epidermis 25 or from attachments to the deeper skin layers 25 ′, as shown in FIG. 6 . Skin dimples 21 , no longer tethered down by fibrous bands 24 and or 24 ′ will be free to rise by natural resiliency to the level of the surrounding skin.
[0053] The operator can repeat the procedure by inserting the needle into each cellulitic skin dimple 21 ′. By operating the device as described, the operator can eliminate, one by one, every skin dimple, restituting normal appearance to the skin.
[0054] FIG. 7 shows another embodiment of device 1 of FIG. 1-6 , generally indicated at 29 . Device 29 is in all similar to device 1 of FIG. 1-6 except that hvpodermic needle or elongated member 34 is mounted with coaxial catheter or flexible sleeve 36 formed with balloon or expandable member 35 . Catheter 36 is sealinglv connected via hub 33 to hub 3 of needle 34 . Needle 34 is formed with entry segment 34 ′, L-shaped, provided with tip 31 and dissecting means or blade 39 as better shown in FIG. 7A . Tip 33 of entry segment 34 ′ is shown blunt in FIG. 7A , but can be also sharp to allow skin penetration.
[0055] As better shown in FIG. 7B which is a cross sectional view of balloon 35 , of catheter 36 and of hollow needle 34 , hollow needle 34 is longitudinally fenestrated via longitudinal opening 37 . Catheter 36 is tightly mounted over needle 34 and is provided with openings 38 which are aligned, and in flow communication, with opening 37 of needle 34 .
[0056] As seen in FIG. 7B , distal segment 36 ′ of catheter 36 extends into an enlarged and/or expandable segment of such catheter, balloon 35 , whose wall or distensible airtight membrane 35 ′ is folded over catheter shaft 36 ″ and, as best seen in FIG. 7C , it extends over proximal segment 32 of catheter 36 reducing its diameter into sleeve 32 ′, which is sealingly bound over proximal segment 32 of catheter 36 .
[0057] This version offers manufacturing advantages over versions where balloon is sealingly bound with adhesives over the needle, because in this version no adhesive binding is necessary between needle on one side and catheter/balloon on the other side. In fact, in use, air or fluidous component is delivered, by advancement of plunger 10 , from syringe 4 into needle 34 which is hollow up to its fenestration 37 . Air will preferentially select the pathway of least resistance, and will enter balloon 35 via openings 37 of needle 34 , then via catheter openings 38 which are aligned in flow communication with needle opening 37 , rather than opening its way and escaping along the interface between tightly adherent catheter shaft 36 and needle 34 . Upon air build up within balloon 35 , consequent pressure build up within balloon 35 will result in increased adherence of catheter shaft 36 ″ to needle 34 , which in turn will prevent escape of air between catheter and needle. Inflated balloon 35 will retain needle 34 from exiting out of the skin when the operator will pull in direction away from the skin the syringe secured to the needle. This action will result with elevation of the skin to such extent of disrupting the attachment of the collagen fibers to the dermis and releasing the skin dimples which characterize the cellulite.
[0058] FIG. 8 through 17 illustrate other embodiments of device 1 of FIG. 1-6 . Despite varying in structure and design, all these apparatuses have the common denominator of being provided, once introduced into the skin of a patient and deployed. as device 1 of FIG. 1 to 6 and 29 of FIG. 7-7C , with a blunt surface contacting the sub-epidermic layers such the dermis or deeper tissue layers allowing traction and elevation of the skin from underneath by the operator.
[0059] Elevation of the skin will result in blunt dissection/disruption of the cellulitic fibrous bands at the skin attachment and or at deeper layer attachment such as at attachment on the fascia. Another application of the devices above and below described, in addition to the treatment of cellulite is the treatment of any depressed scar or even deep wrinkles where dissection/disruption of the fibrotic bands from the dermis or deeper attachments, responsible of the scar tissue or deep wrinkles, will result in elevation of the depressed skin surfaces to an even anatomical level with the surrounding skin surface. An example of this application is the correction and cosmetic amelioration of acne scars.
[0060] FIG. 8 illustrates device 40 composed of handle 42 generally of elongated shape such as cylindrical or hexagonal, formed with handle bar 44 to result into a generally T-shaped combination, and entry segment 47 with dermis or blunt skin lifting segment or sub-epidermic contacting member spirally shaped 46 formed with blunt tip 43 as shown in FIG. 8 and 8 A.
[0061] Elongated member 45 of device 40 can be made of a substantially rigid material such as medical grade steel allowing penetration and manipulation of the device by handle 42 . Elongated member 45 is composed of a stem member 41 and of an arm or lifting means 46 having a blunt surface.
[0062] Handle 42 and handle bar 44 can be made of any suitable material including plastic.
[0063] The device can be made disposable mono-use or re-sterilizable multi-use.
[0064] In operation the skin of a patient is punctured with an ordinary hypodermic needle after proper skin prepping and eventually the skin area is infiltrated with a local anesthetic. Blunt tip 43 of device 40 is then inserted into the skin opening created by the hypodermic needle tip. The operator then rotates device 40 in a clockwise fashion by acting upon handle 42 and handle bar 44 allowing full penetration of entrv segment 46 underneath the skin.
[0065] Once spiral segment or dermis blunt lifting segment 46 is well positioned underneath the skin, the operator will pull upward device 40 . In doing so the cellulitic fibrotic bands present in the dermis as described for device 1 of FIG. 1-6 or for device 29 of FIG. 8-8B will be severed bv traction exerted perpendicularly to the surface of the skin by maintaining the longitudinal axis of the handle oriented perpendicularly to the surface of the skin. The skin will be lifted as dermis lifting segment 46 provides a blunt dermis contacting surface from underneath the skin for skin lifting purposes.
[0066] FIGS. 9 and 9 A illustrates device 40 ′ which, as device 1 of FIG. 1-6 , is composed of syringe 4 to which hollow needle or elongated member 45 ′ is sealingly connected via hub 3 . Needle 45 ′ is formed with spirally shaped entry segment 47 ′ and blunt skin lifting member 46 ′. Elongated member 45 ′ is hollow, in flow communication with syringe 4 and formed with sharp tip 43 ′. Device 40 ′ is used as device 40 except that, being tip 43 ′ sharp, it allows penetration and placement of dermis or skin blunt lifting segment 46 ′ underneath the skin without prior use of an hypodermic needle for creating a skin opening, as needed for described device 40 . Syringe 4 can be pre-filled with any type of medication that the operator believes is suitable to be delivered into the dermis, subcutaneous tissue or into deeper tissues, including anesthetics. and lipolytic or in general tissue-lysing medications such as, for instance, the enzyme collagenase.
[0067] FIG. 10 illustrates device 50 in all similar to device 40 of FIGS. 8 and 8 A in structure, use and operation with the difference that elongated member 55 is double L-shaped with tip 53 being blunt. Blunt lifting member is indicated at 56 . With the longitudinal axis of the device being oriented vertically, the first L is oriented on a vertical plane, and composed of vertical segment or stem member 51 and horizontal segment 56 ′, the second L, is oriented on an horizontal plane and is composed of horizontal segments 56 ′ and 56 ″.
[0068] FIG. 10A illustrates device 50 ′ in all similar to device 50 of FIG. 10 in structure, use and operation with the difference that double L shaped elongated member 55 is formed with tip 53 ′ being sharp.
[0069] Device 50 and 50 ′ are operated as device 40 of FIG. of FIGS. 8 and 8 A and 40 ′ of FIGS. 9 and 9 A.
[0070] To aid fibrous bands detachments being already accomplished by axial upward traction, the operator, beside lifting the skin as already described, can rotate the device by acting upon handle 42 , and handle bar 44 . Rotation of elongated member 55 will dissect any tissue fibrotic attachment met during the rotation.
[0071] FIG. 11 illustrates device 70 , in all similar to device 40 of FIG. 8-8A in use and operation, with the difference that elongated member 75 is composed of stem member 71 and arm or lifting means 76 helicoidally shaped. Tip 73 of elongated member 75 can be either blunt as illustrated in FIG. 11 or sharp.
[0072] The device is operated as device 40 of FIGS. 8 and 8 A and actually is screwed into the skin as a corkscrew into a cork.
[0073] FIG. 12 shows another embodiment of device 40 of FIG. 8-8A , generally indicated at 80 in all similar to device 40 in use and operation except that elongated member 85 is grossly Z shaped. As better shown in FIG. 12A , skin lifting or sub-epidermic contacting member 86 is formed with blunt lifting arm or blunt dermis-contacting arm or member 86 ′, connected via arm 88 to dissecting arm or entry member 87 formed with dissecting blade 84 having edge 84 ′, which can be either sharp blunt or teethed.
[0074] Tip 83 of elongated member 85 is shown blunt but can also be sharp as for the previously described devices.
[0075] Once elongated member 85 is inserted and placed under the skin, and skin lifting or sub-epidermic contacting member 86 is below, or within, the dermis, the operator can pull device 80 upwardly via handle 42 . As a result of the traction exerted on the device, the skin will be also placed under traction by blunt lifting arm or blunt dermis-contacting arm or member 86 engaging the undersurface of the dermis or the inside of the dermis.
[0076] The operator can facilitate or promote detachment of the fibrous bands by imparting rotation to the device by acting upon handle 42 and handle bar 44 . As a result of such rotation, dissecting arm 87 with blade 84 will rotate and, consequently, will sharply or bluntly dissect the fibrous bands attached to the skin, such as fibrotic bands characterizing the skin depressions of cellulite or acne scars, while blunt skin lifting arm 86 will keep the dermis or anything above arm 86 ′ clear from dissection caused bv dissecting arm or member 87 . Arm 87 will induce tensile traction on the fibrous bands, enabling blade 84 , mounted on dissecting arm 87 , to sever such fibrous bands more economically and efficiently than it would be possible without applying tensile traction upon such fibrous bands.
[0077] FIG. 13 shows device 90 in all similar to device 40 of FIG. 8-8A in use and operation except that elongated member 95 as better shown in FIGS. 13A and 13B is L shaped and composed of stem member 91 and of skin lifting and dissecting arm 97 formed with dissecting blade 94 . being blade edge 94 ′ sharp or blunt as for device 80 of FIG. 12 . Tip 93 is illustrated blunt.
[0078] The device is operated as device 80 of FIGS. 12 and 12 A.
[0079] FIG. 14 illustrates device 120 . This embodiment has definite similarities with device 70 of FIG. 11 . Device 120 has two components, components 121 and component 131 . Component 121 , as best seen in FIG. 15 is in all similar to device 70 of FIG. 11 with the only significant difference that vertical segment or stem member 123 is much longer than in device 70 of FIG. 11 . Handle 124 of component 121 has bar 125 to facilitate rotation of component 121 during use. Helicoidal segment or anchoring means 122 of component 121 is in all similar to helicoidal segment 76 of device 70 of FIG. 11 . Component 131 , as best seen in FIG. 16 is also similar to device 70 Of FIG. 11 with the significant difference that vertical segment or stem member 133 is hollow, with distal opening 137 , and telescopically slides over vertical segment 123 of component 121 . Segment 133 of component 131 is connected to handle 134 . Handle 134 is also hollow in order to slides over segment 123 of component 121 , and has bar 135 to facilitate rotation of component 131 during its use. Helicoidal segment 132 of component 131 is also similar to helicoidal segment 76 of device 70 of FIG. 11 . Segment 122 of component 121 and segment 132 of component 131 may have either a sharp tip or a blunt tip. The device is operated by inserting segment 122 of component 121 into the skin. If segment 122 has a sharp tip, segment 122 will be inserted directly into the skin after local anesthesia. If segment 122 has a blunt tip, segment 122 will be inserted into the skin by engaging the blunt tip of segment 122 into a skin hole made with a needle after proper local anesthesia.
[0080] Segment 122 will be advanced into the skin bv the operator bv rotating bar 125 of handle 124 which will result with a type of corkscrew advancement of segment 122 . When segment 122 has advanced into the subcutaneous tissue and is in proximity of the muscle layer, the operator will engage the tip of segment 132 of component 131 into the same skin hole where segment 122 of component 121 had entered. Segment 132 will be advanced into the skin in the fashion segment 122 is advanced, by rotating bar 135 of handle 134 . When segment 132 of component 131 has entered the subcutaneous tissue, the operator will hold handle 134 down on the skin while pulling handle 124 of component 121 away from the skin. This action will result in separating further apart segment 122 from segment 132 , as best seen in FIG. 17 , and, with them the layers they are engaged with. This embodiment has a clear advantage over all the embodiment described above in the fact that it anchors the attachment of the fibrous bands on the deep layers while it exerts traction on the superficial attachments of the fibrous bands avoiding the possibility that traction exerted upon the superficial attachments of the fibrous bands results into an elevation of the deeper layer rather than in detachment of the fibrous bands.
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A dermatological device for subcision of sub-epidermic tissues. The device is provided with a blunt dermis contacting surface enabling the operator to lift or cause traction to the skin from underneath the skin, after placement of the dermal contacting surface of the device under the skin. By mere skin lifting from underneath, fibrous bands present within the dermis are detached/disrupted/dissected from their attachments to the skin or from their attachments to deeper layers. Detachment/disruption/dissection of the fibrous bands can be aided by the adjunct of a dissecting arm which by rotation can enhance detachment/disruption/dissection of the fibrous bands. Pathological skin conditions such as edematous-fibrosclerotic panniculopathy known also as cellulite or any depressed scar or deep wrinkle can benefit from the device as dissection of the fibrous bands. which cause depression of skin areas. restitutes a nearly anatomical evened up skin surface.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/260,019, filed Oct. 2, 2002, which will issue as U.S. Pat. No. 7,204,505 on Apr. 17, 2007, which is a continuation of U.S. patent application Ser. No. 09/559,603, filed Apr. 27, 2000, now U.S. Pat. No. 6,460,870, issued Oct. 8, 2002, which application claims the benefit of earlier-filed U.S. Patent Application Ser. No. 60/162,259, filed Oct. 29, 1999, abandoned, for “Stowaway, Receiver Hitch.” The disclosure of each of the previously referenced U.S. patent applications and patents is hereby incorporated by reference in its entirety.
BACKGROUND
1. The Field of the Invention
This invention relates to towing apparatus and, more particularly, to novel systems and methods for receiver-type hitches on vehicles to tow trailers.
2. The Background Art
Trailers have been towed since the earliest days of the wheel. A cart or wagon towed behind an animal is a trailer. In modern times, trailers are secured to towing vehicles by a multiplicity of methods. Tractor-trailer rigs use fifth-wheel towing systems. Similarly, recreational vehicles sometimes use fifth-wheel towing systems.
A continuing popular apparatus for securing a towed vehicle to a towing vehicle is the “receiver hitch.” A receiver hitch relies on a receiver cavity or tube securely mounted to the frame of a towing vehicle. The receiver is reinforced and provided with an aperture for receiving a trunnion. A trunnion may be secured into the receiver. A hitch may be mounted on the trunnion. Typically, the hitch may be a pin hitch or a ball hitch, but need not be limited thereto.
For recreational users, receiver hitches present two common problems. The more important problem may be the difficulty of attaching a greasy hitch to a vehicle and unattaching the same after use. Although receiver-type hitches are generally adaptable to receive various trunnions with various types of hitches, the very nature of a receiver hitch may make it problematic. If a trunnion is not removed after use, then a person may accidentally strike a shin or knee on the extending hitch or trunnion when no towed vehicle is attached. If the hitch is removed, it is cumbersome to move, requires some immediate storage place, and may be filthy with grease. Due to the weight of the hitch and trunnion assembly, a person removing the trunnion and hitch from a receiver is likely to soil clothing.
Another problem with receiver hitches is the adjustment of altitude of the hitch itself. Recreational users may have multiple towed vehicles. For example, a boat trailer, a snowmobile trailer, a utility hauling trailer, and the like may be manufactured at different and arbitrary hitch heights. Similarly, a trunnion may be used on different vehicles having different heights. Accordingly, it may be advantageous to provide a hitch that is easily adjustable between multiple positions of elevation.
Thus, it would be an advance in the art to provide a receiver-type hitch mount that can be stowed without projecting inconveniently far from the bumper, substantially within the envelope of a vehicle, or even without extending behind the bumper on certain embodiments. Ready access and substantial weightless or self-supporting deployment of a hitch mount is extremely desirable. However, any adjustability in altitude would be a plus.
Along with an adjustment in altitude, it is common to use different sizes of ball hitches. Accordingly, selective stowage and presentation, selectivity of multiple sizes of ball hitches on a single mount without having to use a wrench to replace the ball hitch, alone or in combination, would be a benefit and convenience.
BRIEF SUMMARY AND OBJECTS OF THE INVENTION
In view of the foregoing, it is a primary object of the present invention to provide a mount mechanism for a receiver-type hitch system. The mount should be deployable and stowable at the election of a user. The mount and hitch system should be supportable on a trunnion of a conventional receiver-type hitch system without adaptation thereof. Moreover, the hitch mount system should fit within an envelope or footprint close to that of the vehicle itself. This may reduce the hazards of walking or working near the rear of a vehicle.
It is an additional object of the invention to provide access to multiple levels of hitch height and multiple hitch sizes such as ball diameters. It is a further object of the invention to provide an option to select among hitch heights, deployment and stowage options, and hitch sizes, without requiring substantial lifting of the weight of the trunnion and mount system.
It is another object of the invention to provide a mechanism that does not require substantial effort for alignment by the user in order to be adjusted between a deployed and stowed position, between a first altitude and a second altitude, or between a first and second hitch size.
Consistent with the foregoing objects and in accordance with the invention as embodied and broadly described herein, an apparatus is disclosed in suitable detail to enable one of ordinary skill in the art to make and use the invention. In certain embodiments, an apparatus in accordance with the present invention may include a trunnion connecting to a pivot. The pivot connects a base to a hitch. A base supports a mount which may be moved between a stowed and a deployed position and may include a platform for supporting a hitch. A beam may enable the main pivotal member to rotate or pivot about the base. Usually, the base may be fixed with respect to the trunnion.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and features of the present invention will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only typical embodiments of the invention and are, therefore, not to be considered limiting of its scope, the invention will be described with additional specificity and detail through use of the accompanying drawings in which:
FIG. 1 is a rear quarter perspective view (with respect to the front-to-rear orientation of a vehicle) of one embodiment of a receiver-type hitch-mounting mechanism in a deployed position in accordance with the present invention;
FIG. 2 is a lower rear quarter perspective view of the apparatus of FIG. 1 , in a stowed position;
FIG. 3 is a rear quarter perspective view of an alternative embodiment of an apparatus in accordance with the present invention for implementing a hitch-mounting mechanism in a stowed position;
FIG. 4 is a rear quarter perspective view of the apparatus of FIG. 3 in a deployed position;
FIG. 5 is a rear quarter perspective view of an alternative embodiment of a receiver-type hitch-mounting mechanism in accordance with the present invention in a stowed position;
FIG. 6 is a rear quarter perspective view of the apparatus of FIG. 5 in a deployed position;
FIG. 7 is a rear quarter perspective view of an alternative embodiment of a receiver-type hitch mounting mechanism in a deployed position in accordance with the present invention; and
FIG. 8 is a rear quarter perspective view of the apparatus of FIG. 7 in a stowed position.
DETAILED DESCRIPTION OF THE INVENTION
It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, may be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in FIGS. 1 through 8 , is not intended to limit the scope of the invention. The scope of the invention is as broad as claimed herein. The illustrations are merely representative of certain, presently preferred embodiments of the invention. Those presently preferred embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
Those of ordinary skill in the art will, of course, appreciate that various modifications to the details of the figures may easily be made without departing from the essential characteristics of the invention. Thus, the following description of the figures is intended only by way of example and simply illustrates certain presently preferred embodiments consistent with the invention as claimed.
Referring to FIG. 1 , specifically, while also referring generally to FIGS. 1-8 , an apparatus or hitch mount 10 may be secured to a receiver of a towing vehicle. The apparatus 10 may include a trunnion 12 adapted to slidably fit within a receiver in a comparatively snug, supported, locked position. In general, a pin aperture 13 , or simply an aperture 13 , through the trunnion 12 may receive a pin (not shown) for locking the trunnion 12 with respect to a receiver (not shown).
The trunnion 12 of the apparatus 10 may define certain directions 14 - 24 . The directions 14 - 24 may also define, or be defined by, a vehicle orientation. A longitudinal direction 14 extends in the direction that the trunnion 12 will typically be oriented. A lateral direction 16 is substantially orthogonal to the longitudinal direction 14 . The longitudinal direction 14 and lateral direction 16 define a substantially horizontal plane with respect to a vehicle on a level surface. Of course, all directions 14 - 24 may be aligned with an arbitrary set of reference directions. Accordingly, horizontal and vertical have meaning only by way of example and not by way of limitation.
A transverse direction 18 is substantially orthogonal to the longitudinal direction 14 and the lateral direction 16 . The transverse direction 18 and the longitudinal direction 14 may form or define a first vertical plane. The lateral direction 16 and transverse direction 18 may together define a different vertical plane orthogonal to the first.
With respect to each of the directions 14 , 16 , 18 , rotational directions 20 , 22 , 24 , respectively, may be useful in describing the apparatus 10 . A circumferential direction 20 may describe arcs formed with respect to an axis extending in the axis 14 or longitudinal direction 14 . The circumferential direction 22 may describe arcs formed about the lateral axis 16 or direction 16 . The circumferential direction 24 may describe arcs formed about the transverse axis 18 or direction 18 . As will be clear from the circumferential directions 20 , 22 , 24 , the directions 14 , 16 , 18 may alternatively be referred to as axes 14 , 16 , 18 , respectively.
A trunnion 12 may have a portion thereof defined as a base 26 . Alternatively, a base 26 may actually include a plate, bar, beam, or other structure for strengthening the trunnion 12 . Also, the base 26 may provide a means for attaching a pivot 28 to the trunnion 12 . The pivot 28 may be secured to the trunnion, may be independent therefrom, or may be a removable device 28 . In one embodiment, the pivot 28 is a pin 28 received in and through the base 26 .
A mount 30 , secured by the pivot 28 , is movable with respect to the base 26 . Typically, the mount 30 pivots about the base 26 and about the pivot 28 in a circumferential direction 22 in the embodiment of FIG. 1 .
For convenience, a pivot 28 may be left attached effectively permanently to the base 26 . Likewise, the pivot 28 may secure permanently the mount 30 to the base 26 . In one embodiment, the pivot 28 is removable, but may, as a practical matter, not need to be removed except to perhaps modify the mount 30 .
By leaving the mount 30 secured by the pivot 28 to the base 26 , a lock 32 (sometimes referred to herein as a locking pin) may be easily engaged. The lock 32 may require alignment in a single direction, the circumferential direction 22 about a lateral direction 16 . By promoting and including tolerances suitable for easy alignment, the apparatus 10 may have a lock 32 represented by a single shaft, or the like, to fix the mount 30 with respect to the base 26 and the pivot 28 .
A principal function of the mount 30 is to support a hitch 34 . The hitch 34 may be a ball-type hitch. The hitch 34 is desirably attached opposite the receiver or vehicle end 36 of the trunnion 12 at the load or operational end 38 .
Referring to FIG. 2 , while continuing to refer to FIG. 1 , and more generally to FIGS. 1-8 , a base 26 may be embodied in a block 40 . The block 40 may be drilled, machined, or otherwise worked to provide an aperture or pivot aperture 42 therethrough in a direction 14 , 16 , 18 . In the illustrated embodiment, the aperture 42 extends in a lateral direction 16 .
A deployment aperture or aperture 44 may extend in a direction parallel to that of the pivot aperture 42 in order to receive a lock 32 for securing the mount 30 in a deployed position. In the embodiment of FIGS. 1 and 2 , a stowage aperture 46 opposed to the deployment aperture 44 may receive a lock 32 or locking pin 48 therethrough to secure the mount 30 in a stowed position.
The lock 32 in certain embodiments may be little more than a pin 48 and the pivot 28 may likewise be a suitably sized and fabricated pin 50 . The pins 48 , 50 may be secured by a lynch pin 52 or other type of keeper 54 , respectively. A nut, locknut, key, pin, clip, or other securement mechanism may serve the function of the lynch pin 52 or keeper 54 in securing the pins 48 , 50 .
In one embodiment, the pin 48 may have a head 56 . The head 56 may be integrally formed with the pin 48 or may be welded thereto, threaded thereon, or the like. In one embodiment, the pin 48 may be a monolithic piece of steel of suitable strength and toughness, with the head 56 integrally formed thereon. Similarly, the pivot 28 , embodied as a pin 50 , may include a head 58 . The heads 56 , 58 preclude the pins 48 , 50 from experiencing excessive motion in a lateral direction 16 in their corresponding apertures 42 , 44 , 46 .
A platform 60 may have an aperture (not shown) to act as a pin hitch point or to receive a stud or bolt (not shown) securing the hitch or ball hitch 34 to the platform 60 . The platform 60 may be secured to the mount 30 , or as part of the mount 30 by means of a fastener or weld 62 , such as the weld 62 illustrated.
In one embodiment, a principal portion of the mount 30 may be formed as a beam or pair of beams 64 . In operation and in order to accommodate the geometry of the trunnion 12 , the pin aperture 13 , and so forth, as well as the receiver (not shown) that will receive the trunnion 12 , the beam 64 may have a corner 65 . Thus, the beam 64 may angle between the base 26 and the platform 60 at some suitable orientation. In the embodiments illustrated in FIGS. 3 and 4 the beams 64 have corners 65 formed at right angles. By contrast, the beam 64 in the embodiment of FIGS. 5 and 6 may be formed at a different angle. The angle of the corner 65 may be formed according to good engineering practice and to improve the functionality of the beam 64 in pivoting the mount 30 about the base 26 , without interference with other portions of the apparatus 10 .
The hitch 34 may be a conventional ball hitch. For example, the hitch 34 may have a base 66 formed to fit against the platform 60 . Extending above the base 66 may be an integral or fabricated shank 68 . The shank 68 in a forged hitch 34 is of the same homogeneous material as the ball 70 . In other embodiments, worked metals, such as hot- or cold-worked steel, may be combined in a fabrication to make a base 66 , a shank 68 , and a ball 70 . Nevertheless, in one presently preferred embodiment, the base 66 , shank 68 extending therefrom, and the ball 70 may be formed as a single integral (monolithic), uniform piece.
Typically, a ball 70 may have a flat 72 to provide clearance with a hitch of a towed vehicle. Thus, the load bearing member is supported in all three directions 14 , 16 , 18 by the ball 70 itself. Accordingly, the ball also provides a pivot mechanism. Typically, a hitch 34 may be secured by a stud or bolt (not shown) mounted to the base 66 and secured by a nut 74 opposite the ball 70 through the platform 60 . In certain embodiments, a safety loop may receive a bolt or chain as required by law in some states or a locking pin for orientation during fabrication.
Referring to FIGS. 3 and 4 , while continuing to refer generally to FIGS. 1-8 , the apparatus 10 may include a base 26 that is not rectangular. For example, the pivot 28 securing the mount 30 to the base 26 and trunnion 12 may itself be cylindrical. The mount 30 may have a lock 32 that uses or relies upon a single deployment aperture 44 . For example, a stowage aperture 46 ( FIG. 1 ) may actually be identical to the deployment aperture 44 , but the orientation of the mount 30 about the pivot 28 changes between a deployed position (see FIG. 4 ) and a stowed position (see FIG. 3 ).
As illustrated, the hitch 34 may still be positioned selectively between a stowed position and a deployed position. The pivot 28 , however, may rely on a pin 50 having more functions in certain alternative embodiments. For example, the pin 50 may support the loads in all directions 14 - 24 . By contrast, the loading in the apparatus 10 of FIGS. 1 and 2 is somewhat more complex.
The concept of a lynch pin 52 or keeper 54 ( FIG. 1 ) may still be relied upon. Likewise, a head 58 on the pivot 28 (pivot pin 50 being a specific embodiment) may support a load in a transverse direction 18 , rather than providing retainage in a lateral direction 16 . Nevertheless, as a practical matter, the locking pin 32 may support loads in the transverse direction 18 depending upon the design of clearances between the head 58 and the cylinder 78 of the base 26 . Likewise, the clearance between the locking pin 32 and the aperture 44 through the cylinder 78 and the pin 50 may be significant.
The beam 64 may be monolithic, rather than multiple beams 64 of previously described embodiments. The beam 64 may include a corner 65 in order to orient the platform 60 suitably, while providing clearance for pivoting the hitch 34 between a stowed position (see FIG. 3 ) and a deployed position (see FIG. 4 ). The beam 64 may include a riser or riser portion 80 angled at some interior angle 82 or exterior angle 83 with respect to the platform 60 (see FIG. 6 ).
For convenience, any of the pins 48 , 50 may include a handle 86 for manipulation. When tolerances or clearances are tight, some rotation of a pin 48 , 50 may be beneficial in order to remove or insert the pin 48 , 50 . One additional point concerning the head 58 of the pin 50 is that the head 58 may be either removable or integral. Since the locking pin 32 actually secures the position of the pivot 28 no great risk is presented by the head 58 being threaded or otherwise secured to the pin 50 rather than being secured monolithically. Thus, the pin 50 may be replaceable by one of different length (e.g. height) to provide a desired offset 88 in various embodiments of the apparatus 10 manufactured or sold.
Referring to FIGS. 5 and 6 while continuing to refer generally to FIGS. 1-8 , an apparatus 10 having a first member, such as a trunnion 12 mounted to a base 26 , securing a second member, such as a pivot 28 rotatable about a transverse axis 18 in a circumferential direction 24 , may rely on a lock 32 . The lock 32 may secure the pivot 28 between a stowed position (see FIG. 5 ) and a deployed position (see FIG. 6 ). In the illustrated embodiment, the pin 50 forms a principal element of the pivot 28 in conjunction with the cylinder 78 forming the principal portion of the base 26 . A third member, such as the mount 30 , may include an additional or second pivot 90 . In this embodiment, a more compact profile may position the hitch 34 higher with respect to the trunnion 12 and base 26 , providing more ground clearance between the mount 30 and the ground.
In this alternative embodiment, a fastener or weld 62 , such as a weld 62 , may secure the pivot 90 . The pivot 90 may include a housing 94 receiving a pin 96 therethrough to pivot. The pin 96 may be retained by a keeper 92 , such as a lock ring 92 as illustrated, or the like. Again, the keeper 92 may secure the pin 96 against excessive movement or escape from the housing 94 . Nevertheless, during actual deployment, the security and load bearing to maintain the pin 96 in position are actually the responsibility of the second pin 110 kept in place by a lynch pin or other keeper 112 . Bolts, pins, latches, and other fastening mechanisms may substitute for any of the locks 32 . Nevertheless, as a practical matter, pins 48 , 110 , as well as the head 58 and pivot pin 96 , may be fashioned in any manner suitable for efficient manufacture and function.
In one embodiment, the aperture 97 may extend through the housing 94 and the pin 96 at a single location. Nevertheless, in the embodiment of FIGS. 5 and 6 , the aperture 97 may extend through the pin 96 along mutually orthogonal axis therethrough. Accordingly, the pin 96 may be rotated between a position of deployment with a first ball 70 up and useable and a second deployed position with a second ball 100 up and useable.
In one embodiment, the pivot 28 may rotate the mount 30 to position the ball 70 directly under the trunnion 12 in a stowed position. In an alternative embodiment, the aperture 97 may actually comprise two apertures, positioned at angles substantially orthogonal to one another, through the pin 96 . Thus, the mount 30 may be rotated at right angles along a longitudinal axis 14 and locked there by the pin 110 . Thereafter, the mount 30 may be rotated about a transverse axis 18 of the pin 50 , to position the mount 30 under the trunnion 12 . Thus, the movement of the mount 30 between a deployed position and a stowed position may include two rotations or pivots and two locks 32 , 110 .
One may note that an offset 88 ( FIG. 3 ) characterizing a distance between a platform 60 and a trunnion 12 may be selected in any embodiment of a hitch. However, in certain embodiments, an apparatus 10 in accordance with the invention may provide an offset 102 between the trunnion and the platform 60 or an offset 104 between some dimension or center of the pin 96 and the platform 60 . Thus, the offset 104 may be reversed by rotation of the pin 96 , placing the ball 100 in the upper position with the hitch 34 in the lower position. Thus, the offset 104 may actually be reversed by a rotation on the pin 96 . If the ball 70 and the ball 100 are of different sizes, alternative balls may be mounted-on the same mount 30 . If the balls 70 , 100 are of identical size, the rotation of the pivot pin 96 may provide an elevation difference. Thus, both elevation and ball size may be selectively varied by a user.
A mount 30 pivotably secured to a base 26 portion of a trunnion 12 may support a platform 60 . The platform 60 may receive a bolt or stud for securing thereto a hitch 34 , such as balls 70 , 100 . In certain embodiments, a beam 64 may be formed as part of the mount 30 in order to provide both the pivoting function and the attachment to the base 26 simultaneously with attachment to the hitch. The apparatus may include one or more pins 48 , 50 , 96 , 110 for pivoting the mount 30 with respect to the base 26 , and portions of the mount 30 with respect to other portions of the mount 30 , in order to selectively stow and deploy the hitch 34 . In selected embodiments, additional pivots within the mount mechanism may provide virtually instantly adjustable height of the hitch, without a need for a user to separate load-bearing members of the apparatus 10 from one another. Likewise, a user need not support any substantial portion of the weight of apparatus 10 in order to selectively deploy and stow or to selectively position the hitch 34 .
Referring to FIGS. 7 and 8 , while continuing to refer generally to FIGS. 1-8 , an apparatus 10 having a trunnion 12 supports a pivot 28 rotatable about a transverse axis 18 in a circumferential direction 24 . A lock 32 may secure the pivot 28 between a stowed position and a deployed position. The pin 50 or pivot 50 supports rotation with respect to the trunnion 12 .
In this embodiment, a fastener or weld 62 , such as a weld 62 , may secure a variety of pivots 90 including a housing 94 with a pin 96 for locking. As discussed hereinbefore, the pin 96 may be retained against excessive movement or escape. Similarly, deployment security and load bearing rely on the second pin 110 secured by a lynch pin or other keeper 112 . Again, bolts, pins, latches, and other fasteners may substitute.
The aperture 97 may extend through the housing 94 and the pin 96 at a single location. In the configuration illustrated, the pin 96 may rotate a mounting block 120 between several positions of deployment. For example, the block 120 may present a first ball 70 oriented to protrude up for use. Alternatively, a second deployment position may present a second ball 100 . Similarly a third ball 122 , or more, may secure to one or more apertures 124 in the block 120 .
In one embodiment, the pivot 28 may rotate the block 120 of the mount 30 to position the balls 70 , 100 , 122 directly under the trunnion 12 in a stowed position. The size and geometry of the pin 50 maybe configured to provide a distance 126 or clearance 126 for accepting the block 120 with or without a ball therebetween.
The aperture 97 need only comprise two apertures 97 , or one for each pair of positions (hitches) provided. Thus, the mount 30 may be rotated at right angles along a longitudinal axis 14 and locked there by the pin 110 . Rotating about a transverse axis 18 of the pin 50 positions the mount 30 under the trunnion 12 . As with the simpler version, movement between a deployed position and a plurality of stowed positions may be accomplished by only two rotations and two locking pins 32 , 110 .
In the embodiment of FIGS. 7 and 8 , the block 120 need not be symmetrical. Thus, offsets 102 , 104 , or the like may be built into any dimension of the block 120 to provide various heights for balls 70 , 100 , 122 . Balls 70 , 100 , 122 may be of different sizes, positioned at different heights, or both. That is, balls 70 , 100 , 122 of different sizes may be pivoted into position selectively. Alternatively, offsets 102 , 104 may position balls 70 , 100 , 122 at different heights. Alternatively, certain of the balls 70 , 100 , 122 may be of identical size, others of different sizes, with all positionable by rotation of the pivot pin 96 to provide the predetermined choice of balls 70 , 100 , 122 and height selected by a user.
From the above discussion, it will be appreciated that the present invention provides a trunnion supporting a base. On the base, a pivot secures a mount that may be selectively positioned between a stowed and a deployed position.
The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention is, therefore, indicated by the appended claims, rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
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A trunnion, adapted to fit in a receiver, attached to a vehicle as a receiver-type hitch system, provides selective deployment and stowage of a hitch. An optional base secured to the trunnion may receive a pivot. A mount, secured by the pivot to the base, swings between a deployed and a stowed position. Alignments are one-dimensional, typically circumferentially positioning a locking pin aperture and a corresponding locking pin about a radius with respect to a pivot axis. A platform of the mount may contain an aperture for operating as a pin hitch aperture or for receiving a stud or bolt for securing a ball hitch or two hitches. In certain embodiments, multiple ball hitches may be attached at once to the platform. Selection of ball hitch sizes and positioning of the ball hitch altitude may also be accomplished by pivots built into the mount.
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PRIORITY
[0001] The present Application claims benefit of priority from Provisional Application 61/138,010, which was filed with the United States Patent and Trademark Office on Dec. 16, 2008.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates to optical and infra-red sensor equipment. Specifically, the present invention relates to metallized coatings for sensor windows to allow for effective transmission of optical and infra-red radiation while providing good electro-magnetic shielding.
BACKGROUND
[0003] Untreated optical-quality windows for optical and infrared sensors and for laser transmit/receive systems are often electrically clear, having no exterior surface conductivity and therefore unable to shield sensitive internal components from electromagnetic interference (EMI) or electromagnetic pulses (EMP). A conductive surface coating applied to a sensor window may be used to pass optical energy while blocking EMI/EMP energy, by conducting it directly to the surrounding window frame. Such a conductive coating is typically made of metal or metallic film. Continuous metal films have reasonably good visible-light transmission, but have poor to zero infrared transmission. Therefore, the metallized windows may meet EMI/EMP requirements, but cannot meet broadband optical/infrared transmission requirements.
[0004] Conventionally known solutions widely used in the aircraft and electromagnetic industry involve the application of straight-line wire meshes or photolithographic grids to the optical window glass. The open spaces between the wires or grid lines do not affect the passage of visible light and infra-red energy through the sensor window, while the wires or grid lines, which are thermally and visually opaque, conduct the majority of EMI/EMP RF energy away to the window frame. These straight-line meshes and grids provide adequate EMI/EMP shielding, but the grid and wire patterns they employ generate significant scattering and diffraction of transmitted optical and IR energy. These traditional approaches also had problems when operated away from normal incidence angles, as light transmission dropped and optical scattering increased rapidly with increasing incidence angle.
[0005] In searching for improvements to the above-stated problems, Lockheed Martin developed a new form of conductive pattern termed “hub-spoke” in the early 1990's that was a hybrid of very small metallic film circles, deposited 1 to 2 microns thick, with 10 micron widths and 200-300 micron circle diameters, with straight-line interconnectors. This Lockheed Martin-originated pattern was implemented at Battelle Laboratories, Columbus Ohio, and has been widely applied to a number of military platforms. The center positions for each of the circles (termed “hubs”) was slightly randomized, and the circles did not overlap, but were instead electrically connected with very short straight-line segments, termed “spokes”, having angles that were randomized as well. This new grid pattern greatly reduced optical scattering and diffraction relative to earlier straight-line meshes and grids, while providing the equivalent EMI/EMP shielding.
[0006] The hub-spoke arrangement, however, was still subject to particular diffraction effects associated with grid-like structures. Specifically, the hub-spoke pattern contained many straight-line segments and had a relatively regular pattern. Off-normal operation, even with this pattern, continued to produce significant drops in light transmission and increases in scattering. Despite having a less regular and less angular arrangement, the hub-spoke pattern still contained many of the disadvantages of predecessor grids, albeit to a lesser degree.
INVENTION SUMMARY
[0007] The hub-spoke conductive pattern was the first step away from traditional straight-line wire meshes and grids toward reduced-scattering conductive grids. It was later determined that the spokes, first believed to be necessary to provide electrical continuity between all circles, remained a source of excessive optical scattering and diffraction, even if their angular orientation was totally randomized. It was also first believed that the hubs should be spatially separated and not overlapping, but instead connected with the straight-line spokes. This too was later proven to be overly constraining. Only overlapping ellipses (and/or circles, which are merely ellipses whose major and minor axes are of equal length) were required to provide the necessary EMI/EMP shielding, while generating significantly less diffraction scattering.
[0008] The present invention eliminates the spokes and allows the circles and/or ellipses to overlap. Elimination of the spokes eliminates all sources of −13 dB side lobe scattering characteristic of straight-line diffraction. Overlap of the ellipses and circles may be accomplished by uniformly randomizing the positions of the ellipse centers over the window aperture. In some embodiments, the diameters of the circles, the ratio of minor to major axes for the ellipses, and the orientation of the ellipse major axes, may be randomized as well. This new form of conductive pattern, composed of overlapping ellipses, is generally termed the Randomized Circular Grid, or RCG. Advantages of the inventive pattern include improved overall infra-red transmission and significant reductions in both optical and infra-red diffraction across all incidence angles through the elimination of straight edges from the metallized coating of the sensor window.
[0009] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF DRAWINGS
[0010] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
[0011] FIG. 1 a shows a prior art hub-spoke conductive pattern;
[0012] FIG. 1 b shows a close-up view of a prior art hub-spoke pattern;
[0013] FIG. 2 shows a conductive pattern in a randomized circle grid according to the present invention;
[0014] FIG. 3 shows an alternative conductive pattern mixing randomized circles and ellipses according to the present invention;
[0015] FIG. 4 shows an embodiment of a grid arrangement and creation process according to the present invention;
[0016] FIG. 5 shows an embodiment of a grid having a non-uniform pattern density; and
[0017] FIG. 6 shows an embodiment of a grid having a multi-layer structure.
[0018] The drawings will be described in detail in the course of the detailed description of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The following detailed description of the invention refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. Also, the following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims and equivalents thereof.
[0020] FIG. 1 a depicts a prior art hub-spoke metallization pattern on an optical sensor window. As can be seen in the diagram, the entire sensor window is covered with a metallized hub-spoke pattern for EMI shielding.
[0021] FIG. 1 b shows the hub-spoke pattern in more detail. As can be seen, the solid circles, or “hubs” 110 are connected to each-other (and therefore to any eventual ground or dissipation means) by spokes 120 . This ensures that there are no electrically isolated metallized circles on the sensor window. The remaining un-metallized portions 130 allow both optical and infra-red radiation to pass through the sensor window.
[0022] Through the use of Fourier analysis, it was determined that the spokes in the hub-spoke grid were actually detrimental and should be eliminated, and that the circles could indeed overlap, rather than having to be arranged in tangential, non-overlapping contact with adjacent circles. Elimination of the spokes eliminated all sources of −13 dB side lobe scattering characteristic of straight-line diffraction.
[0023] FIG. 2 shows an embodiment of a spoke-free optical sensor window elliptical metallization pattern according to the present invention. The embodiment depicted uses circle shapes. Each circle 210 may be made of an electro-magnetically opaque metal or metallic substance such as gold, aluminum, platinum, various resistive alloys, graphite, or other similar materials. Some embodiments may also employ an appropriate interfacing primer coating to the substrate to increase bonding durability. The optical substrate 220 between the circles is not coated with conductive material. As can be seen from the diagram, the positions of the circle centers are not uniformly spaced, but instead are uniformly randomized over the window aperture. In the embodiment shown, the circles in the pattern are electrically continuous to each other, with no floating “islands” (clumps of circles contiguous to each other but not to the rest of the grid). Embodiments of RF absorptive mesh patterns utilizing RCG meshes that deliberately utilize RF-resonant organization of clumps of either conductive or resistive circle patterns may also be generated according to the present invention.
[0024] In the embodiment depicted, the diameters of the circle centers were randomized using a Gaussian randomization over a roughly 3× range (typically 200-600 microns with 400 micron mean diameter). The positions of the circles are preferably randomized to some extent to reduce periodicity in the pattern, thereby reducing potentially detrimental effects of laser diffraction sidelobe reinforcement and contrast reduction in sensor imagery. Other embodiments may use different randomization methods, but embodiments using randomized shape size, orientation and location distribution are generally preferred over embodiments having a discernible, repeating pattern. Some embodiments may use elliptical shapes or combinations of elliptical shapes and circles. Also, an embodiment with a randomized metallization pattern is easier to produce as it requires a lesser degree of precision than one having a regular pattern, such as a pattern where all the circles are uniformly sized and tangent without overlapping.
[0025] FIG. 3 shows an embodiment of a spoke-free optical sensor window metallization according to the present invention that employs a randomized elliptical grid metallization pattern. Embodiments of randomization in elliptical grid approaches may include slight randomization of the ratio of minor to major axes and/or changes to the angular orientation of the major axes of the ellipses. Further embodiments may allow for mixed approaches using circles and ellipses.
[0026] Embodiments using randomization may further reduce generation of discernable structure in far-field diffraction patterns. In an embodiment of a conductive EMI/EMP mesh, the individual metallized ellipses are preferably electrically continuous to each other, with no floating “islands” (clumps of ellipses contiguous to each other but not to the rest of the grid). Embodiments of RF absorptive mesh patterns utilizing randomized elliptical meshes of either conductive or resistive materials with ellipses arranged in electrically isolated RF-resonant patterns may also be generated according to the present invention. In the embodiment depicted, both the ratio of the minor and major axes as well as the angular orientation of the ellipses 310 may be varied in addition to randomly dispersing them on the sensor window. The clear areas 320 are the un-metallized portions of the sensor window. The ellipses 310 depicted in this embodiment are therefore hollow in order to minimally obscure the passage of electro-optical radiation through the metallized sensor window. In the embodiment depicted, there are preferably no straight lines to generate straight-line diffraction effects, and no readily discernible pattern that may cause consistent or specific diffraction or noise under normal operating conditions.
[0027] Embodiments of metallizations similar to those depicted in FIGS. 2 and 3 may be fabricated with 1-2 micron deposition thickness and a nominal 10 micron feature width for the metallization. Fabrication techniques may include etching, plating, lithography, chemical or plasma vapor deposition, sputtering, screen printing, and any other suitable technique for the creation of patterned metallization layers. An embodiment of a metallization pattern according to the present invention may be created using a variety of tools aid techniques, including using calculation algorithms based on particular random distributions and/or seed values that may indicate or be predicated on any of: a desired pattern density, overall shape size, extent of variation in shape size, extent of variation in shape orientation, desired average major or minor axis values, level of variation in major or minor axis values, average thickness of a deposited shape, level of variation in shape thickness, and any gradation or change in one or more of the preceding parameters throughout the metallization pattern.
[0028] An embodiment of a pattern generation and fabrication process is depicted in the flowchart on FIG. 4 . The metallization pattern generation 410 process may be divided into steps of selecting seed values for shapes 4101 , selecting a shape distribution scheme 4105 , and selecting a shape variation scheme 4109 . Embodiments of seed values for shapes may include ranges or baseline values for the major and minor ellipse axes, ranges or baseline values for ellipse rotation angles, and ranges or baseline values for shape outline thickness. Further embodiments may include a specific “circles only” or “no circles” feature allowing selection of only circle shapes (ellipses having equal major and minor axes) or suppression of the same. Yet further embodiments may include desired average shape size and rotation values with configurable standard deviation sizes or preset probability distribution curves. Yet further embodiments may permit a desired mean or mode associated with one or more seed values. Some further embodiments may replace or supplement seed values or variation ranges with automatically calculated values based on known or expected performance requirements
[0029] Embodiments of selecting a shape distribution scheme 4105 may include selecting one or more desired baseline or average pattern densities or pattern density ranges. Some embodiments may allow the selection of multiple pattern densities for different local areas of a metallization pattern. Other embodiments may permit the establishment of pattern density gradations and directions such as an increasing or decreasing density value in a particular direction. Embodiments may include selecting a pattern density seed value as a center value in an increasing or decreasing gradation moving across a sensor window or starting from a particular point on the window and radiating outward in two or more directions. Yet further embodiments may have multiple gradations and gradation directions associated with multiple pattern spread directions, such as a pattern originating from a corner of a rectangular window and having increasing density in an x-direction and decreasing density in a y-direction. Yet further embodiments may employ arbitrary origination points or seed points and may employ multiple non-orthogonal spread directions.
[0030] Some embodiments may replace or supplement seed values with automatically calculated values based on known or expected performance requirements. In some further embodiments, pattern density may be increased toward the edge of an optical substrate aperture to synthesize electrical tapering for better impedance matching to the surrounding support frame. An embodiment having increased pattern density towards the edge of a sensor window is depicted in FIG. 5 . Yet further embodiments may include selecting or generating a probability distribution curve based on seed values or automatically calculated values based on performance requirements. Some embodiments may include multiple distribution curves for different local areas of a sensor window. Probability distribution curves may be linear, Gaussian, skewed, logarithmic, or of any other suitable form based on operating requirements and/or design specifications.
[0031] Embodiments of selecting a shape variation scheme 4109 may include selecting or generating probability functions associated with the seed values, ranges, or automatically calculated values generated in the selecting seed values 4101 step. As with embodiments of selecting a shape distribution, embodiments of probability curves dictating shape variation types and ranges may be associated with a pattern or local pattern areas and may further have associated gradients dictating changes in variation range across a pattern or local pattern area. Some embodiments of selecting shape variation schemes may also employ differing deposition thicknesses and/or feature widths to spatially vary RF conductivity or absorptivity. Feature widths may include the sizes of major and minor ellipse axes.
[0032] In the embodiment shown, after a metallization pattern is generated 410 , the substrate receiving the metallization may need to be prepared 420 . For embodiments where a substrate is a sensor window, preparation may include various forms of cleaning (chemical cleaning, plasma cleaning, polishing). Some embodiments may include applying light-absorbing or non-reflective coatings to the sensor window substrate. Further embodiments may include plating the entire substrate with the metallization or applying a precursor layer to those portions of the substrate that will eventually be metallized. In some embodiments, the process of substrate preparation may be omitted or included as part of metallization application 430 .
[0033] In some embodiments, once the substrate is prepared, the metallization pattern may be applied or created 430 . For embodiments where a substrate is fully metallized during substrate preparation, embodiments of pattern creation may include application of masks or templates and an etching process to remove the unwanted portions of the metallization. Alternate embodiments may include chemical or plasma deposition, lithography, screen printing, sputtering, or plating onto prepared or masked-out areas. Embodiments having precursor layers may also employ etching to selectively remove portions of a blanket metallization layer and, in some embodiments, portions of underlying layers.
[0034] Embodiments using circles produce Bessel function diffraction side lobes beginning at about 17 dB below the main lobe. This is fully 4 dB lower than the sin(x)/x diffraction side lobes caused by straight-line hub-spoke segments, which have main side lobes 13 dB down from the main lobe. Embodiments using elliptical patterns produce diffraction sidelobes at similar levels, with the sidelobe ellipticity oriented 90 degrees to each pattern ellipse orientation. Gaussian randomization of the circle radii and/or ellipse major and minor axes and major axis orientations about a mean value may, in some embodiments, further smooth and broaden the 17 dB sidelobes, improving the uniformity of the far-field diffraction pattern. Although shapes having straight edges may be employed in some embodiments of randomized grid patterns, the presence of the straight edges in the shapes may lead to increased diffraction. Embodiments using a circular or mixed circular/elliptical grid without straight edges are therefore preferable for their reduced levels of diffraction.
[0035] Grid embodiments that reduce or eliminate the spokes of the hub-spoke design realize reductions in scattering and haze. The scattered haze produced by propagation through an embodiment of an RCG pattern may be one-fourth the scattering produced by a traditional straight-line mesh or grid of equal EMI/EMP shielding, and may be several dB lower than the hub-spoke pattern. Specific amounts of scattering and haze reduction may vary based on the particular pattern distribution used in an embodiment. In embodiments where circle centers are uniformly spaced in X and Y, the resulting periodicity may coherently add up in the far field to produce undesirable diffraction side lobes and modulation transfer function effects. In embodiments where the positions of the circles or ellipses are randomized while guaranteeing continuous electrical conductivity, the diffraction side lobes and periodic image structure may be eliminated, allowing for substantially improved broadband optical/IR images for a given conductivity. In some randomized embodiments, circle or ellipse randomization may be accomplished with a uniform probability distribution.
[0036] In embodiments seeking to achieve higher conductivity and lower sheet resistance, more random circles and ellipses may be applied, with an attendant reduction in optical/IR transmission. Embodiments seeking to achieve non-uniform conductivity, such as, for example, increasing the conductivity toward the window frame in a gradual taper for better broadband RF impedance matching between an optical window or lens and its surrounding frame, more circles and ellipses may be applied at the periphery of the window or lens than at the center.
[0037] For embodiments configured to detect incident laser radiation, such as in a semi-active laser (SAL) seeker device, laser reflections from a randomized circular grid may be greatly reduced by embodiments having multiple layers, beginning with a light-absorbing surface binder directly on the exterior glass surface. An embodiment of such a multi-layered structure is depicted in FIG. 6 . In the embodiment shown, a first light-absorbing layer 620 disposed on the exterior glass surface 630 may be followed by a primer layer 610 that promotes better adherence of the conductive or resistive material 601 to the absorbing layer. Embodiments using a thin deposition thickness and randomization of metallized ellipses may exhibit reduced sensitivity to incidence angle, thereby minimizing reflection of incident laser signal. Such measures are especially advantageous in laser-guided munitions applications where signal reflection may reveal the trajectory of a munition (and therefore allow for location or identification of the source of said munition). Reflection of laser radiation may also lead to discrepancies in target tracking on the part of the munition or other, nearby, similarly-guided munitions, so a solution that reduces or eliminates reflection of laser radiation from the surface metallization of an optical sensor window would clearly be advantageous. In some embodiments, the primer 610 as well as the metallization 601 may be patterned. In further embodiments, a light-absorbing binder layer 620 may cover the entire substrate 630 to provide improved light absorption and reduced reflection or glare.
[0038] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A randomized elliptical grid disposed on a sensor window for electro-magnetic and/or radio-frequency shielding of sensors, and a method of applying same. Grids may be made of electrically conductive or resistive material and may include elliptical or circular shapes. The shapes are in physical contact with each-other and preferably do not contain straight lines to reduce detection artifacts caused by the coating. Grid element shape, size, orientation, and grid pattern density may be randomized or varied across a sensor window.
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BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for remotely detecting the presence of certain gases in earth atmosphere and their location relative to fixed reference points on the ground.
Detection of hydrocarbon gases seeping from underground oil and gas deposits is of great importance to oil and gas prospectors. Other situations where the detection of a gas in the air is important include, for example, leaks in natural gas pipelines of underground gas lines as well as leaks of industrial gases or volatile materials from chemical reactors, storage tanks and railroad cars.
Various methods of gas detection are available. Most of those require sampling of air near the suspected leak or seepage area and gas analysis by a suitable technique. Detection methods which do not require sampling use, among others, infrared scanners, microwave reflection systems, or optical systems responsive to bioluminescence. An ideal technique should be sufficiently sensitive to detect trace gas concentrations in the air; sufficiently specific to reduce uncertainty as to the gas identity; and sufficiently versatile to be useful for remote surveying of both small, limited areas, such as a building or a pipe and large areas, such as a prospective oil field or plant site.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a method and an apparatus for detecting the presence in the atmosphere of a gas which absorbs or emits infrared radiation within a defined wavelength region and determining its location with respect to at least one fixed background reference point, wherein:
(a) a number of points within a circumscribed background area, which are at a temperature different from the average temperature of the intervening atmosphere are viewed by the imaging optics of a dual sensor system imaging-analyzing means capable of generating electrical output signals that are responsive to the resulting net radiative flux transmitted through the atmosphere;
the first sensor system having a higher sensitivity and the second sensor system having a lower sensitivity to the gas of interest in the defined infrared wavelength region;
(b) the amplitudes of the output signals generated by said sensor systems are continuously or repeatedly ratioed within the defined infrared wavelength region; and
(c) an image signal responsive to the ratio of said output signal amplitudes is produced, said image signal being displayed on a display means, the image indicating the presence of the gas of interest at one or more points within the circumscribed area being surveyed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a suitable infrared imaging-analyzing means and its associated electronic equipment.
FIG. 2 is a circuit diagram of certain electronic components indicated as numbered blocks in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
A gas which can be detected according to the method of this invention must have at least one known characteristic infrared absorption or emission region which would permit its positive identification. As is well known, infrared absorption peaks are located at exactly the same wavelengths in a chemical compound's spectrum as its infrared emisson peaks. Thus, for example, methane has an infrared spectrum which contains a series of very sharp peaks between 7.2 and 8.2 μm. All of those peaks can be selected for the identification of methane. Other gases which have well defined infrared absorption or emission regions include, for example, ammonia, ethylene, propane, sulfur dioxide, and water.
The equipment which is used in the practice of the present invention consists of a dual-detector infrared imaging-analyzing means and associated instrumentation. A block diagram of this equipment is shown in FIG. 1. Block I.A. schematically represents the essential parts of the preferred type of imaging-analyzing means, which are: analytic sensor means 1 consisting of lens a*, infrared detector b, and preamplifier c*; reference sensor means 2 consisting of lens a'*, infrared detector b', and amplifier c'*; gas filter 3; beam splitter 4; mirror 5*; and imaging optics 6*. The imaging-analyzing means I.A. can typically be a Model 210 dual-channel thermal imaging system of Inframetrics Inc., Bedford, Mass., modified by displacing the reference sensor means 2 along the incoming infrared beam path to allow space for gas filter 3. Furthermore, the original wavelength-selective beam splitter is replaced by a substantially spectrally neutral beam splitter which does not discriminate by wavelength. Beam splitter 4 is made of germanium and coated on one side with an antireflective material. This beam splitter reflects about 36% and transmits about 64% of incident light. Lenses a* and a'* are condensing lenses, which have a focal length of about 1 cm, so that they cause convergent beams to fall on the detector. Matched detectors b and b' are of the mercury-cadmium telluride type and have their highest sensitivity to infrared radiation within the 8-12 μm region. They are cooled with liquid nitrogen. Gas filter 3, which is inserted in the light path of the reference sensor system, normally would be filled with the gas of interest. However, a device such as, for example, a carousel containing a selection of reference gases may be installed instead. With such an apparatus, it is possible to determine the presence and location of two or more gases in turn. As a result of loss of some light intensity in the reference sensor system due to the filter as well as to a longer path, the amount of radiation which actually reaches the reference detector b' is about the same as that reaching the analytic detector b. Micrometer adjustable registration means (not shown) are used to bring the images of the scenes viewed by the detectors into exact coincidence. The imaging optics module 6* contains an opening for viewing the area of interest and a system of two oscillating mirrors, which convert a linear scan into a two-dimensional image. Normally, this module is equipped with a suitable lens, which may be of a fixed focal length or a zoom type. Imager control electronics module 6a* controls the scan rate and synchronization.
It has been found advantageous to design an electronic circuit, E.C., especially adapted to the needs of this invention, so that only certain electronic components of the original Inframetrics equipment have been retained and others have been added. The original Inframetrics components are indicated in FIG. 1 by an asterisk. This redesigned circuit includes clamps (D.C. restorer circuits) 7* and 8*, which convert an AC-coupled signal from detector output to a thermally adjusted reference signal; variable gain amplifiers 9 and 10; automatic gain controls 11 and 12; analytical bias level control 13; amplifier 11a; analog-to-digital (A/D) converter 18a*; reference bias level control 14; ratioing analog-to-digital (A/D) converter 15; buffer 16; scan inverter memories 17* and 18*; digital-to-analog (D/A) conveters 18b*, 19, and 20, wherein the ratio output at 19 can be used for testing, calibrating or adjusting the circuit's performance; signal processor 21; color formulator 22; color encoder 23; image processor 24 which is considered to be optional; video monitor 25; and video recorder 26. Optionally, a properly scaled temperature monitoring radiometer 27 may be connected to the bias level control 13.
Equipment not originally supplied with the infrared thermal scanner can be either obtained commercially or built from commercially available components. For example, color encoder 23, which converts red, green, and blue (RGB) inputs into the standard NTSC (National Television System Committee) signal, is LENCO model CCE 850. The color encoder 23 is required in this case because an NTSC TV monitor is used as a video display. The video monitor 25 is Sony PVM 8000 and the video recorder 26 is JVC CR-4400 LU.
In the practical operation of the method of the present invention, the imaging-analyzing means, I.A., and some or all of the associated electronic equipment, E.C., are mounted either in a stationary location or in an aircraft or ground vehicle. The imaging-optics is directed at the area under surveillance and receives the net infrared radiation absorbed or emitted by the intervening atmosphere and background such as buildings, water surfaces, and any objects or vegetation therein. Referring now to FIG. 1, the infrared image is scanned pixel by pixel by a beam formed in the optics module 6*. The scanning beam is then split into two beams, one which is reflected to sensor means 1 and the other one transmitted and reflected to sensor means 2 by beam splitter 4 and mirror 5*, respectively. Since the transmitted beam passes through gas filter 3, which contains the gas of interest, a portion of the total radiation that is transmitted by the beam splitter is attenuated in the region of the infrared absorption of the gas of interest. The baseline of the signal exiting the analytic sensor means 1, A.S., and the signal exiting the reference sensor means 2, R.S., are first independently thermally compensated by clamps 7* and 8* to a repetitive, reference flag level signal. Each D.C restored signal is further biased by subtracting at the input terminal of variable gain amplifiers 9 and 10 an empirically determined constant value furnished by controls 13 and 14. The biased signals are then passed through automatic gain controls 11 and 12, respectively. Ratioing A/D converter 15 generates a ratio of the biased analytic and reference signals in digital form. After passing first through buffer 16, the digitized ratio signal is split into two paths. A first portion is reconverted back to analog form in D/A converter 19. A monitoring device (not shown) may be attached at the output of converter 19, if desired. The other portion passes to the scan converter memory 17* and is then changed from the digital to analog form by converter 20 for input to signal processor 21. Meanwhile a portion of the biased analytic output signal is input to the scan converter memory 18* via amplifier 11a and converter 18a*. After conversion by D/A converter 18b*, the output signal from D/A converter 18b*, and the ratio output signal from signal processor 21 are combined in color formulator 22. This circuit prepares for display the sum of these two signals as functions of the intensity levels of the selected red, blue, and green colors.
The overall function of the electronic equipment associated with the thermal imaging system is to automatically regulate the average or, optionally, peak amplitudes of the analytic and reference signals and compute the pixel-by-pixel instantaneous ratios of the images generated in the imaging system unit shown as block I.A. in FIG. 1, to produce a composite image signal which is indicative of both the location and concentration of the gas of interest. However, processing of the image signals does not necessarily have to take place at the same instant as their formation. The signals may be recorded and processed at a different time or location.
Referring now to FIGS. 1 and 2, the signal from sensor means 2 is transmitted, via the line marked R.S. in FIG. 1, to clamping circuit 8* (not shown in FIG. 2), where it is amplified and clamped to a reference flag temperature. (Clamping circuits are well known in the art, and therefore no further description will be provided of block 8*.) In general, a clamping circuit references a waveform to a given potential. The amplitude of the clamped signal leaving block 8* is approximately 10 mV/°C., which is input to block 10, via the line marked R in FIG. 1. Block 10, shown in greater detail in FIG. 2, is known in the art as an inverting-adder variable gain operational amplifier. Principally, it comprises a resistor R in its feedback circuit whose value changes depending upon the brightness of light-emitting diode L. Also input to amplifier 10 is a constant voltage proportional to the potentiometer settings C 2 and C 1 , represented by blocks 13 and 14, respectively in FIG. 1. The voltage level selected for input to these cascaded potentiometers (FIG. 2) was selected to cover the expected temperature ranges and approximate the effect of the radiometer block 27 (FIG. 1), intended to compensate for an effect of the intervening atmosphere to be described later. The proper settings of C 2 and C 1 are obtained empirically by adjusting the potentiometers while viewing the image at a scene having in it no gas of interest. The output of variable gain amplifier 10 is K 10 (R-C 1 ), where R is the reference signal; C 1 is the bias voltage from potentiometer block 14; and K 10 is the instantaneous gain of amplifier 10 which is determined by the ratio of the values of feedback-connected photoresistor r and the 1KΩ input resistor. This output signal voltage is compared against a constant +1 volt reference signal at the inverting terminal of operational amplifier 12 to obtain a difference signal. Operational amplifier 12, which is configured as an integrator, controls the automatic gain control loop. It integrates the difference signal and applies the resultant output voltage to vary the current through light-emitting diode L, which in turn changes the value of photoresistor r until the output of amplifier 10 averages -1 volt. Time averaging of the automatic gain control signal, effected by amplifier 12, will occur at a rate defined by the value of integrating feedback capacitor C (FIG. 2).
In like manner, variable gain amplifier 9 receives the signal from the analytic-detector channel, via the line marked A.S. in FIG. 1 and the thermal clamping circuit 7* (part of the commercial unit, and not shown in FIG. 2). Amplifier 9 also receives bias voltage signal C 2 from potentiometer 13 (FIG. 1). Amplifier 9 is also an operational amplifier, with a similar feedback circuit, including resistor r' and light emitting diode L'. Similarly, operational amplifier 11 functions as an integrator with capacitor C' to provide automatic gain control. Thus, the signal (A-C 2 ) is amplified by amplifier 9 as a function of gain K 9 until it averages -2 volts, where A is the signal from the analytic detector and C 2 the voltage from block 13. Signals K 10 (R-C 1 ) and K 9 (A-C 2 ) are input to the IN and REF terminals, respectively, of A/D converter 15 (a commercial unit of TRW Corporation, Model TDC 1007J) and produces a digital output proportional to K 10 (R-C 1 )/K 9 (A-C 2 ). This ratio signal is buffered by block 16, which comprises non-inverting digital power drivers, before it is sent to memory 17*. Memory 17* serves to scan-convert this ratio signal from a reciprocating scanned signal to a raster-scanned signal. The ratio is monitored by D/A 19 (a TRW Corp, unit, Model TDC 1016J), whereas Memory 17* output is converted by D/A converter 20 into an analog voltage for use by color formulator 22 after amplification by amplifier 21. The signal K 9 (A-C 2 ) is similarly amplified by amplifier 11a and converted to digital form by A/D converter 18a* (typically TRW Corp. Unit Model TDC 1014J) for loading into memory 18*.
When the gas of interest occupies a large portion of the scene, the automatic gain control (AGC) will tend to reduce the sensitivity of the equipment to changes in gas concentration. Improved performance of the analyzer can be obtained by opening coupled switches S and S' in the feedback loops at the input terminals of integrators 11 and 12, respectively.
When the gas of interest is absent, the output of D/A 20 usually will be a constant other than zero. The zero control Z of amplifier 21 is used to null this constant and thus to zero-adjust the analyzer.
The output of memory 18*, converted by a digital to analog converter 18b* is tied into amplifiers 22, as equal inputs to the Green, Red and Blue color-encoder input terminals. When the presence of gas causes a change of the ratio K 10 (R-C 1 )/K 9 (A-C 2 ), the contribution of the gas signal can be selectively set by switches S 1 , S 2 , and S 3 to any color input. Invert-control I on D/A 20 helps the viewer to specify the location of the gas in the image by providing either positive or negative deviation about the ratio zero-set value.
Since the arrangement of blocks 23-26 in FIG. 1 is optional, and since their functions have already been discussed above, they are not shown in FIG. 2.
The image of the terrain, which is received from scan converter memory 18*, is encoded as a gray scale image, while the ratio output from signal processor 21 can be encoded in color so that a cloud corresponding to the gas of interest appears on the screen of monitor 25 superimposed on the topographic picture of the terrain. The color intensity of the gas cloud will roughly correspond to the gas concentration in the atmosphere.
As an alternative to imaging, the raw A and R signals at the output terminals of clamps 7* and 8*, respectively, can be separately biased and averaged over a number of image frames. The ratio of the averaged signals (A-C 2 )/(R-C 1 ) can then be observed on a meter or converted to an audio signal indicating the presence of the gas.
It is to be noted that, instead of gas filter 3 placed next to the reference sensor system 2, one can have one or more interference filters placed in either sensor system or different interference filters placed in each sensor system. Although each filtering system will produce a different result, the net effect will be the same, that is, one sensor system will have greater sensitivity than the other to the gas of interest within the defined infrared wavelength region. The infrared wavelength region is chosen for each gas of interest so that the gas has a significant characteristic infrared spectral absorption or emission within that region. It may cover the complete infrared range for the gas of interest or only a portion of it, usually that where the characteristic infrared spectral emission or absorption of the gas of interest is the strongest.
The detection method of the present invention is based on the following theoretical considerations:
It shall be assumed that the background (e.g., earth surface, buildings, or bodies of water) and the intervening atmosphere between the background and the infrared radiation detection system are potentially at different but uniform temperatures. An above-ground sensor will receive radiation from three sources: the background emission, radiation reflected from the background, and intervening atmosphere emission or absorption (plus scattering). The total apparent radiance, L, reaching the analyzer for a given field of view can be expressed by the following equation (1): ##EQU1## where:
λ is the wavelength;
τ(λ) is the spectral transmittance of the intervening atmosphere;
ε(λ) is the spectral emissivity of the non-black body background;
M.sub.λ is the spectral radiant emittance of a black body at the temperature of the background; W/cm 2 /μm;
E.sub.λ (sky) is the downwelling spectral irradiance of the object under observation; W/cm 2 /λm; and
M.sub.λ (air) is the spectral emittance of a black body at the temperature of the intervening atmosphere; W/cm 2 /λm.
According to Beer's law:
τ(λ)=e.sup.-k(λ)ct (2)
where
k(λ) is the absorption coefficient of the intervening atmosphere;
c is the concentration of the absorbing medium; and
t is the path length of the intervening atmosphere.
Substituting the above exponential term for τ(λ) in equation (1), one gets: ##EQU2## where r(λ)=1-ε(λ)=the background reflectivity. This is so because the conservation of energy requires r(λ)+α(λ)+τ(λ)=1, where α(λ) is the absorptivity. Furthermore, from Kirchhoff's law, α(λ)=ε(λ) and for an opaque background, τ(λ)=0.
The above equation (3) can be written in the following form: ##EQU3## where I.sub.λ is a function which includes the background image, while K is a function of air temperature only.
Equation (4) can be approximated by
L=K+Ie.sup.-kct (5),
where k is the effective average absorption coefficient, and I is the effective average value of I.sub.λ.
With a dual channel imager-analyzer of the type described above, where the analytic channel is sensitive to the absorbing medium (i.e., k>>0), and the reference channel is insensitive to the same absorbing medium (i.e., k≈0), equation (5) can be expressed as follows for each channel:
Analytic: L.sub.A =K.sub.A +I.sub.A e.sup.-kct (6)
and Reference: L.sub.R =K.sub.R +I.sub.R (7)
Rearranging equations (6) and (7) and dividing the former by the latter, one has: ##EQU4## Since the emittance and irradiance terms vary slowly and essentially in synchronism with one another with respect to a chosen scene we can assume that
I.sub.A =fI.sub.R (9)
where f is a constant.
Finally, substituting equation (9) into equation (8), one obtains: ##EQU5##
Since this biased relationship is independent of the image terms I A and I R , it becomes now a function only of concentration and path length, ct.
Since the K terms are dependent on air temperature, this information can be supplied by a radiometer aimed at the air in a highly absorbing wavelength region. Under controlled conditions, when the air temperature does not change much over a short period, it is possible to replace the radiometer with a constant, which can be determined separately or automatically, as part of the measurement. The electronic equipment illustrated in FIGS. 1 and 2 permits operation without a radiometer using a preset bias voltage value, V.
The net effect of biasing the radiance signal is to provide for a more complete removal of all but the atmospheric absorption or emission effects.
It is not necessary for the purpose of this invention that the temperature of the background always be higher than the average temperature of the intervening atmosphere; the average temperature of the intervening atmosphere may equally well be higher than that of the background, and the only difference in the result will be the change of polarity of the output signals produced by the sensor systems. The present technique is sensitive to infrared radiation whether absorbed or emitted by the gas of interest. The imaging requirement is merely the existence of a temperature difference between the background and the atmosphere containing the gas.
The imaging-analyzing means will be usually transported by a slow plane or a helicopter over the target area at an altitude at which the concentration of the gas of interest is sufficiently high and the interference of water vapor in the air sufficiently low for this analytical technique to provide reasonably accurate and meaningful results. As more advanced equipment becomes available, for example, focal plane array detectors, surveillance overflights at high altitudes may be feasible. The present equipment is capable of detecting temperature differences of about 0.2° C. This, naturally, may be further refined as more advanced equipment becomes available. Presently, meaningful data can be obtained for temperature differences between the background and the intervening atmosphere as small as 1°-2° C.
The present equipment uses gas filter cells to provide the reference signal. It is possible that in the future such cells may be replaced by calibrated interference filters or by other devices. The presently used gas filter cells are 6 cm long, but a longer or shorter cell may be more practical for a particular application. Similarly, depending on the infrared absorption intensity of the reference gas, it may sometimes be practical to use the gas at a 100% concentration or to dilute it with another gas, for example, nitrogen. Such adjustments and modifications are based on determining the point of maximum sensitivity to changes in the value of the analytical-to-reference output signal ratio for each particular gas species to be analyzed. Further, it is possible to use two separate, single channel, time-synchronized imaging means instead of dual channel equipment. Those separate imaging means would produce, respectively, a reference signal and an analytic signal at identical times over the same field of view.
All such alternate embodiments are within the scope of this invention.
EXAMPLE
The operation of the imager-analyzer has been verified by observing the release of ethylene gas from a charged cylinder. The above-described equipment was used, the imaging means being first placed on a loading platform about 2 m off the ground. Gas released through the cylinder regulator was led through an 8 m long rubber hose having an inside diameter of 0.02 m, to a black-painted, stainless steel, 0.6 m diameter funnel, with its apex turned downward. The funnel was placed on the asphalt pavement below at a horizontal distance of 4 m from the imaging means. The gas pressure was maintained at 410 kPa, yielding an ethylene flow rate of 1.5 l/sec. The average gas concentration was 1.5% V/V at a point 12 cm above the funnel, close to ambient air temperature. The funnel itself was warmer than the ambient air. The air temperature was 27° C., and the asphalt pavement temperature about 35° C. The sky was partly cloudy.
The reference optics contained a 6 cm infrared-transmitting gas cell, which was charged with a mixture of equal volumes of ethylene and nitrogen. Red color was selected for displaying the analytic/reference ratio image, and the gain of the ratio image was adjusted to five times the analytic image. Bias levels were adjusted to almost extinguish the detector noise from the ratio signal.
With ethylene gas flow shut off, the funnel was clearly visible on the viewing screen as the background image. With gas flow on, a red image of the gas superimposed on the background image was clearly evident. With gas flow off again, the slow dissipation of the gas from the funnel was readily observed.
The imaging means was next moved to the ground level to view the funnel, about 4 m away, against the sky background.
When the gas flow was off, the funnel was clearly visible on the viewing screen. With the gas flow on, no gas image could be observed above the funnel because the temperature of the ambient air immediately above the funnel and of background ambient air was about the same. However, ethylene gas which swirled downward between the funnel and the imaging means was visible on the screen. Here, the warmer funnel provided suitable background for image formation.
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Presence and location of infrared radiation-absorbing or emitting gases in the atmosphere can be ascertained by means of an infrared imaging-analyzing means which views a given scene and receives infrared radiation therefrom. Analytic and reference beams are produced, the latter having reduced sensitivity to the gas of interest, and are converted to electric signals, which are processed in real time to provide a signal corresponding to their ratio. This ratio signal is further processed to generate an image, which can be displayed and viewed. This technique is particularly suitable for surveying large areas for seepage of methane or other hydrocarbon gases from underground gas and/or oil deposits.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national stage application of International Application No. PCT/EP2006/063025 filed Jun. 8, 2006, which designates the Unites States of America, and claims priority to German application number 10 2005 028 023.4 filed Jun. 16, 2005, German application number 10 2005 049 287.8 filed Oct. 14, 2005, and German application number 10 2005 049 290.8 filed Oct. 14, 2005, the contents of which are hereby incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The invention relates to a sieve apparatus for extracting carrier liquid from a fiber suspension during the production of paper, paperboard or board.
[0003] Furthermore, the invention relates to a method for the treatment of nonwoven fibrous materials in a suspension, in particular as a pulp or fibrous stock, while the suspension is being filtered or its carrier liquid is being extracted, preferably for the operation of the sieve apparatus according to the invention.
BACKGROUND
[0004] In a paper production plant or in parts of a paper production plant, the fiber suspension leaves a head box and, from there, reaches a preferably circulating sieve (fourdrinier wire or sieve cylinder). On the sieve, the sheet is dewatered down to a dryness of preferably 16 to 25%. During dewatering, two different types of sheet formation occur: filtration and thickening. The filtration is a sharp transition between a fiber mat that is already formed and the fiber suspension lying above it. During the thickening, the concentration of fibrous materials increases continuously from top to bottom. With increasing dewatering, a strength of the sheet increases. Paper fibers are preferably composed of numerous cellulose chains with many OH groups. The strength of the paper is produced by water molecules located in between, which connect the fibers to one another via hydrogen bridges. The number of hydrogen bridges can be increased by means of pressing or slight stretching, for example in a press section.
[0005] WO 2004/101891 discloses a method for the treatment of paper with plasma after sheet formation has been completed.
[0006] DE 198 36 669 A1 discloses a method for surface pre-treatment on solid paper after sheet formation has been completed.
SUMMARY
[0007] The processing speed during the paper production can be increased according to an embodiment, by a sieve apparatus for extracting carrier liquid from a fiber suspension during the production of paper, paperboard or board, comprising at least one first electrode, which is connected to a high voltage pulse generator, and arranged over, in or under a sieve area of the sieve apparatus, wherein a plasma is produced in the fiber suspension or in its immediate surroundings.
[0008] According to a further embodiment, the plasma can be produced at a distance of less than 20 cm or less than 10 cm or less than 5 cm, from the fiber suspension. According to a further embodiment, a sieve can be set up as an electrode. According to a further embodiment, there can be at least a second electrode for plasma production. According to a further embodiment, the electrodes can be arranged in the immediate vicinity of a suction chamber area, in particular a wet suction area or a flat suction area. According to a further embodiment, the first electrode and the second electrode can be arranged in the immediate vicinity of the suction chamber area in such a way that the fiber suspension is led between the electrodes. According to a further embodiment, the electrodes can be set up in such a way that a gas discharge can be sucked through the electrodes or past the electrodes, in particular through the fiber suspension. According to a further embodiment, the sieve apparatus may comprise a means for the introduction of gas, or air or oxygen or pure oxygen or oxygen with noble gas, as a carrier gas, between or in the immediate vicinity of the electrodes. According to a further embodiment, at least one electrode can be configured as a plate. According to a further embodiment, at least one electrode can be configured as a sieve. According to a further embodiment, at least one electrode can be configured as a wire braid or as a wire grid. According to a further embodiment, at least one electrode can be configured as a grid or as an arrangement of round rods and/or flat bars crossing at right angles or obliquely or as a (papermaking) sieve. According to a further embodiment, at least one electrode may have one or more tip(s). According to a further embodiment, the electrodes can be arranged as at least two mutually opposite plates preferably running parallel to one another. According to a further embodiment, the electrodes can be arranged as at least two mutually opposite grids preferably running parallel to one another. According to a further embodiment, the electrodes can be arranged in such a way that a sieve or a grid is arranged as a second electrode between two plates which are interconnected via at least one plate connector and which form the first electrode.
[0009] According to another embodiment, a method for the treatment of nonwoven fibrous materials in a suspension, while the suspension is being filtered or its carrier liquid is being extracted, may comprise the step of bringing the suspension into contact with a non-thermal, large-area plasma under at least atmospheric pressure, wherein the plasma is produced in the immediate vicinity of the suspension or a gas discharge or a corona discharge, is produced in the suspension or in the immediate surroundings of the suspension under at least atmospheric pressure.
[0010] According to a further embodiment, the plasma can be produced at a distance of less than 20 cm or less than 10 cm or less than 5 cm, from the suspension. According to a further embodiment, the suspension may be suitable for the production of paper, paperboard or board. According to a further embodiment, the suspension used can be a moist or wet sheet. According to a further embodiment, in order to produce the plasma or the gas discharge, high voltage pulses having a duration of less than 10 us can be produced between the electrodes. According to a further embodiment, the plasma or the gas discharge can be applied to the suspension before and/or during the sheet formation, as it passes through or over a sieve apparatus. According to a further embodiment, the suspension can be brought into contact with the plasma or treated by means of the gas discharge on both sides. According to a further embodiment, the plasma or the gas discharge can be used to bleach the suspension, the pulp or the fibrous stock, or in a digester, in a bleaching container or in a feed line. According to a further embodiment, the pulp or the fibrous stock can be brought into contact with at least one electrode for producing the plasma or the gas discharge. According to a further embodiment, the plasma or the gas discharge can be produced in the suspension. According to a further embodiment, the content of carrier liquid, in the suspension may lie in the range between 40% and 99.9%, or in the range between 80% and 98% or in the range between 85% and 98%. According to a further embodiment, radicals which act on the fibrous material can be produced in the plasma or by means of the gas discharge. According to a further embodiment, radicals of different type or composition can be used for various states of suspensions in a paper, board or paperboard production process, in particular at different process stages. According to a further embodiment, the suspension can be exposed to radicals of different type or composition within a process stage in a paper or board production process. According to a further embodiment, the radicals produced can be ozone, hydrogen peroxide, hydroxyl radicals, HO 2 and/or HO 2 − . According to a further embodiment, during the bleaching in the suspension or in the pulp or in the fibrous stock, the plasma or the gas discharge can be applied in such a way that the radicals predominantly formed are ozone and/or hydrogen peroxide. According to a further embodiment, during the filtering and/or in the two-dimensionally distributed suspension or pulp or fibrous stock or in the forming or formed, as yet unpressed sheet, the plasma or the gas discharge can be applied in such a way that the radicals predominantly formed are hydroxyl, HO 2 and/or HO 2 − . According to a further embodiment, a production rate of the radicals and/or the composition of the radicals produced can be controlled by influencing an amplitude, a pulse duration and/or a pulse repetition rate of the high voltage pulses. According to a further embodiment, in order to control and regulate the production rate and/or the type of radicals produced, a concentration of the radicals produced can be measured. According to a further embodiment, in order to control and regulate the production rate and/or the type of radicals produced, a property of the suspension, preferably a quality property, in particular its opacity, gloss, whiteness, fluorescence or color locus, can be measured. According to a further embodiment, the concentration or the property can be measured “online”. According to a further embodiment, for the purpose of regulation, the amplitude of the high voltage pulses can be changed at a constant repetition rate. According to a further embodiment, for the purpose of regulation, the repetition rate of the high voltage pulses can be changed at a constant amplitude. According to a further embodiment, the suspension, the pulp or the fibrous stock can be enriched with oxygen in the region to which plasma is applied. According to a further embodiment, a high voltage pulse duration of less than 100 ns can be used in the suspension, the pulp or in the fibrous stock. According to a further embodiment, two-dimensionally distributed suspension, pulp or fibrous stock or a forming or formed, as yet unpressed sheet can be surrounded by an atmosphere enriched with water vapor in the region to which plasma is applied, in particular during filtering. According to a further embodiment, a high voltage pulse duration of 100 ns to 1 us can be applied to two-dimensionally distributed suspension, pulp or fibrous stock or a forming or formed, as yet unpressed sheet, in particular during filtering. According to a further embodiment, a high voltage amplitude corresponding to at least twice the value, and preferably at least three times the value, of a corona threshold voltage can be applied to the electrodes in the case of a two-dimensionally distributed suspension, pulp or fibrous stock or a forming or formed, as yet unpressed sheet, in particular during filtering. According to a further embodiment, in order to produce the plasma or the corona discharge, a DC voltage corona discharge is produced and the high voltage pulses are superimposed on the DC voltage corona discharge. According to a further embodiment, a pulse repetition rate between 10 Hz and 5 kHz, or of 10 kHz, can be used. According to a further embodiment, the power injection of electrical energy into the plasma can be predominantly controlled by the regulation of amplitude, pulse duration and pulse repetition rate of the superimposed high voltage pulses. According to a further embodiment, high voltage pulses with a duration of less than 3 μs, or less than 1 μs, or less than 500 ns, can be applied. According to a further embodiment, a homogeneous, large-volume plasma with a high power density can be produced without plasma constrictions or breakdowns occurring. According to a further embodiment, use can be made of a DC voltage of such a height that, in the plasma, a stable DC corona discharge is formed only in conjunction with superimposed high voltage pulses. According to a further embodiment, the DC voltage used may lie below that for stable operation without high voltage pulse superimposition. According to a further embodiment, the total amplitude used may lie above the static breakdown voltage of the electrode arrangement. According to a further embodiment, the total amplitude used may correspond to two to five times the static breakdown voltage of the electrode arrangement. According to a further embodiment, the amplitude of the high voltage pulses can be between 10% and 1000% of the DC voltage used.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Preferred but in no way restrictive exemplary embodiments of the invention will now be explained in more detail by using the drawing. For clarity, the drawing is not to scale and certain features are illustrated only schematically. Mutually corresponding parts are provided with the same designations in the figures. In detail,
[0012] FIG. 1 shows a schematic illustration of a paper production plant having a sieve apparatus according to an embodiment, a press apparatus and a finishing and/or drying system,
[0013] FIG. 2 shows an illustration (section) of an arrangement for the production of radicals in corona plasmas in pulp or air: parallel plate or tube arrangement with wire, on which a pulsed high voltage is superimposed,
[0014] FIG. 3 shows a basic illustration of pulses for the production of radicals in corona discharges in air or aqueous media when short (typically <1 μs) high voltage pulses with a high pulse repetition rate are employed, and
[0015] FIGS. 4 to 9 show electrode arrangements and electrode systems for the production of corona discharges: plate-plate, plate-wire-plate, coaxial wire-tube, point-plate, multiple point-plate, grid-plate (tube), grid-grid arrangements.
DETAILED DESCRIPTION
[0016] As a result of the treatment of the fibers with a corona plasma, preferably a cold corona plasma, on the sieve, preferably before the actual sheet formation, the molecular structure of the fiber surfaces is changed. As a result, the following positive effects are achieved:
increasing the strength of the sheet even before a press section, eliminating colored “molecular groups” (in particular lignin and residual dye molecules from the water circuit) on the surface and simultaneous brightening of the paper.
[0019] In particular as a result of increasing the strength of the sheet, higher processing speeds can be achieved during the paper production. Likewise, the probability of paper breaks is reduced. In the region of the sieve apparatus, the fiber suspension is treated with plasma even before sheet formation has been completed, advantageously with regard to the subsequent material properties.
[0020] It is expedient for the plasma to be produced at a distance of less than 20 cm, preferably less than 10 cm, preferably less than 5 cm, from the fiber suspension. As a result of the direct treatment of the fiber suspension, preferably pulp fibers, with cold plasma, specific radicals are preferably produced in the gas space of the fiber suspension. These radicals promote an increase in the strength of the paper.
[0021] According to an embodiment, a (papermaking) sieve can be set up as an electrode. As a result of the treatment with a preferably cold plasma, more hydrogen bridge bonds are produced on the sieve at an earlier time than without the plasma treatment. The strength of the sheet on the sieve therefore increases further. The strength of the sheet, reached earlier, reduces the risk of paper breaks further.
[0022] It is expedient that there is at least a second electrode for plasma production. An arrangement of at least two electrodes permits two-sided treatment of the fiber suspension or of the unpressed sheet.
[0023] According to an embodiment, the electrodes are arranged in the immediate vicinity of a suction chamber area, in particular a wet suction area or a flat suction area. Advantageously, the plasma treatment of the as yet unpressed fiber stock on the sieve is carried out in the suction chamber areas (flat suction means, wet suction means). As a result, radical-containing air from a plasma reactor region above the sieve is sucked through the fiber stock or the fiber suspension and a particularly intimate connection is produced between radical-containing air and the fiber surface.
[0024] It is expedient in this case if the first electrode and the second electrode are arranged in the immediate vicinity of the suction chamber area in such a way that the fiber suspension is led between the electrodes. Two-sided treatment of the fiber suspension improves the result of the treatment which is achieved by means of the sieve apparatus according to an embodiment.
[0025] The electrodes are preferably set up in such a way that a gas discharge can be sucked through the electrodes or past the electrodes, in particular through the fiber suspension.
[0026] Furthermore, the apparatus can be configured with a means for the introduction of gas, in particular air or oxygen, preferably pure oxygen or oxygen with noble gas, for example, as a carrier gas, between or in the immediate vicinity of the electrodes. As a result of this advantageous arrangement, preferably finely distributed air bubbles or oxygen or oxygen with a carrier gas, such as argon, is caused to flow into the fiber suspension. With the aid of this gas caused to flow in and the simultaneous treatment with plasma, the subsequent tearing strength of the paper is increased further.
[0027] It is also expedient that at least one electrode is configured as a plate. In the case of a preferably flowing suspension, in particular a falling curtain of suspension, an electrode arrangement having two plates can advantageously be used for a two-sided application of plasma to the suspension curtain.
[0028] According to an embodiment, relating to the method, provision is made for the suspension to be brought into contact with a preferably non-thermal, large-area plasma under at least atmospheric pressure, for the plasma to be produced in the immediate vicinity of the suspension or for a gas discharge, in particular a corona discharge, to be produced in the suspension or in the immediate surroundings of the suspension under at least atmospheric pressure.
[0029] During the treatment of the raw, still largely unbonded paper surface with cold plasma, shortly before the sieve, on the sieve or immediately thereafter, for example in the first part of the press section, specific radicals are produced (e.g. OH − , HOO − , O, O 3 ), which react chemically with the paper surface and in particular the fiber suspension.
[0030] Radicals are also able, inter alia, to trigger bleaching chemical reactions, in particular free oxygen O, in particular also a hydroxyl radical OH, in particular ozone O 3 , and also free functional groups such as OH groups, COOH groups. These functional groups are in turn decisively involved in particular in increasing the bonding strength of the fibers to one another, which further improves the tearing strength of the paper and therefore the possible processing speed.
[0031] Preferably, in the event of simultaneous production of radicals, a series of differently oxidizing and functionalizing radicals are produced in a gas phase and used for the purpose of treating these fibers with radicals in the unpressed sheet, still on the sieve or immediately thereafter in the first part of a press section.
[0032] In particular, this treatment is to be used with a content of carrier liquid of 75% to more than 98%. The strength of the paper and therefore the maximum possible working speed is already increased in good time as a result. Furthermore, by means of this type of treatment, the colored dyes located on the surface can also be bleached, for example the adhering lignin or dye residues are de-colorized by oxidation.
[0033] Radicals are produced in gas discharges as a result of the fact that high-energy electrons collide with molecules and, as a result, disassociate or excite the latter and in this way lead to radical formation.
[0034] In the case of disassociation, radicals are liberated immediately while, in the case of excitation, as a result of subsequent radiant transitions, UV light is produced, which in turn reacts with molecules, preferably air and water molecules, and disassociates the latter. In order to obtain sufficiently high-energy electrons in the region of about 5 eV (electron volts) up to >15 eV, extremely high electric fields are needed. These high field strengths occur in particular at the top of streamers, as they are known. Streamers are discharge channels which are found in the structure and are formed because of the applied high external field strengths. The formation of such streamers takes place within less than 10 ns and then changes quickly into a thermal breakdown channel. Since no high-energy electrons are formed in a thermal breakdown channel, the object is, inter alia, to avoid these thermal breakdowns or to reduce them to a minimum. In order to obtain high energy efficiency of the production of preferably radicals in gases, it is therefore necessary to operate with very short individual high voltage pulses. The pulse duration is preferably considerably shorter than that which corresponds to a build-up time of a complete breakdown in the respective medium.
[0035] A pulsed corona discharge directly above the paper or on the fiber suspension by using extremely short high voltage pulses of less than 10 μs, in particular typically of 1 μs and particularly advantageously considerably shorter than 1 μs, with voltages of a few kV to more than 100 kV, depending on a distance of the electrodes from the paper or from the fiber suspension and the properties of the paper, is applied to the paper or the fiber suspension, advantageously with regard to the quality properties. In particular, the use of such short high voltage pulses has been shown to be particularly advantageous, whereas the use of radio frequency (RF) or microwave pulses or of individual high voltage pulses with more than 10 μs duration, as described in WO 2004/101891 A1, is a far less efficient. It is suspected that the reason lies in a rapid transition from a streamer to the breakdown at atmospheric pressure, in particular given the presence of geometric irregularities on the paper surface, such as individual fibers, at which the electric field is considerably superelevated.
[0036] If the paper web or the fiber suspension is located between the electrodes used for the streamer discharge, then this is particularly advantageous, since the paper or the fiber suspension acts partly as a dielectric barrier as a result. By means of the dielectric barrier, the transition from the streamer to the breakdown can be controlled better.
[0037] FIG. 1 shows a schematic illustration of a paper production plant 1 , as is used in current paper mills. Its construction and the combination of different units are determined by the type of paper, board and paperboard grades to be produced and the raw materials employed. The paper production plant 1 has a physical extent of approximately 10 m in width and approximately 120 m in length. The paper production plant produces up to 1400 m of paper 27 per minute. It takes only a few seconds from the first impingement of the fiber suspension or the pulp 39 on the sieve apparatus 9 as far as the finished paper 27 , which is finally reeled up in a reel-up 15. Diluted with water in the ratio of 1:100, the fibrous material 30 , together with auxiliary materials, is applied to the sieve apparatus 9 having the sieve 10 . The fibers are deposited beside and on one another on the sieve 10 . The sieve water 23 can flow away or be extracted by means of a plurality of suction chamber areas 24 . In this way, a uniform fiber composite is produced, which is further dewatered by mechanical pressure in a press apparatus 11 and with the aid of steam heat. The entire paper production process is in this case subdivided substantially into the areas of stock preparation, paper machine, enhancement and finishing.
[0038] Waste paper and, as a rule, also pulp reach a paper mill in dry form, while groundwood is normally produced in the same mill and pumped into the central stock facility 3 as a fiber/water mixture, that is to say a suspension of nonwoven fibrous materials. Waste paper and pulp 30 are likewise pulped in a fiber chest 35 with the addition of water. Constituents that are not part of the paper are removed by various screening units (not illustrated here). In the central stock facility 3 , the mixing of the various raw materials is carried out, depending on the desired paper grade. Here, fillers and auxiliary materials, which are used to improve the paper quality and to increase productivity, are also added.
[0039] The headbox 7 of the paper production plant 1 distributes the fibrous material suspension uniformly over the entire sieve width. At the end of the sieve apparatus 9 , the paper web 27 always still contains about 80% water.
[0040] A further dewatering process is carried out by means of mechanical pressure in the press apparatus 11 . Here, the paper web 27 is led through between rolls of steel, granite or hard rubber by means of an absorbent endless felt blanket and dewatered as a result. Part of the sieve water 23 picked up by the suction chamber area 24 is led to a screen 5 and another part is sent back to a saveall 17 . The press apparatus 11 is followed by a drying system 13 . The remaining residual water is evaporated in the drying system 13 . The paper web 27 runs in slalom fashion through a plurality of steam-heated drying cylinders. At the end, the paper 27 has a residual moisture of a few percent. The water vapor produced in the drying system 13 is extracted and led into a heat recovery system, not illustrated.
[0041] For a treatment of the fiber suspension 39 in accordance with the method according to an embodiment, between the headbox 7 and the initial region of the sieve apparatus 9 according to an embodiment, a first electrode 43 is arranged under the sieve apparatus 9 and a second electrode 44 is arranged above the sieve apparatus 9 . The electrodes 43 and 44 are arranged in such a way that the two-dimensionally distributed fiber suspension 39 runs between them. In order that a large-area plasma for treating the fiber suspension 39 can be produced under atmospheric pressure in the immediate vicinity of the fiber suspension 39 , the electrodes 43 and 44 are connected to a high voltage pulse generator 46 . With the aid of this high voltage pulse generator 46 , a large-volume plasma having a large cross section and a high power density is produced between the electrodes 43 and 44 . In this case, a plasma density is distributed homogeneously over the treatment region which is covered by the electrodes 43 and 44 . According to an embodiment, this large-volume plasma with a high power density is produced by intensive, short high voltage pulses with a high pulse repetition rate of typically about 1 kHz being superimposed on a DC corona discharge. In this operating mode, an extremely homogenous, large-volume plasma having a high power density is produced without the occurrence of the plasma contractions known in the case of DC corona discharges.
[0042] In order to assist the effect of the treatment exerted on the fiber suspension 39 by the cold large-area plasma, oxygen with argon as carrier gas is introduced into the treatment space between the electrodes 43 and 44 via a gas line 80 by means of a gas distributor 81 . With the aid of the oxygen-argon mixture, hydroxyl radicals are particularly advantageously produced. Hydroxyl radicals are particularly aggressive and oxidizing; as a result, in the fiber suspension remaining in the treatment region between the electrodes 43 and 44 for only a few seconds, increased strength is achieved during the subsequent sheet formation.
[0043] In a manner analogous to that described previously, a large-area plasma for the treatment of the paper web 27 is produced by using an electrode system 47 , 48 in the press apparatus 11 . The first electrode 47 in the press apparatus 11 is implemented as a half-round grid electrode. As a result of the half-round configuration of the electrode 47 , it is able to follow the course of the paper web over a transport roll 12 . The second electrode 48 in the press apparatus 11 is configured as a plate electrode and arranged in such a way that the transport roll 12 can be led between the electrodes 47 and 48 . In order to excite the radical formation in the plasma here, too, an oxygen-argon mixture is caused to flow to the plasma treatment region via the gas distributor 81 having the gas line 80 .
[0044] The pressing operation compacts the paper structure, the strength is increased once more and a surface quality is decisively influenced. As a result of the treatment of the pressed paper with cold plasma, in particular with the radicals produced, the molecular structure of the paper surface is changed further. In addition to the strength of the paper 27 , printability is improved.
[0045] By using the aforementioned electrode arrangements 43 and 44 and also 47 and 48 , according an embodiment, it is possible to lead the paper web 27 between streamer discharges.
[0046] A streamer is a specific form of a plasma cloud moving linearly onward, or a discharge channel under development, which is formed on account of the excited high external field strength. A build-up of such streamers takes place within less than 10 ns and changes very quickly into a thermal breakdown channel. The aforementioned arrangements of the electrode systems, the paper web 27 being located between the electrodes used for the streamer discharge, are particularly advantageous since the paper 27 functions partly as a dielectric barrier as a result, which means that the transition from streamer to breakdown can be suppressed.
[0047] By means of direct treatment of the pulp fiber suspension 39 with the cold plasma, the radicals OH − , HOO − , O, O 3 are preferably produced. In addition to an increase in strength, these radicals trigger a bleaching chemical reaction. The high voltage pulse generator 46 is operated in such a way that it produces high voltage pulses with a duration of typically 1 μs between the electrodes 43 and 44 . A DC voltage needed for the production of radicals and ozone in the pulp fiber suspension is around some 10 kV to more than 100 kV. The high voltage pulses are superimposed on the DC voltage and in this way form a total amplitude of typically about 100 kV. As a result of the treatment of the pulp fiber suspension 39 with a cold electric discharge, which is to say the plasma, the radicals are produced in situ. Thus, large total quantities of radicals can be introduced into the suspension 39 . For the electrodes 47 and 48 , the high voltage generator is operated in such a way that it produces high voltage pulses having a duration of typically 0.1 us up to a few μs.
[0048] FIG. 2 shows, as a further exemplary embodiment, a sectional illustration of an arrangement for producing radicals. Arranged at the centre of the arrangement is a high voltage electrode 50 . The outer shell of the arrangement is set up as a mating electrode 51 . In the arrangement there is a pulp fiber suspension 39 to be filtered. A streamer 53 is illustrated between the electrodes 50 and 51 . Radicals are produced in streamers as a result of the fact that high-energy electrons collide with molecules and disassociate or excite the latter as a result. In the case of disassociation, radicals 59 are liberated immediately while, in the case of excitation, UV light is produced by a subsequent radiant transition. This UV light that is produced in turn reacts with water molecules and disassociates the latter.
[0049] FIG. 3 illustrates the course of the applied voltage of the high voltage pulses. The first pulse 66 and a second pulse 67 , each having a pulse width 62 , have an interval of one pulse repetition time 63 . The time is indicated in ms on the abscissa and the voltage is indicated in kV on the ordinate. The units are chosen arbitrarily. A level of typically about 100 kV of the DC voltage coincides with the abscissa illustrated. The pulse voltage illustrated is therefore superimposed on the DC voltage. The pulses 66 and 67 have a pulse width 62 of less than 1 μs, the individual pulses 66 , 67 having a steeply rising flank with a rise time 64 and a less steeply falling flank. The pulse repetition time 63 is typically between 10 μs and 100 ms.
[0050] In this case, the individual pulses 66 , 67 have a total amplitude such that a predefined energy density is achieved beyond the predefined direct voltage. As mentioned, the pulse rise time 64 is short here as compared with the pulse fall time. Such a type of pulses means that electric breakdowns, which would lead to temporal and spatial disruptions in the homogeneous plasma density distribution, are avoided.
[0051] FIG. 4 to FIG. 9 show examples of electrode systems for producing corona discharges in preferably aqueous media. FIG. 4 illustrates a plate-plate arrangement of a first plate 70 a as electrode and a second plate 70 b as electrode. The first plate 70 a and the second plate 70 b are arranged parallel to each other. The first plate 70 a forms the high voltage electrode and is connected to the high voltage pulse generator 46 via a high voltage cable. The second plate 70 b forms the mating electrode and is connected to the high voltage pulse generator 46 as a grounded electrode.
[0052] A corresponding arrangement with specific flat plate electrodes is illustrated in FIG. 5 . Once more, there are two solid plate electrodes 70 a and 70 c at a fixed distance, a high voltage electrode 71 running centrally. In this plate-wire-plate arrangement, the high voltage electrode 71 is implemented as a solid wire and connected to the high voltage output of the high voltage pulse generator 46 . The grounded plates 70 a , 70 c are likewise connected to the high voltage pulse generator.
[0053] FIG. 6 shows a wire-tube arrangement as the electrode system. A high voltage electrode 71 projects centrally into a cylindrical electrode 72 . As in FIG. 5 , the high voltage electrode 71 is implemented as a solid wire and connected to the high voltage pulse generator 46 . The cylindrical electrode 72 , which is preferably configured as a wire braid, is grounded and connected to the high voltage pulse generator 46 .
[0054] FIG. 7 shows a point-plate arrangement as electrode system. Three points 73 are connected via a high voltage line to the high voltage pulse generator 46 . The points 73 are arranged at right angles to a grounded plate electrode 74 . The distance of the point electrodes 73 from the plate electrode 74 is adjustable and can thus be adapted to different process conditions.
[0055] FIG. 8 shows an electrode system arrangement which comprises 3 plates 70 a , 70 d and 70 e . The first plate 70 a , which is connected to the high voltage pulse generator as a high voltage electrode, is arranged centrally between two solid plates 70 d and 70 e . The plates 70 a and 70 d are connected by a plate connector 70 f . Since the plate 70 d is connected to the high voltage pulse generator 46 as a grounded mating electrode, the plate 70 e likewise has the function of a grounded mating electrode via the plate connector 70 f.
[0056] FIG. 9 shows an electrode system as a grid-grid arrangement. In a way analogous to FIG. 4 , here a first grid 75 a and a second grid 75 b are arranged opposite and in parallel. The first grid 75 a in this case forms the high voltage electrode and is connected to the high voltage pulse generator 46 . The second grid 75 b forms the grounded mating electrode and is connected to the high voltage pulse generator 46 .
[0057] A hybrid discharge, one electrode 75 a being located completely outside a fiber suspension 39 to be treated, and a second electrode 75 b being wholly or completely submerged in the fiber suspension 39 , is produced by an alternative arrangement, in which the (papermaking) sieve is configured as an electrode 75 a . The sieve is designed as a grid electrode and forms the high voltage electrode, which is connected to the high voltage pulse generator 46 . The grounded mating electrode 76 b is also designed as a grid electrode and is connected to the high voltage pulse generator 46 .
[0058] In order to produce pulsed discharges in the gas space close to the surface above the fiber suspension 39 , a further electrode arrangement is possible. A high voltage electrode comprising a plurality of electrically interconnected rod electrodes is arranged in the gas space of the fiber suspension 39 , close to the surface, in such a way that its rods run parallel to the surface. A grounded mating electrode is implemented as a solid plate and is arranged at equidistant intervals from the high voltage electrode, distributed over the entire area.
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To increase the processing speed of a sieve mechanism ( 9 ) for extracting carrier liquid from a fiber suspension ( 39 ) during the production of paper ( 27 ), paperboard, or cardboard, the sieve mechanism ( 9 ) is provided with a first electrode ( 43 ) which is disposed above, in, or below a sieve region and is connected to a high-voltage surge generator ( 46 ). A plasma can be generated in the fiber suspension ( 39 ) or in the immediate vicinity thereof, whereby the tensile strength of the paper ( 27 ) is also increased.
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FIELD OF THE INVENTION
[0001] The present invention refers to a manufacturing process of packing labels with Heat Transfer technology, wherein alphanumeric codes are sequentially applied on, between and/or under the layers of specific inks and varnishes which protect said area of eventual friction and wear to which they subject during transportation, handling and productive tests.
BACKGROUND OF THE INVENTION
[0002] Throughout the world, the packages market is becoming more stringent over the years. Manufacturers have invested in technology throughout the service life of the package, from the conception to the disposal thereof. The labels, in this context, have been the target of requirements that go beyond the merely informative function, becoming an extension of the product, with the ecological concern which revolves in the world, the label now has the same fate as the package, recycling. Therefore, the more “life” it has, the better.
[0003] Previously the labels were made of paper, what rendered the life cycle thereof very short because they were not resistant and easily detachable upon contact with water. As a consequence, there has been a demand for solutions in which the label had a longer service life or even the same service life than the package.
[0004] Over time, the papers became more resistant, with special finishes that made the label more lasting; there arose the plastics, as more resistant and practical alternative, and the self-adhesive labels that have good cost-benefit ratio. However, the self-adhesive labels are better suited to flat surfaces, with application limitations in spherical and irregular surfaces.
[0005] Nowadays there is a tendency to replace paper labels by polypropylene and PVC, especially in packs suffering the direct action of water as shampoos, detergents, bleach, among others. It is observed in the industry a gradual replacement movement of papers by self-adhesive films, because in addition to conferring a more beautiful visual appearance, they offer greater resistance to weathering.
[0006] The films have greater resistance and can have the same service life of the product and the package. Also, they have excellent graphic resolution and cost close to the labels made of paper.
[0007] Currently, there are on the market several label models resistant to the action of water and moisture, each has own and unique characteristics, being used according to the market field.
[0008] The present invention is limited to the Heat Transfer technology which is a decorative technology consisting of the direct/reverse printing on paper or polyester substrate with subsequent transfer of the image through heat and pressure to various shapes and sizes of packages and other materials. More specifically, the material is transferred to the product by means of heat and pressure.
[0009] This technology is characterized by the fact that the label seems to be part of the package (“no label look” visual), with no possibility of bubbles, wrinkles or folds in the final result. Thus, the label cannot be taken off or pulled which ensures that the mark remains on the package until it is put away by the consumer.
[0010] The prior art describes several patents that refer to the “heat transfer” process as well as labels using said technology.
[0011] Patent U.S. Pat. No. 9,073,383 in the name of Illinois Tool Works (ITW) refers to “heat transfer” labels used for decorating, marking and branding coding in rubber products, such as hoses, power transmission belts and tires. The “heat transfer” labels described herein may be modified by an end user before the label is applied to a substrate, thereby allowing the customization of the information applied on the substrate, regardless of the amount of articles. The label may also include fixed data and a region where variable data are applied or supplied and through which the data is viewed when the label is affixed to an article or object.
[0012] In this process, several preparation steps for subsequent use are highlighted, the product must be processed and transferred in a gradual manner, it is particularly noted the removal possibility thereof upon the application of specific chemicals characterizing the reversibility of same.
[0013] Patent U.S. Pat. No. 8,852,377 granted to TOMS RAY ALAN describes an insulate label provided for a beverage container to reduce heat transfer, particularly heat transfer by conduction from a consumer's hand to the beverage container, thereby preventing the beverage warm within the bottle in a rapid manner after the container is removed from a refrigerated or cooled environment. The label comprises a dual-ply construction, with a grid pattern placed between the layered materials. Preferably, the label comprises a film base layer secured to the container, the grid pattern comprising a ink and varnish mixture printed over the film base layer, and a laminate top layer secured to the film base layer. Air is trapped in the gaps or spaces between the protrusions created by the grid pattern, and the trapped air insulates the container. The label has a very thin profile, thereby not perceptibly changing the appearance of the container.
[0014] U.S. Pat. No. 8,709,556 describes a “heat transfer” label assembly including a “heat transfer” label including ink and adhesive, and a releasable support joined to the “heat” transfer label. The adhesive may include at least one polyketone resin and a polyamide resin. The “heat transfer” label may be used to decorate a metal article.
[0015] The process is further directed to application of colors in metal containers having an interaction in more surface layers not structurally activating the material as in the case of PET. It is noted the characterization of the term “heat transfer” only for the transfer characteristic of the process.
[0016] Patent application PI 0410639-3 refers to a label and a labeling method applicable to the labeling of bottles for carbonated beverages such as cola. This invention provides a label whereon the label inner portion identifies the product and invites the user to have access to it through a piece of rupture-resistant removable transparent outer label. In use, the entire label assembly is removed by the user during access to the inner information, thereby preparing the bottle for recycling. The label assembly becomes able to withstand the tension applied during the bottling and after bottling, the label being constructed as a homogeneous laminar assembly comprising polypropylene/polypropylene layers of different densities, wherein the stretch characteristics enable the label to accommodate these voltage loads. Such process does not address the numerical sequencing process. Furthermore, it is a reversible process completely different from the “heat transfer” process which is irreversible.
[0017] Patent Application PI 0703841-0 makes reference to gluing labels directly applicable to vitreous surfaces (glass) with reference to a pasteurization process after the application of the label, having as final product the application in beer bottles with high adhesion capacity enhanced by the addition of silane associated with hot-melt.
[0018] Patent application PI 0714513-6 granted to Illinois Tool Works details the selective thermal transfer process to a substrate having this metallic “selectivity”, i.e. the transfer of a metal adhesive layer applied to a surface that can be metallized through a carrier layer composition being activated through heat and pressure transfer.
[0019] This proposal considers the composition of layers so that the transfer is executed by means of a carrier layer, a release layer of the carrier layer, a protective layer applied to the release layer, an applied layer that can be metallized directed to the activation upon the application of heat and pressure to the label. Typically being disseminated in thermoplastic labels, cell phone cases and golf sticks and can be adhered to rigid or semi-rigid surfaces.
[0020] Patent EP 2 264 686 describes the process of printing variable information through a laser printing technology and by means of light beams different from the activation concept of “heat transfer” processes (heat radiation) to laser application process (monochromatic electromagnetic radiation).
[0021] Regarding patent U.S. Pat. No. 7,846,949, the instant study is developed through the no need of activation of the label surface for the application process, which minimizes the cost of energy used for the Heat Transfer process, although these excellent results are observed related to the abrasion resistance with capacity of supporting immersion test in hot or cold water for 20 to 40 minutes (ultrasonic bath).
[0022] Patent U.S. Pat. No. 8,507,616 relates to design of an adhesive pigment named Halo-Free which confers properties to the transfer process by Heat-transfer.
[0023] Patent application US 20130071634, under development by Multi-Color Corporation, describes the process of formulating the solution thereof in Heat-transfer detailing the chemical aspects of the solution thereof.
[0024] The heat transfer process described in document U.S.20130287972 refers to information printed in hybrid manner, that is, by the conventional process such as flexography, rotogravure or pad associated with digital processes. This document combines a digital printing process linked to conventional processes.
[0025] The art application method in heat transfer processes was also discussed in the elaboration of document WO2014126759 being presented application scenarios with unfavorable aspects and comparing application concepts.
[0026] In order to innovate, improve and/or resolve the problems of the aforementioned labels, the present invention describes a process for manufacturing package labels with the Heat Transfer technology, wherein alphanumeric codes are applied sequentially on, between and/or under the layers of inks and varnishes. Such invention was developed with the purpose of promoting relevant information to the supplier about the product manufacturing process allowing to the supplier the labeling traceability in the productive process thereof. Controlling in particular the number of uses of the bottles, providing the evaluation of aspects such as the printing quality and durability or completeness of the returnable PET bottles (REFPET).
[0027] It is also believed that this innovation will provide a greater control of the process capability thereof and a more accurate obsolescence process of REFPET bottles. For Technopack/ITW, it will be enabled the individual and dedicated monitoring of the product thereof, evaluating the same throughout the whole service life thereof, from the manufacturing process until application.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 represents a package label (R) having a hollow area presenting a sequential alphanumeric information code applied between the layers of inks and varnishes.
[0029] FIG. 2 represents a package label (R) having a hollow area presenting a sequential alphanumeric information code applied under or on the layers of inks and varnishes.
[0030] FIG. 3 represents the overlay scheme of inks and varnishes in a label (R) in the Heat Transfer technology.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The label used in the process of the present invention comprises a substrate having a face printed in rotogravure using solvent-based inks.
[0032] The substrate is available on the market in the form of kraft, white or brown paper, with a weight ranging from 35 g/m 2 to 70 g/m 2 , being subsequently improved with the application of a wax layer with a weight ranging from 1.19 up (standard unit) to 1.57 up (standard unit), in the rotogravure process prior to the application of inks or varnishes on the substrate.
[0033] The solvent-based ink used is available on the market as inks for rotogravure.
[0034] The solvents used for mixing the inks and varnishes in machines depend on the colors being applied:
[0035] If the color is white, the solvent used is a mixture at 80% ethyl acetate +20% toluene.
[0036] For the other colors, the solvent used will be 100% T-300 (38% ethyl acetate+62% n-butyl acetate).
[0037] The Protective Varnish (2D) consists of a mixture at 50% MEK (methyl ethyl ketone) +50% T-300 (38% ethyl acetate +62% n-butyl acetate).
[0038] The adhesive Varnish ( 1 D) however consists of a mixture at 50% MEK+50% acetate.
[0039] The application area of the alphanumeric code on the label, object of the present invention, comprises printing of sequential data referring to general product information, where it will be arranged, visible to optical identification system that allows the access and recording of information.
[0040] The content of the information data may vary and it is made to order.
[0041] The confidential information data is printed by a printer using solvent-based ink.
[0042] The information data may be applied on, between or under the layers of inks and varnishes applied on the substrate.
[0043] The information data applied on the ink layers receive the application of a protective varnish layer (2D), in order to increase the resistance to friction and to caustic soda test.
[0044] The information data applied between the ink layers require a window on the label, to make it visible after application. The information data are applied to an adhesive varnish layer (1D) and a ink layer (varying the color according to the art ordered). After the application thereof on the adhesive varnish layer and the ink layer, the other inks are applied (varying according to the art defined in the order), these with a window, avoiding overlapping of the other ink layers to the information data already applied. After the application of the other ink layers, the protective varnish (2D) is applied on all art, including information data, in order to increase the resistance to friction and to the caustic soda test.
[0045] The information data applied under the layers of inks and varnishes are inserted on the verse of the label, with the protection of the other layers of inks and varnishes. The application of information data under the layers of inks or varnishes is performed in production line, during the printing or cutting process and/or in the line of label application on the final substrate. The information codes cannot have a thickness exceeding 4 microns, in order to avoid migration and label exposure to abrasion or contamination to the layers of inks and varnishes, affecting the color or finishing of the label.
[0046] The manufacturing process of the package label with the information code can occur in three different ways.
[0047] When the information code is applied on the ink layers on the label, the manufacturing process of the package label comprise the steps of:
[0048] a) application of the wax on the substrate;
[0049] b) drying this wax;
[0050] c) application of the adhesive varnish layer (1D);
[0051] d) drying this varnish layer;
[0052] e) printing ink layers on the label, according to customer's art;
[0053] f) drying the ink layers;
[0054] g) printing the information data after the application of the ink layers;
[0055] h) application of the protective varnish (2D) on the ink layers and information data; and
[0056] i) drying this protective varnish layer (2D).
[0057] When the information code is applied between the ink layers on the label, the manufacturing process of the package label comprises the steps of:
a) application of the wax on the substrate; b) drying this wax; c) application of the adhesive varnish layer (1D); d) drying this varnish layer; e) printing an ink layer on the label, according to customer's art; f) drying the ink layer; g) printing the information data after the application of the ink layer; h) application of the other ink layers, with visualization window (open in the label) of the information data; i) drying the overlapping ink layers; j) application of the protective varnish (2D) on the ink layers and information data; and k) drying this protective varnish layer (2D).
[0069] When the code information is applied under the ink layers on the label, the manufacturing process of the package label comprises the steps of:
a) application of the wax on the substrate; b) drying this wax; c) application of the adhesive varnish layer (1D); d) drying this varnish layer; e) printing the ink layers on the label, according to customer's art; f) drying the ink layers; g) application of the protective varnish (2D) on the ink layers and information data; h) drying this protective varnish layer (2D); and i) printing information data.
[0079] In all three cases, the confidential information is printed on the labels (R), at room temperature, through a process of rotogravure graphic printing process, using solvent-based ink.
[0080] Drying of the ink applied on the label (R), in each of the stations that apply the colors onto the substrate, varies according to the ink used.
[0081] When using solvent-based inks, the ink drying is carried out through an oven whose temperature ranges from 60-70° C. However, depending on the thickness/weight of ink applied on the substrate and printing speed, the drying temperature can be changed.
[0082] The ink application layer varies according to the customer art, the engraving type of the cylinders and tooling used during the application (knives/scraper blades—the function of which is to make the removal of the excess of inks of the application cylinders and rollers—the function of which is to promote the transfer of inks to the substrate).
[0083] When the engraving is for a flat color, the amount of ink applied is much higher. To gradients, the ink layer is smaller.
[0084] The wax composition that is applied to the substrate is unknown by Technopack, being under the wax supplier's responsibility the development of a composite suitable to rotogravure processes. When it is purchased, it is explained to the supplier the parameter use that it will be willing and normal to this process. Because it is a process already known by the suppliers, such a solution is part of the product portfolio thereof.
Results and Tests
Test of Caustic Soda-Resistance of the Label
Procedure for Execution:
[0085] To prepare the solution, it was used a metal bucket large enough so that the heat transfer label labeled on the bottle was completely submerged. It was added water enough to cover the label of the bottle and the quantity, in liters, of the total added was recorded.
[0086] Then, it was added 4 g of caustic soda (NaOH) per each 1 liter of water used in the test. It's worth emphasizing that the caustic soda should always be added to water, never water to caustic soda. The reversal of this process can lead to abrupt eruptions and consequent burns.
[0087] The solution with the heating iron was heated, maintaining the temperature of 60° C. (±5° C.).
[0088] The heating iron was plugged in after being submerged in the solution, into the metal bucket, to preserve the apparatus. The bottles were filled with water so that the water height in the bottle was greater than the height of the solution and placed into the metal bucket with a weight of 2 kg above them to prevent floating.
[0089] The bottles were kept submerged for 30 minutes. During this period, the solution temperature was controlled to rely within the range (60° C.±5° C.). After 30 minutes, the bottles were removed and evaluated whether or not it has occurred detachment of the label. If not, the label is approved. If so, it is evaluated whether the affected area (where the label detached) is greater than 1 mm. If so, the label is disapproved.
[0090] The same procedure with the same materials and test settings was conducted for the labels which information code thereof is applied on, between or under the ink layers on the label.
[0091] Materials: For the execution of the test, the following materials were used:
Metal container; Skewer type digital thermometer; Loon type water heater; Caustic soda solution; PET bottle labeled with heat transfer label.
Test Setup:
[0000]
Product: PET bottle of 2 liters and 1.5 liters
Number of samples: 50 of each
Date of execution: May 23, 2015
Concentration of the caustic soda solution: 3.5% to 5%
Temperature of the solution: 60° C.±5° C.
Holding time: 2.5 hours (5×30 min)
Ambient light: D65 (Daylight approximation)
Results and Conclusions:
[0104] In the three situations, label detachment was not evident after 5 baths of 30 minutes (total of 2.5 hours) of total immersion of the label in the caustic soda solution, even in ruptured areas.
Friction Resistance Test of the Label
[0105] With the aid of a carbon pencil (for writing), without sharpened point, up and down movements were performed in the labeled area, at an angle of approximately 45° to the label. Such movement was performed in the entire label.
[0106] Again, it was evaluated whether or not it has occurred detachment of the label.
[0107] If not, the label is approved. If so, it is evaluated whether the affected area (where the label detached) is greater than 1 mm. If so, the label is disapproved.
[0108] The amount of 5 reps is the default, but the test can be extended to increase the reliability of the tests referred to herein.
[0109] The labels used for package designed according to the present invention showed good results in resistance to both caustic soda and friction, being capable of being used in the packing industry.
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The present invention refers to a manufacturing process of packing labels with Heat Transfer technology, wherein alphanumeric codes are sequentially applied over, between and/or under the layers of specific inks and varnishes which protect said area of eventual friction and wear to which they are subject during transportation, handling and productive tests.
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This invention relates to N-alkylsulfonyl and N-haloalkylsulfonyl-substituted perfluoroalkanesulfonanilides and processes for their preparation. These compounds and their compositons are useful as herbicides and plant growth modifiers, particularly as pre-emergence and post-emergence herbicides. Plants may be treated with the compounds of the invention as seeds or at various stages of growth, from seeds onward.
The invention also includes processes for the preparation of the compounds, compositions containing them and methods for their use as herbicides, and plant growth modifiers.
It is an object of the invention to provide compounds which modify the growth of plants, i.e. compounds which prevent, alter, destroy or otherwise affect the growth of plants.
It is a further object of the invention to provide a method for controlling unwanted plants.
Still other objects of the invention will be made apparent by the following specification.
DETAILED DESCRIPTION
According to the present invention, there is provided a class of compounds having the general formula: ##SPC1##
Wherein R f is perfluoroalkyl of one to two carbon atoms, R is lower alkyl or lower haloalkyl, Y is selected from halogen, nitro, cyano, alkyl, haloalkyl, alkoxy, haloalkoxy, alkylthio, haloalkylthio, alkanoyl, haloalkanoyl, alkanoylamino, haloalkanoylamino, alkylsulfinyl, haloalkylsulfinyl, alkylsulfonyl, haloalkylsulfonyl, alkylsulfonato and haloalkylsulfonato and n is 0-5. When n is 0, the phenyl ring is unsubstituted (except for the amide nitrogen of the formula). Preferably n is 0-2, most preferably n is 0.
It has been found that compounds wherein R f is trifluoromethyl or perfluoroethyl are very active as herbicides. It appears critical for maximum herbicidal activity that R f contain one or more fully fluorinated carbons. Compounds wherein R f contains hydrogen atoms in place of one or more fluorine atoms are much less active or inactive as herbicides. As the number of carbon atoms in R f increases, cost of the compound increases without a corresponding increase in herbicidal effectiveness. For this reason compounds wherein R f is trifluoromethyl are preferred.
The lower alkyl and lower haloalkyl R groups normally contain from one to four carbon atoms. The compounds are particularly effective herbicides when R contains one carbon atom, and compounds wherein R is methyl are preferred.
Normally the Y groups contain no more than four carbon atoms each. Presently preferred Y groups are halogen (particularly chlorine, fluorine and bromine), haloalkyl and alkylthio. When more than one substituent is present, the substituents may be the same or different.
The compounds of the invention are generally prepared by the reaction of a perfluoroalkanesulfonanilide in the form of its salt with an alkane-or haloalkanesulfonylating agent of the formula RSO 2 Q wherein R is as defined hereinabove and Q is halogen selected from fluorine, chlorine and bromine or the residue of an anhydride, that is the group RSO 2 O--.
The perfluoroalkanesulfonanilides and alkane- and haloalkanesulfonylating agents are generally known to the art, and/or are prepared according to known synthetic methods. Salts of the perfluoroalkanesulfonanilides which are useful in this process are alkali metal, alkaline earth, aluminum and amine salts. They are readily formed and are known, as a class, to the art.
Suitable sulfonylating agents include methanesulfonyl chloride, chloromethanesulfonyl chloride, trifluoromethanesulfonyl fluoride, trifluoromethanesulfonic anhydride, difluoromethansulfonyl chloride and the like.
The reaction is generally run by converting the perfluoroalkanesulfonanilide to its salt in situ by reaction with a base in non-reactive solvent then adding the sulfonylating agent and allowing the reaction to run until complete. Many bases are suitable, among them inorganic bases such as sodium hydride and metal oxides, hydroxides, carbonates, bicarbonates and alkoxides. Sodium salts are preferred since they are generally available and less expensive. Organic bases which are not reactive with the sulfonylating agent (such as tertiary amines, for example N,N-dimethylaniline, triethylamine and the like) may also be used. In general the reaction temperature will vary, from the freezing point to the boiling point of the solvent used, depending upon the reactivity of the reactants. In some cases the reaction proceeds at a satisfactory rate at room or ice bath temperatures. It is usually preferred to accelerate the rate of reaction, in most cases, by heating the reaction mixture to its reflux temperature and maintaining it at this temperature for about one to twenty hours. Ordinarily, the mixture is then filtered to remove the metal or amine salt which is formed as a by-product, then the solvent is removed in vacuo. The residue may contain unreacted starting material which is removed by suspending the residue in water. The desired product is then isolated by extracting with an organic solvent such as dichloromethane, chloroform or diethyl ether. Alternatively the residue may be dissolved in an organic solvent and the solution washed with water and base. The solution is dried, the solvent is removed in vacuo and the residue is purified further, if necessary, by conventional techniques. Usually recrystallization is satisfactory.
Suitable solvents are those in which the salts of perfluoroalkanesulfonanilides have some solubility, and which are non-reactive, such as acetone, 1,2-dimethoxyethane, diethyl ether, diisopropyl ether, chloroform, dichloromethane and the like.
The herbicidal activity of the compounds of the invention has been determined by standard screening methods against both broad-leafed plants and grasses. They are active against broad-leaves and grasses both pre-emergence and post-emergence.
In order to control unwanted plants, the compounds of the invention can be used alone as herbicides, for example, as dusts or granules of the compounds, or preferably they may be applied in formulations containing the active ingredients in a horticulturally acceptable extending medium. Thus, the herbicidal composition applied to the plants may contain from about 5 to 100 percent of the active compound.
The formulations are comprised of one or more active ingredients and one or more herbicidal adjuvants and/or carriers. Specific formulations are useful to facilitate the application of the compounds and to achieve specific biological objectives such as controlling the availability of the herbicide, improving adherence to plants, and the like, as is well known to those skilled in the art.
The compounds of the invention may be formulated as wettable powders, emulsifiable concentrates, aqueous or non-aqueous solutions and/or suspensions, granules, dusts and the like. Said compounds as such can be finely divided and dispersed or suspended in any of the usual aqueous media, in which they are stable, or if appropriate salts are used, a solution may be made. Spreading agents, wetting agents, sticking agents or other adjuvants can be added as desired.
When emulsifiable concentrates are prepared the active ingredient can be present in concentration of about 5 to 60% or more, depending upon its solubility, but it has been found that the compounds of this invention are preferably used in a concentration of 20 to 30%. The units of concentration are weight per unit weight. The active ingredients are soluble in common organic horticultural solvents such as benzene, toluene, xylene, dichloromethane, chloroform, hexane and heptane or less highly refined aromatic or aliphatic hydrocarbons and mixtures thereof. Examples of these are coal tar fractions, straight run petroleum distillates, thermolytically or catalytically cracked hydrocarbon oil, gas oil, light lubricating oil fractions, kerosene, mineral seal oil, and the like. In appropriate cases, oxygenated solvents such as ketones may be used in or as the carriers. These concentrates can be dispersed in water to permit the use of an aqueous spray. A mixture with a small amount of an organic surface active agent capable of lowering the surface tension of water is preferred, so as to produce more or less stable emulsions.
Examples of surface active agents variously known as dispersing agents, wetting agents or emulsifying agents comprise soft or hard soaps, morpholine or dimethylamine oleate, sulfonated fish, castor and petroleum oils, sodium salts of lignin sulfonic acid, alkylated aromatic sodium sulfonates, such as decylbenzene sodium sulfonate, dodecylbenzene sodium sulfonate, butyl or other amine salts of decyl or dodecylbenzene sulfonic acid, sodium lauryl sulfate, disodium monolauryl phosphate, ethylene oxide condensation products of alkyl phenols, as for example octyl phenol, ethylene oxide condensation products of tall oil and ethylene oxide condensation products of higher alcohols or higher mercaptans. Mixtures of two or more surface active agents are also feasible. Generally, the surface active agent will comprise only a small proportion of the composition, say 0.1.15% by weight of the toxicant.
The formulation of dry compositions for application as granules, dusts or for further dilution with liquid carriers is readily accomplished by mixing the toxicant with a solid carrier. Such solid carriers will be of various sizes from dust to granules. The techniques for such formulations are well known to the art. Suitable carriers include charcoal, talc, clay, pyrophyllite, silicas, fuller's earth, lime, diatomaceous earth, flours such as walnut shell, wheat, soya bean, cottonseed and wood flours, magnesium and calcium carbonate, calcium phosphate and the like. Powders may be granulated by the use of suitable binders such as cellulose derivatives, for example ethyl or carboxymethyl, corn syrup, and the like. The compounds or the above formulations are applied by spraying, spreading, dusting or the like. The rate of application will of course vary, but the more active compounds of the invention exhibit satisfactory control of broadleaf and grass weeds at the application rate of about 1 to 15 pounds per acre. It is of course to be expected that local conditions, for example, temperature, humidity, moisture content of the soil, nature of the soil, and the like, may require greater or smaller amounts. Effective resolution of these factors is within the skill of those versed in the herbicidal art. Likewise it is apparent that not all of the compounds included within the scope of the invention have equal activity.
The herbicidal compositions may contain one or more of the herbicidal compounds set out hereinbefore as the sole active species, or they may contain in addition thereto other biologically active substances. Thus insecticides and fungicides may be incorporated in the compositions. Further, if desired, the herbicidal compositions may contain fertilizers, trace metals or the like and when applied directly to the soil may additionally contain nematicides, soil conditioners, plant growth regulators, and/or herbicides of similar or different properties.
The compounds of this invention are broadly active as herbicides. However, many of the compounds of the invention also show various types of plant growth modifying activity. Plant growth modification as defined herein consists of all deviations from natural development, for example, defoliation, stimulation, stunting, retardation, desiccation, tillering, dwarfing, regulation and the like. This plant growth modifying activity is generally observed as the compounds of the invention begin to interfere with certain processes within the plant. If these processes are essential, the plant will die if treated with a sufficient dose of the compound. However, the type of growth modifying activity observed varies among types of plants. It has been found that with certain compounds of the invention, herbicidal activity can be separated from certain plant growth modifying activities by controlling the rate of application.
The following examples are given for the purpose of further illustrating the procedures of the present invention, but are not intended, in any way, to be limiting on the scope thereof. Thus, one detailed example is given for the purpose of illustrating the general synthetic procedure of the invention and number of examples of compounds of the invention wherein R f , R, n and Y are varied are given in table form. It will be understood, however, that these examples are given for the purpose of illustrating the invention. They are not intended to be limiting on the scope of the invention. The melting points in the examples are uncorrected.
EXAMPLE 1
Sodium carbonate (2.97 g., 28 mmole) and 4-methylthiotrifluoromethanesulfonanilide (6.77 g., 25 mmole) in acetone (100 ml) are stirred vigorously for two hours, then methanesulfonyl chloride (3.21 g., 28 mmole) is added in one portion. Stirring is continued at room temperature and maintained at reflux for about four hours. The reaction mixture is filtered and the filtrate is evaporated in vacuo. Water (100 ml) is added and the mixture is extracted with three 50 ml. portions of chloroform. The organic extracts are dried, then filtered and the solvent is removed by evaporation in vacuo. The residue of N-methylsulfonyl-4-methylthiotrifluoromethanesulfonanilide is recrystallized from ethanol, m.p. 112°-114° C.
______________________________________Analysis %C %H %N______________________________________Calculated for C.sub.9 H.sub.10 F.sub.3 NO.sub.4 S.sub.3 : 31.0 2.9 4.0Found: 31.5 3.0 4.0______________________________________
Some examples of compounds of the invention wherein R f is trifluoromethyl and R is methyl, made using the procedure described specifically in Example 1, are given in Table I.
TABLE I__________________________________________________________________________Example Melting PointNo. Compound (in °C)__________________________________________________________________________2 N-methylsulfonyl-2,4-dichlorotrifluoro-methanesulfonanilide 157-159.53 N-methylsulfonyl-2-methylthiotrifluoro-methanesulfonanilide 113-1144 N-methylsulfonyl-4-fluorotrifluoro-methanesulfonanilide 91-935 N-methylsulfonyl-4-bromotrifluoro-methanesulfonanilide 107-1116 N-methylsulfonyl-4-fluoro-3-methyl-trifluoromethanesulfonanilide 103-1057 N-methylsulfonyl-2,5-dichlorotrifluoro-methanesulfonanilide 106-1128 N-methylsulfonyl-4-nitrotrifluoro-methanesulfonanilide 164-1669 N-methylsulfonyl-4-chlorotrifluoro-methanesulfonanilide 86-9210 N-methylsulfonyl-5-acetamido-2-chloro-trifluoromethanesulfonanilide 171-17411 N-methylsulfonyl-5-acetamido-2-methyl-trifluoromethanesulfonanilide 156-165__________________________________________________________________________
Examples of compounds of the invention wherein R f and R as well as Y and n are varied are prepared using the general procedure of Example 1 but varying the anilide and/or the sulfonyl halide used and are given in Table II.
TABLE II__________________________________________________________________________STARTING MATERIALEx.No. Anilide Sulfonyl Halide PRODUCT__________________________________________________________________________12 4-trifluoromethylper- methanesulfonyl N-methylsulfonyl-4-tri- fluoromethanesulfon- chloride fluoromethylperfluoro- anilide ethanesulfonanilide13 4-acetyltrifluoro- chloromethane- N-chloromethanesul- methanesulfon- sulfonyl fonyl-4-acetyltri- anilide chloride fluoromethanesulfon- anilide14 3-cyanotrifluoro- difluoromethane- N-difluoromethanesul- methanesulfon- sulfonyl fonyl-3-cyanotri- anilide chloride fluoromethanesulfon- anilide15 2-methylsulfinyltri- ethanesulfonyl N-ethanesulfonyl-2- fluoromethanesul- chloride methylsulfinyltri- fonanilide fluoromethanesulfon- anilide16 3-methylsulfonylper- butanesulfonyl N-butanesulfonyl-3- fluoroethanesulfon- chloride methylsulfonylper- anilide fluoroethanesulfon- anilide17 5-chloro-2,4-di- methanesulfonyl N-methylsulfonyl-5- methoxytrifluoro- chloride chloro-2,4-dimethoxy- methanesulfon- trifluoromethanesul- anilide fonanilide18 2-(2,2,2-trifluoro- chloromethane- N-chloromethanesul- ethoxy)trifluoro- sulfonyl fonyl-2-(2,2,2-tri- methanesulfon- chloride fluoroethoxy)tri- anilide fluoro-methanesulfon- anilide19 4-(2,2,2-trifluoro- methanesulfonyl N-methylsulfonyl-4- ethylthio)trifluoro- chloride (2,2,2-trifluoroethyl- methanesulfonanilide thio)trifluoromethane- sulfonanilide20 4-trifluoromethyl- perfluoroethane- N-perfluoroethylsul- thiotrifluoromethane- sulfonyl fonyl-4-trifluoro- sulfonanilide chloride methylthiotrifluoro- methanesulfonanilide21 2-(n-butyroyl)tri- trifluoro- N-trifluoromethylsul- fluoromethanesul- methanesulfonyl fonyl-2-(n-butyroyl) fonanilide chloride trifluoromethanesul- fonanilide22 4-trifluoromethyl- methanesulfonyl N-methylsulfonyl-4- sulfonyltrifluoro- chloride trifluoromethylsul- methanesulfon- fonyltrifluoro- anilide methanesulfonanilide23 3-trifluoromethylsul- methanesulfonyl N-methylsulfonyl-3- fonoxytrifluoro- chloride trifluoromethylsul- methanesulfonanilide fonoxytrifluoro methanesulfonanilide24 2,3,4,5,6-pentafluoro- methanesulfonyl N-methylsulfonyl- trifluoromethanesul- chloride 2,3,4,5,6-pentafluoro- fonanilide trifluoromethanesul- fonanilide25 2,4-bis(methylthio)tri- methanesulfonyl N-methylsulfonyl-2,4- fluoromethanesulfon- chloride bis(methylthio)tri- anilide fluoromethanesulfon- anilide__________________________________________________________________________
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N-alkylsulfonyl and N-haloalkylsulfonyl-substituted perfluoroalkanesulfonanilides and processes for their preparation are disclosed. These compounds and their compositions are useful as herbicides and plant growth modifiers.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a tearing machine for use in the textile industry.
2. Description of the Relevant Art
A machine of this type is known, for example, by French Patent 2 283 247. This known machine comprises a feeding station which receives varied textile scraps, and introduces the scraps into a tearing drum with points, which disintegrates the material. The fibers obtained in this way are then evacuated in the form of a fibrous cloth which constitutes a basic pure material, for diverse subsequent fabrications.
Such a known disintegrator presents the distinctive feature of being achieved along a relatively thin width, for example in the order of 80 cm to 140 cm. The feeding is performed manually by an operator who puts the textile scraps on the feeding conveyor belt.
In practice, it would be advantageous to be able to achieve such a tearing along a much larger width (for example on the order of 2 meters). This is impossible to achieve with the known technology cited above. As a matter of fact, for one thing, such a width would be much larger than the breadth of a man in charge of the manual feeding. Additionally, the fibrous cloth obtained at the exit would present, on an equally large width, some significant irregularities, besides irregularities in thickness and density.
The present invention tries to avoid these inconveniences, by providing a tearing machine of large width, for example on the order of 2 meters, and even larger.
SUMMARY OF THE INVENTION
The tearing machine according to the invention comprises a rotary drum with points or teeth extending the entire width of the machine. The feeding of the tearing drum is performed by an automatically functioning station, comprising a vertical stack which receives the scraps to open, and in which these scraps are kept at an approximately constant level, while at least one of the partitions within the vertical stack, between which the scraps go down, comprises a vibrating assembly.
Following another characteristic of the invention, the vibrating wall of the feeding stack extends approximately the entire width of the machine, and accomplishes pulsations whose amplitude and frequency are adjustable.
According to another characteristic of the invention, the transverse and approximately vertical walls of the feeding stack are both achieved with a vibrating method.
According to another characteristic of the invention, at least one of the vibrating walls comprises perforations which make it permeable to the air, which permit recycling the recovered fibrous scraps there more downstream in the machine and forwarded by pneumatic transport.
According to another characteristic of the invention, the pneumatic transport which assures the recycling of the recovered scraps, has a centrifugal separator at the lower part from which are gathered the hard and heavy scraps, while from the upper part, a flux of air moves forward toward the upper part of the feeding stack, the entirety of the usable light fibers.
Following another characteristic of the invention, the machine comprises, downstream from the rotary drum of points, a conveyor strip with multiple perforations. A suction loading device is provided under the conveyor strip and extending the entire width of the cloth. The suction loading device's interior space is divided into several suction compartments divided along the width of the machine. This arrangement assures homogeneity of the fibrous cloth produced over the entire width of the machine, as well as uniformity in thickness and density.
Following another characteristic of the invention, the machine comprises, above the rotary drum with points, a transverse bridge. The length of the bridge can move a sharpening mechanism in both directions. The sharpening mechanism comprises a sharpener with a bushel rotary grindstone, in order to sharpen teeth of the drum over the entire length of the drum.
Following another characteristic of the invention, the machine is made in a modular form, meaning the fibrous cloth flows by successively crossing many modules, each of which comprises a tearing cylinder and its accessories cited above.
Following another characteristic of the invention, the machine in modular form comprises two longitudinal rolling stacks, on which one can displace the sharpening cross-piece. The cross-piece can then be successively brought over each of the rotary drums with points, thereby achieving the sharpening.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and embodiments of the present invention will be understood by reference to the following specification and drawings in which:
FIG. 1 is a front elevational view of a machine according to the invention, constituted by three successive modules side-by-side;
FIG. 2 is an enlarged longitudinal section showing the detail of the feeding station;
FIG. 3 is a longitudinal section, showing the mechanism which presents the textile scraps to the disintegrator drum;
FIG. 4 is a longitudinal section of one of the modules, showing in particular the cloth making device, situated downstream from the disintegrating drum;
FIG. 5 is a view along the direction of arrow V (FIG. 4);
FIG. 6 is a view similar to FIG. 4, after opening the cover which is found at the upper part of the drum with points;
FIG. 7 is a section along line VII--VII in FIG. 4, showing the detail of the compartmentalized suction loading device;
FIG. 8 is a view along the direction of arrow VIII (FIG. 6), when the drum is in position for receiving the sharpening cross-piece; and
FIG. 9 is a schematic view along the direction of arrow IX (FIG. 1), showing the modular structure of the assembly of the machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the machine according to the present invention comprises an automatic feeding station 1, connected to many identical modules 2, 3, 4. At the exit, an evacuation station 5 puts out a fibrous cloth, homogeneous at one and the same time in thickness and in density upon the entire width of the machine.
The usable width 6, as shown in FIG. 5 and 8, is practically equal to the axial length of the tearing drum 7 of each module 2, 3, 4, the tearing drum 7 being disposed within a housing 60. It can be larger, for example equal to several meters. The automatic feeding station 1 comprises a vertical stack 8. The textile scraps for opening are poured through the height of stack 8 (arrow 9 in FIG. 2).
Stack 8 extends itself on the entire width 6 of the housing 60 of the machine. In the interior, stack 8 comprises two approximately vertical partitions or walls 10 and 11, between which pneumatic transport piping 12 pours scraps for opening. At least one of walls 10, 11 vibrates. The vibrating wall 11 is preferably perforated, so that it lets the air from the pneumatic transport 12 (arrows 13) escape, under the suction of an extractor 14. The scraps supplied by the pneumatic transport 31 are received at the bottom of the stack 8 (arrow 15), at the same time as recovered, poured fibers are received along arrow 9.
Due to this arrangement, the fibers and scraps which fall on a feeding conveyor 17 form an approximately uniform cloth on the entire width of the machine. They are forwarded (arrow 15) toward the drum with points or teeth in the first module 2. For that, the cloth 18 in question ends up, in the known manner, between a feeding roller 19, and a reserve trough 20 are shown in FIG. 3. This trough 20 can be formed of a one-piece structure on the entire width of the machine, in a divided form, that is, constituted by placing several pedals or treadles of the same shape side-by-side.
After fibers are opened by the points of the rotary drum 7, fixed but adjustable deflecting sheet metal 21 separates the material in two streams as shown in FIG. 4. The first stream consists of light textile fibers adequately open, which flow along the direction indicated by arrow 22. The other stream consists of solid scraps, or scraps insufficiently open 23, which fall on the horizontal valve 24 of a bushel sieve. This valve 24 extends itself over the entire width of the machine, and it turns periodically (for example, every 10 seconds), following a 180° angle, around its transverse horizontal axle 25. A fixed receiving trough 26 is kept permanently below the horizontal valve 24, by a suction returning the solid scraps in a pneumatic transport shaft 27, extending itself under the entire length of the machine (FIG. 1). At its rear part, the shaft 27 is returning toward piping 28, situated at the upper part of the feeding station 1. This piping 28 emerges tangentially in the tank of a centrifugal separator 29. In the lower part of this tank, one recovers (arrow 30), the hard and heavy scraps. On the contrary, at the upper part of separator 29, the reusable fibers are deducted in advance by piping 31 which recycles them toward feed piping 12.
Downstream from each drum 7, fibers 22 fall on a perforated conveyor strip 32 (FIGS. 4 and 5), which circulates continuously on rollers 33. A fixed suction loading device 34 is provided under this conveyor strip 32, extending the entire width of the machine as seen in FIG. 7. The fixed suction loading device 34 is divided into many compartments such as 35, 36, 37, 38, 39, disposed one next to the other over the entire width 6 of the machine. All of these compartments 35, 36, 37, 38, 39 are connected at a common lateral suction 40, which thus keeps the interior space of loading device 34 hollow and, consequently, the spaces in the perforated conveyor strip 32 are kept clear. Due to this disposition, the fibers forwarded along the direction of arrow 22 form, on this conveyor strip 32, a fibrous cloth 41, whose homogeneity stays satisfactorily uniform over the entire width 6 of the machine, as far as the thickness and density are concerned. The cloth 41 is then sent toward the following module, such as 3, 4, until, finally, at the exit from the machine, the evacuation station 5 provides the fibrous cloth on its evacuation conveyor belt 42 (FIG. 1). The fibrous cloth has all the desired quality and a perfect homogeneity on the entire width of the machine, even if this width is equal to several meters.
In each module 2, 3, 4, the drum with points 7 has a raisable cover or lid 43 mounted on it. (FIGS. 4 and 6). When this lid 43 is raised (FIG. 6), while the machine is at rest, one can conduct the sharpening of the points or needles of the corresponding drums 7. To accomplish this sharpening, the invention provides on both sides of the upper part of the machine, two longitudinal rotating stacks 44, on which the extremities of the cross-piece 45 can rotate. The length of this cross-piece, meaning transversely in comparison with the entirety of the machine (double arrow 46 on FIG. 8), can displace itself over a groove 47, and a sharpener 48 of which the lower extremity carries in rotation a millstone 49, of a type in itself known. In this way, when the cross-piece or sharpening bridge 45 is stopped above a drum 7, it is sufficient to displace it alternatively the length of the groove 47, in order to sharpen all the points of the drum 7 situated on the corresponding generator. A rotation of the drum 7 permits in this way sharpening the totality of these points. Due to this arrangement, one sees that a single sharpening bridge 45 allows the sharpening of the points of all the drum 7 of the machine.
Means are provided for selectively regulating both the amplitude and frequency, the movements of wall 11, and eventually of wall 10 of automatic feeding station 1. This assures a good discharge of the majority of the scraps 16, and provides an even density at the lower part of the passage, before the transfer (arrow 15) toward the feeding apparatus of the tearer, opener, disintegrator, or the like.
Referring to FIG. 4, the suction 50 comprises pneumatic piping 51 and 52, formed with the assembly of the loading device 34, the perforated strip 32 and its support parts 33 or drive parts, and a block 53 that one can take out, in the fashion of a drawer, by lateral sliding (see FIG. 9, arrow 54). This considerably facilitates the maintenance operations of the machine.
It is to be understood that the foregoing description is merely exemplary and not limitative, and that the true scope of the invention is that defined in the following claims.
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The invention comprises a tearing machine of large width. The feeding station is automatic. A centrifugal separator recycles the scraps recovered by the longitudinal pneumatic transport. It recycles them with the new scraps, in the stack with vibrating walls which extends itself over the entire width of the machine. The compartmentalized suction loading devices assure homogeneity of the fibrous cloth. A fibrous cloth of very high quality is produced on an evacuation conveyor belt. This cloth is homogenous over the entire width of the machine, which may extend to several meters.
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TECHNICAL FIELD
The present invention relates to technologies of constructing a superstructure box girder in bridge engineering, and more particularly to an upper-bearing typed movable formwork used for cast-in-situ of concrete box girder.
BACKGROUND OF THE INVENTION
An upper-bearing typed movable formwork is construction equipment for bridge superstructure construction, and especially applicable to production of a concrete simple box girder or continuous box girder. According to different relative positions of an upper-bearing typed movable formwork main girder and the concrete box girder, the upper-bearing typed movable formwork is classified into a deck type and a through type, in which the main girder of the through upper-bearing typed movable formwork is located above the concrete box girder, and the main girder of the upper-bearing typed movable formwork is located below the concrete box girder. Compared with the through upper-bearing typed movable formwork, the upper-bearing typed movable formwork has the advantages of an open working plane and no additional load generated on the concrete box girder when the scaffolding system runs through holes, and is widely applied in engineering practice. For the conventional upper-bearing typed movable formwork, the main girder is located below the concrete box girder; generally, one girder is disposed at two sides of a pier shaft respectively, a transverse truss (or a transverse steel box girder) is usually disposed at the top or one side of the main girder, a formwork system is disposed on the top of the transverse truss (or the transverse steel box girder), and the load (the dead weight of the concrete box girder, and the side pressure of the newly-cast concrete, and so on) of the upper-bearing typed movable formwork is transferred to the transverse truss (or the transverse steel box girder) through the formwork system, and then is transferred onto the main girder of the upper-bearing typed movable formwork.
The technical solution of the conventional upper-bearing typed movable formwork has the following disadvantages:
(a) Large dead weight: firstly, since the formwork system is disposed on the top of the transverse truss (the transverse steel box girder), the rigidity of the formwork system cannot be fully utilized, and the transverse truss (the transverse steel box girder) needs to bear the entire load, which requires the transverse truss to have a great rigidity and a large dead weight; additionally, the deformation value of the upper-bearing typed movable formwork is a sum of the deformation values of the formwork system, the transverse truss (the transverse steel box girder), and the main girder, and thus the structure deformation is great and relatively soft, and in the condition of the same rigidity, the upper-bearing typed movable formwork needs to consume more steel.
(b) High occupation space: below the bottom surface of the concrete box girder, the height of the occupation space of the conventional upper-bearing typed movable formwork is a sum of heights of structures such as the bottom formwork system, the transverse truss (the transverse steel box girder), the main girder, the vertical and horizontal transfer system, and a landing leg; when the height of the pier shaft is close to and even smaller than the sum of the heights, the upper-bearing typed movable formwork operation is difficult, and even cannot be implemented. Low pier shafts are usually used in passenger railway bridges in China.
(c) Unreasonable structure stress: the deployment of the structural system of the conventional upper-bearing typed movable formwork determines the disadvantages that the transverse truss (the transverse steel box girder) is bent, the load of web plates at the inner and outer sides of the girder is not even, and the additional torque is great, and the structure stress is unreasonable, thus resulting in increase of the dead weight of the structures and increase of risks.
(d) Many horizontal transfer mechanisms and complicated operations: for the conventional upper-bearing typed movable formwork, the transverse truss (the transverse steel box girder) and formwork system are divided into several individual action units longitudinally, each unit is equipped with a set of horizontal transfer mechanisms, and when the upper-bearing typed movable formwork runs, the horizontal transfer mechanisms are operated respectively, so that the action units are traversed one by one. The technical solution needs many horizontal transfer mechanisms and many procedures.
SUMMARY OF THE INVENTION
The technical problem to be addressed by the present invention is to solve the problem that the upper-bearing typed movable formwork has a large dead weight and a high occupation space, and the operation of the horizontal transfer mechanisms is complicated. The advantages of the invention are to utilize one energy and impetus in one direction as convenient power source so as to exert the latent energy of the generating equipment and improve the output efficiency.
To solve the above technical problem, the technical solution adopted by the present invention is to provide an upper-bearing typed movable formwork, comprising: left and right landing legs, respectively fixed on upper left and right sides of a pier shaft; left and right vertical and horizontal transfer mechanisms; a bearing device; and a formwork system.
The left and right vertical and horizontal transfer mechanisms are respectively disposed on the left and right landing legs and move horizontally along the left and right landing legs.
The bearing device includes left and right main girders, respectively fixed on the left and right vertical and horizontal transfer mechanisms; and two groups of left and right guide girders, respectively fixedly connected to front and, back ends of the left and right main girders.
The formwork system includes:
A bottom formwork, an inner formwork, and left and right formworks, in which the bottom formwork is formed by connecting the left and right bottom formworks disposed symmetrically with respect to an axis of the concrete box girder through a bolt, two ends of the bottom formwork are respectively fixed on two opposite inner sides of the left and right main girders; the inner formwork is centrally disposed on the bottom formwork; and the left and right formworks are respectively disposed on the bottom formwork, and located at left and right sides of the inner formwork, and gaps for forming the concrete box girder are disposed between left and right outer sides of the left and right formworks and the inner formwork.
In order to strengthen the rigidity of the bottom formwork, left and right bottom formwork struts are further included. An inner web plate is respectively disposed on two opposite sides of the left and right main girders, and left and right bottom formwork connecting hinge support and a bottom formwork strut connecting hinge support are respectively disposed on the inner web plate, two ends of the bottom formwork are respectively hinged with the left and right bottom formwork connecting hinge supports, and the left and right bottom formwork struts are respectively hinged with lower surfaces of the left and right bottom formworks and the bottom formwork connecting hinge supports on the inner web plate of the left and right main girders.
In the above solution, the left and right formworks include a left and right wing formwork and a left and right side formwork respectively. The left and right wing formworks and the left and right side formworks are fixedly connected to each other respectively, and lower ends of the left and right side formworks are fixedly supported on the bottom formwork; outer surfaces of the left and right wing formworks pass through left and right wing formwork upper struts and left and right wing formwork lower struts respectively, and the left and right wing formworks are hinged on upper surfaces of the left and right main girders respectively through left and right side formwork upper struts, left and right side formwork middle struts, and left and right side formwork lower struts.
At least three vertical oblong holes are opened on the inner web plate of the left and right main girders, at least three round holes A are opened on bottom plates of the left and right bottom formwork connecting hinge supports, and the left and right bottom formwork connecting hinge supports are connected with the inner web plate through a bolt. A contact surface of the left and right bottom formwork connecting hinge supports and the inner web plate of the left and right main girders is a rough surface machined with sandblasting for rusting or aluminum spraying.
An outer web plate is respectively disposed at outer sides of the left and right main girders, the inner web plate at two sides of bottom formwork stmt connecting hinge supports is disposed with at least two holes B running through the inner and outer web plates of the left and right main girders symmetrically; and finish rolled threaded steel bars A of a number equal to that of the holes B are fixedly connected with the outer web plate of the left and right main girders respectively through the holes B.
A portion of the finish rolled threaded steel bars A located between the inner and outer web plates of the left and right main girders is respectively sleeved with stiffened steel tubes, and two ends of the stiffened steel tubes are respectively fixed with the inner and outer web plates of the left and right main girders by welding.
Left and right brackets are embedded at two sides of the pier shaft, the left and right landing legs are respectively fixedly connected to the left and right brackets, and left and right landing legs at two sides of the same pier shaft are fixed diagonally with a finish rolled threaded steel bar B.
The left and right bottom formwork struts, the left and right wing formwork upper struts, the left and right wing formwork lower struts, the left and right side formwork upper struts, the left and right side formwork middle struts, and the left and right side formwork lower struts respectively include a supporting steel tube, a left nut, a right nut, left and right screws connected with the left and right nuts through threads, and at least two rotation handles, in which rotation directions of inner threads of the left and right nuts are opposite, the inner threads are respectively welded at two ends of the supporting steel tubes, and the at least two rotation handles are respectively disposed on outer surfaces of the supporting steel tube.
According to the present invention, the bottom formwork is used to replace the transverse truss (or the transverse steel box girder) and has a small dead weight, the main girder can reasonably enter the space above the concrete box girder, and the upper-bearing typed movable formwork occupies less height space below the concrete box girder, and can be adapted to lower pier shafts. With the bottom formwork, the left and right bottom formwork struts, and the finish rolled threaded steel bars A, a stable bearing system is formed, and the rigidity of the bottom formwork is utilized effectively. By reasonably arranging adjustable struts of the wing formworks and the side formworks, the stress of two web plates of the main girder is even, and thus the horizontal deformation of the girder is effectively reduced.
THE DRAWINGS
FIG. 1 is a front view of the present invention;
FIG. 2 is a schematic cross-sectional view along line A-A in a concrete casting state according to the present invention;
FIG. 3 is a schematic structural view of a bottom formwork according to the present invention;
FIG. 4 is a schematic structural view of a formwork system according to the present invention;
FIG. 5 is a schematic view of an adjustable strut according to the present invention;
FIG. 6 is a schematic structural view of an inner web plate on left and right main girders according to the present invention;
FIG. 7 a is a schematic structural view of left and right bottom formwork connecting hinge supports according to the present invention;
FIG. 7 b is a left view of FIG. 7A ;
FIG. 7 c is a top view of FIG. 7A ; and
FIG. 8 is a schematic cross-sectional view along line A-A of the present invention in a running state.
The meanings of the serial numbers in the drawings are as follows:
1 —left and right main girder, 2 —left and right guide girder, 3 —inner formwork, 4 —left and right wing formwork, 5 —left and right side formwork, 6 —bottom formwork, 6 a —left bottom formwork, 6 b —right bottom formwork, 7 —left and right landing leg, 8 —pier shaft embedded bracket, 9 —vertical and horizontal transfer mechanism, 10 —left and right bottom formwork connecting hinge, 11 —left and right bottom formwork connecting hinge support, 12 —bottom formwork strut connecting hinge support, 13 —hinge C, 14 —left and right bottom formwork strut, 15 —left and right wing formwork upper strut, 16 —left and right wing formwork lower strut, 17 —left and right side formwork upper strut, 18 —left and right side formwork middle strut, 19 —left and right side formwork lower strut, 20 —oblong hole, 21 —hole A, 22 —hole B, 23 —finish rolled threaded steel bars A, 24 —anchorage gear A, 25 —stiffened steel tube, 26 —finish rolled threaded steel bars B, 27 —anchorage gear B, 28 —supporting steel tube, 29 —left nut, 30 —right nut, 31 —rotation handle, 32 —left screw, and 33 —right screw.
DETAILED DESCRIPTION
The present invention is described below in detail with reference to the accompanying drawings.
As shown in FIG. 1 and FIG. 2 , the present invention includes left and right landing legs 7 , left and right vertical and horizontal transfer mechanisms 9 , a bearing device, and a formwork system. Left and right brackets 8 are embedded at two sides of a pier shaft. The embedded brackets 8 are installed during the construction of the pier shaft, the left and right landing legs 7 are fixedly connected to the left and right brackets 8 , the landing legs 7 at two sides of the same pier shaft are fixed on the pier shaft by pulling diagonally with a finish rolled threaded steel bars B 26 and an anchorage gear B 27 , and the left and right vertical and horizontal transfer mechanisms 9 are respectively disposed on the left and right landing legs 7 and move left and right along the left and right landing legs 7 horizontally.
The bearing device includes left and right main girders 1 respectively fixed on the left and right vertical and horizontal transfer mechanisms 9 and two groups of left and right guide girders 2 respectively fixedly connected to front and back ends of the left and right main girders 1 .
The formwork system includes a bottom formwork 6 , an inner formwork 3 , and left and right formworks, which are disposed symmetrically with respect to a centerline of the pier shaft; in which the bottom formwork 6 is disposed between the left and right main girders 1 and is close to the top of the left and right main girders 1 , the inner formwork 3 is centrally disposed on the bottom formwork 6 ; and the left and right formworks are respectively located at left and right sides of the inner formwork 3 , and gaps for forming the concrete box girder are disposed between left and right sides of the left and right formworks and the inner formwork 3 .
As shown in FIG. 3 and FIG. 4 , the bottom formwork 6 is formed by connecting left and right bottom formworks 6 a and 6 b through a bolt, the left and right bottom formworks 6 a and 6 b are respectively welded by profiled bars and steel plates and are disposed symmetrically with respect to an axis of the concrete box girder, left and right bottom formwork connecting hinges are respectively disposed at outer ends of the left and right bottom formworks 6 a and 6 b , and a bottom formwork strut connecting hinge support 12 is respectively disposed on bottom surfaces. An inner web plate is respectively disposed on two opposite sides of the left and right main girders 1 , left and right bottom formwork connecting hinge supports 11 and bottom formwork strut connecting hinge supports 12 are respectively disposed on the inner web plate, the left and right bottom formwork connecting hinges 10 on the left and right bottom formworks 6 a and 6 b are respectively hinged with the left and right bottom formwork connecting hinge supports 11 on the inner web plate of the left and right main girders 1 , two ends of left and right bottom formwork struts 14 are respectively hinged with the bottom formwork strut connecting hinge supports 12 on bottom surfaces of the left and right bottom formworks 6 a and 6 b and the bottom formwork connecting hinge supports 12 on the inner web plate of the left and right main girders 1 .
The left and right formworks respectively include left and right wing formworks 4 and left and right side formworks 5 . The left and right wing formworks 4 are supported at an outer side of the top surface of the left and right main girders 1 through left and right wing formwork upper struts 15 and left and right wing formwork lower struts 16 , the left and right side formworks 5 are supported at the outer side of the top surface of the left and right main girders 1 through left and right side formwork upper struts 17 , and is supported at an inner side of the top surface of the left and right main girders 1 through left and right side formwork middle struts 18 and left and right side formwork lower struts 19 ; and the left and right wing formworks 4 and the left and right side formworks 5 are respectively fixedly connected to each other, and lower ends of the left and right side formworks 5 are respectively fixedly supported on the bottom formwork 6 .
The left and right bottom formwork struts 14 , the left and right wing formwork upper struts 15 , left and right wing formwork lower struts 16 , left and right side formwork upper struts 17 , left and right side formwork middle struts 18 , and left and right side formwork lower struts 19 are called as adjustable struts collectively. As shown in FIG. 5 , the common construction features of the adjustable struts are as follows: a supporting steel tube 28 is included, one end is lathed with a left nut 29 with positive inner threads through welding, the other end is lathed with a right nut 30 with reverse inner threads through welding, and the body is lathed with at least two rotation handles 31 through welding; a left screw 32 is lathed with right-hand threads matching the left nut 29 through welding, a right screw 33 is lathed with left-hand threads matching the right nut 30 through welding; and outer diameters of the left screw 32 and the right screw 33 are both smaller than an inner diameter of the supporting steel tube 28 , and the left screw 32 and the right screw 33 are rotatably installed on the left nut 29 and the right nut 30 and extend into the supporting steel tube 28 . Lengths, diameters, and adjustment amounts of the adjustable struts are different, and should be determined by calculation according to actual uses and stress requirements for a specific adjustable strut.
The bottom formwork 6 can be tuned up and down in a vertical direction. As shown in FIG. 6 and FIGS. 7 a to 7 c , at least three oblong holes 20 are disposed at installation positions corresponding to the left and right bottom formwork connecting hinge supports 11 on the inner web plate of the left and right main girders 1 , and at least three holes A 21 are disposed at positions corresponding to the oblong holes 20 on a bottom plate of the left and right bottom formwork connecting hinge supports 11 , so as to be connected to the left and right main girders 1 with a bearing type high-strength bolt; the friction coefficient of contact areas X and Y of the left and right bottom formwork connecting hinge supports 11 and the inner web plate of the left and right main girders 1 is increased by sandblasting for rusting or aluminum spraying, and the design of the oblong holes can realize the up and down tuning of the bottom formwork. At least two round holes B 22 running through the inner and outer web plates of the left and right main girders 1 are disposed symmetrically at two sides of the bottom formwork strut connecting hinge supports 13 ; the finish rolled threaded steel bars A 23 passes through the round holes B 22 , and two ends are respectively connected to an anchorage gear A 24 at outer sides of the left and right main girders 1 ; a stiffened steel tube 25 is disposed between the inner and outer web plates of the left and right main girders 1 , the center of circle is overlapped with that of the round holes B 22 , and the inner diameter is larger than the diameter of the round holes B 22 ; and two ends of the stiffened steel tube 25 respectively press tightly against the inner and outer web plates of the left and right main girders 1 and are fixed by welding.
The functions of each part of the present invention are as follows. The left and right main girders 1 are spandrel girders of the upper-bearing typed movable formwork, and have greater rigidity to ensure the reasonable linear shape of the concrete box girder; the left and right guide girders 2 are extensions of the left and right main girders 1 , and are disposed for meeting the running requirements of the upper-bearing typed movable formwork; the inner formwork 3 , the left and right wing formworks 4 , the left and right side formworks 5 , and the bottom formwork 6 form a fog rework system together, and serve as a supporting structure of a reinforcement scaffolding system and a formworking bed for newly-casting concrete; the left and right landing legs 7 are a supporting structure of the left and right main girders 1 , as well as slideways and reaction seats of vertical and horizontal moving of the upper-bearing typed movable formwork; the pier shaft embedded brackets 8 are a supporting structure of the left and right landing legs 7 , for transferring the load of the landing legs to the pier shaft; and the vertical and horizontal transfer mechanisms 9 are a motion mechanism responsible for rising and falling, vertical transfer, and horizontal transfer of the upper-bearing typed movable formwork.
FIG. 8 is a schematic cross-sectional view along A-A of the present invention in a running state. Before the vertical transfer of the upper-bearing typed movable formwork, connection between the left and right bottom formworks 6 a and 6 b are released, and the vertical and horizontal transfer mechanisms 9 drag the left and right main girders and moves horizontally on the left and right landing legs 7 together with the left and right formworks, until the bottom formwork 6 does not touch the pier shaft in the vertical transfer. During this period, the left and right landing legs 7 are still fixed on the pier shaft, and relative positions of the left and right main girders 1 to the left and right wing formwork 4 and between the left and right side formwork 5 and the bottom formwork 6 are unchanged.
The present invention has the following technical features.
(1) Light dead weight and great rigidity. As the transverse truss (or the transverse steel box girder) is removed, the load transfer is simple, the rigidity of the bottom formwork is reasonably utilized, and the structure deformation is reduced, so the upper-bearing typed movable formwork has a light dead weight and great rigidity.
(2) Reasonable stress. In the load borne by the upper-bearing typed movable formwork, the dead weight load of the concrete box girder and the horizontal pressure of the newly-casting concrete account for a large proportion. In the present invention, the bottom formwork 6 , the left and right bottom formwork struts 14 , and the finish rolled threaded steel bars A 23 are connected to the left and right main girders 1 together, and thus a stable bearing system is formed, and the rigidity of the bottom formwork 6 is utilized. By reasonably arrangement of the adjustable struts of the left and right wing formworks 4 and the left and right side formworks 5 , the stress of two web plates of the left and right main girders 1 is even. Besides, an appropriate pre-stress can be applied to the finish rolled threaded steel bars A 23 , so as to effectively reduce the horizontal deformation of the left and right main girders 1 .
(3) Small net occupation height. After the transverse truss (or the transverse steel box girder) is removed, the left and right main girders 1 can reasonably enter the space above the bottom surface of the concrete box girder, and the height space below the bottom surface of the concrete box girder occupied by the upper-bearing typed movable formwork is much smaller, and thus the mobile scaffolding system can be adapted to lower pier shafts.
(4) Variable span construction. The pre-camber of the bottom formwork can be secondarily adjusted by using the oblong holes 20 on the inner web plate of the left and right main girders 1 , thus creating conditions for variable span construction. For example, after the same upper-bearing typed movable formwork completes the construction of a 32 m span simple box girder, the left and right bottom formwork connecting hinge supports 11 are moved up and down, and the pre-camber of the bottom formwork 6 is re-adjusted; and after the left and right side formworks 5 are changed, the mobile scaffolding system can perform the construction of a 24 m span simple box girder continuously.
(5) Constructible curved box girder. By adjusting lengths and support angles of the adjustable struts of the left and right wide formworks and the left and right side formworks, angles and positions of the left and right wide formworks and the left and right side formworks are changed, and thus the construct a curved box girder can be performed.
(6) Bidirectional construction. The UPPER-BEARING TYPED MOVABLE FORMWORK can construct forward and backward, thus avoiding turnaround in the construction site.
(7) Simplified procedures. Overall deformworking and overall formworking can be achieved without adjusting the formworks for each span, and thus the operation is simple.
Technical parameters of a certain application example (simple supported girder construction) of the present invention are as follows.
(1) construction span: 32 m, variable to 24 m.
(2) load: 900 t
(3) longitudinal slope: ≦1%
(4) plane curve: R≧2000 m
(5) dead weight: 375 t (not comprising the hydraulic internal formwork), lighter than the conventional UPPER-BEARING TYPED MOVABLE FORMWORK by 15-20%.
(6) elastic deflection-span ratio at full load: 1/655
(7) actual deflection-span ratio after the pre-camber included at full load: ≦1/3000
(8) vertical transfer speed: 1 m/min
(9) traverse transfer speed: 0.5 m/min
(10) total power: 100 kW
(11) construction period: 9-12 days/per span
The present invention is applicable in situ casting construction of an equal-height continuous box girder.
The present invention is not limited to the above preferred embodiments. Anyone should understand that, structural variations made under the teachings of the present invention, as well as such variations have technical, solutions the same as or similar to those of the present invention shall fall within the protection scope of the present invention.
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An upper-bearing typed movable formwork used for cast-in-situ of concrete box girder in bridge engineering, comprising left and right legs ( 7 ) which are respectively fixed on a pier, left and right longitudinal/transverse sliding mechanisms ( 9 ), bearing devices and a template system. The left and right longitudinal/transverse sliding mechanisms ( 9 ) are respectively arranged on the left and right legs ( 7 ) and can move horizontally along the left and right legs ( 7 ), the bearing devices are respectively fixed on the left and right longitudinal/transverse sliding mechanisms ( 9 ), the template system comprises a bottom formwork ( 6 ), an internal formwork ( 3 ), a left formwork and a right formwork, the bottom formwork ( 6 ) is formed by screw connection of a left bottom formwork and a right bottom formwork ( 6 a, 6 b ) which are symmetrical about the axis line of the concrete box girder, two ends of the bottom formwork are respectively fixed on two opposite internal side surfaces of the left main beam and the right main beam ( 1 ). The movable formwork also comprises a plurality of adjustable supporting rods ( 14 ) used for supporting the template system.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation in part of U.S. patent application Ser. No. 11/835,412 filed Aug. 7, 2007, now U.S. Pat. No. 7,819,087 which claims priority to Provisional Application No. 60/821,919, filed Aug. 9, 2006 the contents of each of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to animal training systems, and more particularly to a light accessory for electronic animal training systems. The invention has particular utility in connection with dog tracking systems, which may be used alone or in combination with a remote dog training system, and will be described in connection with such utility, although other utilities are contemplated.
BACKGROUND OF THE INVENTION
The invention relates to systems for animal training and tracking, and more particularly to an improvement and accessory for animal training systems to allow for visual tracking of an animal in low ambient light situations.
While a number of devices are known for remotely stimulating dogs and other animals for training purposes, it is difficult to track such animals if they are off-leash and moving far afield. In fact, dogs may be lost during training exercises or competitions should they wander too far from the owner or trainer. In this situation, not only may a prize animal be lost, but also so would the expensive training collar being worn by the animal. These problems are particularly acute in low lighting conditions.
Animal lighting apparatuses are known. For example, U.S. Pat. No. 4,173,201, issued to Chao et al. on Nov. 6, 1979, discloses an illuminated collar including small electric lamps powered by a dry cell battery and disposed along an elongated leather strap. A manually operated switch carried on the collar for operation of the lights. U.S. Pat. No. 3,935,443, issued to Allen P. Simmons on Jan. 27, 1976, discloses an illuminated collar, which includes a plurality of miniature filament lamps connected in parallel. A battery is disposed along the length of the collar which, when secured in its container, completes an electrical circuit to provide power to the lights. U.S. Pat. No. 5,523,927, issued to James A. Gokey on Jun. 4, 1996, discloses a collar for placement on an animal including a light emitting diode, a motion sensitive switch designed to respond to the motion of the animal, an on/off switch to selectively turn the battery power to the circuit, a battery and a timing circuit. U.S. Pat. No. 7,140,327, issued to Sondra Morehead on Nov. 28, 2006, discloses a collar with an illumination source in communication with a light emission inset through light transferring fibers. The illumination source may be manipulated with a control mechanism in communication with the illumination source through a radio frequency transceiver, or possibly an infrared link or other wireless technology. A person may activate the illumination source remotely without the necessity of capturing the animal prior to activating the illumination source.
While the above patents generally disclose an illuminated pet collar or harness, the references require the lighting on the collar to be switched on or off manually. The constant on position of the light source rapidly depletes the energy source for the lighting. Also, the above references do not disclose a light attachment that may be added to an existing wireless training system.
Thus, there is an unmet need for an improved remote training device that reliably provides a remote training device that (1) provides maximum selectability of the intensity of stimulus applied to the animal, (2) achieves very reliable, repeatable electrical contact of the electrodes with the animal's skin over the entire desired range of selectable stimulus intensity settings, and (3) allows for selective illumination of the animal in low lighting conditions to allow greater visibility to the owner.
The present invention provides improvements over the above prior art and other existing animal illumination systems.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the invention to provide a remote control animal training system that overcomes the aforesaid and other disadvantages of the prior art.
It is another object of the invention to provide a remote animal training system with a reliable way for a trainer to monitor whether an animal is moving or motionless when the animal is out of sight and/or to allow the trainer to better locate an animal in low lighting conditions.
It is another object of the invention to provide a remote animal training system that allows visual identification of an animal by a trainer or third party so that animals running off-leash with the device may avoid a vehicle-animal accident since the operator of the vehicle may see them.
Briefly described, and in accordance with one embodiment thereof, the invention provides a system and method for coupling a light accessory to a receiver that is responsive to a transmitter. A command to selectively illuminate a light accessory incorporated into the animal training system is transmitted to the receiver. The received information is demodulated in the receiver to produce a signal representative of the requested lighting status. A microprocessor in the receiver receives and operates on the signal to generate and transmit to the accessory via a low frequency communication channel an output of predetermined duration to light the light accessory.
In one embodiment, the light function is activated and controlled using a RFID function of a transmitter with an associated accessory. An RFID signal is transmitted by an antenna on a transmitter to an accessory receiving antenna and detected by a microcontroller. The received signal is demodulated to create instructions for the accessory device. The RFID signal transmitted to the accessory activates the light when the RFID transmitter is in close range with the accessory.
Accessory light devices may perform a variety of functions. For example, a Locate Feature may be encoded wherein the device will flash when the transmitter is set to accessory setting and a button is pressed. The Locate Mode may instruct the LED units of the device to continuously shine at its highest intensity. The light accessory may be coupled with an infrared (IR) LED for more effective use in the K9 protection functionalities.
In another embodiment, the LEDs may be customized to emit a specific color to allow for multiple dog usage. Further, the LED flash rate, or color, or both may be used for identifying a particular animal. The flash rate, color, or other element of the device may be coupled to, for example, a motion sensor, accelerometer, heart rate monitor, electronic compass or GPS system to indicate to a user whether the animal is in motion, being motionless (pointing), or treeing an animal. A secondary benefit is that the LED provides light to the tree where the dog is baying. In a particular embodiment, a pressure sensor is added to the neck of an animal such as a horse to monitor cribbing or foaling, and provide feedback information to the user. An electronic compass or GPS module may also be used in the accessory unit and coupled to the device such that the flash rate or color will indicate direction or orientation of an animal.
In addition to a light accessory, sound, vibration and other modules may be provided that draw power from an existing power supply and receive instructions via an RFID function of a transmitter. This allows a trainer or owner to add functionality onto an animal training product they have already purchased in an economical fashion.
Furthermore, modules for data collection applications, use in areas related to environments where a human cannot go such as search & rescue, crime scenes, etc. may be provided using the method and apparatus of the invention. In a particular embodiment, a module could hold medical supplies to aid with rescues.
In yet another embodiment of the invention, there is provided a remotely controlled animal training system having a transmitter including a control apparatus for selectively transmitting a signal to a collar mounted receiver, said transmitter and receiver each having a battery, said receiver further including a light source and a connection to couple the light source to the battery of the receiver;
a control to selectively power the light source and to enable various lighting patterns.
In still yet another embodiment of the invention, there is provided an accessory unit for a remotely controlled animal training system having a battery and a receiver, comprising:
a functional unit;
a connection to couple the functional unit to the battery of the animal training system and;
a control to selectively power and enable the functional unit.
The functional unit may comprise, for example, a sensor unit including but not limited to a temperature sensor, a moisture sensor and a biometric sensor, a GPS unit, and a compass.
BRIEF DESCRIPTION OF THE DRAWINGS
Many aspects of the invention can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1A is a perspective view of a receiver of an animal training system including a light accessory of the present disclosure;
FIG. 1B is an exploded view of the receiver of FIG. 1A ;
FIG. 2 is a block diagram of a remote animal training system, in accordance with an embodiment of the present disclosure;
FIG. 3 is a block diagram of the remote animal training system of FIG. 2 , in accordance with an embodiment of the present invention;
FIG. 4 is a circuit diagram of an element of the remote animal training system of FIG. 2 , in accordance with an embodiment of the present invention;
FIGS. 5 and 6 are block diagrams of accessory devices for the remote animal training system of FIG. 2 ;
FIG. 7 is a block diagram of a portion of the accessory device for the remote animal training system of FIG. 2 ;
FIG. 8 is an illustration of an emitter signal for the light module accessory device for the remote animal training system of FIG. 2 ;
FIG. 9 is an illustration of a portion of the emitter signal of FIG. 6 for the remote animal training system of FIG. 2 ;
FIG. 10 is an illustration of a portion of the emitter signal of FIG. 6 for the remote animal training system of FIG. 2 ;
FIG. 11 illustrates actual captured signal in accordance with an embodiment of the present disclosure; and
FIG. 12 is a schematic of a circuit to enact the present disclosure.
DETAILED DESCRIPTION
Referring to FIGS. 1A and 1B , in one embodiment, a light accessory 10 on an animal training system is activated by an accessory function in a receiver 12 of the animal training system. The light accessory or other accessory 10 is coupled to the existing battery 14 and is controlled by receiver 12 and shares power from the battery unit 14 of the animal training system. The receiver 12 and accessory 10 each have a collar strap tab 15 a , 15 b . Thus, if the collar strap tab of the receiver were to break or fail, the collar strap tab of the accessory will continue to secure the receiver and accessory to the animal, and vice versa. In a particular embodiment, the light accessory 10 comprises two or more high intensity light emitting diodes (LEDs) on board. LEDs are commercially available, such as, for example, Everlight Reference Part No. 99113UTC/1318507/TR8. The luminous intensity of the LEDs is preferably greater than about 800mCD. The housing for the light module accessory 10 is transparent and may include reflective material to maximize light visibility.
FIG. 2 is a block diagram of a remote animal training system 110 A, in accordance with a first exemplary embodiment of the present invention. The remote training system 110 A includes a remote transmitter 111 having several push-button switches 113 for setting a stimulus level code that selects one of for example, three to six desired electrode stimulus signal levels. The stimulus level selected is digitally encoded into an RF signal 108 . The RF signal 108 is transmitted by a remote antenna 114 on the remote transmitter 111 to a collar antenna 116 and detected by an RF receiver 115 . The receiver output 117 of the RF receiver 115 is demodulated by a demodulator 120 to produce a digital output 121 . The digital output 121 of the demodulator 120 represents the stimulus code/data selected by push-button switches 113 of remote transmitter 111 . The digital output data 121 is translated by a microprocessor 122 into one of six or more possible stimulus level selection signals 123 . The stimulus level selection signal 123 may be a pulse width signal having one or more pulses, each pulse having a substantially similar width. Intensity selector switch 112 provides a plurality of settings, e.g. six or more settings for selecting from one of several, e.g. six or more available intensity levels. Switches 113 allow the user to select between several functions/types of stimulus such as momentary or continuous stimulation, e.g., light, sound, electric stimulation (shock), or vibrations, and low, medium, or high stimulation by pressing one or more switches.
Referring to FIG. 3 , another embodiment, the remote animal training system 110 A includes a remote transmitter 111 having several push-button switches 113 for setting a stimulus level code that selects one of for example, three to six or more desired electrode stimulus signal levels. The stimulus level selected is digitally encoded into an RF signal 108 . A remote antenna 114 on the remote transmitter 111 transmits the RF signal 108 to a collar-mounted receiver unit 119 carried by the animal. The receiver unit 119 includes an RF receiver and an (LF) magnetic coupling transmitter 119 A ( FIG. 3 ) attached to a collar 119 B ( FIG. 3 ). An accessory magnetic coupling receiver device 151 (e.g., a beeper, light, or similar) also may be attached to the collar 119 B or integrated into the receiver unit 119 . The receiver unit 119 may receive signals from the remote transmitter 111 corresponding to electric stimulus levels and a light selection. At least two electrodes 133 and 134 of the transceiver unit 119 electrically contact the skin of the animal and apply thereto stimulus signals the intensity of which is in accordance with the RF signal 108 sent from the remote transmitter 111 .
A switch or a setting on an ISS knob 132 on the remote transmitter 111 may actuate the collar-mounted accessory device 151 . Upon actuation of the switch or knob 132 , the collar mounted accessory device 151 receives a signal from the LF transmitter in the RF receiver unit 119 A to produce an audible and/or visual signal, e.g., a strobe that enables the trainer to audibly/visually determine if the animal is moving or is motionless, e.g., “pointing” or for purposes of locating. The signal transmitted from remote transmitter 111 to the RF receiver/LF transmitter 119 A may be approximately 27 MHz (RE), for example, and the signal from the receiver/transmitter 119 A to the collar-mounted accessory device 151 may be approximately 125 KHz (LF) for example. Accessory device may be replaced with lighting accessory 10 as shown in FIG. 1 . The light accessory may perform a variety of functions. For example, a LOCATE FEATURE may be encoded wherein LED 186 (see FIG. 5 ) will flash when the transmitter is set to an accessory setting and a button is pressed. The Locate Mode may instruct the LED units of the device 186 ( FIG. 5 ) to continuously shine at its highest intensity.
In another embodiment, the LEDs 186 may be customized to emit a specific color to allow for multiple dog usage. Further, the LED flash rate, or color, or both may be used for identifying a particular animal. The flash rate, color, or other element of the device may be coupled to, for example, a motion sensor, accelerometer, heart rate monitor, electronic compass or GPS system (not shown) to indicate to a user whether the animal is in motion, motionless (pointing), or treeing an animal. In a particular embodiment, a pressure sensor is added to the neck of an animal such as a horse to monitor cribbing or foaling and provide feedback information to the user. An electronic compass or GPS module also may be used in the accessory unit and coupled to the device such that the flash rate or color will indicate direction or orientation of an animal.
The intensity selector switch 112 on the remote transmitter 111 , which may be a rotary switch, may be used to select “zero” level or any one of for example, six or more desired output levels of the pulses of stimulus voltage V o produced by the Flyback transformer 131 ( FIG. 2 ). The several push button switches 113 can be depressed individually or in combination to select the frequency and number of the pulses of stimulus voltage signal V o . The intensity selector switch 112 may be adapted to adjust the accessory module. For example, the intensity selector switch 112 may adjust the light intensity, flash rate, color, or other aspect of the light module, or the volume, frequency, or other aspect of a sound module etc.
FIG. 3 is a block diagram of the remote animal training system 110 A of FIG. 2 , in accordance with another embodiment of the present invention. The remote training system 110 A includes the remote transmitter 111 having several push-button switches 113 for setting a stimulus level code that selects one of the stimulus signal levels. The stimulus signal level selected is digitally encoded into an RF signal 108 . The RF signal 108 is transmitted by a remote antenna 114 on the remote transmitter 111 to a collar antenna 116 (referring back to expanded receiver 119 in FIG. 2 ) and detected by an RF receiver 115 . The collar antenna 116 and the RF receiver 115 are part of the collar-mounted receiver unit 119 carried by the animal.
The receiver output 117 of the RE receiver 115 is connected to the input of a filter and data slicer circuit 120 , which may be separate or part of a microprocessor 122 . An output signal of the filter and data slicer/comparator circuit 120 provides a digital output 121 , a serial digital encoded signal that becomes a data input to the microprocessor 122 . Filter and data slicer/comparator circuit 120 is a conventional circuit that filters and shapes the signals produced from the RF receiver 115 to generate the digital output 121 as an input to the microprocessor 122 .
The microprocessor 122 supplies a stimulus level select signal 123 that includes a pulse width modulated stream of output pulses. Each of the output pulses in the stimulus level selection signal 123 for any one stimulus level selection have a substantially similar width, although pulse widths may differ between different stimulus level selections. The stimulus level selection signal 123 , which includes pulse-widths of which correspond to the stimulus levels selected by the intensity selector switch 112 of the remote transmitter 111 .
The stimulus level selection signal 123 is applied through the resistor 104 to a control electrode of a switch transistor 130 connected to a primary winding 131 A of a Flyback transformer 131 and a diode 102 in series with a Zener or TVS diode 100 . The Zener or TVS diode 100 may have a response time of less than 8 microseconds. The peak-to-peak voltage produced between the pair of electrodes 133 and 134 connected to the secondary winding terminals of the Flyback transformer 131 corresponds to the pulse width of the drive pulses, and hence to the stimulus level selected by push-button switches 113 of the remote transmitter 111 .
When a Flyback signal is produced on the primary winding 131 A of the Flyback transformer 131 , the Zener or TVS diode 100 suppresses the voltage to the primary side. On the primary side, when a signal occurs at the collector of the switch transistor 130 , the diode 102 biases the primary winding 131 A of the Flyback transformer 131 thereby allowing the Flyback transformer 131 to be energized to the proper level for signal delivery to a load and preventing minimal, if any, current flow through the Zener diode 100 . When the transistor 130 is switched “OFF”, the Zener diode 100 charges, thereby delivering the “Flyback signal” across the transformer 131 at an acceptable voltage. The voltage suppression effectuated by the Zener diode 100 that occurs on the primary side corresponds to an open-circuit peak voltage suppression level.
FIG. 4 is a circuit diagram of an element of the remote animal training system 110 A of FIG. 2 , in accordance with the second exemplary embodiment of the present invention. The microprocessor 122 (shown in FIG. 4 ) provides a digital signal via conductor 148 to an encoded magnetic signal generator circuit 149 . Using a magnetic signal is beneficial in that it is easy to comply with FCC regulations, but those having ordinary skill in the art will recognize other types of signal generators may be relied upon for the same purpose described herein. For example, in addition to LF Comm. and other RF based methods, sound, light, etc. could also be used to generate a signal. The encoded magnetic signal generator circuit 149 includes an encoder transistor 149 A with a base connected to conductor 148 , an emitter connected to ground, and a collector connected to one terminal of an inductor 400 . The other terminal of the inductor 400 is connected to a voltage source+V. This inductor in relation with transistor 149 A produces a “boosted” LF signal. Capacitor 106 resonates at the LF frequency 125 KHz to produce the magnetic coupling signal. The inductor 149 B may have a value of, for example, 9 mH; and the capacitor 106 may have a value of, for example, 150 pF. The capacitor 106 tunes an emitter signal 150 emitted from the inductor 149 B. Using the exemplary values above, the equation:
f o =[2π√( LC )] −1
where f o denotes the resonance frequency, the frequency of the emitter signal 150 generated by the encoded magnetic signal generator circuit 149 is around 125 kHz. However, the inductor 149 B and the capacitor 106 values may be designed above 125 kHz to compensate for some other non-ideal effects in the encoded magnetic signal generator circuit 149 .
FIGS. 5 and 6 are block diagrams of an accessory device 151 for the remote animal training system 110 A of FIG. 2 . The accessory device 151 includes an accessory inductor 151 A receiving the emitter signal 150 from the encoded magnetic signal generator circuit 149 . The accessory inductor 151 A is connected to a low frequency communication receiver 151 B, which in one embodiment is incorporated into an accessory microprocessor 180 . Alternatively, the low frequency communication receiver 151 B may be separate from the accessory microprocessor 180 . The accessory microprocessor 180 may control a number of possible accessories, including a light generation circuit 184 of the low frequency communication receiver 151 B. Accessory microprocessor 180 is connected to the light generation circuit/driver 184 . The light generation circuit/driver 184 is connected to an LED or other light emitter 186 .
FIG. 7 is a block diagram of a portion of the accessory device 151 for the remote animal training system 110 A of FIG. 3 in accordance with one embodiment of the present disclosure.
FIG. 8 is an illustration of an emitter signal 150 for the accessory device 151 for the remote animal training system 110 A of FIG. 3 . The emitter signal 150 produced by the encoded magnetic signal generator circuit is a square wave. The emitter signal 150 is initially primed with a preamble signal 192 that contains an initial preamble 125 kHz square wave that lasts for 6 ms. When a signal of this time duration or greater is initially detected, the accessory device 151 prepares to receive more data from the corresponding transmission There is a 0.1 to 0.5 ms of gap time 194 right after the preamble signal 192 . After that, the encoded magnetic signal generator circuit 149 sends out the first sequence of data 196 with “0”s and “1”s for 16 ms duration followed by 44 ms of wait time 198 . The data sequence then repeats with another 6 ms preamble, followed by 0.1 ms of wait time and a second sequence of “0”s and “1”s. This second sequence of “0”s and “1”s is actually the sequence processed by the accessory device 151 . The second sequence of “0”s and “1”s is followed by 88 ms of wait time 198 before the sequence is repeated.
FIG. 9 is an example of one type of an LF communication signal, and illustrates a portion of the emitter signal 150 of FIG. 10 for the remote animal training system 110 A of FIG. 2 , in accordance with the second exemplary embodiment of the present invention. FIG. 9 is operative for explaining the sequence of data 196 shown in FIG. 8 . As shown in FIG. 9 , a “0” is represented by a 0.2 ms long flat line, followed by a 0.1 ms long 125 kHz square wave, and ended with a 0.2 ms long flat line. A “1” is represented by a 0.1 ms long flat line, followed by a 0.2 ms long 125 kHz of square wave, and ended by a 0.2 ms long flat line. Hence, each data bit, whether a “1” or a “0” is 0.5 ms long. There are a total of 32 bits (16 ms of 0.5 ms bits) in the data sequence 196 (4 bits for MSB, 4 bits for LSB, 4 bits for FUNCTION and 4 bits for CHKSUM). Thus, a 16 ms data sequence 196 is transmitted.
With respect to FIG, 9 , depending upon the sensitivity of the receiver and the environmental conditions relative to transmission of the emitter signal 150 , it may be worthwhile to provide fewer, longer bits within the 16 ms data sequence 196 to provide a more reliable system. For instance, using a system similar to that disclosed in FIG. 9 , a total of 8 bits, each up to 2.0 ms long, may be transmitted during the 16 ms data sequence 196 . Further, other patterns, e.g., ⅓-⅔ long modulations, may be available for providing a “1” or a “0” as detailed above.
FIG. 10 is an illustration of a portion of the emitter signal 150 of FIG. 2 and of the signal shown in FIG. 8 for the remote animal training system 110 A of FIG. 2 . FIG. 10 is one of many possible alternatives to the illustration of FIG. 9 and is operative for explaining the sequence of data 196 shown in FIG. 8 , As shown in FIG. 10 , a “0” is represented by a 0.6 ms long 125 kHz square wave and a 1.2 ms long flat line. A “1” is represented by a 1.2 ms long 125 kHz of square wave a 0.6 ms long flat line. Hence, each data bit, whether a “1” or a “0” is 1.8 ms long. There are a total of 8 bits (16 ms of 1.8 ms bits, with 1.6ms to spare) in the data sequence 196 . Thus, a 16 ms data sequence 196 capable of 256 different commands (2 8 ) is transmitted.
The emitter signal 150 represents a command the LF receiver (up to 256 commands are possible). Typically, no addressing is required because of the short range of the magnetic coupling. Commands would appear as addresses for accessory units that only are capable of activating only one response to a command. For example, an accessory unit that only produces an electrical stimulation of a specific intensity level (specific frequency and Vrms value) when it sees the specific command, will not respond to any other command, therefore, the command also appears as an address. There might be accessory units that respond to multiple commands but only when the specific (1 of the 3) 8-bit command is decoded. Other accessory units will respond to a specific command that will activate one of several hardware selected (switch) outputs of the unit. While accessory device 151 is on, it operates in a mode selected by internal DIP switches (not shown). In one selectable mode, if the accessory device 151 is a beeper, two different beeping patterns correspond to two different animals. In another selectable mode, light is emitted only when an ambient light detector within the accessory device 151 detects low levels of light surrounding the animal. The accessory unit also could comprise a strobe, vibration or electric stimulation device.
FIG. 11 illustrates actual captured signal in accordance with a second exemplary embodiment of the present invention.
An LF Comm Transmitter will automatically transmit a minimum of 4 packets of data with a button press from the remote transmitter. The data is modulated at 125 kHz. Detection of 2 valid packets will activate or deactivate the accessory unit. The decoding of packet data is performed by a microprocessor interfaced to the LF Comm receiver chip by 3 lines (UPLND_DATA, UPLND_WAKE, and UPLND_RST (reset)). Activation (or deactivation) requires a minimum of 2 falling edge signals (from VCC to Ground) on the UPLND_WAKE line into the microprocessor within 100 ms of each other. The LF Comm receiver will output a low on the UPLND_WAKE line when a preamble is detected (minimum 5.64 ms Preamble duration) through the receiver antenna input. FIG. 9 illustrates the activation of the accessory function.
As seen in the FIG. 11 , the UPLND_WAKE line is normally high until a preamble is detected. Once the first packet is detected, the microprocessor will reset the LF Comm receiver chip by pulsing the RESET line (Bottom Signal—CH3). If a second preamble signal is detected within 100 ms of the first, the UPLND_WAKE will again go low and the microprocessor will activate the accessory function (or deactivate). After the second preamble detection, data will be available at the UPLND_DATA (second signal from top—CH2) line for command decoding. If a second falling edge signal at the UPLND_WAKE line within 100 ms of the first, the accessory function will fail to activate (or deactivate) and the activation process will be reset and 2 more valid preamble signals will be expected to activate or deactivate the accessory function of the accessory unit.
While the above description relates to a light-emiting type of accessory device, it should generally be understood that this circuit is generally applicable to accessory devices that emit sound (substituting, e.g., the LED 186 out for a piezo-electric transducer 186 ) or the like. The improvements over the art described in any of the embodiments above may be added or excluded in several different combinations, and no description is intended to limit this disclosure to only the combinations described herein. Similarly, signal lengths, frequencies, and amplitudes are provided for exemplary purposes only and are not intended to limit the scope of the invention.
In another embodiment, the light module is activated by detecting a radio frequency (RF) transmission. In this embodiment, the user's animal training system 110 A ( FIG. 3 ) need not comprise an existing accessory channel to allow remote activation of the light module 10 ( FIG. 1 b ) accessory by an existing animal training system. The user would simply hold the transmitter antenna 114 ( FIG. 3 ) close (within a few inches to the module 10 — FIG. 1 b ) and the lights 186 ( FIG. 5 ) would illuminate. The light module 10 ( FIG. 1 b ) would detect the transmission of an RF signal 108 ( FIG. 3 ) and would activate the lighting circuit accordingly. In a particular embodiment, one LF Comm or RF transmission will cause the unit to flash twice every three seconds, another transmission will cause it to glow steady and a third transmission will cause the lights to go out.
If desired, the light accessory module 10 ( FIG. 1 b ) will have a separate main power on/off switch (not shown), and will be powered by the same battery as the receiver to which it is attached. Alternatively, the light accessory module will be turned on by the receiver main power switch, in which case the light accessory module 10 ( FIG. 1 ) will be designed to draw very low (>100uA) standby current, so that the LED's 186 ( FIG. 5 ) can be switched on remotely. The screws 16 ( FIG. 1 b ) that mount the light module to the receiver may be provided as a part of what the user receives when they purchase the device. The screws 16 ( FIG. 1 b ) are the same size and threading of the existing receiver battery screw, but are long enough to thread through the battery 14 ( FIG. 1 b ) and the module into the receiver 12 ( FIG. 1 b ) and provide sufficient torque to effect a seal.
FIG. 10 shows a typical circuit structure used for one embodiment of the invention. Signal 108 ( FIG. 2 ) is received at antenna 116 ( FIG. 2 ) and instructions processed to determine the behavior of LEDs 186 ( FIG. 5 ).
It should be emphasized that the above-described embodiments of the present invention, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiments of the invention without departing substantially from the spirit and principles of the invention. For example, the accessory unit may be packaged as a stand-alone device with electronic circuits for activation/deactivation of the light, control of flash, rate, color, or both, and may also include a monitor sensor, accelerometer, heart rate monitor, electronic compass or GPS system as above described. Also, if desired, the LED(s) may be mounted directly to the circuit boards, and made visible through a transparent window in the device housing or the device housing may be formed from a transparent or translucent material. The accessory unit also comprises two or more devices such as a strobe and an electric stimulation device, which may be separately addressable. Also, two or more separately addressable accessory units may be worn on a single animal. Additionally, the accessory device may include other functionality such as GPS functionality. Still other modifications are contemplated. For example, one having skill in the art may recognize that communications between the transmitter and receiver may be accomplished through methods besides those listed above. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present invention and protected by the following claims.
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A light accessory is provided for a remotely controlled animal training system, allowing visual tracking of an animal in low ambient light conditions. The light accessory may be a stand-alone accessory or be in conjunction with a wireless receiver. The light accessory may be controlled by an accessory channel that exists in the remotely controlled animal training system, or may be controlled by the presence of a generic proximate radio frequency transmission.
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FIELD OF THE INVENTION
[0001] The present invention relates generally to valve assemblies and more particularly to ports for determining process conditions such as temperature and pressure within the valve assemblies.
BACKGROUND OF THE INVENTION
[0002] Valves are well known in the art as a way of regulating fluid flow. Different valves, such as ball valves, gate valves or globe valves, may be utilized depending on the desired fluid dynamics and the specific application. Use of valves often requires different measurements of the fluid in order to maintain the proper internal conditions, for example pressure and temperature. These measurements are typically made at dedicated test openings along the valve body usually before or after the sealing portion of the valve. U.S. Pat. No. RE37,617 E, incorporated herein by reference, describes a pair of test port openings on the inlet side of a ball valve. However, these dedicated test openings require extra machining of the part and a lengthening of the overall assembly which increases the cost and complexity of the assembly. Furthermore, with an increased number of openings there is an increased likelihood of other undesired results including a higher potential for leakage and pressure failure of the assembly.
SUMMARY OF THE INVENTION
[0003] The present invention is embodied in a valve assembly with an integrated port defined through the valve stem assembly in order to easily determine conditions of the fluid flowing through the valve.
[0004] In at least one exemplary embodiment, the invention provides a valve body defining a fluid passage with a valve sealing body positioned therein. The valve sealing body is operable between open and closed positions which allow for fluid-flow and non-flow, respectively. The valve stem has a free end and an engagement end where the engagement end engages the valve sealing body so that rotation of the valve stem operates the valve sealing body between the open and closed positions. A measurement passage is defined through the valve stem from the free end to the engagement end. The measurement passage is in fluid communication with the fluid passage when the valve sealing body is in the open position, and at least one sealing member is positioned within the measurement passage.
[0005] In at least one exemplary embodiment, the invention provides a valve stem assembly comprising a valve stem body having a free end and an engagement end with the engagement end configured to engage a valve sealing body within a valve body such that rotation of the valve stem body relative to the valve body operates the valve sealing body. A measurement passage is defined through the valve stem body from the free end to the engagement end. At least one sealing member is positioned within the measurement passage.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a front view of an exemplary embodiment of the valve assembly of the present invention.
[0007] FIG. 2 is an exploded view of the valve assembly of FIG. 1 with the valve stem assembly exploded from the valve assembly body.
[0008] FIG. 3 is a cross sectional view along the line 3 - 3 in FIG. 1 .
[0009] FIG. 4 is an exploded isometric view of an exemplary valve stem assembly of the present invention.
[0010] FIG. 5 is an isometric view of the valve stem assembly of FIG. 3 .
[0011] FIG. 6 is a cross sectional view along the line 6 - 6 in FIG. 5 .
[0012] FIG. 7 is an exploded isometric view of the valve stem assembly and the valve ball of an exemplary embodiment of the present invention.
[0013] FIG. 8 is an isometric view similar to FIG. 7 and illustrating the valve stem assembly engaged with the valve ball.
[0014] FIG. 9 is an isometric view similar to FIG. 8 in partial section.
[0015] FIG. 10 is a cross sectional view, similar to FIG. 3 , illustrating the valve assembly in a closed position.
[0016] FIG. 11 is a cross sectional view, similar to FIG. 3 , illustrating the valve assembly in an open position with a test probe positioned relative to the valve stem assembly.
[0017] FIG. 12 is an exploded isometric view of an alternative exemplary valve stem assembly of the present invention.
[0018] FIG. 13 is a cross sectional view, similar to FIG. 6 , of the valve stem assembly of FIG. 12 .
[0019] FIG. 14 is a front view, in partial section, of an alternative exemplary embodiment of the valve assembly of the present invention.
[0020] FIG. 15 is a front view, in partial section, of another alternative exemplary embodiment of the valve assembly of the present invention.
[0021] FIG. 1 is a front view, in partial section, of yet another alternative exemplary embodiment of the valve assembly of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.
[0023] Certain terminology is used in the following description for convenience only and is not limiting. The words “forward” and “rear” refer to directions toward and away from, respectively, the geometric center of the valve assembly and designated parts thereof. The terminology includes the words specifically mentioned above, derivatives thereof and words of similar import.
[0024] Referring now to the drawings, a valve assembly 10 that is an exemplary embodiment of the present invention will be described. Referring to FIGS. 1-3 , the valve assembly 10 generally comprises a valve body 12 with an inlet end 14 and an outlet end 16 and a flow path 15 therebetween. The inlet and outlet ends 14 and 16 may be provided with various connectors, for example, internally or externally threaded connectors or smooth connectors. The outlet end 16 is illustrated with a threaded connection to an outlet pipe 18 , however, the invention is not limited to the type of connectors at the inlet and outlet thereof. Additionally, the illustrated embodiment of the valve assembly 10 includes a balancing valve assembly 28 provided along the flow path 15 , however, such is not required. The various components illustrate that the present invention may be utilized with valve assemblies of varying types and configurations.
[0025] A flow control quarter-turn ball valve 100 is rotatably mounted in a ball valve chamber 23 in the valve body 12 on a pair of ball seals 102 and 103 which are retained between a retaining member 104 and a shoulder 106 . While ball seals are illustrated in the current embodiment, any of various types of seals may be provided for the ball valve. The flow control quarter-turn ball valve 100 is rotatably mounted about an axis perpendicular to the longitudinal axis of the valve body 12 . The valve ball 100 includes a main through passage 108 extending therethrough. The valve ball 100 is controllable within the valve ball chamber 23 between an open position wherein the main through passage 108 is parallel to the fluid path 15 (see FIG. 3 ), a closed position wherein the main through passage 108 is substantially perpendicular to the fluid path 15 (see FIG. 10 ), and any desired position therebetween.
[0026] As shown in FIG. 3 , the valve body 12 is provided with a transverse, outwardly extended integral hub 20 which is positioned centrally relative to the ball valve chamber 23 . The hub 20 is provided with a stepped internal bore 22 which is in communication with the ball valve chamber 23 . A valve stem assembly 40 is positioned in the internal bore 22 of the hub 20 and engages the ball valve 100 for controlled operation thereof. The structure and operation of the ball valve 100 will be described in more detail hereinafter. The internal bore 22 defines a seat 25 configured to support the valve stem assembly 40 as described below.
[0027] An exemplary valve stem assembly 40 will now be described with reference to FIGS. 4-6 . The valve stem assembly 40 generally includes a cylindrical body 42 extending between a forward end 41 and a rear end 43 . While the illustrated body 42 is cylindrical, the invention is not limited to such and the body 42 may have other configurations. A stepped bore 45 extends through the body 42 from the rear end 43 to the forward end 41 . The rear end 43 includes an opening 55 into the stepped bore 45 . The forward end 41 includes an engagement portion 46 through which the stepped bore 45 extends.
[0028] The valve stem body 42 extends radially outward adjacent the engagement portion 46 to define a shoulder 50 . An annular groove 52 extends about the body 42 adjacent the shoulder 50 and is configured to receive an o-ring seal 53 . Above the annular groove 52 is an annular locking seat 51 . Referring to FIG. 3 , when the valve stem assembly 40 is positioned in the internal bore 22 of the hub 20 , the shoulder 50 sits upon the seat 25 and the o-ring seal 53 seals against the inside surface of the internal bore 22 . A snap ring 90 is positioned about the stem valve body 42 and is configured to snap fittingly engage an internal annular groove 27 within the hub 20 . With the snap ring 90 engaged in the annular groove 27 , the snap ring 90 engages the annular locking shoulder 51 and thereby locks the valve stem assembly 40 within the hub internal bore 22 . Other mechanisms for retaining the valve stem assembly 40 may also be utilized. For example, in the alternative exemplary valve stem assembly 40 ′ illustrated in FIGS. 12 and 13 , the valve stem body 42 ′ has a generally uniform diameter except for the retaining shoulder 69 extending outward therefrom. The retaining shoulder 69 is configured to be engaged by a locking nut (not shown) threadably engaged within the hub internal bore 22 .
[0029] Referring to FIGS. 2 , 3 and 5 , the rear end 43 of the valve stem body 42 includes opposed flat handle sides 47 which define opposed shoulders 57 configured to support a handle 30 on the rear end 43 of the valve stem body 42 . As shown in FIG. 2 , the handle 30 of the present embodiment includes a central portion 32 with a through hole 37 and outwardly extending handle bar portions 34 . The central portion 32 is positioned on the valve stem body 42 such that it is supported by the opposed shoulders 57 . A snap ring 38 is positioned about the valve stem body 42 and is retained in an external annular groove 44 to retain the handle 30 on the valve stem body 42 . The through hole 37 is formed with opposed flat portions 39 configured to align with the flat handle sides 47 of the valve body 42 such that rotation of the handle 30 will cause the flat portions 39 to engage the flat handle sides 47 and thereby rotate the valve stem body 42 . Rotation of the valve stem body 42 controls the position of the ball valve 100 as will be described hereinafter. A pair of stop members 33 and 35 preferably depend from central portion 32 and are configured to engage external stops 24 (only one shown) on the hub 20 to limit rotation of the handle 30 , and thereby the valve stem body 42 , relative to the valve body hub 20 . While a mechanical handle is illustrated, other means, for example, an electromechanical actuator, may alternatively be utilized.
[0030] Referring to FIGS. 3 and 7 - 9 , engagement of the engagement portion 46 of the valve stem body 42 with the valve ball 100 of the present embodiment will be described. The valve ball 100 includes a secondary passage 110 extending perpendicular to the main through passage 108 . The secondary passage 110 extends from the main through passage 108 to an engagement slot 112 on the external surface of the valve ball 100 . The engagement slot 112 has a generally rectangular shape with opposed flat wall surfaces 114 . The engagement portion 46 of the valve stem body 42 has corresponding opposed flat wall surfaces 48 configured to engage the engagement slot flat wall surfaces 114 . Slots 49 preferably extend between the opposed flat wall surfaces 48 such that the engagement portion 46 may compress slightly during engagement to provide a compression fit between the valve stem engagement portion 46 and the valve ball engagement slot 112 . The orientation of the opposed flat wall surfaces 48 relative to the flat handle sides 47 is controlled such that the orientation of the handle 30 will dictate the position of the ball valve 100 in a controlled manner. In the illustrated embodiment, the surfaces 47 and 48 are offset by 90° such that the ball valve 100 is in the open position when the handle 30 extends parallel to the flow path 15 and is in the closed position when the handle 30 extends perpendicular to the flow path 15 . Other orientations and configurations are also possible.
[0031] As illustrated in FIG. 9 , when the valve stem body 42 is engaged with the ball valve 100 , the secondary passage 110 is aligned with and in fluid communication with the valve stem stepped bore 45 such that a portion of the fluid passing through the main through passage 108 will also flow through the secondary passage 110 to the valve stem bore 45 . Controlled passage of fluid through valve stem bore 45 provides a test port through the valve stem assembly 40 .
[0032] The internal configuration of the valve stem assembly 40 will be described with reference again to FIGS. 3-6 . A pair of elastomeric members 60 and 64 are positioned in the bore 45 . Each elastomeric member 60 , 64 has a tapered cylindrical shape with a larger counter sink bore 61 , 65 , respectively, adjacent the larger end of the cylinder and a smaller counter sink bore 63 , 67 , respectively, adjacent the smaller end of the cylinder. A generally closed through bore 62 , 66 , respectively, extends between the respective counter sink bores 61 , 63 and 65 , 67 . The elastomeric members 60 and 64 may be made from any desired elastomeric material which generally returns to its original shape after pressure is removed therefrom. An illustrative material is ethylene-propylene-diene-monomer (“EPDM”).
[0033] In the present embodiment, the elastomeric members 60 , 64 are positioned opposite to one another such that both members 60 , 64 narrow toward one another. However, as illustrated in the alternative exemplary valve stem assembly 40 ′ shown in FIGS. 12 and 13 , the elastic members 60 and 64 ′ may be alternatively positioned. In valve stem assembly 40 ′, both elastic members 60 and 64 ′ are oriented such that their smaller end extends toward the forward end 41 of the valve stem body 42 ′. Other configurations and arrangements are also possible. For example, a single elastic member or more than two elastic members may be utilized. Additionally, the elastic member(s) may have any of various shapes other than the illustrated tapered shapes.
[0034] The taper of the elastomeric members 60 , 64 and the configuration of the counter sink bores 61 , 63 , 65 , 67 facilitates expansion of the generally closed through bores 62 , 66 during passage of a probe member or the like. In the normal, unpenetrated configuration illustrated in FIG. 6 , the elastomeric members 60 , 64 substantially seal and prevent the passage of fluid through bore 45 .
[0035] An attachment member 70 extends through the open end 55 of the valve stem body 42 with a portion thereof positioned within the bore 45 in engagement with the elatastomeric member 64 . In the present embodiment, the attachment member has radial shoulder 74 configured to be engaged by a lip 54 of the valve stem body 42 to retain the attachment member 70 . To assemble the valve stem assembly 40 , the elastomeric members 60 and 64 are positioned within the stepped bore 45 , an o-ring seal 76 is placed about the forward end the attachment member 70 , the forward end is positioned within the stepped bore 45 , and the open end 55 of the valve stem body 42 is rolled or otherwise inwardly deformed to define the lip 54 which engages and retains the attachment member shoulder 74 . Other means of assembling the attachment member 70 to the valve stem body 42 may also be utilized, for example, the attachment member 70 may be threadably connected to the valve stem body 42 , welded thereto, soldered thereto, press fit therein, or otherwise secured.
[0036] The attachment member 70 has a through bore 72 which is preferably coaxial with the elastomeric member through bores 62 , 66 . As such, the attachment member through bore 72 and the elastomeric member through bores 62 , 66 provide a sealed measurement passage for a test probe or the like to be passed through into communication with fluid which may be in the valve stem bore 45 . When not being utilized for testing, the through bore 72 is preferably covered by a removable cap 80 or the like. In the present embodiment, the external end of the attachment member 70 has a series of external threads 73 which facilitates threaded engagement with the cap 80 . Other engagement means, for example, a snap fit or the like, may also be utilized. An o-ring seal 82 is preferably positioned within the cap 80 to seal against the attachment member 70 .
[0037] Having generally described the components of the exemplary valve assemblies 10 of the present invention, operation thereof will be described with reference to FIGS. 3 , 10 and 11 . Referring to FIG. 10 , the valve assembly 10 is shown in a closed position. The ball valve 100 has been rotated by the handle 30 , via interaction of the handle 30 with the valve stem body 42 and corresponding interaction of the valve stem engagement portion 46 with the valve ball engagement slot 112 , to a position wherein the main through passage 108 is perpendicular to the fluid path 15 . Fluid flows in through the inlet, as indicated by arrow A, but is prevented from further flow by the contact of the valve ball 100 with the ball seal 102 .
[0038] To open the ball valve 100 , as illustrated in FIG. 3 and 11 , the handle 30 is rotated. Rotation of the handle 30 causes the handle flat portions 39 to contact the flat handle sides 47 on the valve stem body 42 which causes rotation of the valve stem body 42 . Rotation of the valve stem body 42 in turn causes rotation of the ball valve 100 via engagement of the engagement portion flat wall surfaces 48 with the engagement slot flat wall surfaces 114 . Referring to FIG. 3 , when the ball valve 100 is in the open position, fluid is free to flow through the main through passage 108 to the valve exit 16 / 18 , as indicated by arrow B. At the same time, a portion of the fluid passing through the main through passage 108 also passes through secondary passage 110 into the valve stem bore 45 , as indicated by arrow C. The fluid is prevented from free passage through valve stem bore 45 by the elastomeric members 60 and 64 . The valve assembly 10 may be operated in a normal manner to control fluid flow through the valve assembly 10 .
[0039] If it is desired to measure a characteristic of fluid passing through the valve assembly 10 , the valve stem assembly cap 80 is removed from the attachment member 70 and a testing instrument 150 is attached thereto, as illustrated in FIG. 11 . The testing instrument 150 may be of any conventional type. The illustrated testing instrument 150 includes a connector 152 configured to be releasably connected to the external end of the attachment member 70 . In the present embodiment, the connector 152 has internal threads configured to engage the external threads 73 on the attachment member 70 . Other connection means may also be utilized. The testing instrument 150 further includes a body 154 connected to the connector 152 and configured to provide an external port 155 . A hollow probe or needle 157 extends from a forward end of the body 154 such that connection of the testing instrument 150 to the attachment member 70 causes the probe or needle 157 to penetrate and extend through the elastomeric member through bores 66 and 62 . The hollow probe or needle 157 extends through both elastomeric members 64 and 60 such that its forward end establishes a fluid communication with the valve stem bore 45 . As such, fluid is free to flow through the secondary passage 110 , the valve stem bore 45 , the probe or needle 157 and to external port 155 , as indicated by arrow D. The fluid characteristics may be measured or otherwise tested through the external port 155 utilizing known equipment.
[0040] While the previous exemplary embodiments have illustrated ball valves, the invention is not limited to such. As illustrated in FIGS. 14-16 , the valve mechanism may have other configurations. Referring to FIG. 14 , the valve assembly 10 ′ provides a plug valve 100 ′ configuration. The valve assembly 10 ′ includes a valve body 12 ′ with an inlet end 14 and outlet end 16 with a plug valve 100 ′ positioned therebetween. The plug valve 100 ′ includes a main through passage 108 ′ with a secondary passage (not shown) configured to communicate with the valve stem bore 45 similar to the ball valve embodiments. The valve stem assembly 40 is substantially as in the previous embodiments, however, may include a longer bore 45 and a different engagement mechanism.
[0041] Referring to FIG. 15 , the valve assembly 10 ″ provides a gate valve 100 ″ configuration. The valve assembly 10 ″ includes a valve body 12 ″ with an inlet end 14 and outlet end 16 with a gate valve 100 ″ positioned in the fluid path 15 therebetween. The gate valve 100 ″ includes a gate 125 configured to move into and out of the flow path 15 . A secondary passage 110 ″ extends into the gate 125 and is configured to communicate with the valve stem bore 45 . The valve stem assembly 40 is substantially as in the previous embodiments, however, it includes a longer bore 45 and a different engagement mechanism.
[0042] Referring to FIG. 16 , the valve assembly 10 ′″ provides a globe valve 100 ′″ configuration. The valve assembly 10 ′″ includes a valve body 12 ′″ with an inlet end 14 and outlet end 16 with a globe valve 100 ′″ positioned in the fluid path 15 therebetween. The globe valve 100 ′″ includes a plug 130 configured to move into and out of contact with a seat 132 within the flow path 15 . A secondary passage 110 ′″ extends through the plug 130 and is configured to communicate with the valve stem bore 45 . The valve stem assembly 40 is substantially as in the previous embodiments, however, it includes a longer bore 45 and a different engagement mechanism. Fluid will generally flow through the secondary passage 110 ′″ even when the valve is closed, however, the fluid will be prevented from free fluid flow by the elastomeric members 60 and 64 within the valve stem assembly 40 .
[0043] While preferred embodiments of the invention have been shown and described herein it will be understood that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those skilled in the art without departing from the spirit of the invention. Accordingly, it is intended that the appended claims cover all such variation as fall within the spirit and scope of the invention.
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A valve body defines a fluid passage and a valve sealing body is positioned there. The valve sealing body is operable between open and closed positions which allow for fluid-flow and non-flow, respectively. The valve stem has a free end and an engagement end where the engagement end engages the valve sealing body so that rotation of the valve stem operates the valve sealing body between the open and closed positions. A measurement passage is defined through the valve stem from the free end to the engagement end. The measurement passage is in fluid communication with the fluid passage when the valve sealing body is in the open position, and at least one sealing member is positioned within the measurement passage.
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BACKGROUND OF THE INVENTION
The popularity of microprocessor-based systems and products has resulted in rapid development and production of new equipment to meet the public demand. Such equipment does not lend itself to diagnosis of faults or malfunctions by conventional testing and trouble-shooting instruments, such as oscilloscopes and the like, because information provided by these instruments is limited or incomplete, and subject to interpretation. Efforts to develop new diagnostic test equipment to service microprocessor-based systems has resulted in such techniques as self-diagnosis by following a predetermined checkout procedure, in-circuit emulation in which an external device emulates or imitates the functions of a host microprocessor, and signature analysis by probing for correct signatures at predetermined test points. While such diagnostic techniques are a step forward, they fail to provide a complete diagnostic capability. For example, self diagnostics are useless in situations where the kernel of the product is down, and prior external devices are typically complex and require considerable skill in operation, and do not give a complete diagnostic capability of both analog and digital measurements.
SUMMARY OF THE INVENTION
In accordance with the present invention, a diagnostic extender test apparatus for use with a processor-based product under test (PUT) incorporates analog and digital measurement functions and logic stimulus functions to give a complete diagnostic picture of the PUT, including fault location and performance checks.
The preferred embodiment of the diagnostic extender test apparatus includes its own microprocessor unit (MPU), random-access memories (RAM's), read-only memories (ROM's) and internal bus. The diagnostic fault location and measurement circuits are connected to the bus, and may include a variety of test functions, such as signature analysis, digital multimeter, logic probe, digital counter, and the like. A keyboard and alpha-numeric display may also be connected to the bus to provide a user interface. Test probes associated with the test and measurement circuits, such as data probes, logic probes, signature analysis probes, and linear probes for analog measurements, may be provided. As a stand-alone instrument, the diagnostic extender test apparatus may be utilized in a variety of test and measurement functions, including diagnosis of faults within the PUT kernel, i.e., those elements essential to the PUT's operation, such as its MPU, memories, clocks, bus, etc.
The diagnostic extender test apparatus also includes an external MPU communication port, allowing the apparatus to be connected to the bus of the PUT, where it becomes essentially a peripheral device of the MPU of the product under test. Of course, for this mode of operation, it is assumed that the test apparatus is set up in the correct address location of the PUT's MPU system, and that the internal diagnostics of the PUT have been written to communicate over the communication port with the test apparatus. The connection of test and measurement probes to various locations within the product under test may be prompted and directed by the product under test in response to results obtained by the test apparatus and returned to the PUT's MPU system. In addition, logic stimulus test signals may be directed over the communication port from the PUT's MPU system to be injected via a logic stimulus probe into predetermined points within the circuits of the product under test to permit self diagnosis of circuit faults, the results being obtained and returned by the test and measurement probes mentioned above.
It is therefore one object of the present invention to provide a diagnostic extender test apparatus incorporating analog and digital measurement functions and logic stimulus functions for obtaining a complete diagnostic picture of a processor-based product under test.
It is another object to provide a diagnostic extender test apparatus which is operable as a stand-alone instrument or as a peripheral of a processor in a product under test.
It is a further object to provide a test apparatus which interacts and communicates with a product under test in diagnosing faults and providing performance and measurement checks.
Other objects and attainments of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings.
DRAWINGS
FIG. 1 shows a simplified block diagram of a diagnostic extender test apparatus in accordance with the present invention;
FIG. 2 shows a detailed block diagram of the preferred embodiment of the apparatus shown in FIG. 1; and
FIG. 3 shows a front panel layout and probe arrangement for a diagnostic extender test apparatus.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a simplified block diagram of a diagnostic extender test apparatus for a processor-based product under test (PUT) 10 in which a processing unit 12, a front panel control unit 14, a digital multimeter (DMM) 16, and a logic stimulus and testing circuit 18 are interconnected by a bus 20, which includes data bus, address bus, and control bus lines to provide interactive communication between the various units in the conventional manner. The processing unit 12 may suitably be an MPU and associated RAM's and ROM's for processing and storing data in accordance with predetermined programs or instructions from front panel control unit 14. Front panel control unit 14 may suitably include a keyboard, mode-selection and function-selection switches, and a display device to provide interface with a human operator.
The diagnostic extender test apparatus includes test probes 22 associated with the DMM 16 and logic stimulus and testing unit 18 to be connected to various points within the PUT 10. The logic stimulus is generated by the internal diagnostics of the PUT and applied as test signals to points within the PUT, and the resulting diagnostic data and information is collected and returned to the processor within the PUT. The test probes 22 may therefore include data probes, logic probes, signature analysis probes, and linear probes for analog measurements. An external MPU communication port 24 permits the diagnostic extender test apparatus to be connected to the internal bus of the PUT 10. Since the diagnostic extender apparatus essentially becomes a peripheral device of the processor inside the PUT and acts in concert therewith, the test apparatus must be set up in the correct location of the PUT's processor system, and the internal diagnostics of the PUT must be written to communicate over the communication port with the test apparatus. The connection of the test probes 22 to various locations within the PUT may be prompted and directed by the PUT's processor in response to results obtained by the diagnostic extender test apparatus.
As a stand-alone instrument, the diagnostic extender test apparatus may be utilized in a variety of test and measurement functions, including diagnosis of faults within the PUT kernel. The PUT kernel comprises those elements essential to the PUT's operation, such as its processor, memories, bus, clocks, and so forth.
In FIG. 2, a product under test (PUT) 30 is shown generally enclosed by a dashed line. Here, the PUT 30 includes a system such as a central processing unit (CPU) 32 and one or more peripheral units 34 interconnected by a PUT bus 36. Such a system may suitably be one of the many commercially-available families of integrated-circuit microprocessors, including any necessary RAM's and ROM's. Circuits 38 within the PUT 30 may include both digital and analog circuits for carrying out whatever tasks the PUT is designed to do, and, in addition, a signal generator 40 may also be included for generating test signals such as start, stop, and clock signals for signature analysis.
The diagnostic extender test apparatus includes an MPU 44, a RAM 46, and a ROM 48 interconnected by a bus 50. Diagnostic fault location and measurement circuits are connected to the bus, and may include a DMM 52, a logic analyzer 54, a signature analyzer 56, and a digital counter 58. A keyboard 60 and an alpha-numeric display device 62 may also be connected to the bus 50 to provide an operator interface with the system.
The microprocessor system of the diagnostic extender test apparatus may be connected to the processing system of PUT by connecting bus 50 to bus 36 via a CPU personality interface 64 and a connection device 66. The CPU personality interface 64 provides compatability between the diagnostic extender test apparatus and the particular type of CPU employed by the PUT, and causes the diagnostic extender test apparatus to appear to the PUT CPU as a peripheral device. As mentioned previously, the internal diagnostics of the PUT must be written to communicate with the diagnostic extender test apparatus, which has its own selectable address within the address space of the PUT CPU and is therefore addressed by the CPU in the same manner as any of the CPU's peripherals. A logic stimulus probe may be connected to the bus 50 for connection to various signal-injection points 70 within the circuits 38 of the PUT. The internal diagnostics of the PUT may permit CPU 32 to call up certain test signals from the peripheral units 34 to be applied over the interface 64 and via the logic stimulus probe to predetermined signal-injection points 70 within the PUT circuits 38 to thereby provide external stimulation of certain circuits for diagnostic purposes. While the logic stimulus probe 68 shows a single tip or lead 72 connected to a signal-injection point 70 to provide a signal path for serial bit streams, signal lead 72 could also be four or more leads to provide a path for parallel digital data. One or more probes may be provided to be connected to various points 74 within the PUT 30 to collect diagnostic data resulting from logic stimulation and information for processing. Shown are a data probe 76 and a signature analysis control signal probe 78; however, other probes, such as a logic probe or a linear probe, may also be used, depending upon the test or measurement situation. While the data probe 76 shows a single input lead 80 connected to a test point 74, input lead 80 actually could be four or eight leads, or more, to provide an input for parallel digital data. The signature analysis control probe is connectable to signal generator 40 to provide an input for the start, stop, and clock signals required to generate signatures. Probes 76 and 78 may suitably include input buffering and automatic threshold level adjustment. One such probe of this type is the Tektronix P6451 Data Acquisition Probe. A signal switching circuit 84 is provided to route the acquired raw data to the appropriate measurement circuit or directly over the bus 50 to the MPU 44 for processing. The signal switching circuit 84 may be operated in response to program commands from CPU 32 or MPU 44, or in response to control signals entered into the keyboard 60. Further, the connection of the logic stimulus probe and the test and measurement probes to various locations within the PUT 30 may be prompted and directed by CPU 32 in response to results obtained by the test apparatus. A communications interface 86 is connected to bus 50 to provide transmission of data from the diagnostic extender test apparatus to other systems. For example, communications interface 86 suitably may provide RS-232 or General Purpose Interface Bus compatibility.
FIG. 3 illustrates one physical embodiment of the diagnostic extender test apparatus in which most of the circuitry is contained in a portable housing 100. The CPU communication port comprises a clip-type connector 102 for attaching to the PUT CPU, a ribbon-cable bus 104, and a CPU personality interface pod 106. A logic stimulus probe 108 connected to the apparatus via a cable 110 may be provided, and this probe may be a single-tip device as shown, or may comprise multiple tips or leads, depending on whether stimulus signals which are applied to a device under test are serial or parallel logic bits. One or more data acquisition probes 112 connected to the apparatus via cable 114 may be provided. The data acquisition probe 112 accepts a plurality of probe-input lead connectors 116 for connection to the PUT internal circuitry. Also shown is a single-input data probe 118 connected to the apparatus via a cable 120. The front panel includes a keyboard 122, an alpha-numeric display 124, mode-selection switches 126, analog function selection switches 128, and digital function selection switches 130. With the mode selection switches 122 set to Internal and the connector 102 clipped onto the PUT CPU, the diagnostic extender test apparatus operates in concert with the internal diagnostic programs of the PUT to apply stimulus signals, locate faults, and make measurements within the PUT, with test results and operator prompting being displayed alpha-numerically by the display 124 as discussed hereinabove in connection with FIG. 2. With the mode selection switches 126 set to Manual, the diagnostic extender test apparatus may be operated as a stand-alone service instrument.
While there has been shown and described the preferred embodiment according to the present invention, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspect. It is therefore contemplated that the appended claims will not be construed in a limiting sense and will cover any such modifications or embodiments as fall within the true scope of the invention.
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A diagnostic extender test apparatus for use with a processor-based product under test incorporates analog and digital measurement functions and logic stimulus functions to give a complete diagnostic picture of the product under test. The diagnostic extender test apparatus according to the preferred embodiment has its own microprocessor system and may be operated as a stand-alone instrument as well as an extension of a product under test.
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BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method of determining the average nature of the materials of the laundry in a laundry washing machine, which method comprises the measurement of the weight of the laundry loaded into the machine, the detection of the volume (V) and the detection of the level (h) of the water admitted to the tub of the machine.
It is important that the nature of the laundry in a washing machine is known, because the specific treatments and washing operations to which said laundry is to be subjected depend on said nature and because an incorrect treatment may be detrimental to said laundry.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method of determining the average nature of the laundry in the machine by electronic means, in order to ensure that the appropriate treatment is applied to laundry of a specific nature.
According to the invention the method is characterized in that at least one of said detections is effected continuously during filling of the tub, that the detected level (h) is compared with at least one reference value, and that when the water level in the tub begins to exceed said reference value the machine determines the nature of the laundry in the tub by comparing the volume of water absorbed per unit of weight of the laundry with a series of typical absorbed values each corresponding to laundry of a specific nature. Thus, by the use of the water-absorption properties of the laundry, which properties influence the water level reached in the tub for a given volume of water admitted to the tub, it is possible to determine the average nature of the materials of the laundry in the tub.
DESCRIPTION OF THE PRIOR ART
It is to be noted that the water-absorption properties of laundry have been used for a different purpose, which is specifically known from German Patent Application No. 29 40 492. Said Application describes a method of controlling a washing machine of the economy type. In accordance with said method the weight of the laundry loaded into the machine is measured. Subsequently, the tub is filled up to a level which is computed starting from the weight and the washing programme selected by the user. When the tub is being filled with water, the water-absorbing capacity of the laundry is determined from the difference between the water level corresponding to the volume of water admitted and the actual level that is reached. Depending on the absorption capacity and the weight of the laundry the water levels for washing and rinsing are determined in order to avoid a waste of water. An indication of the nature of the laundry is given by the user by means of a selection button on the machine. An erroneous selection may therefore result in an incorrect treatment of the laundry.
In order to exclude such human errors the nature of the laundry is therefore determined by the machine itself.
The method in accordance with the invention is specifically characterized in that the volume of water absorbed per unit of weight of the laundry is compared with three typical values, which typical values correspond to three curves representing the level (h) of the water in the tub as a function of the volume (V) of the water, which three curves are a first curve corresponding to the absence of laundry in the machine, a second curve corresponding to the presence of laundry of an absorbent material, and a third curve corresponding to the presence of laundry of a material which is little or not absorbent. In each of these cases the nature of the laundry follows from the geometrical differences of the curves which represent the variation of the water level h in the tub as a function of the volume V of the water admitted in Cartesian coordinates. Specifically, if the tissue is highly absorbent, for example in the case of woolens or cotton, and water is admitted, the water is initially absorbed by the laundry in proportion to the weight of the load of laundry, so that it takes more time until a constant water level is reached. The curve representing the water level has a function of the volume V will exhibit a plateau parallel to the horizontal axis, the length of said plateau, which is equal to the volume of water absorbed, being characteristic of the presence of woolens and their weight. Conversely, in the case of laundry which is little absorbent, for example synthetic materials, the corresponding curve will not exhibit a plateau and will very closely approximate the theoretical curve (without laundry), which is typical of said synthetic materials.
The method in accordance with the invention is especially characterized in that said reference value corresponds to the length of a plateau of said second curve, which plateau is substantially parallel to the volume axis. The choice of the plateau of the second curve as reference value is advantageous because the presence of a plateau indicates the presence of absorbent materials in the tub of the washing machine, which materials will prevent the water level in the tub from rising.
Suitably, the method in accordance with the invention is characterized in that during filling of the tub initially a sequence of alternate periods occur in which the drum of the machine is stationary and rotates respectively, which sequence continues until an indication that the water level has a constant mean value as a function of time disappears. This is because allowance should be made for the rate of water absorption by the laundry, which may retard the formation of the plateau. If simultaneously with the start and stop periods of the drum the water supply to the tub comprises a sequence of off and on periods, the instantaneous water level in the tub will oscillate about a mean value which corresponds to the plateau.
The invention also relates to a laundry washing machine employing the method in accordance with the invention, which machine comprises a device for measuring the weight of the laundry loaded into the machine and electronic means for storage of the laundry-weight value.
In accordance with the invention a machine employing the method is characterized in that it comprises a device for continuously measuring the volume of water admitted to the tub and a device for continuously measuring the water level, a device for determining the volume of water absorbed per unit of laundry weight having a first input connected to the device for continuously measuring the volume of water and a second input connected to the electronic means for the storage of the laundry-weight value, which device has an output connected to a device for identifying the average nature of the materials of the laundry in the tub. In the laundry identification device the value of the volume of water absorbed per unit of weight is compared with typical values in order to determine the average nature of the laundry.
Advantageously a washing machine in accordance with the invention comprising a "volume" memory for storing the value of the volume of water admitted to the machine and is characterized in that it also comprises a first comparator block for comparing the measured water level with a reference level and for generating a validation signal when the measured level exceeds the reference level, which validation signal is applied to the "volume" memory, a divider block, having a first input connected to the "volume" memory and a second input to the electronic means for the storage of the laundry-weight value, for determining the quotient of the value of the volume of water in the tub and the value of the laundry weight upon receipt of the validation signal, which divider block has an output connected to a second comparator block for comparing the quotient signal on the output of the divider block with typical quotients of the volume of water absorbed per unit of weight of various known types of laundry.
In this way the method in accordance with the invention can be utilized in a washing machine in a cheap and simple manner.
The invention employs the information received for controlling the washing programme selection devices depending on the nature of the laundry to be washed and the quantity of laundry present in the machine, which devices form part of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood by means of the following description with reference to the accompanying drawings, of which:
FIG. 1 represents curves which serve to explain the method.
FIG. 2 represents a block diagram of the electronic means for carrying out the method.
FIG. 3 represents a washing machine for carrying out the method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
When considering, for example, the case in which the tub of a washing machine is substantially a cylinder of circular cross-section with a radius R and whose horizontal axis has a length L, the value V of water in the tub in the absence of laundry is related to the water level h in said tub by the expression:
V=L[R.sup.2 arc sin (2Rh-h.sup.2).sup.1/2 /R-(R-h) (2Rh-h.sup.2).sup.1/2 ]
The curve A of FIG. 1 represents the variation of h as a function of V in accordance with this expression. This curve is determined, in accordance with the inventive method, in the absence of laundry by continuously and simultaneously measuring the water level h in the tub and/or the volume of water admitted to the machine during filling of the tub of the machine. Now it is assumed that filling takes place while absorbent laundry, for example woolens, is present. Inherently absorption proceeds with a certain delay. It is promoted by stirring the laundry in the water. In order to promote said absorption, filling of the tub, in accordance with the invention, is initially effected with a sequence of on and off-periods of the water supply to the machine, the off-periods being utilized for stirring the laundry by rotating the rotary drum containing the laundry during each off-period. Owing to said absorption and the periodic stirring of the laundry in the water the water level h in the tub tends to remain low at the beginning of the filling operation and to oscillate about a substantially constant mean value. Laundry stirring is discontinued when the absorption capacity of the laundry is exhausted and when it is found that the water level tends to rise like in the absence of laundry. The curve giving the variation of h as function of V is then the curve of type B situated below A. This curve initially exhibits oscillations of the level h of a substantially constant mean value corresponding to the laundry-stirring period during absorption, said mean value being the ordinate of the plateau PQ, followed by a rising portion. The length of the plateau PQ increases as the amount of laundry or the weight of the laundry increases. For a given weight of laundry said length is characteristic of the nature of the laundry and is proportional to the weight of the laundry. In accordance with the inventive method the length of said plateau PQ, is measured in order to determine the nature of the laundry if the weight of the load of laundry in the machine is known, or in order to determine the weight of the laundry in the machine if the nature of the laundry is known. It is now assumed that filling takes place when a load of laundry is present which is substantially non-absorbent or rather which absorbs an amount of water smaller than its own weight, which corresponds to laundry of a synthetic material. The curve found for h as a function of V is then of type C, close to the curve A, and is generally situated above it as a result of the Archimedes pressure exerted on the laundry. Thus, the measurement of said curve in accordance with the method provides a means of recognizing laundry of a synthetic material.
The method is utilized in washing machines. For this purpose the washing machine is equipped with a volume counter for measuring the water volume V, a device for the continuous measurement of the level h, for example of the type described in the applicant's French Patent Application No. 80 13 201, filed on June 13, 1980, and electronic means for storing the value of the volume of water admitted to the machine and for determining the volume of water absorbed per unit of laundry weight. The level detection device, in accordance with the aforementioned Application, is constituted by electrically insulated conductor, in the form of an arc of circle arranged in a cross-sectional plane common to the tub and the drum in the lower part of the tub, the circle having a radius intermediate between that of the tub and that of the drum and being centered relative to the common axis of the tub and the drum. Furthermore, the weight of the laundry is measured by measuring the variation of the weight of the machine owing to the laundry loaded into the machine. Means which may be utilized is an electrical resistance strain-gauge arranged between the chassis of the machine and the floor on which the machine rests.
In FIG. 2, which by way of example gives a block diagram of the electronic means, enabling the use of the method in the machine, the block 21 represents the counter with which the volume V of the water admitted to the machine is converted into an electric output signal proportional to said volume and the block 22 represents a comparator which receives the signal for the water level h from the level detector and a reference signal R, which corresponds to the water-absortion level of the plateau PQ represented in FIG. 1. Said comparator supplies a signal as soon as the water level h exceeds the reference level. Said signal supplied by the comparator is applied to the memory 23, which also receives the signal of the water flow counter. The memory then stores the value representing the volume of water admitted to the machine, which corresponds to the volume V a of water absorbed by the laundry (abscissa of point Q in FIG. 1). The information from the memory is applied to the divider block 25 and so is the information concerning the weight of dry laundry p received from the block 24. The block 25 computes the quotient V a /P of the volume V 1 of absorbed water and said weight P. Said quotient is applied to the comparator block 26 together with typical quotient values relating to the laundry of a specific nature. The quotient from 15 is compared with said different typical value in order to determine the nature of the laundry present in the machine. Thus, information relating to the nature of the laundry to be washed and the weight of said laundry is available in the machine.
The machine employs said information to control washing-program selection devices as a function of the nature of the laundry to be washed and the amount of laundry contained in the machine, which devices form part of the machine.
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A method of determining the average nature of the materials of a laundry in a laundry washing machine including measuring the weight of the laundry loaded into the machine, detecting the volume and the level of water admitted to the tub of the machine, determining the volume of water absorbed per unit of weight of the laundry and from these factors determining the nature of the materials in the laundry for a determination of the specific treatment and washing operation for such materials. A laundry washing machine with sensors and circuitry to carry out the method is also disclosed.
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CROSS-REFERENCE
This application is a division of U.S. Ser. No. 09/130,334, filed Aug. 6, 1998 U.S. Pat. No. 5,880,136, which is division of U.S. Ser. No. 08/861,545, filed May 22, 1997 U.S. Pat. No. 5,814,643, which is a continuation-in-part of U.S. Ser. No. 07/750,647, filed Aug. 30, 1991 now abandoned, which is a continuation-in-part of U.S. Ser. No. 07/589,130, filed Sep. 27, 1990 now abandoned.
BACKGROUND OF THE INVENTION
The present invention provides novel compounds, novel compositions, methods of their use and methods of their manufacture, such compounds being generally pharmacologically useful as anti-platelet aggregation agents in various vascular pathologies. The aforementioned pharmacologic activities are useful in the treatment of mammals. More specifically, the sulfonamide compounds of the present invention act by blocking the molecular receptor site of the protein fibrinogen. Fibrinogen is a glycoprotein that circulates in the blood plasma, and whose platelet receptor site is glycoprotein IIb/IIIa. By blocking the action of fibrinogen at the receptor (glycoprotein IIb/IIIa), the compounds of the present invention interfere with platelet aggregation, which is a cause of many vascular pathologies. At the present time, there is a need in the area of vascular therapeutics for such a fibrinogen receptor blocking agent. By interfering with hemostasis, such therapy would decrease the morbidity and mortality of thrombotic disease.
Hemostasis is the spontaneous process of stopping bleeding from damaged blood vessels. Precapillary vessels contract immediately when cut. Within seconds, thrombocytes, or blood platelets, are bound to the exposed matrix of the injured vessel by a process called platelet adhesion. Platelets also stick to each other in a phenomenon known as platelet aggregation to form a platelet plug. This platelet plug can stop bleeding quickly, but it must be reinforced by the protein fibrin for long-term effectiveness, until the blood vessel tear can be permanently repaired by growth of fibroblasts, which are specialized tissue repair cells.
An intravascular thrombus (clot) results from a pathological disturbance of hemostasis. The thrombus can grow to sufficient size to block off arterial blood vessels. Thrombi can also form in areas of stasis or slow blood flow in veins. Venous thrombi can easily detach portions of themselves called emboli that travel through the circulatory system and can result in blockade of other vessels, such as pulmonary arteries. Thus, arterial thrombi cause serious disease by local blockade, whereas venous thrombi do so primarily by distant blockade, or embolization. These diseases include venous thrombosis, thrombophlebitis, arterial embolism, coronary and cerebral arterial thrombosis and myocardial infarction, stroke, cerebral embolism, kidney embolisms and pulmonary embolisms.
There is a need in the area of cardiovascular and cerebrovascular therapeutics for an agent which can be used in the prevention and treatment of thrombi, with minimal side effects, including unwanted prolongation of bleeding in other parts of the circulation while preventing or treating target thrombi. The compounds of the present invention meet this need in the art by providing therapeutic agents for the prevention and treatment of thrombi.
The compounds of the present invention show efficacy as antithrombotic agents by virtue of their ability to block fibrinogen from acting at its platelet receptor site and thus prevent platelet aggregation.
SUMMARY OF THE INVENTION
The present invention relates to novel compounds having the general structural formula I: ##STR1## and the pharmaceutically aceptable salts thereof, wherein R 1 is, a four to eight member heterocyclic ring containing 1, 2, 3 or 4 heteroatoms wherein said hetero atoms are N, O or S and wherein said hetero ring is optionally substituted at any atom by H, R 6 or R 7 ; ##STR2## wherein R 6 and R 7 are independently hydrogen and unsubstituted or substituted C 0-10 alkyl and cycloalkyl wherein said substituents are
C 1-10 alkoxy,
C 1-10 alkoxyalkyl,
C 1-10 alkoxyalkyloxy,
C 1-10 alkoxycarbonyl,
C 1-10 alkylcarbonyl,
C 4-10 aralkylcarbonyl,
C 1-10 alkylthiocarbonyl,
C 1-10 aralkylthiocarbonyl,
thiocarbonyl,
C 1-10 alkoxythiocarbonyl, aryl,
a 5 to 6 membered saturated heterocyclic ring containing 1,2,3 or 4 hetero atoms wherein said heteroatoms are taken from the group consisting of N, O and S,
C 1-4 alkanoylamino,
C 1-6 alkoxycarbonyl-C 0-6 alkylamino,
C 1-10 alkylsulfonylamino,
C 4-10 -aralkylsulfonylamino,
C 4-10 aralkyl,
C 1-10 alkaryl,
C 1-10 alkylthio,
C 4-10 aralkylthio,
C 1-10 alkylsulfinyl,
C 4-10 aralkylsulfinyl,
C 1-10 alkylsulfonyl,
C 4-10 aralkylsulfonyl, aminosulfonyl,
C 1-10 alkylaminosulfonyl,
C 4-10 aralkylsulfonylamino,
oxo,
thio,
unsubstituted and mono- and di-substituted 1-ethenyl, 2-ethenyl and 3-propenyl wherein said substituents are selected from the group consisting of hydrogen, C 1-10 alkyl and C 4-10 aralkyl,
carboxy,
hydroxy,
amino,
C 1-6 alkylamino,
C 1-6 dialkylamino,
halogen, where halogen is defined as F, Cl,
Br or I,
nitro, and
cyano,
and further wherein said N can additionally be substituted to form a quaternary ammonium ion wherein said substituent is as previously defined for R 6 and R 7 ;
R 2 and R 3 are independently
hydrogen, aryl and unsubstituted and substituted C 0-10 alkyl and cycloalkyl wherein said substituent is C 1-10 alkoxyalkyl,
a 4 to 8 membered saturated heterocyclic ring system containing 1, 2, 3 or 4 heteroatoms, wherein said heteroatoms are taken from the group consisting of N, O and S,
C 4-10 aralkyl,
C 1-10 alkaryl,
C 1-10 alkylthio,
C 4-10 aralkylthio,
C 1-10 alkylsulfinyl,
C 4-10 aralkylsulfinyl,
C 1-10 alkylsulfonyl,
C 4-10 aralkylsulfonyl, carboxy,
C 1-10 alkylcarbonyl,
C 1-10 alkylthiocarbonyl,
C 4-10 aralkylcarbonyl,
C 4-10 aralkylthiocarbonyl,
C 1-6 alkoxycarbonyl,
C 4-10 aralkoxycarbonyl,
C 1-6 alkoxy,
C 1-6 alkoxycarbonyl-C 1-4 alkyl,
C 4-10 aralkoxycarbonyl-C 1-4 alkyl,
C 4-10 aralkoxy,
C 1-6 alkylamino,
C 1-12 dialkylamino,
C 1-6 alkanoylamino,
C 4-10 aralkanoylamino,
C 4-10 aralkylamino,
R 4 is
aryl,
C 1-10 alkyl or cycloalkyl,
C 4-10 aralkyl,
C 1-10 alkoxyalkyl,
C 1-10 alkaryl,
C 1-10 alkylthioalkyl,
C 1-10 alkoxythioalkyl,
C 1-10 alkylamino,
C 4-10 aralkylamino,
C 1-10 alkanoylamino,
C 4-10 aralkanoylamino
C 1-10 alkanoyl,
C 4-10 aralkanoyl, and unsubstituted or substituted C 1-10 carboxyalkyl wherein said substituent is aryl or C 1-10 aralkyl; further wherein any of the substituents for R 4 may be substituted by substituents selected from the group as defined for R 6 ;
R 5 is a four to eight member saturated or unsaturated heterocyclic ring containing 1, 2, 3 or 4 heterocyclic atoms wherein said heteroatoms are N, O and S and ##STR3## wherein R 8 is hydroxy,
C 1-10 alkyloxy,
C 1-10 alkaryloxy,
C 4-10 aralkyloxy,
C 4-10 aralkylcarbonyloxy,
C 1-10 alkoxyalkyloxy,
C 1-10 alkoxyalkylcarbonyloxy,
C 1-10 alkoxycarbonylalkyl,
C 1-10 alkylcarbonyloxyalkyloxy,
an L- or D-amino acid joined by an amide linkage or an L- or D-amino acid joined by an amide linkage and wherein the carboxylic acid moiety of said amino acid is esterified by C 1-6 alkyl or C 4-10 aralkyl, ##STR4## wherein R 9 and R 10 are selected from the group consisting of hydrogen, C 1-10 alkyl and C 4-10 aralkyl;
X and Y are independently ##STR5## a 4- to 8-membered ring containing 0,1,2,3, or 4 heteroatoms chosen from N, O and S, wherein said ring is independently substituted at any atom with R 6 ,
aryl, ##STR6## Z is an optional substituent that, when present, is independently chosen as defined for X and Y;
m is an integer of from zero to ten;
n is an integer of from zero to ten; and
p is an integer of from zero to three.
A preferred group of compounds of the present invention are those defined for general structural formula II as: ##STR7## wherein R 1 is a five to six member heterocyclic ring wherein said heteroatoms are N, O or S and wherein said heterocyclic ring is optionally substituted by C 1-5 alkyl; or
NR 6 R 7 wherein R 6 and R 7 are independently hydrogen, unsubstituted or substituted C 1-10 alkyl wherein said substituent is
C 1-10 alkoxycarbonyl,
aryl,
C 0-5 dialkylamino-C 1-10 alkyl,
C 4-10 aralkyl,
and further wherein said N can additionally be substituted to form a quaternary ammonium ion wherein said substituent is as previously defined for R 6 and R 7 ;
R 2 and R 3 are
hydrogen and
C 1-4 alkyl, C 4-10 aralkyl;
R 4 is
aryl,
C 1-10 alkyl or cycloalkyl,
C 4-10 aralkyl,
C 1-10 alkoxyalkyl,
C 1-10 alkaryl,
unsubstituted or substituted C 1-10 carboxyalkyl wherein said substituent is aryl, C 1-6 alkyl, or C 4-10 aralkyl;
R 11 is
hydrogen or
C 1-10 alkyl;
X and Y are independently
aryl, ##STR8## a 5 or 6-membered ring containing 0, 1 or 2 heteroatoms chosen from N or O;
Z is an optional substituent that, when present, is
O, SO 2 , --NR 6 CO--, --CONR 6 --,
C 1-10 straight or branched alkyl;
m is an integer of from zero to eight;
n is an integer of from zero to two; and
p is an integer of from zero to two.
A more preferred group of compounds of the present invention are those defined for general structure formula III as ##STR9## wherein R 1 is a five or six membered heterocyclic ring wherein said heteroatoms are N and O and wherein said heterocyclic ring is optionally substituted by C 1-5 alkyl;
NR 6 R 7 wherein R 6 and R 7 are independently
C 1-10 alkyl, or
C 4-10 aralkyl
and further wherein said N can additionally be substituted to form a quaternary ammonium ion wherein said substituted is as previously defined for R 6 and R 7 ;
R 4 is
aryl,
C 1-10 alkyl or cycloalkyl, or
C 4-10 aralkyl;
X and Y are independently
phenyl ##STR10## or a 5- or 6- membered ring containing 0 or 1 heteroatoms chosen from N or O;
Z is an optional substitutent that, when present, is O, SO 2 , --NR 6 CO--, --CONR 6 --, or --CH 2 --; and
m is an integer of from zero to six.
Preferred compounds of the present invention are: ##STR11## 2-S-(2-Styrylsulfonylamino)-3-[4-(piperidin-4-ylbutyloxyphenyl]propionic acid hydrochloride;
2-S-(Phenylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride;
2-S-(2-Phenethylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride;
2-S-(2-Thienylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride;
2-S-(Dansylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride;
2-S-(Butylsulfonylamino)-3-[4-(piperidin-4-yl)oxyphenyloxy]phenylpropionic acid hydrochloride;
2-S-(Butylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]propionic acid hydrochloride;
2-S-(Butylsulfonylamino)-3-[4-(piperidin-4-yl)-2,2-dimethyl]butyloxyphenylpropionic acid;
3-S-(Butylsulfonylamino)-4-[4-piperidin-4-yl)butyloxyphenyl]butanoic acid;
2-S-(Methylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]-propionic acid;
2-S-(Butylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]-propionic acid;
{2-[4-[4-Piperidin-4-yl)butyloxyphenyl]-1-n-butylsulfonylamino)}-ethanephosphonic acid and ethyl ester;
{2-[4-[4-Piperidin-4-yl)butyloxyphenyl]-1-n-butylsulfonylamino)}-ethanephosphonic acid; and
Ethyl-2-S-Benzylsulfonylamino-3-[4-(piperidin-4-yl)butyloxyphenyl]propionate.
DETAILED DESCRIPTION OF THE INVENTION
The term "pharmaceutically acceptable salts" shall mean non-toxic salts of the compounds of this invention which are generally prepared by reacting the free base with a suitable organic or inorganic acid. Representative salts include the following salts:
Acetate
Benzenesulfonate
Benzoate
Bicarbonate
Bisulfate
Bitartrate
Borate
Bromide
Calcium Edetate
Camsylate
Carbonate
Chloride
Clavulanate
Citrate
Dihydrochloride
Edetate
Edisylate
Estolate
Esylate
Fumarate
Gluceptate
Gluconate
Glutamate
Glycollylarsanilate
Hexylresorcinate
Hydrabamine
Hydrobromide
Hydrochloride
Hydroxynaphthoate
Iodide
Isothionate
Lactate
Lactobionate
Laurate
Malate
Maleate
Mandelate
Mesylate
Methylbromide
Methylnitrate
Methylsulfate
Mucate
Napsylate
Nitrate
Oleate
Oxalate
Pamaote
Palmitate
Pantothenate
Phosphate/diphosphate
Polygalacturonate
Salicylate
Stearate
Subacetate
Succinate
Tannate
Tartrate
Teoclate
Tosylate
Triethiodide
Valerate
The term "pharmacologically effective amount" shall mean that amount of a drug or pharmaceutical agent that will elicit the biological or medical reponse of a tissue, system or animal that is being sought by a researcher or clinician. The term "anti-coagulant agent" shall include aspirin, heparin and warfarin. The term "fibrinolytic agent" shall include streptokinase and tissue plasminogen activator.
The term "aryl" shall mean a mono- or polycylic ring system composed of 5- and 6-membered aromatic rings containing 0, 1, 2, 3, or 4 heteroatoms chosen from N, O, and S and either unsubstituted or substituted with R 6 .
The term "alkyl" shall mean straight or branched chain alkane, alkene or alkyne.
The term "alkoxy" shall be taken to include an alkyl portion where alkyl is as defined above.
The terms "aralkyl" and "alkaryl" shall be taken to include an alkyl portion where alkyl is as defined above and to include an aryl portion where aryl is as defined above.
The term "halogen" shall include fluorine, chlorine, iodine and bromine.
The term "oxo" shall mean the radical ═O.
The term "thio" shall mean the radical ═S.
Compounds of the invention may be administered to patients where prevention of thrombosis by inhibiting binding of fibrinogen to the platelet membrane glycoprotein complex IIb/IIIa receptor is desired. They are useful in surgery on peripheral arteries (arterial grafts, carotid endarterectomy) and in cardivascular surgery where manipulation of arteries and organs, and/or the interaction of platelets with artificial surfaces, leads to platelet aggregation and consumption. The aggregated platelets may form thrombi and thromboemboli. They may be administered to these surgical patients to prevent the formation of thrombi and thromboemboli.
Extracorporeal circulation is routinely used for cardivascular surgery in order to oxygenate blood. Platelets adhere to surfaces of the extracorporeal circuit. Adhesion is dependent on the interaction between GPIIb/IIIa on the platelet membranes and fibrinogen adsorbed to the surface of the circuit. (Gluszko et. al., Amer. J. Physiol., 1987, 252:H, pp 615-621). Platelets released from artificial surfaces show impaired hemostatic function. Compounds of the invention may be administered to prevent adhesion.
Other application of these compounds include prevention of platelet thrombosis, thromboembolism and reocclusion during and after thrombolytic therapy and prevention of platelet thrombosis, thromboembolism and reocclusion after angioplasty of coronary and other arteries and after coronary artery bypass procedures. They may also be used to prevent mycocardial infarction.
The compounds of the present invention can be administered in such oral dosage forms as tablets, capsules, pills, powders, granules, elixers, tinctures, suspensions, syrups and emulsions. Likewise, they may also be administered in intravenous, intraperitoneal, subcutaneous or intramuscular form, all using forms well known to those of ordinary skill in the pharmaceutical arts. An effective but non-toxic amount of the compound desired can be employed as an anti-aggregation agent.
The dosage regimen utilizing the compounds of the present invention is selected in accordance with a variety of factors including type, species, age, weight, sex and medical condition of the patient; the severity of the condition to be treated; the route of administration; the renal and hepatic function of the patient; and the particular compound or salt thereof employed. An ordinarily skilled physician or veterinarian can readily determine and prescribe the effective amount of the drug required to prevent, counter or arrest the progress of the condition.
Oral dosages of the present invention, when used for the indicated effects, will range between about 0.01 mg per kg of body weight per day (mg/kg/day) to about 100 mg/kg/day and preferably 1.0-100 mg/kg/day and most preferably 1.0 to 50 mg/kg/day. Intravenously, the most preferred doses will range from about 1 to about 10 mg/kg/minute during a constant rate infusion. Advantageously, compounds of the present invention may be administered in a single daily dose, or the total daily dosage may be administered in divided doses of two, three or four times daily. Furthermore, preferred compounds for the present invention can be administered in intranasal form via topical use of suitable intranasal vehicles, or via transdermal routes, using those forms of transdermal skin patches well known to those of ordinary skill in that art. To be administered in the form of a transdermal delivery system, the dosage administration will, of course, be continuous rather than intermittant throughout the dosage regimen.
In the methods of the present invention, the compounds herein described in detail can form the active ingredient, and are typically administered in admixture with suitable pharmaceutical diluents, excipients or carriers (collectively referred to herein as `carrier` materials) suitably selected with respect to the intended form of administration, that is, oral tablets, capsules, elixirs, syrups and the like, and consistent with conventional pharmaceutical practices.
For instance, for oral administration in the form of a tablet or capsule, the active drug component can be combined with an oral, non-toxic, pharmaceutically acceptable, inert carrier such as lactose, starch, sucrose, glucose, methyl cellulose, magnesuim stearate, dicalcium phosphate, calcium sulfate, mannitol, sorbitol and the like; for oral administration in liquid form, the oral drug components can be combined with any oral, non-toxic, pharmaceutically acceptable inert carrier such as ethanol, glycerol, water and the like. Moreover, when desired or necessary, suitable binders, lubricants, disintegrating agents and coloring agents can also be incorporated into the mixture. Suitable binders include starch, gelatin, natural sugars such as glucose or beta-lactose, corn sweeteners, natural and synthetic gums such as acacia, tragacanth or sodium alginate, carboxymethylcellulose, polyethylene glycol, waxes and the like. Lubricants used in these dosage forms include sodium oleate, sodium stearate, magnesium stearate, sodium benzoate, sodium acetate, sodium chloride and the like. Disintegrators include, without limitation, starch, methyl cellulose, agar, bentonite, xanthan gum and the like.
The compounds of the present invention can also be administered in the form of liposome delivery systems, such as small unilamellar vesicles, large unilamellar vesicles and multilamellar vesicles. Liposomes can be formed from a variety of phospholipids, such as cholesterol, stearylamine or phosphatidylcholines.
Compounds of the present invention may also be delivered by the use of monoclonal antibodies as individual carriers to which the compound molecules are coupled. The compounds of the present invention may also be coupled with soluble polymers as targetable drug carriers. Such polymers can include polyvinylpyrrolidone, pyran copolymer, polyhydroxypropylmethacrylamide-phenol, polyhydroxyethylaspartamide-phenol, or polyethyleneoxide-polylysine substituted with palmitoyl residues. Furthermore, the compounds of the present invention may be coupled to a class of biodegradable polymers useful in achieving controlled release of a drug, for example, polylactic acid, polyglycolic acid, copolymers of polylactic and polyglycolic acid, polyepsilon caprolactone, polyhydroxy butyric acid, polyorthoesters, polyacetals, polydihydropyrans, polycyanoacrylates and cross-linked or amphipathic block copolymers of hydrogels.
The compounds of the present invention can also be co-administered with suitable anti-coagulant agents or thrombolytic agents to achieve synergistic effects in the treatment of various vascular pathologies.
The compounds of formula I can be prepared readily according to the following reaction Schemes and Examples or modifications thereof using readily available starting materials, reagents and conventional synthesis procedures. In these reactions, it is also possible to make use of variants which are themselves known to those of ordinary skill in this art, but are not mentioned in greater detail.
The most preferred compounds of the invention are any or all of those specifically set forth in these examples. These compounds are not, however, to be construed as forming the only genus that is considered as the invention, and any combination of the compounds or their moieties may itself form a genus. The following examples further illustrate details for the preparation of the compounds of the present invention. Those skilled in the art will readily understand that known variations of the conditions and processes of the following preparative precedures can be used to prepare these compounds. All temperatures are degrees Celsius unless noted otherwise.
Reagent symbols have the following meanings:
BOC: t-butyloxycarbonyl
Pd-C: Palladium on activated carbon catalyst
DMF: Dimethylformamide
DMSO: Dimethylsulfoxide
CBZ: Carbobenzyloxy
CH 2 Cl 2 : Methylene chloride
CHCl 3 : Chloroform
EtOH: Ethanol
MeOH: Methanol
EtOAc: Ethyl acetate
HOAc: Acetic acid
THF: Tetrahydrofuran
Generally, compounds of the invention are prepared as follows:
Scheme 1
A suitably N-protected (BOC or CBZ) tyrosine is O-alkylated by treatment with a base, such as NaH or KH, followed by an alkylating agent.* This reaction is typically carried out in DMF or ether (THF) solvents at 0°-40° for from 1-12 hours. The product is esterified, eg. methyl or ethyl ester, with Cs 2 CO 3 /MeI (or EtI) in a polar, aprotic solvent such as DMF and then hydrogenated in the presence of a catalyst such as Pd/C to remove the N-protecting group. Sulfonylation of the amino ester is effected by treatment of a sulfonyl halide, such as a chloride, in an organic solvent, such as EtOAc, THF, or CH 3 CN, in the presence of an inorganic base, such as NaHCO 3 or KHCO 3 or an organic base such as pyridine or triethylamine. Final deprotection is then carried out by hydrolysis in base, LiOH or NaOH in homogeneous solution of THF, CH 3 OH/H 2 O, followed by acid treatment with HCl gas or CF 3 CO 2 H/CH 2 Cl 2 .
Scheme 3
Analogs of tyrosine may be used in similar sequences to that described above. The 4-hydroxyphenylated tyrosine 3-2 is protected on the free amino group with CBZ or similar appropriate reagent and then alkylated on the phenolic oxygen. This former reaction is typically carried out in water/dioxane solution at 0-10° in the presence of an inorganic base, such as Na 2 CO 3 or K 2 CO 3 , by treatment of the phenol with an acid chloride as benzyl chloroformate or similar aryl or alkyl chloroformate. Phenolic oxygen alkylation is typically carried out in a hydrocarbon solvent, such as benzene or toluene, in the presence of Ph 3 P, or similar aryl or alkylphosphine, and the appropriate alkanol, such as N-BOC-piperidin-4-ol. Removal of the N-protecting group by catalytic hydrogenation in the case of N-CBZ and sulfonylation of the free amine gives the advanced intermediate. Sulfonylation is typically carried out in EtOAc solution, halocarbon solvents such as CH 2 Cl 2 are also appropriate, at 0-25° for 1-10 hours in the presence of an inorganic base, such as Na 2 CO 3 or K 2 CO 3 or organic bases such as pyridine and N-methylmorpholine. Final deprotection with base/LiOH or NaOH in THF/alkanol/H 2 O) followed by acid (HCl gas/EtOAc or CF 3 CO 2 H/CH 2 Cl 2 ) provides the final product.
Scheme 4
Modification of the alkylating agent for the tyrosine O allows a variety of amino terminal groups to be used. For example, N-CBZ esters, such as 4-1 can be treated with alkyl organometallic reagents such as methyl lithium or ethyl magnesium bromide to provide substituted alcohols such as 4-2.* Alkylation of phenol as described above in Scheme 3 and analogous structural modification afford diverse final products.
Scheme 5
Novel chain extension at the C-terminus is effected by conversion of the N-protected carboxylic acid of tyrosine to an α-diazo ketone. This conversion typically involves treatment of the acid anhydride or acid chloride with diazomethane, followed by rearrangement under thermal conditions or in the presence of a catalyst such as silver benzoate in an alkanol solvent at 0-40° for from 1-10 hours. The resulting methylene extended ester may then be N-deprotected at the α-amino site, and converted to final products as described above. Typically, the free α-amino group is acylated or sulfonylated as described above to provide a suitable advanced intermediate. This is then deprotected under conditions that remove the carboxy and amino protecting groups to give final products.
The source for the following compounds is as shown: ##STR12## is described below. ##STR13##
2-(4-N-t-Butyloxycarbonylpiperidinyl)ethanol
4-Piperidine-2-ethanol (Available from Aldrich) (130 g, 1.0 mole) was dissolved in 700 mL dioxane, cooled to 0° C. and treated with 3 N NaOH (336 mL, 1.0 mole), and di-t-butylcarbonate (221.8 g, 1.0 mole). The ice bath was removed and the reaction stirred overnight. The reaction was concentrated, diluted with water and extracted with ether. The ether layers were combined, washed with brine, dried over MgSO 4 , filtered and evaporated to give 225.8 g of product (98%).
R f =0.37 in 1:1 EtOAc/Hexanes, ninhydrin stain
1 H NMR (300 MHz, CDCl 3 ) δ 4.07 (bs, 2H), 3.7 (bs, 2H), 2.7 (t, J=12.5 Hz, 2H), 1.8-1.6 (m, 6H), 1.51 (s, 9H), 1.1 (ddd, J=4.3, 12.5, 12 Hz, 2H). ##STR14##
Methyl 4-(4-N-t-butyloxycarbonylpiperidinyl)but-2-enoate
Oxalyl chloride (55.8 mL, 0.64 mole) was dissolved in 1 L CH 2 Cl 2 and cooled to -78° C. under N 2 . DMSO (54.2 mL, 0.76 mole) was added dropwise. After gas evolution had ceased, 2-(4-N-t-butyloxycarbonylpiperidinyl)ethanol (102.5 g, 0.45 mole) dissolved in 200 mL CH 2 Cl 2 was added over 20 minutes. After stirring an additional 20 minutes, triethylamine (213 mL, 1.53 mole) was added dropwise and the cold bath removed. After 1 and 1/2 hours TLC showed starting material gone. Carbomethoxytriphenylphosphorane (179 g, 0.536 mole) was added and the reaction stirred overnight. The solution was diluted with 300 mL Et 2 O, extracted once with 800 mL H 2 O, twice with 300 mL 10% KHSO 4 solution, then once with 300 mL brine. The organic layer was dried over MgSO 4 , filtered and evaporated. Column chromatography (SiO 2 , 5% EtOAc/Hexanes) yielded 78.4 g (62%) of pure methyl 4-(4-N-t-butyloxycarbonylpiperidinyl) but-2-enoate.
1 H NMR (300 MHz, CDCl 3 ) δ 6.9 (ddd J=15.6, 7,6, 7.6 Hz, 1H), 5.8 (d, J=15.6 Hz, 1H), 4.0 (bs, 2H), 3.7 (s, 3H), 2.6 (t, J=12.6 Hz, 2H), 2.1 (t, J=7.4 Hz, 2H), 1.7-1.4 (m, 3H), 1.4 (S, 9H), 1.1 (m, 2H). ##STR15##
4-(4-N-t-Butyloxycarbonylpiperidinyl)butyl bromide
Methyl 4-(4-N-t-butyloxycarbonylpiperidinyl)but-2-enoate (36.2 g, 0.128 mole), was dissolved in 500 mL EtOAc. 10% Palladium on carbon (10 g) was added as a slurry in EtOAc and the reaction was placed under H 2 (in a balloon) overnight. The reaction was filtered through Solka-Floc, the cake washed with EtOAc and the ethyl acetate evaporated to give 34.7 g (90%) of methyl 4-(4-N-t-butyloxycarbonylpiperidin-4-yl)butanoate. TLC R f =0.69 in 30% EtOAc/Hexanes.
1 H NMR (300 MHz, CDCl 3 ) δ 4.0 (bs, 2H), 3.6 (s, 3H), 2.60 (t, J=12.3 Hz, 2H), 2.20 (t, J=7.4, 2H), 1.6 (m, 4H), 1.40 (s, 9H), 1.40 (m, 1H), 1.20 (m, 2H), 1.0 (m, 2H).
The butanoate ester (45.3 g, 0.159 mole) was dissolved in CH 3 OH and treated with 1 N NaOH (500 mL, 0.5 mole) overnight. The solvent was removed in vacuo, water was added and the solution washed with ether, then acidified with 10% KHSO 4 solution. The aqueous layer was washed with ether, the ether layers were combined, washed with brine, dried (MgSO 4 ), and concentrated to give the corresponding acid as a clear oil (41.85 g, 97% yield).
1 H NMR (300 MHz, CDCl 3 ) δ 4.0 (bs, 2H), 2.6 (m, 2H), 2.25 (m, 2H), 1.6 (bs, 4H, 1.4 (s, 9H), 1.3-0.9 (9H).
This acid (20.4 g, 0.077 mole) was treated with borane (BH 3 /THF, 235 mL, 235 mmole) in THF at 0° for 1 hour. NaOH (1N, 250 mL) was added dropwise and the solution stirred overnight. The resulting reaction mixture was concentrated to remove THF and extracted with ether. The ether extracts were combined, dried over MgSO 4 , filtered and evaporated to give the corresponding alcohol as 19.7 g of a colorless oil.
R f =0.7 in 2:1 ethyl acetate/hexanes.
1 H NMR (300 MHz, CDCl 3 ) δ 4.1 (bs, 2H), 3.6 (t, 2H), 2.65 (t, 2H), 2.1 (bs, 1H), 1.65 (bs, 2H), 1.55 (m, 2H), 1.4 (s, 9H), 1.35 (m, 3H), 1.25 (m, 2H), 1.1 (m, 2H).
This alcohol (19.7 g, 76.5 mmole) was dissolved in THF and treated with triphenylphosphine (23.1 g, 88 mmole) and cooled to 0° C. Carbon tetrabromide (29.8 g, 89.9 mmol) was added in one portion, the cold bath was removed and the reaction stirred overnight. Additional triphenyl phosphine (11.71 g) and carbon tetrabromide (14.9 g) was added to drive the reaction to completion. The mixture was filtered and the liquid was diluted with ether and filtered again. After solvent removal the resulting liquid was adsorbed onto SiO 2 and chromatographed with 5% EtOAc/Hexanes to yield 4-(4-N-t-butyloxycarbonylpiperidin-4-yl)butyl bromide as a clear colorless oil (20.7 g, 85% yield).
R f =0.6 in 1:4 ethyl acetate/hexanes
1 H NMR (300 MHz, CDCl 3 ) δ 4.1 (bs, 2H), 3.4 (t, 2H), 2.65 (t, 2H), 1.85 (m, 2H), 1.65 (bd, 2H), 1.4 (s, 9H), 1.35 (m, 2H), 1.3 (m, 3H), 1.1 (m, 2H).
2. BocNH(CH 2 ) 6 Br
Commercial H 2 N(CH 2 ) 5 CH 2 OH was protected as the N-Boc derivative in standard fashion and this was converted to the bromide with Ph 3 P/CBr 4 in THF. Utilization of starting amino alcohols of varying chain lengths provides the analogous halides in this manner. ##STR16##
EXAMPLE 1 ##STR17##
2-S-(Benzyloxycarbonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionic acid (1-2)
N-CBZ-L-tyrosine (1-1) (17.58 g, 0.055 mmole) was dissolved in DME (75 mL), cooled to 0-10° C. and treated with sodium hydride (2.88 g, 0.12 mole). This suspension was stirred at 0-10° C. for 1 hour and then N-t-butyloxycarbonylpiperidin-4-ylbutyl bromide (17.70 g, 0.055 mole) in 25 mL DMF was added dropwise over 15 minutes. The reaction mixture was then stirred at room temperature for 16 hours. The solvent was removed in vacuo and the residue was taken up in a mixture of 500 mL EtOAc/100 mL 10% KHSO 4 . The organic phase was washed with brine, dried (Na 2 SO 4 ) and the solvent was removed to give a viscous oil. This was purified by flash chromatography on silica gel eluting with 98:2:0.5 CHCl 3 /CH 3 OH/HOAc to give pure 1-2 (23.75 g), R f =0.35, as a pale yellow oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.00-1.15 (2H, m), 1.20-1.80 (16H, m), 2.62 (2H, t), 3.10 (2H, m), 3.91 (2H, t), 4.04 (2H, m), 5.10 (2H, m), 5.22 (1H, d), 6.78 (2, d), 7.04 (2H, d), 7.35 (5H, m).
EXAMPLE 2 ##STR18##
Methyl 2-S-(Benzyloxycarbonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionic acid (1-3)
1-2 (10.05 g, 18.1 mmole) was dissolved in CH 3 OH (150 mL) at room temperature and cesium carbonate (2.95 g, 9.06 mmole) was added and the resulting mixture stirred for 15 minutes to give a clear solution. The CH 3 OH was removed at reduced pressure and the residue was then dissolved in DMF (150 mL) and treated dropwise with methyl iodide (2.57), 18.1 mmole). The resulting solution was stirred overnight at room temperature. The solvent was removed in vacuo and the residue was taken up in 400 mL ether and washed with 3×50 mL portions of H 2 O, 50 mL brine and dried (Na 2 SO 4 ). Solvent removal provided 1-3 as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.0-1.15 (2H, m), 1.30-1.70 (16H, m), 2.68 (2H, dt), 3.05 (2H, m), 3.72 (3H, s), 3.91 (2H, t), 4.08 (2H, d), 4.61 (1H, m), 5.10 (2H, m), 5.18 (1H, m), 6.79 (2H, d), 6.98 (2H, d), 7.35 (5H, m).
EXAMPLE 3 ##STR19##
Methyl 2-S-Amino-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)-butyloxyphenyl]propionate (1-4)
To 1-3 (5.0 g, 8.79 mmole) dissolved in absolute ethanol (150 mL) was added 10% Pd/C (0.5 g) and the resulting suspension was hydrogenated under balloon pressure for 12 hours. The catalyst was then filtered off and the solvent was removed in vacuo to give 1-4 (3.6 g) as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.00-1.20 (2H, m), 1.22-1.55 (12H, m), 1.60-1.75 (4H, m), 2.00 (2H, bs), 2.68 (2H, t), 2.87 (1H, dd), 3.05 (1H, dd), 3.72 (3H, s), 3.93 (2H, t), 4.09 (2H, m), 6.82 (2H, d), 7.10 (2H, d).
EXAMPLE 4 ##STR20##
Methyl 2-S-(n-Butylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-8)
1-4 (0.59 g, 1.36 mmole) was dissolved in ethyl acetate (10 mL) and NaHCO 3 (0.7 g, 8.68 mmole) was added with stirring at room temperature followed by butanesulfonyl chloride (0.36 mL, 2.76 mmole) and the resulting mixture was refluxed for 26 hours. The cooled reaction mixture was filtered and concentrated and the residue was purified by flash chromatography on silica gel eluting with 4:1 hexane/EtOAc to give pure 1-8 (0.305 g) R f =0.7 in 1:1 hexane/EtOAc, ninhydrin stain.
1 H NMR (300 MHz, CDCl 3 ) δ 0.82 (3H, t), 1.05 (2H, ddd), 1.45 (9H, s), 1.1-1.6 (1H, m), 1.7 (4H, m), 2.6 (2H, t), 2.6-2.8 (2H, m), 2.78 (1H, dd), 3.05 (1H, dd), 3.7 (3H, s), 3.93 (2H, t), 4.05 (2H, bd), 4.15 (1H, dd), 6.85 (2H, d), 7.15 (2H,d).
EXAMPLE 5 ##STR21##
2-S-(n-Butylsulfonylamino)-3[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride (1-9)
1-8 (0.325 g, 0.59 mmole) was dissolved in 1:1:1 CH 3 OH/H 2 O/THF and LiOH.H 2 O (0.157 g, 3.76 mmole) was added. The resulting solution was stirred at room temperature for 3 hours, then concentrated, diluted with 10% KHSO 4 and extracted with EtOAc. This provided 2-S-(n-butylsulfonylamino)-3[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionic acid. This acid (0.315 g, 0.59 mmole) was dissolved in EtOAc (20 mL) and treated with HCl gas at -20° C. for 15 minutes. The reaction mixture was then stoppered and was stirred at -5° C. for 1 hour at which time all starting material was consumed. Argon gas was bubbled through the reaction mixture for 15 minutes and the solvent was removed to give a residue that was triturated with ether to provide pure 1-9 (0.29 g) as a pale yellow solid.
1 H NMR (300 MHz, CD 3 OD) δ 0.85 (3H,t), 1.2 (2H,dd), 1.2-1.7 (9H,m), 1.7 (2H, m), 1.95 (2H, bs), 2.65 (2H, t), 2.8 (1H, dd), 2.95 (2H, bt), 3.10 (1H, dd), 3.83 (2H, bs), 3.95 (2H, t), 4.1 (1H, dd), 6.85 (2H, d), 7.2 (2H, d).
Analysis for C 22 H 36 N 2 O 5 1S.HCl.0.8 H 2 O
Calculated: C=53.76, H=7.92, N=5.70 Found: C=53.76, H=7.66, N=5.44.
EXAMPLE 6 ##STR22##
Methyl 2-S-(Benzylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-10)
1-4 (0.59 g, 1.36 mmole) was treated with benzylsulfonyl chloride (0.263 g, 1.38 mmole) as described above for 1-8. The crude reaction product was purified by flash chromatography on silica gel eluting with 3:1 hexane/EtOAc to give pure 1-10 (0.35 g) as an oil.
1 H NMR (300 MHz, CD 3 OD) δ 0.85-1.10 (2H, m), 1.10-1.23 (2H,m), 1.35-1.52 (11H, m), 1.61-1.80 (4H, m), 2.65-3.00 (4H, m), 3.65 (3H, s), 3.90-4.14 (5H, m), 6.85 (2H, d), 7.08 (2H, d), 7.22 (2H, m), 7.30 (3H, m).
EXAMPLE 7 ##STR23##
2-S-(Benzylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride (1-11)
Treatment of 1-10 (0.354 g, 0.60 mmole) with LiOH (0.15 g, 3.7 mmole) as described for 1-8 gave 2-S-(benzylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionic acid (0.35 g) as a viscous oil.
1 H NMR (300 MHz CD 3 OD) δ 0.84-1.06 (3H, m), 1.23 (4H, m), 1.34-1.50 (11H, m), 1.60-1.78 (5H, m), 2.65 (2H, bt), 2.82 (1H, m), 3.02 (1H, m), 3.91 (2H, m), 3.96-4.12 (5H, m), 6.83 (2H, d), 7.15 (2H, d), 7.22 (2H, m), 7.29 (3H, m).
This acid (0.35 g, 0.60 mmole) was dissolved. in 20 mL EtOAc and treated with HCl gas as described for 1-9 to give pure 1-11 as a white solid (0.30 g).
1 H NMR (300 MHz, CD 3 OD) δ 1.32 (4H, m), 1.40-1.65 (3H, m), 1.72 (2H, m), 1.92 (2H, d), 2.77-3.08 (4H, m), 3.33 (3H, m), 3.95-4.14 (5H, m), 6.86 (2H, d), 7.17 (2H, d), 7.28 (2H, m), 7.31 (3H, m). ##STR24##
Methyl 2-S-(2-Styrylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-12)
1-4 (0.647 g, 15 mmoles) was dissolved in ethyl acetate (20 ml), and NaHCO 3 (0.454 g, 5.4 mmoles) was added followed by 2-styrenesulfonyl chloride (0.365 g, 18.0 mmoles) and the resulting reaction mixture was heated at reflux with stirring for 16 hours. The cooled reaction mixture was filtered, the solvent removed and the residue was purified by flash chromatography on silica gel eluting with hexane (3)/ethyl acetate (1) to give pure 1-12.
1 H NMR (300 MHz, CDCl 3 ) δ 1.10 (2H, m), 1.30-1.55 (14H, m), 1.65-1.80 (4H, m), 2.68 (2H, t), 3.01 (2H, dt), 3.62 (3H, s), 3.88 (2H, t), 4.09 (2H, m), 4.22 (1H, m), 4.98 (1H, d), 6.45 (1H, d), 6.80 (2H, d), 7.06 (2H, d), 7.40 (4H, s).
2-S-(2-Styrylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl)propionic acid hydrochloride (1-13)
1-12 (0.58 g, 0.97 mmole) was dissolved in THF(1)-H 2 O(1)-MeOH(1) (15 ml) and lithium hydroxide (0.12 g, 5.0 mmole) was added and the resulting clear solution was stirred overnight at room temperature.
The reaction mixture was diluted with 75 ml H 2 O, acidfied to pH 2-3 with 10% KHSO 4 solution and then extracted with 3×50 ml EtOAc. The organic extract was dried, the solvent removed, and the residue purified by flash chromatography on silica gel eluting with CHCl 3 (97)-MeOH(3)-HOAc(1) to give the desired acid (R f =0.2).
This acid was dissolved in EtOAc and treated with HCl gas as described for 1-9 to give 1-13.
1 H NMR (300 MHz, CD 3 OD) δ 1.15-1.70 (10H, m), 1.70-1.82 (2H, t), 1.97 (2H, t), 2.78-3.12 (5H, m), 3.35 (3H, m), 3.87 (2H, t), 4.03 (1H, m), 6.50 (1H, d), 6.69 (2H, m), 7.18 (3H, m), 7.41 (5H, bs). ##STR25##
2-S-(2-Phenethylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionic acid (1-14)
1-12a (0.21 g) was dissolved in 20 ml absolute ethanol, 0.1 g 10% Pd/C was added and the stirred suspension was hydrogenated under balloon pressure. After 4 hours the reaction was stopped and the solvent was removed to give the desired product 1-14 (0.194 g).
1 H NMR (300 MHz, CD 3 OD) δ 1.05 (2H, m), 1.30-1.40 (3H, m), 1.47 (14H, m), 1.72 (5H, m), 2.67-2.93 (8H, m), 3.13 (1H, m), 3.31 (2H, m), 3.82 (2H, m), 4.00-4.20 (4H, m), 6.82 (2H, d), 7.07 (2H, d), 7.21 (5H, m).
2-S-(2-Phenethylsulfonylamino)- 3 -[4-(piperidin-4-yl)butyloxvphenyl]propionic acid hydrochloride (1-15)
1-14 (0.194 g) was dissolved in EtOAc and treated with HCl gas as described for 1-9 to provide pure 1-15 (0.145 g).
1 H NMR (300 MHz, CD 3 OD) δ 1.25-1.68 (8H, m), 1.73 (2H, m), 1.93 (2H, m), 2.78 (3H, m), 2.91 (4H, m), 3.13 (1H, m), 3.33 (4H, m), 3.86 (2H, m), 4.18 (1H, m), 6.80 (2H, d), 7.09 (2H, d), 7.22 (5H, m). ##STR26##
Methyl 2-S-(Phenylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-16).
1-4 (0.647 g, 1.5 mmoles) was treated with phenylsulfonyl chloride (0.318 g, 1.8 mmoles ) as described for 1-8. The crude product was purified by flash chromatography on silica gel eluting with CHCl 3 (98)-MeOH(2) to give pure 1-16 (0.67 g).
1 H NMR (300 MHz, CDCl 3 ) δ 1.09 (2H, m), 1.25-1.40 (3H, m), 1.42 (9H, bs), 1.60-1.85 (6H, m), 2.66 (2H, m), 2.96 (2H, d), 3.55 (3H, s), 3.89 (2H, t), 4.09 (4H, m), 5.12 (1H, d), 6.72 (2H, d), 6.95 (2H, d), 7.40-7.65 (3H, m), 7.75 (2H, m).
2-S-(Phenylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl)propionic acid hydrochloride (1-17).
1-16 (0.525 g) was treated with lithium hydroxide as described for 1-8 to give crude product that was purified by flash chromatography on silica gel eluting with CHCl 3 (97)-MeOH(3)-HOAc(1) to provide pure acid (R f =0.2).
This acid was treated with HCl gas in EtOAc as described for 1-9 to provide pure 1-17.
1 H NMR (300 MHz, CD 3 OD) δ 1.28-1.47 (6H, m), 1.50-1.70 (3H, m), 1.75 (2H, m), 1.97 (2H, d), 2.77 (1H, m), 2.95 (3H, m), 3.35 (4H, m), 3.93 (3H, m), 6.72 (2H, d), 7.02 (2H, d), 7.41 (2H, m), 7.52 (1H, m), 7.67 (2H, m). ##STR27##
Methyl 2-S-(2-Thienylsulfonylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-18).
1-4 (0.304 g, 0.7 mmoles) was treated with 2-thienylsulfonyl chloride (0.155 g, 0.85 mmoles) as described for 1-8 to provide crude product. This was purified by flash chromatography on silica gel eluting with CHCl 3 (98)-CH 3 OH(2) to afford pure 1-18 as a viscous oil, R f 0.3 [silica gel, CHCl 3 (98)-CH 3 OH(2)]
1 H NMR (300 MHz, CDCl 3 ) δ 1.10 (2H, m), 1.31 (4H, m), 1.36-1.80 (16H, m), 2.68 (2H, bt), 3.03 (2H, d), 3.57 (3H, s), 3.91 (2H, t), 4.08 (2H, m), 4.29 (1H, m), 5.16 (1H, d), 6.78 (2H, d), 7.00 (4H, m), 7.55 (2H, dd).
2-S-(2-Thienylsulfonylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride (1-19).
Treatment of 1-18 (0.22 g, 0.38 mmoles) with LiOH (0.045 g, 1.89 mmoles) as described for 1-8 provided the desired acid, which was purified by flash chromatography on silica gel eluting with CHCl 3 (97)-CH 3 OH(3)-HOAc(1).
1 H NMR (300 MHz, CD 3 OD) δ 1.05 (2H, d t), 1.20-1.40 (5H, m), 1.40-1.60 (12H, m) 1.65-1.80 (5H, m), 2.65-2.82 (4H, m), 2.98 (1H, dd), 3.30 (1H, m), 3.92 (2H, t), 4.00-4.13 (5H, m), 6.75 (2H, d), 7.02 (3H, m), 7.39 (1H, d), 7.67 (1H, d).
Treatment of this acid with HCl gas as described for 1-9 provided 1-19 as a white solid after trituration.
Analysis Calcd. for C 22 H 30 N 2 O 5 S 2 .HCl.0.5 H 2 O: C, 51.60, H, 6.30, N, 5.47. Found: C, 51.57, H, 6.20, N, 5.51.
1 H NMR (300 MHz, CD 3 OD) δ 1.29-1.45 (4H, m), 1.47-1.70 (3H, m), 1.71-1.83 (2H, m), 1.91-2.00 (2H, bd), 2.79 (1H, m), 2.90-3.04 (3H, m), 3.95 (2H, t), 4.04 (1H, m), 6.76 (2H, d), 7.05 (3H, m), 7.40 (1H, m), 7.79 (1H, m). ##STR28##
Methyl-2-S-(Dansylamino)-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (1-20).
1-4 (0.304 g, 0.7 mmoles) was treated with dansyl chloride (0.208 g, 0.77 mmoles) as described for 1-8 to provide crude product which was purified by flash chromatography on silica gel eluting with hexane(75)-EtOAc(25) to give pure 1-20. R f 0.25 (silica gel eluting with hexane(75)-EtOAc(25).
1 H NMR (300 MHz, CDCl 3 ) δ 1.10 (2H, m), 1.21-1.38 (6H, m), 1.40-1.53 (11H, m), 1.60-1.80 (6H, m), 2.68 (2H, bt), 2.89 (6H, s), 3.33 (2H, s), 3.89 (2H, t), 4.05-4.19 (4H, m), 5.24 (1H, m), 6.62 (2H, d), 6.82 (2H, d), 7.18 (1H, d), 7.50 (2H, m), 8.19 (2H, t), 8.51 (1H, d).
2-S-(Dansylamino)-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride (1-2H).
Treatment of 1-20 (0.275 g, 0.412 mmoles) with LiOH as described for 1-8 gave the desired acid as a highly fluorescent viscous residue.
1 H NMR (300 MHz, CD 3 OD) δ 1.09 (2H, m), 1.22-1.40 (3H, m), 1.40-1.57 (12H, m), 1.65-1.80 (3H, m), 2.60-2.80 (3H, m), 2.90 (6H, s), 3.31 (3H, m), 3.80 (2H, t), 3.90 (1H, m), 4.01-4.15 (4H, m), 6.47 (2H, d), 7.21 (1H, d), 7.42 (2H, m), 7.98 (1H, d), 8.20 (1H, d), 8.46 (1H, d).
Treatment of this acid in EtOAc with HCl gas as described for 1-9 provided 1-21 as a white solid upon ethylacetate trituration.
Analysis for C 30 H 39 N 3 O 5 S.1.8 HCl.H 2 O: C, 56.53; H, 6.77; N, 6.59; Cl, 10.01. Found: C, 56.48; H, 6.66; N, 6.36; Cl, 10.21.
1 H NMR (300 MHz, CD 3 OD) δ 1.30-1.51 (7H, m), 1.52-1.80 (4H, m), 1.95 (2H, bt), 2.65 (1H, m), 2.95 (3H, m), 3.30-3.40 (4H, m), 3.45 (6H, s), 3.84-3.97 (3H, m), 6.45 (2H, d), 6.77 (2H, d), 7.71 (2H, m), 8.00 (1H, d), 8.16 (2H, d), 8.55 (1H, d), 8.70 (1H, d). ##STR29##
2-S-Methylsulfonylamino-3-[4-(piperidin-4-yl)butyloxyphenyl]propionic acid hydrochloride (1-23).
1-22 (0.39 g, 0.78 mmoles), prepared from 1-4 by sulfonylation with methane sulfonyl chloride is described for 1-20, was dissolved in EtOAc (20 ml) cooled to -78° and treated with HCl gas for 3 minutes. The reaction mixture was warmed to 0° over 30 minutes and the solvent was removed. The resulting residue was purified by flash chromatography to give pure 1-23 as a white solid.
R f 0.54 (silica gel, 9:1:1 HtOH/H 2 O/NH 4 OH. ##STR30##
EXAMPLE 8 ##STR31##
2-S-(Benzyloxycarbonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionic acid (2-1)
N-CBZ-L-tyrosine (15.0 g, 0.045 mole) was dissolved in 75 mL DMF and added at 0-10° C. to a suspension of sodium hydride (2.16 g, 0.09 mole) in 25 mL DMF. The resulting suspension was stirred at 0-10° C. for 1.0 hour and then 6-(t-butyloxycarbonylamino)hexyl bromide (12.6 g, 0.045 mole) in 25 mL DMF was added dropwise at 0-5° C. and the clear, dark reaction mixture was stirred at room temperature overnight.
After solvent removal, the residue was taken up in EtOAc and this was made acidic with 10% KHSO 4 solution. The organic phase was separated, washed with brine, dried (Na 2 SO 4 ) and the solvent removed to give an oil. This was purified by column chromatography on silica gel eluting with 98:2:1 CHCl 3 /CH 3 OH/HOAc to give pure 2-1 as a clear oil.
1 H NMR (300 MHZ, CD 3 OD) δ 1.45 (15H, m), 1.75(2H, m), 2.80-3.15 (6H, m), 3.91(2H, t), 4.38(1H, m), 4.95(6H, m), 6.85(2H,d), 7.06(2H,d)
EXAMPLE 9 ##STR32##
Methyl 2-S-(Benzyloxycarbonylamino)-3-(4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionate (2-2)
Compound 2-1 (10.0 g, 19.43 mmole) in 75 mL DMF was treated with cesium carbonate (3.16 g, 9.72 mmole) with stirring at room temperature for 1.9 hours. Then, methyl iodide (2.76 g, 19.43 mmole) was added dropwise and the reaction mixture was stirred overnight at ambient temperature. The solvent was removed at high vacuum (30° C.) and the residue was taken up in 300 mL EtOAc and washed with 2×40 mL protions of saturated NaHCO 3 solution, brine and dried (Na 2 SO 4 ). Solvent removal provided 2-2 (8.5 g, 83%) as a clear oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.25-1.53 (16H, m), 1.76 (2H, m), 2.96-3.17 (4H, m), 3.71 (3H, s), 3.90 (2H, t), 4.61 (1H, m), 5.10 (2H, m), 5.19 (1H, m), 6.88 (2H, d), 6.98 (2H, d), 7.32 (5H, m).
EXAMPLE 10 ##STR33##
Methyl 2-S-Amino-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionate (2-3)
Compound 2-2 (8.0 g, 15.1 mmole) was dissolved in 150 mL absolute ethanol and 1.0 g 10% Pd/C was added. This suspension was hydrogenated in a Parr apparatus (50 psi) for 3.5 hours. The catalyst was then filtered off and the solvent removed on the rotary evaporator to give pure 2-3 (5.56 g) as a clear oil. R f =0.4 on SiO 2 with 95:5 CHCl 3 /CH 3 OH
1 H NMR (300 MHz, CDCl 3 ) δ 1.30-1.55 (16H, m), 1.70 (2H, m), 2.80 (1H, m), 3.00-3.17 (3H, m), 3.71 (3H, s), 3.93 (2H, t), 6.82 (2H, d), 7.09 (2H,d).
EXAMPLE 11 ##STR34##
2-S-(Methylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionate (2-4)
2-3 (0.40 g, 1.01 mmole) was treated with methanesulfonyl chloride (0.116 g, 1.01 mmole) and NaHCO 3 (0.25 g, 3.0 mmole) as described for 1-8. The crude reaction product was purified by flash chromatography on silica gel eluting with 30% EtOAc/hexanes to give pure 2-4 (0.10 g) as a clear oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.36-1.56 (15H, m), 1.77 (2H, m), 2.70 (3H, s), 3.78 (3H, s), 3.92 (2H, t), 4.36 (1H, m), 4.90 (1H, d). 6.82 (2H, d), 7.09 (2H, d).
EXAMPLE 12 ##STR35##
2-S-(Methylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]propionic acid hydrochloride (2-5)
2-4 (0.1 g, 0.212 mmole) was treated with LiOH (0.026 g, 1.06 mmole) as described for 1-8 to provide 2-S-(methylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionic acid (0.125 g) as a viscous oil.
1 H NMR (300 MHz, CD 3 OD) δ 1.30-1.55 (16H, m), 1.75 (2H, m), 2.63 (3H, s), 2.85 (1H, dd), 3.0-3.13 (3H, m), 3.93 (2H, t), 4.17 (1H, m), 6.83 (2H, d), 7.20 (2H, d).
This acid was dissolved in EtOAc (20 mL) and treated with HCl gas as described for 1-9. Solvent removal provided a residue that was triturated with 30 mL Et 2 O to provide pure 2-5 as a white solid (0.09 g).
1 H NMR (300 MHz, CD 3 OD), δ 1.40-1.60 (4H, m), 1.60 (2H, m), 1.69 (2H, m), 2.68 (3H, s), 2.82 (1H, dd), 2.92 (2H, t), 3.10 (1H, dd), 3.30 (2H, m), 3.97 (2H, t), 4.18 (1H, m), 6.83 (2H, d), 7.19 (2H, d).
Analysis for C 16 H 26 N 2 O 5 S.HCl.0.25 H 2 O
Calculated: C=48.11, H=6.94, N=7.01 Found: C 48.16, H=6.82, N=6.98.
EXAMPLE 13 ##STR36##
Methyl 2-S-(Butylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionate (2-6)
2-3 (0.40 g, 1.01 mmole) was treated with butylsulfonyl chloride (0.47 g, 3.03 mmole) and NaHCO 3 (0.50 g, 6.0 mmole) as described for 1-8. Crude reaction product was purified by flash chromatography on silica gel eluting with 30% EtOAc/hexanes to give pure 2-6 (0.22 g) as a clear oil.
1 H NMR (300 MHz, CDCl 3 ) δ 0.87 (3H, t), 1.35-1.54 (18 H, m), 1.61 (2H, m), 1.77 (2H, m), 2.74 (2H, t), 2.95 (1H, dd), 3.05-3.18 (3H, M), 3.90 (2H, t), 4.32 (1H, m), 4.72 (1H, m), 6.82 (2H, d), 7.07 (2H, d).
EXAMPLE 14 ##STR37##
2-S-(Butylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]propionic acid hydrochloride (2-7)
2-6 (0.2 g, 0.39 mmole) was treated in THF (1)/H 2 O (1)/CH 3 OH(1) solution with LiOH (0.05 g, 2.12 mmole) as described for 1-8 to provide 2-S-(butylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionic acid (0.235 g) as a viscous oil.
2H NMR (300 MHz, CD 3 OD) δ 0.83 (3H, t), 1.35-1.56 (16H, m) 1.76 (2H, m), 2.61 (2H, t), 2.79 (1H, ddd), 3.00-3.14 (3H, m), 3.92 (2H, t), 4.11 (1H, m), 6.82 (2H, d), 7.18 (2H, d).
This acid (0.235 g, 0.7 mmole) was dissolved in EtOAc (30 mL) and treated with HCl gas as described for 1-9. The residue was triturated with a solution of ether (40 mL)/EtOAc (10mL) to provide 2-7 (0.17 g) as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 0.85 (3H, t), 1.24 (2H, m), 1.35-1.60 (6H, m), 1.70 (2H, m), 1.80 (2H, m), 2.66 (2H, t), 2.78 (1H, dd), 2.92 (2H, t), 3.10 (1H, dd), 3.30 (1H, m), 6.85 (2H, d), 7.20 (2H, d).
Analysis for C 19 H 32 N 2 O 5 S.HCl
Calculated: C=52.22, H=7.61, N=6.41 Found: C=51.80, H=7.61, N=6.33.
EXAMPLE 14A
2-S-(Butylsulfonylamino)-3-[4-(6-acetamidinohexyloxy)phenyl]propionic acid (2-7a) ##STR38##
A solution of 2-7 (1.0 g, 2.29 mmole) in THF (30 ml) is treated with ethyl acetimidate (0.2 g, 2.29 mmol) and the resulting reaction mixture is stirred at room temperature for 16 hours. The solvent is then removed and the residue is recrystallized from ethyl acetate to give pure 2-7a.
EXAMPLE 14B ##STR39##
2-S-(Butylsulfonylamino)-3-[4-(6-benzamidinohexyloxy)phenyl]propionic acid (2-7b)
A solution of 2-7 (1.0 g, 2.29 mmole) in THF (30 ml) is treated with ethyl benzimidate (0.34 g, 2.29 mmole) and the resulting solution is stirred at room temperature for 20 hrs. The solvent is removed and the residue is taken up in EtOAc, filtered and recystallized to give pure 2-7b.
EXAMPLE 14C ##STR40##
2-S-(Butylsulfonylamino)-3-[4-(6-guanidinohexyloxyphenyl]propionic acid (2-7c)
A mixture of 2-7 (1.0 g, 2.29 mmol) and N-nitrosomethylthioguanidine (0.32 g, 2.29 mmol) is heated at 40° for 5 minutes in absolute EtOH (15 ml) and then is allowed to stand for 1 day at room temperature. The solvent is removed in vacuo and the residue is purified by flash chromatography on silica eluting with CHCl 3 (95)-CH 3 OH(5)-HOAc(2) to give the desired nitroguanidino intermediate.
This is dissolved in 10% HCl-CH 3 OH (20 ml) and shaken in a Parr apparatus (50 psi) in the presence of 10% Pd--C (100 mg) at room temperature for 8 hours. The catalyst is then removed by filtration, the solvent is removed in vacuo, and the residue dissolved in 10% aqueous HCl solution and heated at reflux for 2 hours. The solvent is removed in vacuo and the residue purified by chromatography on a Dowex 1-X2 column eluting with water to give pure 2-7c.
EXAMPLE 15 ##STR41##
Methyl 2-S-(Benzylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionate (2-8)
2-3 (0.29 g, 0.735 mmole) was treated with benzylsulfonyl chloride (0.14 g, 0.735 mmole) and NaHCO 3 (0.185 g, 2.2 mmole) as described for 1-8. The crude reaction product was purified by flash chromatography on silica gel eluting with 1:1 hexanes/EtOAc to give pure 2-8 (0.27 g) as a clear oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.47-1.69 (15H, m), 1.90 (2H, m), 2.18 (2H, s), 3.08 (2H, d), 3.25 (2H, m), 3.85 (3H, s), 4.05 (2H, t), 4.19-4.20 (4H, m), 4.80 (1H, d), 6.83 (2H, d), 7.12 (2H, d), 7.47 (5H, m).
EXAMPLE 16 ##STR42##
2-S-(Benzylsulfonylamino)-3-[4-(6-aminohexyloxy)phenyl]propionic acid hydrochloride (2-9)
2-8 (0.48 g, 0.875 mmole) was treated with LiOH (0.105 g, 4.37 mmole) as described for 1-8 to give 2-S-(benzylsulfonylamino)-3-[4-(6-N-t-butyloxycarbonylaminohexyloxy)phenyl]propionic acid (0.4 g) as a foam.
1 H NMR (300 MHz, CD 3 OD) δ 1.30-1.52 (15H, m), 1.72 (2H, m), 2.81 (1H, dd), 3.00 (3H, m), 3.93 (2H, m), 4.06 (2H, m), 6.81 (2H, d), 7.13 (2H, d), 7.20-7.32 (5H, m).
This acid (0.4 g, 0.75 mmole) was dissolved in EtOAc (30 mL) and treated with HCl gas as described for 1-9. Crude reaction product was triturated with ether to give pure 2-9 (0.35 g) as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 1.38-1.57 (4H, m), 1.65 (2H, m), 1.73 (2H, m), 2.71 (1H, dd), 2.89 (2H, t), 3.02 (1H, dd), 3.30 (3H, m), 3.94-4.15 (5H, m), 6.83 (2H, d), 7.15 (2H, d), 7.29 (5H, m).
EXAMPLE 16 A ##STR43##
2-S-(Benzylsulfonylamino)-3-[4-(6-(acetamidinohexyloxy-phenyl)]propionic acid (2-9a)
A solution of 2-9 (1.0 g, 2.1 mmol) in THF (30 ml) is treated with ethyl acetimidate (0.18 g, 2.1 mmol) an described in Example 14A to give pure 2-9a after recrystallization from ethyl acetate.
EXAMPLE 16 B ##STR44##
2-S-(Benzylsulfonylamino)-3-[4-(6-(guanidinohexyloxy)phenyl]propionic acid (2-9b)
A mixture of 2-9 (1.0 g, 2.1 mmol) and N-nitrosomethylthioguanidine (0.29 g, 2.1 mmol) is treated as described for Example 14C to give pure 2-9b. ##STR45##
Methyl 2-S-amino-3-[4-(4-hydroxyphenyl)oxyphenyl]propionate (3-2).
CH 3 OH (100 ml) was cooled to 0° and treated with SOCl 2 (47 mmol) with stirring for 15 minutes at 0° and then 3-1 (1.5 g, 5.49 mmol) was added with stirring for 16 hours as the temperature rose to ambient.
The reaction mixture was filtered and the solvent was removed to give an oil that provided 3-2 (1.57 g) after ether washing.
1 H NMR (300 MHz, CD 3 OD) δ 3.10-3.30 (2H, m), 3.81 (3H, s), 6.76-6.90 (6H, m), 7.20 (2H, d).
Methyl 2-S-(N-Benzyloxycarbonylamino)-3-[4-(4-hydroxyphenyl)oxyphenyl]propionate (3-3).
A water(1)-dioxane(1) solution (10 ml) of 3-2 (0.2 g, 0.62 mmol) was cooled to 0° C. and treated with Na 2 CO 3 (0.131 g, 1.23 mmole) and benzylchloroformate (0.619 mmol). After 1.5 hours of vigorous stirring, the dioxane was removed at low pressure and the residue diluted with H 2 O and extracted with EtOAc. The organic extract was washed with brine, dried (Na 2 SO 4 ) and the solvent removed to provide 3-3 as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 3.06 (2H, m), 3.75 (3H, s), 4.64 (1H, m), 5.10 (2H, m), 5.36 (1H, m), 6.83 (6H, m), 7.00 (2H, d), 7.37 (5H, bs).
Methyl-2-S-(N-Benzyloxycarbonylamino)-3-[4-(4-N-t-butyloxycarbonylpiperidin-4-yl)oxyphenyloxy]phenylpropionate (3-4).
A benzene (40 ml) solution of 3-3 (0.5 g, 1.18 mmol) was treated with N-t-butyloxycarbonylpiperidin-4-ol (0.24 g, 1.18 mmol) and Ph 3 P (0.310 g, 1.18 mmol) while stirring at room temperature with constant N 2 purging. Diethyl azodicarboxylate (1.18 mmol) was added and the resulting solution was stirred at room temperature for 16 hours.
The solvent was then removed and the residue was purified by flash chromatography on silica gel eluting with hexane(70)-EtOAc(30) to provide pure 3-4.
1 H NMR (300 MHz, CDCl 3 ) δ 1.48 (9H, s), 1.80 (2H, m), 1.95 (2H, m), 3.08 (2H, m), 3.36 (2H, m), 3.76 (3H, s), 4.40 (1H, m), 4.63 (1H, m), 5.10 (1H, m), 5.25 (1H, m), 6.80-7.04 (8H, m), 7.36 (5H, bs).
Methyl 2-S-(Butylsulfonylamino)-3-[4-(4-N-t-butyloxycarbonylpiperidin-4-yl)oxyphenyloxy]phenylpropionate (3-5).
A solution of 3-4 (0.5 g, 0.082 mmol) in EtOH (40 ml) was treated with 10% Pd/C (125 mg) and this suspension hydrogenated in a Parr flask at 50 psi for 1.5 hour. The catalyst was filtered off and the solvent removed to give the desired amino ester as a clear oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.48 (9H, s), 1.50-1.80 (8H, m), 1.91 (2H, m), 2.82 (1H, m), 3.04 (1H, m), 3.34 (2H, m), 3.76 (3H, s), 4.20 (1H, m), 7.90 (8H, m), 8.11 (2H, d).
This amino ester (0.36 g, 0.77 mmol) was dissolved in EtOAc (10 ml) and treated with NaHCO 3 (0.386 g, 4.6 mmol) and n-butylsulfonylchloride (1.53 mmol) with heating at reflux for 48 hours. The solvent was removed and the residue purified by flash chromatography on silica gel eluting with hexane(65)-EtOAc(35) to provide pure 3-5 as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 0.88-1.02 (4H, m), 1.25-1.45 (3H, m), 1.50 (9H, s), 1.51-1.80 (2H, m), 1.93 (2H, m), 2.80 (2H, m), 2.95-3.20 (2H, m), 3.21-3.40 (2H, m), 3.72 (2H, m), 3.74 (3H, s), 4.38 (2H, m), 4,80 (1H, d), 6.90 (6H, m), 7.10-7.27 (2H, m).
2-S-(Butylsulfonylamino)-3-[4-(piperidin-4-yl)oxyphenyloxy]phenylpropionic acid hydrochloride (3-6).
A solution of 3-5 (0.2 g, 0.34 mmol) in THF(1)-H 2 O(1)-CH 3 OH(1) was treated with LiOH (0.075 g, 1.78 mmol) at room temperature for 8 hours. The solvent was removed and the residue was acidfied with 10% KHSO 4 solution and this extracted several times with EtOAc. The organic extracts were combined, washed with brine, dried (NaSO 4 ) and the solvent removed to give the desired acid. R f =0.3 [silica gel, 97(CHCl 3 )-3(CH 3 OH)-1(HOAc)].
1 H NMR (300 MHz, CDCl 3 ) δ 0.85 (3H, t), 1.20-1.30 (3H, m), 1.46 (9H, s), 1.50-2.0 (6H, m), 2.75 (2H, m), 2.97 (1H, m), 3.18 (1H, m), 3.33 (2H, m), 3.76 (2H, m), 4.35 (2H, m), 5.07 (1H, m), 6.89 (6H, m), 7.13 (2H, m).
This acid (0.15 g, 0.26 mmol) was dissolved in EtOAc and treated with HCl gas as described for 1-9 to give pure 3-6 as a white solid.
1 H NMR (300 MHz, CD 3 OD) δ 0.89 (3H, t ), 1.32 (2H, m), 1.53 (2H, m), 1.97-2.21 (4H, m), 2.75 (2H, m), 2.63 (1H, m), 3.20 (3H, m), 3.40 (2H, m), 4.14 (1H, m), 6.82-7.05 (6H, m), 7.23 (2H, m). ##STR46##
4[4-(N-Benzyloxycarbonylpiperidin-4-yl)-2-methyl]pentan-2-ol(4-2).
Methyl 4-(N-Benzyloxycarbonylpiperidin-4-yl)butanoate (4-1) (10.07 g, 0.032 mol) in THF (200 ml) was cooled to 0° C. and treated with CH 3 MgI (0.095 mol) for 3.0 hours. The reaction mixture was poured into ice, acidified with 10% KHSO 4 and extracted with 3 portions of EtOAc. The combined organic extract was washed with brine, dried (MgSO 4 ) and the solvent removed. The residue was purified by flash chromatography on silica gel eluting with hexane(7)-EtOAc(3) to give pure 4-2. R f =0.3 (silica gel, hexane (7)-EtOAc(3).
Methyl 2-S-(Butylsulfonylamino)-3-[4-(N-Benzyloxycarbonylpiperidin-4-yl)-2,2-dimethyl]butyloxyphenylpropionate (4-3).
N-n-Butylsulfonyl-L-tyrosine methyl ester (7.21 g, 0.023 mole) was dissolved in a mixture of 4-2(1.0 g), CH 2 Cl 2 (30 ml) and benzene (250 ml). Triphenylphosphine (5.97 g, 0.023 mole) was added and after purging with N 2 , diethyl azodicarboxylate (3.6 ml, 0.023 mole) was added at room temperature as the reaction mixture turned red-orange in color. Reaction mixture stirred at room temperature for 7 days. Solvent was removed and the residue was purified by flash chromatography on silica gel eluting with hexane(60)-EtOAc(40) to give pure 4-3.
1 H NMR (300 MHz, CDCl 3 ) δ 0.88 (6H, t), 1.10-1.40 (12H, m), 1.43-1.78 (8H, m), 2.70-2.82 (4H, m), 2.95-3.10 (3H, m), 3.75 (3H, s), 4.18 (2H, m), 4.32 (1H, m), 5.13 (2H, s), 6.88 (2H, d), 7.06 (2H, d), 7.38 (5H, m).
2-S-(Butylsulfonylamino)-3-[4-(N-Benzyloxycarbonylpiperidin-4-yl)-2,2-dimethyl]butyloxyphenylpropionic acid (4-4).
Dissolved 4-3 (0.64 g, 0.001 mole) in THF/H 2 O/CH 3 OH mixture and treated with LiOH (0.26 g, 0.0062 mole) at room temperature for 8 hours. Solvent removal, acidification (KHSO 4 solution) and EtOAc extraction provided crude 4-4 which was purified by flash chromatography on silica gel eluting with CHCl 3 (97)-CH 3 OH(3)-HOAc(1) to give pure 4-4.
1 H NMR (300 MHz, CDCl 3 ) δ 0.86 (6H, s), 1.05-1.50 (13H, m), 1.55-1.80 (5H, m), 2.77 (4H, m), 3.04 (2H, m), 4.10 (2H, bd), 4.17 (1H, m), 4.85 (1H, d), 5.14 (2H, s), 6.88 (2H, d), 7.13 (2H, d), 7.39 (5H, m).
2-S-(Butylsulfonylamino)-3-[4-(piperidin-4-yl)-2,2-dimethyl]butyloxyphenylpropionic acid (4-5).
To ammonium formate (0.23 g, 3.65 mmol) in CH 3 OH (5 ml) was added 4-4 (0.22 g, 3.65 mmole) in 10 ml CH 3 OH and then 10% Pd/C (100 mg) was added at room temperature. After 15 minutes the reaction mixture was passed thru a Solka Floc pad and the solvent removed. This residue was purified by flash chromatography on silica gel eluting with EtOH(9)-H 2 O(1)-NH 4 OH(1) to give pure 4-5.
1 H NMR (300 MHz, CD 3 OD) δ 0.88 (6H, s), 1.15-1.40 (12H, m), 1.42-1.70 (7H, m) 1.90 (2H, d), 2.78-3.00 (6H, m), 3.06 (1H, dd), 3.35 (3H, m), 3.93 (1H, m), 6.86 (2H, d), 7.20 (2H, d). ##STR47##
Methyl 3-S-(Benzyloxycarbonylamino)-4-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]butyrate (5-1).
A solution of compound 1-2 (1.0 g, 1.8 mmole) and N-methylmorpholine (0.21 mL, 1.9 mmole) in EtOAc (10 mL) was stirred at -15° C. and treated with isobutyl chloroformate (0.24 mL, 1.8 mmole). After 15 minutes the heterogeneous mixture was treated portion-wise with an ethereal solution of diazomethane (0.5M:10 mL, 5.0 mmole), followed by continued stirring at 0° for 1.0 hour. The reaction mixture was then purged with argon for 10 minutes to remove excess diazomethane. The organic phase was washed with 2×5 mL portions of H 2 O, brine, dried (MgSO 4 ), and evaporated. The residue was then dissolved in CH 3 OH (15 mL) and treated sequentially with triethylamine (0.7 mL, 5.0 mmole) and AgO 2 CPh (110 mg, 0.5 mmole) while stirring at ambient temperature to effect vigorous gas evolution. After 30 minutes the solvent was evaporated and then the crude reaction product purified by flash chromatography on silica gel eluting with 4:1 hexane/EtOAc to give 5-1 (0.52 g) as an oil. TLC R f =0.23 (30% EtOAc/hexane) ##STR48##
Methyl 3-S-Amino-4-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyvhenyl]butyrate (5-2).
To 5-1 (0.52 g, 0.9 mmole) dissolved in absolute ethanol (20 mL) was added 10% Pd/C (0.25 g) and the resulting suspension was hydrogenated under balloon pressure for 12 hours. The catalyst was then filtered off and the solvent was removed in vacuo to give 5-2 (0.35 g) as an oil.
TLC R f =0.15 (9:1:1 CH 2 Cl 2 /CH 3 OH/AcOH). ##STR49##
Methyl 3-S-(Butylsulfonylamino)-4-[4-N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]butyrate (5-3).
To 5-2 (0.36 g, 0.8 mmole), triethylamine (170 μL, 1.2 mmole), 4-dimethylaminopyridine (12 mg, 0.1 mmole), and THF (5 mL) at 0° C. was added n-butylsulfonyl chloride (130 μL, 1.0 mmole) with stirring. The cooling bath was removed and stirring was continued for 6 hours. The reaction mixture was diluted with 10 mL of EtOAc and then washed with 2×5 mL H 2 O, brine, dried (MgSO 4 ), and concentrated. The crude reaction product was purified by flash chromatography on silica gel eluting with 4:1 hexane/EtOAc to give 5-3 (180 mg) as an oil.
1 H NMR (300 MHz, CDCl 3 ) δ 1.12 (2H, m), 1.25-1.83 (13H, m), 1.29 (3H, t), 1.47 (9H, s), 2.68 (6H, m), 2.87 (2H, d), 3.73 (3H, s), 3.93 (2H, t), 4.08 (1H, m), 4.72 (1H, d), 6.87 (2H, d), 7.12 (2H, d). ##STR50##
3-S-(Butylsulfonylamino)-4-[4-N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]butanoic acid (5-4).
Compound 5-3 (175 mg, 0.33 mmole) in CH 3 OH (4.0 mL) was treated with IN NaOH (1.0 mL, 1.0 mmole) followed by continued stirring at ambient temperature for 20 hours. The reaction mixture was diluted with 15 mL EtOAc and then washed with 10 mL 5% KHSO 4 and brine, dried (MgSO 4 ), and concentrated to give 5-4 (160 mg) as an oil.
TLC R f =0.31 (9:0.5:0.5 CH 2 Cl 2 /CH 3 OH/AcOH). ##STR51##
3-S-(Butylsulfonylamino)-4-[4-piperidin-4-yl)butyloxyphenyl]butanoic acid (5-5)
To a stirred solution, of compound 5-4 (160 mg, 0.30 mmole), CH 2 Cl 2 (2.0 mL), and anisole (100 μL) at 0°C. was added CF 3 CO 2 H (1.0 mL). After 1.5 hours at 0° C. the solvents were evaporated and the crude reaction product purified by flash chromatography on silica gel eluting with 10:0.8:0.8 ethanol/H 2 O/conc. NH 4 OH to give 5-5 (42 mg) as a solid.
1 H NMR (300 MHz, D 2 O/CF 3 CO 2 D) δ 0.82 (3H, t), 1.10-1.70 (11H, m), 1.80 (m, 2H), 1.98 (m, 2H), 2.48 (2H, t), 2.72 (3H, m), 3.00 (3H, m), 3.43 (2H, m), 3.96 (1H, m), 4.10 (2H, t), 7.01 (2H, d), 7.32 (2H, d). ##STR52##
4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyliodide (6-1)
This was prepared from 2-piperidineethanol as described for the corresponding bromide except that Ph 3 P/I 2 was used in the final step to generate the desired iodide. ##STR53##
4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]ethanol (6-3)
A mixture of 6-1 (4.55 g, 12.4 mmol), 4-hydroxyphenylethanol (6-2) (1.88 g, 13.6 mmol) and Cs 2 CO 3 (4.04 g, 12.4 mmol) in DMF (20 ml) was stirred at 23° for 16 hours. The mixture was diluted with Et 2 O, washed with H 2 O (3×50 ml) and the ether layer was dried (MgSO 4 ) and concentrated. This residue was purified by flash chromatography on silica gel eluting with 5% acetone/CH 2 Cl 2 to give 6-3, R f 0.24 (silica gel, 5% acetone/CH 2 Cl 2 ). ##STR54##
4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]acetaldehyde (6-4)
A solution of oxalyl chloride (2.66 g, 20.97 mmol) in CH 2 Cl 2 (25 ml) cooled to -15° was treated with a solution of DMSO (3.57 g, 45.74 mmol) in CH 2 Cl 2 (5 ml) and this was stirred for 2 minutes. Then, 6-3 (3.6 g, 9.54 mmol) in CH 2 Cl 2 (10 ml) was added with stirring at -15° for 5 minutes and then at room temperature. Mixture was diluted with Et 2 O (300 ml) and washed with H 2 O (200 ml) and the organic phase was dried and concentrated. The residue was purified by flash chromatography on silica gel eluting with 10% acetone/CH 2 Cl 2 to give pure 6-4. Rf 0.50 (silica gel, 5% acetone/CH 2 Cl 2 ). ##STR55##
{2-[4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]-1-hydroxy]}ethanephosphonic acid diethyl ester (6-5).
A solution of 6-4 (32.8 mg, 0.087 mmol), and diethylphosphite (18.0 mg, 0.131 mmol) in THF (5 ml) was cooled to 0° and treated with NaN(TMS) 2 (0.131 mmol) with stirring for 8 hours. The reaction mixture was diluted with Et 2 O, washed with 1 M NaHSO 4 solution, brine, dried (MgSO 4 ) and the solvent removed. The mixture was purified by flash chromatography on silica gel eluting with 25% acetone/CH 2 Cl 2 to give pure 6-5. R f 0.31 (silica gel, 25% acetone/CH 2 Cl 2 ). ##STR56##
{2-[4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]-1-azido}ethanephosphonic acid diethyl ester (6-7)
A solution of 6-5 (51.3 mg, 0.1 mmol) in CH 2 Cl 2 (5 ml) was treated with Et 3 N (0.125 mmol) and DMAP (0.01 mmol) and at 0° TsCl (23.8 mg, 0.125 mmol) was added and the resulting solution was stirred at room temperature for 18 hours. The solvent was removed and the residue purified by flash chromatography on silica gel eluting with 7% acetone/CH 2 Cl 2 to provide pure tosylate (6-6).
A solution of 6-6 (66.1 mg, 0.10 mmol) in DMSO (2 ml) was treated with NaN 3 (13 mg, 0.20 mmol) and this was heated at 65° for 20 hours. The cooled reaction mixture was then poured into a mixture of ether (50 ml) and brine (5 ml) and the organic phase was washed with brine, dried (MgSO 4 ) and the solvent removed. This residue was purified by flash chromatography on silica gel eluting with 10% isopropanol/hexane to give pure 6-7. R f 0.28 (silica gel, 10% IPA/hexane). ##STR57##
{2-[4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]-1-amino]}ethanephosphonic acid diethyl ester (6-8)
A solution of 6-7 (0.31 g, 0.575 mmol) in THF (10 ml)/H 2 O (0.5 ml) was treated at rt with Ph 3 P (0.6 g, 2.30 mmol) with stirring for 48 hrs. Solvent removal gave a residue that was purified by flash chromatography in silica gel eluting with 30% IPA/hexane to give pure 6-8. R f 0.22 (silica gel, 30% IPA/hexane). ##STR58##
{2-[4-[4-(N-t-Butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]-1-n-butylsulfonylamino]}ethanephosphonic acid diethyl ester (6-9)
A solution of 6-8 (0.17 g, 0.33 mmol) in DMF (1 ml) at 0-5° was treated with Et 3 N (1.84 mmol) and n-C 4 H 9 SO 2 Cl (0.78 g, 0.495 mmol) in DMF (2 ml) with stirring for 2.0 hours. The reaction mixture was poured into H 2 O (10 ml)/Et 2 O (50 ml) and the organic phase was separated, washed with 1N KHSO 4 , satd. NaHCO 3 , brine, and dried MgSO 4 . Solvent removal provided 6-9.
1 H NMR (300 MHz, CDCl 3 ) δ 0.83 (3H, t), 1.15 (3H, m), 1.35 (4H, m), 1.45 (9H, s), 1.62 (3H, m), 2.30 (2H, t), 2.68 (2H, bt), 2.79 (1H, m), 3.20 (1H, m), 3.91 (2H, t), 4.00 (1H, m), 4.10 (2H, m), 4.18 (2H, m), 4.94 (1H, m), 6.83 (2H, d), 7.19 (2H, d). ##STR59##
{2-[4-[4-(Piperidin-4-yl)butyloxyphenyl]-1-n-butylsulfonylamino]}ethanephosphonic acid ethyl ester (6-10)
A solution of 6-9 (0.09 g, 0.142 mmol) in CH 2 Cl 2 cooled to 0° was treated with TMSBr (0.054, 0.355 mmol) and the resulting solution was stirred at rt for 16 hours with cooling. Et 2 N (100 μl) was added and the solvent was removed. The residue was dissolved in 10% aqueous acetone (5 ml), concentrated, and suspended in toluene to give a solid. This was purified by flash chromatography on silica gel eluting with 10:1:1 EtOH/H 2 O/NH 4 OH to give pure 6-10.
1 H NMR (300 MHz, CD 3 OD) δ 0.84 (3H, t), 1.18 (3H, m), 1.27 (3H, t), 1.42 (6H, m), 1.75 (2H, m), 1.93 (2H, bd), 2.25 (2H, m), 2.63 (1H, m), 2.93 (2H, m), 3.20 (1H, m), 3.35 (4H, m), 3.70 (2H, m), 3.98 (4H, m), 6.82 (2H, d), 7.21 (2H, d). ##STR60##
{2-[4-[4-(Piperidin-4-yl)butyloxyphenyl]-1-n-butylsulfonylamino]}ethanephosphonic acid (6-11)
A solution of 6-9 (0.63 g, 0.142 mmol) in CHCl 3 (5 ml) at rt was treated with TMSBr (0.85 mmol) for 16 hrs. The solvent was removed and the residue was dissolved in 10% aqueous acetone and this stripped to dryness. The residue was mixed with toluene and the resulting gum was purified by flash chromatography on silica gel eluting with 4:1:1 HtOH/H 2 O/NH 4 OH to provide pure 6-11. R f 0.38 (silica gel, 4:1:1 HtOH/NH 4 OH/H 2 O.
Ethyl 2-S-Benzylsulfonylamino-3-[4-(N-t-butyloxycarbonylpiperidin-4-yl)butyloxyphenyl]propionate (7-1)
This compound was prepared analogously to 1-10 employing the appropriate ethyl ester.
Ethyl 2-S-Benzylsulfonylamino-3-[4-(piperidin-4-yl)butyloxyphenyl]propionate (7-2)
A solution of 7-1 (0.79 g, 1.30 mmol) in EtOAc (75 ml) was cooled to -30° and treated with HCl gas for 25 minutes. Solvent removal provided pure 7-2 as a white solid. ##STR61##
Analysis Calcd: C, 58.39; H, 7.41; N, 5.04. Found: C, 58.36; H, 7.34; N, 4.89.
In the above Schemes and Examples, various reagent symbols have the following meanings:
BOC: t-butoxycarbonyl.
Pd--C: Palladium on activated carbon catalyst.
DMF: Dimethylformamide.
CBZ: Benzyloxycarbonyl.
BOP: Benzotriazol-1-yloxytris(dimethylamino)phosphonium hexafluorophosphate.
EtOAc: ethyl acetate
DMF: dimethylformamide
CH 2 Cl 2 : methylene chloride
CHCl 3 : chloroform
MeOH: methanol
HOAc: acetic acid
DMAP: 4-Dimethylaminopyridine
Suitable alternative protecting groups that can be used in the preparation of the present invention include benzyl ester, cyclohexyl ester, 4-nitrobenzyl ester, t-butyl ester, 4-pyridylmethyl ester, benzyloxycarbonyl, isonicotinyloxycarbonyl, O-chlorobenzyloxycarbonyl, p-nitrobenzyloxycarbonyl, p-methoxybenzyloxycarbonyl, t-amyloxycarbonyl, isobornyloxycarbonyl, adamantyloxycarbonyl, 2-(4-biphenyl)-2-propyloxycarbonyl and 9-fluorenylmethoxycarbonyl.
In addition to those compounds specifically exemplified above, additional compounds of the present invention are set forth in tabular form below. These compounds are synthesized by use of the synthetic routes and methods described in the above Schemes and Examples and variations thereof well known to those of ordinary skill in the art, and not requiring undue experimentation. All variables listed in the Tables below are with reference to the following generic structure: ##STR62##
__________________________________________________________________________ExampleR.sup.7 X Y Z m n p__________________________________________________________________________18 --CH.sub.3 --C.tbd.C-- -- 1 1 119 --C.sub.6 H.sub.5 ##STR63## ##STR64## --CH.sub.2 2 3 120 --H ##STR65## ##STR66## ##STR67## 4 1 121 --OCH.sub.3 ##STR68## --CH.sub.2 ##STR69## 6 2 222 --H ##STR70## --CH.sub.2 --O-- 5 1 523 --CH.sub.3 ##STR71## ##STR72## --S-- 5 2 224 --H --O-- ##STR73## --SO-- 2 4 325 --OCH.sub.3 ##STR74## ##STR75## --SO.sub.2 -- 1 3 126 --CN ##STR76## ##STR77## --NH-- 2 2 227 --H ##STR78## --O-- ##STR79## 3 3 328 --CH.sub.3 --CH.sub.2 -- ##STR80## ##STR81## 4 1 129 --H --S-- ##STR82## ##STR83## 0 5 530 --(CH.sub.2).sub.2 C.sub.6 H.sub.5 ##STR84## ##STR85## ##STR86## 3 2 131 --H ##STR87## --O-- -- 1 2 432 --H --CH.sub.2 ##STR88## ##STR89## 6 4 633 ##STR90## ##STR91## ##STR92## ##STR93## 8 2 834 --Br ##STR94## ##STR95## --C═C-- 3 1 335 --H --CH.sub.2 --N(CH.sub.3)-- ##STR96## 1 1 136 --H ##STR97## ##STR98## --C.tbd.C-- 2 1 237 --H ##STR99## --O-- ##STR100## 1 2 138 --OCH.sub.3 ##STR101## --NCH.sub.3 ##STR102## 0 0 539 --H --O-- ##STR103## -- 6 0 640 --CH.sub.3 --NH --SO.sub.2 --O-- 2 4 141 --OH --NCH.sub.2 C.sub.6 H.sub.5 --SO.sub.2 ##STR104## 3 1 042 --H ##STR105## --CH.sub.2 -- ##STR106## 1 1 143 --H --CH.sub.2 -- ##STR107## ##STR108## 3 4 144 --CF.sub.2 CF.sub.3 --O-- --CH.sub.2 -- ##STR109## 2 0 1045 --H ##STR110## --SO.sub.2 ##STR111## 1 3 146 --OH ##STR112## --CH.sub.2 -- -- 10 2 247 --H --CH.sub.2 -- ##STR113## ##STR114## 0 2 448 --CF.sub.3 --NH --CH.sub.3 -- ##STR115## 3 1 249 --H --CH.sub.2 --CH.sub.2 -- 2 2 250 ##STR116## --CH.sub.2 -- ##STR117## ##STR118## 6 0 051 --H --S-- --CH.sub.2 -- ##STR119## 3 1 152 --CH.sub.3 --SO --CH.sub.2 -- -- 0 0 553 --F --SO.sub.2 --NH -- 8 1 254 ##STR120## ##STR121## --NH ##STR122## 4 2 255 ##STR123## ##STR124## --NH ##STR125## 6 1 356 --F --CH═CH-- --NCH.sub.3 ##STR126## 2 2 257 --H --C.tbd.C-- --NCH.sub.3 ##STR127## 3 4 1__________________________________________________________________________Example R.sup.1 R.sup.2 R.sup.3__________________________________________________________________________24 ##STR128## ##STR129## --H25 ##STR130## --H ##STR131##26 ##STR132## --CH.sub.2 SO.sub.2 C.sub.6 H.sub.5 --CF.sub.327 ##STR133## --H ##STR134##28 ##STR135## ##STR136## --CH.sub.329 ##STR137## --(CH.sub.2).sub.2 CH.sub.2 OH --CH.sub.2 CF.sub.330 ##STR138## ##STR139## ##STR140##31 ##STR141## --CH.sub.2 CH --H32 ##STR142## --H --(CH.sub.2)CN33 ##STR143## --CH.sub.2 OC.sub.6 H.sub.5 --C.sub.3 H.sub.734 ##STR144##t-Bu --CH.sub.2 C.sub.6 H.sub.535 ##STR145## ##STR146## --H36 ##STR147## --H ##STR148##37 ##STR149## --H --C.sub.4 H.sub.938 ##STR150## --CH.sub.2 C.sub.6 H.sub.5 --H39 ##STR151## --(CH.sub.2).sub.2 OCH.sub.3 --C.sub.2 H.sub.540 ##STR152## ##STR153## --CH.sub.341 ##STR154## --CH.sub.2 SO.sub.2 CH.sub.3 --C.sub.6 H.sub.542 H.sub.3 C--NH-- ##STR155## --CH.sub.2 CO.sub.2 CH.sub.343 ##STR156## --CH.sub.2 SC.sub.6 H.sub.5 --CH.sub.2 OCH.sub.344 Et.sub.2 N-- --CH.sub.2 OC.sub.3 H.sub.7 --H45 ##STR157## ##STR158## --OC.sub.2 H.sub.546 ##STR159## --(CH.sub.2).sub.3 NHCH.sub.3 --CF.sub.347 (F.sub.3 CH.sub.2 C)HN-- --H --C.sub.3 H.sub.748 H.sub.2 N--t-Bu --H49 ##STR160## ##STR161## --H50 ##STR162## --CH.sub.2 SC.sub.6 H.sub.5 --CH.sub.351 C.sub.2 H.sub.5 O.sub.2 CCH.sub.2 CH.sub.2 --NH --CF.sub.3 --H52 ##STR163## --CH.sub.3 ##STR164##53 ##STR165## --CH.sub.2 CN --H54 ##STR166## --CH.sub.2 CF.sub.3 ##STR167##55 ##STR168## ##STR169## --C.sub.2 H.sub.556 ##STR170## --H --CH.sub.2 C.sub.6 H.sub.557 ##STR171## --H --(CH.sub.2).sub.2 C.sub.6__________________________________________________________________________ H.sub.5Example R.sup.4 R.sup.5 R.sup.6__________________________________________________________________________24 --(CH.sub.2).sub.2 C.sub.6 H.sub.5 --CO.sub.2 C.sub.4 H.sub.9 --CF.sub.325 ##STR172## ##STR173## --H26 --CH.sub.2 SO.sub.2 CH.sub.3 ##STR174## --C.sub.2 H.sub.527 --(CH.sub.2).sub.2 SCH.sub.3 ##STR175## --CH.sub.2 CO.sub.2 C.sub.2 H.sub.528 ##STR176## ##STR177## --F29 ##STR178## ##STR179## --H30 ##STR180## ##STR181## --Cl31 ##STR182## --CO.sub.2 H --CH.sub.2 C.sub.6 H.sub.532 --C.sub.8 H.sub.17 ##STR183## --C.sub.3 H.sub.733 ##STR184## --CO.sub.2 CH.sub.3 --H34 ##STR185## --CO.sub.2 H --CH.sub.335 --CH.sub.3 --CO.sub.2 H --C.sub.2 H.sub.536 --(CH.sub.2).sub.3 NH.sub.2 --CO.sub.2 C.sub.4 H.sub.9 --OC.sub.3 H.sub.737 ##STR186## --CO.sub.2 H --CH.sub.2 C.sub.6 H.sub.538 --(CH.sub.2).sub.4 OCH.sub.3 --CO.sub.2 C.sub.2 H.sub.5 --CH.sub.339 ##STR187## ##STR188## --CH.sub.2 SO.sub.2 CH.sub.340 --CH.sub.2 CH.sub.2 CO.sub.2 -i-pr ##STR189## ##STR190##41 ##STR191## ##STR192## --F42 ##STR193## ##STR194## --CN43 --(CH.sub.2).sub.3 CH.sub.2 OH ##STR195## --C.sub.2 H.sub.544 --(CH.sub.2).sub.4 CO.sub.2 H --CO.sub.2 H --H45 ##STR196## --CO.sub.2 -i-pr --CH.sub.2 CN46 ##STR197## --CO.sub.2 C.sub.6 H.sub.5 --CH.sub.347 --C.sub.6 H.sub.5 --CO.sub.2 H --CO.sub.2 CH.sub.348 ##STR198## --CO.sub.2 CH.sub.3 --F49 ##STR199## --CO.sub.2 C.sub.2 H.sub.5 --CH.sub.2 NO.sub.250 --C.sub.2 H.sub.5 --CO.sub.2 C.sub.3 H.sub.7 --H51 --C.sub.4 H.sub.7 --CO.sub.2 CH.sub.2 C.sub.6 H.sub.5 ##STR200##52 --C.sub.5 H.sub.11 ##STR201## --OC.sub.4 H.sub.953 --C.sub.6 H.sub.13 ##STR202## ##STR203##54 --C.sub.7 H.sub.15 ##STR204## --H55 --C.sub.8 H.sub.17 ##STR205## --C.sub.6 H.sub.556 --C.sub.9 H.sub.19 ##STR206## ##STR207##57 --(CH.sub.2).sub.2 --O--C.sub.6 H.sub.5 ##STR208## --CF.sub.3__________________________________________________________________________
EXAMPLE 58
Blood was drawn into 0.1 volumes of acid-citrate-dextrose (85 mM sodium citrate, 64 mM citric acid, 110 mM dextrose) by venipuncture from normal human volunteers. Platelet-rich plasma was prepared by centrifugation at 400×g for 12 minutes. PGE1 (5 mg/ml) was added and platelets were collected by centrifugation at 800×g for 12 minutes. The platelet pellet was resuspended into human platelet buffer (140 mM NaCl, 7.9 mM KCl, 3.3 mM Na 2 HP04, 6 mM HEPES, 2% bovine serum albumin, 0.1% dextrose, pH 7.2) and filtered over Sepharose 2B that was previously equilibrated in human platelet buffer. Platelets were counted and adjusted to 2×108/ml with human platelet buffer. Human fibrinogen (10-100 mg/ml and CaCl 2 (1 mM) were added and aggregation was initiated by the addition of 10 mM ADP. Aggregation was monitored by the initial rate of increase of light transmittance.
While the invention has been described and illustrated in reference to certain preferred embodiments thereof, those skilled in the art will appreciate that various changes, modifications and substitutions can be made therein without departing from the spirit and scope of the invention. For example, effective dosages other than the preferred doses as set forth hereinabove may be applicable as a consequence of variations in the responsiveness of the mammal being treated for severity of clotting disorders or emboli, or for other indications for the compounds of the invention indicated above. Likewise, the specific pharmacological responses observed may vary acording to and depending upon the particular active compound selected or whether there are present pharmaceutical carriers, as well as the type of formulation and mode of administration employed, and such expected variations or differences in the results are contemplated in accordance with the objects and practices of the present invention. It is intended, therefore, that the invention be limited only by the scope of the claims which follow and that such claims be interpreted as broadly as is reasonable.
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A series of non-peptide derivatives that are antagonists of the fibrinogen IIb/IIIa receptor and thus are platelet anti-aggregation compounds useful in the prevention and treatment of diseases caused by thrombus formation.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to playing card wagering games that can be played with playing cards, including a standard deck(s) of cards or by video machine technology, particularly in a casino environment. In particular, it relates to a method and apparatus for playing a wagering game, wherein the game includes bonus awards for predetermined card combinations, hands or ranks to a player, and where all players at the table have an option at the beginning of the game to place a side bet to participate in all awards to any player for obtaining such predetermined card combinations or hand ranks.
2. Background of the Art
There are many wagering games used for gambling. Such games should be exciting to arouse players' interest and uncomplicated so they can be understood easily by a large number of players. Ideally, the games should include more than one wagering opportunity during the course of the game, yet be able to be played rapidly to a wager resolving outcome. Exciting play, the opportunity to make more than one wager and rapid wager resolution enhance players' interest and enjoyment because the frequency of betting opportunities and bet resolutions is increased.
Wagering games, particularly those intended primarily for play in casinos, should provide players with a sense of participation and control, the opportunity to make decisions, and reasonable odds of winning, even though the odds favor the casino, house, dealer or banker. The game must also meet the requirements of regulatory agencies.
Wagering games, including wagering games for casino play, with multiple wagering opportunities are known. U.S. Pat. Nos. 4,861,041 and 5,087,405 (both to Jones et al.) disclose methods and apparatus for progressive jackpot gaming, respectively. The former patent discloses that a player may make an additional wager at the beginning of a hand, the outcome of the additional wager being determined by of a predetermined arrangement of cards in the player's hand. U.S. Pat. No. 4,836,553 (to Suttle and Jones) discloses a modified version of a five card stud poker game.
Additional symbols may be added to the usual means of playing a game to increase wagering opportunities. This is disclosed in U.S. Pat. No. 5,098,107 (to Boylan et al.). Somewhat similarly, U.S. Pat. No. 3,667,757 (to Holmberg) discloses a board game and apparatus, including a way to allow the player to make a choice with respect to several different alternative types of game play and risk bearing strategies. The alternative play is based on providing cards with additional symbols and therefore, a new set of odds. The game and apparatus disclosed by Holmberg requires new sets of rules, relatively complicated procedures and time for a player to learn the game.
U.S. Pat. No. 5,154,429 (to LeVasseur) involves the dealer playing multiple hands against a player's single hand, whereby the number of hands played in the same amount of time is increased.
U.S. Pat. No. 5,288,081 (Breeding) describes the game Let It Ride® stud poker which is played in many casinos around the world. That wagering game is played with a single, typical (standard) fifty-two card poker deck and broadly involves the generally well recognized and accepted set of rules, procedures and wager-resolving outcomes of five card poker. The game method comprises each player placing an initial, three-part wager to participate in the game. A separate bonus wager (a side bet wager) may be placed to play against a pay table. Cards are dealt by a dealer, three down to each player and two down to the dealer. Players inspect or “sweat” their cards, and the dealer asks “take it or leave it?” or as the name of the game implies, “Let It Ride®?” with regard to the first part of the initial bet. Players can choose to retrieve or remove from play the first part of their initial bet, or leave the first part in play or at risk, based on the value of the three cards in their hand. The side wager or bonus wager cannot be withdrawn and is immediately withdrawn by the house in the play of the game. The dealer then turns over one of the dealer's cards and the dealer's query is repeated with regard to the second part of the initial bet. Players can choose to retrieve or remove from play the second part of their initial bet or leave the second part in play or at risk, based on the value of the four cards consisting of the three cards in the player's hand and the exposed dealer's card. Players have no option with the third part of the bet. Finally, all cards are shown and the payouts and collections are resolved according to the ranking of the poker hand of each player, i.e., the players are not playing against each other or the dealer.
Another element of play in casino games and particularly casino table card games in the wagering structure. There are a multitude of card games that are based on one or more decks of conventional playing cards. Among the most popular of these games is poker, wherein a player's fortunes are determined by a well-known hierarchy of card combinations. Card games that are variants of poker are also very popular, such as Let It Ride® stud poker, Caribbean Stud™ poker, Three Card™ poker and the like. This is due, at least in part, to the basic nature of the underlying game itself, combining elements of both strategy and luck. Additionally, poker-variants allow an existing player-base to capitalize on their preexisting knowledge of a game and to apply that knowledge in novel settings. The two most popular forms of traditional poker are draw poker and stud poker.
In a conventional hand of draw poker, a single 52-card deck of shuffled playing cards is used. Each player begins a hand by contributing an initial or “ante” bet to a common pool or “pot”, the pot ultimately going to the owner of the winning hand. The dealer then distributes five face-down cards to each player, the remaining cards in the deck being set aside for later use. Each player evaluates the cards that he or she has been dealt and each, in turn, is given an opportunity to discard one or more cards from the dealt hand. The dealer gives the player replacement cards for those that have been discarded by dealing additional cards face-down from the top of the deck. Following the deal, one or more rounds of betting take place, during which time each player may make an initial raise, a check wager, fold (drop-out), match a previous raise or raise a previous bet. The meanings of these wagering terms are well know to those skilled in the art and typical definitions of same may be found in, for example, Hoyle's Rules of Games , pp. 75-102, by Morehead and Mot-Smith, 1963, the disclosure of which is incorporated herein by reference. At the conclusion of the wagering rounds, the players display their hands and the holder of the highest ranking poker hand takes all of the money in the pot.
Stud poker is the most popular form of “open poker,” wherein each player is dealt some cards that are face-up and, hence, available for viewing by the other players. Stud poker comes in two varieties: 5-card and 7-card, the two being of approximately equal popularity. In five-card stud poker, the dealer gives each player a face-down (or “hole” card) and then a face-up card. Thus, at the start each player knows his own two cards and one card of each of his opponents. After the first two cards are dealt, a wagering round ensues, during which time each player contributes his or her wager to the pot. A typical description of the rules that govern this round might be found in, for example, Hoyle's Rules of Games, pp. 75-102, by Morehead and Mot-Smith, 1963, the disclosure of which is incorporated herein by reference. After the wagering round, another card is dealt face-up to each player. This is followed by another wagering round. Alternating dealing and wagering rounds continue until each player has a total of five cards: four face-up and a concealed hole card. After the final bets have been placed, each player who has not dropped out during the deal/wager rounds reveals his or her hole card. The owner of the highest ranking 5-card poker hand wins and takes whatever amount is in the pot.
Seven-card stud poker differs slightly from 5-card poker. First, in 7-card poker each player initially receives two cards face-down and one card face-up. A bidding round then ensues. The dealer then gives each player another face-up card, which is followed again by a bidding round. Deals (of one face-up card) and bids are alternated until each player has four face-up cards and two face-down cards. Finally, a third face-down card is dealt to each player (making a total of seven cards). This is followed by a last bidding round. The winner of the hand is the player who can form the highest ranking 5-card poker hand from his seven cards.
As is well known to those skilled in the art, five-card poker hands are ranked from “Royal Flush” (highest) to “High Card(s) in Hand” (lowest) according to the following ordering:
Hand
Description
Example
Royal Flush
The five top cards of a suit
A, K, Q, J, 10
(suited)
Straight Flush
Five cards in sequence in
e.g., 5, 6, 7, 8, 9
the same suit
(suited)
Four of a Kind
Any four cards of the same
e.g., 2, 2, 2, 2, J
rank,
Full House
Three of a kind and a pair
2, 2, 2, J, J
Flush
Five cards of the same suit
2, 4, 8, 10, A
(suited)
Straight
Five cards in sequence
6, 7, 8, 9, 10
(unsuited)
Three of a Kind
Three cards of the same
2, 2, 2, 9, J
rank
Two Pair
Two cards of the same
e.g., 2, 2, Q, Q, A
rank and two others of
(unsuited)
a different rank
One Pair
Two cards of the same rank
e.g., 9, 9, 5, 8, K
High Card(s) in Hand
Five unmatched cards
A, 9, 5, 3, 2
(unsuited)
In some variations of poker, the ace may also act as the lowest card in the deck to form a straight when used in a sequence like A, 2, 3, 4. Additionally, a “wild card”—often the “joker” card may be designated, so that a person who holds that card may declare its value to be that of any card in the deck, the presumption being that the declared card value will help that player form a better poker hand.
At its core, poker is a vehicle for gambling. Commonly the quantities wagered are monetary, but that is not strictly required and poker chips, matches, and other non-pecuniary tokens have been used in place of money to help the players determine who is winning without exposing them to financial loss. Of course, casinos are in the business of providing people with the opportunity to gamble and, given the popularity of poker among the general populous, it only stands to reason that casinos would desire to offer this game in some form or another to those who seek to play it. However, conventional-rules poker is not particularly well suited for use in a casino.
A casino that offers traditional poker to its clientele typically does so by providing a dealer and a room in which to play, but the casino's dealer does not actually participate in the game as a player: his or her function is just to distribute the cards and referee the game. The casino makes its money by taking some percent of all of the money wagered (the “rake”) or by leasing the room to the participants. The cost of the lease may be measured in time (e.g., a fixed amount per hour) or by a count of the number of hands played. Traditional poker games are not particularly favored by casinos because the casino does not make as much money acting as a landlord as it would if it were an active participant in the game.
Similarly, from the standpoint of the gaining public, traditional poker has some disadvantages which have tended to make it less desirable as a casino game. First, traditional poker is readily available “at home,” e.g., at the Friday night poker session, and there is no particular need for most people to travel to a casino to play it. Second, when an individual wins at traditional poker it is at the expense of the other players/participants. Many people prefer to play against the “house” (i.e., the casino) so that their winning hand does not necessarily result in a loss by a fellow player, who may be an acquaintance. Finally, traditional poker does not offer the excitement associated with “jackpot” type games. That is, a royal flush in traditional poker—as improbable as that card combination is—will result in winning only the amount in the pot and nothing more. Many players seek out games where there is some possibility of “winning big,” an option that is not available under conventional poker rules.
As a consequence of these disadvantages, casinos have introduced a variety of poker-type game variants to address the shortcomings discussed previously. One obvious advantage of these poker-type games from the casino's point of view is that the casino becomes an active participant in the game (as the house) and can, as a consequence, increase the revenue taken from the game. Additionally, these poker-type games are very attractive to many of the gambling public, and the mere fact that they are available in a particular casino has the potential to increase consumer traffic and revenue there.
A variety of innovative stratagems have been employed to make poker-type games more appealing to casino gamblers. For example, many poker-variants are designed to let the players compete against the house, rather than against each other. In other cases, progressive betting has been utilized, wherein the player may increase his or her bet during the play of a hand. This makes the game more exciting to the player and potentially more profitable for the casino. Jackpots have been introduced, wherein certain card combinations in the player's hand result in an enhanced payout to that player. Finally, computer implementations of these games is always an attractive possibility, with video based casino games becoming increasingly popular. One such video implementation of a poker-type game is taught by Weingardt, U.S. Pat. No. 5,042,818. Of course, a natural next step is to offer these same video based casino games over the Internet, thereby making the games available to a potentially enormous audience. The most successful casino table poker games to date are Let It Ride® stud poker (as originally described in U.S. Pat. No. 5,288,081), Caribbean Stud™ poker (originally described in U.S. Pat. No. 4,836,533), and Three Card™ poker (as described in U.S. Pat. No. 6,237,916).
In most casinos, a game of blackjack begins by having each player place an initial wager. The blackjack dealer then distributes two cards face-down to each player and two cards—one face up and another face down—to him or herself. After the player has examined the two dealt cards and compared those cards with the face-up dealer's card, a number of options present themselves to the player. The player may “stand” (i.e., take no further cards), draw one or more additional cards in order to increase the numeric sum of the hand, double down (a form of progressive wagering), or split the two cards. Additionally, if the dealer's face-up card is an ace, the player may elect to buy insurance against the possibility that the dealer has a blackjack. If, after the dealer's face-down card is revealed, the dealer does not have a blackjack, the player loses the amount that was paid as insurance (although he or she may go on to ultimately win that deal). If, on the other hand, the dealer has a blackjack, the player collects double the amount of insurance bought (but may still lose the amount of the original wager). The option of purchasing insurance is unique to blackjack type games and has not, heretofore, been available in poker-style games. The broad rules of blackjack are generally known to those skilled in the art and a fuller description may be found in the materials previously incorporated by reference.
In addition to novel games being introduced into casinos, novel betting formats have also been introduced. Side bets have always been common in wagering environments, but the use of side bets for jackpots and bonuses in casino table card games was believed to have been first practiced by David Sklansky in about 1982 in a public showing of Sklansky's Poker in Las Vegas, Nev. The play and/or betting structure of Caribbean Stud™ poker was modeled after that game. Blackjack has allowed surrender play at many tables, where half the original wager is withdrawn and the other half is forfeit to the house at the election of the player. U.S. Pat. No. 5,820,460 (Fulton) describes a method for playing a casino table card game wherein wagers are changed after some cards are viewed by the player. Let It Ride® stud poker advanced that theory significantly as described in U.S. Pat. No. 6,273,424, where specific segments of wagers could be withdrawn from an original wager that was in multiple parts.
It is still beneficial to provide additional wagering formats and structures to add both interest to the game and better control over house retention and player awards.
The desired attributes of wagering games outlined above are in large measure provided by the method and apparatus for a wagering game in accordance with the present invention. The game is uncomplicated, exciting and provides the opportunity for players to make multiple wagers and choices regarding those wagers.
SUMMARY OF THE INVENTION
The wagering game of the present invention is played with at least a single standard fifty-two card poker deck and broadly involves the generally well recognized and accepted set of rules, procedures and wager-resolving outcomes of card games, especially five card poker and variations of five card poker. The table bonus wager and format of the present game is amenable to use with any casino table card game or video gaming equivalent where multiple players play at the same time against a pay table or against the house, and bonus awards are provided for hands or at least a predetermined rank. Each player has the option (before seeing sufficient cards to provide even a preliminary evaluation of the likelihood of winning) of placing a side bet wager that a player at the table will obtain a hand of a predetermined rank that will receive a bonus payout. This is called a table wager, community wager, group wager, or the like. The player may also make an optional individual wager that he/she will receive a hand of a predetermined rank that will receive a bonus payout.
The preferred game method played with this wagering format comprises Let It Ride® stud poker, and a new variant of that game where each player placing an initial, four-part wager (as opposed to the required three-part wager used in Let It Ride® stud poker) to participate in the game. Cards are dealt by a dealer, three down to each player and two down to the dealer. Players inspect or “sweat” their cards, and the dealer asks “take it or leave it?” or “Let It Ride®?” with regard to the first part of the initial bet. Players can choose to retrieve or remove from play the first part of their initial bet, or leave the first part in play or at risk, based on the value of the three cards in their hand. The dealer then turns over one of the dealer's cards and the dealer's query is repeated with regard to the second and third parts of the initial bet, except that withdrawal of the second part results in the house claiming the third part of the wager. This step requires that two parts (the second part and the third part) of the four-part bets (usually equal parts) be considered at the same time of play. Players can choose to retrieve or remove from play the second part and forfeit the third part of their initial bet or leave the second part and third part in play or at risk, based on the value of the four cards consisting of the three cards in the player's hand and the first exposed dealer's card. Players have no option with the fourth part of the bet, which is referred to as the contract wager, as it must remain in play through the conclusion of play of the game. Finally, all cards are shown and the payouts and collections are resolved according to the ranking of the poker hand of each player, i.e., the players are not playing against each other or the dealer.
The pay table in this game (to be marketed as “Dakota Stud™” table card game) can be adjusted from the pay tables in Let It Ride® poker to reflect the change in betting/wagering structure. For example, to compensate for the required forfeit of the third wager part if the second wager part is withdrawn, the qualifying hand for a win may be lowered from the pair of 10's ordinarily required to win against the pay table in Let It Ride® stud poker. For example, the minimum winning hand may be any pair, a pair of 2's, 3's, 4's, 5's, 6's, 7's, 8's or 9's. Additionally, higher odds may be paid on higher ranked hands to make play of the game more attractive to players. The game may also be modified to provide the player with five cards and the dealer with two hole cards or common cards, with the best five-card poker hand playing against a pay table, or with the player being dealt four cards, and the dealer receiving three cards. This may be done with the dealer having one of the three cards exposed immediately before consideration of withdrawal of the first part of the wager, or with three cards provided face down. In the latter circumstance, the dealer's face down cards may be exposed one-at-a-time, or preferably two at one time and one card at another time in the betting/wagering sequence. Two cards may be exposed before consideration of withdrawal of the second (and third) parts of the wager, or first one card exposed at this stage and then two cards exposed at the end of play, after withdrawal of the second and third parts has been considered and exercised.
More specifically, in the preferred play of the game the initial wager placed by each player comprises four equal parts and is made or placed before any cards are dealt. Each player is dealt three cards face down in the customary fashion. Two common cards are dealt face down in front of the dealer for use by all of the players. Each player will use the two common cards in front of the dealer in combination with his or her three cards to create a five card hand. After all players have placed their four wagers/bets (and in an optional play of the game, a special bonus wager or jackpot wager for extra or extraordinary awards for high ranking hands against a pay table) and received and examined their cards, each is given the opportunity to retrieve one part (if equal wagers are placed, that is one-fourth) of the initial wager before the dealer reveals one of the two down cards previously placed in front of him. After all of the players have been queried and decided whether to withdraw the first part of their wager, the dealer turns one of the down cards face up. Each player now has the benefit of four cards, the three he or she is holding down plus the common card, and the dealer again gives each player the opportunity to retrieve further part(s) of the initial wager, In this case, with equal wagers, the player has the option of leaving the second and third parts in play or withdrawing the second part and forfeiting the third part before exposing the second common down card. After the second common down card is revealed, the players turn up the three cards they are holding thereby forming five card hands made up of the three cards dealt to each player and the two dealer cards. The dealer examines each of the players hands and determines what payout, if any, each player is entitled to receive according to that players' remaining wager and a preselected payout schedule. Payouts are made to players with winning hands and the losing wagers are collected. The cards are then reshuffled for the next hand. Where a separate side bet has been placed as a bonus or jackpot wager (against a pay table and/or against a progressive jackpot), that wager must also be resolved.
Apparatus is disclosed for playing the wagering game according to the method outlined above. A typical gaming table, with a playing surface, is modified to include specific areas that provide locations for placing the wagers and for displaying the common cards. A card shuffling machine such as that disclosed in U.S. Pat. No. 4,807,884 or other shuffling machines manufactured by Shuffle Master Gaming, Inc. of Las Vegas, Nev. for facilitating and speeding the play of the wagering game may be used. A display device may be associated with the apparatus for displaying game information, shuffle status, or other information relevant to the dealer, the players or the house.
The present invention provides an exciting and interesting wagering game. The wagering game is easy to learn, largely being based on five card stud poker and the well known ranking of poker hands. The present invention provides a new variation of a well known wagering game, five card poker, and in particular Let It Ride® stud poker, which is made more interesting by providing the opportunity for players to make multiple wagers and decisions related to those wagers based on the progress of the game.
Still another aspect of the present invention is to provide a wagering game that is easy to learn, yet demands skill of players in making strategic decisions about whether to let part of their bet ride. It is yet another aspect of the present invention to provide a unique, exciting card game for play in casinos or at home and on various media including casino tables, video poker machines, video lottery terminals or home computers. It is an advantage of the game of the present invention that wagering decisions are inherent in the game. The game enhances players' sense of participation and takes advantage of players' inclination to let wagers ride once placed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts the table layout and apparatus used in playing the wagering game of the present invention; and
FIG. 2 is a block diagram representing the flow of play in the game.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , the apparatus for the wagering game of the present invention includes a typical casino gambling or gaming table 10 . The table 10 has a curved side 12 for accommodating up to seven players and a straight side 14 for accommodating the dealer. The table 10 has a flat surface 16 covered with felt or other appropriate material. Although seven playing positions or locations 18 a-g for individual players are provided, it is not essential to the game that exactly seven persons play and as many as sixteen players may participate. For casino play, a maximum of seven players provides for a game that is easily manageable by the dealer and house, and one in which the individual players feel more involved. A house dealer position 20 , including an area suitable for displaying the dealer's cards 21 , is provided.
Each of the playing positions 18 a-g includes a wagering zone 22 , comprising four separate and distinct wagering or betting areas 22 a, b, c, d . A separate wagering area 22 e may be provided for placing of a bonus or jackpot (e.g., progressive jackpot) wager. Each position 18 a-g also includes a card area 19 a-g for receiving and displaying cards dealt to the player occupying the position. The wagering areas 22 a, b, c, d are designed to receive appropriate wagering indicators or settling means such as chips (not shown).
At one side of the dealer station 20 , the apparatus for practicing the method of the present invention may include a microprocessor or computer controlled shuffling machine 32 supported by a table extension 34 . The shuffling machine 32 may be of the type disclosed in U.S. Pat. No. 4,807,884 or any other single deck or multideck shuffling apparatus manufactured by Shuffle Master Gaming, Inc., the disclosure of which patent is incorporated herein by reference. The shuffling machine 32 may include a dealing module for automatically and sequentially dealing cards and also may include a display means for displaying wager amounts, the identity of winning players, or other game related information.
Referring to the flow diagram of FIG. 2 , the initial step in playing the game of the present invention is preparing or shuffling a deck of cards, represented at block 40 , by activating the shuffling machine 32 or by hand-shuffling a deck to provide a shuffled deck. Next, the players place the initial wager, block 42 , by putting equal amounts in each of the four betting areas 22 a, b, c, d . Two of the parts of this initial wager, the parts placed in wagering area 22 a and 22 b are retrievable at the option of the player. The third portion placed in area 22 c is a wager that is forfeited if the second wager at 22 b is withdrawn. The fourth part 22 d of the four part wager is a nonwithdrawable bet. After the placing of the wager by each player, the cards are dealt, block 44 , preferably three cards being dealt down to each player and preferably two cards are dealt down in front of the dealer. The players inspect or “sweat” their cards in preparation for reaching decision block 46 . At decision block 46 , the players are queried by the dealer about whether the first part of the initial wager, the part placed in wagering area 22 a , should be left or whether the player wishes to withdraw that portion of the bet. Each player makes the decision at decision block 46 on the basis of the three cards forming the player's incomplete hand at this point. Once each player has been queried and has decided whether or not to let the first portion of the bet ride, and those bets the player chooses to retrieve or remove are physically removed from area 22 a and returned to the player, the dealer shows one of the down common cards, block 48 . Now, each player has four cards to consider, the three cards dealt to that player originally and the single common card showing on the table. Each player must then decide whether to let the second part of the initial wager ride or whether to withdraw it from the game. As noted, if the second part of the wager is withdrawn, the third part of the wager is forfeit and is collected by the house. After each player is queried and decides what to do with regard to the second part of the bet, and those bets to be withdrawn are physically removed from area 22 b (and 22 c if the third part is forfeit) and returned to the player, the dealer reveals the second common down card, as represented at block 52 . Each player now has a five card hand comprised of the three cards each player was originally dealt plus the two revealed common cards. The third bet, the bet placed at wagering area 22 d , is a nonretrievable portion of the initial bet and the flow of the game proceeds to block 54 wherein the players show or reveal their three cards to the dealer. The dealer resolves each player's bet (which includes all three parts, the second and third part or only the third part, depending on the player's choices during play of the hand) based on the five card hand at block 56 and determines what payout, if any, the player is entitled to receive according to the payout schedule at the particular gaming table or casino. Bets on non-winning hands are collected by the dealer or house. The hand is then over and the flow of the game returns to block 40 , preparing and shuffling the deck for a new hand.
The award or payoff is given for each of the optional bets that were allowed to ride to the end of the hand and for the non-withdrawable part of the bet. A typical pay table would be as follows:
Pair, Sixes or Better 1—1 (even money) Two Pairs 2-1 Three of a Kind 3-1 Straight 5-1 Flush 8-1 Full House 11-1 Four of a Kind 50-1 Straight Flush 200-1 Royal Flush 1,000-1
The method of the present invention is not limited to five card poker games, but may be applied or used in other appropriate games such as seven card poker, as described elsewhere herein. The method of the present invention does not require a shuffling machine 32 , dealing module 33 or a display means 36 . However, these facilitate and expedite the play of the game as well as add interest to the game. While the initial wager of the present invention is preferably comprised of four equal bets, the bets do not necessarily have to be equal. The second and third parts should be equal, or the third part may be smaller than or greater than the second part. Similarly, the first, second, third and fourth parts may be of different values, but the fourth bet must be at least equal to a table minimum and may be required to be at least equal to or greater than any other wager part. While equal bets are highly preferred for casino play, unequal bets may be used in home play, if desired. The wagering game of the present invention might be played live in casinos with a dealer, or in casinos or homes in interactive electronic or video form with automatic coin or betting means receptacles and payout capability, wherein appropriate symbols for cards, wagers or score keeping would be displayed electronically. A “board-type game” suitable for home, club or casino use may also be provided for practicing the method of the present invention.
In combination with or separate from the play of Dakota Stud™ casino table poker, a new wagering structure resulting in different bonus structures may be used. The pure wagering structure described above, where the third part of the wager is tied to the election made by the player on the separate part of the wager is itself novel. The use of that wagering structure in combination with certain pseudo-pooling payout outcomes at the table is a further advance in the structure of wagering and play at casino table card games.
An example of the additional wagering structure and alternative payout structures include the use of excess retention by the house because of the unique wagering structure described above in the four-part wager (e.g., retaining a pair of 10's or other rank higher than 6's, 7's, 8's, or 9's as the winning hand) or by providing the option of a side bet to enter the additional award structure described below. Once the player is entered into the additional award structure (either automatically or with the optional or required side bet), the payout can be altered as follows. Those players that are entered into play of the additional award structure can participate in winning awards at the table, even where the awards occur in different hands, that is, hands of other players.
In present table gaming with bonuses or jackpots with side wagers, only the player receiving the hand is paid on the achievement of the bonus hand of at least a predetermined rank. In some poker clubs, certain events are paid both to players at the table and to the winning player from a pool when certain unusual events occur. For example, house rake may be partially deposited in a pool account Where when the event occurs, the pool is paid to the table where it occurs and the money in the pool is distributed proportionally. Such a situation would occur where, for example, the winning event in a pool was where a losing hand at a card table was at least a full house with at least three Aces and two 10's as the losing hand. The pool is distributed among the players and the sometimes the dealer at the table as, for example (70% to the winning hand, 10% to the losing hand and 20% to the remaining players at the table; or 70% to the winning hand, 15% to the second place hand, 20% to the remaining players at the table, and 5% to the dealer). The pool is a form of progressive jackpot which is incremented according to discretionary rules of the poker club or casino. All players at the table partake of the pool winnings if they anted in the play of the hand where the winning event occurred. No distinct side wager or particular wagering element is required to enter into the chance to win the pool, which occurs with only a single specific event occurring, as described.
In the practice of the present invention, accruing take from the third wager (automatically entering the player in the bonus event during the game) or preferably requiring a separate side wager to enter the bonus payout event is used to enable a player to enter the bonus event. The player is either required to place a side bet or has the option of placing a side bet to enter the bonus event. The bonus event is played against a pay table, whereby whenever any player at the table achieves a hand of predetermined rank, all players that are entered into the bonus event (either automatically or by placing the side bet) partakes of the bonus award for the predetermined hand. The rules may vary, so that a) only players that made the side bet wager can participate in the bonus, b) only players that made the side bet wager and remain in the game at the end of the hand can participate in the bonus, c) only players that made the side bet wager and have a qualifying hand can participate in the bonus, or d) only players that made the side bet wager and have a hand that beats the dealer's hand can participate in the bonus. The preferred method of play is a). The play of this bonus event with side bet can even be extended to include multiple tables. For example, certain progressive jackpot games link tables for the jackpot or bonus awards taken out of the jackpot pool. The tables can be linked by having players who had made the side bet wager at a distal table in the last hand before the bonus event was won at a proximal table. This is not a preferred embodiment (because of potential complexities in synchronization of play or debating when hands were played relative to distal side bets), but is within the skill of play and design. Additionally, the bonus may be paid either when any hand at the table achieves the predetermined hand rank, or only when a player that has made a side bet achieves a hand of the predetermined rank. The second format is preferred to stimulate more persons at the table to make the wager.
An aspect of this pay structure is to increase the frequency of bonus events at a table. With more players at a table, there are more hands per game at the table, and the hit frequency of bonus hands increases. Even though the actual size of individual awards per player decreases, the increased frequency improves the overall ambiance of the game. For example, if there are six players at a table, the frequency of bonus hands statistically increases to six times what the frequency was with a single player at the table.
The payouts for each player will necessarily vary according to the number of players that are in the game and/or have made the side bonus bet. The house may require a minimum number of players to engage play of this side bet bonus event, primarily to limit the number of pay tables that must be displayed It is also possible to have a display device (e.g., screen, monitor LED, liquid crystal display, plasma screen, etc.) that is fed by data from a computer or microprocessor or other image source to show the applicable pay table for the number of players involved in the payout for the hands. For example, the display may show separate screen for 2 player, 3 player, 4 player, 5 player, 6 player and 7 player bonus events, each screen having different odds and payouts. Automated equipment indicating the number of wagers placed, the number of players entered, the rank of the hand, and other factors can be provided. For example, camera, scanners, digital readers, and software interpreting the data such as that provided in U.S. Pat. Nos. 6,313,871; 6,460,848; 6,126,166; 5,941,769; and the like could be used to assist in automating the reading of cards, ranks, wagers, and the number of players.
It is also possible for players to elect to play a “double bonus.” In this format, rather than a typical one dollar side bet being placed, two separate one dollar wagers or a single two dollar wager may be placed to enter the player in both an individual bonus payout event and the shared bonus event discussed above. Except where the bonus was a progressive bonus, this system could be highly attractive to players. The rules must be clear in the event that a progressive jackpot is used, so that it would be understood that a 100% jackpot win by a player with both side bets placed would win 50% of the total jackpot for him/herself, and the remaining 50% would be split among players in the bonus event, including the winning player. With a fixed bonus pay table, one of five players at a table with both side bets having been placed (the individual bonus and the shared bonus or group bonus wager) would receive a payment of the fixed amount for obtaining a predetermined rank hand and ⅕ th of the award for the group award on the ranked hand. For example, if the ranked hand were a Straight Flush with a $2,000 fixed award, the player with that hand would win $2,400-$2,000 for the individual bonus side bet and ⅕ th of $2,000 ($400) for the group wager.
The side bets may be made on sensing systems or by placing tokens, chips or money on the table that remain on the table at appropriate locations until conclusion of the game. Typical sensing devices include coin drops, photooptical sensors, proximity detectors, cameras, scales, and the like.
The format of this game is particularly compatible with any poker-type games where bonus awards are provided from a pay table, such as Let It Ride® stud poker, Three Card™ poker, Four Card poker, 3-5-7™ Poker table game, and the like. It is also useful in games where progressive jackpots are used, alone or in combination with pay tables, such as with certain formats of Caribbean Stud™ poker. The wager could also be used in games where there are special bonuses given to players who obtain unique hands. For example, in Pai Gow poker, there may be special awards for perfect Pai Gow hands (e.g., 9, 8, 7, 5, 4, 3 and 2) or uniquely ranked hands (e.g., a front pair of aces and at least four-of-a-kind on the rear hand). The payouts could be made to all players participating in the wager (e.g., on a proportional basis), rather than just to the player who obtains the hand. The bonus wager could also be doubled so that a player could receive both the individual award and the group award for the hand.
The present invention may be embodied in other specific forms without departing from the essential attributes thereof. It is desired that the embodiments described above may be considered in all respects as illustrative, not restrictive, reference being made to the appended claims to indicate the scope of the invention.
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A method of playing a casino table wagering game with at least two players comprises wagering on an underlying game where players may receive a bonus for obtaining a player hand of at least a predetermined rank; placing a side bet that at least one player of the at least two players will obtain a player hand of at least a predetermined rank; playing a hand of the casino table wagering game to conclusion; determining if at least one of the at least two players has obtained a player hand of said at least a predetermined rank; if a player has not obtained a player hand of at least a predetermined rank, but that player has placed the side bet that at least one player of the at least two players will obtain a player hand of at least a predetermined rank, and if another player has obtained a player hand of at least a predetermined rank, awarding that player a predetermined proportional share of the bonus for obtaining a player hand of at least a predetermined rank.
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BACKGROUND OF THE INVENTION
The invention relates to a structural steel that can be bent back (i.e., especially able to be statically and dynamically stressed in the area of a bending point that has been bent back) as well as to the reinforcing connection produced by using such a reinforcing steel.
In structural engineering, structural steels are used in varied ways including use as reinforcement for a variety of concrete structural elements. These structural steels can be provided with ribbing or shaping on their surface, which can be configured in a variety of ways to achieve a sufficient bonding in the concrete.
Although all structural steels approved for concrete construction must meet the so-called "bend-back" test (i.e., from the aspect of their alloy or material structure, they must be made so that during this test the respective reinforcing steel does not harden or become brittle upon bending or bending back in such a manner that with bending back or slight stresses a break occurs afterwards), it is regarded as out of the question to use as structural steels those that have been bent and then bent back again where greater static or dynamic stress occur or can be expected.
Besides the bending of structural steels (but without bending back) quite common in construction engineering, it is often advantageous from the aspect of building construction or work cycle to use structural steels so that they are first bent in a specific area and later again bent up or bent back. A typical example of this are the so-called "reinforcing connections" which are increasingly used today, where to a first concrete structural element that is to be constructed (e.g. to a first concrete wall to be constructed) another concrete structural element (e.g., another concrete wall) is to be connected. In this case, the reinforcing steel, first bent and then bent back, or reinforcing bars, bent and then bent back, form the connecting reinforcement between the two concrete structural elements. These reinforcing connections, which make passing the connecting reinforcement through the form of the first concrete structural element constructed unnecessary, basically consist of a holding element, which can exhibit varied configuration and by which in each case the reinforcing bars, formed from a length of a reinforcing steel and provided with a corresponding ribbing or shaping, project out with a first partial length (anchoring area). With a second partial length (connecting area or part), bent substantially at right angles to the first partial length, the reinforcing bars are placed, in a covered manner, inside the holding element. Such a reinforcing connection is inserted into the concrete form for the first concrete structural element to be constructed so that the anchoring areas of the reinforcing bars are embedded in the concrete of the first concrete structural element constructed and the connection parts of the reinforcing bars are inside the holding element close to the form wall. After removal of the first constructed concrete structural element from the form and before concreting the concrete structural element to be connected, the connecting parts of the reinforcing bars are exposed and bent upward with a suitable tool, so that the connecting part, bent up or back, can be embedded in the concrete of the concrete structural element to be connected and thus form the connecting reinforcement on the transition area.
Despite bending (in making the reinforcing connection), as well as the subsequent bending up and back (in using the reinforcing connection) to achieve to some extent satisfactory results in regard to the carrying capacity of the connecting reinforcement, special heat-treated structural steels as reinforcing bars and special tools for bending the connecting parts upward have already been proposed. Nevertheless, in the case of usual structural steels, especially in bending back, microcracks in the structural steel cannot be avoided. Such microcracks decisively reduce the fatigue limit of the reinforcing steel, so that with all known structural steels, after bending and bending back, only relatively low fatigue limits on the order of 80 n/mm 2 can be achieved. Because of this low fatigue limit, structural steels which have been bent and bent back are often used only where special stresses in the construction are not to be expected. This described problem is particularly serious if structural steels with relatively large diameters (for example, on the order of 6-16 mm) are necessary. For example, where an effort is made to obtain as small a radius of curvature or bending on the bending and bending back area to reduce the overall height of the holding element of a reinforcing connection or for other reasons.
SUMMARY OF THE INVENTION
The object of the invention is to provide a reinforcing steel which, after bending (especially by small bending radii) and bending back, is capable of both substantially higher static and dynamic stress in comparison with known structural steels. Thus providing a reinforcing steel that can be used advantageously, especially where bending and later bending back is necessary in the work cycle. Further, the object of the invention is to provide a reinforcing connection, which has improved properties in comparison with known reinforcing connections and with which an improved fatigue limit for the reinforcing bars is achieved despite the necessary repeated bending of the reinforcing bars (especially even at small bending radius).
This object is achieved by a reinforcing steel having areas provided for bending and bending back that do not exhibit ribbing and/or shaping on one partial area of its periphery, which corresponds to at least approximately one third of the cross section periphery of the reinforcing steel or a reinforcing connection characterized by reinforcing bars, formed by lengths of reinforcing steel, wherein the anchoring areas project over an outside surface of the holding element and are adapted to be embedded in the concrete structural element as well as placed inside the holding element. The anchoring areas form connecting parts to be bent out for connection to a concrete structural element to be connected later. The connecting parts in each case connect by a bending or transition area to an anchoring area wherein in each case the bending or transition areas are made on an area of reinforcing steel provided for bending and subsequent bending back.
The reinforcing steel according to the present invention, at least in certain areas, does not exhibit the otherwise provided shaping or ribbing, or else, is provided only on a part of its periphery with a ribbing or shaping. The certain areas are successively provided where the reinforcing steel can be bent and bent back during use. This is accomplished during the production or the ribbing or the shaping of the structural steel at preferably preset intervals in the moving sense or direction of the structural steel. As a result, the reinforcing steel according to the present invention displays very decisive improvement in the fatigue limit after bending and bending back. But at the same time, the necessary bonding of the reinforcing steel in the concrete is also guaranteed.
The reinforcing steel according to the invention is suitable in a particularly advantageous way for reinforcing bars of reinforcing connections. The use of the reinforcing steel according to the invention is not limited to this special case of application, rather the reinforcing steel according to the invention can be used with the described advantages wherever a bending and then bending back of the latter stressed reinforcing steel in the work cycle is necessary or advisable.
If the bending or bending back areas are not kept completely free of the otherwise provided ribbing or shaping, but the ribbing or shaping is provided only on a part of the peripheral area of the reinforcing steel on these bending or bending back areas, the bending of the reinforcing steel takes place in such a way that, in relation to the bending, the partial area of the cross-sectional periphery not exhibiting the shaping or ribbing is on the outside.
In addition to the described design of the reinforcing steel, a special alloy for this steel contributes decisively to achieving an improved fatigue limit.
In a heat-treated steel, for example produced according to the "TEMPCORE Process", the steel is preferably made from a steel alloy, which contains 0.12 to 0.22% by weight of carbon, 0.5 to 1.0% by weight of manganese, less than 0.05% by weight of phosphorus, less than 0.05% by weight of sulfur, less than 0.6% by weight of copper, less than 0.05% by weight of tin and less than 0.018% by weight of nitrogen.
In a cold-formed or cold-rolled or cold-drawn steel, it is preferably produced from a steel alloy which contains 0.06 to 0.20% by weight of carbon, 0.35 to 0.85% by weight of manganese, less than 0.6% by weight of copper and less than 0.50% by weight of silicon, and the carbon portion preferably is 0.08 to 0.14% by weight.
In a microalloyed steel, the reinforcing steel is preferably made from a steel alloy, which contains less than 0.24% by weight of carbon, less than 1.5% by weight of manganese and less than 0.12% by weight of vanadium. Wherein the carbon portion preferably is 0.16 to 0.22% by weight, the manganese portion preferably is 0.8 to 1.2% by weight and the vanadium portion preferably is 0.03 to 0.08% by weight.
With the reinforcing steel according to the invention with small bending radius on the bent and bent back structural steel, fatigue limits (according to DIN 488) on the order of 230 N/mm 2 , but also greater, can be achieved. In contrast, prior to the present invention, structural steels under the same conditions achieved fatigue limits on the order of about 80 N/mm 2 at most.
The advantages obtained with the invention are caused by keeping the bending or bending back ares free to the greatest extent possible from ribbing or shaping. Also the steel alloy used in producing the reinforcing steel leads to a sufficiently ductile steel, which contributes, on the bending or bending back areas, to the tendency to reduce substantially fissuring in the structuring steel in a bending and then bending back.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred further developments of the invention are the object of the subclaims. The invention and its advantages are explained in greater detail below by the figures in connection with the reinforcing connections, since the use of the reinforcing steel according to the invention in reinforcing connections represents the preferred one of numerous conceivable possible uses. There are shown in:
FIG. 1 is a cross section of a reinforcing connection used for insertion into a form for a concrete structural element, in which the reinforcing connection has reinforcing bars that are produced from a length of a reinforcing steel according to the invention by bending;
FIG. 2 is an enlarged illustration of a partial section corresponding to line I--I of FIG. 1;
FIG. 3 is an enlarged representation of the profile of the ribs of the reinforcing bars according to FIG. 1;
FIG. 4 is a diagrammatic representation of a partial length of the reinforcing connection embedded in the first constructed concrete structural element, with a bent up connecting part as well as with a connecting part not yet bent up;
FIG. 5 is a diagrammatic representation of a horizontal cross section through two concrete structural elements and the reinforcing connection forming the transition area of these concrete structural elements;
FIG. 6 shows a length of reinforcing steel from which the reinforcing bars of the reinforcing connection are produced by cutting the partial lengths and subsequent bending;
FIGS. 7 to 9 show various embodiments of the reinforcing connection illustrated in FIG. 2, where different structural steels are used for the reinforcing bars;
FIG. 10 is a section view corresponding to line II--II of FIG. 9;
FIG. 11 illustrates another embodiment of the reinforcing connection shown in FIGS. 2 to 10, according to the invention;
FIG. 12 illustrates a section corresponding to line III--III of FIG. 11;
FIG. 13 illustrates another embodiment of the reinforcing connection as shown in FIG. 1; and
FIG. 14 illustrates a further embodiment of the reinforcing section connection as shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The reinforcing connection, represented in the figures, consists of a box-shaped or profile-shaped holding element 1, which is produced from sheet steel by bending. Holding element 1 substantially consists of a bottom 2 and two legs 3 constructed from one piece by way bending. Bottom 2, as well as legs 3, extend over the entire length of holding element 1, running perpendicular to the drawing plane of figure and enclose inside space 4 of the holding element 1 which is closed by two ends of the holding element by a removable sealing element (not shown). The removable sealing element may be made of foamed plastic (not shown) or may be a cover on the open side opposite the bottom 2. A longitudinal groove 5, extending over the entire length of holding element 1, and therefore perpendicular to the drawing plane of FIG. 1, is formed in the center of bottom 2. The groove 5 is so designed in the embodiment represented that bottom 2 in the area of this longitudinal groove extends into inside space 4. Longitudinal groove 5 divides bottom 2 into two bottom areas 2', one of which is provided respectively on each side of the longitudinal groove 5 and changes into a corresponding leg 3. Leg 3 and adjacent bottom area 2' form an acute angle so that the holding element exhibits a dovetailed cross section formed by legs 3. Bottom 6 of longitudinal groove 5 is parallel to bottom sections 2' and, by way of leg areas 7, is connected to bottom sections 2'. Each leg area 7 forms an acute angle with the surface of bottom 6 turned away from the open side of holding element 1 as well as with the surface of the adjacent bottom area 2' turned toward the open side of holding element 1. Consequently, in the cross section plane running perpendicular to the longitudinal extension of the holding element 1, longitudinal groove 5 and the bottom areas 2' between leg areas 7 and legs 3 exhibit dovetail cross sections.
Each leg 3, on its free longitudinal edge located away from bottom 2 and extending over the entire light of holding element 1, changes into a bend 8, which projects over the outside surface of relevant leg 3 and encloses an acute angle with this outside surface. The two bends 8 serve first for reinforcing holding element 1 or legs 3 on their free longitudinal edges located away from bottom 2. But especially by bends 8 a reinforced resting surface is achieved, with which holding element 1 rests against the inside surface of the concrete form of the first concrete structural element to be constructed. This resting surface is formed by transition area 9 between the respective leg 3 and related bend 8. At least on this transition area 9, i.e., on the surface, which is outside the acute angle formed by leg 3 and bend 8, there is provided on the free longitudinal edge of each leg 3 a coating 10 with a material, which swells in the moist state and thus causes a sealing effect as will be further described below. This coating consists, for example, of clay or bentonite with a suitable binder and may be applied in the form of a paint. The usual binders used in paints, for example, are suitable as binders as it applies to the present invention. To improve bonding of holding element 1 in the concrete structural element to be constructed first (for example, in concrete wall 11) as well as to improve bonding of holding element 1 in the concrete structural element to be later constructed or connected (e.g., concrete wall 12) holding element 1 is provided at least on bottom 2 or on bottom areas 2' with a coating 13, which gives a particularly rough surface to holding element 1 in this area of the coating. This coating may be applied on the inside surface (turned toward inside space 4) or outside surface (turned away from inside space 4) of bottom 2 or bottom areas 2' and results in improved shear stress or shear force transmission to the connection point between the two concrete structural elements or concrete walls 11 and 12. In the simplest case, coating 13 can be made of sand, which is held on the respective surfaces of holding element 1 with a suitable adhesive or plastic. Preferably however, coating 13 consists of cement clinker, which enters into a close bonding in the concrete of the respective concrete structural element and in the same way is held on the respective surface of the holding element by a suitable adhesive or plastic. Other types of coating 13 are also possible, provided they cause a roughened surface for holding element 1. Moreover, coating 13 may, of course, be provided additionally on other areas. For example, the area of longitudinal groove 5 and/or in the area of legs 3.
Further, the represented reinforcing connection has several reinforcing bars 14, which are bent U-shaped or as stirrups and thus in each case exhibit two legs 15 and a yoke section 16 connecting these legs together. Reinforcing bars 14, are positioned with their yoke sections 16 perpendicular to the longitudinal extension of holding element 1. Legs 15 are put through openings provided in bottom areas 2' so that in each case a leg 15 exhibits a corresponding passage point (through bottom area 2') on left bottom area 2' in FIG. 1 and the other leg 15 exhibits the corresponding passage point on right bottom area 2' in FIG. 1. Legs 15 preferably are bonded to bottom areas 2' by welding or other suitable means at the passage points.
Each leg 15 consists of a first section 15', which is directly connected to yoke section 16 and projects perpendicularly from the outside surface to bottom 2 (i.e., turned away from inside space 4). Together, corresponding sections 15', of the legs 15 and yoke section 16, form the anchoring area of respective reinforcing bar 14. A second section 15" of each leg 15 is bent at 15"' (transition area) approximately perpendicular to section 15' and is placed directly on the inside surface of the respective bottom area 2' (i.e., in inside space 4 of holding element 1). Sections 15" form the connecting parts--to be bent out later--of reinforcing bars 14 or of the reinforcing connection. Reinforcing bars 14 have a cross section, which for example is on the order of 6-16 mm, corresponding to the respective static and/or dynamic requirements.
To improve the bonding or anchoring of reinforcing bars 14 in the concrete of concrete walls 11 and 12, each reinforcing bar 14 is provided on its surface or peripheral area with a multiplicity of ribs 17 running obliquely to the longitudinal extension of the reinforcing bar and projecting over the surface, in a manner common within the art of reinforcing bars or structural steels. These ribs 17, produced in rolling, exhibit the profile represented in FIG. 3. But in accordance with the principles of the present invention, to improve the properties of the reinforcing element or reinforcing connection, reinforcing bars 14 do not exhibit such ribs 17 on transition areas 15"', as will be explained in detail below.
Since bent sections 15" of all reinforcing bars 14 are housed in inside space 4 of holding element 1, its overall height (i.e., the distance which bottom areas 2' exhibit from the free edges of legs 3 in the direction perpendicular to their surface sides) is determined by the diameter of reinforcing bars 14 as well as by the radius of curvature r on transition area 15"' located between section 15' and bent section 15" of each leg 15. Especially in an attempt to save materials, to reduce shipping volume, for static aspects, etc., a low overall height for holding element 1 is sought. That is, as small as possible radius of curvature r in the bending area between sections 15' and 15" is sought. However, it is necessary not to go below the lower boundary value for bending radius r, since otherwise both the bending of sections 15" occurring in the making of the reinforcing connection and also the bending up of sections 15" taking place with the use of the reinforcing connection as described below results in a cold forming of the steel of reinforcing bars 14 and especially the occurrence of microcracks in reinforcing bars 14. Such results adversely affect the strength, especially the fatigue limit of reinforcing bars 14.
The basic use of the reinforcing connection is seen in FIGS. 4 and 5. In making the first concrete structural element to be constructed (for example, concrete wall 11) before introduction of the concrete, the reinforcing connection is placed in the form that is used so that holding element 1 with its open side (i.e., in the area of transitions 9) rests against the inside surface of a form wall of the form used. As such, the placement of the concrete of concrete wall inside space 4 of holding element 1 is kept free from the concrete introduced into the form, because it is delimited by holding element 1 and the form wall. This is achieved primarily by the cooperation of the above-mentioned closing elements and the two ends of holding element 1 as well as the cover. After placing the concrete of concrete wall 11, anchoring areas 15'/16 of reinforcing bars 14 as well as bendings 8 are embedded in the concrete.
After removal of the form of concrete wall 11, the cover, formed in the simplest case from a plastic sheet, is removed. It should be noted that the cover is also used as a covering for coatings 10. Then exposed sections 15" are bent up by bending back of the respective transition areas 15'" so that each section 15" is equiaxial as much as possible with section 15' of the respective leg 15. This bending may be accomplished with the help of a suitable bending tool corresponding to Arrow A of FIG. 4.
The passage points of reinforcing bars 14, or their legs 15, through bottom 2 of holding element 1 are in areas 2'. In comparison with the total bottom 2, bottom areas 2' exhibit a reduced width. This is a result of the connection of a leg 3 and a leg area 7 being connected to each of the bottom areas 2'. As a result of this configuration, in bending up of sections 15", even with the use of thin sheet metal for holding element 1, it is guaranteed that the sheet metal of the holding element 1 in bottom areas 2' is so solidly anchored in the concrete of concrete wall 11 by the dovetail cross section (formed therein by a leg section 7 and a leg 3) that in bending up the sheet metal is not lifted in any area from the concrete of concrete wall 11. Thus, the bonding of holding element 1 by coating 13 in concrete wall Il is not lost. In addition, coating 13 cannot come loose at any point from holding element 1 or peel off from the surface of the holding element turned toward inside space 4. By the described configuration of bottom 2 (i.e., by longitudinal groove 5 provided in bottom 2) an optimal effectiveness of coatings 13 is achieved and thus an optimal transmission of shear force between concrete walls 11 and 12 in the connection area is assured.
After completion of concrete wall 12, sections 15" of reinforcing bars 14 are also embedded in this concrete wall, so that the acting tensions can be transmitted by the connecting reinforcement formed by reinforcing bars 14, between concrete walls 11 and 12. As FIG. 5 shows, the holding element is also completely embedded in the concrete after completion of concrete wall 12. Moisture possibly penetrating into joints 19 between concrete walls 11 and 12 leads to a swelling of coating 10 and thus to a sealing of these joints. In the embodiment represented in FIGS. 1-5, ribs 17 of reinforcing bars 14 are designed so that these ribs 17 form an angle a with the longitudinal extension of the respective reinforcing bar 14. Angle a is smaller than 45.sup.˜, and is preferably in the range between 30 and 45.sup.˜.
Reinforcing bars 14 can be produced as microalloyed, heat-treated or cold-formed steels.
In the production as microalloyed steel, the reinforcing bars are made from a steel alloy, which contains less than 0.24% by weight of carbon, less than 1.5% by weight of manganese, and the portion of vanadium is less than 0.12% by weight. The preferably composition being 0.16-0.22% by weight carbon, 0.8-1.2% by weight manganese, and 0.03-0.08% by weight vanadium.
The use of a heat-treated steel, which is cooled after rolling so that it has a "soft core", guarantees a high bend-back capability, as well as a "hard" outside area or a hard "shell". The area or the shell is mainly responsible for the strength sought. The reinforcing bars produced as heat treated steel are made from a steel alloy which contains 0.12-0.22% by weight of carbon, 0.5-1.0% by weight of manganese, less than 0.05% by weight of phosphorus, less than 0.05% by weight of sulfur, less than 0.6% by weight of copper, less than 0.05% by weight of tin, and less than 0.018% by weight of nitrogen.
With the use of a cold-formed steel, reinforcing bars 14 are made from a steel alloy which contains 0.06%-0.20.% by weight of carbon, preferably 0.08-0.114% by weight of carbon, 0.35-0.85% by weight of manganese, less than 0.6% by weight of copper, and less than 0.5% by weight of silicon.
As was mentioned above, no ribs 17 are provided on the transition areas 15'" of reinforcing bars 14. This lack of ribs, in combination with reinforcing bars 14 which are already highly ductile as a result of the respective steel alloys, results in a reduced tendency in the formation of cracks in bending of reinforcing bars 14 or of reinforcing steel 14' used for these reinforcing bars 14 in making the reinforcing connection. This reduction is also produced in bending back or bending up of sections 15" when forming the connecting parts. Because of this reduction in the formation of cracks, the carrying capacity or the fatigue limit is essentially improved in static and dynamic stressing of reinforcing bars 14, bent back or bent up, in comparison with known reinforcing connections.
FIG. 6 shows a length of structural steel 14' as it is used for making reinforcing bars 14. This reinforcing steel 14' is made so that in the longitudinal or running direction it exhibits areas 21, on which ribs 17 in a dense sequence are provided to achieve the necessary bonding of reinforcing bars 14 in concrete. The need for ribs 17 is especially useful in securing sections 15" in the concrete (even with relatively short lengths for sections 15"'). In each case such an area 21 is followed by an area 22, which is kept free of ribs 17. With the produced reinforcing connection, the bending and transition areas 15'" are formed, in each case, in an area 22.
For production of structural steel 14', tools or rolls are used which exhibit on their working or forming surface at least two sections merging into one another or contacting one another. One section has recesses corresponding to ribs 17 for forming them and thus forms the area 21 provided with ribs 17, while the respective other section of each mold does not have these recesses forming ribs 17 and thus forms areas 22 of structural steel 14'.
With the use of a cold-formed steel or reinforcing steel 14' for reinforcing bars 14, an additional advantage is that the molds used in regard to their forming or working surfaces can be produced in an especially simple way and with long service life. Namely, they may be produced by making the recesses producing ribs 17 by spark erosion in the respective section of the forming or working area used for forming areas 21.
For the production of the reinforcing connection, reinforcing steel 14' is unwound (e.g., from a winding or coil) and then a preset partial length is cut off from the front end in the unwinding direction, which is then bent into a reinforcing bar 14. In this case, it is advisable that the length of areas 21 provided with ribs 17 and the cutting of the partial lengths for the formation of reinforcing bars 14 from reinforcing steel 14' be one selected in such a manner that bending these partial lengths into individual reinforcing bars 14 takes place so that not only the bending or transition areas 15'" between sections 15' and 15", but also the bending and transition areas 15"" between each section 15' and 16, are formed in an area 22 without ribs 17.
Of course, it is also possible for the lengths of areas 21 and 22 of reinforcing steel 14' to be selected so that after production of reinforcing bars 14 several areas 22 alternating with areas 21 are exhibited on sections 15", 15' and/or 16. However, regardless of this selection, bending or transition areas 15'" are formed from areas 22.
With the symmetrical configuration of the stirruplike bent reinforcing bars 14, the separation of the partial lengths from reinforcing steel 14' may occur in the center of either an area 21 or an area 22. Each separated partial length exhibits at least two areas 22 at a distance from each other, which largely corresponds to the sum of the lengths of the two sections 15' as well as a section 16.
In the embodiment reproduced in FIG. 7, reinforcing bars 14a, corresponding in their form to reinforcing bars 14, are produced by bending from a reinforcing steel. The reinforcing steel is produced from one of the alloys described above, but has no ribs 17 on its surface. In the case of relatively short length of sections 15" forming the connecting parts to be bent out later, several rings 23 forming a rib like projection in each case are fastened thereto to achieve a satisfactory bonding of these sections in the concrete. These rings are either clamping rings or clamping sleeves (i.e., rings or sleeves) which are held on sections 15" by force fit. Alternatively, rings 23 or the corresponding sleeves, after sliding onto the respective section 15", may be held there by welding or in any other suitable manner.
FIG. 8 shows an embodiment, in which reinforcing bars 14b, corresponding in turn in their shape to reinforcing bars 14, are produced from a reinforcing steel of one of the above-mentioned alloys, which (the reinforcing steel) also does not exhibit ribs 17. To achieve the necessary bonding of sections 15" in the concrete, the material forming reinforcing bars 14b is upset on the free ends of sections 15" so that a thickened head 24 is produced on these ends. In this embodiment, it is also possible to upset the material forming reinforcing bars 14b several times between the free ends of these sections and the respective bending and transition area 15'" so that, in addition to head 24, ring-shaped or rib-shaped projections 25 are also produced.
As a result of rib-free transition areas 15'", the tendency for the formation of cracks in bending of sections 15" (in the production of the reinforcing connection) as well as in bending back these sections (in later use) is substantially reduced. This reduction is especially enhanced when rib-free transition areas 15'" are found in combination with said alloys of the steel used for the production of reinforcing bars 14. By said measures the static and dynamic strength (fatigue limit) of bent-back reinforcing steel 14 is substantially increased, and also at the same time especially small radii of curvature r for bending transition area 15'" between sections 15' and 15" are possible. Namely, bending radii r on the order of between twice and six times the diameter of reinforcing bars 14 used are possible. With the described measures, fatigue limits of 230 N/mm 2 and greater can be achieved with the bent-back reinforcing bars. With the reinforcing connection made by using the reinforcing steel according to the invention (also considering the necessary additional safety) the bent-up reinforcing bars can be stressed with a fatigue limit of at least 180 N/mm 2 , while with all the reinforcing connections available on the market up to now the maximal admissible fatigue limit is only about 60 mm 2 .
FIGS. 9-12 described below relate to other embodiments of a reinforcing connection produced by using the reinforcing steel according to the invention. These embodiments also exhibit the advantages described above relative to the increased fatigue limit.
In the embodiment shown in FIG. 9 and 10, the reinforcing bars, identified there by 14c, exhibit, at least in the transition or bending back areas 15'", a flat or oval cross section and are bent around an axis running parallel to larger cross section axis 26. Otherwise reinforcing bars 14c are also provided with ribs 17 as illustrated in FIG. 2 or 6 or with other ribbing or shaping usual or usable with reinforcing bars. This ribbing or shaping is interrupted on transition areas 15'" and optionally on transition areas 15"". Deviating from this embodiment, it is also possible for reinforcing bars 14c on transition areas 15'" to be made so that they exhibit ribs 17a, or a corresponding shaping, only where cross-sectional axis 26 intersects the peripheral surface of the respective reinforcing bar 14c, while the remaining part of the peripheral surface is kept free of a ribbing or shaping.
Finally, FIG. 11 and 12 show an embodiment, in which reinforcing bars 14d include ribs 17. A total of three rows of ribs 17 running in the longitudinal direction of the respective reinforcing bar 14d and offset by 120° are provided on the periphery of reinforcing bar 14d. At least on transition areas 15'", ribs 17 of the lower rib row shown in FIG. 11 and 12 are interrupted so that there reinforcing bars 14d have a substantially smooth peripheral surface on the outside with regard to the bending of reinforcing bar 14d.
In the embodiment according to FIG. 11 and 12 it is, of course, also possible for the respective reinforcing bar 14d to exhibit a number of rib rows deviating from the number of three. Thus, for example, it is possible for ribs 17 to be placed in two rib rows, and also in these embodiments, at least on transition areas 15'", for ribs 17 to be omitted on the rib row or rib rows, which is/are on the outside relative to the bend there.
FIG. 13 shows a reinforcing connection, which differs from the reinforcing connection according to FIG. 1, inter alia, by the fact that holding element la has a narrower width in comparison with holding element 1. Reinforcing bars 14e are not made stirrup-shaped but are formed from a bent length of reinforcing steel with a section 15', a section 15", and a transition area 15'". The reinforcing steel used for the production of reinforcing bars 15e exhibits the areas provided for transition areas 15'" (for example, areas 22 at uniformly recurring distances). The reinforcing connection or its reinforcing bars 14e can be made in a particularly simple and efficient way even with different length of sections 15' and thus match different wall thicknesses of concrete structural elements 11. In each case corresponding lengths of reinforcing steel are cut off, which between their ends exhibit at least one area (e.g. area 22) provided for transition area 15'", and then by corresponding bending of ends 27 sections 15' can be adjusted continuously to the desired length.
In the reinforcing connection represented in FIG. 1 an adjustment of the length which sections 15' project over the outside of holding element 1 is also possible. Such adjustment is possible if the reinforcing steel used exhibits, in relative dense sequence, the areas (for example, areas 22) suitable for transition areas 15'". For example, if a greater length for sections 15' is desired, areas 22 located farther away from one another are used as transition areas 15'", and if shorter lengths of sections 15' are desired areas 22 less farther apart are used.
FIG. 14 shows, like FIG. 10, a cross section through reinforcing bar 14f which consists of two substantially circular cross sections 14f' and 14f" merging into one another. Axis 26 corresponding to the larger cross section dimension in this embodiment is parallel to the bending axis in transition areas 15'". Further, reinforcing bar 14f in the area of axis 26 exhibits shaping 17a, while otherwise a shaping or ribbing is lacking at least on transition areas 15'". Despite a relatively large overall cross section, reinforcing bar 14f can easily be bent back.
With all described embodiments it is possible to compensate for the lacking or reduced ribbing or shaping, especially on transition areas 15'", by raising the ribbing or deepening the shaping on the remaining areas of reinforcing bars 14, 14a-14f. Further, with all the described embodiments it is also possible for the reinforcing steel to exhibit a cross section, which has cross section dimensions of different size in two axial directions running perpendicular to one another. The larger cross section dimension or axis then corresponds to axis 26 of FIG. 10 and runs parallel to the bending axis of transition areas 15'", so that the smaller cross section axis is perpendicular to this bending axis. Such a cross section, for example, would be an oval or rectangular cross section. The cross section design has the advantage that despite a relatively large effective cross section, an easy bending back of reinforcing bars 14, 14a-14f is possible.
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A reinforcing steel for use particularly in reinforcing connections. The steel including ribbing and/or shaping along its surface to allow for bonding in concrete, but also including portions where the surface is free of ribbing and/or shaping at points where the steel is intended to be bent. This structure allows for increased load bearing capabilities where bending takes place.
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BACKGROUND
This invention relates to certain penems substituted at the 2-position by a heterocyclylthio group, their pharmaceutically acceptable salts and pharmaceutically acceptable esters, which compounds possess potent antibacterial activity and have high serum half-lives.
There is a continuing need for new antibacterial agents because continued extensive use of effective antibacterials gives rise to resistant strains of pathogens.
Antibacterials of the penem-type are known in the art. U.S. Pat. No. 4,272,437 discloses a large number of penems including those with a 6-(1-hydroxyethyl) substituent as shown e.g., in Examples 41, 58, 60, 61, 62, 63, 64, 65, 66 and 96. Examples 64 and 65 disclose penems with the 5R,6S stereochemical structure. There are no disclosures in the patent of penems with a heterocyclylthio at the 2-position.
U.S. Pat. No. 4,301,074 discloses penems with an --SR substituent at the 2-position. The R can be a 5-member heterocyclic group, but not a saturated heterocyclic group.
British Pat. No. 2,013,674A discloses penems with a hydroxyethyl group at the 6-position, but no saturated 5-membered heterocyclylthio groups at the 2-position.
SUMMARY OF THE INVENTION
This invention relates to certain novel cis and trans isomers of 5R,6S,8R 6-(1-hydroxyethyl)-2-(heterocyclylthio)-penem-3-carboxylates which possess antibacterial activity, pharmaceutical compositions thereof and methods for treating bacterial infections utilizing said compounds and compositions.
More particularly, this invention relates to compounds represented by the following formula I ##STR3## and pharmaceutically acceptable salts or pharmaceutically acceptable esters thereof,
wherein
X represents oxygen, ##STR4## or sulfur, wherein R is hydrogen, lower alkyl, acetate or methoxycarbonyl;
Y is cis, trans or mixtures thereof and is selected from hydroxy, lower alkoxy, aminocarbamoyloxy, methoxy-carbonylamino, lower alkyl carbonyloxy, lower alkylcarbonylamino and lower alkyl sulfonylamino; and the wavy lines indicate cis, trans or mixtures thereof.
As used herein, "lower alkyl" when used alone or in combination with another moiety means straight and branched chain alkyl groups having from 1 to 6 carbon atoms, e.g. methyl, ethyl, n-propyl, iso-propyl, butyl, t-butyl, pentyl, hexyl and the like.
The heterocyclic radicals at the 2-position include for examples, tetrahydro-3-hydroxy-4-furanyl, 3-hydroxy-4-pyrrolidinyl, tetrahydro-3-amino-4-furanyl, tetrahydro-3-methoxycarbonylamino-4-furanyl, tetrahydro-3-acetoxy-4-furanyl, tetrahydro-3-methoxy-4-furanyl, tetrahydro-3-carbamoyloxy-4-furanyl, 1-acetyl-3-hydroxy-4-pyrrolidinyl, tetrahydro-3-hydroxy-1,1-dioxothiophene-4-yl, and the like.
"Pharmaceutically acceptable salts" as used herein means alkali metal salts such as sodium and potassium salts; alkaline earth metal salts such as calcium, magnesium and aluminum salts; amine salts formed from a wide variety of suitable organic amines, i.e., aliphatic, cycloaliphatic, (cycloaliphatic)aliphatic or araliphatic primary, secondary or tertiary mono-, di- or polyamines, or heterocyclic bases, e.g., salts derived from triethylamine, 2-hydroxyethylamine, di-(2-hydroxyethyl)amine, tri-(2-hydroxyethyl)amine, 4-aminobenzoic acid-2-diethylaminoethyl ester, 1-ethylpiperidine, bicyclohexylamine, N,N'-dibenzylethylenediamine, pyridine, collidine, quinoline, procaine, dibenzylamine, 1-ephenamine and N-alkylpiperdine. Acid addition salts formed from mineral acids such as hydrochloric, hydrobromic, hydroiodic, phosphoric or sulfuric acids, or formed from organic carboxylic or sulfonic acids such as trifluoroacetic, para-toluene sulfonic, maleic, acetic, citric, oxalic, succinic, benzoic, tartaric, fumaric, mandelic, ascorbic acid and malic acids. The compounds of this invention which contain a 3-carboxylic group and a basic group (the nitrogen containing heterocyclic group) form an inner salt, i.e., a Zwitterion.
"Pharmaceutically acceptable esters" means physiologically cleavable esters, i.e., metabolizable esters known in the penicillin, cephalosporin and penem arts to be easily cleaved within the body to the parent acid. Examples of such esters are indanyl, phthalidyl, methoxymethyl, glycyloxymethyl, phenylglycyloxymethyl, thienylglycyloxymethyl, acetoxymethyl and pivaloyloxymethyl.
Preparation of the foregoing salts and esters may be carried out according to conventional procedures for forming salts of beta-lactams such as penicillins, cephalosporins and penems. Salts can be formed, for example, by treating with metal compounds such as alkali metal salts of suitable carboxylic acids, or with ammonia or a suitable organic amine, wherein preferably stoichiometric amounts or only a small-excess of the salt-forming agent is used. Acid addition salts are obtained in the usual manner, for example, by treating with an acid or a suitable anion exchange reagent. Inner salts of the compounds of formula I, i.e., a Zwitterion, may be formed by neutralizing salts such as acid addition salts to the isoelectric point. The esters are preparable in a manner analogous to the preparation of the corresponding esters of penicillins and cephalosporins.
Salts may be converted in the usual manner into the free carboxy compounds.
"Inert organic solvent" means an organic solvent which is unreactive at the reaction conditions, typical suitable solvents used in the processes for making compounds of formula I are tetrahydrofuran (THF), methylene chloride, diethylether, dimethylformamide (DMF), a lower alkanol such as methanol, pyridine, acetonitrile and the like.
The compounds of this invention possess 3 or more asymmetric carbon atoms indicated in formula Ia below at the 5, 6, and 8 and the 3' and 4' position carbon atoms on the heterocylic substituent. ##STR5## wherein X is ##STR6## and Y is as defined in formula I.
The absolute stereochemistry at the 5, 6 and 8 positions for the compounds of this invention is 5R, 6S, 8R and at the 3' and 4' positions the cis compounds, i.e. 3'R, 4'S and 3'S, 4'R or the trans compounds, i.e. the 3'S, 4'S and 3'R, 4'R stereoisomers.
DETAILED DESCRIPTION
When tested in standardized microbiological assays, the compounds of this invention are active against such gram-positive organisms as Staphylococcus epidermis and Bacillus subtilis, and such gram-negative organisms as E. coli and Salmonella at test levels of 0.06 to 1.0 micrograms/ml. Additionally, they show activity against organisms which produce beta-lactamases, e.g. penicillinase and cephalosporinase, indicating a resistance to these enzymes.
The compounds of this invention also display good serum half-lives, e.g. up to approximately 7 minutes in mice tests, and they also exhibit low protein binding. Their metabolites have little or no unpleasant odor.
The compounds of this invention are useful for treating warm-blooded animals (including humans) having a susceptible bacterial infection. The compounds can be administered orally, parenterally, transdermally and topically. In addition, the compounds can be used to sterilize materials which are contaminated by susceptible bacteria, e.g. medical and dental instruments. Thus, this invention includes within its scope pharmaceutical compositions comprising the compounds of this invention in admixture with a pharmaceutically acceptable carrier therefor. In addition, the present invention also provides a method of treating bacterial infections in animals, particularly warm-blooded animals including humans, having a susceptible bacterial infection which comprises administering to said animal an antibacterial effective amount of a compound of this invention, or a pharmaceutical composition thereof. In the foregoing compositions, the compounds of this invention can be used as the sole active antibacterial agent or in combination with other antibacterial agents and/or enzyme inhibitors.
For oral administration, the compounds of this invention are typically formulated in the form of tablets, capsules, elixirs, or the like. For parenteral administration, they may be formulated into solutions or suspensions. Typical topical formulations are those such as lotions, creams, ointments, sprays, and mechanical delivery devices, e.g., transdermal.
Typical pharmaceutically acceptable carriers for use in the formulations described above are exemplified by: sugars such as lactose, sucrose, mannitol and sorbitol; starches such as corn starch, tapioca starch and potato starch; cellulose and derivatives such as sodium carboxymethyl cellulose, ethyl cellulose and methyl cellulose; calcium phosphates such as dicalcium phosphate and tri-calcium phosphate; sodium sulfate; calcium sulfate; polyvinyl pyrrolidone; polyvinyl alcohol; stearic acid; alkaline earth metal stearates such as magnesium stearate; vegetable oils such as peanut oil, cottonseed oil, sesame oil, olive oil and corn oil; non-ionic, cationic and anionic surfactants; ethylene glycol polymers; betacyclodextrin; fatty alcohols, hydrolyzed cereal solids; water; polyalkylene glycols; gums; and petroleum; as well as other non-toxic compatible fillers, binders, disintegrants and lubricants commonly used in pharmaceutical formulations. The compositions may also contain preservatives, aerosol propellants and coloring, thickening, suspending, dispensing, emulsifying, wetting, stabilizing and buffering agents.
The dosage of the compounds of this invention which is administered is dependent, in the judgment of the attending clinician, upon a variety of factors, i.e., the age and weight of the individual being treated, the mode of administration, the potency of the administered compound and the type and severity of the bacterial infection being prevented or reduced. Typically, the dosage administered per day will be in the range of from about 25 to 160 mg/kg and preferably from about 50 to 100 mg/kg in divided dosages. Typically, the dosage will be administered in dosage units containing convenient amounts, for example, 0.05, 0.100, 0.250, 0.500, 1 or 2 gms of active ingredient combined with a suitable pharmaceutically acceptable carrier or diluent.
The cis and trans stereoisomers or racemates of the compounds of Formula I can be prepared according to the reaction schemes which follow. The process used is dictated by the stereoisomer desired and the heterocyclyl substituent on the 2-position of the penem.
The preferred preparation of the trans stereoisomer wherein the substituent is a tetrahydrofuran is shown in the following Reaction Scheme I.
SCHEME I ##STR7##
In Step IA, the reaction of 2,5 dihydrofuran and N-bromosuccinimide (NBS) is carried out in an aqueous mixture of an inert organic solvent and water at from about 20° C. to 30° C., preferably room temperature. A preferred solvent is tetrahydrofuran (THF) although other solvents such as diethylether and dimethoxyethane (DME) are also suitable. The product, compound 2, is then recovered by distillation after working up the reaction mixture with Na 2 SO 3 to quench excess NBS, separating the organic and aqueous layers and filtering off precipitated succinimide or N-hydroxysuccinimide.
In Step IB the bromohydrin from step IA is epoxidized by reacting with an aqueous base in an inert organic solvent for about an hour at room temperature. Preferred bases are aqueous potassium or sodium hydroxides. Preferred inert organic solvents are methylene chloride or diethyl ether.
In Step IC, the epoxide produced in step IB is converted to trans 3-triphenylmethanethio-4-hydroxytetrahydrofuran by reaction with the compound produced by the reaction of sodium hydride, and triphenylmethanethiol in an inert, organic solvent at cold temperatures in an inert atmosphere. The preferred inert organic solvent is dimethylformamide (DMF), the preferred inert atmosphere is nitrogen and the preferred temperature is about -10° C. to 5° C., most preferably 0° C.
The epoxide is reacted with the above reaction product in the same solvent, under an inert atmosphere, e.g. nitrogen, at a temperature of about 20° C. to 30° C., preferably room temperature, until the reaction is complete, e.g. about one hour, Compound 4 is then recovered.
In Step ID, compound 4 in a dry inert organic solvent such as a lower alkanol, e.g. methanol substantially free of water, is reacted with silver nitrate in the same inert organic solvent containing an organic base, e.g., triethylamine or pyridine. This causes the silver salt of compound 5 to precipitate. The reaction is conducted at room temperature for about 30 minutes.
The precipitate is recovered and suspended in a suitable inert organic solvent, e.g. acetonitrile, and treated with hydrogen sulfide gas for about 10-15 minutes to remove the silver as silver sulfide. Compound 5, in solution, is then recovered and used in the subsequent reaction with compound 6 without further purification. Although compound 5 can be isolated, it is not necessary when using it to produce penems.
In Step IE, compound 5 in the solution recovered in Step ID is reacted with compound 6 in the presence of aqueous sodium bicarbonate until the reaction is complete, usually about 30 minutes to yield compounds 7 and 8, one as a precipitate and the other as an oil. Compound 6 is prepared by known methods, e.g. as described in European Patent Application No. 0046363, published Feb. 24, 1982, pages 13, 14 and 15.
The allyl protecting group of compounds 7 and 8 are removed by known methods, e.g. as described in U.S. Pat. No. 4,314,942 wherein 2-ethylhexanoic acid or an alkali metal salt thereof and a catalytic amount of an organic soluble palladium complex effects removal of the protecting group. The resulting products 7a and 8a respectively are produced. For purposes of this invention it is preferred to use the sodium salt of 2-ethylhexanoic acid and palladium acetate in Steps IF and IG. The resulting penem products are the sodium salts which can be converted to the corresponding acid by conventional means.
The preferred preparation of the cis stereoisomer wherein the R 1 substituent is a tetrahydrofuran is shown in the following Reaction Scheme II.
SCHEME II ##STR8##
In Step IIA, compound 4 is reacted with the reactive intermediate generated from the addition of dimethylsulfoxide (DMSO) to a cold (-50° C.) solution of oxalyl chloride in an inert organic solvent, e.g. methylene chloride. When the reaction mixture warms to about -35° C., a trisubstituted organic base, e.g., triethylamine, is added in the same inert organic solvent. After the reaction is complete the solvent is removed and the product, compound 9, is recovered.
In Step IIB, the oxo group of compound 9 is reduced to the hydroxy group by reaction with lithium tri secondary butyl borohydride in an inert atmosphere, preferably nitrogen. After completion of the reaction, the product, the cis isomer (compound 10), is recovered.
In Step IIC, compound 10 in a lower alkanol solvent, e.g. methanol, is treated with silver nitrate and pyridine in the same solvent to precipitate silver-(3-hydroxy)-tetrahydrofuran-4-thiolate. After removing the solvent the silver thiolate suspended in an inert organic solvent, e.g. acetonitrile, is treated with anhydrous hydrogen sulfide gas. When the resulting black silver sulfide ceases precipitating the reaction is complete. Compound 11 is then recovered and dissolved in an inert organic solvent, e.g. acetonitrile, for use in the next step of the process.
In Step IID, compound 6 in the same inert organic solvent used in the last part of Step IIC, is added to a cold, i.e. -10° C. to +5° C., aqueous solution of sodium bicarbonate and compound 11 in the same inert organic solvent. The reaction is conducted under an inert atmosphere, e.g. nitrogen, for about 1/2 hour to obtain a mixture of compounds 12 and 13 which mixture is separated into the isomers by crystallization from ethyl acetate. The first crop of crystals is one diastereomer and the second crop is the other diastereomer. The mother liquor also contains the second diastereomer.
In Step IIE, the allyl protecting groups are removed from compounds 12 and 13 by the method of U.S. Pat. No. 4,314,942, i.e. treatment with palladium acetate, triisopropyl phosphite and sodium-2-ethyl hexanoate, to obtain from compounds 12 and 13, respectively, compounds 14 and 15.
The process of Reaction Scheme II is also suitable for producing compounds of formula I wherein X is ##STR9## This is accomplished by using appropriately substituted pyrrolidines in place of tetrahydrofuran in the reaction.
The preferred preparation of the trans stereoisomer wherein the heterocyclyl substituent of formula I is an amino substituted tetrahydrofuran is shown in the following Reaction Scheme III.
SCHEME III ##STR10##
In Step IIIA, compound 1 is converted to compound 16 by means known in the art, i.e. by the procedure disclosed in Hassner et al., J. Org. Chem. 32, 540 (1967). Hassner et al. involves reacting compound 1 in an inert organic solvent, e.g. tetrahydrofuran (THF), with a suspension of silver cyanate in THF which has been previously treated with iodine under an inert atmosphere, e.g. nitrogen, at a cold temperature, i.e. about -20° C. to 0° C., preferably about -10° C. After removing the silver salts and warming to room temperature (about 25° C.), compound 17 is obtained. It is not isolated but is used in situ in the next step of the process.
In Step IIIB, allyl alcohol or a lower alkanol is added to the reaction mixture resulting from step IIIA and allowed to react at room temperature in the dark under an inert atmosphere until the reaction is complete. The product, compound 18, is then recovered.
In Step IIIC, compound 18 in an inert organic solvent, e.g. DMF, is reacted with sodium hydride suspended in the same solvent under an inert atmosphere, e.g. nitrogen, at about -10° C. to 5° C., preferably about 0° C., until the reaction is complete as evidenced by thin layer chromatography (TLC) of the reaction mixture. The product, compound 19, is recovered.
In Step IIID, compound 19 is converted to compound 20 by reaction with sodium triphenylmethylthiolate in an inert organic solvent, e.g. DMF, under an inert atmosphere, e.g. nitrogen, until the reaction is complete, about 2 to 3 hours, and the product, compound 20, is recovered.
In Step IIIE, compound 20 is converted to compound 21 by reaction with silver nitrate in an alkanolic solvent, e.g., methanol containing an organic base, e.g., triethylamine or pyridine. The silver is removed by reacting the resulting silver salt with hydrogen sulfide gas in acetonitrile. The product, compound 21, which results is concentrated to remove excess H 2 S gas and used in the next step without further purification.
In Step IIIF, compound 21, in the solvent from Step IIIE, is reacted with compound 6 under the conditions illustrated in Reaction Schemes I and II, Steps IE and IID, respectively, to produce compounds 22a and 22b as a mixture of side chain trans diastereoisomers.
In Step IIIG, the allyl protecting group is removed from the carboxyl at position 3 of compounds 22a and, 22b and, if that protecting group is present at position 3' of the side chain, by reaction with palladium acetate and triisopropylphosphite followed by 2-ethyl hexanoic acid to yield a mixture of compounds 23a and 23b.
The preferred preparation of the side chain cis stereoisomer wherein the heterocyclyl substituent of formula I is an amino substituted tetrahydrofuran is shown in the following Reaction Scheme IV.
SCHEME IV ##STR11##
In Step IVA, compound 18 (prepared as shown in Reaction Scheme III) is converted to compound 24 by reaction with sodium tritylthiolate, e.g., the compound produced when reacting sodium hydride with triphenylmethylthiol in an inert organic solvent at cold temperatures in an inert atmosphere as described in Step IC of Reaction Scheme I.
In Step IVB, compound 24 is reacted with silver nitrate in pyridine followed by H 2 S under conditions as described in Reaction Scheme II, Step IIC, to yield compound 25 which is not isolated but remains in the reaction mixture for use in the next step of the process.
In Step IVC, compound 6 is added to a cold aqueous solution of sodium bicarbonate and compound 25 under conditions described for Reaction Scheme II, Step IID, to yield a mixture of cis side chain stereoisomers, compounds 26a and 26b.
In Step IVD, compounds 26a and 26b are deprotected by removing the allyl groups at the carboxyl and amino substituents as described for Reaction Scheme III Step G, to yield a mixture of cis side chain stereoisomers, compounds 27a and 27b.
The preferred preparation of the side chain trans stereoisomers wherein the R 1 2-heterocyclic substituent of formula I is an hydroxy substituted pyrrolidine is shown in the following Reaction Scheme V.
SCHEME V ##STR12##
In Step VA, the nitrogen on the pyrrole (compound 28) is protected with an acyl protecting group, e.g. allyloxycarbonyl, by reaction with a compound of the formula Z-L wherein Z is an acyl group, e.g. allyloxycarbonyl, acetyloxycarbonyl or benzyloxycarbonyl and L is a leaving group such as a halogen, e.g., iodine, or a mixed anhydride, e.g., trimethylacetyloxy, to yield compound 29.
Compound 31 is prepared by either converting compound 29 directly to compound 31 by reaction with meta chloroperbenzoic acid as illustrated in Step VB or by converting compound 29 to the bromohydrin (compound 30) by reaction with hypobromous acid in aqueous THF as illustrated in Step VC, then epoxidizing in a basic medium, e.g. 50% KOH in methylene chloride to yield compound 31, as illustrated in Step VD. The use of Steps VC and VD is the preferred route because it results in higher yields and is more widely applicable, whereas in Step VB when Z is allyloxycarbonyl the resulting product contains significant amounts of a diepoxide side product which must be separated.
In Step VE, compound 31 is converted to compound 32 by reaction with sodium triphenylmethylthiolate in an inert organic solvent, e.g. DMF, under an inert atmosphere, e.g. nitrogen, until the reaction is complete.
In Step VF, compound 32 is converted to compound 33 by reaction with silver nitrate in pyridine under conditions as described in Reaction Scheme III Step IIIE.
In Step VG, compound 33 is reacted with compound 6 in the presence of acetonitrile and aqueous NaHCO 3 to yield a mixture of compound 34a and 34b.
The protecting allyl groups are removed from the carboxyl, and the nitrogen, if present, as shown in Step VH by reaction with palladium acetate and triisopropylphosphite followed by 2-ethyl hexanoic acid to yield a mixture of compounds 35a and 35b.
In cases where the group on the nitrogen is not allyloxycarbonyl, the substituent remains and only the allyl on the carboxyl group is removed leaving a hydrogen.
The following illustrates the preparation of compounds and compositions of this invention.
EXAMPLE 1
d,l-trans-3-bromo-4-hydroxytetrahydrofuran
To a solution of 2,5-dihydrofuran (10.0 gm) in THF/H 2 O (175 mL THF, 20 ml H 2 O) add N-bromo succinimide (26.5 gm). Keep the reaction mixture at room temperature overnight. Then add 50 mL of 10% Na 2 SO 3 and stir the mixture for 1/2 hr. Separate the layers by addition of 50 mL water and 50 mL brine. Extract the aqueous layer with ethyl acetate (EtOAc) (3×75 mL). Combine the organic layers, wash with brine (1×100 mL), dry (MgSO 4 ) and remove the solvent by vacuum distillation. Remove precipitated succinimide by filtration (washed with Et 2 O) and distill the product under vacuum (90° C., 10 mmHg) yielding pure title compound. + H'NMR (CDCl 3 ): δ 3.2-4.7 (δ, multiplet, D 2 O exchange removes absorption at δ 3.5)
EXAMPLE 2
2,5-dihydrofuranoxide
Dissolve the bromohydrin from Example 1 (6.485 g) in 60 mL diethylether (Et 2 O) and add 10.5 mL of 50% NaOH (aq). Stir the resulting biphasic mixture rapidly at room temperature for 1 hr. to separate the Layers and extract the aqueous phase with diethylether (Et 2 O) (1×40 mL). Combine the ether layers and extract with brine (15 mL), dry (MgSO 4 ) and remove the ether by distillation at atmospheric pressure to yield the title compound:
H'NMR (CDCl 3 ): δ 4.03 (d, 2, J=10 H z ), 3.76 (s, 2), 3.61 (d, 2, J=10 H z ).
EXAMPLE 3
d,l-trans-3-triphenylmethylthio-4-hydroxytetrahydrofuran
To a suspension of sodium hydride (0.18 gm) in DMF (15 mL) add a solution of triphenylmethylthiol (2.07 gm in 5 mL DMF). Cool the mixture to 0° C. and allow to stir for 1/2 hr. under N 2 atmosphere. Add a solution of the epoxide from Example 2 (0.624 g in 2 mL DMF) and continue stirring for an additional hour at room temperature. Add Water (20 mL) and extract the mixture with ethylacetate (EtOAc) (2×25 mL). Wash the organic layer with brine (1×20 mL), dry (MgSO 4 ) and remove the solvent under vacuum. Purify the title compound by silica gel chromatography (10% acetone/CH 2 Cl 2 ) to yield pure title compound.
H'NMR (CDCl 3 )
EXAMPLE 4
d,l-trans-3-mercapto-4-hydroxytetrahydrofuran
To a solution of the alcohol from Example 3 (4.21 gm) in dry methanol (50 mL) add a solution of silver nitrate (1.98 gm) in 15 mL of methanol:pyridine (15:1). The solution becomes cloudy and precipitation of the silver salt of the title compound occurs over the course of 5-10 min. After 30 min., remove methanol by vacuum distillation and keep the residue under high vacuum for 1 hr. Suspend the resulting gummy residue in acetonitrile (50 mL) and bubble H 2 S gas through the mixture with stirring for 5-10 min. until all of the gummy silver salt reacts leaving a colorless solution of the title compound and a black precipitate of silver sulfide. Bubble nitrogen gas through the reaction mixture for 1 hr. to remove hydrogen sulfide gas. Remove the silver sulfide by filtration through Celite. Reduce the volume of solvent to 30 mL by vacuum distillation and use the resulting solution of the title compound in the following step without further purification.
EXAMPLE 5
allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[tetrahydro-3'S-hydroxy-4'S-furanyl)thio]-penem-3-carboxylate and allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(tetrahydro-3'R-hydroxy-4'R-furanyl)thio]-penem-3-carboxylate)
To the solution prepared in Example 4 (in acetonitrile) add a solution of NaHCO 3 (2.5 gms) in 25 mL of water followed by 1.94 gm of the penem sulfoxide identified as compound 6 in Reaction Scheme I in 10 mL of acetonitrile. After 30 min. the reaction is complete. Partition the mixture between ethylacetate (50 mL) and water (50 mL). Dry the organic layer (MgSO 4 ) and concentrate to a volume of about 25 mL by vacuum distillation. Precipitation of one of the title diastereoisomers occurs during this step, collect the precipitate by filtration. Wash the filtrate with cold ethylacetate and dry the crystalline material under vacuum to yield one diastereoisomer. Concentrate the combined filtrates to yield a second crop of crystals and treat in the same manner as the first crop. Concentrate the filtrate to an oil and purify by silica gel chromatography (15% acetone/CH 2 Cl 2 ) to give a second pure diastereoisomer.
H'NMR of the first diastereoisomer (CDCl 3 ): δ 6.2-5.7 (m, 1H), 5.79 (d, 1H, J=2 H z ), 5.48 (m, 1H), 5.25 (m, 1H), 4.80 (d, 1H, J=5 Hz), 4.60 (m, 2H), 4.4-3.4 (complex multiplet, 10H), 2.8 (singlet, 1H, exchangeable with D 2 O), 1.22 (d, 3H, J=6 Hz).
The following trans compounds of this invention can be made following the procedures of Examples 1-5, but after Example 3 the hydroxy group is derivatized as shown in Table I: ##STR13##
TABLE 1__________________________________________________________________________Starting Compound Reaction Product__________________________________________________________________________ acetylchloride inert organic solvent triethylamine ##STR14## ##STR15## CH.sub.3 I inert organic solvent organic ##STR16## ##STR17## sodium isocynate strong organic acid, e.g., trifluoroacetic acid ##STR18##__________________________________________________________________________
Then the procedures of Examples 4 and 5 are followed.
EXAMPLE 6
3-keto-4-tritylthiotetrahydrofuran
Cool a solution of oxalyl chloride (1 mL) in 20 mL CH 2 Cl 2 to -50° C. Add a solution of DMSO (1.38 mL) in 20 mL CH 2 Cl 2 over the course of 2-3 min. via a pressure equialized addition funnel. Keep the temperature below -40° C. and stir for 10 min., then add a solution of the alcohol prepared in Example 3 in 15 mL CH 2 Cl 2 and remove from the ice bath. Allow to warm to -35° C. and add a solution of triethylamine in 20 mL CH 2 Cl 2 . The mixture will warm to about +10° C. then add 20 mL 10% aq. tartaric acid, stir for 5 min., add 20 mL of brine, 50 mL of water and extract organic layer. Wash CH 2 Cl 2 layer with water (1×100 mL) and dry (MgSo 4 ). Remove the solvent via vacuum distillation and purify the product by silica gel chromatography (100% CH 2 Cl 2 ) to obtain the title compound.
H'NMR (CDCl 3 ): δ 3.1-4.1 (m, 5H), δ 6.9-7.7 (m, 15H).
EXAMPLE 7
d,l-cis-3-tritylthio-4-hydroxytetrahydrofuran
To a solution of purified ketone prepared in Example 6 (1.54 gms) in 15 mL of dry THF, cooled to -10° C., add 5.13 mL of 1M L-selectride (Aldrich Chemical Co.) via syringe and allow the reaction to proceed for 1 hr. at ambient temperature under N 2 atmosphere. Quench the reaction with 5 mL 10% NaOH (aq) and allow to react for 30 min. Partition the reaction mixture between ethylacetate (30 mL) and water (30 mL). Wash the organic layer with 5% tartaric acid (aq) and dry (MgSO 4 ). Remove the solvent by vacuum distillation and purify on silica gel (5%) Et 2 O/hexane→7% Et 2 O/hexane) to obtain the title compound as a pure cis isomer.
H'NMR (CDCl 3 ): δ 2.75-3.2 (m, 2H), δ 3.35-3.70 (m, 1H), 3.71 (d, 1H), J=1.5 Hz) 4.00 (sextet, 2H, J=4 Hz), 7.0-7.76 (m, 15H).
EXAMPLE 8
allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(tetrahydro-3'S-hydroxy-4'R-furanyl)thio]-penem-3-carboxylate and allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(tetrahydro-3'R)-hydroxy-4'S-furanyl)thio]-penem-3-carboxylate)
Dissolve the s-trityl alcohol from Example 7 (3.21 g) in methanol and add a solution of silver nitrate (1.5 gm) and pyridine (0.80 mL) in methanol (10 mL). Silver-(3-hydroxy)tetrahydrofuran-4-thiolate precipitates from solution as a gum. Decant methanol when the reaction is complete (15 min.), and place the reaction flask under high vacuum for 1 hour. Then suspend the silver thiolate in acetonitrine (50 mL) and bubble anhydrous hydrogen sulfide gas through the reaction mixture until precipitation of black silver sulfide ceases (1-2 min.). Remove the silver salts by filtration through celite and remove the solvent by distillation (atmospheric). Redissolve the residue (3-hydroxy-4-mercapto-tetrahydrofuran) in fresh acetonitrile. Add an aqueous solution of sodium bicarbonate (2.9 gm in 50 mL water) to the cold (0° C.) acetonitrile solution of 3-hydroxy-4-mercapto-tetrahydrofuran followed by addition of the penem sulfoxide (compound 6) (1.5 gm) in acetonitrile (10 mL). The reaction is complete after 30 min. of rapid stirring under an atmosphere of nitrogen. Partition the biphasic mixture between ethylacetate and water (50 mL each) and dry the organic phase (MgSO 4 ). Remove the solvent by vacuum distillation then recrystallize from ethyl acetate to give 2 crops of penem allyl ester. The first crop (1.3 gms) consist of a single diastereoisomer. The second crop and the mother liquor are predominantly the other possible diastereoisomer.
MS, M/z=373
EXAMPLE 9
Sodium-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(cis-tetrahydro-3'-hydroxy-4'-furanyl)thio]-penem-3-carboxylate
To dry, oxygen free tetrahydrofuran (20 mL) add palladium acetate (0.0162 gm), followed by triisopropyl phosphite (0.150 gms) and then sodium-2-ethylhexanoate (0.240 gms). Finally add the mixture of penem allyl esters made in Example 8 and stir the reaction under nitrogen for 1 hour. Collect the resulting precipitate by centrifugation, wash the residue several times with ethyl acetate and ether, and then dry under vacuum to give a mixture of title compounds wherein the side chains are cis diastereoisomers.
The following cis compounds of this invention can be made following the procedures of Examples 6-9, but after Example 7 the hydroxy group is derivatized as shown in Table 2: ##STR19##
EXAMPLE 9
TABLE 2__________________________________________________________________________Starting Compound Reaction Product__________________________________________________________________________ ##STR20## acetylchloride inert organic solvent triethylamine ##STR21## ##STR22## CH.sub.3 I inert organic solvent organic ##STR23## ##STR24## sodium isocynate strong organic acid, e.g., trifluoroacetic acid ##STR25##__________________________________________________________________________
Then the procedures of Examples 8 and 9 are followed.
EXAMPLE 10
trans-3-isocyanato-4-iodo-tetrahydrofuran and trans-3-allyloxycarbonylamino-4-iodo-tetrahydrofuran
Prepare the trans iodo isocyanate title compound in situ according to the procedure of Hassner et al. J. Org. Chem. 32, 540, (1967), and then transform to the title allyloxycarbonyl compound without isolation or purification:
To a cold (-10° C.) suspension of silver cyanate (6.07 gms) in dry THF (50 mL) add I 2 (8.5 gms) and stir the mixture vigorously under N 2 for 1 hr. Then add 2,5 dihydrofuran (2.27 mL, 2.1 gms) in 10 mL THF. Remove the mixture from the cold bath and stir at room temperature for 30 min. Remove the silver salts by filtration through Celite and keep the reaction mixture at room temperature in the dark overnight. Then add allyl alcohol (25 mL) along with 2 drops of 1M lithium methoxide/methanol and keep the mixture at room temperature overnight in the dark under nitrogen. Then partition the mixture between ethylacetate and brine (50 mL each). Wash the organic layer several times with water (25 mL), dry (MgSO 4 ) and concentrate to an oil (house-high vacuum). Chromatography on silica gel (100% CH 2 Cl 2 →10% EtOAc/CH 2 Cl 2 ) affords the title compound.
H'NMR (CDCl 3 ): δ 3.6-4.8 (m, 8H), δ 5.15-5.5 (m, 2H), 5.6-6.2 (m, 24), MS (EI), M/z, 297 (M + ).
EXAMPLE 11
6-allyoxycarbonyl-3-oxa-6-azabicyclo[3.1.0]hexane
Dissolve the iodo carbamate made in Example 10 (1.21 gms) in DMF (15 mL) and cool to 0° C. Add a suspension of sodium hydride (115 mgs) in DMF and the stir reaction mixture under N 2 for 1.5 hrs. TLC of the reaction mixture (15% EtOAc/CH 2 Cl 2 ) showed complete conversion to a new compound of slightly higher rf. Carefully treat the mixture with dilute ammonium chloride (20 mL) and extract the product into ether (3×30 mL). Wash the organic layer was washed with brine (1×20 mL), dry (MgSO 4 ) and remove the solvent under vacuum to give the title compound.
M + /z: 169 H'NMR (CDCl 3 ): δ 3.15 (s, 2H), 3.55 (d, 2H, J=6 Hz) 4.15 (d, 2H J=6 Hz), 4.52 (d, 2H, J=4 Hz), 5.1-5.45 (m, 2H), 5.61-6.15 (M, 1H).
EXAMPLE 12
d,l-trans-3-triphenylmethylthio-4-allyloxycarbonylaminotetrahydrofuran
To a solution of triphenylmethylthiol (3.0 gms) in dMF (50 mL) add a suspension of NaH (270 mgs) in DMF (2 mL). Stir the mixture rapidly under nitrogen for two hours or until bubbling ceases. Add the resulting clear brown solution of the sodium thiolate to a solution of 1.4 gms of the aziridine made in Example 11 in 15 mL of DMF and allow the reaction to proceed with stirring under nitrogen for 2.5 hours. Then dilute the reaction mixture with 50 mL of dilute aqueous ammonium chloride and brine (50 mL). Extract the resulting product into ether (3×75 mL), dry (MgSO 4 ) and remove the solvent under vacuum. Chromatography on silica gel (100% CH 2 Cl 2 ) gives the title compound as a crystalline product.
MS, M + /z=445 H'NMR (CDCl 3 ): δ 3.0-3.95 (m, 6H), 3.9-4.4 (m, 2H), 4.45-4.71 (d, 2H, J=4 Hz), 5.0-5.5 (m, 3H), 5.6-6.2 (m, 1H), 7.1-7.6 (m, 15H).
EXAMPLE 13
d,l-trans-3-mercapto-4-(N-allyloxycarbonyl)aminotetrahydrofuran
Dissolve the triphenylmethylsulfide made in Example 12 (1.24 g) in MeOH (15 mL) and silver nitrate (493 mgs) and add 250 μl of pyridine dissolved in 5 ml of methanol. The silver mercaptide is quite soluble in methanol so remove the solvent under high vacuum and redissolve in acetonitrile (25 mL). Bubble hydrogen sulfide gas through the solution to immediately form silver sulfide (Ag 2 S). Remove the solids by filtration through Celite and concentrate the filtrate under vacuum in order to remove dissolved excess H 2 S. Use the resulting concentrated title compound in the following step without further purification.
EXAMPLE 14
allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(trans-tetrahydro-3'-(N-allyloxycarbonyl)amino-4'-furanyl)thio]-penem-3-carboxylate
Add a solution of 4-(N-allyloxycarbonyl)amino-3-mercapto-tetrahydrofuran made in Example 13 (2.78 mmoles) in acetonitrile (10 mL) to a solution containing sodium bicarbonate (250 mgs) acetonitrile (3 mL) and water (1.5 mL). Add to this biphasic mixture 450 mg of penem sulfoxide (compound 6) in 5 ml acetonitrile. Stir the biphasic mixture rapidly at room temperature for 15 min., dilute with brine (20 mL) and extract the product into ethylacetate (30 mL). Wash the organic layer with brine (2×20 mL) and dry (MgSO 4 ). Preparative TLC compound.
MS, M + /z=439.
EXAMPLE 15
(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(trans-tetrahydro-3'-amino-4'-furanyl)thio]-penem-3-carboxylic acid
To dry, oxygen free THF (10 mL), add palladium acetate (17.5 mgs) followed by triisopropylphosphite (154 mgs) in 2 mL THF and then 2-ethylhexanoic acid (163 mgs) and the penem allyl ester made in Example 14 (222.7 mgs) in 2 mL of THF. Stir the reaction under nitrogen for one hour. Add diethylether (25 mL) and collect the precipitate by centrifugation. Decant the solvent and wash the residue several times with diethylether and ethylacetate. Dry the residue under vacuum to give the title compound.
The following trans compounds of this invention can be made following the procedures of Examples 10-15, but in Example 10, a lower alkoxide is used in place of allyl alcohol, as shown in Table 3, then Examples 11, 12, 13, 14 and 15 are followed for compounds 7 and 8 and Examples 12, 13, 14 and 15 are followed for compound 9: ##STR26##
TABLE 3______________________________________Starting Compound Reaction Product______________________________________ ##STR27## + lower alkoxide +##STR28## ##STR29####STR30## (1) H.sup.+ (2) OH.sup.- acetyl chloride ##STR31##______________________________________ [Hassner et al J. Org. Chem. 32 540 (1967)]-
EXAMPLE 16
N-allyloxycarbonyl-3-pyrroline
To a solution of 3-pyrroline (3.5 gms) in ethanol (20 mL) was added ˜25 mL saturated aq. NaHCO 3 and enough water to allow rapid stirring. The mixture was cooled to 10° C. and allyl chloroformate (5.92 mL) was slowly added via pressure equalized addition funnel. The mixture was removed from ice bath and allowed to stir at room temperature for 2 hours. Product was extracted into Et 2 O (3×150 mL). The organic phase was washed with water (2×50 mL), dried (MgSO 4 ) and solvent was evaporated at reduced pressure. Purification on silica (Et 2 O) afforded pure title compound.
MS, M+/z=154, H NMR (CDCl 3 ): δ 6.5-5.75 (m, 1H), δ 5.8 (s, 2H), 5.02-5.5 (m, 2H), 4.6 (dm, 2H, J=6.5 Hz), 4.20 (s, 4H).
EXAMPLE 17
N-allyloxycarbonyl-trans-3-bromo-4-hydroxypyrroline and N-allyloxycarbonyl-3-pyrroline-3,4-oxide
To a cold (0° C.) solution of N-allyloxycarbonyl-3-pyrroline (9.7 gms) in 200 mL of 20% water in THF, was added 15.0 gms (1.15 eq.) of N-Bromosuccinimide. The mixture was removed from ice bath and allowed to stand at room temperature for ˜1 hour. Then water was added (100 mL) followed by the addition of 25 mL of 10% NaHSO 3 (aq.) and the resulting mixture was stirred at room temperature for 30 minutes. Finally, the pH was adjusted to 8.0-8.5 with 1M NaOH and stirring was continued for an additional 30 minutes. The product was extracted into EtOAc (2×200 mL) and the organic phase was washed with brine (1×100 mL), dried (MgSO 4 ) and solvent was evaporated under reduced pressure. Chromatography on silica gel (Et 2 O/Hexane, 7:3) afforded the title compound.
MS, M+/z=170, H'NMR (CDCl 3 ): δ 5.7-6.15 (m, 1H), 5.1-5.4 (m, 2H) 4.55 (d, 2H, J=3 Hz), 3.85 (dd, 2H, J=10, 2 Hz), 3.7 (s, 2H), 3.35 (d, 2H, J=10 Hz).
EXAMPLE 18
N-allyloxycarbonyl-trans-3-hydroxy-4-triphenylmethylthio pyrroline
The compound prepared in Example 17 (870 mgs) was dissolved in 2 mL of dry DMF and cooled in an ice bath. To this was added a solution of sodium triphenyl methy ("trityl") thiolate, prepared by reacting 1.42 gms of tritylthiol with 125 mgs of sodium hydride in 10 mL of dry DMF. The mixture was allowed to stir under a nitrogen atmosphere overnight. Water (25 mL) was cautiously added and product was extracted into ether (3×30 mL). The ether layer was washed with water (2×10 mL) and dried (MgSO 4 ). Evaporation of solvent under vacuum and chromatography on silica gel afforded the title compound.
MS, M+/z 445, H'NMR (CDCl 3 ): δ 7.8-7.1 (m, 15H), 5.9 (m, 1H), 5.2 (m, 2H), 4.5 (br.d, 2H, J=6 Hz), 3.0-3.8 (br.m, 5H), 2.75 (bm, 1H), 1.7 (brm, 1H, D 2 O exchanged).
EXAMPLE 19
N-allyloxycarbonyl-trans-3-hydroxy-4-mercapto pyrroline and allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(N-allyloxy-carbonyl-trans-3'-hydroxy-4'-pyrrolinyl)thio]-penem-3-carboxylate
To a solution of the compound prepared in Example 18 (660 mgs) in 6 mL of methanol, was added a solution of silver nitrate (250 mgs) in 6 mL of methanol and 150 mgs of pyridine. Precipitation of the organic silver salt occurred over 15 minutes and then solvent was decanted. The residue was washed several times with methanol and then dried under oil pump vacuum for several hours. A suspension of the silver salt in 7 mL of acetonitrile was treated with a solution of excess H 2 S in acetonitrile (25 mL). The precipitated silver sulfide was removed by filtration through celite and solvent was evaporated with warming (45° C.) under reduced pressure. The residue was redissolved in acetonitrile (10 mL) and penem sulfoxide (compound 6) (250 mgs) was added. The mixture was cooled in an ice bath with stirring before adding a solution of sodium bicarbonate (0.20 gms) in 7 mL of water. The mixture was stirred under nitrogen for 15 minutes. Brine was added (15 mL) and the product was extracted into ethylacetate (2×30 mL). The organic layer was dried (MgSO 4 ) and solvent was evaporated to give a yellowish oil. Purification by chromatography on silica gel (30% acetate, CH 2 Cl 2 ) gave the title compound.
MS, M+/z=456, H'NMR, (CDCl 3 ): 6.1-5.7 (m, 2H), 5.52-5.0 (m, 2H), 4.8-4.5 (m, 2H), 4.4-3.3 (m, 15H), 1.36 (d, 3H, J=7 Hz).
The following derivatized compounds of this invention can be made following the procedures of Examples 16-19, but after Example 18 the hydroxy group is derivatized as in Table I: ##STR32##
EXAMPLE 20
3-hydroxy-4-triphenylmethylthio sulfolane
To a solution of 3-hydroxy-4-chloro sulfolane (1.7 gms) in 20 mL of DMF, was added a solution of sodium trityl thiolate (3.0 gms) in 20 mL of DMF. The mixture was kept under a nitrogen atmosphere for two hours. The mixture was diluted with water (100 mL) and product was extracted into ether (2×75 mL). The ether layer was washed with water (2×50 mL), dried (MgSO 4 ) and solvent ws evaporated under vacuum. The residue was purified by silica gel chromatography (100% CH 2 Cl 2 ) and crystallized from ether/hexane to give the title compound as a solid.
MS, M+/z=378, H'NMR (DMSO-d 6 ): 7.6-7.1 (m, 15H), 6.1 (d, 1H, J=6 HZ), 4.20 (m, 1H), 3.5-2.3 (br.m, 4H), 2.1 (dd, 1H, J=15, 10 Hz).
EXAMPLE 21
allyl-(5R,6S,8R)-6-(1-hydroxyethyl)-2-[(3'-hydroxy-4'-sulfolanyl)thio]-penem-3-carboxylate
To a solution of the 3-hydroxy-4-tritylthio sulfolane (1.0 gm) (in methanol (15 mL) was added a solution of silver nitrate (0.5 gms) and pyridine (0.25 mL) in 5 mL of methanol. Precipitation of the organic silver salt occurred immediately and after 15 minutes the solvent was decanted and discarded. The residue was washed with methanol (2×10 mL), and dried under vacuum (oil pump) for several hours. The residue was resuspended in acetonitrile (10 mL), a solution of excess H 2 S in acetonitrile (25 mL). The mixture was stirred rapidly for 30 minutes under a nitrogen atmosphere and the black silver sulfide precipitate was removed by filtration through celite. Solvent was evaporated under reduced pressure and the residue was redissolved in acetonitrile. The mixture was cooled in an ice bath before adding a suspension of NaHCO 3 (250 mgs) in water (5 mL). The mixture was stirred under a nitrogen atmosphere for 15 minutes. Brine was added (15 mL) and the product was extracted into ethylacetate (2×25 mL). The organic layer was washed with brine (1×30 mL), dried (MgSO 4 ) and solvent was evaporated to give a yellowish oil. Purification by chromatography on silica gel (30% acetane/CH 2 Cl 2 ) afforded the title compound.
MS, M+/z, 421; H'NMR (CDCl 3 ). δ 5.95 (m, 1H), 5.8 (d, 1H, J=1.5 Hz), 5.45 (d, 1H, J=15 Hz), 5.20 (d, 1H, J=10 Hz), 4.8-4.5 (dd, m, 2H, J=15, 6 Hz), 4.25-3.7 (m, 3H), 3.62 (dd, 1H, J=13, 6 Hz), 3.3 (ddm, 1H, J=13, 6 Hz), 3.15 (dd, 1H, J=13, 6 Hz), 1.27 (d, 3H, J=6.5 Hz).
In the following formulation examples "Drug" means Sodium (5R,6S,8R)-6-(1-hydroxyethyl)-2-[(cis-3'(R)-hydroxy-4'(S)-furanyl)thio]-penem-3-carboxylate or equivalent amounts of a compound of formula I.
EXAMPLE 22
Capsule Formula
______________________________________No. Ingredient mg/capsule______________________________________1 Drug 100 250 502 Lactose 123 185 1233 Corn Starch 50 60 704 Magnesium Stearate 2 5 7 Total 275 500 700______________________________________
Method of Manufacture
Mix Item Nos. 1, 2 and 3 in a suitable mixer for 10-15 minutes. Add Item No. 4 and mix for 1-3 minutes. Fill the mixture into suitable two-piece hard gelatin capsules using suitable encapsulating equipment.
EXAMPLE 23
Tablet Formula
______________________________________No. Ingredient mg/tablet______________________________________1 Drug 100 250 5002 Lactose 194.5 187.5 156.53 Corn Starch, as a 10% paste 5 10 154 Corn Starch 25 50 755 Magnesium Stearate 0.5 2.5 3.5 Total 325 500 750______________________________________
Method of Manufacture
Mix Items Nos. 1, 2 and a portion of Item No. 4 in a suitable mixer for 10-15 minutes. Granulate the mixture with Item No. 3. Pass the wet granulation through a coarse screen (e.g., 1/4") if needed, and then dry the wet granules. Mill the dried granules. Combine Item No. 5 and the remaining portion of Item No. 4 with the dried granules in a suitable blender and mix for 5-10 minutes. Compress the mixture to appropriate tablet size and weight on a suitable tablet machine.
EXAMPLE 24
Injectable Powder
______________________________________No. Ingredient mg/ml______________________________________1 Drug 0.5-1.02 Sodium Phosphate Monobasic 2.0 (0.8-5.0)3 Sodium Phosphate Dibasic 1.0 (0-3.0)4 Mannitol 5.0 (1.0-10.0)5 Water for Injection q.s. ad 10. ml______________________________________
Method of Manufacture
Dissolve Items 1-4 in Item 5. Filter the resultant solution through a 0.22 μm membrane filter. Fill filtered solutions into prewashed and presterilized vials, and load them into a freeze-dryer. The solution is frozen and then vacuum-dried in the frozen state.
EXAMPLE 25
Injectable Solution
______________________________________No. Ingredient mg/ml______________________________________1 Drug 0.5-1.02 Sodium Phosphate Monobasic 2.0 (0.8-5.0)3 Sodium Phosphate Dibasic 1.0 (0-3.0)4 Ascorbic Acid 0.05 (0.01-0.1)5 Phenol 0.4 (0.25-0.5)6 Disodium Edetate 0.03 (0.01-0.05)7 Water for Injection q.s. ad 1.0 ml______________________________________
Method of Manufacture
The injectable solution is manufactured by dissolving Items 1-6 in Item 7. Sterile filter the resultant solution through a 0.22μ membrane filter.
EXAMPLE 26
______________________________________Topical Cream mg/g______________________________________Drug 100.0Cetyl alcohol 40.0Stearyl alcohol 40.0Isopropyl myristate 100.0Polyoxyethylene (2) monostearyl ether (Brij 72) 10.0Polyoxyethylene (20) monostearyl ether (Brij 78) 25.0Propylene glycol 100.0Benzyl alcohol 10.0Purified water q.s. ad 1.0 g______________________________________
Method of Manufacture
Melt together and heat to about 70° the cetyl alcohol, stearyl alcohol, Brij 72, Brij 78 and isopropyl myristate. Add the propylene glycol to water in a separate container, heat to 70° C., and dissolve in this aqueous phase the benzyl alcohol. Dissolve or suspend the Drug in the aqueous phase while stirring. Add the aqueous phase to the oily phase with agitation. Start cooling and continue to agitate until the temperature reaches 25° C.
EXAMPLE 27
______________________________________Gel mg/g______________________________________Drug 200.0Propylene glycol 100.0Hydroxypropylcellulose 25.0Ethyl alcohol q.s. ad 1.0 g______________________________________
Method of Manufacture
Disperse or dissolve the drug alcohol with agitation. Add the propylene glycol and then the hydroxypropylcellulose, maintaining agitation until the hydroxypropylcellulose is evenly dispersed. Cool the resulting gel to allow for completion of hydration.
EXAMPLE 28
______________________________________Topical Lotion mg/g______________________________________Drug 250.0Ethyl alcohol 300.0Polyethylene glycol 400 300.0Hydroxypropylcellulose 5.0Propylene glycol q.s. ad 1.0 g______________________________________
Method of Manufacture
Dissolve or disperse the drug in the solvent mixture of ethyl alcohol, polyethylene glycol 400 and propylene glycol with agitation. Then add the hydroxypropylcellulose maintaining agitation, until the hydroxypropylcellulose is evenly dispersed.
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There is disclosed antibacterial compounds represented by the formula ##STR1## and pharmaceutically acceptable salts or pharmaceutically acceptable esters thereof,
wherein:
X represents oxygen, sulfur, ##STR2## wherein R is hydrogen, loweralkyl, acetate or methoxycarbonyl; Y is cis, trans or mixtures thereof and is selected from hydroxy, lower alkoxy, aminocarbamoyloxy, methoxycarbonylamino, lower alkylcarbonyloxy, lower alkylcarbonylamino and loweralkylsulfonylamino; and
the wavy lines indicate cis, trans or mixtures thereof.
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FIELD OF THE INVENTION
This invention relates to the handling of workpieces sewn by an automatic sewing machine system. In particular, this invention relates to apparatus for processing pallets containing the workpieces.
BACKGROUND OF THE INVENTION
An automatic sewing machine system which processes pallets containing workpieces is illustrated in U.S. Pat. No. 4,422,393 entitled "Sewing Machine Having Automatic Pallet Handling". This system processes pallets from an input location to a sewing location and thereafter to a remote location wherein a further pallet may be automatically processed from the input location to the sewing location. The processing of pallets to the sewing location is accomplished by a set of rotatable shelves that cooperate in a manner which allows first one edge of a pallet to be dropped before a second edge is dropped to the sewing location. The thus dropped pallet is locked to a carriage which is movable in the X and Y directions relative to a reciprocating sewing needle so as to thereby produce a desired stitch pattern on the workpiece. The completed workpiece within the pallet is returned to the location for receiving a dropped pallet from the input location. At this point, the pallet is unlocked from the automatic positioning system. A further mechanism, external to the automatic positioning system, releases an underlying support for the pallet. This allows the pallet to be engaged by an ejector mechanism which moves the pallet to a remote location so as to thereby allow another pallet to be attached to the automatic positioning system.
The aforementioned mechanisms for processing a pallet comprises a number of complex, interdependent mechanisms. The number and complexity of these interdependent mechanisms can interfere with accessing various portions of the sewing machine system. In particular, the structure for supporting the rotatable shelves at the input location occupies space directly in front of the automatic sewing machine. The ejector mechanism also occupies other space in front of the automatic sewing machine. Still other portions of the space in front of the automatic sewing machine are occupied by additional structure not shown in U.S. Pat. No. 4,422,393. This additional structure may include a control console for the automatic sewing machine system. This latter structure in combination with the support structure for the shelves can make access to various portions of the system particularly difficult.
OBJECT OF THE INVENTION
It is an object of the invention to provide pallet handling apparatus within an automatic sewing machine system that provides quick and easy access to various portions of the system.
SUMMARY OF THE INVENTION
The above and other objects are achieved according to the present invention by pallet handling apparatus having a pair of rotatable shelves that receive and thereafter drop the pallet to a carriage associated with the automatic positioning system. One of the rotatable shelves is mounted within support structure that may be easily displaced for further access to the automatic sewing machine. The thus dropped pallet is locked to the carriage for automatic sewing and returned to a location under the rotatable shelves. The locking is released and the pallet is allowed to drop unto a pair of inclined chutes. The inclined chutes are supported at a predefined angle of inclination by supports which are detachably mounted to a base of the system. Removal of the supports allows still further access to various portions of the automatic sewing machine.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features of the invention will now be particularly described with reference to the accompanying drawings, in which:
FIG. 1 is an overall perspective view of an automatic sewing machine system having an automatic pallet handling apparatus in association with an automatic positioning system;
FIG. 2 is a plan view of a pallet in association with the carriage mechanism of the automatic positioning system;
FIG. 3 is a perspective view of a portion of the automatic pallet handling apparatus;
FIG. 4 is a perspective view of a portion of the pallet handling apparatus which absorbs the impact of the front portion of a dropped pallet; and
FIG. 5 is a perspective view of a disassembled pallet handling apparatus illustrating access to various portions of the automatic sewing system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, an automatic sewing machine system having apparatus for processing pallets with respect to a sewing machine 10 is generally shown. A control panel 12 mounted in front of the automatic sewing machine 10 is generally illustrated. The control panel 12 is situated on a panel support 14 which extends upwardly from a fixed base 15.
A pallet 16 is suspended above a bed 18 of the sewing machine 10 by a pair of rotatable shelves 20 and 22. The shelf 20 is rotatably supported within mounts 24 and 26 extending outwardly from a frame 28 attached to the fixed base 15. The shelf 20 is rotated within the mounts 24 and 26 by a pivotally connected actuator 30. The shelf 22 is rotatably supported within side mounts 32 and 34 forming part of a horizontal support structure 36 which is fastened to a vertical support structure 38. The shelf 22 is rotated within the side mounts 32 and 34 by a pivotally connected actuator 40. The actuator 40 is itself pivotally suspended from the horizontal support structure 36.
The left edge of the pallet 16 is first dropped by a downward rotation of the shelf 20. The thus dropped edge will come to rest on a pair of support tabs 42 and 44 associated with a movable carriage 46 that has been previously positioned underneath the shelf 20. The support tabs 42 and 44 are clearly shown in FIG. 2. It is to be noted that the support tab 42 is movable whereas the support tab 44 is fixed relative to the carriage 46.
Referring again to FIG. 1, a sensor switch 48 is operative to detect the downward motion of the shelf 20 so as to thereafter trigger the actuator 40 to retract, thereby causing the shelf 22 to move downwardly. The right edge of the pallet 16 now drops down to the bed 18 of the sewing machine. This causes the pallet 16 to lie in a substantially horizontal plane relative to a reciprocating sewing needle 50. Once the pallet 16 has assumed the aforementioned horizontal position, it is clamped between a pair of wedges 52 and 54 which engage a pair of notches 56 and 58. This wedge engagement of the respective notches is clearly shown in FIG. 2. In this regard, the wedge 52 is illustrated during the course of its movement into engagement with the notch 56. The mechanism by which the wedge 52 is thus moved into engagement is clearly illustrated in both FIGS. 2 and 3. The wedge 52 is attached to a pivotal lever 60 which rotates within a fixture 62 forming part of the casting for the carriage 46. Only a portion of the pivotal lever 60 is illustrated within the fixture 62 in FIG. 3. This portion is seen to include an arm 64 pivotally connected to an output shaft of a pneumatic actuator 66. The pneumatic actuator 66 is operative to move the arm 64 outwardly into contact with an adjustable limit stop 68. This outward movement of the arm 64 is against the bias force of a spring 70. This causes the pivot lever 60 to rotate within the fixture 62 so as to thereby cause the wedge 52 to move inwardly into engagement with the notch 56. The wedge 52 ultimately seats in the notch 56 and urges the opposing notch 58 against the opposing wedge 54. A spring 71, connected to the wedge 52, retains the support tab 42 underneath the pallet 16. The thus clamped pallet can be positioned by the carriage 46 relative to the reciprocating sewing needle 50. It is to be understood that positioning systems for moving carriages relative to reciprocating sewing needles are well known in the art. The X, Y positioning system used in the preferred embodiment is disclosed in detail in U.S. Pat. No. 4,406,234 entitled "Positioning Apparatus".
Following completion of automatic sewing, the carriage 46 is returned to a position underneath the shelf 20. At this point in time, the pneumatic actuator 66 is exhausted so as to thereby cause the bias spring 70 to disengage the wedge 52 from the notch 56. The support tab 42 is next rotated outwardly by a pivotably connected link 72 connected to a pressurized pneumatic actuator 74. The front edge of the pallet 16 drops downwardly as soon as the support tab 42 rotates sufficiently outwardly so as to no longer support the pallet 16. The rear edge of the pallet remains temporarily supported by the support tab 42 and the bed 18 of the sewing machine. Referring to FIG. 1, the front of the pallet drops onto a pair of shock absorbing pins 76 and 78. The shock absorbing pins absorb the free fall impact of the front portion of the pallet which thereafter descends down a pair of inclined slides 80 and 82. The inclined slides are preferably lengths of hard, polished steel having widths of one-half inch which produce minimal frictional resistance to the underside of the sliding pallet. The inclined slides 80 and 82 are mounted within chutes 84 and 86 which are in turn mounted at an inclined angle on supports 87 and 88. The inclined angle is preferably twenty-five degrees with respect to the horizontal surface of the base 15. This inclined angle is sufficient to allow the front edge of the pallet 16 to slide downwardly so as to thereby release the rear edge of the pallet from the support tab 44 and the bed 18 of the sewing machine. The pallet continues to slide downwardly until its front edge contacts one quarter inch thick rubber pads, i.e. 89 located on the inner side of abutments 90 and 91. At this point in time, the pallet will no longer remain on the shock absorbing pins 76 and 78. A contact switch 92 will be moreover closed so as to indicate that a pallet is resting in the chutes 84 and 86.
Referring to FIG. 4, the shock absorbing pin 76 is illustrated in further detail relative to the slide 80. The pin 76 is seen to project upwardly through a hole in the slide 80 so as to contact the underside of the pallet. A soft plastic cap 93 is preferably affixed to the top of the pin 76 so as to provide a cushioned initial contact with the underside of the pallet. The aft end of the pin 76 is connected to a piston head 94 resting on a helical spring 95 within a cylindrical housing 96. The cylindrical housing 96 is filled with a fluid that flows through orifices in the piston head 94. In this manner, impact force is absorbed by the piston head 94 moving against both the helical spring 95 and the fluid dampening resistance within the cylinder 96. It is to be noted that the downward travel of the piston head 94 is sufficient to allow the soft plastic cap 93 to move completely into the hole within the slide 80. This produces a flush relationship between the top of the soft plastic cap 93 and the top surface of the slide 80. The underside of a pallet will hence move smoothly down the slides 80 and 82 over the suppressed plastic caps associated with the pins 76 and 78.
Referring again to FIG. 3, the shelves 20 and 22 will have been reset following the dropping of the pallet 16 to the carriage 46. Another pallet may have been loaded onto the shelves while the workpiece in the pallet 16 was being sewn. The presence of this pallet will be detected by a detection device 98.
The newly loaded pallet whose presence has been detected will be dropped to the carriage 46 in response to the switch 92 sensing the presence of the pallet 16 in the chutes 84 and 86. The support tab 26 will have been previously rotated inwardly by the pneumatic actuator 74 to the dotted outline position illustrated in FIG. 2 so as to support the first edge of the thus dropped pallet. The pallet is clamped between the wedges 52 and 54 and the workpiece mounted therein is moved underneath the reciprocating needle 50 of the sewing machine. The carriage 46 returns to a position below the shelf 20 and will proceed to unlock the clamped pallet and drop the same if the previous pallet 16 has been removed from the chutes 84 and 86 as indicated by an open switch condition of the contact switch 92. In this manner, pallets may be processed from the input location defined by the shelves 20 and 22 through the sewing location defined by the carriage 46 to the output position defined by the chutes 84 and 86.
It is to be appreciated that, access may be required to various portions of the automatic positioning system as well as the structure associated with the sewing machine 10. This is easily accomplished by removing one or both of the supports 87 and 88 from their respective locations in a manner which will now be described. Each support is attached by a pair of clips such as 100 and 102 which engage pins 104 and 106 extending upwardly from the base 15. These clips may be withdrawn from underneath the heads of the pins so as to allow the corresponding support to be removed from the base 15. This allows access to both the positioning system associated with the carriage 46 as well as to the sewing machine 10.
Referring to FIG. 5, it is seen that both of the supports have been removed from the base 15. The vertical support structure 38 has also been displaced from its normal location so as to allow even further access to the sewing machine 10. The displacement of the vertical support structure 38 is facilitated by loosening a pair of holding bolts 108 and 109 from threaded engagement with threaded holes such as 110 in the base 15. The holding bolts are easily loosened by grasping turning pins such as 112 located in the head of each holding bolt. The holding bolts are also spring loaded against a bottom rectangular portion 113 of the vertical support structure 38 by bias springs such as 114. This allows the holding bolts to extend upwardly from the bottom portion of the vertical support structure in such a manner as to allow access to the turning pins when initially loosening the holding bolts. The vertical support structure 38 is now free to pivot about a shoulder bolt 116 located in a corner of the bottom rectangular portion 113. This corner is seen to be located near the panel support 14. It is to be appreciated that the periphery of this corner must clear the panel support 14 when the vertical support 38 is pivoted about the shoulder bolt 116. This is accomplished by locating the threaded hole in the base 15 for the shoulder bolt at a distance from the panel support which is greater than the radial distance from the center of the shoulder bolt 116 to the extreme corner periphery of the corner in which the shoulder bolt is located. Location of the threaded hole for the shoulder bolt 116 also defines the hole locations for the holding bolts 108 and 109.
From the foregoing, it is to be appreciated that a preferred embodiment of certain pallet handling apparatus for an automatic sewing machine system has been disclosed. It is also to be appreciated that alternative structures may be substituted for elements of the preferred embodiment without departing from the scope of the invention.
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Apparatus is disclosed for processing workpieces prearranged within pallets in an automatic sewing machine system. The apparatus is displaceable from fixed positions wherein the pallets are normally processed from an input location to a sewing location and hence to an output location. The displaced apparatus allows access to various portions of the automatic sewing machine system.
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This is a continuation-in-part of Holmes-Farley et al., U.S. Ser. No. 08/105,591, filed Aug. 11, 1993, entitled "Phosphate-Binding Polymers for Oral Administration", now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to phosphate-binding polymers for oral administration.
People with inadequate renal function, hypoparathyroidism, or certain other medical conditions often have hyperphosphatemia, meaning serum phosphate levels of over 6 mg/dL. Hyperphosphatemia, especially if present over extended periods of time, leads to severe abnormalities in calcium and phosphorus metabolism, often manifested by aberrant calcification in joints, lungs, and eyes.
Therapeutic efforts to reduce serum phosphate include dialysis, reduction in dietary phosphate, and oral administration of insoluble phosphate binders to reduce gastrointestinal absorption. Dialysis and reduced dietary phosphate are usually insufficient to adequately reverse hyperphosphatemia, so the use of phosphate binders is routinely required to treat these patients. Phosphate binders include calcium or aluminum salts, or organic polymers such as ion exchange resins.
Calcium salts have been widely used to bind intestinal phosphate and prevent absorption. The ingested calcium combines with phosphate to form insoluble calcium phosphate salts such as Ca 3 (PO 4 ) 2 , CaHPO 4 , or Ca(H 2 PO 4 ) 2 . Different types of calcium salts, including calcium carbonate, acetate (such as the pharmaceutical "PhosLo®"), citrate, alginate, and ketoacid salts have been utilized for phosphate binding. The major problem with all of these therapeutics is the hypercalcemia which often results from absorption of the high amounts of ingested calcium. Hypercalcemia causes serious side effects such as cardiac arrhythmias, renal failure, and skin and visceral calcification. Frequent monitoring of serum calcium levels is required during therapy with calcium-based phosphate binders.
Aluminum-based phosphate binders, such as the aluminum hydroxide gel "Amphojel®", have also been used for treating hyperphosphatemia. These compounds complex with intestinal phosphate to form highly insoluble aluminum phosphate; the bound phosphate is unavailable for absorption by the patient. Prolonged use of aluminum gels leads to accumulations of aluminum, and often to aluminum toxicity, accompanied by such symptoms as encephalopathy, osteomalacia, and myopathy.
Organic polymers that have been used to bind phosphate have typically been ion exchange resins. Those tested include "Dowex®" anion-exchange resins in the chloride form, such as XF 43311, XY 40013, XF 43254, XY 40011, and XY 40012. These resins have several drawbacks for treatment of hyperphosphatemia, including poor binding efficiency, necessitating use of high dosages for significant reduction of absorbed phosphate. In addition, the ion exchange resins also bind bile salts.
SUMMARY OF THE INVENTION
In general, the invention features a method of removing phosphate from a patient by ion exchange, which involves oral administration of a therapeutically effective amount of a composition containing at least one phosphate-binding polymer that is non-toxic and stable once ingested. The polymers of the invention may be crosslinked with a crosslinking agent. Examples of preferred crosslinking agents include epichlorohydrin, 1,4 butanedioldiglycidyl ether, 1,2 ethanedioldiglycidyl ether, 1,3-dichloropropane, 1,2-dichloroethane, 1,3-dibromopropane, 1,2-dibromoethane, succinyl dichloride, dimethylsuccinate, toluene diisocyanate, acryloyl chloride, and pyromellitic dianhydride. The crosslinking agent is present in an amount ranging from about 0.5% to about 75% by weight, more preferably from about 2% to about 20% by weight.
By "non-toxic" it is meant that when ingested in therapeutically effective amounts neither the polymers nor any ions released into the body upon ion exchange are harmful.
By "stable" it is meant that when ingested in therapeutically effective amounts the polymers do not dissolve or otherwise decompose to form potentially harmful by-products, and remain substantially intact so that they can transport bound phosphate out of the body.
By "therapeutically effective amount" is meant an amount of the composition which, when administered to a patient, causes decreased serum phosphate.
In one aspect, the polymer is characterized by a repeating unit having the formula ##STR1## or a copolymer thereof, wherein n is an integer and each R, independently, is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl (e.g., phenyl) group.
In a second aspect, the polymer is characterized by a repeating unit having the formula ##STR2## or a copolymer thereof, wherein n is an integer, each R, independently, is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl (e.g., phenyl) group, and each X - is an exchangeable negatively charged counterion.
One example of a copolymer according to the second aspect of the invention is characterized by a first repeating unit having the formula ##STR3## wherein n is an integer, each R, independently, is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl), and each X - is an exchangeable negatively charged counterion; and further characterized by a second repeating unit having the formula ##STR4## wherein each n, independently, is an integer and each R, independently, is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl).
In a fourth aspect, the polymer is characterized by a repeating unit having the formula ##STR5## or a copolymer thereof, wherein n is an integer, and R is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl).
One example of a copolymer according to the second aspect of the invention is characterized by a first repeating unit having the formula ##STR6## wherein n is an integer, and R is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl); and further characterized by a second repeating unit having the formula ##STR7## wherein each n, independently, is an integer and R is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl).
In a fifth aspect, the polymer is characterized by a repeating group having the formula ##STR8## or a copolymer thereof, wherein n is an integer, and each R 1 and R 2 , independently, is H or a lower alkyl (e.g., having between 1 and 5 carbon atoms, inclusive), and alkylamino (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino) or aryl group (e.g., phenyl), and each X - is an exchangeable negatively charged counterion.
In one preferred polymer according to the fifth aspect of the invention, at least one of the R groups is a hydrogen group.
In a sixth aspect, the polymer is characterized by a repeat unit having the formula ##STR9## or a copolymer thereof, where n is an integer, each R 1 and R 2 , independently, is H, an alkyl group containing 1 to 20 carbon atoms, an alkylamino group (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino), or an aryl group containing 1 to 12 atoms (e.g., phenyl).
In a seventh aspect, the polymer is characterized by a repeat unit having the formula ##STR10## or a copolymer thereof, wherein n is an integer, each R 1 , R 2 and R 3 , independently, is H, an alkyl group containing 1 to 20 carbon atoms, an alkylamino group (e.g., having between 1 and 5 carbons atoms, inclusive, such as ethylamino), or an aryl group containing 1 to 12 atoms (e.g., phenyl), and each X - is an exchangeable negatively charged counterion.
In all aspects, the negatively charged counterions may be organic ions, inorganic ions, or combination thereof. The inorganic ions suitable for use in this invention include the halides (especially chloride), phosphate, phosphite, carbonate, bicarbonate, sulfate, bisulfate, hydroxide, nitrate, persulfate, sulfite, and sulfide. Suitable organic ions include acetate, ascorbate, benzoate, citrate, dihydrogen citrate, hydrogen citrate, oxalate, succinate, tartrate, taurocholate, glycocholate, and cholate.
The invention provides an effective treatment for decreasing the serum level of phosphate by binding phosphate in the gastrointestinal tract, without comcomittantly increasing the absorption of any clinically undesirable materials, particularly calcium or aluminum.
Other features and advantages will be apparent from the following description of the preferred embodiments and from the claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred polymers have the structures set forth in the Summary of the Invention, above. The polymers are preferably crosslinked, in some cases by adding a crosslinking agent to the reaction mixture during polymerization. Examples of suitable crosslinking agents are diacrylates and dimethacrylates (e.g., ethylene glycol diacrylate, propylene glycol diacrylate, butylene glycol diacrylate, ethylene glycol dimethacrylate, propylene glycol dimethacrylate, butylene glycol dimethacrylate, polyethyleneglycol dimethacrylate, polyethyleneglycol diacrylate), methylene bisacrylamide, methylene bismethacrylamide, ethylene bisacrylamide, epichlorohydrin, toluene diisocyanate, ethylenebismethacrylamide, ethylidene bisacrylamide, divinyl benzene, bisphenol A dimethacrylate, bisphenol A diacrylate, 1,4 butanedioldiglycidyl ether, 1,2 ethanedioldiglycidyl ether, 1,3-dichloropropane, 1,2-dichloroethane, 1,3-dibromopropane, 1,2-dibromoethane, succinyl dichloride, dimethylsuccinate, acryloyl chloride, or pyromellitic dianhydride. The amount of crosslinking agent is typically between about 0.5 and about 75 weight %, and preferably between about 1 and about 25% by weight, based upon combined weight of crosslinking agent and monomer. In another embodiment, the crosslinking agent is present between about 2 and about 20% by weight.
In some cases the polymers are crosslinked after polymerization. One method of obtaining such crosslinking involves reaction of the polymer with difunctional crosslinkers, such as epichlorohydrin, succinyl dichloride, the diglycidyl ether of bisphenol A, pyromellitic dianhydride, toluene diisocyanate, and ethylenediamine. A typical example is the reaction of poly(ethyleneimine) with epichlorohydrin. In this example the epichlorohydrin (1 to 100 parts) is added to a solution containing polyethyleneimine (100 parts) and heated to promote reaction. Other methods of inducing crosslinking on already polymerized materials include, but are not limited to, exposure to ionizing radiation, ultraviolet radiation, electron beams, radicals, and pyrolysis.
EXAMPLES
Candidate polymers were tested by stirring them in a phosphate containing solution at pH 7 for 3 h. The solution was designed to mimic the conditions present in the small intestine.
______________________________________ Solution Contents______________________________________ 10-20 mM Phosphate 80 mM Sodium Chloride 30 mM Sodium Carbonate______________________________________
The pH was adjusted to pH 7, once at the start of the test and again at the end of the test, using either aqueous NaOH or HCl. After 3 h the polymer was filtered off and the residual phosphate concentration in the test solution was determined spectrophotometrically. The difference between the initial phosphate concentration and the final concentration was used to determine the amount of phosphate bound to the polymer. This result is expressed in milliequivalents per gram of starting polymer (meq/g).
The table below shows the results obtained for several polymers. Higher numbers indicate a more effective polymer.
______________________________________ Phosphate BoundPolymer (meq/g)*______________________________________Poly(allylamine/epichlorohydrin) 3.1Poly(allylamine/butanediol diglycidyl ether) 2.7Poly(allylamine/ethanediol diglycidyl ether) 2.3Poly(allyltrimethylammonium chloride) 0.3Poly(ethyleneimine)/acryloyl chloride 1.2Polyethyleneimine "C" 2.7Polyethyleneimine "A" 2.2Poly(DET/EPI) 1.5Polyethyleneimine "B" 1.2Poly(dimethylaminopropylacrylamide) 0.8Poly(PEH/EPI) 0.7Poly(trimethylammoniomethyl styrene chloride) 0.7Poly(pentaethylenehexaminemethacrylamide) 0.7Poly(tetraethylenepentaminemethacrylamide) 0.7Poly(diethylenetriaminemethacrylamide) 0.5Poly(triethylenetetraminemethacrylamide) 0.5Poly(aminoethylmethacrylamide) 0.4Poly(vinylamine) 0.4Poly(MAPTAC) 0.25Poly(methylmethacrylate/PEI) 0.2Poly(dimethylethyleneimine chloride) 0.2Poly(diethylaminopropylmethacrylamide) 0.1Poly(guanidinoacrylamide) 0.1Poly(guanidinobutylacrylamide) 0.1Poly(guanidinobutylmethacrylamide) 0.1______________________________________ *The values apply when the residual solution phosphate levels are ˜ mM.
The table below shows results obtained using various other materials to bind phosphate
______________________________________ Phosphate BoundPolymer (meq/g)*______________________________________Calcium Chloride 4.0Calcium Lactate 2.4"Ox-Absorb ®" 0.5"Maalox Plus ®" 0.3Sephadex DEAE A-25, 40-125 m 0.2Aluminum Hydroxide, Dried Gel 0.2______________________________________ *The values apply when the residual solution phosphate levels are ˜ mM.
The table below shows results obtained for a variety of salts made from polyethyleneimine and organic and inorganic acids.
______________________________________ PHOSPHATE BOUNDPOLYMER (meg/g)*______________________________________Poly(ethyleneimine sulfate A) 0.9Poly(ethyleneimine sulfate B) 1.2Poly(ethyleneimine sulfate C) 1.1Poly(ethyleneimine sulfate D) 1.7Poly(ethyleneimine tartrate A) 0.7Poly(ethyleneimine tartrate B) 0.9Poly(ethyleneimine tartrate C) 1.1Poly(ethyleneimine ascorbate A) 0.55Poly(ethyleneimine ascorbate B) 0.65Poly(ethyleneimine ascorbate C) 0.9Poly(ethyleneimine citrate A) 0.7Poly(ethyleneimine citrate B) 1.0Poly(ethyleneimine citrate C) 0.9Poly(ethyleneimine succinate A) 1.1Poly(ethyleneimine succinate B) 1.3Poly(ethyleneimine chloride) 1.1______________________________________ *The values apply when the residual solution phosphate levels are ˜ mM.
"Oxabsorb®" is an organic polymer that encapsulates calcium such that the calcium is available to bind to such ions as phosphate, but may not be released by the polymer and thus is not supposed to be absorbed by the patient.
The amount of phosphate bound by all of these materials, both polymers and inorganic gels, is expected to vary as the phosphate concentration varies.
In a test, the polymer was exposed to an acidic environment prior to exposure to phosphate as might happen in a patient's stomach. The solid (0.1 g) was suspended in 40 mL of 0.1 M NaCl. This mixture was stirred for 10 min., and the pH was adjusted to 3.0 with 1 M HCl, and the mixture was stirred for 30 min. The mixture was centrifuged, the supernatant decanted, and the solid resuspended in 40 mL of 0.1 m NaCl. This mixture was stirred for 10 min., the pH was adjusted to 3.0 with 1 M HCl, and the mixture was stirred for 30 min. The mixture was centrifuged, the supernatant decanted, and the solid residue used in the usual phosphate assay. Results are shown below for a variety of polymers and for aluminum hydroxide dried gel. In most cases the values for the amount of phosphate bound are higher in this test than in the usual assay.
______________________________________ PHOSPHATE BOUNDPOLYMER (meg/g)*______________________________________Poly(ethyleneimine sulfate B) 1.2Poly(ethyleneimine sulfate C) 1.3Poly(ethyleneimine tartrate B) 1.3Poly(ethyleneimine tartrate C) 1.4Poly(ethyleneimine ascorbate B) 1.0Poly(ethyleneimine ascorbate C) 1.0Poly(ethyleneimine citrate B) 1.0Poly(ethyleneimine citrate C) 1.3Poly(ethyleneimine succinate A) 1.1Poly(ethyleneimine succinate B) 1.3Poly(ethyleneimine chloride) 1.4Aluminum Hydroxide 0.7______________________________________ *The values apply when the residual solution phosphate levels are ˜ mM.
RAT DIETARY PHOSPHORUS EXCRETION MODEL
Six 6-8 week old Sprague-Dawley rats were placed in metabolic cages and fed semi-purified rodent chow powder containing 0.28% inorganic phosphorus. The diets were supplemented with 11.7% poly(allylamine/epichlorohydrin) or micro-crystalline cellulose; the animals served as their own controls by receiving cellulose or poly(allylamine/epichlorohydrin) in randomized order. The rats were fed ad libitum for three days to acclimate to the diet. Feces excreted during the next 48 hours were collected, lyophilized, and ground into powder. The inorganic phosphate content was determined according to the method of Taussky and Shorr: Microdetermination of Inorganic P. One gram of powdered feces was burned to remove carbon, then ashed in a 600° C. oven, concentrated HCl was then added to dissolve the phosphorus. The phosphorus was determined with ferrous sulfate-ammonium molybdate reagent. Intensity of the blue color was determined at 700 nm on a Perkin-Elmer spectrophotometer through a 1 cm cell.
URINARY PHOSPHATE EXCRETION IN PARTIALLY NEPHRECTOMIZED RATS
Sprague-Dawley rats, approximately 8 weeks old, were 75% nephrectomized. One kidney was surgically removed; approximately 50% of the renal artery flow to the contralateral kidney was ligated. The animals were fed a semi-purified rodent chow containing 0.385% inorganic phosphorus and either 10% poly(allylamine/epichlorohydrin) or cellulose. Urine was collected and analyzed for phosphate content on specific days. Absorbed dietary phosphate is excreted into the urine to maintain serum phosphate.
None of the animals became hyperphosphatemic or uremic, indicating that the residual kidney function was adequate to filter the absorbed phosphate load. The animals receiving poly(allylamine/epichlorohydrin) demonstrated a trend towards reduced phosphate excretion, indicative of reduced phosphate absorption.
SYNTHESES
Poly(allylamine) hydrochloride
To a 5 L, water jacketed reaction kettle equipped with 1) a condenser topped with a nitrogen gas inlet and 2) a thermometer and 3) a mechanical stirrer was added concentrated hydrochloric acid (2590 mL). The acid was cooled to 5° C. using circulating water in the jacket of the reaction kettle at 0° C. Allylamine (2362 mL; 1798 g) was added dropwise with stirring, maintaining a temperature of 5°-10° C. After the addition was complete, 1338 mL of liquid was removed by vacuum distillation at 60°-70° C. Azobis(amidinopropane) dihydrochloride (36 g) suspended in 81 mL water was added. The kettle was heated to 50° C. under a nitrogen atmosphere with stirring for 24 h. Azobis(amidinopropane) dihydrochloride (36 g) suspended in 81 mL water was again added and the heating and stirring continued for an addition 44 h. Distilled water (720 mL) was added and the solution allowed to cool with stirring. The liquid was added dropwise to a stirring solution of methanol (30 L). The solid was then removed by filtration, resuspended in methanol (30 L), stirred 1 hour, and collected by filtration. This methanol rinse was repeated once more and the solid was dried in a vacuum oven to yield 2691 g of a granular white solid (poly(allylamine) hydrochloride).
Poly(allylamine/epichlorohydrin)
To a 5 gall bucket was added poly(allylamine) hydrochloride (2.5 kg) and water 10 L). The mixture was stirred to dissolve and the pH was adjusted to 10 with a solid NaOH. The solution was allowed to cool to room temperature in the bucket and epichlorohydrin (250 mL) was added all at once with stirring. The mixture was stirred gently until it gelled after about 15 minutes. The gel was allowed to continue curing for 18 h at room temperature. The gel was then removed and put into a blender with isopropanol (about 7.5 L). The gel was mixed in the blender with about 500 mL isopropanol for ˜3 minutes to form coarse particles and the solid was then collected by filtration. The solid was rinsed three times by suspended it in 9 gal of water, stirring the mixture for 1 h, and collecting the solid by filtration. The solid was rinsed once by suspending it in isopropanol (60 L), stirring the mixture for 1 h, and collecting the solid by filtration. The solid was dried in a vacuum oven for 18 h to yield 1.55 Kg of a granular, brittle, white solid.
Poly(allylamine/butanedioldiglycidyl ether)
To a 5 gallon plastic bucket was added poly(allylamine) hydrochloride (500 g) and water (2 L). The mixture was stirred to dissolve and the pH was adjusted to 10 with solid NaOH (142.3 g). The solution was allowed to cool to room temperature in the bucket and 1,4-butanedioldiglycidyl ether (130 mL) was added all at once with stirring. The mixture was stirred gently until it gelled after 4 minutes. The gel was allowed to continue curing for 18 h at room temperature. The gel was then removed and dried in a vacuum oven at 75° C. for 24 h. The dry solid was ground and sieved for -30 mesh and then suspended in 6 gallons on water. After stirring for 1 h the solid was filtered off and rinse process repeated twice more. The solid was rinsed twice in isopropanol (3 gallons), and dried in a vacuum oven at 50° C. for 24 h to yield 580 g of a white solid.
Poly(allylamine/ethanedioldiglycidyl ether)
To a 100 mL beaker was added poly(allylamine) hydrochloride (10 g) and water (40 mL). The mixture was stirred to dissolve and the pH was adjusted to 10 with solid NaOH. The solution was allowed to cool to room temperature in the beaker and 1,2 ethanedioldiglycidyl ether (2.0 mL) was added all at once with stirring. The mixture was allowed to continue curing for 18 h at room temperature. The gel was then removed and blended in 500 mL of methanol. The solid was filtered off and suspended in water (500 mL). After stirring for 1 h the solid was filtered off and the rising process repeated. The solid was rinsed twice in isopropanol (400 mL), and dried in a vacuum oven at 50° C. for 24 h to yield 8.7 g of a white solid.
Poly(allylamine/dimethylsuccinate)
To a 500 mL round bottom flask was added poly(allylamine) hydrochloride (10 g), methanol (100 mL), and triethylamine (10 mL). The mixture was stirred and dimethylsuccinate (1 mL) was added. The solution was heated to reflux and stirring turned off after 30 min. After 18 h the solution was cooled to room temperature and solid was filtered off and suspended in water (1 L). After stirring for 1 h the solid was filtered off and the rinse process repeated twice more. The solid was rinsed once in isopropanol (800 mL), and dried in a vacuum oven at 50° C. for 24 h to yield 5.9 g of a white solid.
Poly(allyltrimethylammonium chloride)
To a 500 mL three necked flask equipped with a magnetic stirrer, a thermometer, and a condenser topped with a nitrogen inlet, was added poly(allylamine) crosslinked with epichlorohydrin (5.0 g), methanol (300 mL), methyl iodide (20 mL), and sodium carbonate (50 g). The mixture was then cooled and water was added to total volume of 2 L. Concentrated hydrochloric acid was added until no further bubbling resulted and the remaining solid was filtered off. The solid was rinsed twice in 10% aqueous NaCl (1 L) by stirring for 1 h followed by filtration to recover the solid. The solid was then rinsed three times by suspending it in water (2 L), stirring for 1 h, and filtering to recover the solid. Finally the solid was rinsed as above in methanol and dried in a vacuum over at 50° C. for 18 h to yield 7.7 g of white granular solid.
Poly(ethyleneimine)/acryloyl chloride
Into a 5 L three neck flask equipped with a mechanical stirrer, a thermometer, and an additional funnel was added polyethyleneimine (510 g of a 50% aqueous solution (equivalent to 255 g of dry polymer) and isopropanol (2.5 L). Acryloyl chloride (50 g) was added dropwise through the addition funnel over a 35 minute period, keeping the temperature below 29° C. The solution was then heated to 60° C. with stirring for 18 h. The solution was cooled and solid immediately filtered off. The solid was rinsed three times by suspending it in water (2 gallons), stirring for 1 h, and filtering to recover the solid. The solid was rinsed once by suspending it in methanol (2 gallons), stirring for 30 minutes, and filtering to recover the solid. Finally, the solid was rinsed as above in isopropanol and dried in a vacuum over at 50° C. for 18 h to yield 206 g of light orange granular solid. ##STR11##
Poly(dimethylaminopropylacrylamide)
Dimethylaminopropylacrylamide (10 g) and methylenebisacrylamide (1.1 g) were dissolved in 50 mL of water in a 100 mL three neck flask. The solution was stirred under nitrogen for 10 minutes. Potassium persulfate (0.3 g) and sodium metabisulfite (0.3 g) were each dissolved in 2-3 mL of water and then mixed. After a few seconds this solution was added to the monomer solution, still under nitrogen. A gel formed immediately and was allowed to sit overnight. The gel was removed and blended with 500 mL of isopropanol. The solid was filtered off and rinsed three times with acetone. The solid white powder was filtered off and dried in a vacuum oven to yield 6.1 g. ##STR12##
Poly(Methacrylamidopropyltrimethylammoniumchloride)=[Poly(MAPTAC)]
[3-(Methacryloylamino)propyl]trimethylammonium chloride (38 mL of 50% aqueous solution) and methylenebismethacrylamide (2.2 g) were stirred in a beaker at room temperature. Methanol (10 mL was added and the solution was warmed to 40° C. to fully dissolve the bisacrylamide. Potassium persulfate (0.4 g) was added and the solution stirred for 2 min. Potassium metabisulfite (0.4 g) was added and stirring was continued. After 5 min the solution was put under a nitrogen atmosphere. After 20 min the solution contained significant precipitate and the solution was allowed to sit overnight. The solid was washed three times with isopropanol and collected by filtration. The solid was then suspended in water 500 (mL) and stirred for several hours before being collected by centrifugation. The solid was again washed with water and collected by filtration. The solid was then dried in a vacuum oven to yield 21.96 g. ##STR13##
Poly(ethyleneimine) "A"
Polyethyleneimine (50g of a 50% aqueous solution; Scientific Polymer Products) was dissolved in water (100 mL). Epichlorohydrin (4.6 mL) was added dropwise. The solution was heated to 55° C. for 4 h, after which it had gelled. The gel was removed, blended with water (1 L) and the solid was filtered off. It was resuspended in water (2 L) and stirred for 10 min. The solid was filtered off, the rinse repeated once with water and twice with isopropanol, and the resulting gel was dried in a vacuum oven to yield 26.3 g of a rubbery solid.
Poly(ethyleneimine) "B" and Poly(ethyleneimine)"C", were made in a similar manner, except using 9.2 and 2.3 mL of epichlorohydrin, respectively.
Poly(methylmethacrylate-co-divinylbenzene)
Methylmethacrylate (50 g) and divinylbenzene (5 g) and azobisisobutyronitrile (1.0 g) were dissolved in isopropanol (500 mL) and heated to reflux for 18 h under a nitrogen atmosphere. The solid white precipitate was filtered off, rinsed once in acetone (collected by centrifugation), once in water (collected by filtration) and dried in a vacuum oven to yield 19.4 g. ##STR14## Poly(diethylenetriaminemethacrylamide)
Poly(methylmethacrylateocodivinylbenzene) (20 g) was suspended in diethylenetriamine (200 mL) and heated to reflux under a nitrogen atmosphere for 18 h. The solid was collected by filtration, resuspended in water (500 mL), stirred 30 min, filtered off, resuspended in water (500 mL), stirred 30 min, filtered off, rinsed briefly in isopropanol, and dried in a vacuum oven to yield 18.0 g. ##STR15##
Poly(pentaethylenehexaminemethacrylamidel, Poly(tetraethylenepentaminemethacrylamide), and poly(triethylenetetraaminemethacrylamide) were made in a manner similar to poly(diethylenetriaminemethacrylamide) from pentaethylenehexamine, tetraethylenepentamine, and triethylenetetraamine, respectively.
Poly(methylmethacrylate/PE1)
Poly(methylmethacrylate-co-divinylbenzene) (1.0 g) was added to a mixture containing hexanol (150 mL) and polyethyleneimine (15 g in 15 g water). The mixture was heated to reflux under nitrogen for 4 days. The reaction was cooled and the solid was filtered off, suspended in methanol (300 mL), stirred 1 h, and filtered off. The rinse was repeated once with isopropanol and the solid was dried in a vacuum oven to yield 0.71 g. ##STR16##
Poly(aminoethylmethacrylamide)
Poly(methylmethacrylate-co-divinylbenzene) (20 g) was suspended in ethylenediamine (200 mL) and heated to reflux under a nitrogen atmosphere for 3 days. The solid was collected by centrifugation, washed by resuspending it in water (500 mL), stirring for 30 min, and filtering off the solid. The solid was washed twice more in water, once in isopropanol, and dried in a vacuum oven to yield 17.3. g. ##STR17##
Poly(diethylaminopropylmethacrylamide)
Poly(methylmethacrylate-co-divinylbenzene) (20 g) was suspended in diethylaminopropylamine (200 mL) and heated to reflux under a nitrogen atmosphere for 18 h. The solid was collected by filtration, resuspended in water (500 mL), filtered off, resuspended in water (500 mL), collected by filtration, rinsed briefly in isopropanol, and dried in a vacuum oven to yield 8.2 g. ##STR18##
NHS-acrylate
N-Hydroxysuccinimide (NHS, 157.5 g) was dissolved in chloroform (2300 mL) in a 5 L flask. The solution was cooled to 0° C. and acryloyl chloride (132 g) was added dropwise, keeping the temperature <2° C. After addition was complete, the solution was stirred for 1.5 h, rinsed with water (1100 mL) in a separatory funnel and dried over anhydrous sodium sulfate. The solvent was removed under vacuum and a small amount of ethyl acetate was added to the residue. This mixture was poured into hexane (200 mL) with stirring. The solution was heated to reflux, adding more ethyl acetate (400 mL). The insoluble NHS was filtered off, hexane (1 L) was added, the solution was heated to reflux, ethyl acetate (400 mL) was added, and the solution allowed to cool to <10° C. The solid was then filtered off and dried in a vacuum oven to yield 125.9 g. A second crop of 80 g was subsequently collected by further cooling. ##STR19##
Poly(NHS-acrylate)
NHS-acrylate (28.5 g), methylenebisacrylamide (1.5 g) and tetrahydrofuran (500 mL) were mixed in a 1 L flask and heated to 50° C. under a nitrogen atmosphere. Azobisisobutyronitrile (0.2 g) was added, the solution was stirred for 1 h, filtered to remove excess N-hydroxysuccinimide, and heated to 50° C. for 4.5 h under a nitrogen atmosphere. The solution was then cooled and the solid was filtered off, rinsed in tetrahydrofuran, and dried in a vacuum oven to yield 16.1 g. ##STR20##
Poly(guanidinobutylacrylamide)
Poly(NHS-acrylate) (1.5 g) was suspended in water (25 mL) containing agmatine (1.5 g) which had been adjusted to pH 9 with solid NaOH. The solution was stirred for 4 days, after which time the pH had dropped to 6.3. Water was added to a total of 500 mL, the solution was stirred for 30 min, and the solid was filtered off. The solid was rinsed twice in water, twice in isopropanol, and dried in a vacuum oven to yield 0.45 g. ##STR21##
Poly(methacryloyl chloride)
Methacryloyl chloride (20 mL), divinyl benzene (4 mL of 80% purity), AIBN (0.4 g), and THF (150 mL) were stirred at 60° C. under a nitrogen atmosphere for 18 h. The solution was cooled and the solid was filtered off, rinsed in THF, then acetone, and dried in a vacuum oven to yield 8.1 g. ##STR22##
Poly(guanidinobutylmethacrylamide)
Poly(methacryloyl chloride) (0.5 g), agmatine sulfate (1.0 g), triethylamine (2.5 mL), and acetone (50 mL) were stirred together for 4 days. Water (100 mL) was added and the mixture stirred for 6 h. The solid was filtered off and washed by resuspending in water (500 mL), stirring for 30 min, and filtering off the solid. The wash was repeated twice in water, once in methanol, and the solid was dried in a vacuum oven to yield 0.41 g. ##STR23##
Poly(guanidinoacrylamide)
The procedure for poly(guanidinobutylacrylamide) was followed substituting aminoguanidine bicarbonate (5.0 g) for the agmatine, yielding 0.75 g.
Poly(PEH/EPI)
Epichlorohydrin (21.5 g) was added dropwise to a solution containing pentaethylenehexamine (20 g) and water (100 mL), keeping the temperature below 65° C. The solution was stirred until it gelled and heating was continued for 4 h (at 65° C.). After sitting overnight at room temperature the gel was removed and blended with water (1 L). The solid was filtered off, water was added (1 L), and the blending and filtration were repeated. The gel was suspended in isopropanol and the resulting solid was collected by filtration and dried in a vacuum oven to yield 28.2 g. ##STR24## Ethylidenebisacetamide
Acetamide (118 g), acetaldehyde (44.06 g), copper acetate (0.2 g), and water (300 mL) were placed in a 1 L three neck flask fitted with condenser, thermometer, and mechanical stirrer. Concentrated HCl (34 mL) was added and the mixture was heated to 45°-50° C. with stirring for 24 h. The water was then removed in vacuo to leave a thick sludge which formed crystals on cooling to 5° C. Acetone (200 mL) was added and stirred for a few minutes after which the solid was filtered off and discarded. The acetone was cooled to 0° C. and solid was filtered off. This solid was rinsed in 500 mL acetone and air dried 18 h to yield 31.5 g. ##STR25## Vinylacetamide
Ethylidenebisacetamide (31.05 g), calcium carbonate (2 g) and celite 541 (2 g) were placed in a 500 mL three neck flask fitted with a thermometer, a mechanical stirrer, and a distilling head atop a vigroux column. The mixture was vacuum distilled at 35 mm Hg by heating the pot to 180°-225° C. Only a single fraction was collected (10.8 g) which contained a large portion of acetamide in addition to the product (determined by NMR). This solid product was dissolved in isopropanol (30 mL) to form the crude solution used for polymerization. ##STR26## Poly(vinylacetamide)
Crude vinylacetamide solution (15 mL), divinylbenzene (1 g, technical grade, 55% pure, mixed isomers), and AIBN (0.3g) were mixed and heated to reflux under a nitrogen atmosphere for 90 min, forming a solid precipitate. The solution was cooled, isopropanol (50 mL) was added, and the solid was collected by centrifugation. The solid was rinsed twice in isopropanol, once in water, and dried in a vacuum oven to yield 0.8 g. ##STR27## Poly(vinylamine)
Poly(vinylacetamide) (0.79 g) was placed in a 100 mL one neck flask containing water 25 mL and concentrated HCl 25 mL. The mixture was refluxed for 5 days, the solid was filtered off, rinsed once in water, twice in isopropanol, and dried in a vacuum oven to yield 0.77g. The product of this reaction (˜0.84 g) was suspended in NaOH (46 g) and water (46 g) and heated to boiling (˜140° C). Due to foaming the temperature was reduced and maintained at ˜100° C. for 2 h. Water (100 mL) was added and the solid collected by filtration. After rinsing once in water the solid was suspended in water (500 mL) and adjusted to pH 5 with acetic acid. The solid was again filtered off, rinsed with water, then the isopropanol, and dried in a vacuum oven to yield 0.51 g.
Poly(trimethylammoniomethylstyrene chloride) is the copolymer of trimethylammoniomethylstyrene chloride and divinyl benzene.
Poly(DET/EPI) is the polymer formed by reaction of diethylenetriamine and epichlorohydrin.
Poly(ethyleneimine) Salts
Polyethyleneimine (25 g dissolved in 25 g water) was dissolved in water (100 mL) and mixed with toluene (1 L). Epichlorohydrin (2.3 mL) was added and the mixture heated to 60° C. with vigorous mechanical stirring for 18 h. The mixture was cooled and the solid filtered off, resuspended in methanol (2 L), stirred 1 h, and collected by centrifugation. The solid was suspended in water (2 L), stirred 1 h, filtered off, suspended in water (4 L), stirred 1 h, and again filtered off. The solid was suspended in acetone (4 L) and stirred 15 min., the liquid was poured off, acetone (2 L) was added, the mixture was stirred 15 min., the acetone was again poured off, and the solid was dried in a vacuum oven to form intermediate "D".
Poly(ethyleneimine sulfate A)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with sulfuric acid (1.1 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine sulfate B)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with sulfuric acid (0.57 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine sulfate C)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with sulfuric acid (0.28 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine sulfate D)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with sulfuric acid (0.11 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine tartrate A)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with tartaric acid (1.72 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine tartrate B)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with tartaric acid (0.86 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine tartrate C)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with tartaric acid (0.43 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine ascorbate A)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with ascorbic acid (4.05 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine ascorbate B)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with ascorbic acid (2.02 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine ascorbate C)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min., and partially neutralized with ascorbic acid (1.01 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine citrate A)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with citric acid (1.47 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine citrate B)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with citric acid (0.74 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine citrate C)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with citric acid (0.37 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine succinate A)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with succinic acid (1.36 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine succinate B)
Intermediate "D" (1.0 g) was suspended in water (150 mL), stirred 30 min, and partially neutralized with succinic acid (0.68 g). The mixture was stirred an additional 30 minutes, the solid was filtered off, resuspended in methanol (200 mL), stirred 5 min., filtered off, and dried in a vacuum oven.
Poly(ethyleneimine chloride)
Polyethyleneimine (100 g in 100 g water) was dissolved in water (640 mL additional) and the pH was adjusted to 10 with concentrated HCl. Isopropanol (1.6 L) was added, followed by epichlorohydrin (19.2 mL). The mixture was stirred under nitrogen for 18 h at 60° C. The solids were filtered off and rinsed with methanol (300 mL) on the funnel. The solid was rinsed by resuspending it in methanol (4 L), stirring 30 min., and filtering off the solid. The rinse was repeated twice with methanol, followed by resuspension in water (1 gallon). The pH was adjusted to 1.0 with concentrated HCl, the solid was filtered off, resuspended in water (1 gallon), the pH again adjusted to 1.0 with concentrated HCl, the mixture stirred 30 min., and the solid filtered off. The methanol rinse was again repeated and the solid dried in a vacuum oven to yield 112.4 g.
Poly(dimethylethyleneimine chloride)
Poly(ethyleneimine chloride) (5.0 g) was suspended in methanol (300 mL) and sodium carbonate (50 g) was added. Methyl iodide (20 mL) was added and the mixture heated to reflux for 3 days. Water was added to reach a total volume of 500 mL, the mixture stirred for 15 min., and the solid filtered off. The solid was suspended in water (500 mL), stirred 30 minutes, and filtered. The solid was suspended in water (1 L), the pH adjusted to 7.0 with concentrated HCl, and the mixture stirred for 10 min. The solid was filtered off, resuspended in isopropanol (1L), stirred 30 min., filtered off, and dried in a vacuum oven to yield 6.33 g.
Use
The methods of the invention involve treatment of patients with hyperphosphatemia. Elevated serum phosphate is commonly present in patients with renal insufficiency, hypoparathyroidism, pseudohypoparathyroidism, acute untreated acromegaly, overmedication with phosphate salts, and acute tissue destruction as occurs during rhabdomyolysis and treatment of malignancies.
The term "patient" used herein is taken to mean any mammalian patient to which phosphate binders may be administered. Patients specifically intended for treatment with the methods of the invention include humans, as well as nonhuman primates, sheep, horses, cattle, goats, pigs, dogs, cats, rabbits, guinea pigs, hamsters, gerbils, rats and mice.
The compositions utilized in the methods of the inventions are orally administered in therapeutically effective amounts. A therapeutically effective amount of compound is that amount which produces a result or exerts an influence on the particular condition being treated. As used herein, a therapeutically effective amount of a phosphate binder means an amount which is effective in decreasing the serum phosphate levels of the patient to which it is administered.
The present pharmaceutical compositions are prepared by known procedures using well known and readily available ingredients. In making the compositions of the present invention, the polymeric phosphate binder may be present alone, may be admixed with a carrier, diluted by a carrier, or enclosed within a carrier which may be in the form of a capsule, sachet, paper or other container. When the carrier serves as a diluent, it may be a solid, semi-solid or liquid material which acts as a vehicle, excipient or medium for the polymer. Thus, the compositions can be in the form of tablets, pills, powders, lozenges, sachets, cachets, elixirs, suspensions, syrups, aerosols, (as a solid or in a liquid medium), soft or hard gelatin capsules, sterile packaged powders, and the like. Examples of suitable carriers, excipients, and diluents include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, alginates, tragacanth, gelatin, calcium silicate, microcrystalline cellulose, polyvinylpyrrolidone, cellulose, methyl cellulose, methylhydroxybenzoates, propylhydroxybenzoates, propylhydroxybenzoates, and talc.
It should be understood, however, that the foregoing description of the invention is intended merely to be illustrative by way of example only and that other modifications, embodiments, and equivalents may be apparent to those skilled in the art without departing from its spirit.
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Phosphate-binding polymers are provided for removing phosphate from the gastrointestinal tract. The polymers are orally administered, and are useful for the treatment of hyperphosphatemia.
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CROSS REFERENCE TO RELATED APPLICATIONS
The subject matter of the present application may also be related to the following U.S. patent applications: “System for Providing a Trustworthy User Interface” Ser. No. 09/979,905, filed Nov. 27, 2001; and “System for Digitally Signing a Document,” Ser. No. 09/979,904, filed Nov. 27, 2001.
FIELD OF THE INVENTION
This invention relates to the identification of a trusted computing entity and/or to monitoring or verifying the trustworthiness of a target computing entity.
BACKGROUND TO THE INVENTION
Conventional prior art mass market computing platforms include the well-known personal computer (PC), and a proliferation of known palmtop, laptop and mobile phone-type personal computers. Generally, markets for such machines fall into two categories, these being domestic or consumer, and corporate. A general requirement for a computing platform for domestic or consumer use is a relatively high processing power, Internet access features, and multi-media features for handling computer games.
On the other hand, for business use, there are a number of different proprietary computer platform solutions available aimed at organisations ranging from small businesses to multi-national organisations. In many of these applications, a server platform provides centralised data storage, and application functionality for a plurality of client stations. For business use, other key criteria are reliability, networking features and security features.
With the increase in commercial activity transacted over the Internet, known as “e-commerce”, there has been much interest in the prior art on enabling transactions between computing platforms, over the Internet. However, because of the potential for fraud and manipulation of electronic data, in such proposals, fully automated transactions with distant in the prior art on enabling transactions between computing platforms, over the Internet. However, because of the potential for fraud and manipulation of electronic data, in such proposals, fully automated transactions with distant unknown parties on a wide-spread scale as required for a fully transparent and efficient market place have so far been held back. The fundamental issue is one of trust between interacting computer platforms for the making of such transactions.
There have been several prior art schemes which are aimed at increasing the security and trustworthiness of computer platforms. Predominantly, these rely upon adding in security features at the application level. That is to say the security features are not embedded in the kernel of operating systems, and are not built into the fundamental hardware components of the computing platform. Although such prior art schemes go some way to improving the security of computer platforms, the levels of security and trustworthiness gained by prior art schemes may be considered insufficient to enable widespread application of automated transactions between computer platforms, and greater confidence in the trustworthiness of the underlying technology is thought to be required for many applications.
In the applicant's co-pending International Patent Application No. PCT/GB00/00528 entitled “Trusted Computing Platform” and filed on Feb. 15, 2000, the entire contents of which are incorporated herein by reference, there is disclosed a concept of a ‘trusted computing platform’ comprising a computing platform which has a ‘trusted component’ in the form of a built-in hardware and software component. Two computing entities each provisioned with such a trusted component may interact with each other with a high degree of ‘trust’. That is to say, where the first and second computing entities interact with each other the security of the interaction is enhanced compared to the case where no trusted component is present, because:
A user of a computing entity has higher confidence in the integrity and security of his/her own computer and in the integrity and security of the computer entity belonging to the other computing entity. Each entity is confident that the other entity is in fact the entity which it purports to be. Where one or both of the entities represent a party to a transaction, e.g. a data transfer transaction, because of the in-built trusted component, third party entities interacting with the entity have a high degree of confidence that the entity does in fact represent such a party. The trusted component increases the inherent security of the entity itself, through verification and monitoring processes implemented by the trusted component. The computer entity is more likely to behave in the way it is expected to behave.
International Patent Application No. PCT/GB00/00528 describes a method of determining whether a target trusted platform is alive and trustworthy, by issuing an “integrity challenge ” and receiving an “integrity response”. This method has been further developed by the Trusted Computing Platform Alliance (TCPA), an industry consortium focussed on improving trust and security on computing platforms. In its version 1.0 of the Trusted Computing Platform Specifications, a clear direction is provided to industry that facilitates trust in computing platforms and environments. It defines a subsystem so that it may be trusted to operate as expected. The subsystem contains an isolated computing engine whose processes can be trusted because they cannot be altered. The specification also describes features that will enable a basic level of trust in a platform in order to be considered trustworthy by local users and by remote entities. In the TCPA specification, a trusted platform obtains a cryptographic identity that proves that the platform is a trusted platform. When a third party sends an integrity challenge (a nonce) to the platform, the platform appends a summary of integrity measurements to the nonce, then signs the concatenated data using the trusted identity. This functionality is provided by the TCPA command named QUOTE. The signed data returned by a QUOTE is used with other TCPA data to determine whether the platform will be trusted by the third party. Such determination is done by the third party, because the trustworthiness of a platform depends on the intended use of that platform, and only the third party is in a position to make that decision.
In the applicant's co-pending British Patent Application No. 0020441.2, filed on Aug. 18 2001 and entitled ‘Performance of a Service on a Computing Platform’, there is described a method of performing a service for a requestor on a computing platform, comprising the steps of the requestor providing to the computing platform a specification of the service to be performed, wherein the specification of the service establishes specified levels of trust for at least some of the processes in the service, the computing platform executing the service according to the specification and logging the performance of at least some of the processes for which a level of trust was specified, and providing the requestor with a log of the performance of the processes performed according to the specified levels of trust.
Thus, the disclosed method allows for the provision of evidence of satisfactory performance of services on a computing platform in response to an electronically received request. The service can be specified to the computing platform, and in addition to the results of the service (if these are required by the requester—these may be required elsewhere), the requestor is provided with evidence that the service has been satisfactorily performed by the computing platform.
While the methods described in the applicant's co-pending disclosures and the TCPA specification provide information that assists in determining whether a target platform may be considered trustworthy, none of them describe a method of indicating to a person that a target platform is considered trustworthy.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, there is provided a host computing platform for accessing one or more electronic sites or services from a target computing platform, the host computing platform including means for visually indicating to a user thereof that said target computing platform includes a physically and logically protected computing environment.
Also in accordance with the first aspect of the present invention, there is provided a method of providing an electronic service via a remote target computing platform to a host computing platform, the method including the step of visually indicating on said host computing platform that said target computing platform includes a physically and/or logically protected computing environment.
In accordance with a second aspect of the present invention, there is provided a host computing platform for accessing one or more electronic sites or services from one or more remote target computing platforms, the host computing platform including means for providing a hyperlink within an active application running thereon, in the presence of which hyperlink, the host computing platform is adapted to continually or at intervals test whether or not said target computing platform is live and/or test the trustworthiness of said target platform, and to indicate, visually or otherwise, to a user of said host computing platform the liveness or otherwise and/or the trustworthiness or otherwise of said target computing platform.
Also in accordance with the second aspect of the present invention, there is provided a method of providing at a host computing platform an electronic site or service executed by a remote target computing platform, the method including the step of providing a hyperlink in an active document on said host computing platform, and, in response to the presence of said hyperlink, testing whether or not said target computing platform is live and/or testing the trustworthiness of said target computing platform and indicating to a user of said host computing platform the liveness or otherwise and/or the trustworthiness or otherwise of said target computing platform.
Thus, the present invention provides a method and apparatus for indicating to a person that a remote target platform is considered trustworthy. Such an indication may help a person initially select an electronic site or electronic service, and later provide confidence that a previously selected site or service continues to be trustworthy. The underlying intent of such an indication is to convey that the target platform may be considered trustworthy on the basis of the information in an integrity response and/or other supportive information (such as that specified in the above-mentioned TCPA specification), the user's policy and their intended use of the platform.
For the avoidance of doubt, the term “hyperlink” is intended to encompass any form of cross-reference in computer-readable text or code which allows direct or substantially immediate access to related material or the like. Thus, in this case, the hyperlink referred to in the second aspect of the present invention refers to a cross-reference in an electronic site or service (running on a target computing platform) which effectively allows direct access by a host computing platform (to which the site or service is being provided) to the target computing platform to test its liveness and/or its trustworthiness.
In the case of both the first and second aspects of the present invention, the indicating means is preferably in the form of a visual display on the screen of the host computing platform. The electronic site or service may be represented on the screen or display of a host computing platform by, for example, conventional source code or icons, all or a portion of which may be highlighted, marked, coloured differently or otherwise visually changed in the case where the service is being executed on a trusted computing platform. In one embodiment of the invention, such visual indication (regarding the liveness or otherwise of the target computing platform and/or the trustworthiness or otherwise of the target computing platform) may take the form of a particular colour (or change of colour) of a hyperlink or symbol associated with the hyperlink.
In accordance with a third aspect of the present invention, there is provided a method of providing an electronic site or service via a host computing platform, the method including the steps of executing said electronic site or service on a remote target computing platform which includes a physically and logically protected computing environment, and providing means in said electronic service for indicating, visually or otherwise, to a user of said service that said electronic service is being hosted by a computing platform which includes a physically and logically protected computing environment.
The third aspect of the present invention also extends to apparatus for providing an electronic site or service to a remote target computing platform, the apparatus comprising a host computing platform which includes a physically and logically protected computing environment, and means for indicating, visually or otherwise, to a user of said site or service that the electronic site or service is being hosted by a computing platform which includes a physically and logically protected computing environment.
The physically and/or logically protected computing environment referred to above may be that provided by a “trusted component” as described in the applicant's co-pending International Patent Application No. PCT/GB00/00528. In a preferred embodiment of the third aspect of the present invention, which beneficially concerns modifications to the visual representation of an electronic service, the electronic site or service (which is executed on a target computing platform) is represented on the screen or display of a host computing platform by, for example, conventional source code or icons, all or a portion of which may be highlighted, marked, coloured differently or otherwise visually changed in the case where the service is being executed on a trusted computing platform. The host computing platform may also be arranged to test, either continually or at intervals, the integrity (i.e. the trustworthiness) of the target computing platform executing the service.
Thus, the present invention is intended to provide a way of conveniently representing to a user the state of trust in a target computing platform, and in a preferred embodiment, a way of visually illustrating to a user that a site or service can be trusted (in the sense that it is executing on a trusted platform).
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described by way of examples only, and with reference to the accompanying drawings, in which:
FIG. 1 illustrates schematically a trusted computing platform as previously described in the applicant's co-pending International Patent Application No. PCT/GB00/00528;
FIG. 2 illustrates schematically connectivity of selected components of the computing platform of FIG. 1 ;
FIG. 3 illustrates schematically a hardware architecture of components of the computing platform of FIG. 1 ;
FIG. 4 illustrates schematically an architecture of a trusted component comprising the computing platform of FIG. 1 ; and
FIG. 5 is a flow diagram which illustrates schematically the functionality of a computing platform according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the invention may be practiced without limitation to these specific details. In other instances, well known methods, structures and terms have not been described in detail so as to avoid unnecessarily obscuring the present invention.
Referring to FIG. 1 of the drawings, there is illustrated schematically one example of a trusted computing platform as previously described in the applicant's co-pending International patent application No. PCT/GB00/00528. Referring to FIG. 2 , there is illustrated schematically the physical connectivity of some of the components of the trusted computing platform of FIG. 1 . Referring to FIG. 3 , there is illustrated schematically an architecture of the trusted computing platform of FIGS. 1 and 2 , showing physical connectivity of components of the platform. Referring to FIG. 4 , there is illustrated schematically an architecture of a trusted component included in the computing platform of FIG. 1 .
In the example shown in FIGS. 1 to 4 , the trusted computing platform is shown in the form of a personal computer suitable for domestic or business use. However, it will be understood by those skilled in the art that this is just one specific example of a trusted computing platform, and other examples may take the form of a palmtop computer, a laptop computer, a server-type computer, a mobile phone-type computer, information appliances, communication devices, display devices and hard copy devices generally, and the like, and the invention is limited only by the scope of the appended claims.
In the example illustrated by FIG. 1 , the computing platform comprises a display monitor 100 , a keyboard data entry means 101 , a casing 102 comprising a motherboard on which is mounted a data processor, one or more data storage means, a dynamic random access memory, various input and output ports (not illustrated in FIG. 1 ), a smart card reader 103 for accepting a user's smart card, a confirmation key 104 , which a user can activate when confirming a transaction via the trusted computing platform, and a pointing device, e.g. a mouse or trackball device 105 . The trusted computing platform also has a trusted component as described in the applicant's previous disclosure and as further described herein.
Referring to FIG. 2 of the drawings, there are illustrated some of the components included in the trusted computing platform, including keyboard 101 which incorporates confirmation key 104 and a smart card reader 103 , a main motherboard 200 on which is mounted first data processor 201 and trusted component 202 , and example of a hard disk drive 203 , and monitor 100 . Additional components which may be included in the computing platform, such as an internal frame to the casing 102 housing one or more local area network (LAN) ports, one or more modem ports, one or more power supplies, cooling fans, and the like, are not shown in FIG. 2 .
Referring to FIG. 3 of the drawings, main motherboard 200 is manufactured comprising a processor 201 , and a preferably permanently fixed trusted component 202 , a memory device 300 local to the processor, a BIOS memory area 301 , smart card interface 305 , a plurality of control lines 302 , a plurality of address lines 303 , a confirmation key interface 306 , and a databus 304 connecting the processor 201 , trusted component 202 , memory area 300 , BIOS memory area 301 and smart card interface 305 . A hardware random number generator 309 is also able to communicate with the processor 201 using the bus 304 .
External to the motherboard and connected thereto by the databus 304 , are provided one or more hard disk drive memory devices 203 , keyboard data entry device 101 , pointing device 105 , monitor 100 , smart card reader 103 , and one or more peripheral devices 307 , 308 , for example, a modem , printer, scanner, or other known peripheral device.
In the illustrated example, smart card reader 103 is wired directly to smart card interface 305 on the motherboard and does not connect directly to the databus 304 . In an alternative example, however, the smartcard reader 103 may be connected directly to databus 304 . To provide enhanced security, confirmation key switch 104 is hard wired directly to confirmation key interface 306 on motherboard 200 , which provides a direct signal input to trusted component 202 when confirmation key 104 is activated by a user such that a user activation the confirmation key sends a signal directly to the trusted component, by-passing the first data processor and first memory means of the computer platform.
Trusted component 202 is positioned logically and physically between monitor 100 and processor 201 of the computing platform, so that trusted component 202 has direct control over the views displayed on monitor 100 which cannot be interfered with by processor 201 .
Confirmation key 104 and confirmation key driver 306 provide a protected communication path (PCP) between a user and the trusted component, which cannot be interfered with by processor 201 , which by-passes databus 304 and which is physically and logically unconnected to memory area 300 or hard disk drive memory device(s) 203 .
The trusted component lends its identity and trusted processes to the computer platform and the trusted component has those properties by virtue of its tamper-resistance, resistance to forgery, and resistance to counterfeiting. Only selected entities with appropriate authorisation mechanisms are able to influence the processes running inside the trusted component. Neither an ordinary user of the trusted computer entity, nor any ordinary user or any ordinary entity connected via a network to the computer entity may access or interfere with the processes running inside the trusted component. The trusted component has the property of being “inviolate”.
In the illustrated example, the trusted component operates to monitor data, including user data files and applications, on the computer platform by creating a set of data files which the trusted component dynamically monitors for any changes in the data, including absence of the data, which may occur as a result of the computer platform being compromised by a virus attack, or other interference. The trusted component is allocated or seizes a plurality of memory location addresses and/or file directories in the first memory area of the computer platform, which become a user space reserved for use by the trusted component.
The reserved memory area comprises a selected proportion of the total memory area of the computer platform. Within the reserved memory area, the trusted component also creates a plurality of data files, which can either be copies from real user data files on the computer platform, or which can be created by the trusted component. The primary purpose of these files is to act as a set of files to which the trusted component has access, and to which ordinary user accounts of the computer platform, under normal operation, do not have access. Because the files in the reserved memory area are reserved for use by the trusted component and under normal operation, are not accessed by applications on the computer platform, the trusted component can use files stored in the reserved memory area as a “control” set of files by which to monitor unauthorised changes to the data, for example as caused by a virus.
Because the files stored in the reserved memory area are either duplicates of user files, duplicates of applications or files created specifically by the trusted component, they are of little or no value to the computer platform for performing its normal operating functions. If the files in the reserved memory area become corrupted for any reason, they may be sacrificed and are easily replaceable. However, since access to the reserve memory area is restricted to the trusted component, any corruption of the files in the reserved memory area is deemed to be indicative of changes to files occurring through undesirable mechanisms, e.g. by a virus program. The files in the reserve memory area are periodically monitored by the trusted component to check for such corruption. If corruption is discovered by the monitoring process, then a measure of the likely corruption of the remaining memory area on the computer platform can be determined by probabilistic methods.
By providing a reserved memory area containing files which can be sacrificed, if the computer platform is compromised by a hostile attack, e.g. a virus, then the sacrificial files stored in the reserved memory area are at least as likely to be affected as other user data files stored in the remaining portion of the memory of the computer platform. Thus any corruption of the files in the reserved memory area, if detected early enough, may give an indication to the trusted component that file corruption is occurring on the computer platform, in which case the trusted component can take action to limit the spread of corruption at an early stage, and preferably before damage is done to important data files stored in the remaining memory area of the computer platform.
Referring to FIG. 4 of the drawings, there is illustrated schematically an internal architecture of trusted component 202 . The trusted component comprises a processor 400 , a volatile memory area 401 , a non-volatile memory area 402 , a memory area storing native code 403 , and a memory area storing one or a plurality of cryptographic functions 404 , the non-volatile memory 401 , native code memory 403 and cryptographic memory 404 collectively comprising the second memory means hereinbefore referred to. The cryptographic functions 404 may include or comprise a source of random numbers.
Trusted component 202 comprises a completely independent computing entity from the computer platform. In the illustrated example, the trusted component shares a motherboard with the computer platform so that the trusted component is physically linked to the computer platform. In a preferred embodiment, the trusted component is physically distinct from the computer processing engine, that is to say it does not exist solely as a sub-functionality of the data processor and memory means comprising the computer platform, but exists separately as a separate physical data processor 400 and separate physical memory area 401 , 402 , 403 , 404 . By providing a physically separate trusted component, the trusted component becomes more difficult to mimic or forge through software introduced onto the computer platform. Programs within the trusted component are pre-loaded at manufacture of the trusted component, and are not generally user configurable. The physicality of the trusted component, and the fact that the trusted component is not configurable by the user enables the user to have confidence in the inherent integrity of the trusted component, and therefore a high degree of “trust” in the operation and presence of the trusted component on the computer platform.
The user's smart card may comprise a “cash card” or a “crypto card”, the functions of which are described in the applicant's co-pending International Patent Application No. PCT/GB00/00751 filed on Mar. 3, 2000 and entitled ‘Computing Apparatus and Methods of Operating Computing Apparatus’.
Referring now to FIG. 5 of the drawings, there is shown a flow diagram which illustrates schematically the functionality of a computing platform according to an exemplary embodiment of the present invention.
Consider the case where a user wishes to access a target site or service from a host platform. Prior to using a site or a service, a user indicated, at step 530 , the intended use of the site or service, preferably by selecting a visual representation of the intended usage or intended service. Such a visual representation may exist exclusively for the purpose of representing the trustworthiness of an instantiation of a process providing the intended usage, or may be an adaptation of the normal representation of the intended usage.
The user then peruses, via the host platform, a selection of potential suppliers on target platforms. Each target may be visually indicated by, for example, an iconic symbol that incorporates an indication as to whether the relevant target platform has proven its trustworthiness to the host platform. The number of trust “states” is not intended to be limited. A range of symbols may be provided to represent various levels of trustworthiness. In the applicant's co-pending international patent application number PCT/GB00/03613 entitled “Operation of Trusted State in Computing Platform”, the entire contents are incorporated herein by reference, there is described a computer platform which is capable of entering a plurality of different states of operation, each state of operation having a different level of security and trustworthiness. Selected ones of the states comprise trusted states in which a user can enter sensitive confidential information with a high degree of certainty that the computer platform has not been compromised by external influences such as viruses, hackers or hostile attacks. Each operating state can be distinguished from other operating states using a set of integrity metrics designed to distinguish between those operating states. The computer platform has a plurality of physical and logical resources, and each operating state utilises a corresponding respective set of the physical and logical resources.
Thus, in one exemplary embodiment of the invention, there are at least two trust state symbols, the first indicating that a target is considered trustworthy and the second indicating that a target has been found to be untrustworthy. In a more preferred embodiment, a third trust state symbol is provided to indicate that the trustworthiness of a target is unknown. However, it will be appreciated that other intermediate trust states may be provided for, as discussed in the above-mentioned co-pending application.
A target symbol may include the URL of the target and opening a symbol may reveal properties of the represented entity, or enable mutual control of administration processes, for example.
At step 540 , the user choses a target for the intended usage, and the host platform takes the necessary actions (at step 500 ) to make a connection with a target computing platform and request the execution of a service, in accordance with a host user request.
While the site or service is being used, the host platform periodically verifies the trustworthiness of the selected site or service for the intended usage, and displays the appropriate version of iconic symbol for that target. At the same time, the visual representation of the intended usage indicates whether the usage is being provided by a trustworthy target.
In this example, in response to a request from the host platform to execute a service, a hyperlink is inserted (at step 510 ) into the active document now running on the host computing platform.
In response to the hyperlink, the host computing platform is arranged to test (either continually or at intervals) whether or not the target computing platform is live (at step 512 ) and also to test the trustworthiness of the target computing platform (at step 522 ). The liveness or otherwise of the target computing platform is displayed, at step 514 , on the screen of the host computing platform, either in the form of a symbol associated with the hyperlink or a particular colour or format of the hyperlink itself. Similarly, at step 524 , the trustworthiness or otherwise of the target computing platform is displayed to the host computing platform user.
In a first example, consider the case that a user wishes to ask for bids for the provision of an item or types of item. The user activates an icon that represents the type of purchase. This may take one form for low value purchases and another form for high value purchases, or may be a visual representation of a specification of a particular item, for example. The usage icon is added to a set of icons including icons representing target platforms that may act as vendors, or as agents for vendors. Initially these target icons are all of the type that indicate that the trustworthiness of the target for the intended purchase is unknown. The host platform interrogates the targets using an integrity challenge, gets the integrity responses back from the targets, then uses the integrity responses, together with supporting information the host platform's policies and the user's policies to determine whether a particular target is trustworthy enough to be asked to tender for the intended purchase. The type or visual representation of the target icon is then changed to trustworthy or untrustworthy, as appropriate. At some point, the user drags the item icon to a target icon or icons, and drops the item icon on the target icon or icons. This causes the host platform to ask the chosen target or targets to provide a bid for the provision of the item.
In a second example, consider the case that a user wishes to execute an electronic service on a target platform, where the methods to execute the service are already known to the target platforms. The service may be specialised or generic. The process proceeds as in the first example. At some point, the user drags the service icon onto a chosen target. This causes the host platform to request the chosen target to start the service, and the unsuccessful target icons are ghosted. While the service is running, the host periodically challenges the successful target and recomputes the trustworthiness (or not) of the successful target. The type of service icon indicates whether it is executing on a target that is considered trustworthy for that particular service. Naturally, it may be the policy of the host or the user that a service is not permitted to execute on a target that is untrustworthy for that particular service. So the host would not contact a target if the user dragged the service icon to an untrustworthy or unproven target. Similarly, the host may terminate a service if the host discovers that a previously trustworthy target has become untrustworthy.
In a third example, consider the case that a user wishes to execute an electronic service on a target platform, where the methods to execute the service are not known to the target platforms. The service could be an entire service and represented by a single icon, or could be part of a larger service and represented by multiple icons, or by modules of source code, or be represented by lines of source code, for example. The process proceeds as in the first example. At some point, the user drags service icons or modules or lines of code onto target icons. Each target executes the appropriate part of the service. So a target may execute all of a service, or part of a service (and be required to co-operate with other targets). While the service is running, the host periodically challenges the successful target(s) and recomputes the trustworthiness (or not) of the successful target(s). Again, it may be the policy of the host or the user that a service is not permitted to execute on a target that is untrustworthy for that particular service. So the host may refuse to start or continue a service on an untrustworthy target. While the service or part of a service is executing, the service icon changes to indicate the trustworthiness of the target providing that part of the service. In the case where the service is represented by textual source code, the trustworthiness of the target executing that code may be indicated by the colour or texture of the text or its background, for example.
In all cases, the request to use a target may be raised by an automatic process. In that case, the method described above is used merely to display the state of targets and/or services to a person, and the person (obviously) does not raise the request nor necessarily select particular targets.
Of course, the degree of effectiveness of the present invention is dependent on the level of trust a user has in their own computing platform. Ideally, the user would have a trusted computing platform, as described above with reference to FIGS. 1 to 4 of the drawings. However, while the concept of the above-described trusted component goes a long way to providing a user with a substantial degree of trust in a computer platform, there are still times when the user requires an even higher degree of trust in his equipment, for example during an electronic transaction, such as digitally signing a document, or digitally transferring funds from the platform to a remote platform.
The conventional method of signing a document is to physically write a signature on the medium (usually paper) upon which an image of a document is reproduced. This method has the advantages that it is clear what is being signed, and the signed image is proof of what was signed. However, it does not meet the needs of e-commerce.
Nowadays it is also possible to digitally sign a document, using a conventional computer platform and standard encryption techniques. In conventional computer platforms, however, the present inventors have appreciated that the electronic rendition of a document which is digitally signed is typically not the same rendition of the document that is visible to the user. It is therefore possible for a user to unintentionally sign data that is different from that which he intended to sign. Conversely, it is also possible for a user to intentionally sign data and later fraudulently claim that the signed data does not correspond to that displayed to him by the computer platform. Such problems would still be present, even if a trusted platform, as described above, were used.
Conventional electronic methods of signing are well known to those skilled in the art. Essentially, digital data is compressed into a digest, for example by the use of a hash function. Then that digest is encrypted by the user of some encryption method that has been initialised by a secret key (or simply a ‘secret’). This is normally done on a computer platform, such as a PC. One implementation is to sign data using a private encryption key held secret on a user's smartcard, which is plugged into a smartcard reader attached to the computer platform. In the specific case of a textual document, the digital data may be the file produced by a word processor application, such as Microsoft's Notepad, Wordpad, or Word. As usual, the act of signing implies that the signer accepts some legal responsibility for the meaning of the data that was signed.
Hash functions are well known in the prior art and comprise one way functions which are capable of generating a relatively small output data from a relatively large quantity of input data, where a small change in the input data results in a significant change in the output data. Thus, a data file to which is applied a hash function results in a first digest data (the output of the hash function). A small change e.g. a single bit of data in the original data file will result in a significantly different output when the hash function is reapplied to the modified data file. Thus, a data file comprising megabytes of data may be input into the hash function and result in a digital output of the order of 128 to 160 bits length, as the resultant digest data. Having a relatively small amount of digest data generated from a data file stored in the reserved directory is an advantage, since it takes up less memory space and less processing power in the trusted component.
During known signing processes, a user will typically interpret a document as it has been rendered on the computer's monitor at normal magnification and resolution. In existing applications, the user's smartcard signs data in a format that is the representation of the document by the application used to create and/or manipulate the document. The present inventors believe, however, that there is potential for software to send data to the smartcard that has a different meaning from that understood by the user when viewing the screen. This possibility may be sufficient reason to introduce doubt into the validity of conventional methods of digitally signing electronic representations of documents that are to be interpreted by people.
Thus, in the applicant's co-pending international patent application number WO00/73913 entitled “System for Providing a Trustworthy User Interface”, the entire contents of which are incorporated herein by reference, the concept of a “trusted display” is introduced. The above-mentioned co-pending application describes a computer system which employs a trust display processor, which has a trusted processor and trusted memory physically and functionally distinct from the processor and memory of the computer system. The trust display processor is immune to unauthorised modification or inspection of internal data. It is physical to prevent forgery, tamper-resistant to prevent counterfeiting, and has crypto functions to securely communicate at a distance.
Obviously, the highest degree of effectiveness can be achieved by the present invention of the user's computer platform is a trusted computer platform having a trusted display. However, these are not essential to the usefulness of the present invention. For example, the user's platform may be a trusted computer platform which does not have a trusted display. Although the degree of trustworthiness of the user's equipment is somewhat reduced in these circumstances, the user may (a) not require the higher degree of trust provided by a trusted display or (b) have a greater degree of confidence in his own equipment than he would have in an unknown system, in which case the present invention is at least nearly as effective as it would be if the user's equipment included a trusted display.
Similarly, even if the user's platform is not a trusted computer platform, so that the degree of trustworthiness thereof is somewhat further reduced, the user may once again have sufficient confidence in his equipment for the present invention to be considered effective.
An embodiment of the present invention has been described above by way of example only, and it will be apparent to a person skilled in the art that modifications and variations can be made to the described embodiment without departing from the scope of the invention as defined by the appended claims.
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A computing platform for receiving one or more electronic sites or services from a remote target computing platform is adapted to indicate, visually or otherwise, to a user thereof that the target computing platform includes a physically and logically protected computing environment.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 11/990,563 filed on Feb. 15, 2008, which is a national stage application of International Application No. PCT/GB2006/002711 filed on Jul. 20, 2006, which claims the benefit of British Application No. GB0516724.2 filed on Aug. 15, 2005, the contents of all of which are incorporated by reference herein.
BACKGROUND
1. Field of the Invention
[0002] The invention relates to a security device for security substrates, such as paper, used for making security documents, such as bank notes, having anti-counterfeitable features.
2. Description of Related Art
[0003] It is generally known to include elongate elements in paper or other substrates, usually as a security feature. Such elements can be threads, strips or ribbons of, for example, plastics film, metal foil, metallized plastic, metal wire. These elongate elements are included in the thickness of the substrate to render imitation of documents produced therefrom more difficult. These elements help in the verification of the documents as they render the view of the documents in reflected light different from that in transmitted light. To increase the security provided by the inclusion of such an elongate element, it is also known to endow the element itself with one or more verifiable properties over and above its presence or absence. Such additional properties include magnetic properties, electrical conductivities, the ability to absorb x-rays, fluorescence, optically variable effects and thermochromic behavior.
[0004] As a further security feature, it has been found to be particularly advantageous to provide windows in one side of the surface of the substrate, which expose such elongate elements at spaced locations. Examples of methods of manufacturing paper incorporating security elements with or without windows are described below. It should be noted that references to “windowed thread paper” include windowed paper incorporating any elongate security element.
[0005] EP-A-0059056 describes a method of manufacture of windowed thread paper on a cylinder mold paper-making machine. The technique involves embossing the cylinder mold cover to form raised regions and bringing an impermeable elongate security element into contact with the raised regions of the mold cover, prior to the contact entry point into a vat of aqueous paper stock. Where the impermeable security element makes intimate contact with the raised regions of the embossing, no fiber deposition can occur and windows are formed in the surface of the paper. After the paper is fully formed and couched from the cylinder mold cover, water is extracted from the wet fiber mat and the paper is passed through a drying process. In the finished paper the regions of the security element which are exposed in the windows are visible in reflected light on one side of the paper, which is commonly used for mainly banknotes.
[0006] As an alternative to elongate elements, patches and foils can be applied to a surface of a substrate to cover a window or aperture.
[0007] The widespread use of security documents having security elements exposed on windows along the length of the element has resulted in enhanced security. A security document of this type provides this enhancement as, when viewed in transmitted light, the security element provides a different view from that which is seen under reflected light, where parts of the security element are readily visible in the window. However, there is a continual need for further enhanced security features to render the task of a would be counterfeiter more difficult.
[0008] U.S. Pat. No. 5,573,639 describes a safeguarding thread in which metallic stripes are provided on a transparent or translucent plastic substrate. Visually and/or machine readable information extends over several of the stripes and is made up of metal free or partly metal free characters having a contrasting appearance to the metal stripes.
[0009] EP-A-0659587 also describes a security element which has a first information portion which is visually recognizable without aids and a second information portion which is harder to resolve visually due to its smaller size as compared to the first information portion. Effectively the design contains two sets of demetallized indicia, one significantly smaller than the other. A security element of this type therefore provides two levels of authentication and the fact that the two designs are visually similar increases the security.
SUMMARY
[0010] It is an object of the present invention to further enhance the security of security devices such as elongate security elements, foils and particles.
[0011] According to the invention there is provided a security device for a security substrate said device comprising a carrier of an at least partially light transmitting polymeric material, said carrier bearing a plurality of first indicia which are easily visible to the human eye, said first indicia being defined by a plurality of smaller second indicia which are less visible to the human eye positioned relative to each other to enable the first indicia to be visualized.
[0012] The invention provides an improvement in the anti-counterfeitability of the security devices over the construction described in EP-A-659587 in that it introduces complex requirements of positioning and registration of the smaller indicia to enable the larger indicia to be visualized. In addition, as the smaller indicia are used to create the larger indicia, the overall design takes up less space on the security element than on the prior art threads, where the smaller and larger construction portions are in separate locations. This is particularly important for windowed security devices where design space is limited to the window region.
[0013] The present invention also allows the controlled use of a limited set of characters, such as a bank's initials or note dominations, which can be laid out on a security device such that even when the vertical position is not registered, there is the ability to have a full set of characters falling within a window space on each banknote. This improves the readability of the security feature as it is given a uniform background. Such a set of characters can then combine both macro- and micro-elements in the limited space compared to the prior art devices.
[0014] An additional advantage is that the invention presents a visual image which is more interesting than those of the prior art. Making the security element interesting to the viewer increases the probability that a member of the public will view and inspect the device, and the security document as a whole, which means that the security device has a greater security impact. This has a benefit over visually complex devices, such as those described in U.S. Pat. No. 5,573,639, which very easily become confusing, particularly when the document in which the security device is incorporated is overprinted. Due to the manner in which the images are built up in the present invention, this is not a problem and the large characters remain easily visible.
[0015] With the improvements in modern scanners and desk-top printing equipment, it is also necessary for manufacturers to increase the complexity of designs used on security documents, but this must be done without compromising the public accessibility or the readability of the security features. The present invention provides a simple to recognize public security feature, with a more complex feature, which is much harder to copy with modern scanning equipment
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention will now be described, by way of example only, with reference to, and as shown in the accompanying drawings in which:
[0017] FIG. 1 is a plan view of an elongate security element according to the present invention having metallized indicia;
[0018] FIG. 2 is a plan view of an alternative embodiments of the present invention, in which the security device is provided with a different form of indicia;
[0019] FIG. 3 is a plan view of another alternative embodiments of the present invention, in which the security device is provided with a different form of indicia;
[0020] FIG. 4 is a plan view of a security article incorporating the security device of FIG. 3 ;
[0021] FIGS. 5 to 11 are plan views of alternative embodiments of the present invention, in which the security device is provided with different forms of indicia; and
[0022] FIG. 12 is yet another alternative embodiment of the security device according to the invention wherein the indicia are of different sizes.
DETAILED DESCRIPTION
[0023] FIG. 1 shows a security device in the form of an elongate security element 10 according to a first embodiment of the present invention for partially embedding into a fibrous substrate, such as security paper. The security element 10 comprises a carrier 11 of a suitable plastic material which is flexible and water impermeable, and which is at least translucent and partially light transmissive, but preferably substantially transparent. A suitable material would be PET. The security element 10 is provided with large easily legible indicia 12 which are formed from smaller indicia 13 .
[0024] In the example shown in FIG. 1 , the large indicia 12 comprise the numerals “2” and “0” forming the number “20”, wherein the “2” and “0” are constructed from the small, less easily legible metallized letters 13 which read in sequence “STARCHROME” and “CLEARTEXT”. The small indicia 13 are of a size which is more difficult to discern visually by the unaided eye, but which provides an additional degree of anti-counterfeitability as they are significantly more difficult for the counterfeiter to produce. However, once the eye has focused on the large text, it becomes easier to realize the presence of the small indicia 13 and to recognize them. The smaller indicia 13 may be provided by printed, conductive or non-conductive, metallic or other opaque inks or by other known metallization or demetallization processes.
[0025] Preferably, the width of the security element 10 is in the range of 1 to 30 mm whilst the height of the larger indicia 12 is in the range of 0.8 to 28.0 mm, and more preferably 0.8 to 8.0 mm. The height of the smaller indicia 13 is preferably in the range of 0.2 to 6 mm and more preferably 0.2 to 2.00 mm.
[0026] In a preferred embodiment, for a security element of 8 mm width, the height of the large indicia 12 is preferably 6 mm, with the height of the smaller indicia 13 being 1 mm. For a security element of 4 mm width, the height of the large indicia 12 is 2 mm and the height of the smaller indicia 13 is 0.4 mm. The smaller indicia 13 can be of a size where they can only be resolved by a viewing aid such as a magnifying glass.
[0027] As shown in FIG. 2 , the smaller indicia 13 may alternatively comprise demetallized indicia. In this example the carrier 11 is metallized to provide a metal layer of aluminum or another suitable metal. This can be done by vacuum deposition, electroplating or another suitable method. The metallized carrier 11 is then partially demetallized using a known method, such as the resist and etch method, to provide clear regions which form the indicia 13 . The indicia may be formed from regions of reduced metal thickness, as described in WO 2004/014665.
[0028] In both of the embodiments shown in FIGS. 1 and 2 , the metallic regions may be provided by printing the security element 10 with a metal effect ink having a metallic appearance such as Metalstar® inks sold by Eckart. Such metal effect inks do not, however, necessarily provide conductivity. It is advantageous, however, that the indicia 12 / 13 , where these comprise metallic material, and/or the security element 10 as a whole, provide conductive properties that enable the thread to be machine detectable for authentication or denomination sorting purposes.
[0029] In the current invention only the small indicia are physically produced during the metallization, demetallization or printing process. The larger indicia are created by the positioning and registration of the smaller indicia. Generating a conventional metallic security thread with large and small demetallized characters cab be problematic because of the large difference in stem width between the large and small characters. It is difficult to optimize the etchant process to efficiently achieve both fine and coarse demetallized regions. For example, if the process is optimized for the fine regions then the coarse regions will not be completely demetallized, and if the machine is optimized for the coarse regions, then the resolution of the fine regions is reduced due to too much metal being removed. An advantage of the current invention is that as the smaller indicia are used to define the larger indicia the demetallization process can be optimized for the stem width of the smaller characters and therefore the optimum resolution can be achieved. The demetallization process can be further optimized by generating the small characters with a constant stem width.
[0030] As a further alternative the indicia can be provided by printing the security element 10 with an optically variable ink, such as OVI® as supplied by Sicpa, or other colored opaque or transparent inks. One or more colors may be used to create multicolored designs, such as national flags. In the embodiment shown in FIG. 3 , the first indicia 12 comprise the French flag. A first section 14 is printed with the second indicia 13 , namely small numerals representing the denomination of a banknote (e.g., £10) which are printed in red ink. A second section 15 is left clear, so that the white color of the underlying paper shows it through and a third section 16 is printed with similar numerals to those in section 14 , but in blue ink. The outline is shown for the sake of clarity and is not part of the design.
[0031] In FIG. 4 the security device 10 of FIG. 3 is shown as an elongate security element which is partially embedded in a security substrate from which a banknote or other security article 17 is formed. The security element is partially exposed at windows at the surface of the substrate.
[0032] Obviously any of the above mentioned inks can be combined either with other inks or with vacuum deposited metal layers.
[0033] As shown in FIGS. 5 and 6 , symbols or pictorial elements may be used as the smaller indicia 13 instead of alphanumeric characters, which make up the alphanumeric large indicia 12 in those figures “DLR” and “70” respectively.
[0034] FIG. 7 shows a further example whereby the smaller indicia 13 comprise positive opaque symbols, such as stars, this time making up the larger indicia 12 , which is also a symbol of a larger star 12 . The carrier 11 is clear so the indicia 12 / 13 will be seen as a positive design on a clear background. FIGS. 8 and 9 are further embodiments whereby the large indicia 12 are numerals “5”, made up of smaller indicia 13 which are also the numerals “5”. In FIG. 8 , the large indicia 12 would appear as negative metallized characters, made up of smaller indicia 13 which are negative demetallized characters formed on a metallized carrier 11 . In FIG. 9 , similar to FIG. 7 , the large indicia 12 would appear positive, being made up of smaller indicia 13 which are positive metallized characters on a clear carrier 11 .
[0035] FIG. 10 shows a further alternative embodiment of a security device according to the invention. In this embodiment the carrier 11 is metallized and then partially demetallized to form repeating smaller indicia 13 (the numerals “20”) which closely repeat along the length and across the width of the security element 10 . The larger indicia 12 are provided by solid metal regions (forming the numerals “10”) outlined by a plurality of the smaller indicia 13 .
[0036] In FIG. 10 the large indicia 12 would appear positive, being made up of smaller negative indicia 13 . FIG. 10 a shows a further alternative embodiment in which the smaller indicia 13 are metallized characters on a clear carrier 11 . The larger indicia 12 are provided by regions of the clear carrier 11 outlined by a plurality of the smaller metallized indicia 13 . In FIG. 10 a the large indicia 12 would appear negative, being made up of smaller positive indicia 13 .
[0037] FIG. 11 shows an embodiment of a security device similar to that shown in FIG. 10 , which has been modified such that smaller indicia 13 are provided along and across the entire security element 10 . However, the large indicia 12 are created by modifying the appearance of the smaller indicia 13 to provide a visible contrast. For example the font or stem width of indicia 13 may be changed. Alternatively the density of the metal used in forming the smaller indicia 13 may be changed to provide the contrast for example by chemical etching to remove some but not all of the metal present in the regions of the said indicia 13 . In a further embodiment, the color of the smaller indicia may be changed to provide the contrast.
[0038] In a further alternative embodiment of the invention in which the sizes of both the smaller indicia 13 and the large indicia 12 on the security device vary along the length of a security element 10 . In the embodiment illustrated in FIG. 12 the size of the indicia 12 , 13 reduces over a first length of the element 10 from a starting size to a finishing size until a point is reached whereby the larger indicia 13 are replaced by single line indicia of a size a little smaller than the finishing size of the larger indicia 12 . The single line indicia continue reducing in size over a second length of the element 10 until they nearly reach the starting size of the smaller indicia 13 . At this point a further first length of larger and smaller indicia 12 , 13 commences. The first and second lengths appear to merge into each other. In further examples in the invention, either the size of the large indicia 12 may vary or the size of the smaller indicia 13 , but not both.
[0039] A further variation on the embodiments described previously is to provide the device 10 with an optical effect layer. Examples of suitable optical effect layers include liquid crystal polymers, liquid crystal pigmented ink layers, iridescent print layers, dielectric thin film structures.
[0040] The optical effect layer may be used in addition to or instead of a demetallized layer. For example, an iridescent or liquid crystal pigmented ink layer can be printed to define the large and small indicia 12 / 13 . More preferably the large and small indicia 12 / 13 are defined by printing a darkly colored ink layer that can contain other functional pigments such as carbon black or magnetics, which is then overprinted all-over with the iridescent or liquid crystal ink layer.
[0041] Where a polymer liquid crystal film layer, holographic layer or thin film dielectric structure is applied this is preferably, but not necessarily, done in conjunction with a metal layer. For example, where the security device 10 is to be provided with a holographic layer, the demetallized layer can be used as a reflection-enhancing layer. A polymer carrier 11 is first coated with an embossing lacquer which is then embossed with a holographic relief. The embossed layer is then metallized and the resulting metal layer partially demetallized. The resulting structure can be provided with an optional protective layer
[0042] In an alternative holographic embodiment, a polymer film 11 is coated with an embossing lacquer and then embossed with a holographic relief structure. A transparent high refractive index layer (e.g., ZnS) is coated over the holographic relief layer. The large and small indicia are then provided by printing opaque or transparent inks. The ink may be a metal effect ink.
[0043] In a further alternative embodiment, a holographic transfer construction may be used. This is essentially the same as described above, but with the addition of a wax release layer and an adhesive layer. The wax release layer is provided between the polymer carrier 11 and the metal or lacquer layer such that after transfer the polymer can be removed. A hot melt or pressure sensitive adhesive layer is provided on the opposite surface to the carrier 11 , i.e., the surface that comes into contact with the substrate.
[0044] In a further variation thermochromic and liquid crystal materials can be used, such as those described in EP-A-608078 and WO-A-03061980.
[0045] It is also widely known, in the field of manufacturing security devices 10 , to provide additional machine readable features. Machine readable properties typical to this class of security device 10 are conductivity, magnetism, and luminescence. Numerous methods have been described within the prior art for producing security devices with machine readable characteristics. Examples of such devices can be found in EP-A-319517, EP-A-516790, EP-A-998396, EP-A-961996 and EP-A-1334844.
[0046] Where the security devices are security elements, they may be inserted into a paper, or other, substrate so that they are either wholly or partially embedded within the substrate. Whilst security elements can be used in wholly embedded or windowed form, the latter is preferred as the indicia are then easily recognizable in both reflected and transmitted light, rather than in just transmitted light as in the wholly embedded form. The security elements 10 of the present invention may also be used in the construction such as those described in EP-A-1141480 whereby the element is exposed in windows on one surface of the substrate and the element is wholly exposed along its length on the other side.
[0047] In other embodiments, instead of elongate security elements, patches, foils and the like may be applied to a surface of the substrate. These may be applied such that they cover windows or apertures formed during the manufacture of the substrate or in a subsequent cutting process, such as laser or die cutting, so that part of the device is revealed on one side of the substrate in those windows or apertures.
[0048] The indicia or repeating pattern may be registered with the windows in the machine direction, so that an identical portion of the indicia or pattern is seen in each window. This requires the use of a registration process, such as that described co-pending application GB 0409736.6.
[0049] The finished security paper may be printed on one or both sides to identify the article or document formed from the paper. This printing may include indicia which matches the indicia 12 or 13 .
[0050] The security substrate is used to manufacture security articles such as banknotes, vouchers, bonds, passports, security labels, certificates and the like.
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A security device for security substrates, such as paper used for making security documents, such as banknotes, having anti-counterfeitable features and methods of making are provided. The security device has a carrier of at least partially light transmitting polymeric material. A carrier bears a plurality of first indicia which are easily visible to the human eye. The first indicia are defined by a plurality of smaller second indicia which are less visible to the human eye positioned relative to each other to enable the first indicia to be visualized.
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This application is a continuation-in-part of U.S. patent application Ser. No. 09/382,869, filed Aug. 25, 1999, which is a continuation-in-part of U.S. patent application Ser. No. 09/090,723, now U.S. Pat. No. 5,947,690, filed Jun. 4, 1998, and also claims priority to U.S. Provisional Application No. 60/049,234, filed Jun. 9, 1997. The entire contents of each of these applications is incorporated herein by reference.
BACKGROUND OF THE INVENTION
Electrically operated pumps are used to supply water from wells and to boost the pressure of municipal water systems. Such pumps are operated by electric motors under the control of a pressure sensitive switch. Some prior art systems operate by keeping a reservoir tank substantially filled with water. In such a system, the pump motor turns on when pressure drops below a pre-set value and turns off when the pressure reaches another higher pre-set value. The duty cycle for the electric motor in such a system is high, with numerous transitions from off to on and off again.
Alternative systems are known in which the pump runs when there is a demand for water and is off when the demand ceases. U.S. Pat. Nos. 5,190,443 and 5,509,787 are directed to actuators which control a pump based on demand. In these two patents, the interplay of hydrostatic and hydrodynamic forces moves a shuttle member which alternately opens and closes a passageway to allow pressure to communicate with a pressure-activated switch for controlling the pump motor. Another design as set forth in U.S. Pat. No. 3,871,792 utilizes a combination of hydrodynamic forces and spring forces to control a switch operate the pump motor. In particular, the configuration set forth in the '792 patent requires two springs, one to control the moving member of a poppet valve and another spring to control the motion of a flexible diaphragm. The design is also complicated by first and second internal auxiliary passageways to provide for pump motor control.
SUMMARY OF THE INVENTION
In one aspect, the invention is a hydraulic actuator comprising an actuator body which includes an inlet, at least one outlet, a port communicating with a pre-charged diaphragm tank, and a port communicating with a pressure switch. The actuator body includes a movable member which, in a first position, fills the inlet port and provides fluidic communications with the pressure switch. In a second position, the movable member opens the inlet's port and seals the pressure switch port. The actuator further comprises a spring disposed within the actuator body, which urges the movable member towards the first position. The movable member includes a bypass which provides fluidic communication between the inlet and interior of the actuator body when the movable member is in the first position. The actuator may include a check valve assembly, which, in an open position, allows fluidic communication from the pressure switch to the actuator valve.
In a preferred embodiment, the movable member comprises a lubricious material or a lubricous coating. The lubricious material or coating may be a fluoropolymer such as Teflon™ or an acetal such as Delrin™. Other appropriate fluoropolymers include fluorinated ethylene propylene, perfluoroalkoxy copolymers, and ethylene-tetrafluoroethylene copolymers. Other appropriate lubricious coatings include diamond, diamond-like coatings, silver, metal oxides and fluorides, molybdenum sulfide, tungsten sulfide, carbon, graphite, titanium nitride, nickel alloys, parylenes, poly(vinylpyrrolidone), silicone, boron nitride, polyimides, or plasma vapor deposited polymers.
In another aspect, the invention is a hydraulic actuator comprising an actuator body which includes an inlet, at least one outlet, a port communicating with a pre-charged diaphragm tank, a port communicating with a pressure switch, and a passageway communicating with the port which communicates with the pressure switch and an interior of the actuator body. The actuator body includes a movable member which seals the inlet port and provides fluidic communication with the pressure switch when it is in a first position. In a second position, the movable member opens the inlet port and seals the pressure switch port. The actuator further comprises a spring disposed within the actuator body which urges the movable member toward the first position. The movable member includes a bypass which provides fluidic communication between the inlet and an interior of the actuator body which the movable member is in the first position. The actuator may further include a support member which includes a transverse passageway in fluidic communication with an axial passageway, wherein the axial passageway communicates with the port which communicates with the pressure switch. The support member may include plurality of spaced apart seals. The movable member may include a passageway which enables fluidic communication between the interior of the actuator body and the port in communication with the pressure switch when the movable member is in the first position.
The bypass may comprise at least one groove oriented longitudinally with respect to the movable member, which is cut into a surface of the movable member, or the by-pass may comprise at least one channel drilled through a base portion of the movable member. The movable member may include an axial passageway which enables fluid communication between the port which communicates with the pressure switch and the interior of the actuator body when the movable member is in the first position. When the movable member is in the first position, it may be seated in a recess in the actuator body and may seal the inlet port by means of an o-ring seated in the recess. A flow rate of greater than 2.5 gal/min through the inlet may exert a force on the movable member greater than that exerted by the spring. The minimum flow rate to overcome the force of the spring may be 2, 1.5, 1, or 0.5 gal/min. The actuator may further include a support member which guides the movable member in a sliding motion. The support member may include a transverse passageway which is in fluidic communication with an axial passageway, which in turn communicates with the port communicating with the pressure switch. The movable member may include a passageway which enable fluidic communication between the transverse passageway and the interior of the actuator body when the movable member is in the first position.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a cross-sectional view, partly exploded, of the actuator valve of the invention along with a pressure switch.
FIGS. 2A, 2 B, and 2 C are cross-sectional views of the actuator valve in different states of operation.
FIG. 3A is a cross-sectional view of the movable member of the actuator valve.
FIG. 3B is an end-on view of the movable member of the actuator, showing the low-flow bypass.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference first to FIG. 1, an actuator system 10 includes an actuator body portion 12 . The body portion 12 includes an inlet connection portion 14 which is adapted to be connected to a pump (not shown). As will be appreciated by those skilled in the art, the pump is connected to a source of water such as a well or a municipal water supply. The actuator body 12 also includes an outlet port 16 from which water is discharged as, for example, through a faucet (not shown). There may be additional outlet ports. A pressure switch assembly 18 includes an electrical switch which, when closed, turns on a pump and which, when opened, turns off a pump. The pressure switch assembly 18 is connected to a port 20 which communicates with the pressure switch 18 . A port 22 is connected to a pre-charged diaphragm tank assembly 24 . The tank assembly 24 includes an outer enclosure 26 and an inner diaphragm 28 . Water fills the diaphragm 28 which expands against air entrapped between the diaphragm 28 and the enclosure 26 to pressurize the water. If tank assembly 24 is a cold water expansion tank, the maximum working temperature should be 200° F.
The actuator assembly 10 will now be described in more detail in conjunction with FIG. 2 . Disposed within the actuator body 12 is a movable member 30 which is guided in its sliding motion by a fixed support 33 . As shown in the figure, the movable member 30 seats within a recess portion 32 and is in sealing relation by virtue of an o-ring seal 34 . Because movable member 30 slides against fixed support 33 , it is desirable that movable member 30 be manufactured from a lubricious material, or, alternatively, have a lubricious coating. In a preferred embodiment, movable member 30 is fabricated from a fluoropolymer, such as Teflon™ (polytetrafluoroethylene), fluorinated ethylene propylene, perfluoroalkoxy copolymers, or ethylene-tetrafluoroethylene copolymers. An acetal such as Delrin™ would also be appropriate. Alternatively, the movable member 30 can be fabricated from a material and then coated with a lubricious coating. Exemplary coatings include diamond, diamond-like coatings, silver, metal oxides and fluorides, carbon, graphite, titanium nitride, various nickel alloys, parylenes such as poly(vinylpyrrolidone), silicone, boron nitride, polyimides, and plasma vapor deposited polymers. Materials such as molybdenum sulfide, tungsten sulfide, and titanium nitride can either be used as coatings or added to a resin matrix which is used to coat the moveable member 30 . Where the movable member number 30 is seated in recessed portion 32 , the base of the movable member is tapered (FIG. 3 A). The angle, n, of the taper may be 15°, and the distance x over which the taper extends may be 0.015 in. (0.38 mm). The support member 33 includes spaced apart o-ring seals 36 and 38 . The fixed support 33 includes a transverse passageway 40 which is in fluid communication with an axial passageway 42 . The axial passageway 42 communicates with the port 20 leading to the pressure switch 18 (FIG. 1 ).
The operation of the actuator 10 of the invention will now be described in conjunction with FIGS. 2A-C. When the movable member 30 is fully seated within the recess 32 , the inlet port 14 is closed while the port 40 is in fluidic communication with fluid within the actuator body 12 via passageway 41 . Thus, the pressure switch 18 responds to pressure within the actuator body 12 through the passageways 40 and 42 . The diaphragm 28 is distended by being filled with water; pressure is provided by air compressed between the diaphragm 28 and the enclosure 26 . A low flow bypass 62 in movable member 30 enables pressure equalization between the fluids in the actuator body 12 and the inlet connection 14 . FIG. 3B depicts bypass 62 as two longitudinal grooves in movable member 30 . The bypass may also only comprise one groove or may comprise a channel or hole which is cut through the base or bottom of movable member 30 . The bypass may also comprise a combination of channels and grooves, depending on the desired pressure within the actuator body 12 . Because o-ring 34 is seated in recess 32 , when the movable member 30 is seated within the recess, the inlet port 14 is not completely sealed from the interior of actuator 12 but rather enjoys a finite amount of fluidic communication with the interior of the actuator 12 via the bypass 62 .
When a faucet is opened, water will be discharged from the pre-charged diaphragm tank 24 through the outlet port 16 . For example, the pre-charged tank may exhibit a pressure of approximately 50 psi. As water flows through the outlet port 16 , pressure will decrease as the diaphragm 28 decreases in volume. The pressure decrease will be communicated through the unsealed passageway 40 to the pressure switch 18 . The pressure switch 18 , as will be appreciated by those skilled in the art, is adjusted to have a cut-in pressure setting, for example, 30 psi, below which the switch activates a pump motor and a cut-out pressure setting which deactivates the pump motor. Thus, when the pressure falls the pump motor will be activated, causing fluid to flow through the inlet port 14 . Pressure generated by the pump will cause the movable member 30 to move out of the recess 32 by overcoming the force of a spring 44 which urges the movable member downwardly. Under the influence of the pump, the movable member 30 moves upwardly as shown in FIGS. 2B and 2C. The spring 44 is not shown in FIGS. 2A-C for clarity. Hydrodynamic forces arising from the flow of water through the inlet port 14 keep the movable member in the upward position against the force of the spring 44 . Thus, water continues to flow through the output port 16 . Of course, the cross-sectional area of the grooves and channels contributing to bypass 62 will reduce the force inserted on the movable member 30 by a given flow rate of water. It is important to note that when the movable member 30 is in its upward position as shown in FIG. 2C, the transverse passageway 41 is above the o-ring seal 38 so that the passageway 40 is now sealed off from, and cannot respond to, fluid pressure changes in the actuator body 12 . Therefore, the pump will remain running as long as fluid is flowing through the outlet 16 . When, however, a faucet is turned off, flow through the outlet port 16 will stop. For a while, flow will continue through the port 22 into the diaphragm 28 . As the flow slows, the pressure in the tank will gradually increase so that the hydrodynamic force holding the movable member 30 open will be less than the downward force exerted by spring 44 . The movable member 30 will then reverse its path along fixed support 33 , moving downwardly as shown in FIG. 2 B and finally all the way downwardly into its resting position in the recess 32 as shown in FIG. 2 A. When the member 30 is in the downward position shown in FIG. 2A, the passageway 41 is now beneath the o-ring seal 38 and in fluidic communication with the fluid within the actuator body 12 via port 40 so that the passageway 40 is unsealed and “feels” the pressure in the body 12 . This high pressure is communicated to the pressure switch 18 which shuts off the pump motor. For example, a flow rate of 2 gal/min may be enough to hold up the movable member 30 against the force of spring 44 , but if the flow rate decreases to less than ½ gal/min, the force will not be sufficient, and the pump will shut off. When a faucet is once again opened, the process just described is repeated with an activation of the pump motor for as long is fluid is flowing through the outlet 16 and a deactivation of the motor once fluid flow ceases.
However, the consumer may not always turn on a faucet to its maximum flow. There are many situations in which full flow is not necessary and lower flow is preferred. In case a faucet is not completely opened, it will take longer for the diaphragm 28 to empty, the pressure in the interior of the actuator body 12 to decrease, and the pressure switch to open. However, the total flow through the actuator body will not be very high. If the flow rate is low enough, the water may not exert enough pressure on movable member 30 to move it all the way up to the top of support 33 . FIG. 2B shows the movable member 30 partially elevated in accordance with this example. Despite the low flow, passageway 41 is above o-ring 38 , sealing passageway 40 between o-rings 38 and 36 and preventing fluidic communication of the pressure switch with the interior of the actuator body 12 . The bypass 62 in movable member 30 enables increased flow from inlet connection 14 to outlet 16 even though movable member 30 is not completely elevated. Thus, the pump is able to operate, and the pressure switch will not cut off, at flows of a given flow rate, e.g., 2.5 gal/min. The minimum flow required to keep movable member 30 elevated can be reduced by decreasing the force constant of the spring 44 or increasing the total cross-sectional area of bypass 62 . In alternative embodiments, the minimum flow rate to elevate movable member 30 may be 2, 1.5, 1, or 0.5 gal/min. When the faucet is turned off and water is no longer being used, water flows slowly from inlet 14 through the bypass 62 into the interior of actuator body 12 until the pressure exerted by the diaphragm 28 and the water flowing through inlet 14 is the same, further slowing the flow rate. At this point, as in the full flow example, movable member 30 will again move downwardly and be seated in recess 32 . Passageway 40 will be in fluid communication with the interior of actuator body 12 via passageway 41 and will be able to communicate that pressure to the pressure switch via passageway 42 . The pressure switch will thus cut out.
For applications where the consumer desires even lower flow, on the order of ½ gal/min or less, water will flow out of the diaphragm, and the pump will not come on until a significant amount of water has been drawn by the consumer. At this point, the pump will come on, not so much to further provide water to the consumer as to repressurize the diaphragm.
Also shown in FIG. 2A is a check valve assembly 60 . The check valve assembly allows communication from the pressure switch port to the actuator body. When the valve 60 opens, the high pressure of the pressure switch port is relieved to the actuator body, assuring that the pressure switch will cut in.
Those skilled in the art will appreciate that the embodiments disclosed herein may be made of any suitable materials such as metals or plastics or a combination thereof. The embodiments disclosed herein have several advantages over prior art designs based on hydrostatic/hydrodynamic principles. In U.S. Pat. No. 5,509,787 discussed above, the area on one side of the movable member had to be smaller than that on the other side so that hydrostatic forces would re-seat the movable member. In the present invention, the areas may be equal since a spring is used to re-seat the movable member 30 . Importantly, only the single spring 44 is required to provide pressure switch control, unlike the dual spring design in U.S. Pat. No. 3,871,792. In the present invention, the spring 44 need only overcome the sliding friction of the movable member 30 over the fixed support 33 and no other spring is required.
It is intended that all modifications and variations of the present invention be included with the scope of the appended claims.
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Hydraulic actuator. An actuator body includes an inlet, an outlet, a port communicating with a pre-charged diaphragm tank, and a port communicating with a pressure switch. The actuator body includes a movable member which, in a first position, closes the inlet port and provides fluidic communication with the pressure switch port while allowing pressure equalization between the inlet and an interior of the actuator body. In a second position, the movable body opens the inlet port and seals the pressure switch port. A spring is disposed within the actuator body to urge the movable member toward the first position. The invention eliminates the need for multiple springs as shown in one prior art design and eliminates the need for reliance on a hydrostatic force differential to move the movable member.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of making a plurality of optical record disc substrates, and an apparatus therefore, wherein optical record disc substrates such as optical record discs and magnet-optic discs are formed, in particular a method of making a plurality of optical record disc substrates and an apparatus therefore, wherein at least two disc-shaped cavities are arranged in a mold, and optical record disc substrates can be made in multiple-molding.
2. Discussion of the Background
It has been known that a conventional optical record disc injection-molding process injects a molten resin into a mold with a cavity, compresses the injected resin by using an external force to lessen the volume of the cavity, and gives a predetermined shape to the compressed resin. The conventional means for lessening the volume of the cavity includes the use of a mold closing force of a molding device or the use of a hydraulic cylinder provided in a mold.
In such a type of optical disc molding, a single-molding mold has mostly been utilized because equal application of a mold closing force, and the presence of a radial flow where the flow of a resin in the cavity spreads out from the center to radial directions of a disc substrate are required in accordance with characteristics needed for the disc substrate.
However, such a single-molding mold involves inefficient productivity, and a plurality of molding devices are installed to increase a production capacity for increased production. This arrangement has a disadvantage in that improvement in cost is difficult. A multiple-molding process and an apparatus therefore which have efficiency productivity are coming into practice.
The multiple-molding according to a conventional inject-molding process involves a problem in that variations in charge among plural cavities have a direct effect to the molded product to create variations among them. This is because the volume of resin charge, the actuation timing of core bodies and cut punches, and the distribution of a mold closing force with respect to the plural cavities are controlled together as the entire mold without being independently controlled at the respective cavities. In other words, such variations in charge have a direct effect to the molded product to create variations in thickness and internal strain of the molded discs, thereby creating problems in that the discs warp optical characteristics are poor. When a single mold is used to carry out a multiple-molding process wherein two record discs or more are molded simultaneously, a single stream of molten resin which has been injected from a molding device cannot be equally distributed to the two cavities or more. All gates at a molten resin inlet through which the distributed molten resin is injected into the cavities are difficult to be formed in the same sizes in terms of the structure of the mold. For these reasons, all cavities cannot have the molten resin injected therein under the same conditions, creating a problem in that all disc substrates cannot meet required characteristics.
SUMMARY OF THE INVENTION
It is an object of the present invention to eliminate those disadvantages, and to provide in an inexpensive manner a method of making a plurality of optical record disc substrates and an apparatus therefore, wherein optical record discs which can meet characteristics required for optical discs and have good quality can be molded in a multiple-molding process, and productivity can be remarkably improved.
The present invention provides a method of making a plurality of optical record disc substrates, comprising: injecting a resin material into a plurality of disc-shaped cavities which are formed by closing a fixed mold half and a movable mold half; and cooling the injected resin material in the cavities; wherein the cavities are grouped into a plurality of groups so that each group includes not less than one cavity, and each group is provided with a common actuation means so that each actuation means is independently operated.
It is preferable that the movable mold half includes a plurality of core bodies and a plurality of cut punches to be slidable, the core bodies and the cut punches are provided with hydraulic actuation mechanisms, respectively, and either one of a group and a plurality of groups of the hydraulic actuation mechanisms are independently operated.
The present invention also provides, for an apparatus for making a plurality of optical record disc substrates, comprising: a fixed mold half; a movable mold half; a plurality of core bodies which are provided in the movable mold half to be slidable and to form a plurality of cavities; and a plurality of actuation mechanisms, each including a hydraulic cylinder for sliding its cooperating core body, and a hydraulic control circuit having a hydraulic pressure control valve for controlling its corresponding hydraulic cylinder; wherein the actuation of the respective core bodies is independently made in a multistage control with a hydraulic pressure and timing combined.
It is preferable that each actuation mechanism comprises a core compression hydraulic cylinder connected to the core body through a core block to slide the core body, and a cut punch cylinder and an ejection cylinder connected to a gate cut, an ejection pin and an ejection sleeve through a block to slide the gate cut, the ejection pin and the ejection pin.
It is preferable that each core body is arranged to confront its associated fixed cavity, and is fit in an outer peripheral ring to be slidable therein, and has a central portion provided with a movable gate cutter, an ejection sleeve and an ejection pin to be slidable is an axial direction.
It is preferable that a plurality of region flow passage for the cavities are arranged to be located at equal distances about an injection molding mold spool for charging a molten region, and are placed between a movable platen and a fixed platen.
The present invention further provides an apparatus for making a plurality of optical record disc substrates, comprising: a fixed mold half; a movable mold half; a driving means for opening and closing the movable mold half with respect to the fixed mold half; a plurality of cavities which are formed between the movable mold half and the fixed mold half; an injection means for injecting a resin material into the cavities; and a plurality of cut punches which come in and out of the respective cavities to punch a hole in the center of discs formed in the core bodies; wherein the cavities are grouped into a plurality of groups so that each group includes not less than one cavity, and each group is provided with a common actuation means so that the actuation of the respective actuation means is independently made in either one of a combination of a hydraulic pressure and timing, and timing control.
It is preferable that each cut punch has a movable ejection pin passed through its central portion, and the ejection pin is actuated by a common pin actuation means.
In accordance with an optical disc multiple-molding process of the present invention, even if there are variations in charge of a molten resin among the plural cavities, the actuation of the core bodies or the cut punches can be independently done at appropriate timing in the respective cavities to make the amount of charge in the cavities a uniform level. In particular, when the molten resin is injected from a nozzle after the mold is closed, the injected resin diverges in the mold with a high temperature kept, and passes through a heating medium with a high temperature kept. Then, it is equally charged in such a manner that it spreads out from the center to radial directions of the respective cavities. Actuation mechanisms of the hydraulic cylinders for core compression or the cut punches are operated from the time when charging the molten resin starts. The actuation mechanisms can be controlled with a hydraulic pressure, timing, or a combination of a hydraulic pressure and timing in the charge step, a pressure-maintaining step a cooling step of the molten resin to compensate shrinkage of the resin due to cooling, thereby obtaining a sufficient transfer from the surface of a stamper, minimizing the occurrence of optical deformation, eventually satisfying characteristics required for optical record disc substrates, and forming a central aperture in the receptive optical disc substrates in the mold.
In addition, after cooling the molten resin in the mold has been completed and the mold has been opened, actuation mechanisms for ejection are operated to eject the optical record disc substrates by ejection sleeves through ejection blocks, and to remove runners by removers which are protruded from the mold by ejection pins.
The present invention can solve the problems, improve the quality of optical record discs significantly, provide reliable discs in quantity production, and contribute a decrease in cost. Further, the compression operation of the respective core bodies, or a combination of a hydraulic pressure and timing for the cut punch actuation cylinders can be independently controlled at optimum conditions to cope with imbalance in charge of the molten resin which occurs among the plural cavities in the single mold. In this manner, optical record disc molding can be effectively done in a multiple-molding manner wherein two record discs or more can be simultaneously molded, characteristics required for optical record disc substrates can be satisfied, multiple-molding of optical discs having high quality can be done with high-precision, and productivity can be remarkably increased.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross sectional view showing a first embodiment of the present invention;
FIG. 2 is an enlarged longitudinal cross sectional view showing a portion of FIG. 1;
FIG. 3 is a graph showing characteristic curves with respect to the relation between hydraulic pressures and charge progress in a charge step in the apparatus of FIG. 1;
FIG. 4 is a schematic view showing an embodiment of the method of making optical record discs according to the present invention;
FIG. 5 is a cross sectional view showing a cut punch portion of a mold according to the present invention;
FIG. 6 is a cross sectional view showing the operation of the cut punch portion of FIG. 5;
FIG. 7 is a graph showing an operating method of a cut punch;
FIG. 8 is a graph showing another operating method of the cut punch; and
FIG. 9 is a graph showing another operating method of the cut punch.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, the present invention will be described in detail with reference to preferred embodiments illustrated in the accompanying drawings.
An embodiment of the present invention shown in FIGS. 1--3, i.e. a case wherein two movable core compressing cylinders are incorporated between a two optical disc molding mold and a movable platen of a molding device will be explained. Cavity bodies 1 as a fixed mold half, and core bodies 2 and outer peripheral rings 3 as a movable mold half to confront the fixed mold half form two disc-shaped cavities A in an injection molding mold 18. The core bodies 2 and 2 are provided with hydraulic actuation mechanisms having compression cylinders 11. The respective compression cylinders 11 are arranged to communicate with hydraulic control circuits 20 including hydraulic control valves 19 which can control the cylinders in an independent and multi-stage manner. The actuation of the core bodies 2 and 2 can be independently done in a multi stage control with a combination of a hydraulic pressure and timing. An optical disc molding apparatus according to the present invention is provided to have such an arrangement, and can mold reliable optical discs having good quality.
As the hydraulic actuation mechanisms including the compression cylinder 11 are used ones which include the compression cylinder 11 connected to the movable core 2 through one or a plurality of core blocks 4 in order to slide the core body 2, and cut punch cylinders 12 and ejection cylinders connected to cut punches 5, ejection pins 9 and ejection sleeves 8 through blocks 10 in order to slide the cut punches, the ejection pins and the ejection sleeves. The two core bodies 2 and 2 are arranged to confront the cavity bodies 1 on the fixed mold half, respectively, and are fitted in the outer peripheral rings 3 and 3 to be slidable in an axial direction by the compression cylinders 11. The respective core bodies have their central portions provided with the cut punches 5, the ejection sleeves 8 and the ejection pins 9 to be slidable in the axial direction.
The compression cylinders 11 are incorporated in the respective movable core bodies 2, and have such a structure that the respective movable core bodies are operated in a multi-stage control with a combination of the optimum hydraulic pressure and the optimum timing to cope with imbalance in charge of a molten resin so that both optical record disc substrates can meet required characteristics.
The disc-shaped cavities A which are constituted by the core bodies 2 and other members are arranged in a plural manner at equal distance on both sides of the center of a sprue bushing 15 for charging the molten resin in a mold body, or in a radial or H-shaped pattern in the case of the presence of three cavities or more. The cavities are arranged between a movable platen 21 and a fixed platen 22 of the molding apparatus.
The cut punches 5 are used to form a central aperture in the disc substrates during molding, and are engaged with the ejection sleeves 8 to be protruded and withdrawn by the cut punch cylinders 12 through cut punch blocks 7. When the cut punches 5 are protruded, their leading edges get in touch with fixed gate cuts 6 to form center apertures in the substrates. When the cut punches 5 are withdrawn, their leading edges and the fixed gate cuts 6 form spaces to provide molten resin inlets (gates).
In FIGS. 1 and 2, reference numeral 8 designates the ejection sleeve which is formed to be in a sleeve shape for ejecting an optical recording disc substrate. Reference numeral 9 designates the ejection pin for removing a runner. The ejection sleeve and the ejection pin can be protruded and withdrawn by the ejection hydraulic cylinder through the ejection block 10. Reference numeral 13 designates an ejection rod. Reference numeral 17 1 designates a heating medium passage. The injection molding mold 18 is provided with a cooling means as usual.
In a resin charging step, the molten resin is injected into the sprue bushing 15 from a nozzle 14 of an injection molding device. The injected molten resin diverges in a divergent block 16 in the mold with a predetermined temperature kept. The molten resin passes through a heating medium 17 with a predetermined temperature maintained. From the spaces (gates) defined by the fixed gate cuts 6 and the withdrawn cut punches 5, the injected resin is equally charged in the disc shaped cavities A and A constituted by the cavity bodies 1, the core bodies 2 and the outer peripheral rings 3 so that the resin spreads out from the center of the cavities to radial directions in a radial flow pattern.
In the first embodiment, when the molten resin starts to be charged, the compression cylinders 11 are actuated to move the movable core bodies 2 toward the fixed cavity bodies 1 through the core blocks 4 and 4. In the charge step, a pressure-maintaining step and a cooling step of the molten resin, hydraulic pressure for actuating the compression cylinders 11 can be adjusted under a multi step control with a combination of timing to modify the volumes of the cavities, thereby avoiding variations in the charge into the two cavities and compensating shrinkage of the resin due to cooling. As a result, sufficient transfer of the surface of the stamper can be obtained, the occurrence of optical deformation can be minimized, and various characteristics required for optical record disc substrates can be eventually satisfied.
Specifically, the respective movable core bodies are actuated under the multi step control with a combination of the optimum hydraulic pressures and timing in order to cope with imbalance in the charge of the molten resin, so that the two optical record disc substrates all can satisfy the required characteristics. For example, in the case of the multi step control where hydraulic pressures and timing of the two compression cylinders 11 and 11 are combined as shown in FIG. 3, a cavity with slow charge is pressurized at a lower level in charging and at a higher level in cooling than the other cavity with rapid charge. Timing is also more delayed with respect to the cavity with slow charge as shown in FIG. 3. In that manner, optical record discs having the same characteristics can be obtained simultaneously. Next, after the molten resin has been charged, the respective cut punch cylinders 12 in control circuits 20 1 with control valves 19 1 are actuated at arbitrary timing during the pressure-maintaining step or the cooling step to move the cut punches 5 forward through the movable cut punch blocks 7 until the cut punches get in touch with the fixed gate cuts 6. As a result, central apertures in the optical record disc substrates are formed in the mold. When the mold is opened after the molten resin has been cooled in the mold, the ejection rods 13, and consequently the ejection blocks 10 are actuated to eject from the mold the optical record disc substrates by the ejection sleeves 8 and runners by the ejection pins 9. The substrates and runners ejected from the mold are by e.g. a remover.
Although in the embodiment shown, the hydraulic actuation mechanisms are located between the optical record disc mold with the core bodies 2 and the cavity bodies 1 included therein, and the injection molding device, the hydraulic actuation mechanisms can be housed in the movable platen of the injection molding device. The hydraulic cylinders for the ejection pins can be arranged in the mold. The compression cylinders 11 and the cut punch cylinders 12 for the cut punches 5 in the core bodies 2 can be governed under a combination of hydraulic pressures and timing, or under timing control to make the amount of charge in the respective cavities a uniform level.
Now, another preferred embodiment of the present invention will be described in detail. In the embodiment shown in FIGS. 4-9, there is shown one of suitable embodiments wherein the actuation of cut punches can be changed at appropriate timing in the respective cavities to make the amount of resin charge a uniform level. In the state shown in FIG. 5, a resin material is charged from an injection molding device 23 into the cavity A through a runner 32. As soon as the charge has been completed, a cut punch 5 in a sleeve 8 is protrudently actuated to punch out a central aperture 33 as shown in FIG. 6. As a result, the flow of the resin is completely cut, thereby determining the amount of the resin charge.
On the other hand, charging can be carried out in several ways as shown in FIGS. 7-9. If charging is made rapidly as shown in FIG. 7, it is difficult to control actuation timing of the cut punches 5, and variations in the amount of charge become great. For these reasons, it is a usual manner that charging is done slowly at the last stage, and the cut punches 5 is actuated at appropriate timing of charging speed as shown in FIG. 8, or that after excessive charging has been done, the amount of charge is slowly restored, and the cut punches 5 is actuated at appropriate timing as shown in FIG. 9. However, even if such operations are made, simultaneous actuation of the plural cut punches 5 is difficult to obtain an adequate amount of charge in the respective cavities. In order to cope with this problem, the respective cut punches are independently actuated so that adequate actuation timing is determined for each cut punch, and the amount of charge in all cavities can reach an adequate level.
The dual molding device shown in FIG. 4 is constituted by a fixed mold half 24 mounted to a fixed platen 22 thereof, and a movable mold half 25 mounted to a movable platen 21 thereof. Both mold halves have mating surfaces formed with cavities A and A, the number of which corresponds to the molding number of discs. The fixed mold half 24 has a runner block 16 incorporated thereinto to distribute in the respective cavities A and A a resin material injected from an injection device 23 of the molding device.
On the other hand, into the movable mold half 25 are incorporated the cut punches 5 and 5 for punching out central runners of discs to form central apertures, and pins 9 and 9 for ejecting the punched runners. Into the movable platen 21 are incorporated a cylinder 30 of a driving mechanisms for driving the runner ejection pins 9 and 9, and cylinders 12 of a driving mechanisms for independently driving the cut punches 5 and 5. The cut punch driving mechanisms are provided with independent controllers (not shown) which enable the respective cut punch driving mechanisms to be actuated at their own arbitrary timing. The cut punches 5 and 5 have leading edges engaged with holes of the movable mold half to be slidable. The leading edges form part of the walls of the cavities A and A when the mold halves are closed. The runner ejection pins 9 and 9 are engaged in axial holes of the cut punches 5 and 5 to be slidable. An injection molding mold constituted by the mold halves is provided with a cooling means as usual.
Now, a molding step will be explained. First, the movable platen 21 is moved to the right direction in the drawings to close both mold halves 24 and 25, and a resin material is injected from the injection device 23. The injected resin material is divided by the runner block 16, and are charged into the respective cavities A and A. At that time, variations in manufacturing process of the runner block and the cavities cause a difference between the two cavities A and A in terms of how much the resin material is charged. In order to minimize the difference, the cut punch driving mechanisms are actuated in such a control that a time difference is introduced between their actuations. Specifically, the cut punches 5 and 5 are moved forwardly in the cavities at their own timing so that the amounts of resin charge in the cavities in molding become the same. After that, cooling progresses in the mold halves, and plasticization measure is carried out in the injection device 23 to prepare for the next injection. Then, the movable platen 21 is moved to open the movable mold half 25, and the ejection driving mechanisms 30 are actuated to eject the molded discs and the punched runners. In that manner, one cycle has been completed.
Although in the embodiment shown in FIG. 4, the cut punch driving mechanisms 12 and 12 are arranged in the movable platen, they may be arranged in the movable mold half. The division of the resin material may be done in the injection device 23 instead of the runner block 16. In addition, the amount of charging the resin material can be intentionally changed in every cavity, which can realize multiple-molding wherein a plurality of discs having different shapes are obtained in a single mold.
Although explanation has been made for the dual molding, in order to mold four discs at the same time, independent actuation of the cut punches, and the actuation of every two cut punches by use of two driving means which is applied only when distribution of the resin is stable can be thought out. This can be also applied to the case wherein eight discs are molded at the same time.
That is to say, in order to group a plurality of cavities, in the case of two cavities, the cavities are divided into two groups so that each cavity is included in the different group; in the case of four cavities, the cavities are divided into four groups so that each cavity is included in the different group, or cavities are paired to make two groups; in the case of six cavities, the cavities are divided into six groups so that each cavity is included in the different group, cavities are paired to make three groups, or cavities are coupled in trios to make two groups; and in the case of eight cavities, the cavities are divided into eight groups so that each cavity is included in the different groups, cavities are paired to make four groups, or cavities are coupled in quartettes to make two groups, for example.
Although at least one of the core compression cylinders 11 as the hydraulic actuation mechanisms, or at least one of the actuation mechanisms for the cut punches 5 is constituted to be independently controlled, in the embodiments stated earlier, the core compression cylinders 11 can be independently controlled in each group, the cut punches 5 can be independently controlled in each group, or the core compression cylinders and the cut punches can be independently controlled.
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A method of making a plurality of optical record disc substrates includes the steps of injecting a resin material into a plurality of disc-shaped cavities which are formed by closing a fixed mold half and a movable mold half; and cooling the injected resin material in the cavities. The cavities are grouped into a plurality of groups so that each group includes not less than one cavity, and each group is provided with a common actuation device so that each actuation device is independently operated.
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BACKGROUND
[0001] In integrated circuits, such as microprocessors, memories, and the like, signals may be routed for relatively long distances using transmission lines. A transmission line may be a bus, a printed circuit board trace, or other types of electrical conductors for transporting a signal. Typically, a printed circuit board trace has a characteristic impedance of between 50 and 75 ohms. In complementary metal-oxide semiconductor (CMOS) circuits, the input impedance of a gate of a CMOS transistor is usually very high. The receiving end, or far end, of the transmission line is typically connected to an input of a logic circuit, where the input impedance is higher than the characteristic impedance of the transmission line. If the impedance coupled to the far end of the transmission line is different than the impedance of the transmission line, the signal will be reflected back to the sending end. Depending on the sending end impedance, the signal may overshoot/undershoot a planned steady-state voltage for the logic state. The signal may be reflected back and forth many times between the near end and the far end, causing oscillatory behavior of the signal at both ends. This repeated overshooting and undershooting of the signal is commonly known as “ringing,” and results in reduced noise immunity and increased time for the signal to become, and remain, stable at the far end. Impedance matching is the practice of matching the impedance of the driver and/or the load to the characteristic impedance of the transmission line to reduce ringing and facilitate the most efficient transfer of signals.
[0002] Accordingly, output drivers are important building blocks in the input/output path of integrated circuits like microprocessors and memory systems. Output drivers are the primary interface through which data transmission takes place between the integrated circuit and external systems via transmission lines. The output driver converts chip-internal logic levels and noise margins to those required for driving the inputs of chip-external circuits in digital systems.
[0003] As bus speeds increase above 100 MHz, impedance mismatches become a significant concern as timing margins are reduced as a result of the increased clock frequency. A number of different approaches have been used to account for impedance mismatches in electronic data systems. Some of these approaches include adding passive external elements (resistors, inductors, etc.); adjusting the drive strength of output drivers; and actively terminating signal transmission lines.
[0004] Adding passive external elements requires printed circuit assembly area, increases power consumption and does not account for impedance variations due to variations in supply voltage, temperature, and age.
[0005] Solutions that adjust the drive strength typically provide a limited number of discrete settings or levels of drive strength. These discrete settings do not always allow the output driver to match the characteristic impedance of the transmission line that will be used to communicate signals. In addition, many solutions of this type use an external discrete resistor as a reference. The resistance of the discrete resistor does not always match the characteristic impedance of the transmission line at the operating frequency. While technicians can add additional discrete resistors in various combinations or networks to adjust the reference resistance, these solutions also do not account for impedance variations due to variations in supply voltage, temperature, and age.
[0006] Other on-chip solutions require the use of separate test input/output (I/O) pads for determining suitable impedance matching. In one example, an external test pad is used to determine a suitable pull-up circuit impedance whereas a separate additional test pad is used to determine suitable impedance matching for a pull-down circuit of the output buffer. The use of additional test pads and additional external resistors can impact board density, reliability, and cost.
[0007] Solutions that actively terminate transmission lines share many of the drawbacks of solutions that use external passive elements and solutions that adjust output drive strength. That is, active termination requires additional off chip elements, increases power consumption, and is susceptible to process, voltage, and temperature variations.
[0008] Therefore, it is desirable to introduce low-cost systems and methods for dynamic impedance matching.
SUMMARY
[0009] One embodiment of a system, comprises a reference driver coupled to a first tuning element, the reference driver and the first tuning element configured to receive a first input signal and generate a reference signal comprising a primary reference component and a reflected reference component, a test driver coupled to a second tuning element, the test driver and the second tuning element configured to receive a second input signal and generate a test signal comprising a primary test component and a reflected test component, and an integrator configured to receive the reference signal and the test signal and generate an error signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present systems and methods for adjusting an output driver, as defined in the claims, can be better understood with reference to the following drawings. The components within the drawings are not necessarily to scale relative to each other, emphasis instead is placed upon clearly illustrating the principles of the systems and methods.
[0011] FIG. 1 is a combination circuit schematic and functional block diagram illustrating an embodiment of an output driver calibration system.
[0012] FIG. 2 is a graph illustrating an embodiment of a reference signal over time as applied to the output driver calibration system of FIG. 1 .
[0013] FIG. 3 is a graph illustrating an embodiment of a test signal over time as applied to the output driver calibration system of FIG. 1 .
[0014] FIG. 4 is a graph illustrating an embodiment of an error signal over time as generated by the output driver calibration system of FIG. 1 .
[0015] FIG. 5 is a graph illustrating an embodiment of a corrected test signal over time as generated by the output driver calibration system of FIG. 1 .
[0016] FIG. 6 is a graph illustrating the corrected test signal of FIG. 5 over a narrow time period.
[0017] FIG. 7 is a flow diagram illustrating an embodiment of a method for adjusting an output driver.
[0018] FIG. 8 is a flow diagram illustrating an alternative embodiment of a method for adjusting an output driver.
[0019] FIG. 9 is a flow diagram illustrating an embodiment of a method for generating an error signal.
DETAILED DESCRIPTION
[0020] Present systems and methods for adjusting an output driver measure the characteristic impedance of an example transmission line and apply a correction signal responsive to the characteristic impedance at a desired frequency to one or more output drivers. By measuring and responding to actual dynamic circuit conditions, the systems and methods for adjusting an output driver provide improved impedance matching in signal-processing systems across a range of conditions that can result from process, voltage, and temperature variation. Output driver calibration can be implemented at system start up and/or at other times as may be desired. Improved impedance matching guarantees signal timing margins and data integrity.
[0021] The characteristic impedance of transmission lines is measured using an electrically open tuning element coupled to the output of a reference driver by inserting an input signal having a desired frequency at the input to the reference driver. The reference driver generates a primary component of a reference signal. The tuning element generates a reflected component of the reference signal. In one embodiment, the tuning element is a printed-circuit board trace. The tuning element has a length such that input signal reflections due to input signal transitions at the desired frequency return to the output of the reference driver in synchronization with the input signal.
[0022] The reference signal is applied to an integrator in a feedback loop along with a test signal to calibrate an output driver. The integrator generates an error signal that can be applied to an output driver to automatically match output driver impedance to the characteristic impedance of transmission lines in a data processing system. The test signal, like the reference signal, is applied to a tuning element. In one embodiment, the tuning element is an electrically open transmission line. The test-tuning element has a length that closely approximates the length of the reference-tuning element. In one embodiment, the test signal is a square wave with a low duty cycle. When the output impedance of the output driver is not matched to the characteristic impedance of the open transmission line, the low on time (with respect to the off time) of the low duty cycle test signal permits the observation of signal reflections caused by the mismatch. When the controlled output driver is matched to the characteristic impedance of the transmission line, a single pulse having the same magnitude as the test signal is reflected back to the output driver.
[0023] Turning to the drawings that illustrate various embodiments of systems and methods for adjusting an output driver, FIG. 1 is a combination circuit schematic and functional block diagram illustrating an embodiment of an output driver calibration system 100 . Embodiments of the present systems for adjusting an output driver may be implemented in any system configured to transfer data. As such, the present systems for adjusting an output driver may be implemented in devices or systems across many different levels such as, but not limited to microprocessors, memory devices, application specific integrated circuits (ASICs) and a host of devices that use these types of components to transfer data, such as computers, test equipment, audio-video electronics, hand-held devices, etc.
[0024] Once an appropriate error signal has been identified, the error signal can be applied to an adjustable output driver. The determination of an appropriate error signal need not be fast relative to the operational frequency of the output driver. As long as transmission line impedance in the host system does not change appreciably over time, temperature, voltage, etc., then the error signal need not be adjusted at the operational frequency of the output driver. If the transmission line impedance in the host system does change, a new error signal could be determined and applied to the adjustable output driver. Although the output driver may be operating in the GHz range, transmission line impedance feedback provided by the output driver calibration system 100 could operate at lower frequencies.
[0025] As illustrated in FIG. 1 , the output driver calibration system 100 receives two input signals, input signal 111 and input signal 141 , and produces a single error signal 177 , labeled V ERROR . V ERROR is returned to the calibration system 100 to provide closed-loop feedback control. Input signal 111 , illustrated as a square wave with a 50% duty cycle, is applied along conductor 112 to reference driver 110 . Input signal 141 , illustrated as a square wave with a much lower duty cycle than that of input signal 111 , is applied along conductor 142 to test driver 140 .
[0026] Reference driver 110 amplifies or otherwise buffers input signal 111 and generates a primary reference component 117 which is applied via conductor 115 to first tuning element 120 . First tuning element 120 includes a length-tuned transmission line 122 having a first end 124 electrically coupled to conductor 115 and an electrically open end 126 . The electrically open end 126 causes signal transitions in the primary reference component 117 to be reflected back towards the reference driver 110 along conductor 115 . Length-tuned transmission line 122 has a length such that signal reflections due to rising edge transitions in the primary reference component 117 reflected by the open length-tuned transmission line 122 reach node 125 at substantially the same time as the next subsequent rising edge transition from primary reference component 117 . For example, if input signal 111 is a clock signal with a period of 20 nanoseconds (nS), then the length of length-tuned transmission line 122 is such that signal reflections reach node 125 in 10 nS.
[0027] The length of length-tuned transmission line 122 is a function of various physical properties of the underlying transmission line and the desired clock frequency for managing data transmissions. For example, when the transmission line is a signal trace on a printed circuit board, the length is a function of at least the material, width, and thickness of the signal trace in addition to the desired clock frequency. When the transmission line is a signal trace in an ASIC, the length is a function of at least the material, width, and thickness of the signal trace as well as process variation that affects these physical characteristics across a desired signal layer of the ASIC.
[0028] Signal reflections generated by the electrically open length-tuned transmission line 122 produce a reflected reference component 127 . Reference signal 129 , labeled V REF , is generated by the combination of the primary reference component 117 and the reflected reference component 127 . Reference signal 129 is forwarded to sample and hold circuit 130 via conductor 132 .
[0029] Test driver 140 amplifies or otherwise buffers input signal 141 and generates a primary test component 147 which is applied via conductor 145 to second tuning element 150 . Second tuning element 150 includes a length-tuned transmission line 152 having a first end 154 electrically coupled to conductor 145 and an electrically open end 156 . The electrically open end 156 causes signal transitions in the primary test component 147 to be reflected back towards the reference driver 140 along conductor 145 . Length-tuned transmission line 152 has a length substantially the same as the length of length-tuned transmission line 122 . Signal reflections generated by the electrically open length-tuned transmission line 152 produce a reflected test component 157 . Test signal 149 , labeled V TEST , is generated by the combination of the primary test component 147 and the reflected test component 157 . Test signal 149 is forwarded to sample and hold circuit 160 via conductor 162 .
[0030] Delay element 180 receives input signal 141 via conductor 142 . Delay element 180 generates a control signal responsive to input signal 141 along conductor 185 , which is applied as a control input to sample and hold circuits 130 , 160 . In accordance with the control signal, sample and hold circuit 130 samples the reference signal 129 and provides time-sampled reference signal 135 via conductor 134 to integrator 170 . Similarly, in accordance with the control signal, sample and hold circuit 160 samples the test signal 149 and provides time-sampled test signal 165 via conductor 164 to integrator 170 .
[0031] As illustrated in FIG. 1 , integrator 170 includes operational amplifier 171 . Operational amplifier 171 has a positive input terminal and a negative input terminal and a single output terminal. The positive input terminal is coupled to sample and hold circuit 130 via conductor 134 . The negative input terminal is coupled to sample and hold circuit 160 via conductor 164 and series resistor 172 . The output terminal and the negative input terminal are coupled via capacitor 174 . In operation, integrator 170 receives the time-sampled reference signal 135 and the time-sampled test signal 165 and generates error signal 177 . As further illustrated in FIG. 1 , error signal 177 is returned via conductor 175 to test driver 140 to adjust the drive strength of test driver 140 .
[0032] Components of the systems for adjusting an output driver such as the reference driver 110 , the test driver 140 , the sample and hold circuits 130 , 160 , the integrator 170 , and delay element 180 can be implemented with any or a combination of the following technologies, which are all well known in the art: a discrete logic circuit(s) having logic gates for implementing logic functions upon data signals, an ASIC having appropriate combinational logic gates (as described in the illustrated embodiment), a programmable gate array(s) (PGA), a field programmable gate array (FPGA), etc.
[0033] The graphs presented in FIGS. 2 through 6 represent embodiments of the various voltages that can be expected over time in the output driver calibration system 100 of FIG. 1 . The graphs reflect the various voltages from output driver calibration system turn-on from an off or inactive state. FIG. 2 is a graph 200 illustrating an embodiment of reference signal 129 over time as generated within the output driver calibration system 100 of FIG. 1 . The horizontal axis illustrates elapsed time in nanoseconds (nS). The vertical axis illustrates reference signal amplitude in volts.
[0034] Due to impedance mismatches between the reference driver 110 and the length-tuned transmission line 122 , first response signal peak 210 reaches approximately 0.96 volts. Subsequent response signal voltage peaks increase in magnitude until a steady-state peak voltage 220 is reached. The steady-state peak voltage is set by the output of the reference driver 110 , which for the example illustrated in FIG. 2 is 1.25 volts. As illustrated, reference signal 129 reaches a steady-state peak voltage after approximately 40 nS. The particular signal trace illustrated in FIG. 2 is representative of an output-driver output impedance of 80 ohms and a transmission line characteristic impedance of 50 Ohms.
[0035] FIG. 3 is a diagram illustrating an embodiment of a test signal over time as generated within the output driver calibration system 100 of FIG. 1 . Specifically, FIG. 3 is a graph 300 illustrating an example test driver output signal 149 before application of an error signal (i.e., before tuning). The horizontal axis illustrates elapsed time in nanoseconds. The vertical axis illustrates test signal amplitude in volts.
[0036] The test driver output voltage in the embodiment illustrated in FIG. 3 is the result of a single positive pulse from input signal 141 . Input signal 141 is selected such that its magnitude closely resembles the magnitude of input signal 111 . However, input signal 141 has a significantly longer “off” time (i.e., a period during which the input signal is not above the logic threshold) when compared to the off time of input signal 111 . Input signal 111 has an approximately 50% duty cycle and completes a cycle every 20 nS. Input signal 141 has an approximately 10% duty cycle and completes a cycle every 100 nS. Input signal 141 is configured such that reflections due to signal transitions dampen before the next signal transition. Impedance mismatches between the output stage of the test driver and the characteristic impedance of length-tuned transmission line 152 are valid during the first positive pulse of input signal 141 . After the first positive pulse (i.e., when input signal 141 is off) reflections distort the test voltage waveform.
[0037] As illustrated in graph 300 , the test driver output voltage 149 due to a single positive peak in input signal 141 generates a first positive pulse 310 that overshoots the magnitude of the buffered test signal (i.e., the primary test component). A first reflected test signal pulse 320 is generated due to the electrical open at the end of the length-tuned transmission line 152 . Subsequent reflected signal pulses 330 and 340 are also observed in the first 30 nS after the completion of first positive pulse 310 . Each subsequent reflected signal pulse is characterized by a voltage peak that is lower in magnitude than an immediately preceding signal pulse, until reflected signal pulses are no longer detectable. Because of the relatively low duty cycle of input signal 141 , reflected signal pulses damp out (i.e., are no longer detectable) prior to the next subsequent signal pulse from input signal 141 .
[0038] In operation, if the sample and hold circuits 130 , 160 of FIG. 1 can be adjusted via delay element 180 to sample the reference signal 129 and test signal 149 at an appropriate frequency (e.g., every 5 nS), then the integrator 170 can be used to generate an error signal 177 that can be used to correct or otherwise adjust the output drive strength of test driver 140 and other similarly configured output drivers designated to drive similarly configured transmission lines.
[0039] Signal trace 350 represented by the dashed line in graph 300 of FIG. 3 is representative of a desired output driver output voltage (i.e., test driver output impedance matched with characteristic impedance of length-tuned transmission line 152 .)
[0040] FIG. 4 is a diagram illustrating an embodiment of an error signal 177 over time as generated by the output driver calibration system 100 of FIG. 1 . Specifically, FIG. 4 is a graph 400 illustrating an example error signal 177 used to adjust the test driver 140 in the output driver calibration system 100 of FIG. 1 . The horizontal axis illustrates elapsed time since the output driver calibration system 100 was activated in microseconds (μS). The vertical axis illustrates error signal amplitude in volts. Near time 0 , the output driver calibration system 100 produces an error signal 177 that is corrupted (i.e., incorrect) because of the initial activation of the system. By approximately 2.0 μS, error signal 177 has reached a steady-state correction value 410 . The steady-state correction value 410 is the desired control signal to be returned to the output driver calibration system 100 and perhaps other similarly situated output drivers to adjust drive strength to match the characteristic impedance of transmission lines in the system. Error signal 177 converges toward steady-state correction value 410 in accordance with a time constant which is a function of the resistance of resistor 172 and the capacitance of capacitor 174 within integrator 170 ( FIG. 1 ).
[0041] FIG. 5 is a diagram illustrating an embodiment of a corrected test signal over time as generated by the output driver calibration system 100 of FIG. 1 . Specifically, FIG. 5 is a graph 500 illustrating an example test signal 149 after adjustment of the test driver 140 using the error signal 177 generated by the output driver calibration system 100 of FIG. 1 . The horizontal axis illustrates elapsed time since the output driver calibration system 100 was activated in microseconds. The vertical axis illustrates test signal amplitude in volts.
[0042] FIG. 5 illustrates multiple cycles of test signal 149 with correction via error signal 177 taking place. As indicated in graph 500 , positive peak voltages associated with positive transitions of input signal 141 are reduced over time as indicated by positive envelope 510 . Negative reflections associated with reflections due to impedance mismatches are also removed over time as indicated by negative envelope 520 . After approximately 3 μS, the test driver 140 output strength has been suitably corrected and voltage overshoots and undershoots due to impedance mismatches have been substantially removed.
[0043] FIG. 6 is a diagram illustrating the corrected test signal 149 of FIG. 5 over a narrow time period. Specifically, FIG. 6 is a graph 600 illustrating an example test signal 149 after adjustment of the test driver 140 using the error signal 177 generated by the output driver calibration system 100 of FIG. 1 . The horizontal axis illustrates elapsed time since the output driver calibration system 100 was activated in microseconds (μS). The vertical axis illustrates test signal amplitude in volts.
[0044] As illustrated in FIG. 6 , test signal pulses 610 responsive to second input signal transitions (and application of the error signal 177 ) have a magnitude of 1.25 volts. After calibration (i.e., application of the error signal 177 ) first reflected pulses 615 corresponding to respective test signal pulses have the same amplitude and there are no further reflections due to the test signal pulses 610 .
[0045] Any process descriptions or blocks in the flow diagrams illustrated in FIGS. 7-9 should be understood as representing steps in an associated process. Alternative implementations are included within the scope of the present methods for adjusting an output driver. For example, functions may be executed out-of-order from that shown or discussed, including substantially concurrently or in reverse order, depending on the functionality involved.
[0046] FIG. 7 is a flow diagram illustrating an embodiment of a method 700 for adjusting an output driver. As illustrated in FIG. 7 , method 700 begins with input/output block 702 where a first signal is received. After the first signal is received, the first signal is applied to a first tuning element to generate a reference signal as indicated in block 704 .
[0047] As indicated in input/output block 706 , a second signal is received. As illustrated in block 708 , the second signal is applied to a second tuning element to generate a test signal. While the functions listed in blocks 706 and 708 have been illustrated and described following the functions listed in blocks 702 and 704 , it should be understood that the functions associated with blocks 706 and 708 can occur before, after, or substantially simultaneously with the functions associated with blocks 702 and 704 .
[0048] Once the reference and test signals have been generated as illustrated and described in blocks 704 and 708 , the reference and test signals are sampled to generate a time-sampled reference signal as indicated in block 710 and a time-sampled test signal as indicated in block 712 . While the sampling function listed in block 712 has been illustrated and described as following the sampling function associated with block 710 , it should be understood that the functions associated with blocks 710 and 712 can occur in reverse order or substantially simultaneously with one another.
[0049] Thereafter, as illustrated in block 714 , an error signal responsive to the time-sampled reference signal generated in block 710 and the time-sampled test signal generated in block 712 is generated by integrating the time-sampled reference signal and the time-sampled test signal generated in blocks 710 and 712 , respectively. As indicated in block 716 , the error signal generated in block 714 is applied to an output driver to adjust the driver.
[0050] FIG. 8 is a flow diagram illustrating an alternative embodiment of a method 800 for adjusting an output driver. As shown in FIG. 8 , method 800 begins with input/output block 802 where a first signal is received. The first signal is a time-varying signal having a frequency that approximates a desired data processing rate. After the first signal is received, the first signal is applied to a first tuning element to generate a reference signal as indicated in block 804 . As further illustrated in block 804 , the reference signal is responsive to the characteristic impedance of transmission lines. The reference signal is a composite signal having a primary component and a reflected component.
[0051] As indicated in input/output block 806 , a second signal is received. The second signal is configured such that signal transitions are suitably spaced (in time) to enable reflections to dampen before subsequent signal transitions occur. As illustrated in block 808 , the second signal is applied to a second tuning element to generate a test signal. The test signal is responsive to the characteristic impedance of transmission lines. The test signal is a composite signal having a primary component and a reflected component. While the functions listed in blocks 806 and 808 have been illustrated and described following the functions listed in blocks 802 and 804 , it should be understood that the functions associated with blocks 806 and 808 can occur before, after, or substantially simultaneously with the functions associated with blocks 802 and 804 .
[0052] Once the reference and test signals have been generated as illustrated and described in blocks 804 and 808 , the reference and test signals are sampled to generate a time-sampled reference signal as indicated in block 810 and a time-referenced test signal as indicated in block 812 . While the sampling function listed in block 812 has been illustrated and described as following the sampling function associated with block 810 , it should be understood that the functions associated with blocks 810 and 812 can occur in reverse order or substantially simultaneously with one another.
[0053] Thereafter, as illustrated in block 814 , an error signal responsive to the time-sampled reference signal generated in block 810 and the time-sampled test signal generated in block 812 is generated. As indicated in block 816 , the error signal generated in block 814 is applied to an output driver to adjust the drive strength of the driver.
[0054] FIG. 9 is a flow diagram illustrating an embodiment of a method 900 for generating an error signal. As illustrated in FIG. 9 , method 900 begins with block 902 where a reference signal is generated in response to a first input signal. The reference signal emulates signal reflections due to a characteristic impedance of a transmission line in a data transfer system. In block 904 , a test signal is generated in response to a second input signal. The test signal enables signal reflections responsive to second input signal transitions and the characteristic impedance of transmission lines within the system to dampen before subsequent second input signal transitions occur. After the reference and test signals have been generated as described above, the reference and test signals are used to generate an error signal as indicated in block 906 .
[0055] It should be emphasized that the above-described embodiments are merely examples of implementations of the systems and methods for adjusting output drivers. Many variations and modifications may be made to the above-described embodiments. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
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Systems and methods for dynamically adjusting an output driver are invented and disclosed. One embodiment comprises receiving a first signal. Applying the first signal to a first tuning element to generate a reference signal. Receiving a second signal. Applying the second signal to a second tuning element to generate a test signal, wherein the second tuning element is configured similarly to the first tuning element. Sampling the reference signal to generate a time-sampled reference signal. Sampling the test signal to generate a time-sampled test signal. Integrating the time-sampled reference signal and the time-sampled test signal to generate an error signal. Then, applying the error signal to adjust an output driver.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims priority to U.S. provisional patent application Ser. No. 60/386,524, filed Jun. 5, 2002, and entitled “Method and Apparatus for Efficient ADSL Data Transmission in a Time Varying Noise Environment”, hereby incorporated herein by reference.
BACKGROUND
Telephone companies offer customers a number of ways to transport data. One popular way is called Asymmetric Digital Subscriber Line (ADSL). In ADSL, a small portion of the frequency spectrum is used for communicating data from the customer to the central office, and a much larger portion of the frequency spectrum is used for communicating data from the central office to the customer.
Discrete multi-tone (DMT) modulation is used within each portion of the frequency spectrum, i.e., data are carried on equally-spaced carrier signals. The combined number of carrier signals from both portions of the spectrum is implementation-dependent. ADSL implementations that comply with the ITU-T G.992.1 standard have 256 carrier signals, while implementations that comply with the ITU-T G.992.2 standard have 128 carrier signals. Future implementations are expected to have 512 or even 1024 carrier signals (see, e.g., ITU-T G.992.5).
DMT modulation provides for very efficient use of the available communication spectrum because the amount of data carried by each carrier signal is individually customized to fit the signal-to-noise ratio profile of the channel. Each carrier signal is allocated a number of data bits, and the allocation of bits may be dynamically adjusted as channel conditions change. Each carrier signal may also be allocated a small individual gain factor to further improve communications performance.
The allocation of bits and gain factors to carrier signals are typically performed using tables. A gain table includes an individual gain factor for each carrier signal. A bit table includes an individual number of bits allocated to each carrier signal. A tone table may be used to allocate specific data bits to specific carrier signals.
Some channels actually have two signal-to-noise ratio profiles. An example of such a channel is a twisted wire pair in a binder that also carries TCM-ISDN (Time Compression Multiplexing—Integrated Services Digital Network) traffic. TCM-ISDN employs time division multiplexing at a rate of 400 Hz, i.e. the central office alternately transmits data for 1.25 milliseconds, then listens for data from the customer for 1.25 milliseconds. This causes other channels to experience a noise profile that alternates at a rate of 400 Hz.
The interference can be divided into two types: near-end cross talk (NEXT) and far-end cross talk (FEXT). Some confusion can arise when discussing NEXT and FEXT since the meaning of NEXT and FEXT changes with respect to the chosen reference point. For clarity herein, the central office is hereby chosen as the arbitrary reference point, and this reference point will be used consistently throughout. NEXT interference on a given channel is caused by central office transmissions on other channels. FEXT interference on a given channel is caused by transmissions from customers on other channels. TCM-ISDN signaling alternately causes NEXT interference and FEXT interference. The NEXT interference is generally significantly worse than the FEXT interference, although this depends on the distance that the twisted wire pair travels alongside interfering channels.
The ITU-T G.992.1 and G.992.2 standards each address TCM-ISDN interference in their respective Annex C. Two solutions are offered: dual mode solution and FEXT-only solution. In the dual mode solution, two sets of tables (gain, bit, and tone) are used. One set of tables is used to construct symbols for transmission during periods of NEXT interference (“NEXT symbols”), and the other set of tables is used to construct symbols for transmission during periods of FEXT interference (“FEXT symbols”). Although TCM-ISDN signaling uses a 50% duty cycle, it is expected that on average, only 126/340 (about 37%) of the symbols will be free of NEXT interference, and hence constructible as FEXT symbols.
Although the dual mode solution offers a higher data rate, it does add significant cost to the modem in the form of additional memory for the second set of tables. This additional cost is expected to be significant for future ADSL implementations having 512 or more carrier signals due to the increased size of the tables.
The FEXT-only solution is similar to the dual mode solution except that no symbols are constructed or sent during the periods of NEXT interference. Because only FEXT symbols are used, only one set of tables is needed. Although the FEXT symbols typically carry more data than NEXT symbols, sacrificing 63% of the symbols can impose a substantial performance penalty.
Accordingly, it would be desirable to have a memory-efficient method for ADSL transmission in a time-varying noise environment. Such a method would preferably avoid the performance penalty of the FEXT-only solution without suffering the prohibitive expense of the dual mode solution.
SUMMARY
Accordingly, there is disclosed herein a method of communicating data across a channel that experiences near-end cross talk (NEXT) interference and far-end cross talk (FEXT) interference in alternate intervals. In one embodiment, the method comprises: a) determining NF, the number of bits per symbol usable in a FEXT-only mode of operation; b) determining N S , a number of bits per symbol usable in a single mode of operation; c) determining whether the FEXT-only mode or the single mode provides a higher data rate; and d) configuring a modem to transmit using the mode having a higher data rate. The FEXT-only mode may be determined to have a higher data rate when 126N F >340N S .
In another embodiment, the method comprises: a) performing a bit table determination procedure for FEXT symbols; b) performing a bit table determination procedure for NEXT symbols; and c) constructing a bit table for single mode symbols. The single mode bit table may be constructed by setting each single mode bit table entry equal to the lesser of the corresponding entries in a FEXT symbol bit table and a NEXT symbol bit table. The number of bits per symbol usable in the FEXT-only mode may be determined by summing entries from the FEXT-only symbol bit table, and the number of bits usable in the single mode may be determined by summing entries from the single mode symbol bit table.
In yet another embodiment, the method comprises: a first modem determining that FEXT-only mode or single mode is preferred communication mode; a second modem determining that FEXT-only mode or single mode is a preferred communication mode; and each modem transmitting using the preferred communication mode of the other modem. The preferred communication modes may be different.
Also contemplated is a modem that comprises: a memory and a processor. The memory is configured to store a single bit table. The processor is configured to transmit and receive data via a channel that experiences alternate intervals of NEXT and FEXT interference. The processor determines the number of bits per symbol usable in FEXT-only mode and single mode, and stores in memory the bit table for the mode offering the higher data rate.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the present invention can be obtained when the following detailed description of the preferred embodiment is considered in conjunction with the following drawings, in which:
FIG. 1 is a functional-block diagram of one ADSL modem embodiment;
FIG. 2 is a schematic block diagram of the ADSL modem embodiment of FIG. 1 ;
FIG. 3A is a flow diagram of a setup method of a preferred ADSL modem embodiment;
FIG. 3B is a flow diagram of a setup method of a preferred ADSL/ADSL+ modem embodiment;
FIG. 4 is a graph showing relative data rates of different downlink communication modes on a time-varying noise channel; and
FIG. 5 is a graph showing relative data rates of different uplink communication modes on the time-varying noise channel.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
Turning now to the figures, you will find a functional block diagram of one embodiment of an ADSL (“Asymmetric Digital Subscriber Line”) modem 100 in FIG. 1 . A control and data bus conveys to modem 100 data that is to be transmitted. A multiplexer/synchronization controller 102 routes the data via two paths: a fast path, and an interleaved path. Data that needs to be sent with a low latency is routed through the fast path, while data that needs to be sent with a low error rate is routed through the interleaved path. The two data types may be intermixed and identified by a bus protocol.
The fast path data is delivered to CRC (cyclic redundancy code) block 104 , which aligns the data into frames and appends a CRC checksum value. The interleaved path data is delivered to an independent CRC block 106 for the same processing. CRC blocks 104 and 106 forward the data frames to scrambling and forward error correction (FEC) blocks 108 and 110 , respectively.
Blocks 108 and 110 each combine on a bit-wise basis the bits of the frame data with a pseudo-random bit sequence to randomize, or “scramble”, the data. An error correction coding process is then applied to the randomized frame data to add redundancy. This redundancy may be used by the receiver to detect and correct errors caused by channel interference. In the fast path, block 108 provides the randomized and encoded data to rate converter block 112 , while in the interleaved path, block 110 provides the randomized and encoded data to an interleaver block 114 .
Interleaver block 114 re-orders the data in the stream of randomized and encoded data frames in a manner that interleaves the data from one frame among the data from other frames. By “spreading out” the data of a given frame in this manner, the modem provides increased resistance to “error bursts” on the channel. That is, a closely-spaced set of errors caused by channel interference will not be concentrated in the data of a single frame, but rather, the errors will be “scattered” at the receiver so that only one or two errors will appear in the data of a given frame. This prevents an error burst from overwhelming the error correction ability of the error correction code, however, it also introduces a significant latency in the travel time of the data. The stream of interleaved data is provided to rate converter block 116 .
Rate converter blocks 112 and 116 may be buffers designed to “even out” the data rate required from the preceding blocks. The following blocks operate at two different data rates because the modem uses different data rates during periods of NEXT and FEXT interference.
A tone ordering block 118 retrieves data streams from the rate converter blocks 112 , 116 , and allocates bits from the data streams to outgoing carrier signals in accordance with a tone ordering table. It is generally preferred to allocate the bits in a manner that avoids having adjacent bits of the data stream carried on the same or adjacent carrier signals. Spreading out the bits in the frequency domain provides added resistance to interference that is localized in a given frequency region.
A constellation encoding and gain scaling block 120 receives the carrier-allocated bits from block 118 and converts them into amplitude values for the carriers. The conversion may be done in two steps: First the bits may be mapped to a quadrature amplitude modulation (QAM) constellation point, e.g. a four-bit value corresponds to a predetermined point in a 16-point QAM constellation. Second, the constellation point coordinates are multiplied by a gain value for the carrier signal to obtain the carrier signal amplitude.
Note that blocks 118 and 120 may rely on one or two sets of tone ordering, bit, and gain tables. A modem operating in the dual mode may employ two sets of tables, while a modem operating in a FEXT-only mode may employ just one set of tables.
An inverse Discrete Fourier Transform (IDFT) block 122 applies an inverse Discrete Fourier Transform to the carrier signal amplitudes to obtain one “symbol”, that is, samples of a time domain signal having a frequency spectrum with the specified carrier signal amplitudes. Block 124 converts the symbol to serial form. The serial form of the symbol includes a cyclic prefix. The cyclic prefix is a copy of some number of samples from the end of the symbol, added as a prefix to the symbol. This prefix causes the convolution with the channel impulse response to mimic cyclical convolution, allowing for simpler equalization at the receiver.
Block 126 converts the sequence of symbols in serial form into an analog signal, which may then be filtered and amplified to form a transmit signal. The transmit signal is supplied via hybrid 128 to the channel, through which it travels to a receiver. A transmitter at the other end of the channel simultaneously transmits a signal for reception by modem 100 .
The hybrid 128 operates to extract the receive signal from the channel while at the same time conveying a transmit signal to the channel. The hybrid may include one or more bandpass filters to prevent the transmit signal from interfering with the receive signal.
The receive signal from hybrid 128 may be equalized by block 130 and converted into digital form. Block 132 converts the sequence of symbols in serial form into symbols in parallel form, dropping the cyclic prefix. Block 134 applies a Discrete Fourier Transform (DFT) to the symbols, thereby determining amplitudes of carriers in the symbol. However, the amplitudes have been affected by transit through the channel.
Block 136 applies a spectral filter to the carrier amplitudes. A spectral filter is a gain factor for each carrier that compensates for channel attenuation and transmit gain table. Block 136 also maps the filtered carrier amplitudes to bits represented by the closest constellation points.
The detected bits are re-ordered by block 138 to put adjacent bits back together. Block 138 further segregates the bits into two bit streams, one for the fast path, and one for the interleaved path. The bit streams are provided to respective rate converter blocks 140 , 142 to smooth the data rate for the ensuing blocks.
Note that blocks 136 and 138 may rely on one or two sets of filter, bit, and tone ordering tables to perform their functions. Two sets would be used when operating in dual mode, whereas only a single set would be needed when operating in FEXT-only mode.
The rate converter block 140 for the fast path provides a sequence of randomized and encoded data frames to block 144 , while the rate converter block 142 for the interleaved path provides an interleaved data stream to block 146 . Block 146 performs a de-interleaving process on the interleaved data stream to reconstruct a sequence of randomized and encoded data frames. The sequence is provided to block 148 .
Blocks 144 and 148 perform an error correction (“decoding”) process and a de-scrambling process on the randomized and encoded data frames. The decoding process identifies and corrects channel-induced errors in the data, dropping the previously-introduced redundancy in the process. The de-scrambling process again applies the pseudo-random bit sequence in a bit-wise fashion to undo the data randomization. Blocks 144 and 148 provide data frames to blocks 150 and 152 , respectively.
Blocks 150 , 152 perform a CRC checksum confirmation. If the CRC check fails, some form of error handling is carried out—typically a processor interrupt may be asserted by modem 100 , thereby causing the processor to request that the data be re-transmitted. Assuming that the CRC check succeeds, the data is extracted from the frame structure and provided to block 154 . Block 154 makes the data streams from the fast and interleaved data paths available to the system via the control and data bus.
Further details on the operation of the above-described embodiment of modem 100 are available in the ITU-T G.992.1 (06/99) standard, which is hereby incorporated by reference. Special reference should be made to Annex C of the standard.
FIG. 2 shows a preferred implementation of modem 100 , in which many of the functional blocks are implemented by a digital signal processor (DSP) 202 that operates in accordance with software 203 stored in a memory 204 . Memory 204 may also include one or two sets of tables, each set consisting of a gain table 206 , a bit table 208 , a tone table 210 , and a filter table 212 . The DSP 202 may be coupled to a system bus via interface logic 214 .
The above-described embodiment of modem 100 operates in one of two modes: dual mode or FEXT-only mode. The operating mode may be determined by the capabilities of the modem on the other end of the channel. If the other modem supports dual mode, then dual mode will be used. Otherwise FEXT-only mode is used. The dual mode may support over twice the data rate of the FEXT-only mode on short loops. However, the increased cost to support the dual mode may be prohibitive due to the memory required for a second set of tables.
In a first preferred, alternative embodiment, the modem 100 may operate in one of two modes: single mode or FEXT-only mode. In the single mode, a single set of tables is used for constructing and decoding symbols sent during both NEXT- and FEXT-interference periods (“NEXT symbols” and “FEXT symbols”, respectively). In the FEXT-only mode, a single set of tables is used for constructing and decoding symbols send during the FEXT-interference periods, and no symbols are sent during the NEXT interference periods. It is expected that this first preferred embodiment will nearly achieve the dual mode data rates at the same complexity as a modem that supports only the FEXT-only mode. The advantages of this embodiment will become more pronounced as future technologies support a greater number of carrier signals and require larger tables.
In a second preferred embodiment, the modem 100 may support different numbers of carrier signals (e.g. 256 in ADSL, and 512 in ADSL+). When operating at the higher number of carrier signals, the modem may support only those modes requiring a single set of tables, i.e. single mode and FEXT-only mode. However, when operating at the lower number of carrier signals (i.e., operationg in a reduced-carrier-number mode), the modem in the second preferred embodiment also supports modes requiring two sets of tables, i.e. the dual mode. The added flexibility of this embodiment is expected to enhance performance relative to the first preferred embodiment.
In the preferred embodiments, modem 100 will determine modes supported by the modem on the other end of the channel, and will avoid operating in modes not supported by the other modem. Hence, if the modem on the other end of the channel does not support single mode, modem 100 will operate in FEXT-only mode or dual mode (if supported). Assuming all modes are supported by the other modem, the software 203 causes the DSP 202 in the preferred modem embodiments to follow the appropriate setup procedure shown in FIG. 3A or 3 B.
In block 302 of FIG. 3A , the modem characterizes the channel, identifying the signal-to-noise ratio profiles for both NEXT-interference periods and FEXT-interference periods. In block 304 , the modem goes through the bit table (and possibly the gain table) determination procedure assuming operation in the FEXT-only mode. At least one result of block 304 is a calculation of N F , the number of bits that would be carried by each FEXT symbol.
In block 306 , the modem calculates an expected data rate for operation in the FEXT-only mode. The expected data rate may be determined exactly or an approximation may be used, since the exact data rate calculation may be too involved. The expected FEXT-only data rate (R OF ) may be calculated in accordance with the following expression:
R FO = ( N F bits data symbol ) · ( 126 340 ) · ( 4000 data symbols second ) , ( 1 )
where 126/340 is the overall fraction of symbols that are free from NEXT-interference.
In block 308 , the modem goes through the bit table (and possibly gain table) determination procedure assuming operation in the single mode. The bit table is determined from a combination of the bit tables for the NEXT and FEXT symbols, although it is expected to be unnecessary to completely determine the bit tables separately. The FEXT symbol bit table was determined in block 304 . As the bit table for the NEXT symbols is determined, it is combined with the bit table for the FEXT symbols to determine the single mode bit table.
Recall that the bit table specifies the number of bits allocated to each carrier signal. The single mode bit table has for each carrier the lesser of the two numbers in the bit tables for the FEXT and NEXT symbols. Thus the number of bits for a given carrier in a NEXT symbol is compared to the number of bits for a given carrier in a FEXT symbol, and the smaller number is stored in the bit table for the single mode. At least one result of block 308 is a calculation of the N S , number of bits that would be carried by each symbol.
If gain table calculations are also being performed at this stage, the gain factor for a given carrier is in accordance with the selected mode (i.e., FEXT-only mode or single mode). That is, if FEXT-only mode is chosen, the gain table is preferably computed for the bit table used in FEXT-only mode. If single mode is chosen, the gain table is computed for the bit table used in single mode.
In block 310 , the modem calculates an expected data rate for operation in the single mode. As before, the expected data rate may be determined exactly or an approximation may be used. The expected single mode data rate (RSM) may be calculated in accordance with the following expression:
R
SM
=
(
N
S
bits
data
symbol
)
·
(
4000
data
symbols
second
)
.
(
2
)
In block 312 , the modem compares the data rates for the two modes. In an alternative embodiment, blocks 306 and 310 may be omitted, and the equations (1) and (2) may be collapsed into a single comparison to determine whether:
126 N F >340 N S (3)
The modem makes a decision based on the outcome of the comparison. If the data rate for the FEXT-only mode is greater, then in block 314 , the modem configures for FEXT-only operation. If the FEXT-only bit table has been overwritten, the modem may repeat the FEXT-only bit table determination. If the data rate for the single mode is greater, then in block 316 , the modem configures for single mode operation.
Note that the operating mode is preferably determined by the receiving modem, so it is contemplated that modems at both ends of the channel perform this procedure. Note that the outcome may be different for each modem, so it is conceivable that one modem may be transmitting using the FEXT-only mode and receiving using the single mode.
The setup procedure shown in FIG. 3B is similar to that of FIG. 3A . However, in FIG. 3B , the procedure is extended to consider operation with different numbers of carriers. Such a circumstance may arise in a modem that supports both ADSL (256 carriers) and ADSL+(512 carriers). That is, a modem that supports a first carrier-number mode (e.g., ADSL+ using 512 carriers) and a reduced-carrier-number mode (e.g., ADSL using 256 carriers). In this procedure, the data rates for high carrier number FEXT-only mode (“OF”); high carrier number single mode (SM); and reduced-carrier-number mode (i.e., low carrier number dual mode (“DM LO ”) are determined and compared. Thus in block 304 , the OF bit allocation is determined and the number of bits per symbol N F is calculated. The data rate calculation of block 306 is unchanged. In block 308 , the SM bit allocation is determined and the number of bits per symbol N S is calculated. Again the data rate calculation of block 310 is unchanged.
In block 320 , the dual bit table allocation procedure is followed and the number of bits for FEXT symbols (N F−LO ) and the number of bits for NEXT symbols (N N−LO ) are determined. The data rate calculation in block 322 may take the following form:
R
DM
-
LO
=
[
(
N
F
-
LO
bits
data
symbol
)
·
(
126
340
)
+
(
N
N
-
LO
bits
data
symbol
)
·
(
214
340
)
]
·
(
4000
data
symbol
second
)
,
(
4
)
In block 324 , the modem compares the data rates for the three modes. In an alternative embodiment, blocks 306 , 310 and 322 may be omitted, and the equations (1) and (2) (as calculated for the high carrier number) may be collapsed with equation (4) into three-way comparison to determine which of the following is largest:
max{126 N F , 340 N S , (126 N F−LO +214 N N−LO )} (5)
The modem makes a decision based on the outcome of the comparison. If the data rate for the OF+ mode is greater, then in block 314 , the modem configures for OF operation. If the OF bit table has been overwritten, the modem may repeat the OF bit table determination. If the data rate for the SM mode is greater, then in block 316 , the modem configures for SM operation. Again, if the SM bit table has been overwritten, the modem may repeat the SM bit table determination. Finally, if the DM LO mode has the largest data rate, then in block 326 , the modem configures for DM LO operation.
FIGS. 4 and 5 compare performance simulations for the single mode, dual mode, and FEXT-only mode. These simulations were done considering only a single number of carriers, namely, 256 (ADSL). FIG. 4 shows the performance of a modem transmitting from the central office (downstream), and FIG. 5 shows the performance of a modem transmitting from the customer (upstream). The following assumptions were used for the simulations:
Downstream band carriers 36-255 Dwnstream Transmit PSD Mask −40 dBm/Hz constant Upstream band carriers 6-31 Upstream Transmit PSD Mask −38 dBm/Hz constant Coding gain 3 dB Margin 6 dB Allowed range of bits/carrier 1-15
The assumed noise environment assumed 9 TCM-ISDN FEXT and NEXT interferers in the same binder, and 9 ADSL FEXT disturbers (no NEXT disturbers due to frequency division duplex operation). The downstream receiver experienced −140 dBm/Hz of additive white Gaussian noise, and the upstream receiver experienced −123 dBm/Hz of additive white Gaussian noise.
The NEXT- and FEXT-interference models used for the simulations are as follows:
PSD FEXT = PSD DISTURBER × H ( f ) 2 × 10 - X FEXT 10 × ( l l 0 ) × ( f f 0 ) 2 ( 6 ) PSD NEXT = PSD DISTURBER × 10 - X NEXT 10 × ( f f 0 ) 1.5 ( 7 )
where f 0 =1 MHz, l 0 =500 m, and X FEXT and X NEXT are the crosstalk coefficients. Cables using color-coded polyethylene (CCP) coatings have X FEXT =36.6 dB and X NEXT =40.2 dB. Cables using paper coatings (performance not shown in figures) have X FEXT =28.6 dB and X NEXT =38.0 dB. The figures assume 0.4 mm conductors.
FIGS. 4 and 5 each show 3 curves. The solid curve shows the performance of a modem sing dual mode operation, the dash-dotted curve shows the performance of a modem using FEXT-only mode, and the dashed curve shows the performance of a modem using single mode. In the single mode case, the bit loading for all symbols is performed based on the worst case noise which is usually NEXT-interference for all loop lengths.
The FEXT-only mode demonstrates relatively poor performance for short loop lengths, but converges to the dual mode level of performance at long loop lengths. Conversely, the single mode demonstrates relatively poor performance for long loop lengths, but converges to the dual mode performance for short loop lengths. Hence the preferred modem embodiment performs well at both extremes and suffers only minor degradation relative to the dual mode at intermediate lengths. Since the crossover point is different for upstream and downstream directions, the preferred embodiment further enhances performance by allowing for the use of different modes in upstream and downstream communications.
It is noted that the constants 126, 214 and 340 were chosen as appropriate for the preferred embodiments, but other numbers may prove suitable for different embodiments.
Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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A method of communicating data across a channel that experiences near-end cross talk (NEXT) interference and far-end cross talk (FEXT) interference in alternate intervals. In one embodiment, the method comprises: a) determining N F , the number of bits per symbol usable in a FEXT-only mode of operation; b) determining N S , a number of bits per symbol usable in a single mode of operation; c) determining whether the FEXT-only mode or the single mode provides a higher data rate; and d) configuring a modem to transmit using the mode having a higher data rate. The FEXT-only mode may be determined to have a higher data rate when 126N F >340N S .
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotary looptaker in a sewing machine, more particularly toan arrangement for avoiding trouble or problems due to friction caused by rotation between a looptaker and a bobbin case.
2. Description of the Prior Art
in a conventional vertically rotary looptaker according to which a looptaker is driven to rotate with an annular rib of a bobbin case fitted into an annular groove of the looptaker, the rotational speed of the looptaker is at most 7,000 rpm, since the loopertaker and the bobbin case are made of iron. Even in the arrangements wherein lubricant oil is supplied to the annular groove of the looptaker and the annular rib of the bobbin case, the rotational speed is yet at most 12,000 rpm. In such a conventional mechanism, although sliding resistance is reduced by the lubricant oil, friction is still produced between the annular groove of the looptaker and the annular rib of the bobbin case. Besides, the use of the lubricant oil brings about attachment of oil to the thread thereby preventing the sewing operation from being smoothly performed.
SUMMARY OF THE INVENTION
To solve the aformentioned problem, it is an object of the present invention to provide an improved and novel rotary looptaker.
It is another object of the invention to provide a rotary looptaker wherein sliding resistance is reduced to enable the looptaker to rotate at a high speed and soiling of the thread due to oil is prevented.
To accomplish the above objects, in a rotary looptaker being of the type comprising a looptaker having an annular groove formed therein and a bobbin case having an annular rib formed thereon, said looptaker being driven for rotation with the annular rib of the bobbin case fitted into the annular groove of the looptaker, the improvement in accordance with the invention comprises means for producing a repulsive magnetic force acting between the annular groove and the annular rib.
In a preferred embodiment, said repulsive magnetic force producing means comprises a first permanent magnet means provided on both sides of the annular rib and a second permanent magnet means secured to both interior sides of the annular groove in opposite relation to the first permanent magnet means, the first and the second permanent magnet means being adapted such that facing magnetic poles of the first and the second permanent magnet means are identical to each other with respect to magnetic polarity.
In another preferred embodiment, said magnetic repulsive force producing means comprises a first permanent magnet member magnetized radially of the bobbin case and secured to the periphery of the annular rib, and a second permanent magnet member magnetized radially of the looptaker and secured to the bottom of the annular groove of the looptaker, the first and second permanent magnet members being adapted such that facing magnetic poles of the first and second permanent magnet members are identical to each other with regard to magnetic polarity.
In still another preferred embodiment, said magnetic repulsive force producing means comprises a first permanent magnet member substantially constituting the annular rib and magnetized axially of the bobbin case, and second permanent magnet members, each of which is secured to an interior side of the annular groove, the first and second permanent magnet member being adapted such that facing magnetic poles of the first and second permanent magnet members are identical with each other with regard to magnetic polarity.
In a further preferred embodiment, said repulsive force producing means comprises a third permanent magnet member secured to the bottom of the track groove and extending along the first permanent magnet member, the first and third permanent magnet members being adapted such that facing magnetic poles of the first and third permanent magnet embers are identical to each other with regard to magnetic polarity.
In a still further preferred embodiment, at least one of the first and second permanent magnet members is formed in the shape of a circular arc.
In a yet further preferred embodiment, at least one of the first, second, and third permanent magnet members is formed in the shape of a circular arc.
Preferably, the first permanent magnet member comprises a plurality of first permanent magnet pieces provided at intervals circumferentially of the bobbin case.
Still preferably, the second permanent magnet member comprises a plurality of permanent magnet pieces provided at intervals circumferentially of the looptaker.
Further preferably, the third permanent magnet member comprises a plurality of magnet pieces provided at intervals circumferentially of the bobbin case.
Hence, in accordance with the invention, since the permanent magnet pieces are utilized so that the magnetic repulsive force may be produced between the annular groove of the looptaker and the annular rib of the bobbin case, sliding resistance existing therebetween may be reduced remarkably. Consequently, abrasion of those members may be prevented and high speed of rotation of the looptaker may be effected, thereby accomplishing high-speed sewing performance. Furthermore, since lubricant oil or the like is not employed, soil of thread due to such oil lubricant is prevented, thereby enabling a sewing operation to be smoothly executed.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will become more apparent upon a reading of the following detailed specification and drawings in which:
FIG. 1 is a sectional view of an embodiment of the invention;
FIG. 2 is an enlarged sectional view of the portion encircled by reference numeral II of FIG. 1;
FIG. 3 is an exploded perspective view of part of the embodiment;
FIG. 4 is a sectional view of another embodiment of the invention;
FIG. 5 is a sectional view of still another embodiment of the invention; and
FIG. 6 is a perspective view of part of yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, preferred embodiments of the invention are described below.
FIG. 1 is a sectional view of a vertical full rotation shuttle according to an embodiment of the invention. A bobbin case 3 is accommodated in a looptaker 2. A bobbin 4 for winding bobbin thread therearound is mounted in the bobbin case 3. The bobbin case 3 is held from rotating by a rotation restraining member therefor (not shown) secured to the machine body. An annular rib 5 in the shape of an outward flange is formed on the outer periphery of the bobbin case 3. The annular rib 5 is fitted into an annular groove 6 formed on the inner periphery of the looptaker 2. The looptaker is driven to rotate about the axis thereof in one direction by a driving means connected to a rotary shaft 7.
FIG. 2 is an enlarged sectional view showing the portion encircled by reference numeral II of FIG. 1. The looptaker 2 is made of iron, aluminum, or the like. In the annular groove 6 are fixed permanent magnets 8, 9, and 10, the fixed permanent magnet 9 being magnetized radially with respect to the axis of the looptaker and the fixed permanent magnets 8 and 10 being magnetized axially with respect to the axis of the looptaker, each of which can be formed in the shape of a circular arc, whose perspective views are shown in FIG. 3. The looptaker 2 is made of iron, aluminum, or the like as mentioned above, and accordingly is capable of having sufficient strength. Furthermore, the looptaker 2 is free from deformation which might be caused by centrifugal force while rotating at a high speed.
The bobbin case 3 is made of synthetic resin etc., and its annular rib comprises a flange part 11, and permanent magnets 12, 13, and 14, the magnet 13 being magnetized radially with respect to the axis of the looptaker and the magnets 12 and 14 being magnetized axially with respect to the axis of the looptaker, each of which can be formed in the shape of a circular arc. The opposed magnetic poles of the permanent magnet pieces 8, 12 facing each other are identical (of the same polarity) with each other. Opposite faces of magnetic pieces 9, 13 are identical to each other and each of the facing poles is a north pole in this embodiment. Opposite faces of magnetic poles of the permanent magnet pieces 10, 14 are likewise identical with each other and each of the facing poles is a north pole in this embodiment. Thus, a magnetic repulsive force is produced between the annular groove 6 and the annular rib 5. Consequently, the looptaker is capable of rotating with the annular groove 6 and the annular rib 5 hardly contacting with each other.
FIG. 2 thus shows a rotary looptaker 2 being of the type accommodating a bobbin case 3 therein, with the bobbin case 3 having an annular rib 5 in the shape of an outward flange having a radially outermost surface and upper and lower axially facing surfaces formed on an outer peripheral portion of the bobbin case, and the looptaker 2 having an annular groove 6 formed on an inner peripheral portion thereof having a radially innermost surface and upper and lower axially facing surfaces and being driven for rotation about an axis of rotation with the annular rib 5 fitted into the annular groove 6. At least one first permanent magnet 12 or 14 forms at least part of the annular rib 5 of the bobbin case 3, the at least one first permanent magnet 12 or 14 being magnetized in an axial direction with respect to the axis of rotation and having a surface thereof of one polarity, which is North in FIG. 2, forming at least part of one of the axially facing surfaces of the annular rib 5. At least one second permanent magnet 8 or 10 forms at least part of the annular groove 6 of the looptaker and the at least one second permanent magnet 8 or 10 is magnetized in the axial direction and has a surface thereof having a North polarity forming at least part of one of the axially facing surfaces of the annular groove facing the axially facing surface of the annular rib formed at least in part by the art least one first permanent magnet 12 or 14, whereby a magnetic repulsive force is generated between the annular rib the annular groove.
The embodiment shown in FIG. 2 includes at least one third permanent magnet 13 which forms at least part of the radially outermost surface of the annular rib and which is magnetized radially with respect to the axis of rotation of the looptaker. At least one fourth permanent magnet 9 forms at least part of the radially innermost surface of the annular groove 6 and is magnetized radially with respect to the axis of rotation of the looptaker. As shown in FIG. 2, the radially outermost surface of the annular rib formed by the at least one third magnet 13 is of the same polarity (North) as the radially innermost surface of the annular groove formed by the at least one fourth permanent magnet 9.
From FIG. 2 it will be seen that one first permanent magnet 12 is provided on the upper axially facing surface and another first permanent magnet 14 forms at least part of the lower axially facing surface of the annular rib, with the another first permanent magnet 14 being magnetized in an axial direction with respect to the axis of rotation of the looptaker. Likewise, in addition to the one second permanent magnet 8 provided on the upper axially facing surface of the annular groove 6, another second permanent magnet 10 is provided which has a surface forming at least part of the lower axially facing surface of the annular groove, the another second permanent magnet 10 being magnetized in an axial direction with respect to the axis of rotation.
FIG. 4 is a sectional view of another embodiment of the invention. In this embodiment, permanent magnet pieces 8a and 10a are secured to the sides of annular groove 6 of looptaker 2 and piece 9a is secured to the bottom of the annular groove of the looptaker 2. The annular rib 5 of the bobbin case 3 is formed by a permanent magnet piece 13a which is magnetized axially of the bobbin case 3. The permanent magnet piece 13a is adapted such that its magnetic poles are identical with those magnetic poles of the permanent magnet pieces 8a, 9a, 10a which face the magnetic poles of the permanent magnet piece 13a. Consequently, a magnetic repulsive force acts between the annular groove 6 and the annular rib 5. Other construction of this embodiment is similar to that of the previous embodiment.
The embodiment shown in FIG. 4 thus comprises a single first permanent magnet 13a which forms at least part of the upper and lower axially facing surfaces of the annular rib 5, the single first permanent magnet 13a being magnetized in an axial direction with respect to the axis of rotation of the looptaker and having the portion thereof forming at least part of the upper axially facing surface of one polarity (North) and the portion thereof forming at least part of the lower axially facing surface of the opposite polarity (South). A second permanent magnet 8a is provided having a surface of the one polarity (North) forming at least part of the upper axially facing surface of the annular groove, the second permanent magnet 8a being magnetized in an axial direction with respect to the axis of rotation of the looptaker. Another second permanent magnet 10a is provided having a surface of the opposite polarity (South) forming at least part of the lower axially facing surface of the annular groove, the another second permanent magnet 10a being magnetized in an axial direction with respect to the axis of rotation of the looptaker. In addition, at least one permanent magnet 9a is provided forming at least part of the radially innermost surface of the annular groove 6, the magnet 9a being magnetized axially with respect to the axis of rotation of the looptaker.
FIG. 5 is a sectional view of still another embodiment of the invention. Although this embodiment is similar to that shown in FIG. 4, it is noteworthy in this embodiment that a fixing hole 15 is formed in the annular rib 5 of the bobbin case 3 and a permanent magnet piece 13b is fixed into the fixing hole 15. The permanent magnet pieces 8a, 9a, and 10a are each formed in the shape of a circular arc as shown in FIG. 3. The permanent magnet piece 13b is bar-shaped, extending in the axial direction of the bobbin case (in the vertical direction as viewed in FIG. 5). Such permanent magnet pieces 13b are disposed at intervals in the circumferential direction around the bobbin case 3. Such an arrangement as mentioned above also produces the magnetic repulsive force between the annular groove 6 and the annular rib 5.
The embodiment shown in FIG. 5 thus shows at least one first permanent magnet 13b which forms at least part of the upper and lower axially facing surfaces of the annular rib, the at least one first permanent magnet 13b being magnetized in an axial direction with respect to the axis of rotation of the looptaker and having the portion thereof forming at least part of the upper axially facing surface of North polarity and the portion thereof forming at least part of the lower axially facing surface of South polarity. As mentioned above, a plurality of first permanent magnets 13b are provided at intervals in the circumferential direction of the bobbin case and each magnet 13b extends axially through the annular rib and is spaced radially inward from the radially outermost surface of the annular rib. At least one second permanent magnet 8a is provided having a surface of North polarity forming at least part of the upper axially facing surface of the annular groove, the second permanent magnet 8a being magnetized in an axial direction with respect to the axis of rotation of the looptaker. Another second permanent magnet 10a is provided having a surface of South polarity forming at least part of the lower axially facing surface of the annular groove, the another second permanent magnet 10a being magnetized in an axial direction with respect to the axis of rotation of the looptaker. At least one permanent magnet 9a is provided forming at least part of the radially innermost surface of the annular groove, the magnet 9a being magnetized axially with respect to the axis of rotation of the looptaker.
FIG. 6 is a perspective view showing part of yet another embodiment of the invention. In this embodiment, permanent magnet pieces 8b, 9b, 10b are buried in the looptaker 2 at intervals circumferentially around the looptaker. The permament magnet pieces 13b fixed in the bobbin case 3 are the same as that in the previous embodiment shown in FIG. 5. Likewise in this embodiment, friction contact of the permanent magnet pieces 13b with permanent magnet pieces 8b, 9b and 10b is resisted by the magnetic repulsive force acting therebetween.
The embodiment shown in FIG. 6 thus shows a plurality of first permanent magnets 13b each of which form a part of the annular rib of the bobbin case, each of the plurality of first permanent magnets 13b being magnetized in the axial direction and each of the plurality of first permanent magnets 13b having a surface thereof of North polarity forming a part of the upper axially facing surface of the annular rib. A plurality of second permanent magnets 8b each form a part of the annular groove of the looptaker, each of the plurality of second permanent magnets 8b being magnetized in the axial direction and each of the plurality of second permanent magnets 8b having a surface thereof of North polarity forming a part of the upper axially facing surface of the annular grove. Also, each of the plurality of first permanent magnets 13b have another surface of South polarity forming a part of the lower axially facing surface of the annular rib, and another plurality of the second permanent magnets 10b each form a part of annular groove of the looptaker, each of the another plurality of second permanent magnets 10b being magnetized in the axial direction and having a surface thereof of Sourth polarity forming a part of the lower axially facing surface of the annular groove. A plurality of third permanent magnets 9b are disposed in the looptaker, each of the plurality of third permanent magnets 9b being magnetized in the axial direction and spaced at intervals circumferentially around the looptaker and spaced radially from the radially innermost surface of the annular groove.
The present invention can be applied to a horizontally rotary looptaker and a semirotary looptaker as well as a vertically full-rotary looptaker.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the means and the range of equivalency of the claims are therefore intended to be embraced therein.
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A rotary looptaker having an annular groove formed therein and a bobbin case having a track rib formed thereon, wherein the looptaker is driven for rotation with the annular rib fitted into the annular groove and permanent magnetic pieces are respectively provided in the annular rib and the annular groove so that magnetic repulsive forces are produced therebetween.
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BACKGROUND OF THE INVENTION
The present invention relates to automated public key certificate transfer.
Public key cryptography uses public-private key pairs for electronic signatures, electronic signature verification and encryption and decryption of data for security during electronic transmission. In simple terms, a public key owned by an individual receiving the data (the “recipient”) is used by a sender to encrypt the data. The recipient then uses the recipient's corresponding private key to decrypt the data. In order to encrypt the data, the sender must have access to the recipient's public key.
When electronically signing data, a sender signs the data using the sender's private key, an operation that can involve using the private key to encrypt a “cryptographic hash” of the data that is being signed, and then making available to the recipient the signed data and the encrypted hash (the “signature”). The recipient verifies the signature by computing a new hash over the data using the sender's public key, decrypting the encrypted hash of the signature and comparing the two hashes. If the hashes match, then the data integrity is proven.
Typically, a public key for another individual (the sender for example) is obtained by obtaining the individual's public key certificate directly or indirectly from that individual. A certificate is an electronic data object including a public key, and can be issued by a trusted third party, a certificate authority, that verifies the identity of the certificate holder. The certificate can also include the name of the certificate authority and the name of the individual or entity for whom the certificate is issued. The recipient of another individual's certificate should take steps to verify the trustworthiness or authenticity of the certificate, which can then be added to a personal certificate database for later use. The recipient of an electronically signed document can verify the identity of the sender (signer) by verifying the certificate of the sender.
Currently, there are a number of ways to obtain someone's certificate, some of which are covered by standards issued by the Internet Engineering Task Force public-key infrastructure (X.509) working group (IETF-PKIX). For instance, the certificate can be found in a searchable database on a server. Such a server would typically be provided and managed by a trusted party that undertakes to ensure the validity of the database's contents, including the certificates it contains.
A certificate owner can also manually include the certificate as an attachment to an e-mail message sent to a recipient. This requires the owner to place the certificate into a file that will be attached to the e-mail message, and the recipient must manually add the certificate to a personal certificate database for later use.
SUMMARY
The present invention provides methods and apparatus, including computer program products, for exchanging certificates. In general, in one aspect, the invention features generating a first container object including one or more of a sender's certificate and a request for a recipient's certificate, wherein the first container object has a recognizable container type, and transmitting the first container object to a recipient's address.
Implementations of the invention can include one or more of the following. Prior to generating a first container object, input can be received from a sender specifying the recipient's address and specifying one or more of a certificate of the sender and a request for the recipient's certificate to include in the first container object. The first container object can be transmitted by electronic mail or Hypertext Transfer Protocol, and the first container object can be generated by a server. If the sender has multiple certificates, input can be received from the sender selecting one or more of the sender's multiple certificates, which selected certificates can be retrieved from a certificate database and included in the first container object. If the first container object includes a request for a recipient's certificate, input can be received from a sender specifying a return address for receiving the recipient's certificate and instructions for returning the recipient's certificate, and the return address and instructions for returning the recipient's certificate can be included in the first container object. If the first container object includes a sender's certificate, validation information to be used to validate the sender's certificate can be included in the first container object. The container type can be Forms Data Format.
In general, in another aspect, the invention features receiving a container object having a container type, recognizing the container type and that the container object may include a certificate of a sender of the container object, and determining if the container object contains a certificate of the sender.
Implementations of the invention can include one or more of the following. The container object can be received by electronic mail or Hypertext Transfer Protocol. The container type can be Forms Data Format. The container object can include a certificate and validation information and the certificate can be accepted or rejected using the validation information. If the certificate is accepted, the certificate can be extracted and stored.
In general, in another aspect, the invention features receiving a first container object having a container type, recognize the container type and that the first container object may include a request for a certificate of a recipient of the container object, determining if the first container object includes a request for a certificate of the recipient, and, if a request is included in the first container object, then responding to the request. A request can be responded to by generating a second container object including a certificate of the recipient, extracting a return address from the first container object, and transmitting the second container object to the return address. The first container object and the second container object can be a Forms Data Format container type. The first container object can be received from a networked server and can be responded to by transmitting the recipient's certificate back to the networked server by Hypertext Transfer Protocol.
In general, in another aspect, the invention features generating a first container object including a sender's certificate and a request for a recipient's certificate, wherein the first container object has a recognizable container type, transmitting the first container object to a recipient's address, and receiving a second container object generated in response to the request for the recipient's certificate, the second container object having the recognizable container type. It can be determined if the second container object includes the recipient's certificate and, if the second container object includes the recipient's certificate, then the recipient's certificate can be accepted or rejected.
In general, in another aspect, the invention features generating a first container object including one or more of instructions for retrieving a sender's certificate and instructions requesting a recipient's certificate, wherein the first container object has a recognizable container type, and transmitting the first container object to a recipient's address.
The invention can be implemented to realize one or more of the following advantages. A user can request a certificate from another user. The recipient of such a request can respond to the request by sending the recipient's certificate automatically, without the recipient manually exporting the certificate into a file or cutting and pasting the certificate into an e-mail message. A user can send a certificate over a computer network without having to export manually the certificate into a file or cut and paste the certificate into an e-mail message. The certificate transfer process can take place across multiple network elements of different kinds. A server can request a certificate from a specific user. A server can push certificates over a communications network to a user.
The details of one or more implementations of the invention are set forth in the accompanying drawings and the description below. Other features and advantages of the invention will become apparent from the description, the drawings, and the claims.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A is a block diagram of a system for exchanging certificates.
FIG. 1B is a block diagram of a container object.
FIG. 2 is a flowchart showing a method for sending a certificate and request for a certificate.
FIG. 3 is a flowchart showing a method for receiving a certificate.
FIG. 4 is a flowchart showing a method for validating a certificate.
FIG. 5 is a flowchart showing a method for receiving and responding to a request for a certificate.
Like reference symbols in the various drawings indicate like elements.
DETAILED DESCRIPTION
As shown in FIG. 1A , a system for exchanging certificates includes computers 100 , 160 that communicate over a computer network 155 . The computers 100 , 160 each have a computer program 105 , 165 that includes a container object generator module 110 , 175 and a container object extractor module 115 , 170 . The computer programs 105 , 165 have access to a data store storing certificate information. In the illustrative system, this is a certificate database 120 , 180 stored on storage media locally connected to the respective computer 100 , 160 . The certificate database 120 , 180 includes certificates of a user of the computer 100 , 160 and certificates the user has obtained from others. Any convenient form of database including a simple text file, and any convenient form of storage can be used, including, for example, a remote database stored on a server.
The container object generator 110 , 175 operates to create container objects 125 , shown in FIG. 1B . A container object 125 includes data 130 . This data 130 can include some or all of: a certificate or certificates 140 ; a request for a certificate 145 ; a return address 150 ; and validation information 152 . Container objects 125 are generated to be transmitted to another computer.
A computer program running in a computer, such as computer program 105 , can implement a method 200 for transmitting a sender's certificate, a request for a recipient's certificate, or both, as shown in FIG. 2 . A sender can have multiple certificates. For example, a sender can have different certificates for different purposes, such as a certificate for electronically signing a document and a certificate for encryption. Further, a sender can have different sets of certificates for use with different recipients. For example, a sender can have a set of certificates for use with the sender's bank and a second set of certificates for use with the sender's brokerage house. If a sender selects to send a certificate (‘yes’ branch of decision step 205 ) and the sender has multiple certificates, then the sender is prompted to select the certificate or certificates to send ( 210 ), which certificate or certificates are retrieved from a data store, such as certificate database 120 ( 215 ). If the sender does not have multiple certificates, then the sender's certificate is automatically retrieved from the certificate database 120 ( 215 ). The sender is also prompted to input an address for the recipient of the sender's certificate or certificates ( 220 ).
The computer program 105 also determines whether the sender desires to request a certificate of the recipient ( 225 ). This can be done by receiving input from the sender or by referring to a previously set user preference. For example, a preference can indicate that a certificate should be requested, if a certificate of the recipient does not appear in the sender's certificate database. Optionally, computer program 105 can prompt the sender to specify a return address to which the recipient's certificate is to be delivered ( 230 ), or alternatively, a default or previously set address can be used. The sender can also provide instructions for returning the recipient's certificate, such as specifying a protocol. A return address can be any convenient return path for the recipient's certificate, so long as the protocol is specified, the address is specified for that protocol and the protocol supports this type of operation. For example, the return address can be an e-mail address or a URL. The container object generator module 110 of the computer program 105 then generates a container object including the sender's certificate or certificates (if the sender selected to include a certificate), the sender's request for the recipient's certificate (if any), and the return address (if any) ( 235 ). The container object is then transmitted to the recipient's address ( 240 ).
FIG. 3 shows a method 300 for receiving a container object including a sender's certificate. Recipient's computer 160 receives the container object and recognizes the container object as one that potentially includes a certificate (‘yes’ branch of decision step 310 ), based on the container type of the container object. The computer program 160 determines if a certificate is embedded in the container object ( 315 ) and, if so, the container object extractor 170 extracts the certificate from the container object ( 320 ). The extracted certificate can be stored in the certificate database 180 .
As shown in FIG. 4 , the recipient of the sender's certificate should validate the certificate before adding the certificate to the recipient's certificate database 180 . For example, the container object can include validation information 152 that can be used to verify the authenticity (trustworthiness) of the sender's certificate before accepting the sender's certificate, which validation information 152 can be extracted from the container object by the container object extractor 170 ( 405 ). Upon receipt of the sender's certificate, the computer program 165 can generate a fingerprint of the certificate ( 410 ). A fingerprint is a cryptographic function, e.g., a one-way hash function, of the bytes of the certificate. The validation information 152 and the generated fingerprint can be displayed to the recipient ( 415 ). The validation information included in the container object can be contact information for the sender, which the recipient can use to contact the sender to confirm that the generated fingerprint of the received certificate matches a fingerprint of the certificate generated by the sender's computer 100 using computer program 105 . If the fingerprints match, then the authenticity is verified and the recipient can accept the certificate (‘yes’ branch of decision step 420 ) and computer program 165 can add the certificate to the certificate database 180 ( 425 ). If the fingerprints do not match, then verification fails, and the certificate should be rejected and not added to the certificate database 180 (‘no’ branch of decision step 420 ).
In another implementation, the validation information 152 can include contact information of a third party authority that can verify the authenticity of the sender's certificate received by the recipient. For example, the contact information can be a URL to a Web site where the recipient can validate the sender's certificate through a trusted third party, such as a certificate registry. Any other convenient means to validate the sender's certificate can be used.
FIG. 5 shows a method 500 for receiving and responding to a request for the recipient's certificate. Recipient's computer 160 receives and recognizes the container object as one that could potentially include a request for a certificate (‘yes’ branch of decision step 505 ) based on the container type of the container object. If the container object includes a request for the recipient's certificate (‘yes’ branch of decision step 510 ), the user can optionally be prompted to specify whether permission is granted to send a certificate of the recipient in response to the request ( 515 ). If permission is granted (‘yes’ branch of decision step 515 ), then if the recipient has more than one certificate, the recipient is optionally prompted to select the certificate or certificates to send in response to the request ( 520 ), which certificates are retrieved from certificate database 180 ( 525 ). As discussed above, the recipient could have different certificates for use with different parties, such as a bank or a brokerage house. The request for a certificate can be tailored to assist the recipient in selecting the appropriate certificate or certificates to send in response to the request. If the recipient has only one certificate, then the certificate is automatically retrieved from certificate database 180 ( 525 ).
Container object generator 175 generates a new container object including the recipient's certificate or certificates ( 530 ). A return address to which the certificate is to be delivered is extracted from the received container object ( 535 ). The new container object is transmitted to the return address ( 540 ).
In another implementation, a server generates a container object including a request for a certificate. For example, a Web server can generate a container object including a request for a certificate and a recipient's Web browser can execute computer program 105 , 165 to process the container object. The request for a certificate can be processed as described above in reference to FIG. 5 . Alternatively, the request for a certificate can specify a particular network protocol for a direct response that contains the recipient's certificate. The computer program 165 could, for example, transmit the recipient's certificate back to the Web server using Hypertext Transfer Protocol.
For illustrative purposes, the following example describes an instance when a Web server is the sender of a request for a certificate. A bank providing online banking services allows the bank's customers to receive their banking statements electronically over HTTP from a Web server. For security purposes, the bank requires a customer's public key certificate to encrypt the customer's banking statements before transmitting them to the customer electronically. Accordingly, if the bank does not have a customer's certificate in a certificate database, the bank generates a container object including a request for a certificate. A customer's Web browser associates the container object with an application program, such as computer program 105 , 165 , to process the container object and respond to the request for a certificate included in the container object.
In another implementation, certificates can be downloaded from a server. For example, a company having a number of employees could maintain a certificate database containing the certificates of the employees on a Web server. Employees of the company could access a Web site and request certificates of their fellow employees to enable the employees to share encrypted documents. Upon receiving a request by an employee for a certificate, the Web server generates a container object including the certificate. The employee's Web browser associates the container object with computer program 105 , 165 and processes the container object using the method 300 shown in FIG. 3 .
In one implementation, the container object is a Forms Data Format (FDF) file, which is described in “PDF Reference”, 2 nd ed., Addison-Wesley Publishing Company, (2000) at pp. 460-468. The FDF file type provides a convenient tunneling protocol for passing data between users using e-mail, HTTP, or other network protocols. A Web browser of an operating system of a computer 100 , 160 will generally be instructed to associate an application computer program 105 , 165 , for example, Adobe Acrobat™ 5.0 (“Acrobat”) by Adobe Systems Incorporated of San Jose, Calif., with the FDF file type or Multipurpose Internet Mail Extensions (MIME) type. The Web browser or operating system checks whether Acrobat is open, opens Acrobat if it is not open, and sends the FDF file to Acrobat for processing.
The invention can be implemented in digital electronic circuitry, or in computer hardware, firmware, software, or in combinations of them. Apparatus of the invention can be implemented in a computer program product tangibly embodied in a machine-readable storage device for execution by a programmable processor; and method steps of the invention can be performed by a programmable processor executing a program of instructions to perform functions of the invention by operating on input data and generating output. The invention can be implemented advantageously in one or more computer programs that are programmed on a programmable system including at least one programmable processor coupled to receive data and instructions from, and to transmit data and instructions to, a data storage system, at least one input device, and at least one output device. Each computer program can be implemented in a high-level procedural or object-oriented programming language, or in assembly or machine language if desired; and in any case, the language can be a compiled or interpreted language. Suitable processors include, by way of example, both general and special purpose microprocessors. Generally, a processor will receive instructions and data from a read-only memory and/or a random access memory. The essential elements of a computer are a processor for executing instructions and a memory. Generally, a computer will include one or more mass storage devices for storing data files; such devices include magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and optical disks. Storage devices suitable for tangibly embodying computer program instructions and data include all forms of non-volatile memory, including by way of example semiconductor memory devices, such as EPROM, EEPROM, and flash memory devices; magnetic disks such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM disks. Any of the foregoing can be supplemented by, or incorporated in, ASICs (application-specific integrated circuits).
To provide for interaction with a user, the invention can be implemented on a computer system having a display device such as a monitor or LCD screen for displaying information to the user and a keyboard and a pointing device such as a mouse or a trackball by which the user can provide input to the computer system. The computer system can be programmed to provide a graphical user interface through which computer programs interact with users.
The invention has been described in terms of particular embodiments. Other embodiments are within the scope of the following claims. For example, steps of the invention can be performed in a different order and still achieve desirable results. The computer program 105 , 165 is not limited to Adobe Acroba™5.0. Also, computer program 105 , 165 need not be a standalone program, but can be a plug-in installed in conjunction with another program. Similarly, a container object format different from the FDF file format can be used as the container object 125 and the new container object. Further, one or both of the computers 100 , 160 can be one or more server or servers. Accordingly, the return address 150 may be any network address using any network protocol, in addition to HTTP server addresses and e-mail addresses.
Accordingly, other embodiments are within the scope of the following claims.
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Methods and apparatus, including computer program products, implementing and using techniques for exchanging certificates, including generating a first container object including one or more of a sender's certificate and a request for a recipient's certificate, wherein the first container object has a recognizable container type, and transmitting the first container object to a recipient's address. Upon receipt of the first container object, it can be determined the first container object includes one or more of a certificate and a request for a certificate of the recipient. A request for a certificate can be responded to by generating a second container object including a certificate of the recipient, extracting a return address from the first container object, and transmitting the second container object to the return address.
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CROSS REFERENCE TO RELATED APPLICATIONS
This is a division of application Ser. No. 374,405, filed June 28, 1973, which is a continuation-in-part of my copending application Ser. No. 289,317 filed Sept. 15, 1972, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to novel compositions of matter, to novel methods for producing those, and to novel chemical intermediates useful in those processes. Particularly, this invention relates to certain novel analogs of prostaglandins E 2 , F 2 .sub.α, and F 2 .sub.β in which the configuration at C-8 is beta and at C-12 is alpha, and in which there is variable chain length, or methyl or phenyl substitution in the hydroxysubstituted side-chain.
The known prostaglandins include, for example, prostaglandin E 2 (PGE 2 ), prostaglandin F 2 alpha and beta (PGF 2 .sub.α and PGF 2 .sub.β), and prostaglandin A 2 (PGA 2 ). Each of the above-mentioned known prostaglandins is a derivative of prostanoic acid which has the following structure and atom numbering: ##STR1## See, for example, Bergstrom et al., Pharmacol. Rev. 20, 1 (1968), and references cited therein. A systematic name for prostanoic acid is 7-([2β-octyl]-cyclopent-1β-yl]- heptanoic acid.
PGE 2 has the following structure: ##STR2##
PGF 2 .sub.α has the following structure: ##STR3##
PGF 2 .sub.β has the following structure: ##STR4##
PGA 2 has the following structure: ##STR5##
In formulas II to V, as well as in the formulas given hereinafter, broken line attachments to the cyclopentane ring indicate substituents in alpha configuration, i.e., below the plane of the cyclopentane ring. Heavy solid line attachments to the cyclopentane ring indicate substituents in beta configuration, i.e., above the plane of the cyclopentane ring.
The side-chain hydroxy at C-15 in formulas II to V is in alpha (S) configuration. See Nature, 212, 38 (1966) for discussion of the stereochemistry of the prostaglandins.
Molecules of the known prostaglandins each have several centers of asymmetry, and can exist in racemic (optically inactive) form and in either of the two enantiomeric (optically active) forms, i.e. the dextrorotatory and levorotatory forms. As drawn, formulas II to V each represent the particular optically active form of the prostaglandin which is obtained from certain mammalian tissues, for example, sheep vesicular glands, swine lung, or human seminal plasma, or by carbonyl and/or double bond reduction of that prostaglandin. See, for example, Bergstrom et al., cited above. For convenience hereinafter, use of the terms PGE 2 , PGF 2 .sub.α, and the like, will mean the optically active form of that prostaglandin with the same absolute configuration as PGE 2 obtained from mammalian tissues.
PGE 2 , PGF 2 .sub.α, PGF 2 .sub.β, and PGA 2 , and their esters, acylates, and pharmacologically acceptable salts, are extremely potent in causing various biological responses. For that reason, these compounds are useful for pharmacological purposes. See, for example, Bergstrom et al., cited above. A few of those biological responses are stimulation of smooth muscle as shown, for example, by tests on strips of guinea pig ileum, rabbit duodenum, or gerbil colon; potentiation or other smooth muscle stimulants; antilipolytic activity as shown by antagonism of epinephrine-induced mobilization of free fatty acids or inhibition of the spontaneous release of glycerol from isolated rat fat pads; inhibition of gastric secretion in the case of the PGE and PGA compounds as shown in dogs with secretion stimulated by food or histamine infusion; activity on the central nervous system; controlling spasm and facilitating breathing in asthmatic conditions; decrease of blood platelet adhesiveness as shown by platelet-to-glass adhesiveness, and inhibition of blood platelet aggregation and thrombus formation induced by various physical stimuli, e.g., arterial injury, and various biochemical stimuli, e.g., ADP, ATP, serotonin, thrombin, and collagen; and in the case of the PGE and PGB compounds, stimulation of epidermal proliferation and keratinization as shown when applied in culture to embryonic chick and rat skin segments.
Because of these biological responses, these known prostaglandins are useful to study, prevent, control, or alleviate a wide variety of diseases and undesirable physiological conditions in birds and mammals, including humans, useful domestic animals, pets, and zoological specimens, and in laboratory animals, for example, mice, rats, rabbits, and monkeys.
For example, these compounds, and especially the PGE compounds, are useful in mammals, including man, as nasal decongestants. For this purpose, the compounds are used in a dose range of about 10 μg. to about 10 mg. per ml. of a pharmacologically suitable liquid vehicle or as an aerosol spray, both for topical application.
The PGE, PGF.sub.α, PGF.sub.β, and PGA compounds are useful in the treatment of asthma. For example, these compounds are useful as bronchodilators or as inhibitors of mediators, such as SRS-A, and histamine which are released from cells activated by an antigen-antibody complex. Thus, these compounds control spasm and facilitate breating in conditions such as bronchial asthma, bronchitis, bronchiectasis, pneumonia and emphysema. For these purposes, these compounds are administered in a variety of dosage forms, e.g., orally in the form of tablets, capsules, or liquids; rectally in the form of suppositories; parenterally, subcutaneously, or intramuscularly, with intravenous administration being preferred in emergency situations; by inhalation in the form of aerosols or solutions for nebulizers; or by insufflation in the form of powder. Doses in the range of about 0.01 to 5 mg. per kg. of body weight are used 1 to 4 times a day, the exact dose depending on the age, weight, and condition of the patient and on the frequency and route of administration. For the above use these prostaglandins can be combined advantageously with other anti-asthmatic agents, such as sympathomimetics (isoproterenol, phenylephrine, ephedrine, etc); xanthine derivatives (theophylline and aminophyllin); and corticosteroids (ACTH and prednisolone). Regarding use of these compounds see South African Pat. No. 68/1055.
The PGE and PGA compounds are useful in mammals, including man and certain useful animals, e.g., dogs and pigs, to reduce and control excessive gastric secretion, thereby reducing or avoiding gastrointestinal ulcer formation, and accelerating the healing of such ulcers already present in the gastrointestinal tract. For this purpose, the compounds are injected or infused intravenously, subcutaneously, or intramuscularly in an infusion dose range about 0.1 μg. to about 500 μg. per kg. of body weight per minute, or in a total daily dose by injection or infusion in the range about 0.1 to about 20 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful whenever it is desired to inhibit platelet aggregation, to reduce the adhesive character of platelets, and to remove or prevent the formation of thrombi in mammals, including man, rabbits, and rats. For example, these compounds are useful in the treatment and prevention of myocardial infarcts, to treat and prevent post-operative thrombosis, to promote patency of vascular grafts following surgery, and to treat conditions such as atherosclerosis, arteriosclerosis, blood clotting defects due to lipemia, and other clinical conditions in which the underlying etiology is associated with lipid imbalance or hyperlipidemia. For these purposes, these compounds are administered systemically, e.g., intravenously, subcutaneously, intramuscularly, and in the form of sterile implants for prolonged action. For rapid response, especially in emergency situation, the intravenous route of administration is preferred. Doses in the range about 0.005 to about 20 mg. per kg. of body weight per day are used, the exact dose depending on the age, weight, and condition of the patient or animal, and on the frequency and route of administration.
The PGE, PGF.sub.α, and PGF.sub.β compounds are especially useful as additives to blood, blood products, blood substitutes, and other fluids which are used in artifical extracorporeal circulation and perfusion of isolated body portions, e.g., limbs and organs, whether attached to the original body, detached and being preserved or prepared for transplant, or attached to the new body. During these circulations and perfusions, aggregated platelets tend to block the blood vessels and portions of the circulation apparatus. This blocking is avoided by the presence of these compounds. For this purpose, the compound is added gradually or in single or multiple portions to the circulating blood, to the blood of the donor animal, to the perfused body portion, attached or detached, to the recipient, or to two or all of those at a total steady state dose of about 0.001 to 10 mg. per liter of circulating fluid. It is especially useful to use these compounds in laboratory animals, e.g., cats, dogs, rabbits, monkeys, and rats, for these purposes in order to develop new methods and techniques for organ and limb transplants.
PGE compounds are extremely potent in causing stimulation of smooth muscle, and are also highly active in potentiating other known smooth muscle stimulators, for example, oxytocic agents, e.g., oxytocin, and the various ergot alkaloids including derivatives and analogs thereof. Therefore, PGE 2 , for example, is useful in place of or in combination with less than usual amounts of these known smooth muscle stimulators, for example, to relieve the symptoms of paralytic ileus, or to control or prevent atonic uterine bleeding after abortion or delivery, to aid in expulsion of the placenta, and during the puerperium. For the latter purpose, the PGE compound is administered by intravenous infusion immediately after abortion or delivery at a dose in the range about 0.01 to about 50 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, subcutaneous, or intramuscular injection or infusion during puerperium in the range 0.01 to 2 mg. per kg. of body weight per day, the exact dose depending on the age, weight, and condition of the patient or animal.
The PGA compounds and derivatives and salts thereof increase the flow of blood in the mammalian kidney, thereby increasing volume and electrolyte content of the urine. For that reason, PGA compounds are useful in managing cases of renal disfunction, especially in cases of severely impaired renal blood flow, for example, the hepatorenal syndrome and early kidney transplant rejection. In cases of excessive or inappropriate ADH (antidiuretic hormone; vasopressin) secretion, the diuretic effect of these compounds is even greater. In anephric states, the vasopressin action of these compounds is especially useful. Illustratively, the PGA compounds are useful to alleviate and correct cases of edema resulting, for example, from massive surface burns, and in the management of shock. For these purposes, the PGA compounds are preferably first administered by intravenous injection at a dose in the range 10 to 1000 μg. per kg. of body weight or by intravenous infusion at a dose in the range 0.1 to 20 μg. per kg. of body weight per minute until the desired effect is obtained. Subsequent doses are given by intravenous, intramuscular, or subcutaneous injection or infusion in the range 0.05 to 2 mg. per kg. of body weight per day.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful in place of oxytocin to induce labor in pregnant female animals, including man, cows, sheep, and pigs, at or near term, or in pregnant animals with intrauterine death of the fetus from about 20 weeks to term. For this purpose, the compound is infused intravenously at a dose of 0.01 to 50 μg. per kg. of body weight per minute until or near the termination of the second stage of labor, i.e., expulsion of the fetus. These compounds are especially useful when the female is one or more weeks post-mature and natural labor has not started, or 12 to 60 hours after the membranes have ruptured and natural labor has not yet started. An alternative route of administration is oral.
The PGE, PGF.sub.α, and PGF.sub.β compounds are useful for controlling the reproductive cycle in ovulating female mammals, including humans and animals such as monkeys, rats, rabbits, dogs, cattle, and the like. By the term ovulating female mammals is meant animals which are mature enough to ovulate but not so old that regular ovulation has ceased. For that purpose, PGF 2 .sub.α, for example, is administered systemically at a dose level in the range 0.01 mg. to about 20 mg. per kg. of body weight of the female mammal, advantageously during a span of time starting approximately at the time of ovulation and ending approximately at the time of menses or just prior to menses. Intravaginal and intrauterine are alternative routes of administration. Additionally, expulsion of an embryo or a fetus is accomplished by similar administration of the compound during the first third of the normal mammalian gestation period.
As mentioned above, the PGE compounds are potent antagonists of epinephrine-induced mobilization of free fatty acids. For this reason, this compound is useful in experimental medicine for both in vitro and in vivo studies in mammals, including man, rabbits, and rats, intended to lead to the understanding, prevention, symptom alleviation, and cure of diseases involving abnormal lipid mobilization and high free fatty acid levels, e.g., diabetes mellitus, vascular diseases, and hyperthyroidism.
The PGE compounds promote and accelerate the growth of epidermal cells and keratin in animals, including humans, useful domestic animals, pets, zoological specimens, and laboratory animals. For that reason, these compounds are useful to promote and accelerate healing of skin which has been damaged, for example, by burns, wounds, and abrasions, and after surgery. These compounds are also useful to promote and accelerate adherence and growth of skin autografts, especially small, deep (Davis) grafts which are intended to cover skinless areas by subsequent outward growth rather than initially, and to retard rejection of homografts.
For these purposes, these compounds are preferably administered topically at or near the site where cell growth and keratin formation is desired, advantageously as an aerosol liquid or micronized powder spray, as an isotonic aqueous solution in the case of wet dressings, or as a lotion, cream, or ointment in combination with the usual pharmaceutically acceptable diluents. In some instances, for example, when there is substantial fluid loss as in the case of extensive burns or skin loss due to other causes, systemic administration is advantageous, for example, by intravenous injection or infusion, separate or in combination with the usual infusions of blood, plasma, or substitutes thereof. Alternative routes of administration are subcutaneous or intramuscular near the site, oral, sublingual, buccal, rectal, or vaginal. The exact dose depends on such factors as the route of administration, and the age, weight, and condition of the subject. Especially for topical use, these prostaglandins are useful in combination with antibiotics, for example, gentamycin, neomycin, polymyxin B, bacitracin, spectinomycin, and oxytetracyline, with other antibacterials, for example, mafenide hydrochloride, sulfadiazine, furazolium chloride, and nitrofurazone, and with corticoid steroids, for example, hydrocortisone, prednisolone, methylprednisolone, and fluprednisolone, each of those being used in the combination at the usual concentration suitable for its use alone.
SUMMARY OF THE INVENTION
It is a purpose of this invention to provide novel 8-beta, 12-alpha-prostaglandin E 2 and F 2 analogs. It is a further purpose to provide such analogs having variable chain length, or methyl or phenyl substitution in the hydroxy-substituted side-chain. ##STR6##
There are also included the alkanoates of 2 to 8 carbon atoms inclusive, and the pharmacologically acceptable salts derived from these compounds when R 13 is hydrogen.
In formulas VI to XIV, inclusive, R 4 , R 5 , and R 7 are hydrogen or methyl, being the same or different, R 6 is n-butyl or ##STR7## wherein s is zero, one, 2, or 3; R 13 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl of one to 4 carbon atoms, inclusive; and R 21 is hydrogen or alkyl of one to 5 carbon atoms, inclusive.
Formulas VI to XIV represent 8-beta, 12-alpha-prostaglandin E and F type compounds, i.e. analogs of PGE 2 , PGF 2 .sub.α and PGF 2 .sub.α in which the configuration at C-8 is beta rather than alpha as in the natural prostaglandins, and at C-12 is alpha rather than beta. For example, formula VI represents 8β,12α-PGE 2 when R 4 , R 5 , R 7 , and R 13 are hydrogen, and R 6 is n-butyl.
Formulas IX to XI represent analogs wherein the hydroxyl at C-11 is in beta configuration rather than in the alpha configuration of the natural prostaglandins. For example, formula X represents 8β,9α,11β,12α-PGF 2 , methyl ester, (alternately 8β,11β,12α-PGF 2 α, methyl ester) when R 4 , R 5 , and R 7 are hydrogen, R 6 is n-butyl, and R 13 is methyl.
Formulas XII to XIV represent analogs wherein --OR 21 at C-15 is in beta configuration rather than in the alpha configuration of the natural prostaglandins. For example, formula XIV represents 8β,9β,15β-PGF 2 when R 4 , R 5 , R 7 , R 13 , and R 21 are hydrogen, and R 6 is n-butyl.
In formulas VI to XIV, when R 6 is ##STR8## the chain length of the hydroxy-substituted side-chain is 5 carbon atoms plus the terminal phenyl group. For example, Formula VI represents 17-phenyl-18,19,20-trinor-8β,12α-PGE 2 when R 4 , R 5 , R 7 , and R 13 are hydrogen, and R 6 is ##STR9## wherein s is zero, i.e. benzyl. In the name of this formula-VI example, "18,19,20-trinor" indicates absence of three carbon atoms from the hydroxy-substituted side-chain of the PGE 2 structure. Following the atom numbering of the prostanoic acid structure, C-18, C-19, and C-20 are construed as missing. The phenyl substitution on C-17, therefore, terminates the side chain.
In formulas VI to XIV, when R 7 is methyl, each formula represents a 15-methyl prostaglandin analog. For example, formula VII represents 15-methyl-8β,9α,12α-PGF 2 when R 4 , R 5 , and R 13 are hydrogen, R 6 is n-butyl, and R 7 is methyl.
In formulas VI to XIV, when one or both of R 4 and R 5 are methyl, a formula represents either 16-methyl or 16,16-dimethyl substitution. For example, formula VIII represents 16-methyl-8β,9β,12α-PGF 2 when R 4 is methyl, R 5 , R 7 , and R 13 are hydrogen, and R 6 is n-butyl; formula IX represents 16,16-dimethyl-8β,11β,12α-PGE 2 , methyl ester, when R 4 , R 5 , and R 13 are methyl, R 6 is n-butyl, and R 7 is hydrogen.
With regard to formulas VI to XIV, examples of alkyl of one to 12 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomeric forms thereof. Examples of cycloalkyl of 3 to 10 carbon atoms, inclusive, which includes alkyl-substituted cycloalkyl, are cyclopropyl, 2-methylcyclopropyl, 2,2-dimethylcyclopropyl, 2,3-diethylcyclopropyl, 2-butylcyclopropyl, cyclobutyl, 2-methylcyclobutyl, 3-propylcyclobutyl, 2,3,4-triethylcyclobutyl, cyclopentyl, 2,2-dimethylcyclopentyl, 2-pentylcyclopentyl, 3-tert-butylcyclopentyl, cyclohexyl, 4-tert-butylcyclohexyl, 3-isopropylcyclohexyl, 2,2-dimethylcyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, and cyclodecyl. Examples of aralkyl of 7 to 12 carbon atoms, inclusive, are benzyl, phenethyl, 1-phenylethyl, 2-phenylpropyl, 4-phenylbutyl, 3-phenylbutyl, 2-(1-naphthylethyl), and 1-(2-naphthylmethyl). Examples of phenyl substituted by one to 3 chloro or alkyl of one to 4 carbon atoms, inclusive, are p-chlorophenyl, m-chlorophenyl, o-chlorophenyl, 2,4-dichlorophenyl, 2,4,6-trichlorophenyl, p-tolyl, m-tolyl, o-tolyl, p-ethylphenyl, p-tert-butylphenyl, 2,5-dimethylphenyl, and 4-chloro-2-methylphenyl.
Accordingly, there is provided an optically active compound of the formula ##STR10## wherein R 4 , R 5 , and R 7 are hydrogen or methyl, being the same or different; wherein R 6 is n-butyl or ##STR11## wherein s is zero, one, 2, or 3; wherein R 13 is hydrogen, alkyl of one to 12 carbon atoms, inclusive, cycloalkyl of 3 to 10 carbon atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 chloro or alkyl of one to 4 carbon atoms, inclusive; R 21 is hydrogen or alkyl of one to 5 carbon atoms, inclusive; and wherein W is ##STR12## including the lower alkanoates thereof, and the pharmacologically acceptable salts thereof when R 13 is hydrogen.
Formula XV represents PGE 2 analogs when W is ##STR13## PGF 2 .sub.α analogs when W is ##STR14## and PGF 2 .sub.β analogs when W is ##STR15##
There is also provided an optically active compound of the formula ##STR16## wherein R 4 , R 5 , R 6 , R 7 , R 13 , R 21 , and W are as defined above.
There is further provided an optically active compound of the formula ##STR17## wherein R 4 , R 5 , R 6 , R 7 , R 13 , R 21 , and W are as defined above, representing the C-11 epimers of formula-XV compounds.
The novel formula VI-to-XVII compounds of this invention each cause the biological responses described above for the PGE, PGF.sub.α, PGF.sub.β, and PGA compounds, respectively, and each of these novel compounds is accordingly useful for the above-described corresponding purposes, and is used for those purposes in the same manner as described above.
The known PGE, PGF.sub.α, PGF.sub.β, and PGA compounds are all potent in causing multiple biological responses even at low doses. For example, PGE 2 causes vasodepression and smooth muscle stimulation at the same time it exerts antilipolytic activity. Moreover, for many applications, these known prostaglandins have an inconveniently short duration of biological activity. In striking contrast, the novel prostaglandin analogs of formulas VI to XVII are substantially more specific with regard to potency in causing prostaglandin-like biological responses, and have a substantially longer duration of biological activity. Therefore, each of these novel prostaglandin analogs is surprisingly and unexpectedly more useful than one of the corresponding above-mentioned known prostaglandins for at least one of the pharmacological purposes indicated above for the latter, because it has a different and narrower spectrum of biological potency than the known prostaglandin, and therefore is more specific in its activity and causes smaller and fewer undesired side effects than when the known prostaglandin is used for the same purpose. Moreover, because of its prolonged activity, fewer and smaller doses of the novel prostaglandin analog can frequently be used to attain the desired result.
To obtain the optimum combination of biological response specificity, potency, and duration of activity, certain compounds within the scope of formulas VI to XVII are preferred. For example, it is preferred that the hydroxyl at C-15 be in the alpha configuration. It is also preferred that the hydroxyl at C-11 be in the alpha configuration. Another preference is that when R 7 is methyl, R 4 and R 5 are hydrogen. Still another preference is that when R 6 is ##STR18## and s is not zero, at least one chloro is in the para position to the methylene attachment to the ring.
Another advantage of the novel compounds of this invention, especially the preferred compounds defined hereinabove, compared with the known prostaglandins, is that these novel compounds are administered effectively orally, sublingually, intravaginally, buccally, or rectally, in addition to usual intravenous, intramuscular, or subcutaneous injection or infusion methods indicated above for the uses of the known prostaglandins. These qualities are advantageous because they facilitate maintaining uniform levels of these compounds in the body with fewer, shorter, or smaller doses, and make possible self-administration by the patient.
The 8β,12α prostaglandin E and F analogs encompassed by formulas VI to XVII including their alkanoates, are used for the purposes described above in the free acid form, in ester form, or in pharmacologically acceptable salt form. When the ester form is used, the ester is any of those within the above definition of R 13 . However, it is preferred that the ester be alkyl of one to 12 carbon atoms, inclusive. Of those alkyl, methyl and ethyl are especially preferred for optimum absorption of the compound by the body or experimental animal system; and straight-chain octyl, nonyl, decyl, undecyl, and dodecyl are especially preferred for prolonged activity in the body or experimental animal.
Pharmacologically acceptable salts of these formula VI-to-XVII compounds useful for the purposes described above are those with pharmacologically acceptable metal cations, ammonium, amine cations, or quaternary ammonium cations.
Especially preferred metal cations are those derived from the alkali metals, e.g., lithium, sodium and potassium, and from the alkaline earth metals, e.g., magnesium and calcium, although cationic forms of other metals, e.g., aluminum, zinc, and iron are within the scope of this invention.
Pharmacologically acceptable amine cations are those derived from primary, secondary, or tertiary amines. Examples of suitable amines are methylamine, dimethylamine, trimethylamine, ethylamine, dibutylamine, triisopropylamine, N-methylhexylamine, decylamine, dodecylamine, allylamine, crotylamine, cyclopentylamine, dicyclohexylamine, benzylamine, dibenzylamine, α-phenylethylamine, β-phenylethylamine, ethylenediamine, diethylenetriamine, and like aliphatic, cycloaliphatic, and araliphatic amines containing up to and including about 18 carbon atoms, as well as heterocyclic amines, e.g., piperidine, morpholine, pyrrolidine, piperazine, and lower-alkyl derivatives thereof, e.g., 1-methylpiperidine, 4-ethylmorpholine, 1-isopropylpyrrolidine, 2-methylpyrrolidine, 1,4-dimethylpiperazine, 2-methylpiperidine, and the like, as well as amines containing water-solubilizing or hydrophilic groups, e.g., mono-, di-, and triethanolamine, ethyldiethanolamine, N-butylethanolamine, 2-amino-1-butanol, 2-amino-2-ethyl-1,3-propanediol, 2-amino-2-methyl-1-propanol, tris(hydroxymethyl)aminomethane, N-phenylethanolamine, N-(p-tert-amylphenyl)diethanolamine, galactamine, N-methylglycamine, N-methylglucosamine, ephedrine, phenylephrine, epinephrine, procaine, and the like.
Examples of suitable pharmacologically acceptable quaternary ammonium cations are tetramethylammonium, tetraethylammonium, benzyltrimethylammonium, phenyltriethylammonium, and the like.
The compounds encompassed by formulas VI to XVII are used for the purposes described above in free hydroxy form or also in the form wherein the hydroxy moieties are transformed to lower alkanoate moieties, e.g., --OH to --OCOCH 3 . Examples of lower alkanoate moieties are acetoxy, propionyloxy, butyryloxy, valeryloxy, hexanoyloxy, heptanoyloxy, octanoyloxy, and branched chain alkanoyloxy isomers of those moieties. Especially preferred among these alkanoates for the above described purposes are the acetoxy compounds. These free hydroxy and alkanoyloxy compounds are used as free acids, as esters, and in salt form all as described above.
As discussed above, the compounds of formulas VI to XVII are administered in various ways for various purposes; e.g., intravenously, intramuscularly, subcutaneously, orally, intravaginally, rectally, buccally, sublingually, topically, and in the form of sterile implants for prolonged action. For intravenous injection or infusion, sterile aqueous isotonic solutions are preferred. For that purpose, it is preferred because of increased water solubility that R 13 in the formula VI-to-XVII compound be hydrogen or a pharmacologically acceptable cation. For subcutaneous or intramuscular injection, sterile solutions or suspensions of the acid, salt, or ester form in aqueous or non-aqueous media are used. Tablets, capsules, and liquid preparations such as syrups, elixirs, and simple solutions, with the usual pharmaceutical carriers, are used for oral sublingual administration. For rectal or vaginal administration, suppositories prepared as known in the art are used. For tissue implants, a sterile tablet or silicone rubber capsule or other object containing or impregnated with the substance is used.
The 8β,12α-prostaglandin E 2 and F 2 analogs encompassed by formulas VI through XVII are produced by the reactions and procedures described and exemplified hereinafter.
Reference to Charts A, B, C, and D herein will make clear the process steps. In Chart A is shown the transformation of the starting material containing an anion of the formula ##STR19##
CHART A______________________________________ ##STR20## ##STR21## ##STR22## ##STR23## ##STR24## ##STR25## ##STR26## ##STR27## ##STR28## ##STR29##______________________________________
wherein R 1 is methyl or benzyl to a key intermediate ##STR30## wherein M' is ##STR31## wherein R 8 is hydrogen or a blocking group Z, as defined hereinafter, and wherein Q is ##STR32## wherein R 4 , R 5 , and R 6 are as defined above. The starting material is readily available. See E. J. Corey et al., J. Am. Chem. Soc. 92, 397 (1970) describing the resolution of XVIII with (-)-ephedrine.
Iodolactone XIX is obtained by methods known in the art, e.g. treatment of the sodium salt of XVIII in water with potassium triiodide. The formula-XX compound is obtained by deiodination of XIX using a reagent which does not react with the lactone ring, e.g. zinc dust, sodium hydride, hydrogen-palladium, hydrogen and Raney nickel or platinum, and the like. Especially preferred is tributyltin hydride in benzene at about 5° C. with 2,2'-azobis-(2-methylpropionitrile) as initiator.
Compound XXI is obtained by reacting the formula-XX compound with a hydrocarbonsulfonyl or halohydrocarbonsulfonyl chloride or bromide, preferably a lower alkanesulfonyl chloride or bromide, especially methanesulfonyl chloride, or a benzene- or substituted- benzenesulfonyl chloride or bromide, e.g. 2-bromobenzenesulfonyl chloride or p-toluenesulfonyl chloride. This reaction is done in the presence of a sufficient amount of tertiary amine, e.g. triethylamine or pyridine, to absorb the hydrogen chloride or hydrogen bromide by-product, and at a low temperature, preferably not over 30° C.
Inversion from beta configuration at the 3-position of the formula-XXI lactone to the alpha configuration at the 3-position of the formula-XXII lactone is achieved by reaction of the formula-XXI sulfonate with an alkali metal salt of an aliphatic acid, preferably lower aliphatic of one to 8 carbon atoms, especially acetic acid, or an aromatic acid, including benzoic, substituted benzoic, monoesterified phthalic or its isomers, naphthoic, and substituted naphthoic. This reaction is done in an organic liquid medium such as dimethyl sulfoxide in the range of 50°-100° C. At about 85° C. the reaction is complete in 3-4 hours, resulting in inversion and replacement at the 3-position of the sulfonate moiety by R 3 , defined herein as ##STR33## wherein T is alkyl of one to 4 carbon atoms, inclusive, phenylalkyl of 7 to 10 carbon atoms, inclusive, or nitro, and s is zero to 5, inclusive, provided that not more than two T's are other than alkyl, and that the total number of carbon atoms in the T's does not exceed 10 carbon atoms; ##STR34## wherein R 14 is alkyl of one to 4 carbon atoms inclusive; ##STR35## wherein T and s are as defined above; or (d) acetyl.
Examples of R 3 are benzoyl, substituted benzoyl, e.g. (2-, 3- or 4-)methylbenzoyl, (2-, 3-, or 4-)ethylbenzoyl, (2-, 3-, or 4-)isopropylbenzoyl, (2-, 3-, or 4-)tert-butylbenzoyl, 2,4-dimethylbenzoyl, 3,5-dimethylbenzoyl, 2-isopropyltoluyl, 2,4,6-trimethylbenzoyl, pentamethylbenzoyl, α-phenyl-(2-, 3-, or 4-)toluyl, 2-, 3-, or 4-phenethylbenzoyl, 2-, 3-, or 4-nitrobenzoyl, (2,4-, 2,5-, or 3,5-)dinitrobenzoyl, 3,4-dimethyl-2-nitrobenzoyl, 4,5-dimethyl-2-nitrobenzoyl, 2-nitro-6-phenethylbenzoyl, 3-nitro-2-phenethylbenzoyl; mono-esterified phthaloyl, e.g. ##STR36## isophthaloyl, e.g. ##STR37## or terephthaloyl, e.g. ##STR38## (1- or 2-)naphthoyl; and substituted naphthoyl, e.g. (2-, 3-, 4-, 5-, 6-, or 7-)methyl-1-naphthoyl, (2- or 4-)ethyl-1-naphthoyl, 2-isopropyl-1-naphthoyl, 4,5-dimethyl-1-naphthoyl, 6-isopropyl-4-methyl-1-naphthoyl, 8-benzyl-1-naphthoyl, (3-, 4-, 5- or 8-)nitro-1-naphthoyl, 4,5-dinitro-1-naphthoyl, (3-, 4-, 6-, 7- or 8-)methyl-1-naphthoyl, 4-ethyl-2-naphthoyl, and (5- or 8-)nitro-2-naphthoyl.
The formula-XXIII compound is obtained by demethylation (or debenzylation) of XXII with a reagent that does not attack the OR 3 moiety, for example, boron tribromide or trichloride. The reaction is carried out preferably in an inert solvent at about 0°-5° C.
The formula-XXIV compound is obtained by oxidation of the --CH 2 OH of XXIII to --CHO, avoiding decomposition of the lactone ring. Useful for this purpose are dichromatesulfuric acid, Jones' reagent, or lead tetraacetate. Especially preferred is Collins' reagent (pyridine-C r O 3 ) at about 0°-10° C.
The formula-XXV compound is obtained by Wittig alkylation of XXIV, using a ylide consisting of a phosphonate anion of the formula ##STR39## wherein R 15 is alkyl of one to 8 carbon atoms, inclusive, and R 4 , R 5 , and R 6 are as defined above. The trans enone lactone is obtained stereospecifically (see D. H. Wadsworth et al., J. Org. Chem. 30, 680 (1965)).
The phosphonates are available or prepared by methods known in the art, e.g. by reaction of a dialkyl methylphosphonate with an ethyl ester of an appropriate aliphatic acid or phenyl-substituted aliphatic acid.
The formula-XXVI compound, wherein M is ##STR40## wherein R 7 is hydrogen and wherein Q is as defined above, is obtained as a mixture of the alpha and beta isomers with respect to M, by reduction of XXV. For this reduction, use is made of any of the known ketonic carbonyl reducing agents which do not reduce ester or acid groups or carbon-carbon double bonds when the latter is undesirable. Examples of those are the metal borohydrides, especially sodium, potassium, and zinc borohydrides, lithium (tri-tert-butoxy) aluminum hydride, metal trialkoxy borohydrides, e.g., sodium trimethoxyborohydride, lithium borohydride, diisobutyl aluminum hydride. The alpha and beta isomers are separated by chromatography, e.g. silica gel chromatography or high pressure liquid chromatography. See, for example, "Modern Practice of Liquid Chromatography", J. J. Kirkland, ed., Wiley-Interscience, 1971.
The formula-XXVII compound is obtained, if desired, by deacylation of XXVI with an alkali metal carbonate, for example potassium carbonate in methanol at about 25° C. Thereafter, compound XXVII may be used directly in the steps shown in Chart B, in which case XXVII is identical with XXVIII.
CHART B______________________________________ ##STR41## ##STR42## ##STR43## ##STR44## ##STR45## ##STR46##______________________________________
Alternately, compound XXVIII of Charts A and B is made by replacing hydrogen atoms on all hydroxyls with a blocking group Z.
The blocking group, Z, is any group which replaces hydrogen of the hydroxyl groups, which is not attacked by nor is reactive to the reagents used in the respective transformations to the extent that the hydroxyl group is, and which is subsequently replaceable by hydrogen at a later stage in the preparation of the prostaglandin-like products.
Several blocking groups are known in the art, e.g. tetrahydropyranyl, acetyl, and p-phenylbenzoyl (see Corey et al., J. Am. Chem. Soc. 93, 1491 (1971)).
Those which have been found useful include (a) carboxyacyl within the scope of R 3 , defined above, i.e. acetyl, benzoyl, naphthoyl, and the like; (b) tetrahydropyranyl; (c) tetrahydrofuranyl; (d) a group of the formula ##STR47## wherein R 16 is alkyl of one to 18 carbon atoms, inclusive, cycloalkyl of 3 to 10 atoms, inclusive, aralkyl of 7 to 12 carbon atoms, inclusive, phenyl, or phenyl substituted with one, 2, or 3 alkyl of one to 4 carbon atoms, inclusive, wherein R 17 and R 18 are the same or different, being hydrogen, alkyl of one to 4 carbon atoms, inclusive, phenyl or phenyl substituted with one, 2, or 3 alkyl of one to 4 carbon atoms, inclusive, or, when R 17 and R 18 are taken together, --(CH 2 )a-- or --(CH 2 )b-- O-- (CH 2 )c-- wherein a is 3, 4, or 5, b is one, 2, or 3, and c is one, 2, or 3 with the proviso that b plus c is 2, 3, or 4, and wherein R 19 is hydrogen or phenyl; or (e) --Si(A) 3 wherein A is alkyl of one to 4 carbon atoms, inclusive, phenyl, phenyl substituted with one or 2 fluoro, chloro, or alkyl of one to 4 carbon atoms, inclusive, or aralkyl of 7 to 12 carbon atoms, inclusive.
It is desirable that the formula-XXVIII intermediate have a blocking group Z at R 8 , although this is not essential. It is preferred, however, that intermediate XXXII (Chart B) have a blocking group at R 9 , and for this purpose R 9 includes the blocking groups of R 8 but without the carboxyacyl groups. It is evident, therefore, that If intermediate XXXII is to be made, it is advantageous to prepare XXVIII with either the ether-linked blocking group of types (b), (c) or (d) above, or the silyl of type (e).
In replacing the hydrogen atoms of the hydroxyl groups with a carboxyacyl blocking group, methods known in the art are used. Thus, for example, benzoic anhydride is reacted with the formula-XXVII compound in the presence of pyridine.
Preferably, however, an acyl halide, for example, benzoyl chloride, is reacted with the formula-XXVII compound in the presence of a tertiary amine such as pyridine, triethylamine, and the like. The reaction is carried out under a variety of conditions using procedures generally known in the art. Generally, mild conditions are employed, e.g. 20°-60° C., contacting the reactants in a liquid medium, e.g. excess pyridine or an inert solvent such as benzene, toluene, or chloroform. The acylating agent is used either in stoichiometric amount or in excess. If the acyl chloride is not available, it is made from the corresponding acid and phosphorus pentachloride as is known in the art.
When the blocking group is tetrahydropyranyl or tetrahydrofuranyl, the appropriate reagent, e.g. 2,3-dihydropyran or 2,3-dihydrofuran, is used in an inert solvent such as dichloromethane, in the presence of an acid condensing agent such as p-toluenesulfonic acid or pyridine hydrochloride. The reagent is used in slight excess, preferably 1.0 to 1.2 times theory. The reaction is carried out at about 20°-50° C.
When the blocking group is of the formula ##STR48## as defined above, the appropriate reagent is a vinyl ether, e.g. isobutyl vinyl ether or any vinyl of the formula R 16 -O-ClR.sub. 17)=CR 18 R 19 wherein R 16 , R 17 , R 18 , and R 19 are defined above; or an unsaturated cyclic or heterocyclic compound, e.g. 1-cyclohex-1-yl methyl ether ##STR49## or 5,6-dihydro-4-methoxy-2H-pyran ##STR50## See C. B. Reese et al., J. Am. Chem. Soc. 89, 3366 (1967). The reaction conditions for such vinyl ethers and unsaturates are similar to those for dihydropyran above.
When the blocking group is silyl of the formula --Si(A) 3 , the formula-XXVII compound is transformed to a silyl derivative of formula XXVIII by procedures known in the art. See, for example, Pierce, "Silylation of Organic Compounds," Pierce Chemical Co., Rockford, Ill. (1968). The necessary silylating agents for these transformations are known in the art or are prepared by methods known in the art. See, for example, Post "Silicones and Other Organic Silicone Compounds," Reinhold Publishing Corp., New York, N.Y. (1949). These reagents are used in the presence of a tertiary base such as pyridine at temperatures in the range of about 0° to +50° C. Examples of trisubstituted mono- chlorosilanes suitable for this purpose include chlorotrimethylsilane, chlorotriisobutylsilane, chlorotriphenylsilane, chlorotris(p-chlorophenyl)silane, chlorotrim-tolylsilane, and tribenzylchlorosilane. Alternately, a chlorosilane is used with a corresponding disilazane. Examples of other silylating agents suitable for forming the formula-XXVIII intermediates include pentamethylsilylamine, pentaethylsilylamine, N-trimethylsilyldiethylamine, 1,1,1-triethyl-N,N-dimethylsilylamine, N,N-diisopropyl-1,1,1-trimethylsilylamine, 1,1,1-tributyl-N,N-dimethylsilylamine, N,N-dibutyl-1,1,1-trimethylsilylamine, 1-isobutyl-N,N,1,1-tetramethylsilylamine, N-benzyl-N-ethyl-1,1,1-trimethylsilylamine, N,N,1,1-tetramethyl-1-phenylsilylamine, N,N-diethyl-1,1-dimethyl-1-phenylsilylamine, N,N-diethyl-1-methyl-1,1-diphenylsilylamine, N,N-dibutyl-1,1,1-triphenylsilylamine, and 1-methyl-N,N,1,1-tetraphenylsilylamine.
Continuing with Chart B, there are shown the steps by which intermediate XXVIII is transformed to PGE analogs of formula XXXIV and to PGF analogs of formulas XXXI and XXXV. In Chart B, M'" is ##STR51## wherein R 10 is (a) hydrogen; (b) tetrahydropyranyl; (c) tetrahydrofuranyl; (d) a group of the formula ##STR52## wherein R 16 , R 17 , R 18 , are R 19 are as defined above; or (e) --Si(A) 3 wherein A is as defined above. Also in Chart B, R 11 is hydrogen, methyl, or --Si(A) 3 wherein A is as defined above; R 12 is hydrogen or methyl; ˜ indicates attachment of hydroxyl in alpha or beta configuration; and M, M', Q, R 8 and R 9 are as defined above.
Lactol XXIX is obtained on reduction of the formula-XXVIII lactone without reducing the 13,14-ethylenic group. For this purpose, diisobutylaluminum hydride is used. The reduction is preferably done at -60° to -78° C.
The formula-XXX compound is obtained from lactol XXIX by the Wittig reaction, using a Wittig reagent derived from 4-carboxybutyltriphenylphosphonium bromide. HOOC--(CH 2 ) 4 --P(C 6 H 5 ) 3 Br, and sodio dimethylsulfinylcarbanide. See E. J. Corey et al., J. Am. Chem. Soc. 91, 5675 (1969). The reaction is conveniently carried out at about 25° C. This formula-XXX compound serves as an intermediate for preparing either the PGF 2 .sub.β analog XXXI or the PGE 2 analog XXXIV. The latter may serve as an intermediate for the preparation of PGF 2 .sub.α analog XXXV, wherein ˜ is alpha.
The formula-XXXI PGF 2 .sub.β -type product is obtained on hydrolysis of any blocking groups at R 10 , e.g. tetrahydropyranyl or silyl groups. For this purpose, the formula-XXX compound is contacted with methanol-HCl or with acetic acid/water/tetrahydrofuran at 40°-55° C. Specifically for the silyl groups, milder conditions may be employed. See Pierce, cited above, especially p. 447 thereof. A mixture of water and sufficient of a water-miscible organic diluent to give a homogeneous hydrolysis reaction mixture represents a suitable reaction medium. Addition of a catalytic amount of an organic or inorganic acid hastens the hydrolysis. The length of time required for the hydrolysis is determined in part by the hydrolysis temperature. With a mixture of water and methanol at 25° C., several hours is usually sufficient for hydrolysis. At 0° C., several days is usually necessary.
The formula-XXXIV PGE 2 -type product is obtained by first transforming the formula-XXX intermediate to intermediate XXXII having a blocking group R 9 , by one of the methods described above. When R 7 at C-15 of compound XXX is hydrogen, the hydrogen on the C-15 hydroxyl is also replaced by a blocking group in the above reaction. When R 7 is methyl, it is immaterial whether M'" contains a free hydroxyl or a blocking group, since the tertiary hydroxyl at C-15 is less susceptible to oxidation than the secondary hydroxyl at C-9 in the subsequent step. When silylation is employed and R 12 in the formula-XXX intermediate is hydrogen, the --COOH molety thereby defined is simultaneously transformed to --COO--Si--(A) 3 , additional silylating agent being used for this purpose. It is immaterial whether R 12 is completely silylated or not for the purposes of Chart B, so that R 11 may be all or partially hydrogen.
Successive steps in Chart B relate to the transformation of intermediate XXXII to a PGE 2 -type product by (1) oxidizing intermediate XXXII at the 9-hydroxy position by known methods, e.g. with Jones or Collins reagent, and (2) replacing the blocking groups at R 9 , R 10 , and R 11 with hydrogen, i.e. by hydrolysis as discussed above for removal of tetrahydropyranyl or silyl groups.
The formula-XXXV PGF 2 .sub.α analog wherein ˜ is alpha is made from the formula-XXXIV PGE 2 analog by reduction of the carbonyl at C-9 by methods known in the art. See, for example, Bergstrom et al., Arkiv Kemi 19, 563 (1963), Acta. Chem. Scand. 16, 969 (1962), and British Specification No. 1,097,533. Any reducing agent is used which does not react with carbon-carbon double bonds or ester groups. Preferred reagents are lithium(tri-tert-butoxy)aluminum hydride, the metal borohydrides, especially sodium, potassium and zinc borohydrides, the metal trialkoxy borohydrides, e.g., sodium trimethoxyborohydride. The mixtures of alpha and beta hydroxy reduction products are separated into the individual alpha and beta isomers by methods known in the art for the separation of analogous pairs of known isomeric prostanolc acid derivatives. See, for example, Bergstrom et al., cited above, Granstrom et al., J. Biol. Chem. 240, 457 (1965), and Green et al., J. Lipid Research 5, 117 (1964). Especially preferred as separation methods are partition chromatographic procedures, both normal and reversed phase, preparative thin layer chromatography, and countercurrent distribution procedures.
As stated above, the C-15 epimers may be separated at the formula-XXVI stage, in which case they are subjected to the successive steps of Charts A and B individually. They may also be separated at any later stage in Chart A or B, or if desired, left together as a mixture.
In Charts C and D are shown the steps by which the 11β analogs of this invention are prepared. The reactions whereby starting material XX is transformed to intermediate XLIV are substantially as described herein for Charts A and B, with the exception of the C-11 isomerization of Chart A employing the sulfonate-carboxylate transformation from formula XXI to formula XXII. This isomerization is, of course, not used where the products of Chart C retain the configuration of starting material XX.
In Chart C are shown intermediates XLIV and XLV which are readily transformed to the respective8β,9β,11β,12α-PGF 2 and 8β,11β,12α-PGE 2 analogs by methods known in the art or described herein.
CHART C______________________________________ ##STR53## ##STR54## ##STR55## ##STR56## ##STR57## ##STR58## ##STR59## ##STR60## ##STR61## ##STR62## ##STR63## ##STR64## ##STR65##______________________________________
CHART D______________________________________ ##STR66## ##STR67## ##STR68## ##STR69## ##STR70##______________________________________
The chromatographic separation of the C-15 epimers of the 15-methyl analogs is readily, and in fact preferably, effected on intermediate XLIII, thereafter carrying forward the individual 15α and 15β epimers through the sequential steps of Charts C and D. Those C-15 epimers wherein R 7 is hydrogen are separable at the formula-XL stage or any subsequent stage, thereafter being subjected to the successive steps of Charts C or D individually. The separation is readily achieved by methods described herein, for example silica gel chromatography.
In Chart C is also shown the transformation of a PGE 2 -type compound to a PGA 2 analog. For this purpose intermediate XLVI is subjected to acid dehydration, using methods known in the art. See, for example, Pike et al., Proc. Nobel Symposium II, Stockholm (1966), interscience Publishers, New York, pp. 162-163 (1967); and British Specification 1,097,533. Alkanoic acids of 2 to 6 carbon atoms, inclusive, especially acetic acid, are preferred acids for this acidic dehydration. Dilute aqueous solutions of mineral acids, e.g., hydrochloric acid, especially in the presence of a solubilizing diluent, e.g., tetrahydrofuran, are also useful as reagents for this acidic dehydration, although these reagents may cause partial hydrolysis of an ester reactant.
Alternately when R 7 is methyl, and preferably when R 8 is acetyl, compound XLVI is contacted with potassium acetate in solution, e.g. in methanol. the reaction proceeds smoothly at about 20°-30° C. and is substantially free of side reactions.
The formula-XLVII PGA 2 analogs are useful compounds not only for their prostaglandin-like properties discussed above, but as intermediates for preparing the 11α PG 2 analogs of this invention and the C-9 epimers of the PGF 2 analogs according to the steps of Chart D.
In Chart D are shown the transformations of the formula-XLVII PGA 2 analog to the formula LI, LII, LIII, and LIV analogs, using methods known in the art. See, for example, G. L. Bundy et al., J. Am. Chem. Soc. 94, 2123 (1972). There are first formed the formula-XLVIII 10,11-epoxides, using any agent known to epoxidize an α,β-unsaturated ketone without reacting with isolated carboncarbon double bonds, for example see Steroid Reactions, Carl Djerassi, ed., Holden-Day Inc., 1963, p. 593. Especially preferred are aqueous hydrogen peroxide or an organic tertiary hydroperoxide. See, for example, Organic Peroxides, A. V. Tobolsky et al., Interscience Publishers, N. Y., 1954. For this purpose, the peroxide or hydroperoxide is employed in an amount of at least one equivalent per mole of Formula-XLVII reactant in the presence of a strong base, e.g., an alkali metal hydroxide, a metal alkoxide, or a quaternary ammonium hydroxide. For example, there is employed lithium hydroxide, sodium hydroxide, potassium hydroxide, lithium ethoxide, lithium octyloxide, magnesium methoxide, magnesium isopropoxide, benzyltrimethylammonium hydroxide, and the like.
It is advantageous to use an inert liquid diluent in the epoxidation step to produce a mobile homogenous reaction mixture, for example, a lower alkanol, dioxane, tetrahydrofuran, dimethoxyethane, dimethylsulfoxide, or dimethylsulfone. A reaction temperature in the range -60° C. is generally preferred, especially below -10° C. At a temperature of -20° C., the epoxidation is usually complete in 3 to 6 hours. It is also preferred that the reaction be carried out in an atmosphere of an inert gas, e.g., nitrogen, helium, or argon. When the reaction is complete as shown by the absence of starting material on TLC plates (5% acetone in dichloromethane), the reaction mixture is neutralized, and the epoxy product is isolated by procedures known in the art, for example, evaporation of the diluent and extraction of the residue with an appropriate waterimmiscible solvent, e.g., ethyl acetate.
This transformation of XLVII to XLVIII usually produces a mixture of formula-XLVIII alpha and beta epoxides. Although these mixtures are separable into the individual alpha and beta isomers, for example, by chromatography by procedures known to be useful for separating alpha and beta epoxide mixtures, it is usually advantageous to transform the formula-XLVIII mixture of alpha and beta epoxides to the corresponding mixture of formula-XLIX 11α and 11β hydroxy compounds. The latter mixture is then readily separated into the 11α and 11β compounds, for example by chromatography on silica gel.
Referring again to Chart D, the transformation of epoxide XLVIII to hydroxy compound XLIX is accomplished by reduction with chromium (II) salts, e.g., chromium (II) chloride or chromium (II) acetate. Those salts are prepared by methods known in the art, e.g., Inorganic Syntheses, VIII, 125 (1966); ibid., VI, 144 (1960); ibid. III, 148 (1950); ibid. I, 122 (1939); and references cited in those. This reduction is carried out by procedures known in the art for using chromium (II) salts to reduce epoxides of αβ-unsaturated ketones to β-hydroxy ketones. See, for example, Cole et al., J. Org. Chem. 19, 131 (1954), and Neher et al., Helv. Chem. Acta 42, 132 (1959). In these reactions, the absence of air and strong acids is desirable.
Amalgamated aluminum metal has also been found to be useful as a reducing agent in place of chromium (II) salts for the above purpose. Amalgamated aluminum is prepared by procedures known in the art, for example, by contacting aluminum metal in the form of foil, thin sheet, turnings, or granules with a mercury (II) salt, for example, mercuric chloride, advantageously in the presence of sufficient water to dissolve the mercury (II) salt. Preferably, the surface of the aluminum metal is free of oxide. That is readily accomplished by physical removal of the usual oxide layer, e.g., by abrasion or scraping, or chemically, e.g., by etching with aqueous sodium hydroxide solution. It is only necessary that the aluminum surface be amalgamated. The amalgamated aluminum should be freshly prepared, and maintained in the absence of air and moisture until used.
The reductive opening of the formula-XLVIII epoxide ring is accomplished by contacting said epoxide with the amalgamated aluminum in the presence of a hydroxylic solvent and sufficient inert organic liquid diluent to give a mobile and homogeneous reaction mixture with respect to the hydroxylic solvent and said epoxide. Among hydroxylic solvents, water is especially preferred although lower alkanols, e.g., methanol and ethanols are also operable.
Examples of inert organic liquid diluents are normally liquid ethers such as diethyl ether, tetrahydrofuran, dimethoxyethane, diglyme (dimethyl ether of diethylene glycol), and the like. Especially preferred is tetrahydrofuran. When a water-immiscible liquid diluent is used, a mixture of water and methanol or ethanol is especially useful in this reaction since the latter two solvents also aid in forming the desired homogeneous reaction mixture. For example, a mixture of diethyl ether and water is used with sufficient methanol to give a homogeneous reaction mixture.
As a modification of the above-described process for reductive opening of the epoxide, it has been found that instead of employing a formula-XLVIII compound wherein R 20 is hydrogen, the reductive opening reaction proceeds more smoothly and completely if there is used, instead, an epoxide wherein R 20 is either methyl or a cation of an alkali or alkaline earth metal or a quaternary ammonium group.
Thus, a free acid formula-XLVIII epoxide compound is treated with a hydroxide or oxide of lithium, sodium, potassium, magnesium, calcium, barium, or strontium prior to contacting with the aluminum amalgam. Optionally, the quaternary ammonium bases are used for this neutralization, for example benzyltrimethylammonium hydroxide. By using the above-described salts, the reduction step proceeds smoothly without formation of insoluble aluminum salts which hinder the reaction. Following the reduction or hydrolysis step, the R 20 cations are replaced with hydrogen by means known in the art, for example by acidification and extraction of the acid compound into an organic phase, to form the formula-L compound.
The separate C-11 epimers of formula LI and LIII, PGE 2 analogs within the scope of this invention, are useful prostaglandin analogs for the purposes discussed above. They may also be transformed to the corresponding PGF 2 analogs of formula LII and LIV, respectively, by methods known in the art or described herein.
The 15-alkyl ether prostaglandin-type compounds included within formulas VI to XIV are produced by the sequence of reactions illustrated in Charts, E, F, and G. In general, by these methods, the 15-alkyl ether group is introduced into the bicyclic lactone intermediates XXVI (Chart A) and XL (Chart C) prior to the lactol formation and Wittig reaction for forming the carboxy side chain. Alternatively, the 15-alkyl ether compounds are prepared by alkylation of a suitably blocked prostaglandin-type compound. See Belg. Pat. No. 783,028, Nov. 6, 1972; Netherlands Application No. 7205997, Derwent Farmdoc 74818 T.
Referring to Chart E, starting material XXVI is available by the processes of Chart A, discussed above. In Chart E, M, Q, R 3 , R 8 , R 9 , R 10 , R 11 , and R 12 have the same meanings as in Charts A and B; M 1V is defined as ##STR71## wherein R 7 is hydrogen or methyl and R 22 is alkyl of one to 5 carbon atoms, inclusive.
The formula-LVI compound is prepared by alkylation of the side-chain hydroxy of the formula-XXVI compound thereby replacing hydroxy with the --OR 22 moiety.
CHART E______________________________________ ##STR72## ##STR73## ##STR74## ##STR75## ##STR76## ##STR77## ##STR78## ##STR79## ##STR80##______________________________________
CHART F______________________________________ ##STR81## ##STR82## ##STR83## ##STR84## ##STR85## ##STR86## ##STR87## ##STR88## ##STR89## ##STR90##______________________________________
CHART G______________________________________ ##STR91## ##STR92## ##STR93## ##STR94## ##STR95## ##STR96##______________________________________
For this purpose, diazoalkanes may be employed, preferably in the presence of a Lewis acid, e.g. boron trifluoride etherate, aluminum chloride, or fluoboric acid. When R 22 is methyl, diazomethane is used. See Fieser et al., "Reagents for Organic Synthesis," John Wiley and Sons, Inc., N.Y. (1967), p. 191. Other --OR 22 groups are formed by using the corresponding diazoalkane. For example diazoethane and diazobutane yield --OC 2 H 5 and --OC 4 H 9 respectively. The reaction is carried out by mixing a solution of the diazoalkane in a suitable inert solvent, preferably ethyl ether, with the formula-XXVI compound. Generally the reaction proceeds at about 25° C. Diazoalkanes are known in the art or can be prepared by methods known in the art. See, for example, Organic Reactions, John Wiley and Sons, Inc. N.Y. Vol. 8, pp. 389-394 (1954).
Another method for the alkylation of the side chain hydroxy is by the reaction of an alcohol in the presence of boron trifluoride etherate. Thus, methanol and boron trifluoride etherate yield the methyl ether wherein R 22 is methyl. The reaction is done at about 25° C. and is conveniently followed with thin layer chromatography (TLC).
Another method for the alkylation of the side-chain hydroxy is by the reaction of an alkyl halide, e.g. methyl iodide, in the presence of a metal oxide or hydroxide, e.g. barium oxide, silver oxide, or barium hydroxide. An inert solvent may be beneficial, for example benzene or dimethylformamide. The reactants are preferably stirred together and maintained at temperatures of 25°-75° C.
Still another method is by first converting the hydroxy to mesyloxy (i.e. methanesulfonate) or tosyloxy (i.e. toluenesulfonate) and thence transforming the mexyloxy or tosyloxy to the --OR 22 moiety by reaction with a metal alkoxide, e.g. potassium tert-butoxide. The mesylate or tosylate is prepared by reaction of the formula-XXVI intermediate with either methanesulfonyl chloride or toluenesulfonyl chloride in pyridine. Thereafter, the mesylate or tosylate is mixed with the appropriate potassium or sodium alkoxide in pyridine, the reaction proceeding smoothly at about 25° C. An equivalent amount of the alkoxide based on the mesylate is preferred to avoid side reactions. In this manner, the formula-LVI intermediate is prepared wherein R 22 is normal alkyl, secondary alkyl, or tertiary alkyl of one to 5 carbon atoms. The method is especially useful for tertiary alkyl substitutions for hydrogen, e.g. where R 2 is tert-butyl or tert-pentyl.
The formula-LVII compound is then obtained by deacylation of LVI with an alkali metal carbonate, for example potassium carbonate in methanol at about 25° C.
The formula-LVIII compound is the same as the formula-LVII compound when R 8 is hydrogen, or is obtained from the formula-LVII compound by reactions discussed above when R 8 is a blocking group, such as tetrahydropyranyl, tetrahydrofuranyl, or silyl. Thereafter lactol LIX is obtained by reduction and converted to LX by a Wittig reaction. Thereafter the steps by which products LXI, LXIV, and LXV are obtained are analogous to those described above for Chart B.
Referring to Charts F and G, there are shown the steps by which the 11β analogs of the 15 alkyl ethers are prepared. The reactions are analogous to those shown above in Charts C and D. In Charts F and G, M 1V is defined as it is in Chart E above. Starting material XL of Chart F is available by the processes of Chart C, discussed above. The formula-LXXIV 15-alkyl ether PGA 2 analogs of Chart F are useful per se and as intermediates for preparing the 11α 15-alkyl ether products LXIV and LXV according to Chart G.
As discussed above, the processes of Charts A-D, inclusive, lead variously to acids (R 12 is hydrogen) or to esters (R 12 is alkyl, cycloalkyl, aralkyl, phenyl or substituted phenyl, as defined above). When an acid has been prepared and an alkyl ester is desired, esterification is advantageously accomplished by interaction of the acid with the appropriate diazohydrocarbon. For example, when diazomethane is used, the methyl esters are produced. Similar use of diazoethane, diazobutane, and 1-diazo-2-ethylhexane, and diazodecane, for example, gives the ethyl, butyl, and 2-ethylhexyl and decyl esters, respectively.
Esterification with diazohydrocarbons is carried out by mixing a solution of the diazohydrocarbon in a suitable inert solvent, preferably diethyl ether, with the acid reactant, advantageously in the same or a different inert diluent. After the esterification reaction is complete, the solvent is removed by evaporation, and the ester purified if desired by conventional methods, preferably by chromatography. It is preferred that contact of the acid reactants with the diazohydrocarbon be no longer than necessary to effect the desired esterification, preferably about one to about ten minutes, to avoid undesired molecular changes. Diazohydrocarbons are known in the art or can be prepared by methods known in the art. See, for example, Organic Reactions, John Wiley and Sons, Inc., New York, N.Y., Vol. 8, pp. 389-394 (1954).
An alternative method for esterification of the carboxyl moiety of the acid compounds comprises transformation of the free acid to the corresponding silver salt, followed by interaction of that salt with an alkyl iodide. Examples of suitable iodides are methyl iodide, ethyl iodide, butyl iodide, isobutyl iodide, tert-butyl iodide, and the like. The silver salts are prepared by conventional methods, for example, by dissolving the acid in cold dilute aqueous ammonia, evaporating the excess ammonia at reduced pressure, and then adding the stoichiometric amount of silver nitrate.
Examples of alkyl of one to 4 carbon atoms, inclusive, are methyl, ethyl, propyl, butyl, and isomeric forms thereof. Examples of phenylalkyl of 7 to 10 carbon atoms, inclusive, are benzyl, phenethyl, 1-phenylethyl, 2-phenylpropyl, 4-phenylbutyl, and 3-phenylbutyl. Examples of phenyl substituted with one or 2 fluoro, chloro, or alkyl of one to 4 carbon atoms, inclusive, are p-chlorophenyl, m-fluorophenyl, o-tolyl, 2,4-dichlorophenyl, p-tert-butylphenyl, 4-chloro-2-methylphenyl, and 2,4-dichloro-3-methylphenyl. Examples of aralkyl of 7 to 12 carbon atoms, inclusive, other than the phenylalkyl examples above, are α-naphthylmethyl, and 2-(β-naphthyl)ethyl.
Examples of alkyl of one to 12 carbon atoms, inclusive, are, in addition to those alkyl examples above, pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, and isomeric forms thereof. Examples of cycloalkyl of 3 to 10 carbon atoms, inclusive, which includes alkyl-substituted cycloalkyl, are cyclopropyl, 2-methylcyclopropyl, 2,2-dimethylcyclopropyl, 2,3-diethylcyclopropyl, 2-butylcyclopropyl, cyclobutyl, 2-methylcyclobutyl, 3-propylcyclobutyl, 2,3,4-triethylcyclobutyl, cyclopentyl, 2,2-dimethylcyclopentyl, 2-pentylcyclopentyl, 3-tert-butylcyclopentyl, cyclohexyl, 4-tert-butylcyclohexyl, 3-isopropylcyclohexyl, 2,2-dimethylcyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, and cyclodecyl.
Examples of alkyl of one to 18 atoms, inclusive, are, in addition to those alkyl examples above, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, and isomeric forms thereof. Examples of phenyl substituted with one, 2, or 3 alkyl of one to 4 carbon atoms, inclusive, are (o, m, or p)-tolyl, 3,5-xylyl, (o, m, or p)-ethylphenyl, 2,5-diethylphenyl, (o, m, or p)-butylphenyl, (o, m, or p)-sec-butylphenyl, (o, m, or p)-tert-butylphenyl, 2-isopropyl-3-methylphenyl, 2-ethyl-4-propylphenyl, 2,6-diisopropylphenyl, 3,4,5-trimethylphenyl, and 2,4,6-tributylphenyl.
When the processes of Charts A-D yield an ester, R 12 being methyl, the free acid products are obtained by methods known in the art. For example, the PGF 2 analogs are subjected to saponification in an aqueous alkaline medium to form an alkaline salt, which is then acidified to yield the free acid. A preferred method for the PGE 2 analogs, and useful for the PGF 2 analogs as well, is by enzymatic hydrolysis using an esterase enzyme composition obtained from the marine invertebrate Plexaura homomalla (Esper), 1792. Plexaura homomalla is a member of the subclass Octocorallia, order Gorgonacea, suborder Holaxonia, family Plexauridae, genus Plexaura. See, for example, Bayer, "The Shallow-Water Octocorallia of the West Indian Region," Martinus Nijhoff, The Hague (1961). Colonies of these Plexaura homomalla are abundant on the ocean reefs in the zone from the low-tide line to about 25 fathoms in the tropical and subtropical regions of the western part of the Atlantic Ocean, from Bermuda to the reefs of Brazil, including the eastern shore reefs of Florida, the Caribbean island and mainland reefs, and the Gulf of Mexico island and mainland reefs. These colonies are bush-like or small tree-like in habit and are readily identified for collection as Plexaura homomalla (Esper), 1792, by those of ordinary skill in this art. Two forms exist, the R form and the S form. See W. P. Schneider et al., J. Am. Chem. Soc. 94, 2122 (1972).
The esterase enzyme composition is produced by the steps: (1) extracting colonies or colony pieces of the marine invertebrate Plexaura homomalla (Esper), 1792, forma R or forma S, with liquid acetone for a sufficient time to remove substantially all soluble lipids, and
(2) recovering the acetone-insoluble matter as said composition.
The colonies of Plexaura homomalla are used either in their as-harvested form or in broken or chopped pieces. It is immaterial whether they are used fresh from their natural environment, or after freezing and thawing, or even after drying under ambient conditions.
The extraction with acetone may be done batch-wise, as by stirring in a container, or by percolation, or by continuous methods of extraction known in the art. If stirring is used, it is advantageous to first chop the Plexaura homomalla into small pieces, for example less than 3 mm. in greatest dimension. The product is accordingly then a powder consisting of pieces smaller than 3 mm. Contact with acetone is continued until substantially all of the soluble lipids are removed. Normally 1 hour is sufficient, although a longer time is required for whole colonies and a shorter time is sufficient for chopped colonies with efficient extraction. The end-point can be determined simply by examination of the acetone, as by evaporation and by physical measurements on any residue thus obtained. The extraction temperature is kept below 50° C. to avoid denaturation of the enzyme, and is preferably in the range 20° to 30° C. Lower temperatures may be used but the extraction then proceeds more slowly. The extraction is generally done at atmospheric pressure, but it may be carried out at higher or lower pressures provided the acetone is in a liquid state when contacting the Plexaura homomalla.
The acetone-insoluble enzyme composition is recovered from the acetone by decantation, filtration, centrifugation, or other convenient method for separating solids and liquids. A small amount of adherent acetone, for example, 10% of the weight of the composition, may be left on the product but it is preferred that the amount be lowered to less than 1%, for example by drying under ambient conditions or under reduced pressure. The product can then be stored without deterioration, preferably at about -20° C.
in utilizing the above esterase enzyme composition for the purposes of this invention, the prostaglandin ester is contacted with a mixture of the enzyme composition and water. The ester is conveniently added as a solution, for example in ethanol or benzene, to about 50-100 times its weight of water. The enzyme composition is added in an amount about 1-15 times the weight of ester. The mixture is stirred until the ester is hydrolyzed, generally about 18-24 hours at 25° C. Temperatures of about 0°-50° C. may be employed, although about 25° C. is preferred. The progress of hydrolysis is readily followed by analysis, for example by thin-layer chromatography by methods known in the art. See, for example, Hamberg et al., J. Biol. Chem. 241, 257 (1966). Finally, several volumes of acetone are added and the acid products dissolved in the acetone are recovered by filtration, concentration, and extraction using methods known in the art.
The final formula VI-to-XVII compounds prepared by the processes of this invention, in free acid form, are transformed to pharmacologically acceptable salts by neutralization with appropriate amounts of the corresponding inorganic or organic base, examples of which correspond to the cations and amines listed above. These transformations are carried out by a variety of procedures known in the art to be generally useful for the preparation of inorganic, i.e., metal or ammonium, salts, amine acid addition salts, and quaternary ammonium salts. The choice of procedure depends in part upon the solubility characteristics of the particular salt to be prepared. In the case of the inorganic salts, it is usually suitable to dissolve the formula VI-to-XVII acid in water containing the stoichiometric amount of a hydroxide, carbonate, or bicarbonate corresponding to the inorganic salt desired. For example, such use of sodium hydroxide, sodium carbonate, or sodium bicarbonate gives a solution of the sodium salt. Evaporation of the water or addition of a water-miscible solvent of moderate polarity, for example, a lower alkanol or a lower alkanone, gives the solid inorganic salt if that form is desired.
To produce an amine salt, the formula VI-to-XVII acid is dissolved in a suitable solvent of either moderate or low polarity. Examples of the former are ethanol, acetone, and ethyl acetate. Examples of the latter are diethyl ether and benzene. At least a stoichiometric amount of the amine corresponding to the desired cation is then added to that solution. If the resulting salt does not precipitate, it is usually obtained in solid form by addition of a miscible diluent of low polarity or by evaporation. If the amine is relatively volatile, any excess can easily be removed by evaporation. It is preferred to use stoichiometric amounts of the less volatile amines.
Salts wherein the cation is quaternary ammonium are produced by mixing the formula VI-to-XVII acid with the stoichiometric amount of the corresponding quaternary ammonium hydroxide in water solution, followed by evaporation of the water.
The final formula VI-to-XVII acids or esters prepared by the processes of this invention are transformed to lower alkanoates by interaction of the formula VI-to-XVII hydroxy compound with a carboxyacylating agent, preferably the anhydride of a lower alkanoic acid, i.e., an alkanoic acid of two to 8 carbon atoms, inclusive. For example, use of acetic anhydride gives the corresponding acetate. Similar use of propionic anhydride, isobutyric anhydride, and hexanoic acid anhydride gives the corresponding carboxyacylates.
The carboxyacylation is advantageously carried out by mixing the hydroxy compound and the acid anhydride, preferably in the presence of a tertiary amine such as pyridine or triethylamine. A substantial excess of the anhydride is used, preferably about 10 to about 10,000 moles of anhydride per mole of the hydroxy compound reactant. The excess anhydride serves as a reaction diluent and solvent. An inert organic diluent, for example, dioxane, can also be added. It is preferred to use enough of the tertiary amine to neutralize the carboxylic acid produced by the reaction, as well as any free carboxyl groups present in the hydroxy compound reactant.
The carboxyacylation reaction is preferably carried out in the range about 0° to about 100° C. The necessary reaction time will depend on such factors as the reaction temperature, and the nature of the anhydride and tertiary amine reactants. With acetic anhydride, pyridine, and a 25° C. reaction temperature, a 12 to 24-hour reaction time is used.
The carboxyacylated product is isolated from the reaction mixture by conventional methods. For example, the excess anhydride is decomposed with water, and the resulting mixture acidified and then extracted with a solvent such as diethyl ether. The desired carboxyacylate is recovered from the diethyl ether extract by evaporation. The carboxyacylate is then purified by conventional methods, advantageously by chromatography.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The invention can be more fully understood by the following preparations and examples.
All temperatures are in degrees centigrade.
Infrared absorption spectra are recorded on a Perkin-Elmer model 421 infrared spectrophotometer. Except when specified otherwise, undiluted (neat) samples are used.
Mass spectra are recorded on an Atlas CH--4 mass spectrometer with a TO-4 source (ionization voltage 70 ev).
NMR spectra are recorded on a Varian A-60 spectrophotometer in deuterochloroform solutions with tetramethylsilane as an internal standard (downfield).
Brine, herein, refers to an aqueous saturated sodium chloride solution.
The A-IX solvent system used in thin layer chromatography is made up from ethyl acetate-acetic acid- 2,2,4-trimethylpentane-water (90:20:50:100) according to M. Hamberg and B. Samuelsson, J. Biol. Chem. 241, 257 (1966).
Skellysolve-B refers to mixed isomeric hexanes.
Silica gel chromatography, as used herein, is understood to include elution, collection of fractions, and combination of those fractions shown by TLC (thin layer chromatography) to contain the desired product free of starting material and impurities.
Names of compounds used in these examples are understood to refer to compounds having the same configuration as the corresponding prostaglandins of natural configuration unless otherwise indicated in the name. For example, the product of Example 11, 8β,12α-PGE 2 , methyl ester, has the alpha configuration at C-11 and at C-15, but has the 8-beta and 12-alpha configurations characteristic of the analogs of this invention.
Preparation 1
Dimethyl 2-Oxo-3-methylheptylphosphonate, ##STR97##
n-Butyllithium (150 ml.) is added slowly to a solution of dimethyl methylphosphonate (25.6 g.) in 475 ml. of tetrahydrofuran (THF) at about -65° C. To the mixture is added a solution of racemic ethyl 2-methylhexanoate (18.4 g.) in 50 ml. of THF, and the resulting mixture is stirred at -70° C. for 2 hrs. Then, 16 ml. of acetic acid is added, and the mixture is concentrated under reduced pressure. The residue is mixed with dichloromethane (about 400 ml.) and water (about 50 ml.), shaken, and separated. The organic phase is dried over magnesium sulfate and concentrated. Distillation yields the title compound, 16.7 g., b.p. 126°-129° C./1 mm.
Following the procedures of Preparation 1 but replacing racemic ethyl 2-methylhexanoate with the ethyl esters of the (+) and (-) isomers of 2-methylhexanoic acid (see P. A. Levene et al., J. Biol. Chem. 70, 211 (1926) and 84, 571 (1929)) there are obtained the corresponding optically active (+) and (-) title compounds.
Preparation 2
Dimethyl 2-Oxo-3,3-dimethylheptylphosphonate, ##STR98##
n-Butyllithium (400 ml.) is added slowly to a solution of dimethyl methylphosphonate (73.7 g.) in 1.3 l. of THF at about -66° C. To the mixture is added a solution of ethyl 2,2-dimethylhexanoate (53 g.) in 150 ml. of THF, and the resulting mixture is stirred at -70° C. for 2 hrs. Then, 46 ml. of acetic acid is added, and the mixture is concentrated under reduced pressure. The residue is mixed with portions of dichloromethane (about 1.2 l.) and water (about 150 ml.), shaken, and separated. The organic phase is dried over magnesium sulfate and concentrated. Distillation yields the title compound, 41.6 g., b.p. 117°-120° C./1 mm.
Preparation 3
Dimethyl 2-oxo-4-phenylbutylphosphonate, ##STR99##
A solution of dimethyl methylphosphonate (115.5 g.) in 2.1 l. of tetrahydrofuran is treated, while stirring at -65° C., with a solution of butyl lithium (660 ml. 1.6 M. in hexane). A solution of ethyl hydrocinnamate (93.5 g.) in 225 ml. of tetrahydrofuran is added at -65° C. Stirring is continued at -65° C. for 2 hrs. and then at about 25° C. for 16 hrs. Acetic acid (70 ml.) is added and the mixture concentrated under reduced pressure. The residue is partitioned between dichloromethane and water. The organic phase is dried and concentrated. Distillation yields the title compound, b. 188°-191° C./2 mm., having a mass spectral peak at 256.
Preparation 4
Aluminum Amalgam.
Granular aluminum metal (50 g.) is added to a solution of mercuric chloride (50 g.) in 2 l. of water. The mixture is swirled until hydrogen gas evolution starts to become vigorous (about 30 seconds). Then, most of the aqueous solution is decanted, and the rest is removed by rapid filtration. The amalgamated aluminum is washed rapidly and successively with two 200-ml. portions of methanol and two 200-ml. portions of anhydrous diethyl ether. The amalgamated aluminum is then covered with anhydrous diethyl ether until used.
EXAMPLE 1
3β,5β-Dihydroxy-2α-methoxymethyl-1β-cyclopentaneacetic Acid γ-Lactone (Formula XX: R 1 is methyl).
A. Refer to Chart A. The formula-XIX iodo lactone is first prepared. For this purpose the formula-XVIII starting material of the proper configuration is obtained by resolution of the racemic hydroxy acid with (-)-ephedrine following the procedure of E. J. Corey et al. (J. Am. Chem. Soc. 92, 397 (1970)). The sodium salt of the laevorotatory formula-I hydroxy acid is then treated in water at 0°-5° C. with potassium triiodide (2.5 equivalents) for 20 hrs. to yield the formula-XIX compound, namely 3β,5β-dihydroxy-4-iodo-2α-methoxymethyl-1β-cyclopentaneacetic acid γ-lactone.
B. A solution of the product of step A (20.5 g.) in 125 ml. of benzene is treated at about 25° C. with 250 ml. of an ethereal solution (0.3 M.) of tributyltinhydride. When the reaction is complete, in approximately one hr. as shown by TLC (thin layer chromatography), the solution is concentrated under reduced pressure to a liquid residue. There is added 300 ml. of Skellysolve B (a mixture of isomeric hexanes) and 300 ml. of water, and the mixture is stirred about 16 hrs. The aqueous phase, together with washings of the organic phase, is saturated with sodium chloride and extracted with ethyl acetate. The ethyl acetate solution is dried over sodium sulfate and concentrated to the title compound, an oil, 7.5 g; having infrared absorption at 3300, 1755, 1170, 1037, 959, and 890 cm.sup. -1 .
EXAMPLE 2
3β-p-Toluenesulfonyloxy-5β-hydroxy-2α-methoxymethyl-1β-cyclopentaneacetic Acid γ -Lactone (Formula XXI: R 1 is methyl and R 2 is p-toluenesulfonyl).
Refer to Chart A. A solution of the formula-XX compound (Example 1, 1.0 g.) in 20 ml. of pyridine is stirred at about 25° C. with p-toluenesulfonyl chloride (1.9 g.) for 2 days. The mixture is diluted with ice, made slightly acidic with 10% sulfuric acid, and extracted with ethyl acetate. The organic phase is washed with saturated sodium bicarbonate solution and brine, dried over sodium sulfate, and concentrated to the title compound, m.p. 85°-90° C., 1.8 g. An analytical sample has m.p. 97°-98° C., and NMR peaks at 7.80, 7.34, 5.1-4.7, 3.31, 3.23, and 2.98-2.12 δ.
EXAMPLE 3
3α-Benzoyloxy-5β-hydroxy-2α-methoxymethyl-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXII: R 1 is methyl and R 3 is benzoyl).
Refer to Chart A. A mixture of the formula-XXI compound (1.8 g.) and sodium benzoate (5.0 g.) in 100 ml. of dimethyl sulfoxide is stirred at 80°-85° C. for 3.5 hrs. The mixture is then diluted with 500 ml. of ice water and extracted with diethyl ether. The organic phase is washed with saturated sodium bicarbonate solution and brine, dried over sodium sulfate, and concentrated to the title compound, an oil, 1.5 g; having NMR peaks at 8.30-7.91, 7.73-7.31, 5.80-5.55, 5.34-4.98, 3.74-3.43, 3.28, and 3.11-2.0 δ.
EXAMPLE 4
3α-Benzoyloxy-5β-hydroxy-2α-hydroxymethyl-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXIII: R 3 is benzoyl).
Refer to Chart A. A solution of the formula-XXII compound (Example 3, 0.5 g.) in 20 ml. of ethyl acetate is treated at 0° C., while stirring, with 0.7 ml. of boron tribromide. After 0.5 hr., stirring is continued for 2 hrs. at about 25° C. There is then added 75 ml. of saturated sodium bicarbonate solution, the mixture is equilibrated, and the organic phase is washed with brine, dried over sodium sulfate, and concentrated to an oil, 0.47 g. The product is subjected to silica gel chromatography, eluting with 50% ethyl acetate in Skellysolve B, then 75% and finally ethyl acetate. Concentration under reduced pressure yields the title compound, an oil, 0.33 g; having infrared absorption at 3300, 1590, 1570, 1530, 1250, 1150, 1095, 1055, 1030, 1010, 900, 804, and 710 cm.sup. -1 ; and NMR peaks at 8.17-7.83, 7.67-7.29, 5.76-5.57, 5.35-4.93, 3.27, and 3.13-1.95 δ.
EXAMPLE 5
3α-Benzoyloxy-5β-hydroxy-2α-(3-oxo-trans-1-octenyl)-1.beta.-cyclopentaneacetic Acid γ-Lactone (Formula XXV: R 3 is benzoyl, R 4 and R 5 are hydrogen, and R 6 is n-butyl).
A. Refer to Chart A. There is first prepared the formula-XXIV aldehyde. A solution of the formula-XXIII compound (Example 4, 0.33 g.) in 2 ml. of dichloromethane is added to Collins reagent (prepared from 1.2 g. of pyridine and 1.0 g. of anhydrous chromium trioxide in 25 ml. of dichloromethane), with stirring at 0° C. After 5 min. at 0° C. and another 5 min. at about 25° C., the solution is decanted from the solids and used in step B below.
B. A solution of the appropriate ylide is prepared from a mixture of sodium hydride (0.12 g., 50%) and dimethyl 2-oxoheptylphosphonate (0.64 g.) in 22 ml. of tetrahydrofuran at 0° C. To the cold ylide solution is added the solution of the formula-XXIV aldehyde from step A and the mixture is stirred at about 25° C. for 4 hrs. The reaction mixture is added to a mixture of 150 ml. of 2 M. sodium hydrogen sulfate, and 100 ml. of diethyl ether. The organic phase is washed with saturated sodium bicarbonate solution and brine, dried over sodium sulfate, and concentrated to a dark liquid, 0.77 g. The residue is subjected to silica gel chromatography, eluting with 10% and 50% ethyl acetate in Skellysolve B. Concentration under reduced pressure yields the title compound, 0.28 g., as an oil which slowly crystallizes. An analytical sample, obtained by recrystallization from hexane-ethyl acetate, has m.p. 64°-65.5° C.; mass spectral peaks at 370, 248, and 192; optical rotation [α] D -149° (in chloroform); and NMR peaks at 8.13-7.82, 7.60-7.22, 7.10-6.64, 6.20, 5.75-5.50, 5.33-4.98, 4.29-3.91, and 3.45-0.57 δ.
EXAMPLE 6
3α-Benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXVI: M is ##STR100##
Q is n-pentyl, and R 3 is benzoyl) and 3α-Benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXVI: M is ##STR101##
and Q and R 3 are as defined above).
Refer to Chart A. A solution of the formula-XXV compound (Example 5, 0.61 g.) in 40 ml. of methanol is added to a mixture of sodium borohydride (90 mg.) in 40 ml. of methanol, with stirring at about -15° C. under nitrogen. After 1.5 hrs., 5 ml. of acetic acid is added, the mixture left to warm to about 25° C., and then 5 ml. of water is added. Concentration under reduced pressure gives an oil which is dissolved in ethyl acetate and equilibrated with 0.2 M. sodium hydrogen sulfate. The organic phase, including washings of the aqueous phase, is washed with saturated sodium bicarbonate solution and brine, over sodium sulfate, and concentrated to an oil, 0.59 g. The residue is subjected to silica gel chromatography, eluting with 50% ethyl acetate-Skellysolve B, and dividing the eluant into 95 fractions. Fractions 48-56, when combined and concentrated, yield the 3β-hydroxy title compound, an oil, 0.16 g. Fractions 63-95 similarly yield the 3α-hydroxy title compound, an oil, 0.12 g.; having R f 0.35 (TLC on silica gel in 50% ethyl acetate-Skellysolve B) for the 3β-hydroxy compound, 0.30 for the 3α-hydroxy compound.
EXAMPLE 7
3α,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic Acid γ-Lactone (Formula XXVII: M is ##STR102##
and Q is n-pentyl).
Refer to Chart A. A mixture of the 3α-hydroxyoctenyl formula-XXVI compound (Example 6, 2.8 g.), potassium carbonate (1.4 g.), and 250 ml. of methanol is stirred for 24 hrs. at about 25° C. The solids are filtered off and the filtrate concentrated. The residue is taken up in ethyl acetate and equilibrated with brine. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the title compound, 1.9 g. as an oil which slowly crystallizes. An analytical sample, obtained by recrystallization from hexane-ethyl acetate, has m.p. 79°-81° C.; mass spectral peaks at 250, 193, and 179; and [α] D -39° (in chloroform).
Following the procedure of Example 7, but replacing the 3α-hydroxyoctenyl formula-XXVI compound of that example with the corresponding 3β-hydroxyoctenyl formula-XXVI compound (Example 6), there is obtained 3α,5β-dihydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic acid γ-lactone, having R f 0.34 (TLC on silica gel in ethyl acetate).
EXAMPLE 8
3α,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic Acid γ -Lactone, Bis(tetrahydropyranyl) Ether (Formula-XXVIII: M is ##STR103##
wherein THP is tetrahydropyranyl, Q is n-pentyl, and R 8 is tetrahydropyranyl).
Refer to Chart B. A solution of the 3α-hydroxyoctenyl formula-XXVII compound (Example 7, 1.6 g.) in dihydropyran (6.2 g.), pyridine hydrochloride (0.16 g.) and 37 ml. of dichloromethane is stirred at about 25° C. for 4 hrs. The solution is filtered through silica gel, and concentrated under reduced pressure to an oil, 2.8 g. The oil is subjected to silica gel chromatography, yielding the title compound, an oil, 1.7 g., having R f 0.63 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Following the procedure of Example 8, but replacing the 3α-hydroxyoctenyl formula-XXVII compound of that example with the 3β-hydroxyoctenyl formula-XXVII compound obtained following Example 7, there is obtained 3α,5β-dihydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic acid γ-lactone, bis(tetrahydropyranyl) ether having R f 0.63 (TLC) on silica gel in 50% ethyl acetate-Skellysolve B).
EXAMPLE 9
3α,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetaldehyde γ-Lactol, Bis(tetrahydropyranyl) Ether (Formula XXIX: M is ##STR104##
Q is n-pentyl, and R 8 is THP, wherein THP is tetrahydropyranyl, and ˜ is alpha or beta).
Refer to Chart B. A solution of the 3α-hydroxyoctenyl formula-XXVIII compound (Example 8, 1.7 g.) in 18 ml. of toluene is treated with stirring at -78° C. under nitrogen with 12.4 ml. of 10% diisobutylaluminum hydride in toluene. After 1 hr. there is added dropwise to the cold mixture 24 ml. of tetrahydrofuran-water (2:1) solution. The organic phase is filtered, washed with brine, dried over sodium sulfate, and concentrated to the title compound, an oil, 1.7 g. having R f 0.4 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Following the procedure of Example 9, but replacing the 3α-hydroxyoctenyl formula-XXVIII compound of that example with the 3β-hydroxyoctenyl formula-XXVIII compound obtained following Example 8, there is obtained 3α,5β-dihydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetaldehyde γ-lactol, bis(tetrahydropyranyl) ether, having R f 0.4 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Example 10
8β,9β,12α-PGF 2 , Methyl Ester, Bis(tetrahydropyranyl) Ether (Formula XXXII: M'" is ##STR105##
Q is n-pentyl, R 9 is THP (tetrahydropyranyl), and R 11 is methyl).
Refer to Chart B. There is first prepared the Wittig ylide. 4-Carboxybutyltriphenylphosphonium bromide (E. J. Corey et al., J. Am. Chem. Soc. 91, 5677 (1969)) (5.0 g.) is added to a solution of sodio dimethylsulfinylcarbanide prepared from sodium hydride (50%, 1.1 g.) and 125 ml. of dimethylsulfoxide and the resulting solution is stirred 1.5 hrs. at about 25° C.
To the above solution is added a solution of the 3α-hydroxyoctenyl formula-XXIX compound (Example 9, 1.7 g.) in 50 ml. of dimethylsulfoxide and the resulting mixture is stirred at about 25° C. for 16 hrs. The mixture is then stirred with a mixture of aqueous 0.2 M. sodium hydrogen sulfate at pH about 3 and diethyl ether, and the two phases separated. The organic phase is extracted with aqueous 1 N. sodium hydroxide and then water, and the aqueous extract is acidified with aqueous 2 M. sodium hydrogen sulfate and extracted with diethyl ether. The organic extracts are washed with water and brine, dried over sodium sulfate, and concentrated to 8β,9β,12α-PGF 2 bis(tetrahydropyranyl) ether, an oil, 1.9 g. having R f 0.7 (TLC, silica gel plates, in A-IX solvent system).
The methyl ester is prepared by treating the above product in ether-methanol (1:1) solution at 0° C. with excess diazomethane, and concentrating the mixture to an oil, 1.8 g. Silica gel chromatography yields the title compound as an oil, 1.0 g., having R f 0.45 (TLC on silica fel in 50% ethyl acetate-Skellysolve B).
Following the procedure of Example 10, but replacing the 3α-hydroxyoctenyl formula-XXIX compound of that example with the 3β-hydroxyoctenyl formula-XXIX compound obtained following Example 9, there is obtained the corresponding C-15 epimer of the title compound, namely 8β,9β,12α,15β-PGF 2 , methyl ester, bis(tetrahydropyranyl) ether, having R f 0.45 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
EXAMPLE 11
8β,12α-PGE 2 , Methyl Ester (Formula XXXIV: M is ##STR106##
Q is n-pentyl, and R 12 is methyl).
Refer to Chart B. A solution of the 15α formula-XXX bis(tetrahydropyranyl) ether (Example 10, 1.0 g.) in 30 ml. of dichloromethane is added to previously cooled (0° C.) Collins reagent prepared from pyridine (2.6 g.) and chromium trioxide (1.7 g.) in 80 ml. of dichloromethane. The mixture is stirred at about 25° C. for 10 min. and filtered. The filtrate is concentrated to an oil. A solution of the oil in diethyl ether is washed with aqueous 0.2 M. sodium hydrogen sulfate, saturated aqueous sodium bicarbonate solution, and brine, dried over sodium sulfate, and concentrated to the bis(tetrahydropyranyl) ether of the title compound, an oil, 0.84 g., having R f 0.5 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
The above product is treated with 50 ml. of a solution of acetic acid, water, and tetrahydrofuran (20:10:3) at 40° C. for 3 hrs., cooled to 25° C., diluted with 70 ml. of water, and freeze-dried to the title compound, an oil, 0.74 g. Silica gel chromatography, taking 25 ml. fractions and eluting with 500 ml. of 20% acetone in dichloromethane, and 1000 ml. of 30% acetone in dichloromethane yields the title compound in fractions 21-26, an oil, 0.5 g., having mass spectral peaks (for the trimethylsilyl derivative) at 495, 492, 479, 420, and 349; and NMR peaks at 5.83-5.60, 5.50-5.20, 4.49-3.95, 3.67, and 2.98-0.67 δ.
There is also obtained, in fractions 8-10, 8β,12α-PGA 2 methyl ester, an oil, 0.06 g., having mass spectral peaks (for the trimethylsilyl derivative) at 420, 405, 389, 349, and 330.
Following the procedure of Example 11, but replacing the 15α formula-XXX compound of that example with the 15β formula-XXX compound obtained following Example 10, there is obtained 8β,12α,15β-PGE 2 , methyl ester, having mass spectral peaks (for the trimethylsilyl derivative) at 510, 495, 492, 439, 420, and 349; NMR peaks at 5.82-5.69, 5.52-5.24, 4.49-4.00, 3.68 (singlet), and 2.75-0.73 δ: and R f 0.4 (TLC on silica gel in 30% acetone-dichloromethane).
There is also obtained, as a fraction in silica gel chromatography, 8β,12α,15β-PGA 2 , methyl ester, having mass spectral peaks at 420, 405, 389, 349, and 330, and TLC R f 0.4 on silica gel in 10% acetone-dichloromethane.
EXAMPLE 12
8β,9α,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR107##
Q is n-pentyl, R 12 is methyl, and ˜ is alpha) and 8β,9β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR108##
Q is n-pentyl, R 12 is methyl, and ˜ is beta).
Refer to Chart B. A solution of the 15α formula-XXXIV PGE 2 analog (Example 11, 0.2 g.) in 12 ml. of methanol is added, with stirring, to a slurry of sodium borohydride (0.03 g.) in 12 ml. of methanol at -15° C. under nitrogen and stirred for one hr. There is then added 10 ml. of acetic acid, dropwise, and the mixture is concentrated. The residue is triturated with ethyl acetate, separated, and the organic solution concentrated to an oil. Silica gel chromatography, eluting with 10% methanol in chloroform (saturated with boric acid) and collecting 10 ml. fractions, yields in fractions 8-11 the 9α title compound, about 0.11 g.; in fractions 12-15 the 9β title compound. Further processing of the 9α material by silica gel chromatography, eluting with 15-50% acetone in dichloromethane yields an analytical sample of the 9α title compound, an oil, 0.06 g., having mass spectral peaks (for the trimethylsilyl derivative) at 569, 553, 541, 513, 494, and 404; and NMR peaks at 5.84-5.37, 4.27-3.87, 3.67 (singlet), and 2.70-0.73 δ.
Following the procedure of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the 15β formula-XXXIV compound obtained following Example 11, there is obtained 8β,9α,12α,15β-PGF 2 , methyl ester, having mass spectral peaks at 584, 569, 553, 541, 513, 494, and 404. Likewise there is obtained 8β,9β,12α-15β-PGF 2 , methyl ester, having the same properties as the product following Example 13.
Example 13
8β,9β,12α-PGF 2 , Methyl Ester (Formula XXXI: M is ##STR109##
Q is n-pentyl, and R 12 is methyl).
Refer to Chart B. The 15α formula-XXX bis(tetrahydropyranyl) ether (Example 10, 0.46 g.) is treated with 28 ml. of a solution of acetic acid, water, and tetrahydrofuran (20:10:3) at 40° C. for 3 hrs., cooled, and freeze-dried to the title compound, an oil, 0.34 g. Silica gel chromatography, taking 20 ml. fractions and eluting with 250 ml. of 50 % acetone in dichloromethane yields, from fractions 4-6, an analytical sample of the title compound, an oil, 0.21 g., having mass spectral peaks (for the trimethylsilyl derivative) at 569, 553, 541, 513, 494, and 404; and having NMR peaks at 5.75-5.30, 4.47-3.95, 3.67, and 2.70-0.73 δ.
Following the procedure of Example 13, but replacing the 15α formula-XXX compound of that example with the 15β formula-XXX compound obtained following Example 12, there is obtained 8β,9β,12α,15β-PGF 2 , methyl ester, having mass spectral peaks at 584, 569, 553, 541, 513, 494, and 404; and NMR peaks at 5.75-5.30, 4.49-3.97, 3.68 (singlet), 2.53-0.72 δ.
EXAMPLE 14
3β-Benzoyloxy-5β-hydroxy-2α-methoxymethyl-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXXVI: R 1 is methyl and R 3 is benzoyl).
A. Refer to Charts A and C. A solution of the formula-XIX iodo lactone (Example 1A, 18 g.) in 30 ml. of pyridine at 25° C. is mixed, while stirring, with 7.5 ml. of benzoyl chloride added dropwise and stirring is continued for 1 hr. The mixture is diluted with 60 ml. of toluene and concentrated to an oily residue. The residue is partitioned between ethyl acetate and 10% sulfuric acid. The organic phase is washed with saturated sodium bicarbonate and brine, dried over sodium sulfate, and concentrated to yield 3β-benzoyloxy-5β-hydroxy-4-iodo-2α-methoxymethyl-1β-cyclopentaneacetic acid γ-lactone, 21.8 g. An analytical sample has m.p. 85°-89° C., mass spectral peaks at 416, 294, 289, 262, 167, and 105, and optical rotation [α] D -5° C. in chloroform.
B. A solution of the product of part A (16.8 g.) in 100 ml. of benzene at 25° C. is mixed, with stirring, with 2.5 ml. of 0.3 M. tributyltin hydride in diethyl ether, and stirred for an additional 0.5 hr. The solution is concentrated to an oily residue. The residue is partitioned between 200 ml. of water and 200 ml. of Skellysolve B. The aqueous phase is extracted first with Skellysolve B and then with ethyl acetate. The combined organic extracts are washed with brine, dried over sodium sulfate, and concentrated to the title compound, an oil, 11.2 g., having NMR peaks at 8.04-7.80, 7.54-7.14, 5.44-4.84, 3.35, 3.25, 3.03-1.95, and 1.38-0.86 δ.
EXAMPLE 15
3β-Benzoyloxy-5β-hydroxy-2α-hydroxymethyl-1β-cyclopentaneacetic Acid γ-Lactone (Formula XXXVII: R 3 is benzoyl).
Refer to Chart C. A solution of boron tribromide (175 g.) in 400 ml. of dichloromethane is added slowly to a stirred solution of the formula-XXXVI compound (Example 14, 101 g.) in 800 ml. of dichloromethane at 0° C. After 20 hrs. The reaction is quenched by careful addition of a solution of sodium carbonate (405 g. in 1050 ml. of water). The mixture is saturated with sodium chloride at about 25° C. and extracted with ethyl acetate. The organic phase is washed with brine, dried over sodium sulfate, and concentrated. The residue is recrystallized from dichloromethane-carbon tetrachloride, to yield the title compound, 85 g., m.p. 115°-116° C., having mass spectral peaks at 276, 154, and 136, optical rotation [α] D +81° in chloroform, and NMR peaks at 8.01-7.82, 7.54-7.14, 5.54-4.89, and 3.80-2.03 δ.
EXAMPLE 16
3β-Benzoyloxy-5β-hydroxy-2α-(3-oxo-trans-1-octenyl)- 1β-cyclopentaneacetic Acid γ-Lactone (Formula XXXIX: Q is n-pentyl and R 3 is benzoyl).
A. Refer to Chart C. There is first prepared the formula-XXXVIII aldehyde. A solution of the formula-XXXVII compound (Example 15, 30.5 g.) in 300 ml. of dichloromethane is added to Collins reagent (prepared from 107 g. of pyridine and 84 g. of anhydrous chromium trioxide in 1500 ml. of dichloromethane), with stirring at 0° C. After 5 min. at 0° C. and another 5 min. at about 25° C., the solution is decanted from the solids and used in step B below.
B. The ylide is prepared from a mixture of sodium hydride (10.6 g., 50%) and dimethyl 2-oxoheptylphosphonate (48.8 g.) in 1600 ml. of tetrahydrofuran at 0° C. To the cold ylide solution is added the solution of the formula-XXXVIII aldehyde from step A and the mixture is stirred at about 25° C. for 4 hrs. The reaction mixture is added to a mixture of 2000 ml. of 2 M. sodium hydrogen sulfate and ice, then extracted with chloroform. The organic phase is washed with saturated sodium bicarbonate solution and brine, dried over sodium sulfate, and concentrated to an oily residue. The residue is taken up in diethyl ether and subjected to silica gel chromatography, eluting with 10% and 50% ethyl acetate in Skellysolve B. Concentration under reduced pressure yields the title compound, 26.2 g., as an oil which slowly crystallizes. An analytical sample, recrystallized from hexane-ethyl acetate, has m.p. 60°-62° C., and NMR peaks at 8.11-7.84, 7.62-7.20, 6.95-6.50, 6.17, 5.46-4.92, 3.52, and 3.10-0.62 β.
EXAMPLE 17
3β-Benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula XL: M is ##STR110##
Q is n-pentyl, and R 3 is benzoyl) and 3α-Benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula XL: M is ##STR111##
and Q and R are as defined above).
Refer to Chart C. The formula-XXXIX compound (Example 16, 33.6 g.) in 250 ml. of methanol is added to a stirred mixture of sodium borohydride (5.30 g.) in 500 ml. of methanol at -20° C. under nitrogen. After 2 hrs., 250 ml. of acetic acid is added slowly at -20° C., and the solution is warmed to 25° C. and concentrated. The residue is partitioned between ethyl acetate and 0.2 M. sulfuric acid. The organic phase is washed with saturated aqueous sodium bicarbonate and brine, dried over sodium sulfate, and concentrated to a mixture of the title compounds, an oil, 41.6 g. Silica gel chromatography yields the separate title compounds; the 3α-hydroxy compound, m.p. 76.1°-76.9° C., having mass spectral peaks at 345, 301, and 250, and optical rotation [α] D +98° (chloroform); and the 3β-hydroxy compound, m.p. 69.0-70.1° C., having mass spectral peaks at 314, 301, and 250, and optical rotation [α] D +77° (chloroform).
EXAMPLE 18
3β,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl) -1β-cyclopentaneacetic Acid γ-Lactone (Formula XLI: M is ##STR112##
Q is n-pentyl, and R 8 is hydrogen).
Refer to Chart C. The formula-XL compound (Example 17, 10.2 g.) is stirred with potassium carbonate (5.62 g.) in 100 ml. of methanol at about 25° C. for 2 hrs. The mixture is filtered through silica gel and concentrated to an oil. The oil is partitioned between brine and ethyl acetate. The organic phase is dried over sodium sulfate and concentrated to a residual oil. The brine extract also yields an oil on acidification (2 M. sulfuric acid), extraction with ethyl acetate, and concentration. The combined oils are treated with pyridine hydrochloride (0.1 g.) in 250 ml. of ethyl acetate at reflux for one hour, filtered, and concentrated to the title compound, an oil, 6.9 g., having NMR peaks at 5.68-5.50, 5.13-4.76, 4.25-3.80, 3.70-3.08, and 2.97-0.67 δ.
Following the procedure of Example 18 but replacing the 3α-hydroxyoctenyl formula-XL compound of that example with the 3β-hydroxyoctenyl compound following Example 17, there is obtained the corresponding formula-XLI compound, namely 3β,5β-dihydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic acid γ-lactone, having NMR peaks at 5.65-5.43, 5.07-4.74, 4.25-3.76, 3.54-3.28, and 2.92-0.50 δ.
EXAMPLE 19
3β,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl) -1β-cyclopentaneacetic Acid γ-Lactone, bis(tetrahydropyranyl) Ether (Formula XLI: M' is ##STR113##
Q is n-pentyl, and R 8 is THP).
Refer to Chart C. A solution of the formula-XLI compound (Example 18, 0.66 g.) in 20 ml. of dichloromethane, together with dihydropyran (2.5 g.) and pyridine (0.075 g.) is stirred at about 25° C. for 24 hrs. The mixture is filtered through silica gel and concentrated to an oil, 1.2 g. Silica gel chromatography yields the title compound, an oil, 0.67 g., having R f 0.5 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Following the procedure of Example 19 but replacing the 3α-hydroxyoctenyl formula-XLI compound with the corresponding 3β-hydroxyoctenyl compound following Example 18, there is obtained 3β,5β-dihydroxy-2α-(3β-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic acid γ-lactone, bis(tetra-hydropyranyl) ether, having R f 0.5 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
EXAMPLE 20
3β,5β-Dihydroxy-2α-(3α-hydroxy-trans-1-octenyl)-1.beta.-cyclopentaneacetic Acid γ-Lactol, Bis(tetrahydropyranyl), Ether (Formula XLII: M' is ##STR114##
Q is n-pentyl, and R 8 is THP).
Refer to Chart C. A solution of the formula-XLI compound (Example 19, 0.67 g.) in 20 ml. of toluene is treated, while stirring at -78° C. under nitrogen, with 5 ml. of 10% diisobutylaluminum hydride in toluene. After one hr. there is slowly added to the cold mixture 24 ml. of tetrahydrofuran-water (2:1) solution. The organic phase is filtered, washed with brine, dried over sodium sulfate, and concentrated to the title compound, an oil, 0.67 g., having TLC R f 0.3 on silica gel in 50% ethyl acetate-Skellysolve B.
Following the procedure of Example 20 but replacing the 3α-hydroxyoctenyl formula-XLI compound of that example with the corresponding 3β-hydroxyoctenyl compound following Example 19 there is obtained 3β,5β-dihydroxy--(:(3β-hydroxy-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactol, bis(tetrahydropyranyl) ether, an oil, having R f 0.3 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
EXAMPLE 21
8β,9β,11β,12α-PGF 2 , Methyl Ester, Bis(tetra-hydropyranyl) Ether (Formula XLIII: M' is ##STR115##
Q is n-pentyl, R 10 is THP, and R 12 is methyl).
Refer to Chart C. Following the procedure of Example 10, the Wittig ylide prepared from 4-carboxybutyltriphenylphosphonium bromide is reacted with the 3α-hydroxyoctenyl formula-XLII compound (Example 20, 10.7 g.). Thereafter, following the procedure of Example 10, the title compound is obtained, an oil, 0.55 g., having R f 0.6 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Likewise following the procedure of Example 10, but employing the 3β-hydroxyoctenyl formula-XLII compound following Example 20 (18.2 g.), there is obtained the corresponding C-15 epimer of the title compound, namely 8β,9β,11β,12α,15β-PGF 2 , methyl ester, bis(tetrahydropyranyl) ether, an oil, 12.5 g., having R f 0.5 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
EXAMPLE 22
8β,11β,12α-PGE 2 , Methyl Ester (Formula XLVI: M'" is ##STR116##
Q is n-pentyl, R 8 is hydrogen, and R 12 is methyl).
Refer to Chart C. Following the procedures of Example 11, the 15α formula-XLIII PGF 2 -type compound (Example 21, 0.55 g.) is treated with Collins reagent to yield the corresponding bis(tetrahydropyranyl) ether of the title compound, an oil, 0.50 g., having R f 0.6 (TLC on silica gel in 50% ethyl acetate-Skellysolve B).
Following the procedures of Example 11, the above product is treated with acetic acid-water-tetrahydrofuran to yield the title compound, an oil, 0.17 g. having mass spectral peaks at 495, 479, 439, 420, and 349; NMR peaks at 5.77-5.60, 5.50-5.26, 4.32-3.87, 3.67 (singlet), and 3.05- 0.61 δ; and optical rotation [α] D +67° (in tetrahydrofuran).
As in Example 11, there is also obtained the PGA 2 analog, namely 8β,12α,15α-PGA 2 methyl ester.
Likewise following the procedures of Example 11, but employing the 15β formula-XLIII PGF 2 -type compound (Example 21, 12.5 g.) there are obtained the corresponding C-15 epimers of the above compounds, namely: 8β,11β,12α,15β-PGE 2 , methyl ester, bis(tetrahydropyranyl) ether, having R f 0.6 (TLC on silica gel in 50% ethyl acetate-Skellysolve B). 8β,11β,12α,15β-PGE 2 , methyl ester, having mass spectral peaks at 495, 492, 439, 420, and 349, NMR peaks at 5.72- 5.37, 4.32-3.83, 3.68 (singlet), and 2.75-0.69 δ, and optical rotation [α] D +55° (in tetrahydrofuran); and 8β,12α,15β-PGA 2 , methyl ester.
EXAMPLE 23
8β,9α,11β,12α-PGF 2 , Methyl Ester (Formula LIV: M is ##STR117##
Q is n-pentyl, R 12 is methyl, and ˜ is alpha) and 8β,9β,11β,12α-PGF 2 , Methyl Ester (Formula LIV: M is ##STR118##
Q is n-pentyl, R 12 is methyl, and ˜ is beta).
Refer to Chart D. Following the procedures of Example 12, the 15α formula-LIII 8β,11β,12α-PGE 2 , methyl ester (Example 22, 0.12 g.) is reduced with sodium borohydride, yielding the title compounds. The 9α title compound is the more polar material, an oil, 0.021 g., having mass spectral peaks at 569, 553, 541, 513, and 494. The 9β title compound is an oil, having mass spectral peaks at 569, 553, 541, 513, and 494; NMR peaks at 6.10-5.32, 4.32-3.81, 3.67 (singlet), and 2.60-0.76 δ; and optical rotation [α] D -9° (in tetrahydrofuran).
Likewise following the procedures of Example 12, but employing the 15β formula-LIII compound, namely 8β,11β,12α, -15β-PGE 2 , methyl ester (Example 22, 1.0 g.) the corresponding C-15 epimers of the above compounds are obtained, namely: 8β,9α,11β,12α,15β-PGF 2 , methyl ester, m.p. 90°-91° C., having mass spectral peaks at 569, 553, 541, 503, 494, 479, 463, and 457; NMR peaks at 5.64-5.34, 4.17-3.78, 3.67 (singlet), and 3.00-0.45 δ; and optical rotation [α] D +7° (in ethanol); and 8β,9β,11β,12α,15β-PGF 2 , methyl ester, identical with the 15β product of Example 24.
Example 24
8β,9β,11β,12α-PGF 2 , Methyl Ester (Formula LIV: M is ##STR119##
Q is n-pentyl, R 12 is methyl, and ˜ is beta).
Following the procedure of Example 12, the 15α formula-XLIII 8β,9β,11β,12α-PGF 2 , methyl ester, bis(tetrahydropyranyl) ether (Example 21, 0.11 g.) is treated in acetic acid-water-tetrahydrofuran to yield the title compound having the same properties as the 15α product of Example 23.
Likewise following the procedure of Example 13, but employing the 15β formula-XLIII compound, namely 8β,9β,11β,-12α,15β-PGF 2 , methyl ester, bis(tetrahydropyranyl) ether following Example 21, there is obtained the corresponding C-15 epimer of the title compound, namely 8β,9β,11β,12α, 15β-PGF 2 , methyl ester, an oil, having mass spectral peaks at 569, 553, 541, 513, 423, and 404. NMR peaks at 5.64-5.26, 4.27-3.77, 3.67 (singlet), 3.34-2.86, and 2.53-0.67 δ; and optical rotation [α] D -24° (in ethanol).
EXAMPLE 25 3β-Benzoyloxy-5β-hydroxy-2α-(3-methyl-trans-1-octenyl)-1.beta.-cyclopentaneacetic Acid γ- Lactone (Formula XL: M is ##STR120##
Q is n-pentyl, and R 3 is benzoyl).
Refer to Chart C. A solution of the formula-XXXIX compound (Example 16, 0.20 g.) in 15 ml. of tetrahydrofuran is treated, while stirring at -78° C., with methyl magnesium bromide (3 M. solution in diethyl ether) added dropwise. After 2 hrs. stirring, 10 ml. of saturated aqueous ammonium chloride is added dropwise and the mixture is warmed to 25° C. The mixture is diluted with diethyl ether and water, equilibrated, and separated. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the title compounds, on oil.
EXAMPLE 26
3β,5β-Dihydroxy-2α-(3-methyl-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula XLI: M' is ##STR121##
Q is n-pentyl, and R 8 is hydrogen).
Refer to Chart C. A solution of the formula-XL compounds (Example 25, 0.50 g.) in 10 ml. of methanol is treated, while stirring at about 25° C. under nitrogen, with 1.0 ml. of a 25% solution of sodium methoxide in methanol. After 20 min., 2 ml. of acetic acid is added, and the mixture is concentrated under reduced pressure to an oil. The residue is dissolved in ethyl acetate and extracted with saturated aqueous sodium bicarbonate. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the title compounds, a yellow oil.
EXAMPLE 27
3β,5β-Dihydroxy-2α-(3-methyl-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactol (Formula XLII: M' is ##STR122##
Q is n-pentyl, and R 8 is hydrogen).
Refer to Chart C. A solution of the formula-XLI compounds (Example 26, 0.50 g.) in 15 ml. of tetrahydrofuran is treated, while stirring at -78° C. under nitrogen, with 12 ml. of 12% diisobutylaluminum hydride in toluene. Saturated aqueous ammonium chloride (15 ml.) is added. The reaction mixture is warmed to 25° C., shaken with ethyl acetate and water, and filtered. The filtrate is equilibrated with brine and ethyl acetate. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the title compounds, an oil.
EXAMPLE 28
Mixed 15-Epimers of 15-Methyl-8β,9β,11β,12α-PGF 2 , Methyl Ester (Formula XLIII: M'" Is ##STR123##
Q is n-pentyl, R 10 is hydrogen, and R 12 is methyl).
Refer to Chart C. The formula-XLII compounds (Example 27, 0.51 g. are added to a Wittig reagent prepared from 4-carboxybutyl triphenylphosphonium bromide (2.4 g.) and sodio dimethylsulfinylcarbanide (from 0.52 g. of 50% sodium hydride and 15 ml. of dimethylsulfoxide). The reaction mixture is stirred at about 25° C. for 16 hrs., and then added to a mixture of 0.2 M. sodium bisulfate in ice water and diethyl ether, whereby the resulting pH is about 1.0. After equilibration, the aqueous phase is extracted with diethyl ether. The organic extracts are combined, washed with 1 N. sodium hydroxide and water. The aqueous washings are combined and acidified to pH less than 3.0 with 2 M. sodium bisulfate. The mixture is extracted with diethyl ether, and the organic phase is washed with water, dried over sodium sulfate, and concentrated to the free acids corresponding to the title compounds (wherein R 12 is hydrogen), an oil.
The above product is dissolved in ether, dichloromethane, and methanol, and treated with excess ethereal diazomethane to give the title compounds, an oil.
EXAMPLE 29
15-Methyl-8β,9β,11β,12α-PGF 2 , Methyl Ester (Formula-XLIV: M'" is ##STR124## CL Q is n-pentyl, R 9 is hydrogen, and R 11 is methyl) and its C-15 epimer, 15-Methyl-8β,9β,11β ,12α,15β-PGF 2 , Methyl Ester.
The formula-XLIII mixed C-15 epimers of Example 28 are subjected to silica gel chromatography, eluting with 30% acetone in dichloromethane. The less polar compound is the 15α isomer, obtained by combining the early (less polar) fractions. The 15β title compound is obtained by combining the later fractions.
The 15α isomer has mass spectral peaks at 583, 527, 508, 437, and 418; NMR peaks at 5.7-5.2, 4.35-3.80, 3.70 (singlet), 1.28 (singlet), and 2.6-0.7 δ; optical rotation [α] D -29° (in ethanol).
The 15β isomer has mass spectral peaks at 583, 528, 508, 437, and 418; NMR peaks at 5.7-5.2, 4.35-3.80, 3.70 (singlet), 1.28 (singlet), and 2.6-0.7 δ; optical rotation [α] D -25° (in ethanol).
EXAMPLE 30
15-Methyl-8β,11β,12α-PGE 2 , Methyl Ester (Formula-XLVI: M'" is ##STR125##
Q is n-pentyl, R 9 is hydrogen, and R 11 is methyl).
A. Refer to Chart C. The formula-XLIV 15-methyl-8β ,9β,11β,12α-PGF 2 , methyl ester, 11-trimethylsilyl ether is first prepared. A solution of the formula-XLIV 15-methyl-8β,9β,11β,12α-PGF 2 , methyl ester (Example 29, 0.50 g.) in 20 ml. of acetone is treated, while stirring at -45° C. under nitrogen, dropwise with 2.0 ml. of N-trimethylsilyl-diethylamine. After one hour at -45° C., the solution is diluted with 80 ml. of diethyl ether and partitioned with 5% aqueous sodium bicarbonate. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the 11-trimethylsilyl ether.
B. The product of step A (0.61 g.) in 15 ml. of dichloromethane is added to Collins reagent at 0° C. (previously prepared from 1.0 g. of chromium trioxide, 1.6 g. pyridine, and 50 ml. of dichloromethane). The mixture is stirred for 10 min., then decanted and filtered. The filtrate is concentrated under reduced pressure to the formula-XLV 15-methyl-8β,11β,12α-PGE 2 , methyl ester, 11-trimethylsilyl ether.
C. The product of step B (0.57 g.) in 30 ml. of methanol is treated, while stirring at about 25° C., with a solution of 1.5 ml. of acetic acid in 15 ml. of water. After the mixture is homogeneous, it is partitioned between diethyl ether and 0.2 M. sodium hydrogen sulfate. The organic phase is washed with saturated aqueous sodium bicarbonate and brine, dried over sodium sulfate, and concentrated. The residue is subjected to silica gel chromatography to obtained the title compound, having mass spectral peaks at 519, 493, 453, 434, 363, and 344; NMR peaks at 5.7-5.2, 4.4-3.8, 3.68 (singlet), 1.28 (singlet) and 3.0- 0.7 δ; and optical rotation [α] D +78° (in chloroform).
Following the procedures of Example 30, but replacing the formula-XLIV 15-methyl-8β,9β,11β,12α-PGF 2 , methyl ester with the formula-XLIV 15-methyl-8β,9β,11β,12α,15β-PGF 2 , methyl ester (Example 29), there are obtained, respectively:
15-methyl-8β,9β,11β,12α,15β-PGF 2 , methyl ester, 11-trimethylsilyl ether,
15-methyl-8β,11β,12α,15β-PGE 2 , methyl ester, 11-trimethylsilyl ether, and
15-methyl-8β,11β,12α,15 β-PGE 2 , methyl ester.
The last-named compound has a mass spectral peak at 524.3326 for the silylated derivative; NMR peaks at 5.7-5.2, 4.4-3.8, 3.67 (singlet), 1.29 (singlet), and 3.0-0.7 δ; and optical rotation [α] D +77° (in chloroform).
EXAMPLE 31
15-Methyl-8β,9α,11β,12 α-PGF 2 , Methyl Ester. (Formula-LIV: M is ##STR126##
Q is n-pentyl, R 12 is methyl, and ˜ is alpha).
Refer to Chart D. The formula-LIII 15-methyl-8β,11β,12 α-PGE 2 , methyl ester (Example 30, 0.12 g.) is added to a stirred mixture of sodium borohydride (0.018 g.) in 6 ml. of methanol at -20° C. under nitrogen. After 30 min., 6 ml. of acetic acid is added, the mixture is warmed to about 25° C., and concentrated. The residue is dissolved in ethyl acetate and washed with 0.2 M. sulfuric acid. The organic phase is washed with saturated aqueous sodium bicarbonate and brine, dried over sodium sulfate, and concentrated. The mixed C-9 epimers are separated by silica gel chromatography, the less polar material being 15-methyl-8β,9β,11β,12 α-PGF 2 , methyl ester; the more polar material being the title compound (43% yield) having R f 0.13 (TLC on silica gel in 30% acetone in dichloromethane) and mass spectral peaks (for the trimethylsilyl derivative) at 583, 567, 527, 508, 493, 486, and 217.
Following the procedures of Example 31 but replacing the formula-LIII 15-methyl-8β,11β,12 α-PGE 2 , methyl ester with the formula-LIII 15-methyl-8β,11β,12α,15 β-PGE 2 , methyl ester following Example 30, there are obtained 15-methyl-8β,9β,11β,12α,15 β-PGF 2 , methyl ester, and 15-methyl-8β,9α,11β,12α,15 β-PGF 2 , methyl ester.
EXAMPLE 32
15-Methyl-8β,12 α-PGA 2 , Methyl Ester (Formula XLVII: M' is ##STR127##
Q is n-pentyl, and R 12 is methyl).
A. Refer to Chart C. There is first prepared 15-methyl-8β,11β,12 α-PGE 2 , 11-acetate, methyl ester. A solution of the formula-XLVI 15-methyl-8β,11β,12 α-PGE 2 , methyl ester (Example 30, 0.52 g.) in 52 ml. of pyridine is treated, while stirring at about 25° C. under nitrogen, with 5.4 ml. of acetic anhydride. After 5 hrs. stirring, the mixture is added to 500 ml. of 2 M. sodium hydrogen sulfate, ice, and ethyl acetate, and equilibrated. The organic phase is washed with saturated aqueous sodium bicarbonate and brine, dried over sodium sulfate, and concentrated to an oil, 0.68 g., having R f 0.34 (TLC on silica gel in 5% acetone-dichloromethane).
B. The 11-acetate from step A (0.68 g.) is stirred with potassium acetate (1.2 g.) in 45 ml. of methanol at about 25° C. After 18 hrs. the mixture is added to a mixture of saturated aqueous sodium bicarbonate and ethyl acetate, and equilibrated. The organic phase is washed with brine, dried over sodium sulfate, and concentrated to the title compound, an oil, 0.51 g., having R f 0.41 (TLC on silica gel in 5% acetone-dichloromethane); and NMR peaks at 7.6-7.4, 6.25-6.05, 5.6-5.3, 3.67 (singlet), 3.4-3.1, 1.27 (singlet), and 2.7-0.7 δ.
EXAMPLE 33
15-Methyl-8β,12 α-PGA 2 , 10,11-Epoxide, Methyl Ester (Formula XLVIII: M'" is ##STR128##
Q is n-pentyl, and R 20 is methyl).
Refer to Chart D. The formula-XLVII compound (Example 32, 0.18 g.) in 5 ml. of methanol is treated, while stirring at -25° C. under nitrogen, with a solution of 0.7 ml. of 30% aqueous hydrogen peroxide and 0.35 ml. of 1 N. sodium hydroxide. After 1 hour, there is added 2 N. hydrochloric acid dropwise to pH 5- 6. The mixture is diluted with brine and extracted with diethyl ether. The organic phase is washed with saturated aqueous sodium bicarbonate and brine, dried over sodium sulfate, and concentrated to the title compound, an oil.
EXAMPLE 34
15-Methyl-8β,12 α-PGE 2 , Methyl Ester (Formula L: M is ##STR129##
Q is n-pentyl, and R 12 is methyl) and 15-Methyl-8β,11β,12 α-PGE 2 , Methyl Ester (Formula L: M is ##STR130##
Q is n-pentyl, ˜ is beta, and R 12 is methyl).
Refer to Chart D. A mixture of the formula-XLVIII 15-methyl-8β,12 α-PGA 2 , 10,11-epoxide, methyl ester (Example 33, 0.20 g.), aluminum amalgam (Preparation 4, 0.16 g.), 8 ml. of diethyl ether, 1.6 ml. of methanol, and 4 drops of water is stirred at about 25° C. for 48 hrs. The mixture is filtered and the filtrate is concentrated to the mixed title compounds, an oil, 0.17 g. Separation by silica gel chromatography eluting with ethyl acetate-Skellysolve B yields the 11α compound as the less polar compound, and the 11β compound as the more polar compound. The 11α isomer has NMR peaks at 5.8-5.6, 5.5-5.2, 4.5-4.2, 3.67 (singlet), 1.30 (singlet), 3.0-0.7 δ.
EXAMPLE 35
15-Methyl-8β,12α,15 β-PGE 2 , Methyl Ester (Formula LI: M is ##STR131##
Q is n-pentyl, and R 12 is methyl) and 15-Methyl-8β,11β,12α,15 β-PGE 2 , Methyl Ester) Formula LIII: M is ##STR132##
Q is n-pentyl, and R 12 is methyl).
Refer to Charts C and D. Following the procedures of Example 32 but replacing the formula-XLVI 15-methyl-8β,11β,12 α-PGE 2 , methyl ester of that example with the formula-XLVI 15-methyl-8β,11β,12α,15β -PGE 2 , methyl ester following Example 30, there are obtained, respectively 15-methyl-8β,11β,12α,15β -PGE 2 , 11-acetate, methyl ester and 15-methyl-8β,12α,15 β-PGA 2 , methyl ester.
Following the procedure of Example 33 but employing the above PGA 2 analog, there is obtained the formula-XLVIII 15-methyl-8β,12α,15 β-PGA 2 , 10,11-epoxide, methyl ester.
Finally, following the procedure of Example 34, the above PGA 2 epoxide analog is transformed to the title compounds. The formula-LI (11α) compound (obtained in 23% yield) has R f 0.5 (TLC on silica gel in 30% acetone in dichloromethane; mass spectral peaks (for the trimethylsilyl derivative) at 537, 535, 493, 453, 434, 419, 363, 344, and 309; and NMR peaks at 5.84-5.60, 5.48-5.24, 4.50-4.24, 4.50-4.25, 3.68 (singlet) and 3.20-0.67 δ.
EXAMPLE 36
15-Methyl-8β,9α,12 α-PGF 2 , Methyl Ester (Formula LII: M is ##STR133##
Q is n-pentyl, and R 12 is methyl) and 15-Methyl-8β,9β,12 α-PGF 2 , Methyl ester (Formula LII: M is ##STR134##
Q is n-pentyl, and R 12 is methyl).
Refer to Chart D. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the formula-LI 15-methyl-8β,12 α-PGE 2 , methyl ester of Example 34, yields after silica gel chromatography the title compounds. The 9α compound (obtained in 39% yield) has R f 0.3 (TLC on boric acid-impregnated silica gel in chloroform-methanol-acetic acid (95-5- 1); mass spectral peaks (for the trimethylsilyl derivative) at 508, 455, 418, and 217; and NMR peaks at 5.82-5.35, 4.26-3.77, 3.68 (singlet), and 3.17-0.68. The 9β compound (obtained in 4% yield) has R f 0.1 (TLC on boric acid-impregnated silica gel in chloroform-methanol-acetic acid (95-5- 1)) and mass spectral peaks at 583, 567, 527, and 508.
Likewise following the procedures of Example 12 but employing the formula-LI 15-methyl-8β,12α,15 β-PGE 2 , methyl ester of Example 35, there are obtained 15-methyl-8β,9α,12α,15 β-PGF 2 , methyl ester, and 15-methyl-8β,9β,12α,15β -PGF 2 , methyl ester. The 9α compound (obtained in 68% yield) has R f 0.3 (TLC on boric acid-impregnated silica gel in chloroform-methanol-acetic acid (95-5- 1); mass spectral peaks (for the trimethylsilyl derivative) at 583, 527, 508, 455, and 418; infrared absorption at 3400, 2950, 1740, 1413, 1210, 1083, 976, and 758 cm.sup. -1 ; and NMR peaks at 5.80-5.10, 4.14- 3.80, 3.68 (singlet), 3.16 (singlet), and 2.57-0.62 δ.
EXAMPLE 37
16-Methyl-8β,12 α-PGE 2 , Methyl Ester (Formula XXXIV: M is ##STR135##
Q is --CH(CH 3 )--(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Charts A and B. Following the procedures of Examples 5 and 6, but replacing the ylide of Example 5 with the ylide prepared from dimethyl 2-oxo-3-methylheptylphosphonate (Preparation 1), there are obtained the corresponding formula-XXV compounds, 3α-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-4-methyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone and 3α-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-4-methyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedures of Examples 7-11, inclusive, the above 3α-hydroxy-4-methyloctenyl intermediates are transformed to the above title compounds.
Likewise following the procedures of Example 7-11, inclusive, but employing the 3β-hydroxy-4-methyloctenyl intermediates above, there are obtained the corresponding C-15 epimers, namely 16-methyl-8β,12α,15 β-PGE 2 , methyl ester.
EXAMPLE 38
16-Methyl-8β,9α,12 α -PGF 2 , Methyl Ester (Formula XXXV: M is ##STR136##
Q is --CH(CH 3 )--(CH 2 ) 3 --CH 3 , and R 12 is methyl) and 16-Methyl-8β,9β,12 α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR137##
Q is --CH(CH 3 )--(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Chart B. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the product of Example 37, namely 16-methyl-8β,12 α-PGE 2 , methyl ester, the above title compounds are obtained.
Likewise following the procedures of Example 12, but employing the 15β analog, namely 16-methyl-8β,12α,15 β-PGE 2 , methyl ester obtained following Example 37, there are obtained the corresponding C-15 epimers, namely 16-methyl-8β,9α,12α,15 β-PGF 2 , methyl ester, and 16-methyl-8β,9β,12α,15β -PGF 2 , methyl ester.
EXAMPLE 39
16-Methyl-8β,11β,12 α-PGE 2 , Methyl Ester (Formula XLVI: M'" is ##STR138##
Q is CH(CH 3 )--(CH 2 ) 3 --CH 3 , R 8 is hydrogen, and R 12 is methyl).
Refer to Charts A and C. Following the procedures of Example 16 and 17, but replacing the ylide of Example 16 with the ylide prepared from dimethyl 2-oxo-3-methylheptylphosphonate (Preparation 1), there are obtained the corresponding formula-XL compounds, 3β-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-4-methyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone and 3β-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-4-methyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedures of Examples 18-22, inclusive, the above 3α-hydroxy-4-methyloctenyl intermediates are transformed to the above title compounds.
Likewise following the procedures of Examples 18-22, inclusive, but employing the 3β-hydroxy-4-methyloctenyl intermediates above, there are obtained the corresponding C-15 epimers, namely 16-methyl-8β ,11β ,12α ,15β -PGE 2 , methyl ester.
EXAMPLE 40
16-Methyl-8β,9α,11β ,12α-PGF 2 , Methyl Ester (Formula LIV: M is ##STR139##
Q is --CH(CH 3 )--(CH 2 ) 3 --CH 3 , and R 12 is methyl) and 16-Methyl-8β,9β,11β,12 α-PGF 2 , Methyl Ester (Formula LIV: M is ##STR140##
Q is --CH(CH 3 )--(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Chart D. Following the procedures of Example 12, the 15α formula-LIII 16-methyl-8β,11β,12 α-PGE 2 , methyl ester of Example 39 is reduced with sodium borohydride to the title compounds, which are separated by silica gel chromatrography.
Likewise following the procedures of Example 12, but employing the 15β formula-LIII 16-methyl-8β,11β,12α,15 β-PGE 2 , methyl ester following Example 39, there are obtained the corresponding C-15 epimers, namely 16-methyl-8β,9α,11β,12α,15 β-PGF 2 , methyl ester, and 16-methyl-8β,9β,11β,12α,15 β -PGF 2 , methyl ester.
EXAMPLE 41
16,16-Dimethyl-8β,12 α-PGE 2 , Methyl Ester (Formula XXXIV: M is ##STR141##
Q is --CH(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Charts A and B. Following the procedures of Examples 5 and 6, but replacing the ylide of Example 5 with the ylide prepared from dimethyl 2-oxo-3,3-dimethylheptylphosphonate (Preparation 2), there are obtained the corresponding formula-XXV compounds, 3α-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-4,4-dimethyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone and 3α-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-4,4-dimethyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedures of Examples 7-11, inclusive, the above 3α-hydroxy-4,4-dimethyloctenyl) intermediate is transformed to the above title compound (42% yield) having R f 0.5 in ethyl acetate; mass spectral peaks (for the trimethylsilyl derivative) at 583, 523, 507, 439, 349, and 295; and NMR peaks at 5.88- 5.19, 4.50-4.29, 3.98-3.85, 3.67 (singlet), 3.10-2.85, 2.70-0.70, 1.25 (singlet) and 0.88 (singlet) δ.
Likewise following the procedures of Examples 7-11, inclusive, but employing the 3β-hydroxy-4,4-dimethyloctenyl intermediate above, there is obtained the corresponding C-15 epimer, namely 16,16-dimethyl-8β,12α,15 β-PGE 2 , methyl ester (56% yield) having R f 0.4 in ethyl acetate; mass spectral peaks (for the trimethylsilyl derivative) at 537, 523, 507, 439, 349, and 295; and NMR peaks at 5.87-5.70, 5.53-5.24, 4.48-4.28, 3.98-3.77, 3.67 (single), 3.30-0.71, 1.25 (singlet) and 0.90 (singlet) δ.
EXAMPLE 43
16,16-Dimethyl-8β,9α,12 α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR142##
Q is --C(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , and R 12 is methyl) and 16,16-Dimethyl-8β,9β,12 α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR143##
Q is --C(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Chart B. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the product of Example 41, namely 16,16-dimethyl-8β,12 α-PGE 2 , methyl ester, the above title compounds are obtained. The 9α compound (obtained in 62% yield) has R f 0.3 (TLC on silica gel in ethyl acetate); mass spectral peaks (for the trimethylsilyl derivative) at 611, 597, 581, 555, 522, 513, 507, 491, 423, 397, 333, 307, and 217; and NMR peaks at 5.86- 5.30, 4.24-3.75, 3.67 (singlet), 3.17 (singlet), 2.50-0.37, 1.25 (singlet), and 0.90 (singlet). Following the procedures of Example 13, the 9β compound is obtained in 69% yield, having R f 0.3 (TLC on silica gel in ethyl acetate); mass spectral peaks (for trimethylsilyl derivative) at 597, 581, 522, 513, 423, 397, 333, 307, and 217; and NMR peaks at 5.50-5.26, 4.47-3.77, 3.67 (singlet), 2.71-0.63, 1.25 (singlet) and 0.88 (singlet) δ.
Likewise following the procedures of Example 12, but employing the 15β analog, namely 16,16-dimethyl-8β,12α,15 β-PGE 2 , methyl ester, obtained following Example 41, there are obtained the corresponding C-15 epimers, namely 16,16-dimethyl-8β,9α,12α,15 β-PGF 2 , methyl ester, and 16,16-dimethyl-8β,9β,12α,15 β-PGF 2 , methyl ester. The 9α compound (obtained in 73% yield) has R f 0.2 (TLC on silica gel in ethyl acetate); mass spectral peaks (for the trimethylsilyl derivative) at 611, 597, 581, 555, 522, 513, 507, 491, 423, 397, 333, 307, and 217; and NMR peaks at 611, 597, 581, 555, 522, 513, 507, 491, 423, 397, 333, 307, and 217 δ. Following the procedure of Example 13, the 9β compound is obtained in 91% yield, having m.p. 41°-42.8° C. (from diethyl ether-hexane); R f 0.2 (TLC on silica gel in ethyl acetate); mass spectral peaks (for trimethylsilyl derivative) 597, 581, 555, 522, 513, 423, 397, 333, 307, and 217; and NMR peaks at 5.50-5.27, 4.52-3.57, 3.67 (singlet), 3.01-0.63, 1.25 (singlet), and 0.90 (singlet) δ.
EXAMPLE 43
16,16-Dimethyl-8β,11β ,12α-PGE 2 , Methyl Ester (Formula XLVI: M'" is ##STR144##
Q is --C(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , R 8 is hydrogen, and R 12 is methyl).
Refer to Charts A and C. Following the procedures of Examples 16 and 17, but replacing the ylide of Example 16 with the ylide prepared from dimethyl 2-oxo-3,3-dimethylheptylphosphonate (Preparation 2), there are obtained the corresponding formula-XL compounds, 3β-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-4,4-dimethyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone and 3β-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-4,4-dimethyl-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedures of Examples 18-22, inclusive, the above 3α-hydroxy-4,4-dimethyloctenyl intermediate is transformed to the above title compound.
Likewise following the procedures of Examples 18-22, inclusive, but employing the 3β-hydroxy-4,4-dimethyloctenyl intermediate above, there is obtained the corresponding C-15 epimer, namely 16,16-dimethyl-8β,11β,12α,15β-PGE 2 , methyl ester.
EXAMPLE 44
16,16-Dimethyl-8β,9α,11β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR145##
Q is --C(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , and R 12 is methyl) and 16,16-Dimethyl-8β,9β,11β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR146##
Q is --C(CH 3 ) 2 --(CH 2 ) 3 --CH 3 , and R 12 is methyl).
Refer to Chart B. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the product of Example 43, namely 16,16-dimethyl-8β,11β,12α-PGE 2 , methyl ester, the above title compounds are obtained.
Likewise following the procedures of Example 12, but employing the 15β analog, namely 16,16-dimethyl-8β,11β,12α,-15β-PGE 2 , methyl ester, obtained following Example 43, there are obtained the corresponding C-15 epimers, namely 16,16-dimethyl-8β,9α,11β,12α,15β-PGF 2 , methyl ester, and 16,16-dimethyl-8β,9β,11β,12α,15β-PGF 2 , methyl ester.
EXAMPLE 45
17-Phenyl-18,19,20-trinor-8β,12α-PGE 2 , Methyl Ester (Formula XXXIV: M is ##STR147##
Q is ##STR148##
and R 12 is methyl).
Refer to Charts A and B. Following the procedures of Examples 5 and 6, but replacing the ylide of Example 5 with the ylide prepared from dimethyl 2-oxo-4-phenylbutylphosphonate (Preparation 3), there are obtained the corresponding formula-XXV compounds, 3α-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-5-phenyl-trans-1-pentenyl)-1β-cyclopentaneacetic acid γ-lactone and 3α-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-5-phenyl-trans-1-pentenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedure of Examples 7-11, inclusive, the above 3α-hydroxy-5-phenylpentenyl intermediate is transformed to the above title compound (76% yield) having R f 0.5 (TLC on silica gel in ethyl acetate) and NMR peaks at 7.20 (singlet), 5.87-5.67, 5.48-5.20, 4.47-3.90, 3.63 (singlet), and 3.58-1.05 δ.
Likewise following the procedures of Examples 7-11, inclusive, but employing the 3β-hydroxy-5-phenylpentenyl intermediate above, there is obtained the corresponding C-15 epimer, namely 17-phenyl-18,19,20-trinor-8β,12α,15β-PGE 2 methyl ester.
EXAMPLE 46
17-Phenyl-18,19,20-trinor-8β,9α,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR149##
Q is ##STR150##
R 12 is methyl) and 17-Phenyl-18,19,20-trinor-8β,9β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR151##
Q is ##STR152##
R 12 is methyl).
Refer to Chart B. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the product of Example 45, namely 17-phenyl-18,19,20-trinor-8β,12α-PGE 2 , methyl ester, the above title compounds are obtained. The 9α compound (obtained in 62% yield) has R f 0.5 (TLC on silica gel in ethyl acetate) and NMR peaks at 7.2 (singlet), 5.87-5.67, 5.48-5.20, 4.47-3.90, 3.63 (singlet), and 3.58-1.05 δ. The 9β compound (obtained in 14% yield by the procedures of Example 12 and 93% yield by the procedures of Example 13) has R f 0.3 (TLC on silica gel in 30% acetone in dichloromethane) and NMR peaks at 7.23 (singlet), 5.80-5.23, 4.48-3.82, 3.65 (singlet), and 3.02-0.80 δ.
Likewise following the procedures of Example 12, but employing the 15β analog, namely 17-phenyl-18,19,20-trinor-8β,12α,15β-PGE 2 , methyl ester, obtained following Example 45, there are obtained the corresponding C-9 epimers, namely 17-phenyl-18,19,20-trinor-8β,9α,12α,15β-PGF 2 , methyl ester, and 17-phenyl-18,19,20-trinor-8β,9β,12α,15β-PGF 2 , methyl ester.
EXAMPLE 47
17-Phenyl-18,19,20-trinor-8β,11β,12α-PGE 2 , Methyl Ester (Formula XLVI:M'" is ##STR153##
Q is ##STR154##
R 8 is hydrogen, and R 12 is methyl).
Refer to Charts A and C. Following the procedures of Examples 16 and 17, but replacing the ylide of Example 16 with the ylide prepared from dimethyl 2-oxo-4-phenylbutylphosphonate (Preparation 3), there are obtained the corresponding formula-XL compounds, 3β-benzoyloxy-5β-hydroxy-2α-(3α-hydroxy-5-phenyl-trans-1-pentenyl)-1β-cyclopentaneacetic acid γ-lactone and 3β-benzoyloxy-5β-hydroxy-2α-(3β-hydroxy-5-phenyl-trans-1-pentenyl)-1β-cyclopentaneacetic acid γ-lactone.
Thereafter, following the procedures of Examples 18-22, inclusive, the above 3α-hydroxy-5-phenylpentenyl intermediate is transformed to the above title compound.
Likewise following the procedures of Examples 18-22, inclusive, but employing the 3β-hydroxy-5-phenylpentenyl intermediate above, there is obtained the corresponding C-15 epimer, namely 17-phenyl-18,19,20-trinor-8β,11β,12α,-15β-PGE.sub. 2, methyl ester.
EXAMPLE 48
17-Phenyl-18,19,20-trinor-8β,9α,11β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR155##
Q is ##STR156##
and R 12 is methyl) and 17-Phenyl-18,19,20-trinor-8β,9β,12α-PGF 2 , Methyl Ester (Formula XXXV: M is ##STR157##
Q is ##STR158##
and R 12 is methyl).
Refer to Chart B. Following the procedures of Example 12, but replacing the 15α formula-XXXIV PGE 2 analog of that example with the product of Example 47, namely 17-phenyl-18,19,20-trinor-8β,11β,12α-PGE 2 , methyl ester, the above title compounds are obtained.
Likewise following the procedures of Example 12, but employing the 15β analog, namely 17-phenyl-18,19,20-trinor-,11β,12α,15β-PGE 2 , methyl ester, obtained following Example 47, there are obtained the corresponding C-9 epimers, namely 17-phenyl-18,19,20-trinor-8β,9α,11β,12α,15 β-PGF 2 , methyl ester, and 17-phenyl-18,19,20-trinor-8β,9β,11β,12α,15β-PGF.sub.2, methyl ester.
EXAMPLE 49
3α-Benzoyloxy-5β-hydroxy-2α-(3α-methoxy-trans-1-octenyl)-1β-cyclopentaneacetic Acid γ-Lactone (Formula LVI: M'v is ##STR159##
Q is n-pentyl, and R 3 is benzoyl)
Refer to Chart E. A mixture of the formula-XXVI alpha hydroxy compound (Example 6, 2.0 g.), silver oxide (4.0 g.), and 50 ml. of methyl iodide is stirred and heated at reflux for 68 hr. The mixture is cooled and filtered, and the filtrate concentrated. The residue is subjected to silica gel chromatography to obtain the formula-LVI title compound.
Following the procedure of Example 49, but replacing the methyl iodide of that example with other alkyl halides, there are obtained the corresponding formula-LVI alkyl esters. Thus, with methyl bromide, ethyl chloride, isopropyl iodide, butyl bromide, or pentyl iodide, there are obtained the formula-LVI compound in which R 22 is methyl, ethyl, isopropyl, n-butyl or n-pentyl.
EXAMPLE 50
8β,9β,12α-PGF 2 , Methyl Ester, 15-Methyl Ether (Formula LXI: M'v is ##STR160##
Q is n-pentyl, and R 12 is methyl); and 8β,12α-PGE 2 , Methyl Ester, 15-Methyl Ether (Formula LXIV: M 1v is ##STR161##
Q is n-pentyl, and R 12 is methyl).
Refer to Chart E. Following the procedures of Example 7, 8, 9, 10, and 11, but starting with the formula-LVI 3α-methoxyoctenyl compound of Example 49, there are obtained the corresponding intermediates and products as follows:
3α,5β-dihydroxy-2α-methoxy-trans-1-octenyl)-1β-cyclopentaneacetic acid γ-lactone (formula LVII) and its tetrahydropyranyl ether (formula LVIII);
3α,5β-dihydroxy-2α-(3α-methoxy-trans-1-octenyl)-1.beta.-cyclopentaneacetaldehyde γ-lactol, tetrahydropyranyl ether (formula LIX;
8β,9β,12α-pgf 2 , methyl ester, 11-tetrahydropyranyl ether, 15-methyl ether (formula LX);
8β,12α-pge 2 , methyl ester, 11-tetrahydropyranyl ether, 15-methyl ether (formula LXIII);
and the title compounds.
EXAMPLE 51
15-Methyl-8β,11β,12α-PGE 2 (Formula LIII: M is ##STR162##
Q is n-pentyl, and R 12 is hydrogen).
There is first prepared an esterase composition from Plexaura homomalla, which see W. P. Schneider et al., J. Am. Chem. Soc. 94, 2122 (1972). Freshly harvested colony pieces of Plexaura homomalla (Esper), 1792, forma S (10 kg.), are chopped into pieces less than 3 mm. in their longest dimension, and then covered with about three volumes (20 l.) of acetone. The mixture is stirred at about 25° C. for about 1 hour. The solids are separated by filtration, washed with 1-2 liters of acetone, air dried, and finally stored at about -20° C. as a coarse enzymatic powder.
A suspension of the above powder (2.5 g.) in 25 ml. of water is combined with a solution of 15-methyl-8β,11β,-12α-PGE 2 , methyl ester (Example 30, 0.5 g.) in about 0.8 ml. of ethanol previously acidified to pH 6 with phosphoric acid. The mixture is stirred at about 25° C. for 24 hrs. Then, 50 ml. of acetone is added, the mixture is stirred briefly and filtered, and the filtrate is concentrated under reduced pressure. The aqueous residue is acidified to pH 3.5 with citric acid and extracted with dichloromethane. The combined extracts are concentrated under reduced pressure to the title compound.
Following the procedure of Example 51, but replacing the methyl ester of that example with the methyl esters of and following Examples 11, 12, and 13 there are obtained the corresponding free acids, namely
8β,12α-PGE 2
8β,12α,15β-pge 2
8β,12α-pga 2
8β,12α,15β-pga 2
8β,9α,12α-pgf 2
8β,9α,12α,15β-pgf 2
8β,9β,12α-pgf 2 and
8β,9β,12α,15β-PGF 2
Likewise, applying the procedure of Example 51 to the methyl esters of and following Examples 22, 23, 24, 29, 30, 31, and 34-50, inclusive, there are obtained the corresponding free acids.
EXAMPLE 52
8β,12α-PGE 2 , Ethyl Ester.
A solution of diazoethane (about 0.5 g.) in 25 ml. of diethyl ether (25 ml.) is added to a solution of 8β,12α-PGE 2 (following Example 51, 50 mg.) in 25 ml. of a mixture of methanol and diethyl ether (1:1). The mixture is allowed to stand at 25° C. for 5 min. Then, the mixture is concentrated to give the title compound.
Following the procedure of Example 52, each of the other 8β,12α-PGE 2 or -PGF 2 type free acids defined above is converted to the corresponding ethyl ester.
Also following the procedure of Example 52, but using in place of the diazoethane, diazobutane, 1-diazo-2-ethylhexane, and diazocyclohexane, there are obtained the corresponding butyl, 2-ethylhexyl, and cyclohexyl esters of 8β,12α,15α-PGE 2 . In the same manner, each of the other 8β,12α-PGE 2 or -PGF 2 type free acids defined above is converted to the corresponding butyl, 2-ethylhexyl, and cyclohexyl esters.
EXAMPLE 53
8β,12α-PGE 2 , Methyl Ester, Diacetate.
Acetic anhydride (5 ml.) and pyridine (5 ml.) are mixed with 8β,12α-PGE 2 , methyl ester (following Example 51, 20 mg.), and the mixture is allowed to stand at 25° C. for 18 hrs. The mixture is then cooled to 0° C., diluted with 50 ml. of water, and acidified with 5% hydrochloric acid to pH 1. That mixture is extracted with ethyl acetate. The extract is washed successively with 5% hydrochloric acid, 5% aqueous sodium bicarbonate solution, water, and brine, dried and concentrated to give the title compound.
Following the procedure of Example 53, but replacing the acetic anhydride with propionic anhydride, isobutyric anhydride, and hexanoic acid anhydride, there are obtained the corresponding dipropionate, diisobutyrate and dihexanoate derivatives of 8β,12α-PGE 2 , methyl ester.
Also following the procedure of Example 53, but replacing the 8β,12α-PGE 2 compound with 8β,9α,12α-PGF 2 and 8β,9β,12α-PGF 2 there are obtained the corresponding triacetate derivatives of the 8β,12α-PGF 2 compounds.
Also following the procedure of Example 53, each of the 8β,12α-PGE 2 or -PGF 2 type esters and free acids defined above is transformed to the corresponding acetates, propionates, isobutyrates, and hexanoates, the PGE-type derivatives being dicarboxyacylates, and the PGF-type derivatives being tricarboxyacylates.
EXAMPLE 54
8β,12α-PGE 2 Sodium Salt.
A solution of 8β,12α-PGE 2 (following Example 51, 100 mg.) in 50 ml. of a water-ethanol mixture (1:1) is cooled to 5° C. and neutralized with an equivalent amount of 0.1 N aqueous sodium hydroxide solution. The neutral solution is evaporated to give the title compound.
Following the procedure of Example 54 but using potassium hydroxide, calcium hydroxide, tetramethylammonium hydroxide, and benzyltrimethylammonium hydroxide in place of sodium hydroxide, there are obtained the corresponding salts of 8β,12α-PGE 2 .
Also following the procedure of Example 54 each of the 8β,12α-PGE-type or-PGF-type acids defined above is transformed to the sodium, potassium, calcium, tetramethylammonium, and benzyltrimethylammonium salts.
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This invention is a group of 8-β, 12-α-PG 2 (prostaglandin-type) analogs having variable chain length, or methyl or phenyl substitution in the hydroxy-substituted side-chain, and processes for making them. These compounds are useful for a variety of pharmacological purposes, including anti-ulcer, inhibition of platelet aggregation, increase of nasal patency, and labor inducement at term.
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This divisional application is related to U.S. patent application Ser. No. 09/507,855 filed Feb. 22, 2000, now U.S. Pat. No. 6,237,408, which is a divisional of U.S. patent application Ser. No. 09/104,507 filed on Jun. 25, 1998, now U.S. Pat. No. 6,026,682, which is a continuation-in-part of U.S. patent application Ser. No. 08/886,770 filed on Jul. 2, 1997, now U.S. Pat. No. 5,811,674, which is a continuation of U.S. patent application Ser. No. 08/557,835, filed Nov. 14, 1995, which is now abandoned.
TECHNICAL FIELD
This invention relates to automated welding apparatus, and more particularly to a device to detect coolant leakage and automatically shut off a coolant supply valve in response thereto.
BACKGROUND ART
Automated welding systems, either “hard” automated systems or robotic arms fitted with welding end-of-arm units, are now in common use in many types of manufacturing. The heat generated by automated welding systems is sufficiently great that a source of forced cooling is required. Typically, automated welding units are liquid-cooled, with coolant (typically water) being supplied from a source of pressurized coolant remote from the welding unit. In many installations, a large number of automated welding machines are plumbed to a common source of coolant liquid under pressure.
The typical coolant flow through an automated spot-welding gun, a common variant, is about six gallons per minute. Tie SCR weld control is typically supplied 1-2 gpm, the weld gun upper tip 1.5 gpm, weld gun lower tip 1.5 gpm, the shunts 1 gpm, and the cable 1.5 gpm. The usage of a liquid coolant with high-powered electrical equipment necessitates some sort of safety system to detect coolant leakage in the event of broken coolant lines or other failures in the coolant system. In addition, it is desirable to detect either excessive flow or insufficient flow conditions. An excessive flow condition can mean that coolant supply pressure has exceeded its design level or that a necessary restriction within the cooling system has been removed. Similarly, an insufficient flow condition can indicate a failure of the coolant supply or a general blockage of the coolant supply or return lines.
Present solutions to the requirement of sensing and monitoring coolant flow in automated welding arms have used complicated and expensive mechanical leakage detection devices. For example, a water control valve manufactured by Norco of Troy, Michigan relies on a complicated spool valve having opposed surfaces on opposite sides of the flow circuit to sense pressure imbalances. Numerous o-rings, diaphragms and moving parts make reliable operation of this device as questionable as the proper operation of the cooling system it is designed to protect. Thus, in addition to the expense of such a system, there are concerns about the maintenance and reliability of the prior art safety systems.
Thus, there presently exists a need for a coolant safety system for an automated welding machine that is simple, inexpensive and reliable with minimal maintenance requirements. Furthermore, there is a need for coolant safety system for an automated welding machine that includes an auxiliary sensor on board, a multi gun unit, and an easily programmable unit for different welding applications.
SUMMARY OF THE INVENTION
The present invention provides a coolant system safety device for an automated welding machine that combines electronic control by way of a microprocessor with flow level and leakage detection provided by inexpensive yet reliable differential pressure transmitters. An integral digital flow rate display is also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention and its advantages will be apparent from the Detailed Description taken in conjunction with the accompanying Drawings, in which:
FIG. 1 is a top view of an apparatus constructed in accordance with the invention;
FIG. 2 is a sectional view taken along lines 2 — 2 of FIG. 1;
FIG. 3 is a sectional view taken along lines 3 — 3 of FIG. 2;
FIG. 4 is a circuit schematic;
FIG. 5 is a top view of an alternate embodiment constructed in accordance with the invention;
FIG. 6 is a side view in detail of the alternate embodiment;
FIG. 7 is a side view of the alternate embodiment;
FIG. 8 is a partial cross section of the alternate embodiment;
FIG. 9 is a side view of the alternate embodiment;
FIG. 10 is a bottom view of the alternate embodiment;
FIG. 11 is a cross section taken along line A—A of FIG. 10;
FIG. 12 is a sectional view of the bottom of the alternate embodiment;
FIG. 13 is a side view of the alternate embodiment;
FIG. 14 is a circuit schematic;
FIGS. 15A, B, C, are a circuit schematic of the alternate embodiment; and
FIGS. 16A, B, C, D, E are a flow chart of a methodology for the alternate embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIGS. 1-3, where like numerals refer to like and corresponding elements, safety system 10 includes a manifold 12 and an electronic module housing 14 . A toggle switch 16 and a push button switch 18 extend from a side surface of housing 14 . LED display 20 includes a three-digit numerical display 22 and an array 24 of single LEDs. The following description is applicable to a safety system in a robotic environment, but persons skilled in the art that the system is usable in “hard” automated systems with minor modifications.
Four coolant lines connect to manifold 12 : coolant supply line 30 , welding gun supply line 32 , welding gun return line 34 , and coolant return line 36 . An electrical control cable 38 is plugged into a side of housing 14 . Solenoid valve 40 is located in coolant supply line 30 close to system 10 . A control cable 42 connects housing 14 and valve 40 .
As best shown in FIG. 3, manifold 12 is machined to include a supply passageway 50 and a return passageway 52 . Each passageway 50 , 52 has an identically-sized orifice 54 , 56 , respectively. A port 58 is drilled into each side of orifices 54 , 56 for a total of four ports 58 . As will be known to one skilled in the art, the provision of a port 58 on each side of orifices 54 and 56 enables the precise measurement of differential pressure across the orifices 54 , 56 . Differential pressure across an orifice is a direct function of flow rate.
Referring now to FIG. 4, safety system 10 measures the flow of water to and from the device being cooled, in this case an automated welding gun, using two differential pressure flow sensors 100 , 102 that are constantly monitored by a microprocessor 104 . In the preferred embodiment, coolant will be shut-off via electric solenoid valve 40 if one or more of the following conditions are met (all values may be adjusted in software or by gain pots):
1. Flow exceeds approximately 7 g.p.m.;
2. Flow is below approximately 1 g.p.m.; or
3. Flow difference is greater than 0.5 g.p.m.
Power module 106 receives 120 VAC power or optional 24 VDC (through cable 38 and connector 108 , FIGS. 1 and 2) through fuse 110 and transformer 112 . Transformer 112 has two input leads T 1 and T 2 . Transformer 112 is bypassed using jumpers if the application requires 24 VDC. The voltage is transformed to 20 VAC in transformer 112 and is fed into a full wave bridge rectifier 114 . Diode 116 insures against reverse polarity. The rectified power is filtered into DC using capacitor 118 to generate 15 VDC. This power is used for the 15 VDC supplied to the op amps described below. 15 VDC is also regulated down to 5 VDC using regulator 120 . Capacitor 122 provides additional filtering of the 5 VDC power. 15 VDC is fed to voltage inverter 124 . Inverter 124 periodically charges capacitor 126 , then uses the equivalent of an internal double pole switch to rapidly place capacitor 126 's inverted voltage into capacitor 128 . The voltage on capacitor 128 is therefore negative with respect to ground to provide the minus 15 VDC supply to the op amps described below. 15 VDC is also supplied to regulator 130 to regulate and supply the extremely stable and precise 10,000 volts for flow sensors 100 , 102 . Regulator 130 in the preferred embodiment is a Harris voltage inverter Model No. ICL7662CPA.
The input module 131 of the circuit has the primary function of measuring the return and supply flow by way of sensors 100 , 102 . In the preferred embodiment, differential pressure sensors are used in preference to other available methods for measuring flow. One alternative method of measuring flow, for example, uses the calorimetric principle, or the measure of heat transfer from an object to a fluid. This method, while highly accurate, is not preferred due to its prohibitive costs. Additional methods employ ultrasonic, vane, and impeller techniques for measuring flow. It will be recognized that these alternative methods are equivalent to the preferred method, though more costly.
Water flowing through an orifice normally follows the equation Q=C v (P in −P out ). Q is flow in gallons per minute, C v is a constant, P in is the pressure before the orifice and P out is the pressure after the orifice. Referring to FIG. 3, as well as FIG. 4, pressure sensors 150 and 152 each have two hose attachments which plumb into ports 58 in flow manifold 12 . In flow manifold 12 , passageways 50 , 52 preferably have a mean diameter of 0.74 inches and an orifice 54 , 56 diameter of 0.375 inches. Differential pressure is applied to opposing sides of a diaphragm within sensors 150 , 152 that has an “X” etched into the surface. Excitation current is passed longitudinally through the diaphragm, and the pressure that stresses the diaphragm is applied at a right angle to the current flow. The stress establishes a transverse electric field in the diaphragm, acting as a resistor, that is sensed as a voltage at the midpoint at the resistor. The single element transverse voltage strain gauge of sensors 150 , 152 can be viewed as the mechanical analog of a Hall effect device. The device is temperature, gain, and zero compensated. In the preferred embodiment, the differential pressure sensors 150 , 152 are each a model no. MPX2010D manufactured by Motorola.
A full flow differential pressure of no more than 1.5 psi results in a signal of 0.025 V on the output of sensors 150 , 152 . This small voltage is amplified in instrumentation op amps 154 , 156 . Instrumentation op amps 154 , 156 are each a model no. INA114BP manufactured by Burr Brown. Gain is adjusted on resistors 158 , 160 so that the amps 154 , 156 output the same voltage when the flows are the same. The output of the amps 154 , 156 are low pass filtered for inherent slight cavitation pressure spikes in manifold 12 using resistors 162 , 164 and capacitors 166 , 168 . The filtered 0-5 VDC raw voltages from the amps 154 , 156 are fed to microprocessor 104 for interpretation.
The microprocessor module 157 for the system uses a microprocessor 104 , because it eliminates a much more complex hard-wired circuit and may be easily altered in software. Microprocessor 104 has internal ram/rom, several eight-bit analog inputs, the ability to output variable duty cycle square waves, and discreet inputs and outputs. In the preferred embodiment, microprocessor 104 is a Signetics model no. S87C752-IN28.
Since Q=C v (P in −P out ), and C v is only important when scaling Q to units (English, Metric, etc) the constant C v is ignored for now. The supply P in −P out is the voltage from sensor 152 and op amp 156 . The return P in −P out is the voltage from sensor 150 and op amp 154 . Microprocessor 104 uses a look-up square root table twice to determine supply flow(S) and return flow (R). The difference in flow is S−R. A user-settable threshold trimpot 170 is stabilized by capacitor 172 and is fed directly to microprocessor 104 on an analog channel and compared with S−R. Coolant will be shut-off if the flow difference threshold is exceeded for a full two seconds. (S−R>T). Likewise flow is shut-off if flow exceeds approximately 7 g.p.m. (S or R>7 g.p.m.) or is lower than 1 g.p.m. (S or R<1 g.p.m.).
Microprocessor 104 includes a digital output port, which is used to directly drive LED display 24 in module 173 to keep the user informed of the system's status. The indicator lights in display 24 are a row of LEDs driven directly by the microprocessor 104 . Dropping resistors 182 limit the drive current.
Microprocessor 104 also uses its variable duty cycle square wave PWM capability to notify the user of the actual flow rate using digital numeral display 22 in module 174 . The PWM cycles at 20 Khz. As flow changes, the duty cycle changes. The 20 Khz is filtered to a DC level using a low pass filter comprised of resistor 175 and capacitor 176 . Op amp 178 provides the C v in the equation Q=C v (P in −P out ) to convert volts to a scaled, meaningful flow rate on the display 22 . Resistor 180 is provided to adjust the amp gain to display C v during factory calibration.
Digital display meter 22 provides the user with actual gallons per minute from both sensors 150 , 152 . Microprocessor 104 periodically changes between the supply and return flow data going to display 22 . Indicator lights in LED display 24 tell the user which sensor the digital display 22 is currently reporting. The digital display is preferably a self-contained volt meter with 0-20 volt capability, model DMS-20PC-2RH manufactured by Datel. Amp 178 and gain resistor 180 scale the PWM signal from microprocessor 104 to make the volt meter represent the “gallons per minute” flowing through the selected sensor 150 , 152 .
Microprocessor 104 uses the “supply g.p.m.” or “return g.p.m.” LEDs in display 24 to tell the user which flow sensor 150 or 152 is currently represented on the digital flow meter 22 . A “flow not equal” LED is illuminated when unscaled S−R exceeds threshold T 1 LEDs labeled “low supply flow” or “low return flow” are lit when either sensor 150 , 152 indicates flow is less than 1 g.p.m. Similarly, “high supply flow” or “high return flow” LEDs will light when either sensor 150 , 152 indicates flow is more than 7 g.p.m. Microprocessor 104 will allow brief, intermittent faults caused by harmless conditions such as water hammering, pressure glitches, and rugged actual factory situations. However, the “stop LED” will turn on if any of the above conditions occur for a full two seconds. This fault condition will turn the coolant valve off, as described below.
In Output module 183 , power is supplied to the system over a 4-pin connector 184 . Wire 186 is chassis ground, wire 188 is hot, and wire 190 is common. Wire 192 performs a dual purpose: when wire 192 is attached to a robot control input relay, it will tell the robot when coolant is flowing when high; when wire 192 is off, coolant is off, and a call to maintenance signal will be made. Wire 192 should also be attached to a robot output relay. When briefly energized, the coolant valve 40 will be turned on and flow restored.
Mechanical relay 194 is normally on and is driven directly by microprocessor 104 . Relay 194 provides power to the coolant solenoid 40 to keep it open. If a fault condition occurs, relay 194 opens and turns off solenoid valve 40 . Momentary push button switch 196 temporarily provides power to solenoid valve 40 to allow water to flow again. If microprocessor is satisfied that the problem has been solved, relay 194 stays closed to keep the valve 40 on when the user releases switch 196 . Preferably, a light in switch 196 indicates to the user that the valve is operating properly. If there is a major circuit malfunction, the user may toggle locking override switch 198 to turn valve 40 on permanently and bypass system 10 . As shown in FIGS. 1 and 2, push button switch 196 has a button 18 extending from housing 14 , and override switch 198 has a toggle 16 extending from the housing 14 .
Optoisolator 200 watches the status of coolant solenoid valve 40 and reports it to the microprocessor 104 . When the user or robot attempts to restart coolant flow, the microprocessor 104 will give the flow sensors 150 , 152 “another chance” and will compare their values to see if a restart is justified. Microprocessor 104 will ignore a restart unless optoisolator 200 says to give another chance. After a shut down, microprocessor 104 will not inadvertently latch valve 40 on again unless the robot or user intentionally intends it by electrically turning valve 40 on.
In operation, leaks typically occur when a coolant line breaks or a welding gun tip breaks off. The shut-off valves currently in use employ mechanical or electronic means to measure the coolant flow to a welding gun. If shop water pressure changes, grunge builds up in welding gun tips or valves, hoses are not properly dressed for minimal flow restrictions, adjacent robots cause flow changes or a myriad of other problems occur, these prior art shut-off systems fail. The failure of prior art systems is mainly attributed to the fact that they only measure flow or coolant to the gun and jam under realistic dirty water conditions. The shut-off valve is typically “hair” triggered to shut-off water with about plus or minus 20% of the flow.
An alternate embodiment apparatus 210 has generally the same setup and configuration as that described above. However, there are some differences which will be described, such as a modular electrical connector 202 which is capable of being changed in the field and completely unplugged from the system and replaced depending on the needs of the welding environment. The alternate embodiment apparatus 210 also includes user friendly buttons to reset 212 the apparatus, setup 214 the apparatus, enter 216 the apparatus, auto calibrate 218 the apparatus, review the history 220 of water flow conditions and leaks of the apparatus since initialization, and to select 222 various features such as gallons per minute flow, liters per minute flow, trigger points for low flow alarms, and the such.
In the alternate embodiment water saver system the manifold 224 is machined to include a supply passageway 226 and return passageway 228 . The water saver system measures the flow of water to and from the device being cooled, in this case an automated welding gun or guns, using two paddle wheel rotors 230 , 232 . The two rotors 230 , 232 are mounted in the brass manifold 224 and sealed with a plastic lid 234 and an o-ring seal 236 . Each of the rotors preferably have eight legs and they are radially magnetized. It should be noted that the rotors may also be made of plastiform, which has magnetic grains that are magnetized after being injection molded. Furthermore, an alternate embodiment would have each rotor arm made of plastic and having magnets embedded or secured by glue or other means into the ends to achieve the same results. To monitor the flow a hall effect sensor 238 is embedded within the brass manifold 224 such that it senses each rotor leg as it passes by the hall effect sensor 238 . The hall effect sensors 238 will output a square wave from approximately 0 to 200 Hz as the water flow increases from 0 to 10 gallons per minute. The apparatus includes two LEDs 240 , 242 which are mounted on the outside of the system and are used to monitor the rotor operation and will flash as the rotors turn. The frequency of the rotor 230 , 232 turning is virtually linear as the flow rate increases.
The rotors are constantly being monitored by a microprocessor 244 . The hall effect sensors 238 square wave output is directly connected to the microprocessor 244 which counts the number of pulses from each hall effect sensor 238 within a predetermined time frame. In the preferred embodiment each sensor 238 is approximately sampled three times per second. A “watch dog” timer is included in the microprocessor 244 and will cause an internal interrupt at precise intervals of approximately one third of a second. With the interrupt occurring approximately three times per second a software flag will instruct the microprocessor that the total number of counts should be sampled soon and the gallons per minute determined in the supply and return tubes. An interrupt is used to determine the flow rate to ensure that the computer is not busy executing a lengthy interrupt routine which could cause a lock out of the microprocessor during a critical power down interrupt routine. Therefore, the flow is determined in a regular subroutine which allows a power interrupt flag to get immediate attention any time during such subroutine. To determine the gallons per minute the flow routine subroutine will sample the computer counter 246 which is the supply flow and 248 which is the return flow and store their values on the chip. The counters are then cleared to allow new pulses to come through. In the preferred embodiment the counter values typically range from 15 to 150 decimal depending on the flow rate and normally the value of 246 and 248 are slightly different which is accounted for in the calibration process of the microprocessor unit.
The power module 202 is connected to a single circuit board and may be used for either 24 volts DC or 120 volts AC The connection is created by a 16 pin header connector which accesses key circuit points which are voltage specific. In the case of a 120 volt AC power the voltage will enter through pins 1 and 2 with pin 1 passing through a fuse 250 before going into the power suppression and step down power transformer 252 . Capacitor 254 will suppress any high frequency power surges by creating a lower impedance across the power wires during high frequency transients. Furthermore, the voltage is clamped by metal oxide varistor (MOV) 256 to keep spikes from being generated greater than 150 volts AC. Next the voltage is stepped down by transformer 252 and then it is rectified using a full wave bridge rectifier 258 . The output of the transformer 252 feeds into zener diode 260 which clamps the voltage less than 30 volts and capacitor 262 which smooths the power output of the full wave bridge rectifier 258 .
The system is also capable of operating 24 volt DC applications if necessary. The power enters after the bridge rectifier 258 and is clamped under 30 volts by the zenerdiode 260 and smoothed by capacitor 262 . Then the power is fed to a power trans PT5101-ND DC/DC convertor or any other similar voltage convertor which is a high frequency switching power supply that converts the DC voltage to 5 volts DC to run virtually the entire circuit.
The microprocessor 244 has internal ROM and RAM but in the event of a power loss the parameters programed by the user must be stored. Storage of such parameters is accomplished by reducing and turning off most functions of the computer except for the RAM until power is restored. Two one fared capacitors 264 provide the necessary energy, approximately one month of battery backup, to the computer in case of power loss. The capacitors 264 are used instead of batteries because they do not need to be replaced after years or months of use. The diode 266 keeps the capacitors 264 voltage from feeding the rest of the circuit while the power is off. It should also be known that the microprocessor 244 which is a Philips P87C5570EV has a power down mode. When a specific power down bit is set the internal RAM registers will shut down all counters, interrupts, I/O and the clock to use the minimum amount of power possible. When the power is restored and the computer is reset the computer will exit the power down mode. The circuit has been designed to give as much advanced notice of the pending power loss to the microprocessor 244 as possible by the use of a power detector chip 268 which will send a signal to the computer when power dips below 4.9 volt DC from the normal 5 volt DC voltage of the circuit. A low signal from the power detector chip 268 executes an interrupt in the microprocessor of the highest possible priority. An interrupt will cause the execution of a subroutine which sets the power down bit. Once the power down bit is set the computer will use approximately 4 microamps of power to keep the RAM backed up.
The microprocessor 244 will execute a calibration process based on the values of timers T 2 and T 3 because there is an inherent difference between the rotation rate of the supply and return rotors of a few percent. An objective of the water saver system is to detect several differences between the supply and return flow rates which leads to the conclusion that rotation rates must be scaled identically. This is accomplished using an auto calibration procedure which is started by pressing the calibration button 218 on the front panel of the water saver apparatus or by the microprocessor itself after the user changes the units of measure or the manifold sizing on the unit. During the calibration of the device it must be determined what the actual flow of the unit is likely to be so that external means such as an auxiliary external flow sensor does not have to be used to scale the unit. Furthermore, the unit must scale the two sensor readings to be identical to reliably determine when a leak has occurred or low flow conditions are occurring. A predetermined orifice size of the manifold 224 will create a predictable rotor speed and thus frequency to the microprocessor 244 . As an example, a rotor speed of 30 counts per sample for a ¾ inch NPT manifold corresponds approximately to 4 gallons per minute while 60 counts would correspond to 8 gallons per minute for the same manifold. Whereas if a ⅜ inch MPT manifold had a rotor speed of 30 counts per sample that corresponds to approximately 2 gallons per minute. The user defined orifice size in the setup of the unit makes it straight forward to determine the actual flow by taking a simple reading of the counts of the sample and multiplying it by a constant K. Then to get the sensors to exactly match each other a sensor reading is taken during the calibration process. This value is used on each of the subsequent flow readings. The calibration routine makes the following determinations: the supply flow T 2 , to the return flow T 3 , if a ⅜ inch manifold is being used and if it is used in gallons per minute or liters per minute, if a ¾ inch manifold is being used and if it is used in gallons per minute or liters per minute units. Then a scale number F is determined by taking the supply flow times the constant K divided by 100. These values are then saved until the next time the auto calibration routine is executed. Soon after each sampling of the flow sensors, which are monitored three times per second, the actual flow rate in the desired units by the user can be displayed using the following equations; supply flow=T 2 ×F/supply 0. The return flow=T 3 ×F/return 0. These equations will give the actual instantaneous flow and is used in all determinations of low and unequal flow conditions. These values will also be outputted to a LCD display at frequent intervals. It should be noted that the supply zero and return zero essentially cancel out the fact that one sensor may run 8% slower than the other. The constant F is the scaling factor to scale the raw sensor counts to actual engineering units of flow.
The display used on the apparatus or unit is a mechanical lid 270 which protects the circuit from the harsh environment and houses the key pad, liquid crystal display 272 and LED lights. The LCD is a two line by 16 character display preferably from Shelly having number SSM21686HGB-GS. It should be noted that a larger display may be used that includes more lines and characters if such features are needed such as more in depth help, spare parts information, customer support, diagnostics or other screens. Data is sent to the display in parallel over Port P 0 274 of the microprocessor computer 244 . An enable line from the computer and character command signal is used to properly clock data into the display. The LCD has LED back lighting for use in dim lighting where the contrast is adjusted by varying the intensity of the back lighting via resistor 276 .
The key pad 278 is used to control the unit and has membrane push buttons directly attached to the lid which are then directly attached to the computer 244 . The push buttons will pull the computer input lines low when pressed. It should be noted that most of the buttons are electrically pulled high by pull-up resistors in the computer. As shown in the FIGS. 15A-B some pins on Port P 1 without internal pull-up resistors require external pull-up resistors 280 . The lid is connected to the circuit board with ribbon connectors 282 and 284 .
The system also includes two output signals from the computer interface to the welding environment. One is the valve signal the other is the stop signal. These signals are isolated from mechanical relays through optoisolators 286 . Relays 288 and 290 connect to the user signals. Switches 292 and 294 bypass the relays 288 and 290 for operation and bypass mode. In the bypass mode the valve will be turned on and the flow O.K. signal will be sent to the weld control system. The capacitors 296 , 298 and diodes 300 , 302 surpress spikes when the relay changes state. It should be noted that whenever the relay changes state a power spike reaches the computer which can cause the rotor counters to fail. The software will reinitialize the counters and interrupts after commanding a relay to change state so no apparent lock up condition appears to the user.
The unit can be commanded to perform a water flow restart by pressing the reset button on the front panel of the unit. It should also be noted that the external reset signal from the weld control can tell the computer to restart water flow via optoisolator 304 . This in turn will have the software turn the valve 306 on for four seconds to try to reestablish water flow. A new fault condition will be evaluated after this four second period elapses. The water valve is supplied power by relay 290 as operated by the computer. While there is no leak condition 290 will be on with the valve. However if a leak occurs, relay 290 will turn off which in turn will turn the valve off. A suppression metal oxide varistor 308 and capacitor 310 suppress inductive power spikes from reaching the computer 244 via the water valve.
The water saver system also can track the history of the unit. History can be reviewed by the user by depressing a button 220 on the lid which will quickly determine the age of the unit, the number of leaks, and low flow conditions that have occurred since initialization of the system. The history counters can be restored to zero by pressing three keys simultaneously on the key pad. The history button is also very useful in identifying problem robots in a multi-robot environment. The computer generates interrupts at 3 Hz in the system. The counters in the unit count the number of interrupts to determine minutes, hours, days and weeks. These numbers are displayed first after the history button is pressed, after a brief delay, the leak and low flow condition counters are next displayed. The counters are incremented whenever an occurrence first occurs. Additional counters for more specific conditions could be added such as when the unit was adjusted, up time, weld count and a variety of other information.
An additional counter used to measure the temperature of t1. Coolant in the return line. A temperature sensor IC 334 , preferably a Dallas Semiconductor DS1620 or DS1820, is embedded upside down in the manifold 224 near the return coolant flow. A thermal transfer grease is used in conjunction with the chip to transfer the coolant temperature to the sensor 334 . The sensor is directly connected to the microprocessor 244 . The microprocessor 244 then can execute an instruction to display the coolant temperature in real time on the LED. The microprocessor 244 will have user set trip points for the sensor 334 . Welding will stop if the trip points are reached, which indicates the coolant temperature is too high or too low. DS1820 “single wire” temperature sensors can be strung in series like ‘Christmas lights’. Temperature sensors could potentially be strung throughout the welding robot cell at critical locations for total monitoring. Individual thresholds at each sensor could be set.
Another feature of the alternate embodiment unit is the use of an onboard auxiliary circuit 312 . The auxiliary circuit 312 is used to make certain that water is flowing even if the main water saver fails and the primary circuit has been placed in a bypass made. However, without such monitoring it is easy for an accident to happen and the robot operated without any water flow. This would lead to problems such as expensive cables being burned up and other catastrophes of the robot arm. The onboard auxiliary sensor 238 removes the need and use of an external auxiliary sensor. The auxiliary circuit 312 is wired in series with the main circuit in the unit and relies only on the power section of the main circuit board and the rotation of the return rotor. The auxiliary circuit is used to detect low flow conditions only it is not used to detect leaks. The intention being to determine which cable would be damaged by low flow of the coolant. However, both the main and auxiliary circuit can be placed in bypass using separate mechanical switches. The rotors will output a square wave from 0 to 200 HZ depending upon water flow in each of the pipes. A one shot multivibrator 314 is used to determine when the rotation speed is too low by opening a signal when the frequency drops below a desired level. The multivibrator 314 acts like a delay off switch. As long as the rotor rotation is getting pulses and the multivibrator 314 is getting retriggered the out put of 314 will be positive. The trigger is sent directly from the return rotor hall effect sensor and is the same one hooked up to the microprocessor. However, if the triggers are not arriving quickly enough, 314 will time out before the trigger occurs and the output of 314 will begin to oscillate. The timing for the circuit is done by an RC circuit which is internal to 314 and is also comprised of resistor 316 and capacitor 318 . Resister 320 keeps the value of 316 from being adjusted so low that it damages 314 . By changing the value of resistor 316 you can extend the on time of 314 to allow for varying trigger frequencies and thus flow. An auxiliary flow okay light 242 will flash on the lid of the unit as flow decreases until it remains off. This flashing signal will be sent to the robot control through optoisolators 322 and 324 . Optoisolator 322 has a TRIAC output for 120 volt “flow O.K.” signals and optoisolator 324 has a Darlington output for 24 volt DC “flow O.K.” signals. The user will be able to select if the output is to be 24 volts DC or 120 volts AC by selecting switch 326 .
The unit has also been designed with a welding water saver feature that will automatically shut off the water supply if there is no activity for a certain period of time on the welding guns. The time allowed during periods of activity can vary from 0 to 255 minutes and is field settable. The default setting for this feature sets the weld timer to zero. A separate signal from the weld control will instruct the water saver when a weld is being made through an optical isolator 328 to the microprocessor. Resistor 330 and capacitor 332 will smooth out the ripple which will occur in 60 Hz AC applications. Thereafter, every time a weld occurs, the weld timer is reset to zero. The weld timer acts as a clock which is always trying to increment as time elapses but is frequently being set to zero as a weld occurs on the weld gun. If no activity is occurring on the weld gun the weld timer will exceed the allowed time and the water will shut off automatically. However, when welding resumes the water saver will automatically restart. It should be noted that a true leak condition will lock out the weld timer and disable the restart from the weld timer signal. It should also be noted that leak detection in normal operation will shut off the solenoid to stop water flow. However, it should be noted that the continued rotation of the supply sensor would indicate that the solenoid valve is in the manual bypass mode. The user would then have to check that the solenoid valve is not in any bypass if the “Leak. Valve in Manual Bypass” error is shown on the screen or the leak detection would not be able to shut off the water if necessary.
The present invention differs from the prior art in that flow is measured both to and from the welding gun, and the difference is compared to a preset leak threshold. Thus, the system is isolated from nonleak-related changes such as shop water pressure changes, which affect both supply and return flow rates. As a result, not only are false alarm shut-offs avoided, but the system monitors leakage throughout the entire cooling system due to an increased accuracy.
Whereas, the present invention has been described with respect to a specific embodiment thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art and it is intended to encompass such changes and modifications as fall within the scope of the appended claims.
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In an automated welding machine, where a flow of liquid coolant is supplied to welding components on the machine from a source of coolant and then returned to the source of coolant, a safety system is provided that shuts down the flow of coolant in the event of a fault. Faults are detected by a supply sensor and a return sensor for measuring the flow rates of coolant in the supply and return lines. A microprocessor is adapted to compare the supply flow rate and return flow rate and detect differences between the two rates. The difference between the detected rates as compared to a leak threshold value, and the microprocessor is adapted to generate a valve shutoff signal in the event the detected difference in flow rates exceeds the leak threshold value. A value in the supply coolant line is responsive to the valve shutoff signal to shutoff flow of coolant in response thereto.
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This invention relates to skateboards and more particularly to a skateboard having four wheel front and rear trucks to improve its operation.
BACKGROUND OF THE INVENTION
Conventional skateboards include a foot board having front and rear under carriages mounted thereon supporting front and rear axles. Two front wheels are mounted on opposite ends of the front axle respectively and two rear wheels are mounted on opposite ends of the rear axle respectively.
When the skateboard passes over small bumps or stones, its operation can become unstable, particularly if the amplitude or raising of the skateboard as a consequence of one or both wheels passing over the bump is large. As is known to those versed in the art, the under carriage mounting for the front and rear axles is such that tilting of the skateboard on one side or the other causes the wheels to toe inwardly in a direction to cause the skateboard to execute a turn in the direction of the tilt. In such a turn, one skateboard wheel is at a different level than the other relative to the underside surface of the board. It will thus be appreciated that should the skateboard pass over a small bump such that only one wheel engages the bump while on a straight line course, inadvertent turning of the skateboard can result.
Any means whereby the effective amplitude of bumps encountered by the skateboard can be decreased would thus constitute a great improvement in overall skateboard operation.
BRIEF DESCRIPTION OF THE PRESENT INVENTION
The present invention contemplates the provision of a new wheel arrangement for skateboards adaptable to the presently available under carriage structures normally supporting the front and rear wheel axles.
In accord with the present invention, rather than front and rear pairs of wheels, there are substituted onto the front and rear axles, front and rear trucks. Each truck is in the form of a rectangular frame having four wheels mounted adjacent to its four corners. Intermediate points on the longitudinal sides of the rectangular frames are pivotally mounted on the front and rear axles so that each of the trucks can rock about these axles.
The provision of the trucks resulting in an eight wheel skateboard effectively cuts the amplitude of bumps and the like over which the wheels successively pass approximately in one half. On the other hand, since the entire truck structure is mounted as a substitute for the normal wheels, the truck structure with its four wheels will toe in for proper turning control of the skateboard when the board surface itself is tilted so that the skateboard of the present invention can be maneuvered in substantially the same manner as a normal skateboard.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of this invention will be had by referring to the accompanying drawings in which:
FIG. 1 is a perspective, underside view of the improved skateboard of this invention;
FIG. 2 is a fragmentary bottom plan view looking in the direction of the arrows 2--2 of FIG. 1 illustrating the front truck and carriage of the skateboard; and,
FIG. 3 is a fragmentary side elevational view partly broken away taken in the direction of the arrows 3--3 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, there is shown a skateboard 10 which may be a conventional shape provided with the usual front and rear undercarriage structures 11 and 12 supporting front and rear axles 13 and 14.
In accord with the present invention, rather than mounting the conventional skateboard wheels on opposite ends of the axles 13 and 14, front and rear trucks 15 and 16 are substituted therefor. Each of the trucks 15 and 16 is identical in construction and therefore a detailed description of one will suffice for both.
Referring to the truck 15 as illustrated in FIG. 2, this truck is in the form of a rectangular frame made up of longitudinal sides 17 and 18 and outer and inner transverse sides 19 and 20. By outer side is meant that side closest to an end of the skateboard and by inner side is meant that side closest to the inner or center portion of the skateboard. Four wheels 21, 22, 23, and 24 are respectively mounted at the four corners of the rectangular frame making up the truck 15.
As will be evident from FIG. 2, the front axle 13 pivotally mounts the truck at intermediate points 25 and 26 on the longitudinal sides 17 and 18 so that the truck can execute rocking movements about this axle.
In the particular embodiment illustrated, the trailing wheels 23 and 24 are wider apart than the leading wheels 21 and 22, this effect being accomplished by the provision of small spacing collars 27 and 28 between the trailing wheels and the longitudinal side portions of the frame to which they are rotatably mounted. Increasing the spacing between the trailing wheels for each of the trucks increases the transverse stabilization but such increased spacing is not an essential feature of this invention.
Still referring to FIG. 2, a stop means is provided as indicated at 29 secured to the undercarriage structure 11 and passing over the inner transverse side 20 to limit the rocking movement of the truck to a given degree.
The foregoing stop arrangement can be better understood by reference to the side elevational view of FIG. 3 wherein the trailing wheel 23 has been broken away to expose the stop means 29. Essentially, this stop means takes the form of a hairpin shaped wire having the ends of its arms 30 and 31 secured to the undercarriage 11 and its loop portion receiving the inner transverse side 19 of the rectangular shaped frame making up the truck. Essentially, the limit of rocking movement is determined by the length of this hairpin shaped wire. The main purpose for the stop means 29 is to permit the skateboard to be tilted up on its rear truck in such a manner that only the two trailing wheels of the rear truck engage the ground. In this respect, reference is had to the rear truck 16 of FIG. 1 wherein it will be noted that the hairpin shaped wire limits the rocking movement of this particular truck in a counterclockwise direction so that the trailing rear wheels which are wider apart will only engage the ground when a skater is performing what is known in the art as "wheelies".
Referring back to FIG. 3, there is indicated by the dashed lines 32 a hump or bump in the surface upon which the skateboard is riding which, when engaged by the front wheels such as the wheel 21, will cause a rocking movement of the truck 15 about the axle 13. Because of the central pivoting of the rectangular frame intermediate the leading and trailing wheels, the board itself will only be raised to approximately one half the amplitude of the hump 32 as it successively passes beneath the leading and trailing wheels 21 and 23. Thus, as indicated by the dashed lines in FIG. 3 as at 21' and 13', the moved positions of the wheel and axle are illustrated respectively as a consequence of the bump 32 wherein it will be appreciated that the axle and thus the front portion of the skateboard itself is only raised to approximately half the distance of the wheel 21.
Since the same axle 13 which is provided for normal wheels is untilized to pivotally mount the truck intermediate the leading and trailing wheels on the truck, the truck will execute toeing in movements in response to tilting of the skateboard by a shifting of the user's weight as is the case with the conventional single wheels on each end of the axle 13 so that the skateboard can maneuver in the same manner as a conventional skateboard and yet provide the desired advantage of greatly cushioning bumps and the like.
From the foregoing description, it will thus be evident that the present invention has provided an improved skateboard by the provision of eight wheels, four such wheels being mounted on a front truck and four such wheels being mounted on a rear truck, all as described.
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A skateboard has front and rear trucks each supporting four wheels centrally pivoted to the axle on the undercarriages of the skateboard normally provided for the conventional type front and rear wheels. Each truck can rock about its central pivot on the axis and thereby reduce the amplitude of small bumps experienced by the board successively passed over by the leading and trailing wheels of each truck.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The present document is based on Japanese Priority Document JP 2004-016185, filed in the Japanese Patent Office on Jan. 23, 2004, the entire contents of which being incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an antenna apparatus capable of performing a switching of a directivity pattern.
[0004] 2. Description of Related Art
[0005] Conventionally, it is known that a use of an antenna having no directivity pattern leads to a degradation of a communication quality with an interference wave caused by a reflection from a building wall etc. in a multi path propagation environment in which multiple radio waves are available. Thus, an antenna apparatus capable of turning a directivity pattern in a specific direction has attracted attention.
[0006] A phased array antenna apparatus shown in FIG. 13 and an adaptive array antenna apparatus shown in FIG. 14 are known as such an antenna apparatus capable of turning a directivity pattern in a specific direction. The phased array antenna apparatus shown in FIG. 13 has N pieces of antenna elements 101 - 1 , 101 - 2 , . . . and 101 -N. Then, an amplification of signals having been received by the N pieces of antenna elements 101 - 1 , 101 - 2 , . . . and 101 -N is performed by amplifiers (AMP) 102 - 1 , 102 - 2 , . . . and 102 -N. The received signals having been amplified by the amplifiers 102 - 1 , 102 - 2 , . . . and 102 -N are outputted to a synthesizer 104 after a phase adjustment by variable phase shifters (phase shifters) 103 - 1 , 103 - 2 , . . . and 103 -N. The synthesizer 104 performs a synthesis of the received signals from the respective variable phase shifters 103 - 1 , 103 - 2 , . . . and 103 -N. A frequency converter (a down-converter) 105 is operated to output the resultant received signal obtained by the synthesizer 104 through a conversion into a signal of a lower frequency.
[0007] An adaptive array antenna 110 shown in FIG. 14 has N pieces of antenna elements 111 - 1 , 111 - 2 , . . . and 111 -N. In the adaptive array antenna 110 of this type, the amplification of signals having been received by the N pieces of antenna elements 111 - 1 , 111 - 2 , . . . and 111 -N is performed by amplifiers (AMP) 112 - 1 , 112 - 2 , . . . and 112 -N at the time of a receiving operation of the above antenna. Then, the received signals having been amplified by the amplifiers 112 - 1 , 112 - 2 , . . . and 112 -N are respectively down-converted (DC) by frequency converters 113 - 1 , 113 - 2 , . . . and 113 -N and subsequently undergo an analog signal-to-digital signal conversion by AD/DA converters 114 - 1 , 114 - 2 , . . . and 114 -N. Following the conversion, an output of the obtained digital signals is performed through a so-called adaptive signal processing such as weighting and synthesizing with a digital signal processing unit 115 .
[0008] On the contrary, at the time of a transmitting operation, digital transmitting signals having been given a required signal processing by the digital signal processing unit 115 are converted into analog transmitting signals with the AD/DA converters 114 - 1 , 114 - 2 , . . . and 114 -N and subsequently undergo an up-conversion (UC) with the frequency converters 113 - 1 , 113 - 2 , . . . and 113 -N. Following the conversion, the amplification is performed by the amplifiers 112 - 1 , 112 - 2 , . . . and 112 -N, leading to a transmission (a radiation) from the antenna elements 111 - 1 , 111 - 2 , . . . and 111 -N.
[0009] However, the phased array antenna as shown in FIG. 13 requires that a receiving system should be configured with a plurality of variable phase shifters 103 - 1 to 103 -N at a high frequency band. Further, the adaptive array antenna as shown in FIG. 14 requires that the adaptive signal processing should be performed using a plurality of transmitting/receiving systems. For the above reasons, either of the above antenna apparatuses calls for a complicated system and costs much, resulting in a difficult application to a consumer apparatus requiring to be produced at low cost.
[0010] By the way, a Yagi-Uda antenna widely used for a reception of television broadcasting is well known as an antenna having a directivity pattern in a specific direction. The Yagi-Uda antenna shown in FIG. 15A comprises a radiator 121 that radiates a radio wave, a director 122 having an electrical length slightly smaller than an electrical length (2/λg, where λg is a guide wavelength) of the radiator 121 and a reflector 123 having an electrical length slightly larger than the electrical length of the radiator 121 , wherein the director 122 and the reflector 123 are disposed before and behind the radiator 121 to ensure that the directivity as shown in FIG. 15B is obtained.
[0011] Then, a patent document 1 proposes an antenna apparatus that is configured based on the above Yagi-Uda antenna to ensure that a switching of a direction of the directivity is performed. Further, a patent document 2 proposes an antenna apparatus in which a sharing of a director is applied to attain a reduction in antenna size, with reference to an antenna apparatus that performs the switching of a feed point to ensure that a formation of multi-beams is attained. Furthermore, a patent document 3 proposes a multi-beam antenna of multi-frequency sharable type.
[Patent document 1] Japanese Patent Application Publication (KOKAI) No. Hei 11-27038 [Patent document 2] Japanese Patent Application Publication (KOKAI) No. 2003-142919 [Patent document 3] Japanese Patent Application Publication (KOKAI) No. Hei 11-168318
SUMMARY OF THE INVENTION
[0015] However, the antenna apparatus of the above patent document 1 is in the form of an array of multiple Yagi-Uda antennas, and thus requires more than one director and more than one reflector, resulting in a disadvantage of being difficult of a downsizing. Further, the antenna apparatus of the above patent document 1 is supposed to be of a structure in which a monopole antenna is projecting in a vertical direction of a ground plate, also resulting in a difficulty in attaining a reduction in thickness. Alternatively, it is also suggested that a dipole antenna should be used in place of the monopole antenna, for instance, to form the antenna on a printed circuit board, in which case, however, the ground plate fails to be disposed in the vicinity of the antenna, resulting in a difficult packaging of a selector switch etc. Further, the monopole antenna, even if formed with a dielectric substance, has little effect of shortening a wavelength, resulting in a disadvantage of being difficult of the downsizing.
[0016] The antenna apparatus of the above patent document 2 applies the sharing of the director to reduce an antenna size, so that there is a limitation to the downsizing. Further, the antenna apparatus of the above configuration needs a selector switch between transmitting and receiving systems for each beam direction to attain the formation of multi-beams, resulting in a disadvantage in that the selector switch leads to a degradation of efficiency as the antenna. Furthermore, the antenna apparatus of the above configuration is basically supposed to have one transmitting/receiving system, so that a one-to-multiple switching is required for the selector switch, resulting in a disadvantage of being very difficult of a manufacturing adaptive to an available frequency band of a radio communication.
[0017] Moreover, the antenna apparatus of each of the above patent documents 1 and 2 has been considered to be incapable of using a transmitting/receiving frequency at more than one frequency. On the contrary, the multi-frequency sharable multi-beam antenna of the above patent document 3 is supposed to be available at more than one frequency, in which case, however, the antenna of this type is merely in the form of the array of antennas to individual frequencies, resulting in a disadvantage of being difficult of the downsizing.
[0018] Thus, the present invention has been undertaken in view of the above problems, and is intended to realize that an antenna apparatus being small in size and capable of performing the switching of a directivity pattern is adaptive to multiple frequencies.
[0019] To attain the above object, an antenna apparatus according to the present invention comprises a first antenna element having a prescribed electrical length, first feed means capable of performing a feed to the first antenna element, second antenna elements respectively having an electrical length larger than the electrical length of the first antenna element and disposed at the opposite sides of the first antenna element, second feed means capable of performing, at respectively different phases, the feed to the second antenna elements disposed at the opposite sides of the first antenna element, and changing means of changing each electrical length of the second antenna elements.
[0020] According to the above configuration, a first antenna circuit may be formed by performing the feed from the first feed means to the first antenna element, for instance, and by changing, by the changing means, the electrical length of either of the second antenna elements disposed at the opposite sides of the first antenna element. Further, a second antenna circuit may be formed by performing the feed at the respectively different phases from the second feed means to the second antenna elements disposed at the opposite sides of the first antenna element.
[0021] Thus, according to the present invention, a formation of more than one antenna circuit ensures that a multi-frequency antenna being adaptive to more than one frequency and besides, capable of controlling the directivity pattern is realizable. Further, in this case, the second antenna elements may be used in common as the first antenna circuit and the second antenna circuit, so that the downsizing of the antenna apparatus is attainable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a view for illustrating a configuration of a Yagi slot antenna specified as an embodiment of the present invention.
[0023] FIG. 2 is a view showing directivity patterns of the Yagi slot antenna of the embodiment of the present invention.
[0024] FIG. 3 is a view showing the directivity patterns of the Yagi slot antenna of the embodiment of the present invention.
[0025] FIG. 4 is a view illustrating a different configuration of the Yagi slot antenna of the embodiment of the present invention.
[0026] FIG. 5 is a view showing the directivity patterns of the Yagi slot antenna of the embodiment of the present invention.
[0027] FIG. 6 is a view showing the directivity patterns of the Yagi slot antenna of the embodiment of the present invention.
[0028] FIG. 7 is a view showing a configuration of a switch provided for the Yagi slot antenna of the embodiment of to the present invention.
[0029] FIG. 8 is a view showing the directivity patterns of the Yagi slot antenna shown in FIG. 7 .
[0030] FIG. 9 is a view showing a mechanism of a phase-difference feed antenna.
[0031] FIG. 10 is a view showing a structure of a multi-frequency antenna specified as the embodiment of the present invention.
[0032] FIG. 11 is a view showing directivity patterns of the multi-frequency antenna of the embodiment of the present invention.
[0033] FIG. 12 is a view showing an electronic apparatus mounted with the Yagi slot antenna of the embodiment of the present invention.
[0034] FIG. 13 is a block diagram showing the configuration of a conventional phased array antenna.
[0035] FIG. 14 is a block diagram showing the configuration of a conventional adaptive array antenna.
[0036] FIG. 15 is a view showing the configuration of a conventional Yagi-Uda antenna.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] A description on a basic structure of an antenna apparatus specified as an embodiment of the present invention is hereinafter given. Incidentally, the embodiment of the present invention is described by taking a case of an antenna apparatus suitable to a wireless LAN (Local Area Network) in which a radio wave of 5.2 GHz band, for instance, is available.
[0038] FIG. 1A is a view showing a configuration of a slot antenna that forms the basis of the antenna apparatus specified as the embodiment of the present invention. A slot antenna 1 shown in FIG. 1A has, at an approximately center position of a planar printed circuit board 2 , a driven element 11 given a feed, and before and behind the driven element 11 , parasitic elements 12 and 13 respectively given no feed. Then, the slot antenna 1 having the above configuration is supposed to be capable of radiating radio waves from the driven element 11 .
[0039] The driven element 11 is in the form of a slot (a slit) provided in a conductor (a ground plate) 2 a formed at one surface side of the planar printed circuit board 2 , for instance. The driven element 11 is given the feed with a micro-strip transmission line 14 formed at the other surface side of the planar printed circuit board 2 . Each of the parasitic elements 12 and 13 is also in the form of a slot provided in the conductor 2 a of the planar printed circuit board 2 , for instance.
[0040] In this case, a slot length (an electrical length) of the driven element 11 is specified as a length equivalent to a ½ wavelength (0.5 λg) of a transmitting/receiving frequency required for the slot antenna 1 to perform a transmission and a reception.
[0041] Each slot length (the electrical length) of the parasitic elements 12 and 13 is supposed to be larger than the slot length (0.5 λg) of the driven element 11 . Further, the driven element 11 and the parasitic elements 12 and 13 are spaced at intervals of about ¼ wavelength (0.25 λo, where λo represents a free space wavelength), respectively.
[0042] Then, the antenna apparatus of the embodiment of the present invention ensures that the antenna apparatus is configured using the slot antenna 1 having the above structure. FIG. 1B is a view showing the configuration of a Yagi slot antenna available as the antenna apparatus of the embodiment of the present invention. A Yagi slot antenna 10 shown in FIG. 1B sets the driven element 11 of the slot antenna 1 shown in FIG. 1A to function as a radiator 21 as it is. As to the parasitic element 12 similarly shown in FIG. 1A , a function as a director 22 is provided by means of making the electrical length thereof equal to or slightly smaller than the electrical length (the ½ wavelength) of the radiator 21 . As to the parasitic element 13 , a function as a reflector 23 is provided by means of taking advantage of the electrical length larger than the electrical length of the driven element 11 as it is. Thus, a directivity of the Yagi slot antenna 10 of the embodiment of the present invention as shown in FIG. 1B is directed as shown by an arrow, that is, in a direction from the radiator 21 toward the director 22 .
[0043] Incidentally, in the present specification, the electrical length required to set the parasitic elements 12 and 13 to function as the director 22 is hereinafter referred to as a director length. Further, the electrical length required to set the parasitic elements 12 and 13 to function as the reflector 23 is referred to as a reflector length. Further, in the slot antenna, there is a change of a resonant frequency also depending on a dielectric constant of a board material of the planar printed circuit board 2 , so that each electrical length of the driven element 11 and the parasitic element 12 is determined in consideration of the dielectric constant etc. of the planar printed circuit board 2 .
[0044] FIGS. 2 and 3 are views showing directivity patterns of the Yagi slot antenna 10 shown in FIG. 1B . Incidentally, each of the directivity patterns shown in FIGS. 2 and 3 is assumed to be one obtained when the planar printed circuit board 2 has thereon the director 22 , the radiator 21 and the reflector 23 that are 2 mm in slot width and respectively 18 mm, 17 mm and 20.5 mm in slot length. Further, a FR-4 board formed with a glass epoxy resin having a planar size of 40 mm×40 mm, a thickness of 1 mm and a dielectric constant of 4.2 as a material is used for the planar printed circuit board 2 . Further, the directivity pattern shown in FIG. 2B is assumed to be one obtained when a length direction of the slot, a width direction of the slot and a thickness direction of the printed circuit board 2 are specified as a X-direction, a Y-direction and a Z-direction, respectively.
[0045] Analytic values and measured values of the directivity patterns of a horizontal polarized wave Eφ and a vertical polarized wave Eθ in a YZ-plane of the above Yagi slot antenna 10 are given as shown in FIG. 2A , wherein it may be appreciated that the direction of the directivity undergoes a control by the director 22 and the reflector 23 . Incidentally, the measured value of an average gain in this case is assumed to be −6.05 dBi, and an average gain in a radial direction is assumed to be −1.16 dBi.
[0046] For reference, the analytic values and the measured values of the directivity patterns of the horizontal polarized wave Eφ and the vertical polarized wave Eθ in an XY-plane and an XZ-plane of the Yagi slot antenna 10 are given as shown in FIG. 3A , and the respective average gains (the measured values) are assumed to be −9.14 dBi and −10.3 dBi.
[0047] FIG. 3B is a view showing an input feature of the Yagi slot antenna 10 shown in FIG. 1B , wherein it may be appreciated from the input feature in FIG. 3B that the Yagi slot antenna 10 causes a resonance with the length of the radiator 21 assumed to be about a ½ wavelength of the guide wavelength.
[0048] The Yagi slot antenna 10 of the embodiment of the present invention ensures that an antenna apparatus having different directions of the directivity is configured by taking advantage of the above slot antenna 1 . FIG. 4A is a view showing the slot antenna 1 that forms the basis of the Yagi slot antenna 10 specified as the embodiment of the present invention, wherein the above slot antenna 1 is supposed to have the same configuration as the slot antenna in FIG. 1A .
[0049] The Yagi slot antenna 10 in this case sets the driven element 11 shown in FIG. 4A to function as the radiator 21 as it is, as shown in FIG. 4B . In addition to the above, the function as the reflector 23 is provided by means of setting the electrical length of the parasitic element 12 at the reflector length, while the function as the director 22 is provided by means of setting the electrical length of the parasitic element 13 at the director length.
[0050] In other words, the Yagi slot antenna 10 shown in FIG. 4B is supposed to set the parasitic element 12 having been set to function as the director 22 in FIG. 1B to function as the reflector 23 , and the parasitic element 13 having been set to function as the reflector 23 to function as the director 22 . Thus, the directivity of the Yagi slot antenna 10 of the embodiment of the present invention shown in FIG. 4B is directed as shown by an arrow in FIG. 4B , resulting in the opposite direction to that shown in FIG. 1B .
[0051] FIGS. 5 and 6 are views showing the directivity patterns of the Yagi slot antenna 10 shown in FIG. 4B .
[0052] Incidentally, each of the directivity patterns shown in FIGS. 5 and 6 is also assumed to be one obtained when the planar printed circuit board 2 has thereon the director 22 , the radiator 21 and the reflector 23 that are 2 mm in slot width and respectively 18 mm, 17 mm and 20.5 mm in slot length. Further, the FR-4 board formed with the glass epoxy resin having the planar size of 40 mm×40 mm, the thickness of 1 mm and the dielectric constant of 4.2 as the material is also used for the planar printed circuit board 2 . Further, the directivity pattern shown in FIG. 5B is assumed to be one obtained when the length direction of the slot, the width direction of the slot and the thickness direction of the planar printed circuit board 2 are specified as the X-direction, the Y-direction and the Z-direction, respectively.
[0053] The analytic values and the measured values of the directivity patterns of the horizontal polarized wave Eφ and the vertical polarized wave Eθ in the YZ-plane of the above Yagi slot antenna 10 are given as shown in FIG. 5A , wherein it may be also appreciated that the direction of the directivity undergoes the control by the director 22 and the reflector 23 . Incidentally, the measured value of the average gain in this case is assumed to be −6.80 dBi, and the average gain in the radial direction is assumed to be −1.08 dBi.
[0054] For reference, the analytic values and the measured values of the directivity patterns of the horizontal polarized wave Eφ and the vertical polarized wave Eθ in the XY-plane and the XZ-plane of the Yagi slot antenna shown in FIG. 4B are given as shown in FIG. 6A , wherein the respective average gains are assumed to be −11.5 dBi and −7.39 dBi.
[0055] FIG. 6B is a view showing the input feature of the Yagi slot antenna 10 shown in FIG. 4B , wherein it may be also appreciated from the input feature in FIG. 6B that the Yagi slot antenna 10 causes the resonance with the length of the radiator 21 assumed to be about the ½ wavelength of the guide wavelength.
[0056] As described the above, the Yagi slot antenna 10 of the embodiment of the present invention, provided that the driven element 11 of the basic slot antenna 1 as shown in FIG. 1A ( FIG. 4A ) is set to function as the radiator 21 , performs a change of the electrical length of either of the parasitic elements 12 and 13 to set the parasitic element 12 to function as the director 22 and the parasitic element 13 to function as the reflector 23 , or on the contrary, the parasitic element 12 to function as the reflector 23 and the parasitic element 13 to function as the director 22 .
[0057] Thus, the embodiment of the present invention is provided with switches SW 1 and SW 2 as changing means at prescribed positions of the parasitic elements 12 and 13 to change each electrical length of the parasitic elements 12 and 13 , provided that each electrical length of the parasitic elements 12 and 13 is preliminarily set at the reflector length as shown in FIG. 7A . Then, the change of each electrical length of the parasitic elements 12 and 13 from the reflector length to the director length is performed with the switches SW 1 and SW 2 . In this case, the switches SW 1 and SW 2 are supposed to be at positions where each electrical length of the parasitic elements 12 and 13 reaches the director length.
[0058] FIG. 7B is a view showing the configuration of the switch SW used for the above Yagi slot antenna 10 . Incidentally, in FIG. 7B , there is shown the switch SW 1 provided for the parasitic element 12 . The switch SW 1 shown in FIG. 7B is specified as a switch that has one end connected to the conductor 2 a of the planar printed circuit board 2 and allows the other end to be switched over to either of an on state (a short-circuited state) making a connection to the conductor 2 a and an off state (an open-circuited state) making no connection to the conductor 2 a . Then, when the switch SW 1 is placed in the short-circuited state, the electrical length of the parasitic element 12 , for instance, may be changed from the reflector length to the director length. Incidentally, an MMIC (Monolithic Microwave IC) switch or a MEMS (Micro Electro Mechanical System) switch is supposed to be available for the switch SW 1 .
[0059] As described the above, the embodiment of the present invention is provided with the switches SW 1 and SW 2 respectively at the prescribed positions of the parasitic elements 12 and 13 to ensure that the electrical length of either of the parasitic elements 12 and 13 is changed from the reflector length to the director length by the switches SW 1 and SW 2 .
[0060] FIG. 8 is a view showing the directivity patterns of the Yagi slot antenna 10 shown in FIG. 7A . Specifically, in FIG. 8A , there is shown the directivity pattern obtained when only the switch SW 2 of the parasitic element 13 is set to the on state, and in FIG. 8B , there is shown the directivity pattern obtained when only the switch SW 1 of the parasitic element 12 is set to the on state. Incidentally, each of the directivity patterns in this case is also assumed to be one obtained when the planar printed circuit board 2 has thereon the parasitic element 12 , the driven element 11 and the parasitic element 13 that are 2 mm in slot width and respectively 20.5 mm, 17 mm and 20.5 mm in slot length, as shown in FIG. 8C . The FR-4 board formed with the glass epoxy resin having the planar size of 40 mm×40 mm, the thickness of 1 mm and the dielectric constant of 4.2 as the material is also used for the planar printed circuit board 2 . Further, each of the directivity patterns shown in FIGS. 8A and 8B is assumed to be one obtained when the length direction of the slot, the width direction of the slot and the thickness direction of the planar printed circuit board 2 are specified as the X-direction, the Y-direction and the Z-direction, respectively.
[0061] It may be appreciated from the directivity pattern of the Yagi slot antenna 10 shown in FIG. 8A that a setting of only the switch SW 2 to the on state enables the directivity to be directed as shown by an arrow A in FIG. 8C . Further, it may be also appreciated that the setting of only the switch SW 1 to the on state enables the directivity to be changed to a direction as shown by an arrow B in FIG. 8C . That is, it may be understood that the setting of either of the switches SW 1 and SW 2 to the on state enables the directivity pattern to be changed.
[0062] According to the Yagi slot antenna of the embodiment of the present invention, the parasitic elements 12 and 13 may be used in common as the director or the reflector, so that the antenna apparatus having two different directivities may be configured with the single Yagi slot antenna 10 . That is, the use of the parasitic elements 12 and 13 in common as the director and the reflector makes it possible to realize the antenna apparatus being small-sized and having the two different directivities.
[0063] Further, the Yagi slot antenna 10 of the embodiment of the present invention eliminates the need to provide the switch SW for the driven element 11 , resulting in no degradation of a radiation feature of the radiator. In addition, the Yagi slot antenna 10 of the embodiment of the present invention also eliminates the need to provide the phase shifter, unlike the conventional phased array antenna shown in FIG. 13 , resulting in no degradation of the radiation feature of the radiator as well from this point of view.
[0064] Furthermore, according to the Yagi slot antenna 10 of the embodiment of the present invention, the driven element 11 operative as the radiator and the parasitic elements 12 and 13 operative as the director or the reflector may be formed directly on the conductor 2 a of the planar printed circuit board 2 , so that the antenna may reduce the thickness down to a level of a board thickness of the planar printed circuit board 2 .
[0065] Moreover, the parasitic elements 12 and 13 operative as the director or the reflector are supposed to be formed on the conductor 2 a of the planar printed circuit board 2 , so that there is also an advantage of easily performing a packaging of components such as the switches SW 1 and SW 2 for changing each electrical length of the parasitic elements 12 and 13 . In addition, the use of the dielectric substrate ensures that the effect of shortening the wavelength is obtained, resulting in an advantage of attaining a downsizing.
[0066] By the way, the Yagi slot antenna 10 having been described the above is merely effective in controlling the directivity pattern on a single frequency. A multi-frequency antenna capable of controlling the directivity pattern on more than one frequency is, however, desired to meet a great variety of radio communications in recent years.
[0067] For the above reason, in the embodiment of the present invention, the above Yagi slot antenna (a first antenna circuit) and a phase-difference feed antenna (a second antenna circuit) are configured to ensure that the multi-frequency antenna capable of controlling the directivity pattern on more than one frequency is realized.
[0068] Then, a mechanism of the phase-difference feed antenna employing a hybrid coupler is now described with reference to FIG. 9 , in advance of a description on the multi-frequency antenna specified as the embodiment of the present invention. A 3 dB-hybrid coupler 41 shown in FIG. 9A is in the form of a four-terminal circuit, and an S-matrix thereof may be expressed as follows.
[ S ] = 1 2 [ 0 0 1 - j 0 0 - j 1 1 - j 0 0 - j 1 0 0 ] [ Expression 1 ]
[0069] Thus, an entry of (1, 0) into input terminals t 1 and t 2 of the hybrid coupler 41 shown in FIG. 9A is supposed to provide a phase difference of 90 degrees between output terminals t 3 and t 4 at an amplitude equal to [Expression 2]
(1,0) (1/{square root}{square root over (2)}, − j/ {square root}{square root over (2)}).
Further, the entry of (0, 1) into the input terminals t 1 and t 2 is supposed to allow the output terminals t 3 and t 4 to invert phases to [Expression 3]
(0,1) (− j/ {square root}{square root over (2)}, 1/{square root}{square root over (2)}).
The use of a phase inversion of 90 degrees as described above enables the switching of the directivity to be performed, in which case, the phase inversion of two monopole antennas a and b spaced at an interval of ¼ λ as shown in FIG. 9B , for instance, is supposed to provide the directivity in an xy-plane as follows.
F ( θ ) = 1 ± j ⅇ - j π 2 sin θ [ Expression 4 ]
[0070] The above directivity is in the form of two Cardioid patterns symmetrical with respect to a y-axis to ensure that an inverted directivity with respect to the y-axis is obtained as shown in FIG. 9C . The phases of the monopole antennas a and b are switched over by the 3 dB-hybrid coupler 41 , so that a two-way switching of the beams is made possible.
[0071] While the two-way switching is supposed to be attainable with the 3 dB-hybrid coupler 41 and a non-directional antenna, the use of the directivity of the antenna contained in an antenna array may lead to a four-way switching of beams.
[0072] When four micro current elements each having a figure-8 pattern within a horizontal plane, for instance, are arranged as shown in FIG. 9D , an excitation of the above elements with two 3 dB-hybrid couplers 41 a and 41 b is supposed to enable the four-way switching of the beams to be performed within the horizontal plane.
[0073] FIG. 10 shows a structure of the multi-frequency antenna specified as the embodiment of the present invention. A multi-frequency antenna 30 of the embodiment of the present invention as shown in FIG. 10 has an antenna element 31 at the approximately center position of the planar printed circuit board 2 , and antenna elements 32 and 33 before and behind the antenna element 31 . The antenna element 31 is connected to a first feed unit 34 and is given the feed from the first feed unit 34 . One end of the antenna element 32 is connected to a second feed unit 35 to ensure that the feed is given with the second feed unit 35 . One end of the antenna element 33 is connected to a third feed unit 36 to ensure that the feed is given with the third feed unit. In this case, the slot length of the antenna element 31 is specified as the length equivalent to the ½ wavelength of the transmitting/receiving frequency. Further, each slot length of the antenna elements 32 and 33 is supposed to be larger than that of the antenna element 31 .
[0074] The antenna element 32 has switches SW 1 and SW 2 . Further, the antenna element 33 has switches SW 3 and SW 4 . The antenna element 31 and the antenna elements 32 and 33 are spaced at intervals of about ¼ wavelength respectively.
[0075] In the multi-frequency antenna 30 of the above configuration, when setting this antenna to operate at a first frequency F 1 of 5.2 GHz band, for instance, the feed from the first feed unit 34 only to the antenna element 31 is firstly performed. That is, only the antenna element 31 is set to function as the driven element (the radiator), while the antenna elements 32 and 33 are set as the parasitic elements. Then, a control of the switches SW 1 and SW 2 of the antenna element 32 or the switches SW 3 and SW 4 of the antenna element 33 is performed to control the electrical length of either of the antenna elements 32 and 33 to reach the director length. Thus, the antenna apparatus having the two-way directivity at the first frequency F 1 may be realized by setting the multi-frequency antenna 30 of the embodiment of the present invention to operate like the Yagi slot antenna 10 shown in FIG. 7A .
[0076] On the contrary, when setting the multi-frequency antenna 30 of the embodiment of the present invention to operate at a second frequency F 2 of 2.45 GHz band, for instance, the feed from the second feed unit 35 and the third feed unit 36 is performed at different phases (0 degree and 90 degrees), provided that the switches SW 1 to SW 4 are placed in the open-circuited state. With this operation, the multi-frequency antenna 30 of the embodiment of the present invention may be set to operate as the above phase-difference feed antenna for reason that the antenna elements 32 and 33 are spaced at a fixed interval, thereby providing the antenna apparatus having the two-way directivity also at the second frequency F 2 .
[0077] That is, according to the multi-frequency antenna 30 of the embodiment of the present invention, the control of the directivity pattern of the radio waves at two different frequency bands of the first frequency F 1 and the second frequency F 2 may be ensured.
[0078] Further, in this case, the antenna elements 32 and 33 may be used in common as the parasitic element in the Yagi slot antenna and a radiation element in the phase-difference feed antenna, so that there is also an advantage of attaining the downsizing of the multi-frequency antenna.
[0079] FIG. 11 shows the directivity patterns of the multi-frequency antenna of the embodiment of the present invention shown in FIG. 10 . It may be appreciated that when using the multi-frequency antenna 30 at the first frequency F 1 , the directivity of the multi-frequency antenna is made controllable by setting the switches SW 1 and SW 2 of the antenna element 32 to a short-circuited position (the short-circuited state) and the switches SW 3 and SW 4 of the antenna element 33 to an opened position (the open-circuited state) or by changing over the switches SW 1 and SW 2 of the antenna element 32 to the opened position (the open-circuited state) and the switches SW 3 and SW 4 of the antenna element 33 to the short-circuited position (the short-circuited state), as shown in FIGS. 11A and 11B .
[0080] It may be also appreciated that when using the multi-frequency antenna 30 of the embodiment of the present invention at the second frequency F 2 , the directivity pattern of the multi-frequency antenna is made controllable by performing the feed, with the second feed unit 35 set to have the phase of 90 degrees and the third feed unit 36 set to have the phase of 0 degree or on the contrary, with the second feed unit 35 set to have the phase of 0 degree and the third feed unit 36 set to have the phase of 90 degrees, as shown in FIGS. 11C and 1D .
[0081] Thus, a mounting of the multi-frequency antenna 30 of the embodiment of the present invention in an apparatus body 52 of a wireless LAN base station apparatus 51 available at any place irrespective of indoor and outdoor places as shown in FIG. 12A , in a mobile information terminal 53 such as a notebook-sized personal computer as shown in FIG. 12B or in a non-illustrated wireless television receiver makes it possible to realize the multi-frequency antenna adaptive to more than one radio communication. Further, the multi-frequency antenna in this case enables the control of the directivity, leading to a possibility of restraining the degradation of the communication quality with the interference wave caused by the reflection from the wall etc.
[0082] Further, while the multi-frequency antenna 30 of the embodiment of the present invention limits the number of the antenna elements 32 and 33 available also as the director or the reflector to one, respectively, this is merely given as one instance, and it is also allowable to form each of the antenna elements 32 and 33 with more than one antenna element. Furthermore, while the embodiment of the present invention has been described by taking the case of the antenna configured on the basis of the slot antenna, it is a matter of course that the above antenna may be also configured on the basis of antennas other than the slot antenna.
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In order to have an antenna apparatus small in size and capable of switching its directivity pattern to be adaptive to multiple frequencies, the present invention provides an antenna apparatus having a first antenna element formed at an approximately center position of a planar printed circuit board and second antenna elements formed before and behind the first antenna element. It is possible to construct an antenna in which the first antenna element functions as a radiator and the second antenna elements function as a director or a reflector, respectively, by changing electrical length of the second antenna elements. The antenna becomes adaptive to multiple frequencies by feeding the second antenna elements at different phases to have the second antenna elements functioning as radiators.
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BACKGROUND OF THE INVENTION
The theft rate of automobiles and other wheeled vehicles has stimulated the development of burglar alarm systems which are adapted to let out a noise when triggered through the actions of an intended thief in endeavoring to remove portions of a given vehicle or even to gain access thereto.
So far as I am now aware, such alarm arrangements have been heretofore actuated, that is, armed or disarmed, by either one or two techniques. Thus, by one technique, a special lock is provided somewhere on the body of the vehicle which can be opened or closed by a key controlled by an operator exteriorly located with respect to the vehicle. The lock in this case only activates or deactivates a mercury switch controlling alarm activation. The lock itself is located somewhere on the vehicle and serves no function in actually locking or unlocking portions thereof. This technique suffers from the disadvantage that any intended thief by merely inspecting exterior surfaces of the vehicle, can determine whether the vehicle is equipped with an alarm system, thereby suggesting techniques for foiling operation of the system. For example, a sharp rap of the lock itself will break the glass vial of the switch. Another disadvantage of this technique lies in the fact that a vehicle operator must not only lock up his vehicle upon leaving same, but must also separately unlock the alarm system, requiring extra time-consuming operations. A further disadvantage is that such technique requires the employment of expensive lock and key switches and installation charges.
The other technique involves a delay mechanism which permits a vehicle operator a short interval of time after unlocking, for example, a door, to enter his vehicle and accomplish engine ignition before an alarm system is triggered. This technique suffers from the disadvantage that skilled thieves require only a few seconds of time to reach and accomplish removal of expensive accessory components in an automobile. Another disadvantage lies in the fact that this technique requires expensive auxiliary equipment and associated installation charges.
So far as I am now aware, no one has heretofore provided a simple and commercially practical technique for arming and disarming alarm systems for vehicles which operates directly by merely inserting a key into a vehicular lock, such as a door lock and using such key to, for example, lock or unlock the door, thereby arming or disarming, respectively, some prechosen alarm system associated with the vehicle.
BRIEF SUMMARY OF THE INVENTION
More particularly, by the present invention there is provide a key controlled alarm activating apparatus. In one aspect, this apparatus employs a combination of a key actuated lock tumbler assembly including a housing therefor, an electrical switch, lever means interconnecting said tumbler assembly with said electrical switch, and lost motion means for preventing movements of the lock tumbler assembly from excessive movement of said electrical switch between the open and closed positions thereof. The lost motion means is further adapted to maintain the switch in a desired closed or open position, even though the lock tumbler assembly is returned to a neutral position at the termination of a normal locking or unlocking operation, as the case may be.
In one preferred aspect, the present invention relates to a key actuatable switch assembly which is adapted to be interconnected with a key actuated lock tumbler assembly and which is further adapted to combine the electrical switch means, the lever means, and the lost motion means into a single small compact assembly.
A primary aim of the present invention is to provide an improved system for arming or disarming a vehicular alarm system in which normal key operation in locking or unlocking a door lock or the like concurrently serves to arm or disarm the alarm apparatus.
Other and further objects, aims, purposes and the like will be apparent to those skilled in the art from a reading of the present invention taken with the drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a fragmentary view in side elevation, some parts thereof being broken away and some parts thereof being shown in section, of one embodiment of an alarm activating system of the present invention;
FIG. 2 is a view taken generally along line II--II of FIG. 1;
FIG. 3 is a view taken along the line III--III of FIG. 1;
FIG. 4 is an illustrative schematic diagram of one electrical circuit for an alarm system activatable by the alarm activating system shown in FIGS. 1 through 3;
FIG. 5 is a side elevational view illustrating an alternative embodiment of an alarm activating system of the present invention;
FIG. 6 is a view taken along the line VI--VI of FIG. 5;
FIG. 7 is a vertical sectional view in fragmentary form through a portion of an automobile door illustrating a still further embodiment of an alarm activating system of the present invention;
FIG. 8 is a sectional view taken along the line VIII--VIII of FIG. 7;
FIG. 9 is a view taken along the line IX--IX of FIG. 8;
FIG. 10 is a sectional view taken along line X--X of FIG. 8;
FIG. 11 is a fragmentary view which is similar to the view shown in FIG. 8, but illustrating a still further alternative embodiment of an alarm activating system of the present invention; and
FIG. 12 is a fragmentary view which is similar to the view shown in FIG. 8, but illustrating a still further embodiment of an alarm activating system of the present invention.
DETAILED DESCRIPTION
Turning to the drawings there is seen in FIGS. 1 through 3 an embodiment of a key controlled alarm activating system of this invention herein designated in its entirety by the numeral 21. The system 21 employs a conventional key activated, axially revolvable arcuately, lock tumbler assembly designated in its entirety by the numeral 22, the housing of which is illustrated, for example, in FIG. 2. This lock tumbler assembly 22 is of the type conventionally found upon an automobile and the assembly 22 is shown mounted through the outside door panel 23 being retained in place by means of a retaining ring 24 on the inside of the door panel 23. A shaft member 26 which is axially aligned with the tumbler assembly 22 undergoes revolvable movements with the tumbler assembly internally. The shaft member 26 projects rearwardly from the housing of the tumbler assembly 22 and has a pair of integral ears radially extending in opposed relationship to one another from the terminal portion of the shaft 26. A flattened lever is pivotally mounted over the end of shaft member 26 being secured thereby by means of a retaining ring 29. The lever 28 is adapted to provide pivotal movements at the outside end 31 thereof whenever the tumbler assembly is pivoted with a key (not shown), the degree of pivotal movement afforded to the lever 28 being controlled by abutment of the ears 27 against the circumferentially spaced recesses formed in the lever 28 in the region of ears 27 at the location where the shaft member 26 extends through the lever 28, thereby providing a species of lost motion to the lever 28 with respect to arcuate rotational movements of the tumbler assembly 22, for reasons that will hereinafter be explained more fully.
The outside end 31 of the lever 28 is interconnected with a lever arm 32 at one end thereof. The opposite end of lever arm 32 interconnects with a fulcrum member 34 protruding from the gear box 33 of the door actuating mechanism employed for a vehicular door. Gear box 33 is of conventional design; for example, a gear box is found in the door of a Mercury Cougar automobile and also in the doors of all American and foreign made automobiles. Pivotal movement of the fulcrum 34 actuates a door locking mechanism interiorly contained within the gear box 33. Also, pivotal movement of the fulcrum 34 incidentally produces a pivotal movement of the lever arm 36 projecting in generally opposed relationship to the fulcrum 34. Lever arm 36 has joined thereto at one end thereof a lever arm 37.
Fulcrum 34 pivots on shaft 38 in gear box 33 as does lever arm 36. As the fulcrum 34 moves downwards, in this embodiment, the lever arm 36 moves upwards. When the lever arm 36 moves upwards, so does the lever arm 37 (lever arm 37 can also be considered to be the connecting rod 37). Connecting rod 37 is joined at its opposite end to a pivot link 39 as shown in FIGS. 1 through 3 (but see especially FIG. 3). As the connecting rod 37 moves upwards, pivot link 39 oscillates about bearing buttons 41 (paired). The bearing buttons 41 are supported in a door panel 42. Thus, as one end of pivot link 39 moves upwards, so does its opposite end. Such opposite end of pivot link 39 is flattened similarly to the starting end but is turned at 90° with respect to the starting end. Through a hole formed in the terminal end of pivot link 39 is extended a switch actuator rod 43. The switch actuator rod 43 at its gravitationally upper end has a hook formed therein which is inserted through the button 44 of a switch assembly 46 thus, as the switch actuator rod 43 moves upwards and downwards, the switch assembly is controlled in on and off positions through movement of the button 44 by the switch actuator rod 43.
The gravitationally lower end of the switch actuator rod 43, as mentioned, projects through a hole formed in the terminal end of the pivot link 39. The lower end of the switch actuator rod 43 is threaded and provided with a pair of nuts or clamps 47. Nuts 47 or like adjustable means are presently preferred in order to provide adjustability of their respective relative positions on the rod 43. The nuts 47 are used to control the position of the pivot link relative thereto and also to limit upwards and downwards travel of the rod 43. Also, the nuts 47, by the spacing therebetween, provide a species of lost motion. The amount of lost motion is predetermined by the distance through which the button 44 is to travel during movement of the switch button 44 during closing and opening movements. Thus, as a key is turned in tumbler assembly 22, the switch assembly 46 is turned on or off as the case may be. Turning in a locking direction activates the alarm system turning in an open direction opens the switch assembly 46. In this embodiment, as those skilled in the art will appreciate, the switch actuator rod 43 replaces a similar rod used to control the door locking pin projecting conventionally upwardly through the window frame of an automobile door.
While the lost motion means provided by the combination of the nuts 47 on rod 43 coacting with the pivot link 39 serves to prevent over-run in operation of the button 44 of switch assembly 46, the lost motion provided by the lever 28 in combination with the ears 27 of the shaft member 26 serves a different purpose. Thus, most tumbler assemblies are designed so that a key inserted thereinto is not removable unless the tumbler assembly is in a neutral position. Therefore, after a locking or opening operation of a key in a tumbler assembly, it is typically necessary to turn a tumbler assembly to a neutral position as, or before, a key therein is removed. In the system of the present invention, such a reverse turning action, where the lost motion arrangement indicated is not present, would result in a deactivation of the alarm system. Therefore, the ears 27 permit the lever 28 to first operate the switch assembly 46, and then, as the ears reverse their direction of rotational movement as the key is withdrawn, no movement of the lever 28 occurs, so that the switch assembly remains in a locked or closed position. During switch deactivation, a reverse procedure occurs.
FIG. 4 illustrates a typical circuit of the type employed in an alarm system of the vehicular type. Here a car battery 48 is used as a power source. In the line 49 leading to switch 46 from battery 48, as those skilled in the art will appreciate, a number of other electrically operated components are connected. Switch 46, however, is electrically directly interconnected with the battery 48. The other terminal of the switch 46 leads an alarm assembly 50. When the switch 46 is closed, a circuit through the switch 46 to the alarm 50 is formed. A branch line 51 in the alarm line 52, which line 51 is interconnected with the relay 53 at the second terminal of the relay, feeds back into a line 54 which joins an alarm return line 55. The line 56 interconnects the alarm line 55 and the relay return line 54 with a plurality of switches designated generally by the number 57.
Each of the switches 57 can be considered to be a normally closed switch which is physically held open by the particular accessory to which the switch is interconnected or associated physically. If that accessory, door member, or the like is tampered with, or altered in its physical relationship to the vehicle involved, the switch is released and closes. When a switch 57 closes the complete circuit results and the alarm is actuated via ground. A line termed the relay contact line 58 at this point is activated because the relay with the closing of the circuit becomes activated and pulls down a relay contact 59 with which the line 58 is associated and returned to ground. As soon as the relay contact 59 is closed the secondary or holding circuit is established which maintains the functioning of the alarm 50 even if the switch or switches 57 is allowed to be reopened, as when a burglar releases his grasp of a car object or returns such car object to its initially normal position. The entire alarm circuit is turned off simply by inserting a key into the tumbler assembly 22 and turning the switch assembly 46 to an off position.
Turning to FIGS. 5 and 6, there is seen a further embodiment of a system of this invention which system is herein designated in its entirety by the numeral 61. System 61 employs a tumbler assembly 62 similar to tumbler assembly 22. The shaft 63 associated with the tumbler assembly 62 correctly interconnects with a lever 64 which, consequently, pivots at its outer end portion 65. A pin 66 extending from outer end 65 extends through a hook formed in the gravitationally upper end of a rod 67, the rod 67 being comparable to the rod 43 in the system 21. Rod 67 interconnects with the switch assembly 68. The switch assembly 68 can be considered comparable to the switch assembly 46 of the system 21 both in structure and in function. This hook at the upper end of the rod 67 in embodiment 61 provides the same lost motion function that is provided by the nuts 47 on the rod 43 as a protection against over-travel of a switch 68 in embodiment 21.
The fork link 70 is a conventional part of the door locking assembly in certain automobiles, such as a Volkswagen, and does not constitute any part of the present invention.
The switch 68 is, as shown, conveniently mounted on a bracket 71 which is associated with the automobile door panel. Wires 49 and 52 interconnect the switch 68 with a circuit such as that shown in FIG. 4.
Turning to FIGS. 7 through 10, there is seen one embodiment of a key actuatable switch assembly of this invention herein designated in its entirety by the numeral 200. The switch assembly 200 employs an electrically non-conductive housing 201 which has cylindrical side walls 202 and an interconnecting end wall 203. The end wall 203 has an axially extending channel 204 defined therein.
The switch assembly 200 is provided with an electrically conductive or non-conductive key receiver 206 which has an integral, cross-sectionally circular body portion 207 extending through the channel 204 and having an axially extending key way 208 defined therein on the outer face 209 thereof. The key receiver 206 further has an integral cross-sectionally circular base portion 211 which is generally coaxial with the body portion 207. The base portion 211 is located in the interior of the housing 201 and has a shorter radius than does the body portion 207.
The key receiver 206 is provided with flange means. Thus, in the embodiment shown, a circumferentially extending flange 212 extends radially outwardly from the body portion 207 between the body portion 207 and the base portion 211. The flange means is adapted to make sliding face-to-face engagement within side regions 213 of the housing 201 rotated adjacent the channel 204.
A pair of integral wings 214 and 216 are associated with the key receiver 206. The wings 214 and 216 extend in radially opposed relationship to one another and also in radially outwardly extending relationship from the circumferential side wall portions 217 of the base portion 211.
The assembly 200 is also provided with an electrically non-conductive ring member 218 which is positioned interiorly of the housing 201 and is generally coaxially located with respect thereto. The ring member 218 has a cross-sectionally circular aperture 219 defined in the forward face 220 thereof. The aperture 219 is adapted for receipt therein of the base portion 211 in the assembled switch assembly 200.
A pair of arcuately extending recesses 222 and 223 are defined in the forward face 220 in radially opposed relationship to one another and also in radially outwardly extending relationship to the circumferential side wall portions 224 of the aperture 219 in the ring member 218. The recesses 222 and 223 are adapted for receipt therein of the wings 214 and 216, wing 214 being in recess 222 and wing 216 being in recess 223. The recesses 222 and 223 cooperate with the wings 214 and 216 to permit limited rotational movement of the wings 214 and 216 within the recesses 222 and 223 between radially extending, circumferentially spaced engagement positions therebetween.
A cross-sectionally circular opening 226 is defined in the rearward face 227 of ring member 218. Also, a radially extending passageway 228 is defined in the ring member 218 between the opening 226 and circumferentially extending side wall portions 229 of ring member 218.
An electrically conductive, cross-sectionally circular pin 231 is positioned in the opening 226 and the pin 231 projects across the radially inner mouth 232 of the passageway 228. The pin 231 includes spring biasing means 233 yieldingly urging the pin 231 axially outwardly away from the ring member 218 with respect to the rearward face 227 thereof.
An electrically conductive ball, 234 is positioned in the radially outer mouth 236 of the passageway 228. The ball 234 includes an electrically conductive biasing means such as a metallic spring 237 which both yieldingly urges the ball 234 radially outwardly from the ring member 218 and also electrically interconnects the ball 234 with the pin 231.
Assembly 200 is provided through the wall of housing 201 thereof with at least one first electrically conductive contact means. Thus, in the embodiment shown, such contact means is provided by the hollow rivet 238 and by the hollow rivet 239. Each of the hollow rivets 238 and 239 terminates inwardly and adjacently with respect to the inside surfaces 241 of the side walls 202 of housing 201 in a cup shaped pocket 242 and 243, respectively. Each pocket 242 and 243 is adapted for receipt therein of a portion of the ball 234. Each rivet 238 and 239 is radially and axially aligned with the ball 234. Also, each rivet 238 and 239 is circumferentially spaced from the other thereof in the side wall 202 of housing 201 by an angle greater than the angle subtended by each of the recesses 222 and 223 to enhance positive switching action in an assembly 200.
The assembly 200 or the like in accordance with the teachings of this invention is further provided with a second electrically conductive contact means for making electrical contact with the pin 231. This second electrically conductive contact means is so located relative both to the pin 231 and to the first contact means (above described) that an electrically conductive path between the first contact means and the second contact means exists which passes through the pin 231 when the ball 234 is engaged with the first contact means (such as hollow rivet 239, see FIG. 8) when the ball 234 is engaged with the first contact means (here hollow rivet 239) through rotational movement of the key receiver 206.
For example, referring to assembly 200, a stationary electrically conductive contact plate or pin 244 is provided which abuts against the outside end 246 of the pin 231. Support means for the plate 244 is provided as follows: the assembly 200 is secured through flanges outwardly extending from the housing 201 to a bracket 247 mounted against a frame of a door member (not detailed) by means of nut and bolt assemblies 248. An aperture 249 is provided in the upstanding ear of bracket 247. A gromet 251 is extended through the aperture 249 and the plate 244 is then mounted through the gromet 251 on its inside edge, the plate 244 is secured to the bracket 247 by means of a retaining ring 252 on its outside face, the plate 244 is retained in position by means of electrical connector members 253. Thus, the plate 244 is adapted to maintain electrical contact with the pin 231 relative to the housing 201. The electrical connector 253 and a second electrical connector 254 (the latter being held in place by the hollow rivet 238) provide electrical connector means functionally associated with each of the first and second contact means (here, in assembly 200, in the configuration shown, rivet 239 and plate 244).
Assembly 200 can be modified so as to incorporate thereinto a different form of second electrically conductive contact means within the spirit and scope of the present invention. Thus, referring to FIG. 11, there is seen another embodiment of a switch assembly of this invention which is similar to the embodiment of assembly 200 and which other embodiment is herein designated for convenience generally by the numeral 256. Assembly 256 is generally similar to assembly 200 except that assembly 256 is provided with a second radially extending passageway 257 defined in the ring member 218 between the opening 226 and the circumferentially extending side wall portions 229 of the ring member 218.
In addition assembly 256 is provided with a second electrically conductive ball means 258 positioned in the radially outer mouth 259 of the passageway 257. The ball 258 is similarly provided with an electrically conductive biasing spring means 261 which both yieldingly urges the ball 258 radially outwardly away from the ring member 218 and which electrically interconnects the ball 258 with the pin 231.
A hollow rivet 262 which is similar in construction to the hollow rivets 238 and 239 extends through cylindrical side wall 202 of housing 201 to provide electrical contact means for contacting the ball 258. The hollow rivet 262 is both radially and axially aligned with the ball 258 and also is circumferentially spaced from the rivets 238 and 239. The spatial respective locations of the hollow rivet 262 with respect to the hollow rivets 238 and 239, as those skilled in the art will appreciate, is such that, when the first ball 234 is engaged with the rivet, for example, 239 the second ball 258 is engaged with the rivet 262.
As in the case of assembly 200, the assembly 256 can be provided with two hollow rivets 262 analogous to the hollow rivets 238 and 239. Preferably hollow rivets 262 are axially offset with respect to the hollow rivets 238 and 239 together with the engageable ball 258 operating therewith. The assembly 256 can likewise employ a plurality of hollow rivets 238 and 239 although preferably a pair thereof is used. The relationship between first contact means and second contact means in an assembly of the type illustrated by assembly 256 is such that when the first ball 234 is engaged with the first contact means (here hollow rivet 239) a second contact means (here rivet 262) is interconnected therewith by means of an electrically conductive path through the pin 231 of the assembly 256. It will be appreciated that certain components in the respective assemblies 256 and 200 are similarly numbered strictly as a matter of convenience in the present description.
Each of the assemblies 200 and 256 is engageable for functional purposes with a key activated, axially arcuately revolvable lock tumbler assembly of a conventional nature herein briefly illustrated in FIG. 7 by the component numbered 62. Such engagement is accomplished through the use of a suitably formed stub shaft 63. At its forward end (not detailed in either of FIGS. 7 or 9) the stub shaft 63 is axially aligned with the tumbler assembly 62 and is adapted for revolvable movements therewith. The rear end of stub shaft 63 is shaped so as to be extendable into the key way 208. Conveniently, for example, the rear end of stub shaft 63 and the key way 208 can have cross-sectionally circular rectangular configurations so that turning movements of the stub shaft 63 cause rotational movements of the key receiver 206 in either of the assemblies 200 or 256, as those skilled in the art will readily appreciate.
Turning to FIG. 12, there is seen one further embodiment of the invention which is designated in its entirety by the numeral 266. Assembly 266 is similar to assembly 256, except that here a center pin is entirely eliminated and the single channel 267 is formed diametrically through the ring member 268. In channel 267, a coiled compression spring 269 is positioned and in the opposed ends and at each opposed end 267 a ball 271 is positioned. Aligned with each ball 271 is a hollow rivet 272. Each rivet 272 (paired) extends through the housing 273 of the assembly 266. An electrical connector 274 here of the stock out type is clamped by each rivet 272 to the housing 273 and each connector 274 then provides means for connecting wires to the assembly 266. The assembly 266 is shown in an alarmed or on position, as those skilled in the art will appreciate. In order to disarm the assembly 266 through the operation of a key in a tumbler assembly (not shown) with which the assembly 266 is connected, neutral positions are provided in the assembly 266 which are, in assembly 266, located at 90° with respect to the on positions illustrated. However, any circumferential spacing between the neutral position and the on position can be used, as desired, which those skilled in the art will readily appreciate. The neutral or off position in assembly 266 is provided by a pair of opposed rivets 276, each of which is mounted through housing 273 in the manner of the rivets 272. Thus, when the ring 268 is rotated about its axis 277, the balls 271 become detented in the respective mouths of the rivets 276 at the neutral point, one ball 271 in each rivet 276.
Other and further embodiments of the present invention will be apparent to those skilled in the art without departing from the teachings of the present invention.
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A system particularly adapted for vehicular use enabling a theft alarm system to be armed or disarmed through normal key locking and unlocking operations as in a door. The system employs a switch mechanism and lever means interconnecting the switch mechanism with the tumbler assembly of a door locking mechanism. A key-actuatable switch assembly is provided for preferred systems.
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This is a division of application Ser. No. 192.569, filed Sept. 30, 1980, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a modular member or module for forming composite false-ceilings.
Various types of false-ceilings are currently available which comprise essentially modular pre-formed blocks which are then joined together by cementing in some cases and by clasps of various description in other cases.
Those methods have shown to be impractical both during the assembling steps and from the standpoint of their poor aesthetic appeal.
SUMMARY OF THE INVENTION
This invention sets out to provide a novel module for forming composite false-ceilings which can overcome the problems presented by conventional approaches, and features ease of assembling, versatility of application, and low manufacturing cost.
Within that general aim, it can be arranged that said modules are provided with multiple engagement means such as to enable modules of the same type to be assembled together in various fashion, while having different geometrical configurations, thereby variable pattern false-ceilings can be produced.
It is further possible to arrange that the module according to the invention has a simple construction, which can be readily manufactured as by molding from a plastics material, thus increasing the production output and reducing costs.
Furthermore, it is possible to arrange that this novel module is formed with internal projections serving as engagement means for additional accessory items intended for improving the color effects and appearance of the assembled false-ceiling.
According to one aspect of the present invention, there is provided a modular member or module for forming composite false-ceilings, characterized in that it comprises two paired engagement elements, respectively a male pair and female pair, including matching female socket lugs and male socket lugs, and means for locking said male and female engagement elements to mating female and male parts, each engagement pair being provided with locking elements of its own also formed with holes for suspension elements, an annular ridge being further provided as a resting means for a cylindrical element included for aesthetic purposes or to enhance the color effects, or for a closing cap.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will become more clearly apparent from the following detailed description of a preferred embodiment thereof, given herein by way of example only and illustrated in the accompanying drawings, where:
FIG. 1 is a plan view of several modular members or modules having different geometrical configurations;
FIG. 2 is a side view of a module, showing the engagement elements (male pair and female pair);
FIG. 3 is a fragmentary perspective view of the male pair of engagement elements;
FIG. 4 is a perspective view of the female pair of engagement elements;
FIG. 5 is a sectional view taken along the line V--V of FIG. 4;
FIG. 6 is a fragmentary perspective view of a false-ceiling incorporating cylindrical elements effective to enhance its appearance;
FIG. 7 is a fragmentary perspective view of a first embodiment of the module according to this invention;
FIG. 8 is a fragmentary perspective view of the female socket in said first embodiment;
FIG. 9 is a fragmentary perspective view of the male socket or plug in said first embodiment; and
FIG. 10 is a sectional view of the interconnection area, taken along the line X--X of FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the drawing figures, the modular member or module according to the invention is generally indicated at 1 and comprises a continuous surface 2 of either circular or quadrangular configuration and having at equal distances apart (substantially every 90°) two pairs of engagement elements, respectively a male pair 3 and female pair 4.
Said first male pair 3 includes two vertical pins or plugs 5 and 5a which taper substantially conically toward their lower ends and are associated with the wall 2 of the circular module 1 by means of a vertical rib 6 and 6a.
At the top said two pins are associated by and integral with a quasi-rectangular continuous surface 7 with a rounded off lower side 8 to form an integral part thereof.
At the middle region thereof, said continuous surface has a through hole 9 for the insertion of suspension elements from the coiling therein, as explained hereinafter.
On the front, that same surface carries an additional locking member 10 comprising a rigid lug, also quasi-rectangular in shape with bevels and rounded sides in order to facilitate the assembling of the individual modules together.
The female engagement pair 4 comprises instead two externally cylindrical elements 11 and 11a (having a slightly shorter length dimension with respect to the actual height dimension of the module 1), which are connected to said module by means of similar ribs 12 and 12a forming an integral part of the module itself.
Said two cylindrical elements are provided internally with two quadrangular seats or sockets 13 and 13a, wherein said two pins 5 and 5a of the male engagement pair are forcibly inserted for engagement therewith.
On the front, said cylindrical elements with quadrangular sockets 13 and 13a have two vertically extending slots 14 and 14a having the purpose of allowing for a limited elastic deformation during the operation of interconnecting two contiguous modules.
These two cylindrical elements are spaced apart from each other, while being interconnected to form a single piece by a frontally rounded sector 15 having at its middle portion a smaller diameter hole 16a whereinto a threaded element 17 is engaged which enables the individual assembled modules to be suspended from and secured to the ceiling.
Rearwardly from said sector 15, there is provided a vertically extending seat 18, into which said lug 10 engages to lock the individual modules together.
FIG. 5 shows a sectional view through the joint area between two modules 19 and 19a, illustrating the perfect match being obtained between the male and female joint pairs, which is further enhanced by the presence of the engaging lugs 10 to complete a stable and secure connection between said modules.
Obviously, in order to suspend from the ceiling the multiple modular structure obtained by assembling together either similar or different individual modules, provision is made for the insertion of the threaded suspension element.
In fact, the operator will thread it into the hole 16, provided for the female joint pair, thus achieving at the same time a definitive engagement of the male pair as well, owing to the provision of the through hole 9.
As shown in FIG. 3, each individual module is formed at the base thereof with an annular ridge 20 extending peripherally thereto and forming a means for securing a cylindrical element 21 to be inserted for aesthetic or coloring purposes.
Of course, the same can be replaced with a cap 22, also intended to accomplish a varying volume composition to produce peculiar visual effects.
It is noteworthy that the invention fully achieves its objects.
A novel module structure for false-ceilings has in fact been provided which is extremely simple, easily manufactured with conventional methods, and ensures low production costs.
It should be noted, in particular, that novel jointing means have been provided, which are also simplified, while quite effective in actual practice, said means being obviously strengthened in their action by the presence of additional engagement means, of the protruding lug type, such as to improve the overall reliability of the connection.
A further, and not negligible advantage of this invention is that it affords the possibility, without changing the configuration of the joint, of assembling different geometric configurations or patterns such as to produce varying false-ceilings of pleasing volumetric and aesthetic effects.
Finally, another advantage is that each module is provided with an internal protruding annular ridge, extending peripherally thereto, for engagement with other lugs of different shape and color, thereby improving the visual effect of the false-ceiling.
As a variation of the embodiment described hereinabove, the Applicant has deemed it suitable to modify somewhat the invention subject matter, while retaining the teachings thereof; in a particular way, this second solution finds it application ideally to those false-ceilings which result from the assembling of quadrangular modules, or modules provided with side pairs extending perpendicularly to each other and having a plurality of small cells forming a nest. In particular, as visible from Fig. 7, each module 101 is defined by a substantially rectangular grid formed by walls 112 extending perpendicularly to each other in a first and in a second direction. The end portions of said walls 112 define the outer sides of the grid, wherein in particular first two adjacent outer sides are delimited by side walls 121 having the same height as the walls 112 and defining the height of the module. As visible in the drawing, the side walls are connected with first end portions of said walls 112 which form said two adjacent outer sides, whereas second two outer sides, formed by the second end portions of the walls 112 are not delimited by side walls.
The clasp means which enable consecutive modules to be united together are shown in the already cited FIGS. 7 to 10, where the module, generally indicated at 101, is respectively provided, on the second two mutually perpendicular outer sides thereof, with male engagement elements 102, and female engagement elements 103 on the first two outer sides (also normal to each other). Male engagement elements 102 and female engagement elements 103 form matching engagement means extending outwardly to the grid 101.
These engagement elements are substantially the subject matter of the variation, and for this reason have been shown detailedly in FIGS. 8 and 9.
The female engagement element 103, which as visible from the drawing, are arranged at the side walls 121 at the connection points thereof with the said portion of the walls 112 comprises a hollow vertical seat or cylindrical body 104 having a shorter length than the actual height of the module walls, the seat being rounded externally and having an inside hole, the cross-section thereof being quasi-quadrangular.
At the front thereof, the seat is interrupted by a vertical or longitudinal slot 105 which stops at the base 106 of said female engagement element 103 and defines a corner of the quadrangolar hole.
The top portion of that same engagement element opens to a housing or free portion 107 (for the subsequent male element), formed by a recess in the side wall 121 and provided respectively with two parts 108 and 109 devided by the respective end portion the wall 112 and an upper retaining cross-price 110.
The male elements, provided at the second end portion forming the second two adjacent outer sides and generally indicated at 102, comprises each a slightly conical pin 111 extending throughout the height of the wall 112 and having at the larger base thereof a pair of clasps or snap means 113 rigidly associated with a head 114. As visible in particular from FIG. 9, said head 114 extends substantially perpendicularly to the conical pin but parallel to the respective outer side of the grid, the head presenting a face looking towards the pin and supporting the snap means 113. The snap means 113, provided at the two sides of the pin 111, are formed by a lug departing from the head 114 in a direction substatially parallel to the pin.
Said pair of clasps 113 have, at the lower ends, an engagement tooth 115 which is bent at 90° such as to project outwardly from the grid and to engage in a stable manner into said ports 108 and 109 of the female engagement element.
During the assembling step, the vertical pin 111 is seated in said vertical groove 104, which is deformed elastically, while the wall 112 of the male element is inserted into the slot 105, thus aligning the entire connection. This same male element, when moved to the end of its travel, causes the pair of clasps 113 to insert their release-preventing teeth 115 into the ports 108 and 109, thus providing a stable and perfect connection of one module to the following one.
It will be apparent from the description of this first variation that the invention achieves its objects.
In fact, this solution also provides a module for composing false-ceilings, which is extremely simple, functional, and effective.
It should be noted in particular that this male/female connection is highly resistant to accidental shocks, owing to the presence of said projecting teeth, as well as resisting tensile efforts.
Another and not negligible advantage is that the connection is structurally simple, easily implemented from plastics material by injection molding, and variously adaptable to different shape modules, to result in aesthetically and visually pleasing false-ceilings.
Of course, in practicing the invention, some modifications may occur to the expert, and the materials, dimensions, and shapes may be any ones to suit individual requirements, without departing from the scope of the invention.
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A modular member for forming composite false-ceilings comprises two paired mating male and female cylindrical hollow lugs, each pair being provided with locking elements formed with holes for suspension elements, an annular ridge being furthermore provided as a rest for a cylindrical element included for aesthetic purposes or for a closing cap.
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RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119(e) to provisional patent application Ser. No. 60/333,403 filed Nov. 26, 2001; the disclosure of which is incorporated by reference herein.
GOVERNMENT RIGHTS
[0002] This invention was made with Government support under Contract No. 0205-G-BB853, awarded by MURI/ONR/UCLA, Contract No. N00167-98-K-0024 awarded by the Department of the Navy, Contract No. N00014-96-1-0802 awarded by the Department of the Navy and DARPA, Subcontract No 0205-G-7A114 awarded by MURI, and Grant No DMR-98-04734 awarded by NSF. The Government has certain rights in this invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally to porous anodic alumina films and more specifically to a method and apparatus incorporating porous anodic alumina films as a template for the fabrication of nanostructured devices.
BACKGROUND OF THE INVENTION
[0004] Porous anodic alumina (PAA) films are films generated by electrochemical oxidation of aluminum under selective conditions (electrolyte, temperature and voltage). These films have a unique morphology of a honeycomb array of channels, several nanometers in diameter and several microns in length, which are perpendicular to the surface of the film. At the alumina-aluminum interface however there is a non-porous undulated alumina barrier layer several nanometers thick. Since the pore size, the pore length, the inter-pore distance, and the barrier layer thickness can all be controlled by the anodization conditions, PAA films have attracted a lot of interest as a nanotechnology tool. PAA films have found applications as filters, collimators, as templates for nano-patterning and nanowire growth, and as photonic bandgap materials
[0005] PAA films have several disadvantages associated with them. These disadvantages have precluded the use of PAA films in a wider range of applications. Free-standing anodic films are extremely fragile and cannot sustain stress. Even when the film is attached to the aluminum substrate, the film may fracture since aluminum is a soft metal. Such uniform, small-feature and controllable porous structures have being successfully grown only on aluminum, and not on any other substrate. The growing porous film is separated from the underlying metallic aluminum by a scalloped layer of oxide, known as the barrier layer. The barrier layer prevents electrical contact to be established with the bottoms of the pores of the film.
[0006] The conventional way of fabricating the PAA films starts with an aluminum sheet that goes through several steps of mechanical and electrochemical polishing. Once the surface roughness of the sheet is down to the sub-micron level, the metal is anodized in an acidic bath and the porous alumina is obtained. The quality of the starting anodic alumina is usually low in terms of the ordering and uniformity of the pores. Therefore, this initial film is typically etched away and a new PAA film is grown under the same or similar anodization conditions. The pores cannot be provided all the way through the aluminum, since an electrical path through the aluminum is necessary to perform the anodization, and the aluminum substrate functions as an electrode for the anodization process. In order to obtain a PAA membrane in which the pores run completely through the film and are open (and accessible) on both sides, it is necessary to etch away the metallic aluminum sustaining the oxide and subsequently also to etch away the barrier layer, or to detach the membrane from the aluminum substrate by one of the available methods to do so.
[0007] In practice, this process has several disadvantages associated with it. The mechanical polishing steps introduce imperfections and contamination, limit the active area of the film, and limit the throughput of the process. Another disadvantage with the prior art process is that after the removal of the sustaining metal, the free-standing PAA film is very brittle and is hard to manipulate effectively. Further, during the etch steps the surface topography of the film is degraded thereby affecting the optical properties of the film and its use as a mask.
[0008] It would, therefore, be desirable to provide a method which allows for the fabrication of PAA films on a wide variety of substrates. When a rigid substrate is used, the resulting anodic film is more tractable, easily grown on extensive areas in a uniform manner, and can be manipulated without danger of fracturing. It would be further desirable to provide the film on patterned and non-planar surfaces. It would still further be desirable to provide the PAA film missing the barrier layer (partially or completely) such that the bottom of the pores can be readily accessed electrically such as by a conducting layer on the substrate. Having such a film, an array of nanowires perpendicular to the surface of the film can be deposited into the pores.
[0009] It would be further desirable to provide the PAA film on a patterned conducting layer such that the resulting anodic film can be provided with one set of pores filled with one type of nanowire material (e g n-type material) and another set of pores provided with a different nanowire material (e.g. p-type). It would be further desirable to provide the PAA film missing the barrier layer on a patterned conducting layer such that pores, or nanowires within the pores, can be electrically addressed independently from each other. It would further be desirable to provide the PAA templates such that multiple stages of the templates can be built, and can be stacked to form a multi-stage device.
SUMMARY OF THE INVENTION
[0010] The present new technology described herein allows for the fabrication of PAA films on a wide variety of substrates. The substrate comprises a wafer layer and may further include an adhesion layer deposited on the wafer layer. An alumina template is formed on the substrate. When a rigid substrate such as a conventional silicon wafer is used, the resulting anodic film is more tractable, easily grown on extensive areas in a uniform manner, and manipulated without danger of cracking. PAA films can also be grown this way on patterned and non-planar surfaces. Furthermore, under certain conditions the resulting PAA is missing the barrier layer (partially or completely) and the bottom of the pores can be readily accessed electrically. The resultant film can be used as a template for forming an array of nanowires wherein the nanowires are prepared by filling the pores of the template by a different material. The nanowires may be formed from various materials within the same template. Arrays of nanowires may be stacked on top of each other into a multi-stage architecture.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0012] FIG. 1 is a schematic illustration of the presently disclosed process for fabricating a PAA film, FIG. 2A is a SEM micrograph of a top surface of a PAA film formed by the presently disclosed method;
[0013] FIG. 2B is a SEM micrograph of a bottom surface of the PAA film of FIG. 2A ;
[0014] FIG. 2C is an AFM micrograph of a top surface of a PAA film of FIG. 2A ;
[0015] FIG. 2D is an AFM micrograph of a bottom surface of a PAA film of FIG. 2A ;
[0016] FIG. 3 is a SEM image showing the presence of nanowires within the template;
[0017] FIG. 4 is a cross-sectional view of a PAA template filled with nanowires;
[0018] FIG. 5 is a cross-sectional view of the interface between the barrier layer and a silicon oxide adhesion layer;
[0019] FIG. 6 is an image of nanowires attached to a substrate after the removal of the template;
[0020] FIG. 7A is a side view SEM image of a PAA film grown in a trench between two pieces of other material;
[0021] FIG. 7B is a top view SEM image of the PAA film grown in a trench between two pieces of other material,
[0022] FIG. 7C is a magnified view of a portion of FIG. 7A ;
[0023] FIG. 7D is a magnified view of a portion of FIG. 7B ;
[0024] FIG. 8A is a diagram of a thermoelectric element arranged as a cooling device;
[0025] FIG. 8B is a diagram of a thermoelectric element arranged as a power generating device;
[0026] FIG. 9A is a diagram showing the first stage of fabrication of a multicomponent nanowire array;
[0027] FIG. 9B is a diagram showing the second stage of fabrication of a multicomponent nanowire array;
[0028] FIG. 9C is a diagram showing the third stage of fabrication of a multicomponent nanowire array;
[0029] FIG. 9D is a diagram showing the fourth stage of fabrication of a multicomponent nanowire array;
[0030] FIG. 10 is a diagram of the steps in the assembly of a multi-component, multi-stage thermoelectric device.
[0031] FIG. 11 is a diagram of a multistage nanowire-based thermoelectric device.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Porous anodic alumina (PAA) has received considerable attention as a template for the fabrication of nanostructures. The ordered triangular array of pores of high aspect ratio, whose dimensions can be accurately tuned by the process parameters, has made PAA a suitable host for the fabrication of nanowires of a wide range of materials. Applications of these arrays of nanowires include dense magnetic storage devices, field emission devices, thermoelectric devices, photovoltaic devices, nano-electrodes, sensing devices, photonic components and the study of low-dimensional quantum effects. Several researchers have used PAA as a mask for etching or deposition processes.
[0033] More recently, it was found that the optical properties of alumina together with the proper positioning of the voids in the film result in a 2-dimensional photonic crystal with a bandgap which can be controlled in the wavelength range of 520-600 nm (for certain polarizations and propagation directions of the light).
[0034] A new approach for the use of porous alumina films as a template for nanofabrication is presented. In this process the porous films are prepared on silicon substrates, as an example for a technology-relevant rigid substrate, simplifying both the template fabrication and subsequent processing, and improving the quality of the films and their surfaces. Structural analysis of the film was carried out. Porous films without a barrier layer separating the substrate from the pore channel were prepared. The aspect ratio of the channels, i.e. the ratio between its length and its diameter, was controlled between ˜10 to ˜1000. Therefore, the film is suitable as a template for the growth of nanorods and nanowires. Prior techniques have produced PAA films on substrates having pores with a maximum aspect ratio of ˜50 and included a barrier layer. Nanowires of various materials (metals, semiconductors, and polymers) were prepared by pressure injection or electrochemical deposition in alumina films 5-10 μm thick with parallel ordered pores 40 nm in diameter. The films were also patterned by lithography, offering new opportunities for area-selective anodization, anodization of non-planar structures, and area-selective growth of nanowires. The new approach offers a straightforward method for the fabrication of arrays of nanostructures and their incorporation into electronic and optical devices The fabrication of PAA films on a silicon wafer which can be used as templates for providing nanowire arrays involves the following steps and is shown in FIG. 1 . While a specific implementation and process is described, it should be appreciated that similar process steps and materials could also be used. Preparation of the substrate 10 is the first step. While the use of silicon is described, other solid materials, such as III-V type materials, oxides, glasses and polymers, may serve as a substrate as long as their electrically conducting surfaces and their chemically reactive surfaces can be isolated from the electrolytes used in the process. This can be achieved by applying a suitable coating on the substrate or by confining the electrolyte. For example, we have used as wafer 10 glass slides, and silicon wafers whose back side was coated with silicon dioxide. The purpose of the substrate or wafer layer 10 is (1) to give mechanical strength to the device structure and (2) to mold the shape and topography of the PAA film. The PAA device may not, in general, be fabricated directly on the surface of the wafer 10 . This is because of the mechano-chemical constraints imposed by the process. The top surface of the substrate (the surface facing the PAA film) needs to strongly adhere to aluminum and to alumina, and it needs to support the strain associated with the volume expansion of the aluminum layer when it is converted to PAA. For this reason previous works dealt only with thin, therefore less strained, PAA films on substrates. These films have too low of an aspect ratio to grow nanowires.
[0035] For this reason, additional layers of material 20 may be deposited on the wafer. The purpose of the layers 20 , so called adhesion layers, is (1) to serve as an adhesion layer that holds together the stack of layers of the device and relieves structural stress, (2) to permit, in case of a conducting layer, the anodization process to react completely with the entire layer of aluminum, (3) to define the structure and properties of the interface between the bottom end of the channels and the substrate, in particular whether the barrier layer will be removed or will remain in the structure (vide infra), (4) to guide the filling of the pores and the formation of nanowires, for example as working electrodes during electrochemical deposition, and (5) to introduce other functionalities to the device, such as sensing and addressing capabilities. For example, an adhesion layer on a silicon wafer may consist of a film of deposited titanium, or a coating of thermal oxide, or a multi-layer structure (SiO 2 /Ti/Pt). At this stage conventional patterning techniques can be used to pattern the layers.
[0036] Nevertheless, omitting the use of the adhesion layer can be advantageous. The PAA film may be fabricated directly on wafer 10 . When the PAA is grown on a silicon wafer with its back side covered with SiO 2 the PAA film will separate from the wafer at the end of the anodization step. This is a convenient way to obtain high-quality free-standing PAA films with a surface topography precisely complementary to the topography of the wafer surface. For example, atomically flat substrates afford PAA films with extremely flat surfaces, particularly suitable as nanoscale pattern-transfer contact masks.
[0037] The next step after the substrate has been prepared involves providing a layer of aluminum 30 on the substrate. This step may be best accomplished by thermal evaporation of aluminum on the substrate. Other methods may include electron beam evaporation, rf-sputtering, electrochemical plating or other means as are known by those of reasonable skill in the art. The layer of aluminum may have a thickness of several hundreds of nanometers to several hundreds of microns. Depending on the method by which the aluminum was provided on the substrate, annealing might be required in order to enlarge the aluminum grain size to the level necessary for the proper formation of uniform pores during the anodization step.
[0038] Electrochemical polish of the aluminum surface is performed next. The surface can be polished by various techniques known by those of reasonable skill in the art. A preferred technique is to expose the aluminum surface to an H 3 PO 4 /H 2 SO 4 /CrO 3 solution at 85° C. and 20 volts for 1-2 seconds.
[0039] The next step comprises anodization of the entire aluminum. The conditions for the anodization vary according to the desired feature size. A clear change in the appearance of the film 40 is observed once the aluminum has been completely consumed: As long as aluminum is present, the film has a metallic reflective appearance, while the PAA film itself is transparent. Furthermore, features in the current vs time profile can be used to monitor the completion of the anodization.
[0040] Three cases need to be considered depending on the nature of the top surface of the adhesion layer (at the interface with the aluminum layer). In case I, this layer is a noble metal which in contact with the electrolyte and under the applied potential will generate oxygen gas. The anodization needs to be stopped as the electrolyte reaches the adhesion layer and the current rises, otherwise gas bubbles will rupture the PAA film. In case II, this layer is an insulator, and the current will approach zero. There is no critical time for terminating the anodization process. In case III, the adhesion layer is a valve metal or other material that gets slowly oxidized under the anodization conditions, after the anodization of the aluminum layer. The most appropriate time to terminate the anodization process needs to be found experimentally depending on the material used and the anodization conditions.
[0041] The next step is optional. In some instances it may be desirable to widen the pores of the alumina film. This widening of the pores may be accomplished by chemical etching in a solution of H 3 PO 4 .
[0042] Depending on the nature of the top surface of the adhesion layer, cases I, II and III above, measures may need to be applied to remove the barrier layer at the interface between the PAA film and the adhesion layer. In case I (noble metals), the barrier layer is normally missing from the areas where anodization was carried out till completion, so no further treatment is necessary. However, the treatment that will be discussed in the context of case III may be applied nevertheless. In case II (insulators), the conventional undulated thick barrier layer is usually present at the pore ends, and the measures discussed below will not act as to remove it. Therefore insulators should be used under pores that need to remain blocked. In case III (valve metals, etc), it has been observed that an inverted and thinner than usual barrier layer is obtained. This barrier layer is removed by a substrate-assisted localized etching as will be described below.
[0043] When the barrier layer is only partially missing it might be necessary to dissolve, etch or remove a thin layer of alumina at the bottom of the pores. The substrate layers are used for the local generation of a chemical agent or a force to rupture the barrier layer without inflicting damage on the rest of the alumina film. For example, cathodic polarization of an adhesion film made of titanium in a potassium chloride solution is used to generate hydrogen gas bubbles and hydroxide ions in the voids under the inverted barrier layer.
[0044] The resulting film 40 can be used as a template for the fabrication of nanowires 50 . The nanowire material is formed into the pores of the array. Methods for filling the pores include, but are not limited to, electrochemical deposition, chemical vapor deposition, pressure injection of a liquid, and impregnation.
[0045] This method enables the fabrication of thick (several microns) PAA films on substrates other than aluminum. This technique offers a unique, facile, and versatile approach for the incorporation of anodic alumina films or arrays of nanowires 50 into a variety of environments and devices.
[0046] As an alternative, the adhesion layers may be deposited on a thick aluminum film and then a wafer may be deposited or otherwise attached to the adhesion layers.
[0047] In a particular example, the results of which are shown in FIGS. 2-7 , thick aluminum films (6-12 μm) were obtained by thermal evaporation of Al (Plasmaterials, 99.999%) on n-type silicon substrates (Wafernet, 1-10 Ωcm) in a custom-built chamber (base pressure: 10 −6 torr). Ti and SiO 2 films were obtained by sputtering (Applied Materials Endura System) Ti and Pt films were obtained by electron-beam evaporation.
[0048] Electrochemical polishing of the films was carried out in an H 3 PO 4 \H 2 SO 4 \CrO 3 solution at 85° C. and 20 volts. The anodization was carried out at constant voltage (50V) in an oxalic acid solution (4 wt %) at 18° C. In both processes a Pt sheet was used as a counter electrode. The resulting alumina film was etched away in an H 3 PO 4 \CrO 3 solution for 16 hours, and the remaining aluminum was reanodized under the same conditions until the metal film was fully oxidized. Subsequently the alumina film was dipped for 30 minutes in 5% H 3 PO 4 . The alumina at the bottom of the pores was thinned and removed by applying a negative bias (2 25 V) to the template in a 2-electrode cell with a 0.1M KCl solution for 20 minutes.
[0049] The Bi 2 Te 3 nanowires were fabricated by electrodeposition from a solution of bismuth and tellurium (7 mM and 10 mM, respectively) in 1 M nitric acid in a 3-electrode cell at −10 mV vs. a saturated calomel electrode (SCE) using a PAR Model 273 potentiostat. The bismuth nanowires were fabricated by the pressure injection technique or by electrochemical deposition from an aqueous solution of 40 mM bismuth nitrate and 76 mM ethylenediaminetetraacetic acid (EDTA) at −650 mV vs. SCE.
[0050] Scanning electron microscopy (JEOL 6320FV) and atomic force microscopy (Digital Instruments Nanoscope IIIa, tapping mode) were employed for the structural analysis of the alumina films.
[0051] The PAA film was fabricated in accordance with the process previously described with respect to FIG. 1 . The aluminum film was thermally evaporated on a silicon wafer, its back side covered with a silicon oxide layer and its front side coated with a titanium layer. The film was electrochemically polished in a phosphoric acid—sulfuric acid—chromium oxide solution. The porous oxide was formed by anodization in an oxalic acid bath. A prominent change in the appearance of the film and a drop in the current indicated when the aluminum film had been completely oxidized. In order to selectively etch the side of the membrane in contact with the wafer and remove the thin oxide at the end of the pores, the wafer was held under negative bias in an aqueous potassium chloride bath. This process resulted in a high quality PAA film over the full area of the wafer, that was used for further processing, for example: patterning, etching and deposition. In contrast to the conventional PAA films, the films on the silicon substrates can be obtained without an insulating barrier layer at the bottom of the pores, they are very easy to handle due to the mechanical strength of the substrate, and they are suitable for incorporation into larger architectures and devices in the wafer.
[0052] It was found that the adhesion of the PAA film to the wafer could be controlled by the predeposition of other materials on the wafer. When the aluminum was evaporated on a bare silicon wafer, the alumina detached from the substrate as the anodization endpoint was reached. If a titanium layer was sputtered on the substrate before the aluminum film, the alumina adhered permanently to the substrate. Since free standing PAA films can be obtained if no adhesion layer is used, both faces of the PAA film can be analyzed.
[0053] Referring now to FIGS. 2A and 2B SEM images of the top side (facing the solution) and the bottom side (facing the wafer) of the PAA film 40 is shown. These images show that the porous structure is continuous through the membrane 40 with a noticeable hexagonal pattern, and that the barrier layer is missing. The AFM images of the surfaces shown in FIGS. 2C and 2D show a striking difference between the faces: the bottom side of the film 40 is inherently flat, mirroring the smoothness of the silicon surface, while the top side of the PAA film 40 shows the typical roughness associated with the effects of the etch solutions. The flat surface of the PAA film improves its performance as a contact mask for pattern-transfer, compared to PAA films made by other methods, increasing the fidelity of the pattern-transfer process.
[0054] The alumina-on-silicon system was considered as a template for the fabrication of nanowires. Two methods of pore filling and two materials of relevance to thermoelectric applications were employed. The first method and material comprised bismuth nanowires, 40 nm in diameter, were prepared by a pressure injection technique. By stripping the filled alumina from the substrate, it was verified through SEM imaging that the nanowires are continuous, sticking out of both ends of the channels. FIG. 3 shows the bottom (wafer) side of the porous template 40 , partly filled with bismuth nanowires 50 (bright spots in the channels).
[0055] The second method and material comprised Bi 2 Te 3 nanowires prepared by electrochemical deposition from a nitric acid solution. The titanium layer under the oxide film served as the working electrode from which the nanowires began growing. FIG. 4 shows a cross section of a bismuth telluride filled template 40 . A high filling factor of continuous nanowires 50 (bright sticks) is observed.
[0056] These two examples demonstrate the accessibility of the pores from either end, despite the fact that the membrane is attached to a substrate. The pores can be filled either by depositing material from the bottom ends (wafer side) up as in the electrochemical deposition, or by inserting material from the top ends (solution side) into the pores. In the same fashion, the obtained nanowires can be contacted physically, mechanically, electrically, thermally and possibly optically from both ends. The resulting nanochannel arrays and nanowire arrays can thus be incorporated into electronic and optical devices on the wafer and be further utilized in nano-scale and micro-scale patterning. When a patterned conductor layer is used under the PAA film, it is possible to provide different types of nanowires on different areas within the same template.
[0057] In another example, the silicon wafer was thermally oxidized Aluminum was deposited on the wafer, electrochemically polished, and anodized as described in the previous example. The anodization was continued till the current value reached 0.01% of the maximum anodization current. FIG. 5 shows a cross section of the interface between the scalloped alumina barrier layer 40 and the silicon dioxide layer 20 . This thick barrier layer is resistant to the localized etching process described above.
[0058] In another example, the silicon wafer was thermally oxidized. Electron-beam evaporation was used to deposit a titanium layer followed by a platinum layer on the front side of the wafer Aluminum was deposited on the wafer, electrochemically polished, and anodized as described in the previous examples. The anodization was carried out until a surge in current was observed. No further steps were necessary to remove the barrier layer. Bismuth nanowires were electrochemically deposited in the pores from an aqueous solution of bismuth nitrate and EDTA. FIG. 6 shows the bismuth nanowires attached to the platinum film on the surface of the wafer after the alumina was etched away.
[0059] The presently disclosed method provides the ability to pattern the PAA film by the fabrication of a series of bars of alumina in between slabs of silicon oxide predeposited on the wafer. FIGS. 7A-7D show an example of a 25 μm wide, 5 μm thick, and 1500 μm long PAA strip 40 obtained by the anodization of an aluminum bar between bars of silicon oxide 60 . It is interesting to notice the lateral growth of pores from the sidewalls in addition to the vertical growth of pores from the top surface. The different growth rates lead to the curved shape observed in the cross section view of FIG. 7A . Clearly, the anodization of non-planar features displays an additional complexity, which could be exploited to obtain a new variety of structures.
[0060] Referring now to FIGS. 8 A-B, thermoelectric devices 100 and 101 are shown schematically. The thermoelectric device 100 is arranged to operate as a cooling device. The devices include a leg of n-type material 110 , a leg of p-type material 120 and a junction 130 interconnecting the n-type leg 110 with the p-type leg 120 . Device 100 further comprises a voltage source 140 coupled across the n-type leg 110 and p-type leg 120 . This arrangement results in current flowing from the n-type leg, across junction 130 and through p-type leg 120 . Whenever electrical current flows through two dissimilar materials, depending on the direction of current flow through the materials, the junction of the p-type and n-type material will either absorb or release heat. When the thermoelectric device 100 is connected to a voltage source 140 such that the n-type leg 110 is connected to the positive lead of the voltage source and the p-type leg 120 is connected to the negative lead of the voltage source, the following phenomenon occurs. Charge carriers, also known as electrons, in the n-type material are repelled by the negative potential and attracted to the positive potential of the voltage source. Similarly, the positive charge carriers, also known as holes, in the p-type material are repelled by the positive voltage potential and attracted by the negative potential of the voltage source. The charge carriers are carrying heat away from the junction 130 connecting the p-type and n-type material, thus the device is providing a cooling function at the junction connecting the p-type and n-type materials.
[0061] Conversely, when the thermoelectric device 100 is connected to a voltage source such that the p-type leg is connected to the positive lead of the voltage source and the n-type leg is connected to the negative lead of the voltage source the opposite effect takes place. The negative charge carriers (electrons) in the n-type material are repelled by the negative potential and attracted to the positive potential of the voltage source. Similarly, the positive charge carriers (holes) in the p-type material are repelled by the positive voltage potential and attracted by the negative potential of the voltage source. The charge carriers are carrying heat to the junction of the p-type and n-type material, thus the device is providing a heating function at the junction of the n-type and p-type materials.
[0062] Referring now to FIG. 8B , when a heat source is brought into proximity with junction 160 of device 101 , a voltage differential is provided across p-type leg 120 and n-type leg 110 . In the n-type side of the deice 101 , the heat causes negative charge to flow from the junction 160 to the colder end of the n-type leg 110 of the thermoelectric device. In the p-type side of the device 101 , the heat is causing positive charge to flow from the junction region to the colder end of the p-type leg 120 . In this configuration, the thermoelectric device is converting heat to electrical energy, thus functioning as a power generator.
[0063] A device comprising a thermoelectric element formed from nanowire arrays and the process for making such a device is shown in FIGS. 9A-9D . As shown in FIG. 9A , a silicon substrate 210 is provided as the support for the device. A pair of electrodes 230 is patterned on the silicon substrate. A porous anodic alumina film is provided on the electrodes and substrate. The process for providing such a porous anodic alumina film has been described in detail above.
[0064] Referring now to FIGS. 9B and 9C , a plurality of p-type nanowires 222 are provided in the film over one of the electrodes, and as shown in FIG. 9C a plurality of n-type nanowires 224 are provided in the film over the other electrode.
[0065] As shown in FIG. 9D a junction 260 is deposited on the top surface of the film 220 . Junction 260 provides an electrical path and a thermal path between the n-type nanowires 222 and the p-type nanowires 224 . The resulting device can perform as a cooling device, similar to the thermoelectric device shown in FIG. 8A when a voltage source is provided across the electrodes. The thermoelectric device can also function as a power generator when a heat source is provided to junction 260 .
[0066] Referring now to FIGS. 10 and 11 , a multi-stage nanowire-based thermoelectric device is shown. A single stage 300 of the device is the same as the device described above with respect to FIGS. 9A-9D . However, in order to turn the single thermoelectric device into a multistage thermoelectric device, additional steps are required. As shown in FIG. 10 , once a single nanowire based thermoelectric device 300 is produced, a thermally conducting electrically insulating material 270 (such as a ceramic) is deposited over the junction 260 . This material extends over the junction 260 and also over the array of p-type nanowires and over the array of n-type nanowires. Another device 300 is provided on top of the material 270 of the first device, using material 270 as a base support. This process is repeated any desired number of times resulting in a multi-stage nanowire based thermoelectric device, 310 as shown in FIG. 11 . These devices 310 generate a larger temperature gradient than single stage devices 300 .
[0067] As described above, high quality porous alumina membranes are fabricated on silicon substrates by a novel process. Improvements in terms of the effective area of the films and the flatness of the surfaces resulted from the new process. The films may be formed lacking the insulating barrier layer, making the pores accessible from both ends. The adhesion of the porous alumina to the substrate can be modified by intermediate layers, making it possible to obtain both free standing films and films strongly held to the wafer. The films were used as templates for the growth of bismuth and bismuth telluride nanowires. Silicon processing techniques were used for the area-selective growth and patterning of the porous films. In summary, this new approach simplifies the preparation of the porous oxide and allows much more flexibility in the processing of the film, making porous alumina a convenient and versatile tool for the assembly of devices based on nanostructures. Single stage and multistage nanowire-based thermoelectric devices are produced using the present process.
[0068] Having described preferred embodiments of the invention it will now become apparent to those of ordinary skill in the art that other embodiments incorporating these concepts may be used. Accordingly, it is submitted that the invention should not be limited to the described embodiments but rather should be limited only by the spirit and scope of the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.
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The presently disclosed invention provides for the fabrication of porous anodic alumina (PAA) films on a wide variety of substrates. The substrate comprises a wafer layer and may further include an adhesion layer deposited on the wafer layer. An anodic alumina template is formed on the substrate. When a rigid substrate such as Si is used, the resulting anodic alumina film is more tractable, easily grown on extensive areas in a uniform manner, and manipulated without danger of cracking. The substrate can be manipulated to obtain free-standing alumina templates of high optical quality and substantially flat surfaces PAA films can also be grown this way on patterned and non-planar surfaces. Furthermore, under certain conditions the resulting PAA is missing the barrier layer (partially or completely) and the bottom of the pores can be readily accessed electrically. The resultant film can be used as a template for forming an array of nanowires wherein the nanowires are deposited electrochemically into the pores of the template. By patterning the electrically conducting adhesion layer, pores in different areas of the template can be addressed independently, and can be filled electrochemically by different materials. Single-stage and multi-stage nanowire-based thermoelectric devices, consisting of both n-type and p-type nanowires, can be assembled on a silicon substrate by this method
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FIELD OF THE INVENTION
The present invention generally relates to battery end-of-life indicators for implantable pulse generators-especially those suitable for neuromuscular stimulation.
BACKGROUND OF THE INVENTION
Muscle-powered cardiac assist systems been developed to aid patients with chronically and unacceptably low cardiac output, and who cannot have their cardiac output raised to acceptable levels by traditional treatments such as drug therapy. (See G. L. Anstadt & W. E. Britz, Jr., Continued Studies in Prolonged Circulatory Support by Direct Mechanical Ventricular Assistance, 14 Trans. Amer. Soc. Artif. Int. Organs 297 (1968)). U.S. Pat. No. 4,813,952 issued to Khalafalla, which is hereby incorporated by reference, teaches a cardiac assist system powered by surgically modified muscle tissue, such as the latissimus dorsi flap, using cardiomyoplasty techniques. Being fast twitch muscle tissue, the latissimus dorsi can be converted to slow twitch tissue for efficient long-term use by using the techniques taught in U.S. Pat. No. 4,411,268 issued to Cox, and also hereby incorporated by reference.
In a system using muscle wrapped about an ailing heart, an implantable pulse generator (IPG) senses contractions of a heart via one or more sensing leads, and stimulates the appropriate nerves of the muscle tissue (via stimulation leads) to cause the muscle tissue to contract in synchrony with the heart chamber of interest. As a result, the heart is made to contract more forcefully, raising the stroke volume, and hence cardiac output.
IPGs typically include end-of-life (EOL) indication circuitry for detecting and indicating an approaching depleted battery state. In prior art cardiac pacemakers, a typical response to an EOL condition is to lower the pacing rate.
A special EOL indication signal can be transmitted transtelephonically from the IPG (whether cardiac, neuromuscular, etc.) when the patient is at a remote location. However, this requires specific special equipment at the receiver end to properly interpret the signal as an EOL signal. Thus, without the special equipment, a clinician interpreting the transtelephonic data would not know that an EOL condition is imminent, and would not then be able to advise the patient that the time for replacement of the IPG has arrived.
SUMMARY OF THE INVENTION
The following are objects of the present invention in view of the above.
A first object of the present invention is to provide a battery EOL indicator for an IPG which is functional via transtelephonic monitoring, and without the need for a special receiver/programmer.
A second object of the present invention is to provide a battery EOL indicator for an IPG which indicates an approaching EOL condition without the need to make reference to stimulation signal parameters.
A third object of the present invention is to provide an IPG with a battery EOL indicator in which current consumption is reduced upon an indication of an approaching EOL condition, thus increasing the effective operation time of the unit.
A fourth object of the present invention is to provide a neuromuscular stimulation IPG capable of meeting all of the above objects.
There is provided in accordance with the present invention, a pacemaker system at least including:
an IPG at least including stimulation pulse generator means, battery EOL monitoring means for detecting an approaching battery EOL condition, and stimulation pulse generator modifier means coupled to the stimulation pulse generator means for intelligently modifying stimulation pulse signals generated by the stimulation pulse generator; and
a battery EOL condition indicator means coupled to the EOL monitoring means and to the stimulation pulse generator modifier means;
wherein, upon the detection of an approaching battery EOL condition, the EOL condition indicator means activates the stimulation pulse generator modifier means, and the stimulation pulse signals form discernible patterns indicating the approaching EOL condition, without reference to stimulation pulse signal parameters.
In an IPG at least including stimulation pulse generator means, and telephonic signal generator means coupled to the stimulation pulse generator means adapted to transmit an ECG, there is provided in accordance with the present invention, a battery EOL condition indicator at least including:
battery EOL monitoring means for detecting an approaching battery EOL condition; and
stimulation pulse generator modifier means coupled to the stimulation pulse generator means for intelligently modifying stimulation signals output by the stimulation pulse generator;
wherein, upon the detection of an approaching battery EOL condition, the ECG is modified to display discernible patterns indicating the approaching EOL condition, without reference to stimulation pulse signal parameters.
And, there is also provided in accordance with the present invention, a battery EOL condition indication method for an IPG at least including stimulation pulse generator means for generating stimulation pulse signals, the method at least including the steps of:
detecting an approaching battery EOL condition; and
intelligently modifying stimulation signals output by the stimulation pulse generator;
wherein, upon the detection of an approaching battery EOL condition, the stimulation pulse signals form to display discernible patterns indicating the approaching EOL condition, without reference to stimulation pulse signal parameters.
The details of the present invention will be revealed in the following description, with reference to the attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
The various figures of the drawing are briefly described as follows:
FIG. 1 is a first embodiment of a cardiac assist system capable of use with the present invention, wherein the skeletal muscle is wrapped about the myocardium
FIG. 2 is an alternative embodiment of a cardiac assist system capable of use with the present invention, wherein the skeletal muscle is wrapped about the descending aorta.
FIG. 3 is yet another alternative embodiment of a cardiac assist system capable of use with the present invention, wherein the skeletal muscle performs counter-pulsation of the descending aorta.
FIG. 4 is a block diagram of the IPG of the present invention.
FIG. 5A is a sample electrocardiogram (ECG).
FIG. 5B is an electrogram (EG) of muscle stimulation bursts corresponding to the ECG in FIG. 5A, prior to the detection of an approaching EOL condition.
FIG. 5C is an EG of muscle stimulation bursts of a first embodiment of the present invention corresponding to the ECG in FIG. 5A, after the detection of an approaching EOL condition.
FIG. 5D is an EG of muscle stimulation bursts of a second embodiment of the present invention corresponding to the ECG in FIG. 5A, after the detection of an approaching EOL condition.
FIG. 5E is an EG of muscle stimulation bursts of a third embodiment of the present invention corresponding to the ECG in FIG. 5A, after the detection of an approaching EOL condition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention employs a sensor to monitor cardiac electrical activity and cardiac demand in a skeletal muscle-powered cardiac assist system (CAS). A basic CAS may be configured in a variety of ways as described in the aforementioned patent to Khalafalla. Several of these configurations are discussed herein by way of illustration, and are not intended to limit the present invention.
FIG. 1 is an embodiment of the present invention wherein skeletal muscle 22 is wrapped about a human heart 100. Skeletal muscle 22 is conditioned as a slow twitch muscle according to the aforementioned patent to Cox. An IPG 36 is coupled to a pacing lead 34 to produce a demand pacemaker. In addition, the IPG 36 stimulates skeletal muscle 22 to contract in synchrony with the heart 100. The simultaneous contraction of the skeletal muscle 22 provides assistance to the heart 100 to increase its systolic pressure in the descending aorta 102 and elsewhere in the circulatory system.
According to the present invention, the IPG 36 employs an activity sensor 104 to, in addition to sensing cardiac activity via the pacing lead 34, sense and output indicia of the patient's activity, and hence cardiac demand.
FIG. 2 is an alternate embodiment of the CAS in FIG. 1. In this embodiment, skeletal muscle 22 is wrapped about an artificial chamber 20, which chamber is inserted in series with the descending aorta 102. Unlike the embodiment in FIG. 1, the IPG 36 stimulates the skeletal muscle 22 to contract following evacuation of the heart 100, which is accomplished by the insertion of a delay between a paced or sensed beat of the heart 100 and the stimulation of the skeletal muscle 22 as discussed infra.
FIG. 3 is another alternate embodiment of the CAS in FIG. 1 wherein an artificial chamber 20 is coupled external to the descending aorta 102. In this configuration the skeletal muscle 22 is stimulated to counter-pulse the heart 100, which raises its diastolic pressure, thereby increasing its perfusion. This is accomplished by the generation of sufficient delay by the IPG 36, between and sensed or paced contraction of the heart 100 and stimulation of the skeletal muscle 22 to cause the desired counter-pulsation.
FIG. 4 is a schematic block diagram of the IPG of the present invention. It includes a demand pacing generator 154 as is known in the art. In operation, the electrical activity of the patient's heart is monitored via the pacing lead 34. A sense amplifier 156 detects any naturally occurring heart depolarization (representing a contraction), and notifies the pacing generator 154. If the natural depolarization is sensed within an allotted time, the output of the pacing generator 154 is inhibited. However, if the pacing generator 154 determines that sufficient has elapsed since the previous depolarization, it generates a pacing pulse to the heart via the pacing lead 34 to artificially stimulate the heart 100 to contraction.
A stimulation generator 166 generates a burst of pulses in a manner known in the art to cause contraction of the skeletal muscle 22 in the proper timing relation to the contraction of the heart 100. Accordingly, an OR-gate 160 produces an output whenever the sense amplifier 156 senses a naturally occurring contraction, or whenever the pacing generator 154 generates a pacing pulse. The output of the OR-gate 160 enables timing logic 162, which generates a desired amount of delay. The delay is nearly zero for the embodiment of FIG. 1 because maximum assistance to the heart 100 is provided when the skeletal muscle 22 contracts in synchrony with the heart.
The embodiment of FIG. 2 requires a longer delay, on the order of one-half the cardiac cycle (i.e., the R-to-R interval). The embodiment of FIG. 3 requires yet a longer delay, being somewhat greater than one-half the cardiac cycle. This is necessary because that embodiment is intended to increase diastolic pressure in the aorta.
The output of the timing logic 162 is a timing pulse timed according to the specific embodiment (e.g., FIGS. 1, 2 or 3). The timing pulse is supplied to a duty cycle timing circuit 164, which is a variable digital counter producing an output corresponding to a variable number of pulses received from the timing logic 162. The normal output of the duty cycle timing circuit 164 is one pulse for each pulse received from the timing logic 162, corresponding to one-for-one stimulation of skeletal muscle rate compared to the cardiac rate. It should be understood that a lower rate is possible.
Overall cardiac rate is determined by an integrator 158, which receives input signals from both the sense amplifier 156 and the pacing generator 154, representing naturally occurring contractions and paced contractions, respectively. The integrator 158 produces an average current heart rate, which is used by the duty cycle timing circuit 164 to adjust its variable rate counter.
The output from the duty cycle timing circuit 164 controls the generation, vel non, of muscle stimulation pulses from a stimulation generator 166 via a stimulation lead 32. The pulses from the stimulation generator 166 typically form a series of bursts needed for neuromuscular stimulation.
Activity signals from the activity sensor 104 are processed by a signal processing circuit 152 to filter out noise and other unwanted components. The processed activity signals modulate the duty cycle timing circuit 164 and the stimulation generator 166, so as to change the burst rate and number of burst pulses in accordance with anticipated cardiac demand.
In accordance with the present invention, an EOL detector 180 detects an approaching EOL condition of the IPG batteries (not shown), in any one of a number of ways well known in the art, such as disclosed in U.S. Pat. No. 3,841,336 issued to Daynard, and U.S. Pat. No. 3,882,322 issued to Gobeli, to name just two. The aforementioned letters patents are hereby incorporated by reference. The EOL detector 180 sends an EOL signal to the pacing generator 154, which according to a pre-programmed protocol can cause the number of pulses in a burst to be reduced, cause the synchronization ratio (number of cardiac contractions compared to the number of powering muscle contractions) to increase, or a combination of the two.
FIG. 5A is an ECG of a muscle-assisted heart, absent the corresponding muscle stimulation burst signals. In actuality, the resulting ECG of a CAS using cardiomyoplasty, for example, would be expected to contain indicia of the muscle stimulation burst signals. As such, FIGS. 5B-5E are merely convenient representations of possible muscle stimulation burst signals which may occur at the same time as the partial ECG in FIG. 5A. FIG. 5B is a representation of a standard muscle stimulation burst signal pattern for the powering muscle tissue before the battery voltage V B reaches the EOL indication level V I .
The ECG is transtelephonically transmitted from the patient's remote location to a clinician's receiver and display monitor by a device (not shown) external to the IPG in the preferred embodiment. In an alternate embodiment, a telemetered signal generated from within the IPG could transmit the ECG when the muscle pacing artifact cannot be seen very well, for example.
In response to an EOL signal from the EOL detector 180 (i.e., V B ≦V 1 ), the IPG 36 changes the muscle stimulation burst signals from the standard pattern shown in FIG. 5B to any of the patterns shown in FIGS. 5C-5E (all corresponding in time to the ECG in FIG. 5A), or combinations thereof. In FIG. 5C the muscle stimulation burst signals have a reduced number of pulses in the burst. In that example, the number of pulses is halved by reducing them from four in FIG. 5B to two. A clinician viewing a telephonically transmitted ECG would expect the muscle stimulation burst signal to appear as shown in FIG. 5B. Therefore, any discernible departure from a typical muscle stimulation burst signal is an indication of the EOL condition, and is readily apparent to a clinician viewing the ECG alone, without the need for special circuitry. So, the drop in the number of burst pulses in FIG. 5C is a clear indication that the EOL condition is approaching.
As an alternative to the response represented by FIG. 5C, the synchronization ratio can be increased. Thus, in FIG. 5D the number of burst pulses remains standard (the same as in FIG. 5B), but the synchronization ratio changes from 1-to-1 to 2-to-1. This would be another form of an EOL indication to the clinician.
In yet another alternative to the EOL indication pattern, the burst pulses can alternate between two different numbers on alternate cycles. Thus, in FIG. 5E, the number of burst pulses alternates between four and two.
With further battery depletion, the number of burst pulses can be further reduced, and the synchronization ratio can be further raised, and the amount of change in these parameters can be made to be proportional to the amount of battery depletion.
In addition to providing a simple EOL indicator, the present invention also results in reduced battery current consumption, thus prolonging the before-replacement useful battery life.
Variations and modifications to the present invention may be possible given the above disclosure. However, all such variations and modifications are intended to be within the scope of the invention claimed by this letters patent. For example, the present invention is intended for use with therapeutic pulse generators in general, and not necessarily limited to muscle stimulators.
Additional changes to the stimulation bursts, and hence the EGG, could be used to indicate further battery voltage depletion after the EOL condition is reached. For example, the number of pulses in the burst is not only an indication of the EOL condition (when less than the full number are included in each burst), but is also proportional to the battery voltage, with further reductions in pulse number indicating further reduction in the battery voltage. The synchronization ratio can be varied in a similar (but opposite in the preferred embodiment) manner.
The present invention could also be manually triggered by a magnet to transmit an ECG which indicates the battery voltage by the presence, vel non, and magnitude of the previously-mentioned muscle pacing artifact pattern changes.
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An end-of-life (EOL) indicator for an implantable pulse generator (IPG)--especially of the neuromuscular stimulation variety--indicates an approaching battery EOL condition via an electrocardiogram (ECG) by changing the nature of the muscle stimulation burst signals. IPG internal circuitry detects an approaching EOL condition and modifies the burst signals by, for example, decreasing the number of pulses in a burst, increasing the heart contraction-to-powering-muscle contraction ratio, or alternating between two numbers of pulses in successive burst cycles. The approaching battery EOL condition can be easily ascertained via trans-telephonic monitoring by analyzing a transmitted ECG alone, for the above-mentioned burst signal changes. By observing the patterns in the ECG caused by the burst signal changes, a clinician could be aware of an approaching EOL without having known the original muscle stimulation burst signal parameters.
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This application is a division of application Ser. No. 08/591,791, filed Jan. 25, 1996, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ultraviolet absorber, and particularly to an ultraviolet absorber which is useful as a treating agent to improve the color fastness to light of materials made of polyester fibers, and other synthetic fibers, which undergo changes in color when exposed to light.
2. Description of the Related Art
Car seats, car mats, seat belts and the like, which require high durability and high color fastness to light and consist of materials made of polyester fibers and other synthetic fibers, are commonly treated with an ultraviolet absorber added to a dyeing bath or a printing paste.
Japanese Unexamined Patent Publications No. 60-59185 and No. 2-41468, for example, disclose fiber materials impregnated with 2-(2'-hydroxy-3'-t-butyl-5'-methylphenyl)-5-chlorobenzotriazole but, upon heating to 160°-190° C. in the post-dyeing thermal treatment (finish setting) step, sublimation occurs from the surface of the fibers, creating the problems of contamination of the finish setting machine and lower color fastness to light. As alternatives, Japanese Unexamined Patent Publication No. 4-91274 discloses 2- 2'-hydroxy-3'-(3",4",5",6"-tetraphthalimidomethyl)-5'-methylphenyl! benzotriazole and 2,2'-dihydroxy-4,4'-dimethoxybenzophenone, indicating that they are sublimation-resistant ultraviolet absorbers. The problems of the former, however, include the fact that it is inferior to conventional products in terms of its effect of preventing color changes due to light, and it undergoes whitening and yellowing by photodecomposition of the compound itself upon prolonged exposure to xenon light sources which are said to have a wavelength near that of sunlight. On the other hand, the problems of the latter compound include the fact that the deep yellow color of the compound itself leads to changes in color when used to treat light colors.
In addition, Japanese Unexamined Patent Publication No. 6-192972 discloses 1,4-bis-(4-benzoyl-3-oxyphenoxy) butane, and recently 2-(2'-hydroxy-4'-methoxyphenyl)-4,6-diphenyl-s-triazine has become known, both of which have excellent resistance to sublimation, and are useful for improving the color fastness to light of dyed polyester-based fibers with high-temperature treatment; nevertheless, these compounds do not adsorb well onto materials made of cation-dyeable polyester-based fibers, which have been used in recent years in car seats and the like, and thus do not exhibit an effect of improving the color fastness to light of such fibers.
In addition, although Japanese Unexamined Patent Publication No. 49-61069 discloses an epoxy-addition reaction to 2-(2',4'-dihydroxyphenyl)benzotriazoles, it contains no concrete description regarding the properties or performance of compounds according to the present invention.
SUMMARY OF THE INVENTION
In light of the prior art described above, it is an object of the present invention to provide an ultraviolet absorber which undergoes minimal sublimation, has excellent thermal resistance, provides satisfactory light fastness for materials made of polyester-based synthetic fibers, particularly cation-dyeable polyester-based fibers, and which is also inexpensive, generates few by-products and is easy to produce industrially.
In order to achieve this object, the present invention provides an ultraviolet absorber comprising as an effective component a benzotriazole compound represented by the following general formula (I) ##STR2## wherein R represents hydrogen, methyl, ethyl or phenyl.
The present inventors have completed the present invention on the basis of the finding that improved color fastness to light may be imparted to a fiber material by adsorbing at least one type of the general compound indicated above onto the fiber material in an amount usually of 0.01-10%, and preferably 0.1-5%, with respect to the fiber weight, and that these compounds, having excellent resistance to sublimation, do not result in contamination of finish setting machines or lower light fastness even after the thermal treatment process, and furthermore that they adsorb well onto cation-dyeable polyester-based fiber materials and are thus very useful as ultraviolet absorbers for the treatment of fibers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Fiber materials which may be effectively treated with the ultraviolet absorber of the invention include fabrics and knits made of polyester-based synthetic fibers or composite materials comprising both polyester-based synthetic fibers and cotton, rayon, wool, nylon, acetate or other fibers, as well as carpets, car seats, car mats, seat belts and the like made of the corresponding raised fabrics. Any of a variety of methods including continuous treatment by padding with an aqueous dispersant, adsorption by immersion, printing, treatment with a solvent, etc. may be used to apply the above-mentioned ultraviolet absorber to the fiber material, and it is not necessarily limited to these methods. These treatments may be carried out either before or after the steps of dyeing or printing, or they may be carried out in the same treatment bath. Treatment in an aqueous system requires uniform dispersion in the water, which may be easily accomplished by a publicly known method such as fine crushing with a bead mill using an appropriate amount of an anionic surfactant and/or a nonionic surfactant.
The compound represented by the above-mentioned general formula (I) may be produced by an addition reaction of 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole represented by the following formula (II) ##STR3## with an epoxy compound represented by the following general formula (III) ##STR4## wherein R represents the same species as stated previously, the compound being ethylene oxide, propylene oxide, butylene oxide or styrene oxide.
Here, the epoxy compound represented by the general formula (III) is preferably used in an amount of 1.0 to 5.0 equivalents, and especially 1.0 to 2.0 equivalents, to one equivalent of the 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole represented by formula (II). If it is present in a lower amount, a large amount of the starting material remains after the reaction, while if it is present in too great an amount, it is added at 2 equivalents or more, making it impossible to obtain the desired ultraviolet absorbing property.
Commonly employed, publicly known processes may be used for the reaction, i.e. a pressure reaction with or without a solvent, using an alkali metal, alkaline earth metal, organometallic compound, Lewis acid, amine, quaternary ammonium salt, etc. as the catalyst. A solution process wherein the reaction is conducted in a solvent is especially suitable from the standpoint of ease of scaling-up, high reaction efficiency and minimal by-products. Solvents which may be used include aromatic hydrocarbon solvents such as benzene, toluene, xylene and mesitylene, alcoholic solvents such as methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol, t-butanol, n-hexanol and cyclohexanol, and water/alcohol mixture solvents such as water/methanol, water/ethanol, water/n-propanol and water/isopropanol. Catalysts which may be used include sodium hydroxide, potassium hydroxide, calcium hydroxide, sodium acetate, calcium acetate, sodium methoxide, sodium ethoxide, t-butoxypotassium, methylithium, butylithium, triphenylphosphine, boron trifluoride, zinc chloride, aluminum chloride, triethylamine, pyridine, tetramethylammonium chloride, benzyltrimethylammonium chloride, etc., of which tetramethylammonium chloride is particularly suitable.
The reaction temperature is preferably between 50° C. and 150° C., and more suitably between 90° C. and 120° C.
The ultraviolet absorber of the present invention is synthesized by an addition reaction of an epoxide to 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole which is easily obtainable, and since the desired product is obtained in a roughly quantitative manner, industrial production thereof is possible. Furthermore, since the molecule contains an alcoholic hydroxyl group, it has excellent resistance to sublimation and stability at high temperatures. Its adsorbence is particularly high when it is crushed finely and impregnated into the polyester fibers, which then exhibit the same character as cation-dyeable polyester fibers, and thus the result is a very satisfactory improvement in the color fastness to light.
The ultraviolet absorber of the present invention may also contain a mixture of 2 or more compounds represented by the general formula (I). If necessary, it may also be used in combination with a conventional publicly known ultraviolet absorber, antioxidant, photostabilizer, or the like.
The present invention will now be explained in detail by way of the following examples.
The melting points given in these examples were determined based on the endothermic peaks obtained using a differential scanning calorimeter (hereunder abbreviated to DSC) manufactured by Shimazu Seisakusho. The nuclear magnetic resonance (hereunder abbreviated to NMR) spectra were measured using an FT-NMR R-1900 manufactured by Hitachi Seisakusho. The infrared absorption (hereunder abbreviated to IR) spectra were measured using a Perkin-Elmer 1650 manufactured by Perkin-Elmer. The thermal weight loss ratios were measured using a DTG-50 simultaneous differential thermal/thermogravimetric apparatus manufactured by Shimazu Seisakusho.
The compound represented by formula (I) may usually be obtained by diazotizing an o-nitroaniline by a common method, coupling it with resorcin by a common method to make an azo compound, reducing this to obtain 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole, and then adding an epoxy compound thereto by an addition reaction. A production process for this compound is described in detail below.
EXAMPLE 1
Into a 1000 ml autoclave were charged 400 g of isopropyl alcohol, 100 g of 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole, 0.5 g of tetramethylammonium chloride and 83 g of 1,2-butylene oxide, and the temperature was raised to 90° C. over a period of an hour. After 4 hours of reaction at this temperature, the system was cooled to 60° C., the excess butylene oxide was removed under reduced pressure, and upon cooling a crude product precipitated. This was recrystallized in methanol to obtain the desired 2- 2'-hydroxy-4'-(2"-hydroxy) butoxyphenyl!-5-chlorobenzotriazole in an amount of 110 g. This represented an 86% yield. The melting point of the product was 121° C., and 1 H-NMR and IR both confirmed the identity of the desired compound.
EXAMPLE 2
Into a 1000 ml autoclave were charged 400 g of isopropyl alcohol, 100 g of 2-(2',4'-dihydroxyphenyl)-5-chlorobenzotriazole, 0.5 g of tetramethylammonium chloride and 138 g of styrene oxide, and the temperature was raised to 110° C. over a period of an hour. After 6 hours of reaction at this temperature, the system was cooled to 60° C., the excess styrene oxide was removed under reduced pressure, and upon cooling a crude product precipitated. This was recrystallized in isopropanol to obtain the desired 2- 2'-hydroxy, 4'-(2"-hydroxy-2"-phenylethoxy)phenyl!-5-chlorobenzotriazole in an amount of 124 g. This represented an 85% yield. The melting point of the product was 137° C., and 1 H-NMR and IR both confirmed the identity of the desired compound.
EXAMPLE 3
The same procedure as in Example 1 was followed using ethylene oxide as the epoxy compound, to obtain 2- 2'-hydroxy, 4'-(2"-hydroxy)ethoxyphenyl!-5-chlorobenzotriazole at a 90% yield. The melting point of the compound was 147° C.
EXAMPLE 4
The same procedure as in Example 1 was followed using propylene oxide as the epoxy compound, to obtain 2- 2'-hydroxy, 4'-(2"-hydroxy)propoxyphenyl!-5-chlorobenzotriazole at an 80% yield. The melting point of the compound was 147° C.
Comparative Example 1
The same procedure as in Example 1 was followed using 2-(2',4'-dihydroxyphenyl)-benzotriazole, and ethylene oxide as the epoxy compound, to obtain 2- 2'-hydroxy, 4'-(2"-hydroxy)ethoxyphenyl!-benzotriazole at an 89% yield. The melting point of the compound was 160° C.
Comparative Example 2
The same procedure as in Example 1 was followed using 2-(2',4'-dihydroxyphenyl)-benzotriazole, and propylene oxide as the epoxy compound, to obtain 2- 2'-hydroxy, 4'-(2"-hydroxy)propoxyphenyl!-benzotriazole at a 75% yield. The melting point of the compound was 130° C.
The results of thermogravimetric analysis of the compounds of Examples 1-4 and Comparative Examples 1-2 are shown in Table 1. The analysis was performed by raising the temperature by 5° C./min in air, holding the temperature at 210° C. for 30 minutes, and measuring the weight loss (%). The same measurement was made under the same conditions for the compounds of Comparative Examples 3-5 (commercially available products) shown below. The corresponding results are also shown in Table 1.
Comparative Example 3 ##STR5##
Comparative Example 4 ##STR6##
Comparative Example 5 ##STR7##
TABLE 1______________________________________ Melting Weight Color shade point (°C.) loss (%)______________________________________Example 1 light yellow 121 1.8Example 2 white 137 0.9Example 3 white 147 2.2Example 4 light yellow 147 1.9Comp. Example 1 white 160 4.6Comp. Example 2 light yellow 130 6.2Comp. Example 3 light yellow 128 30.4Comp. Example 4 light yellow 141 14.3Comp. Example 5 yellow 205 2.3______________________________________
All of the compounds of Examples 1-4 had low thermal weight loss, and excellent sublimation resistance and thermal resistance.
Application Examples
Preparation of aqueous dispersion
Mixtures of 150 g each of the compounds of Examples 1-4 and Comparative Examples 1-5 with 100 g of Lipotol B-12 (anionic surfactant, product of Nikka Chemical Co., Ltd.) and 250 g of water were treated for 4 hours with a sand grinder manufactured by Igarashi Kikai Seizo, KK., to obtain fine aqueous dispersions with an average particle size of 0.40 μm. The particle sizes were measured with a SALD-1100 particle size distribution measuring apparatus manufactured by Shimazu Seisakusho, KK.
Performance Test 1
Each of the aqueous dispersions obtained above were evaluated as to their performance when used to treat fiber materials.
a) Test fabrics
A car seat raised polyester fabric (weight: 650 g/m 2 ) (test fabric 1) and a regular polyester/cation-dyeable polyester (50/50) crossknit fabric (test fabric 2) were treated according to the method described below, and then used for a color fastness to a light test and an adsorption test.
b) Treatment method
A Minicolor dyeing machine manufactured by Techsam Giken (KK.) was used under the conditions listed below for 30 minutes of treatment at 130° C. and 30 minutes of reduction cleaning at 80° C. followed by drying to obtain a grey dyed fabric. This was then subjected to dry heat treatment for 2 minutes at 160° C. using a pin tenter manufactured by Ueno Santekko, KK.
Treatment bath composition
Sumitomo Chemical disperse dye Red-GF 0.6% o.w.f.
Sumitomo Chemical disperse dye Yellow-GF 0.8% o.w.f.
Sumitomo Chemical disperse dye Blue-GF 1.6% o.w.f.
Nikka Sunsalt SD-07 (Nikka Chemical disperse level dyeing agent) 0.5 g/l
90% acetic acid 0.5 g/l
Fine particle aqueous dispersion 2.0% o.w.f.
Liquor ratio 1:20
Reduction cleaning bath composition Sunmol RC-1 (Nikka Chemical soaping agent) 2.0 g/l
c) Method of evaluation
(1) Color fastness to light
Method A
A high-temperature fade-o-meter (product of Suga Shikenki, KK.) was used for 400 hours of irradiation at 83° C. (1 cm polyurethane backing). The degree of color change was then judged as a series based on a color change grey scale (JIS-L-0804) (with a larger series indicating better color fastness to light).
Method B p A xenon fade-o-meter (product of Suga Shikenki, KK.) was operated for 50 cycles, one cycle consisting of 4.8 hours of irradiation at 89° C. followed by 1 hour of darkness at 38° C. (cumulative irradiance: 105,000 KJ/m 2 , 1 cm polyurethane backing). The degree of color change was then judged as a series based on a color change grey scale (JIS-L-0804) (with a larger series indicating better color fastness to light).
The results are listed in Tables 2 and 3.
TABLE 2______________________________________ Color fastness to light (test fabric 1) Method Method A B______________________________________No fine particle aqueous dispersion added 2 2Fine particle aqueous dispersion: Example 1 3-4 3-4Fine particle aqueous dispersion: Example 2 3-4 3-4Fine particle aqueous dispersion: Example 3 4 4Fine particle aqueous dispersion: Example 4 3-4 3-4Fine particle aqueous dispersion: Comp. Example 1 3 3Fine particle aqueous dispersion: Comp. Example 2 3 2-3Fine particle aqueous dispersion: Comp. Example 3 3 3Fine particle aqueous dispersion: Comp. Example 4 3-4 3-4Fine particle aqueous dispersion: Comp. Example 5 3-4 3______________________________________
TABLE 3______________________________________ Color fastness to light (test fabric 2) Method A Method B Cation Cation Regular dyeable Regular dyeable portion portion portion portion______________________________________No fine particle aqueous 2 2 2 2dispersion addedFine particle aqueous 3-4 3-4 3-4 3-4dispersion: Example 1Fine particle aqueous 3-4 3-4 3-4 3-4dispersion: Example 2Fine particle aqueous 4 4 4 4dispersion: Example 3Fine particle aqueous 3-4 3-4 3-4 3-4dispersion: Example 4Fine particle aqueous 3 3 3 3dispersion: Comp. Example 1Fine particle aqueous 3 2-3 3 3dispersion: Comp. Example 2Fine particle aqueous 3 3 3 3dispersion: Comp. Example 3Fine particle aqueous 3-4 3-4 3-4 3dispersion: Comp. Example 4Fine particle aqueous 3-4 3 3-4 3dispersion: Comp. Example 5______________________________________
From these results it is clear that the compounds of Examples 1-4 according to the present invention exhibit superior performance in terms of color fastness to light.
(2) Evaluation of adsorption
Each of the treated fabrics was subjected to Soxhlet extraction (3 hours in chloroform) and the amount of the compound adsorbed into the fabric was measured. The adsorption was calculated according to the following equation, based on comparison with the amount of the compound in a dyeing solution prepared in the same manner prior to dyeing.
Adsorption=(amount of compound extracted/amount of compound in treatment solution)×100
The results are given in Table 4.
TABLE 4______________________________________ Adsorption (%) Test Test fabric 1 fabric 2______________________________________No fine particle aqueous dispersion added -- --Fine particle aqueous dispersion: Example 1 93.8 93.2Fine particle aqueous dispersion: Example 2 93.9 93.5Fine particle aqueous dispersion: Example 3 93.7 93.1Fine particle aqueous dispersion: Example 4 93.3 93.0Fine particle aqueous dispersion: Comp Example 1 92.8 92.6Fine particle aqueous dispersion: Comp Example 2 92.3 91.5Fine particle aqueous dispersion: Comp Example 3 89.6 89.0Fine particle aqueous dispersion: Comp. Example 4 87.0 88.5Fine particle aqueous dispersion: Comp. Example 5 91.2 76.8______________________________________
(3) Evaluation of dry heat sublimation
Each of the treated fabrics was subjected to Soxhlet extraction (3 hours in chloroform) before and after dry heating, and calculation was made of the residue rate of the compound after dry heating and the amount of compound adsorbed onto the fibers after thermal treatment as the final adsorption.
Residue rate=(amount adsorbed after dry heating/amount adsorbed before dry heating)×100
The results are given in Table 5.
TABLE 5______________________________________ Residue rate after dry heating (%) Test Test fabric 1 fabric 2______________________________________No fine particle aqueous dispersion added -- --Fine particle aqueous dispersion: Example 1 96.8 96.5Fine particle aqueous dispersion: Example 2 97.9 97.8Fine particle aqueous dispersion: Example 3 96.7 97.1Fine particle aqueous dispersion: Example 4 96.3 96.0Fine particle aqueous dispersion: Comp. Example 1 94.8 95.1Fine particle aqueous dispersion: Comp. Example 2 95.3 94.8Fine particle aqueous dispersion: Comp. Example 3 56.8 55.2Fine particle aqueous dispersion: Comp. Example 4 72.8 71.2Fine particle aqueous dispersion: Comp. Example 5 96.2 95.4______________________________________
As mentioned above, the ultraviolet absorber of the present invention is capable of imparting excellent color fastness to light and resistance to sublimation when applied to dyed fiber materials, and particularly dyed polyester fiber materials.
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An ultraviolet absorber comprising, as an effective component, a benzotriazole compound represented by the following general formula (I) ##STR1## wherein R represents hydrogen, methyl, ethyl or phenyl. The ultraviolet absorber undergoes minimal sublimation, has excellent thermal resistance, provides satisfactory light fastness for materials made of polyester-based synthetic fibers, particularly cation-dyeable polyester-based fibers, and is also inexpensive, generates few by-products and is easy to produce industrially.
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This is a continuation of application Ser. No. 07/937,303 filed on Aug. 31, 1992.
TECHNICAL FIELD OF THE INVENTION
This invention relates to a novel refrigerant mixture for use in refrigeration systems. The refrigerant is not harmful to the ozone layer, and is particularly applicable in systems such as automobile air-conditioning and home refrigeration.
BACKGROUND OF THE INVENTION
A continuing demand exists for a simple, inexpensive refrigerant which can be used to reduce the level of ozone damaging compounds which can escape and harm the earth's atmosphere. In particular, there exists a need for a simple, low cost refrigerant which can be used as a substitute for refrigerant R-12, also commonly known as dichlorodifluoromethane. At normal atmospheric pressure, R-12 boils a −21.7° F., thus, any substitute must have properties sufficiently comparable that equipment can be used without costly modification.
In addition to the undesirable ozone depletion consequences which have been widely reported, those familiar with refrigeration systems will also recognize that R-12 and other fluorchlorocarbon refrigerants can contribute to the formation of acids under as a result of decomposition in a refrigerant system. Formation of such acids is not uncommon, and when it occurs, severe damage to metal surfaces in a refrigerant system can result. Moisture in an R-12 based refrigeration system can contribute to such acid formation, as can use of contaminated lubricating oils.
For the most part, the R-12 substitutes which have been proposed have been various substituted hydrocarbons, utilizing addition of bromine or other atoms, primarily in an attempt to produce a non-flammable refrigerant. Such substitutes have their own problems, such as undesirable toxicological effects on exposed individuals.
SUMMARY OF THE INVENTION
I have now invented, and disclose herein, a novel, refrigerant mixture which does not have the above-discussed drawbacks common to the fluorchlorocarbon refrigerants heretofore used of which I am aware. Unlike the refrigerants heretofore available, my product is simple, relatively inexpensive, easy to manufacture, and otherwise superior to those heretofore used or proposed. In addition, it provides a significant, demonstrated improvement with regard to protection against release of ozone depleting compounds.
Another important feature is the fact that my novel refrigerant is not conducive to formation of undesirable acid compounds while in use in a refrigeration system. This provides a unique safety feature when compared to many previously known refrigerants.
My novel refrigerant mixture is essentially a 50-50 mixture of propane and butane. However, up to as much as 75% of propane, or alternately, butane, may be utilized.
My novel refrigerant differs from those prior art products mentioned above in one respect in that no substitution of hydrogen molecules by halogen or other species is required. In its simplest form, my invention is the discovery that a mixture of propane and butane will provide suitable properties for direct substitution in R-12 systems.
Thus, the dual advantages of protection of the ozone layer, and low cost of the commonly available gases propane and butane gases, become important and self-evident in direct refrigerant substitution applications.
OBJECTS, ADVANTAGES, AND FEATURES OF THE INVENTION
From the foregoing, it will be apparent to the reader that one important and primary object of the present invention resides in the provision of a novel, improved refrigerant which does not contribute to the destruction of the ozone layer.
Other important but more specific objects of the invention reside in the provision of a refrigerant which may be directly substituted in R-12 based refrigeration systems, and which:
can be manufactured in a simple, straightforward manner;
results in comparatively low cost refrigerant mixtures;
in conjunction with the preceding object, have the advantage that they can be widely used without cost penalty in selected refrigeration systems; and,
which provides a refrigerant gas mixture which is easy to use, install and remove.
Other important objects, features, and additional advantages of my invention will become apparent to the reader from the foregoing and the appended claims and as the ensuing detailed description and discussion proceeds in conjunction with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing:
FIG. 1 is a process flow diagram for an automobile refrigeration system, in which the present invention may be employed.
FIG. 2 is a process flow diagram for a refrigerator refrigerant circuit, showing the components of a typical residential refrigerator system.
DETAILED DESCRIPTION OF THE INVENTION
Widely utilized refrigerant systems which utilize R-12 include automotive and home refrigeration systems. Although the refrigerant mixture disclosed herein may be used with other types of refrigerant circuits, the invention will be disclosed with reference to several of the most commonly used types.
Turning now to FIG. 1, there is shown an automotive type refrigeration system 10 ; this type of system is commonly utilized to cool the passenger compartment of cars and trucks. Critical components of the refrigeration system 10 include the compressor 11 which is used to raise the pressure (and the temperature) of a circulating refrigerant 12 from the cold, low pressure suction side 14 to the high temperature, high pressure discharge side 16 . The refrigerant 12 pressure is raised so that it is capable of being condensed based at the internal temperature achievable in the condenser 18 . Actual operating temperatures and pressures will vary widely and may be reviewed in a variety of texts on refrigeration. However, for a convenient point of reference, when the outside air entering an automotive condenser is 100° F., the high pressure circuit may operate at about 220 to 270 psig, while the low pressure circuit may operate at about 20-30 psig. Thus, the low pressure circuit pressure corresponds to a temperature of the cold refrigerant of roughly 20 to 30° F. Refrigerant 12 vapors which are condensed in condenser 18 are passed through a receiver 20 , to accumulate the liquid refrigerant. The receiver may also include a desiccant (internal and not shown) for removal of water from the circulation refrigerant 12 , so as to minimize the tendency of the refrigerant to form harmful, normally acid decomposition products.
In order to allow the high pressure refrigerant 12 to enter the low operating pressure evaporator 22 , the refrigerant is metered through a thermal expansion valve 24 . The liquid refrigerant 12 is allowed to escape into the lower pressure evaporator 22 , and most of the refrigerant 12 will enter as a liquid to a pool 24 at the bottom of the evaporator 22 . As heat is introduced to the evaporator 22 (as via an airstream 26 passing through the air passageways 28 ), liquid refrigerant 12 boils and becomes low pressure vapor, and travels to the low pressure side suction side 14 of the compressor 11 , to repeat the process.
In most automotive type refrigeration systems, dichlorodifluoromethane (R-12) is used as the refrigerant. Unfortunately, this compound has been found to contribute to depletion of the upper atmospheric ozone layer. As a result, its use is being discontinued, as urged or as required by specific limitations in legislation in the United States and elsewhere.
I have found that a mixture comprised essentially of propane and butane can be directly substituted for R-12 in air-conditioning and refrigeration systems. Although the preferred composition is about 50% propane by liquid volume, with the remainder butane, the composition may be somewhat varied without encountering great difficulty. In fact, a mixture consisting essentially of up to about 75% propane, with the remainder butane, may be used. Preferably, as noted above, at least 50% propane may be used. In most cases, not less than 25% propane is desirable.
The aforementioned mixture is advantageous in that it does not contain halogen substituted molecules to cause problems such as acid formation and the resultant metal attack problems internal to the refrigeration circuit, as may be encountered with dichlorodifluoromethane. Also, both propane and butane are commonly available, at lower cost than most currently available refrigerants. Particularly in automotive applications, as set forth above, the flammable properties of propane and butane should not cause particular concern, in the quantities required for small refrigeration circuits, in view of the quantities of flammable fuel already successfully and safely transported on a regular basis.
My refrigerant mixture is also amenable for use in a home refrigerator system, such as is depicted in FIG. 2. A refrigerator 40 is shown having therein a compressor 42 , a condenser 44 , an expansion valve 46 , an evaporator 48 , and a low pressure vapor line 50 which returns to the compressor 42 . Operation of the system is similar to that set forth above for the automotive refrigeration system, and need not be repeated in detail as it will be quickly recognized by those skilled in the art and to whom this invention is addressed. For reference, it is common for R-12 based refrigerator systems to operate at about 120 psig on the high pressure side, and at about 0 psig on the low pressure side. As a 50-50 mixture of propane and butane will condense at about 75 psig, this mixture provides a change of state of the refrigerant within an ideal range.
I have now discovered that the refrigerant gas commonly used in home refrigerator systems, dichlorodifluoromethane (R-12) may be advantageously replaced by a propane-butane mixture, preferably containing about 50% butane and the rest essentially propane. Also, I have discovered that the refrigerant mixture of about 50% propane and about 50% butane is more energy efficient than utilization of an R-12 refrigerant in home refrigerators. The exact savings, however, will vary according to the mixture utilized and the size of the system, particularly the compressor.
Thus, it can be seen that I have developed and have set forth herein an exemplary refrigerant mixture, and a method for use of same in common refrigeration machinery. The material is of low cost, is easily prepared, and does not tend to produce harmful acid breakdown products in refrigeration systems. Further, the mixture is quite compatible with refrigeration oils, and can be safely used in refrigeration systems.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalences of the claims are therefore intended to be embraced therein.
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A refrigerant mixture. The mixture of propane and butane may be advantageously used as a substitute for R-12, thus eliminating the use of ozone depleting R-12 refrigerant. Ideally, the mixture is comprised of approximately 50% propane and 50% butane by liquid volume. Alternately, the mixture may contain up to about 75% of either propane or butane. A refrigeration process utilizing the mixture is also disclosed.
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FIELD OF THE INVENTION
[0001] The present invention relates to the field of wind energy capture devices, and more particularly to a device for harnessing wind energy from rooftops in areas where present technology is unsuitable. This includes but is not limited to inner-city neighborhoods and rural subdivisions where real estate is at a premium and wind turbine towers may be prohibited by or deemed unfeasible due to lack of available space, local ordinances, and/or environmental factors such as excessive wind turbulence near ground surface.
BACKGROUND
[0002] The ongoing search for alternative and renewable energy sources has led many to investigate the harnessing of wind power. Millions of dollars have been invested in large numbers of windmills and wind turbines that are propelled by wind, ultimately converting wind energy into electricity on fairly large scales. These systems are esoterically referred to as big wind technology. Smaller scale wind harnessing devices for use by individuals is referred to as small wind technology. The present use of big wind technology is dominated by environmental factors. Specifically, ambient wind velocity and duration determine the amount of wind power available for electricity production. Thus big wind energy production projects (wind farms) are immediately limited to suitable locations. Present big wind technology is such that the amount of wind power harnessed is directly dependant on the length of wind turbine blades, as this determines the wind swept area captured. In order to harness more power, larger turbines are used. Apart from location, turbulence is considered the single-most problematic factor in wind energy production. Turbulence is predominantly caused by surface friction and impediments such as terrain irregularities, forests and vegetation, and man made structures. To minimize turbulence, big wind technology includes the use of towers high enough to place turbines above the influence of surface friction. These towers are typically 100-300 feet in height. Even so, on wind farms each turbine becomes a change agent by creating turbulence in its own wake stream, which poses problems for additional turbines downwind. Turbulence causes mechanical stress and wear on the most vulnerable and costly components of wind turbine generators. Present small wind technology is largely imitative of big wind technology and is therefore similarly dependant. For most people who might otherwise make use of wind power technology, using a tower high enough to avoid turbulence is unfeasible. Therefore, relatively little attention has been paid to smaller scale wind harnessing devices for use by individuals.
[0003] One such device is described in U.S. Pat. No. 7,315,093 B2. This patent issued very recently (Jan. 1, 2008) to inventor J. J. Graham, sr. That patent concerns a vertically mounted rooftop fan, with deflector. U.S. Pat. No. 6,606,823, which issued on Apr. 19, 2003, to inventors W. McDonough et al., depicts a roof covering for cooling a structure with water. No fan is involved in this invention.
[0004] Related art is also presented in U.S. Pat. No. 6,838,782, which issued on Jan. 4, 2005 to inventor T. H. Vu. This patent describes a fan and pulley system for moving vehicles, especially trucks. U.S. Pat. No. 6,327,994, which issued to inventor G. Labrador on the fateful day of Sep. 11, 2001. This describes a wide-faced open fan-like device for fluid impelling or solar collection.
[0005] Although the above prior art is considered to be relevant to the current invention, no description has been found that anticipates the current invention, nor that renders the current invention obvious.
SUMMARY OF THE INVENTION
[0006] The invention herein described and presented includes a moveable wind-capturing device (wind scoop), a conduit for conveying and directing wind onto a specific part of a turbine rotor, and a turbine rotor which is enclosed to minimize turbulence. It is designed for mounting on building rooftops. The wind scoop can be manually or automatically positioned to face in any horizontal direction so as to always be directed into the wind, for maximum wind energy capture.
[0007] It is therefore an object of the present invention to provide an innovative method for the capturing of wind energy in a near surface environment, which necessitates a means of minimizing or eliminating the effect of turbulence on the most vulnerable and expensive components of the device.
[0008] It is further an object of the present invention to separate the relationship of wind capture area from the length of wind turbine rotor blades, thus enabling a smaller turbine rotor to be powered by a larger amount of wind than would be possible using present technology.
[0009] It is further an object of the present invention to achieve energy savings through endpoint generation of electricity by harnessing and converting wind energy.
[0010] It is further an object of the present invention to provide an easily visible display of energy consciousness of the owner, while producing a tasteful and esthetically pleasing article that will not raise objections from neighbors.
[0011] It is further an object of the present invention to maximize power available via unique application of natural physical laws.
[0012] It is further an object of the present invention to provide a system which is adaptable to a wide variety of locations which would otherwise not be considered using present technology.
[0013] It is further an object of the present invention to adapt specific components for additional related uses. This includes but is not limited to the adaptation of the enclosed rotor/turbine to be resized and powered by pressurized water in existing pipelines, such as the main culinary water lines to houses and buildings. This would require adaptation for dual use as an adjustable pressure regulator.
[0014] Other objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The many objects and advantages of the present invention will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
[0016] The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
[0017] FIG. 1 shows a device of a preferred embodiment of the current invention from above, mounted on a rooftop. It is herein emphasized that the rotor enclosure may be mounted at any angle, and could be alternatively mounted on a side wall of a building rather than on the rooftop (configuration not shown).
[0018] FIG. 2 shows detail of the wind scoop in a preferred embodiment of the current invention, and the turning device, also called a turret, that allows the scoop to move 360 degrees facing any horizontal direction. The duct as shown appears rigid, however in practice it is expected that an airtight flexible tube would be used. Note that the duct is smaller in diameter than the wind capture area. It is expected this would increase velocity of the wind, which is known to be an exponential factor in wind power generation. As a result, this configuration could produce greater power than a present technology open-air turbine with a diameter and subsequent wind capture area similar to the area of the wind scoop in this submitted design.
[0019] FIG. 3 shows detail of the rotor and enclosure box in an expanded view of portions the current invention. It should be noted that a generator can be mounted either on the top or bottom of the enclosure (enclosure top cover not shown).
[0020] FIG. 4 displays further details of individual rotor components. While each component may be constructed using lightweight, thin and otherwise flexible materials, when assembled they creates a structurally rigid rotor. It should be noted that the rotor blades could be more efficient using a different geometry, such as a curved blade rather than an angled blade. The curved blade (not shown) would be similar in shape to a pipe split in half lengthwise. Such refinements are pending working model construction and testing.
[0021] FIG. 5 a displays the rotor in a position perpendicular to the channeled wind stream. This illustration demonstrates the utility of the blade fence (see FIG. 4 ) in guiding air movement along the desired path.
[0022] FIG. 5 b displays the rotor turned approximately 30 degrees clockwise. This is intended to illustrate the progression of wind through the outlet, which allows expansion of the wind stream. This configuration is expected to result in lower pressure on the backside of the rotor blade and higher pressure on the front side of the rotor blade at all positions of the rotor.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Detailed descriptions of the preferred embodiment are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
[0024] The present invention comprises a moveable wind energy-capturing device. It is designed for mounting on a rooftop. The device can be manually or automatically positioned to face in any direction, so as to always be directed into the wind, for maximum wind energy effect.
[0025] A preferred embodiment of the current invention comprises a large air scoop; a turret or other means for positioning the scoop into the wind; and a turbine, within a housing, which is moved by the wind. The turbine powers a standard electrical generator, which produces electricity for local usage.
[0026] Preferably the turbine rotor is contained in an enclosure (rotor box). The blades of the turbine are especially designed to capture as much of the wind energy as possible, while minimizing the leakage of air around the blades. The housing aids in this capture of wind energy.
[0027] Turning now to FIG. 1 , a preferred embodiment of the present invention is shown from above. The invention comprises a wind scoop 100 , turret 200 , and a wind turbine assembly 300 . The device is shown in position on the roof of a standard suburban house.
[0028] FIG. 2 shows the same preferred embodiment of the present invention, with the cover 310 removed from the turbine assembly 300 . The cover 310 is displayed alone in FIG. 3 . The cover has two open ends, which comprise a wind inlet scoop 360 , and a wind exit aperture 370 .
[0029] FIG. 4 illustrates the turbine blade assembly 320 from a top plan view of a preferred embodiment of the present invention. The turbine blades, propelled by wind, drive a power axle, which in this view appears in cross section as a circle in the center of the turbine blade assembly.
[0030] FIG. 5 displays the turbine blade assembly 320 from a perspective view. The blades in this preferred embodiment form one continuous body. The blades are connected by spokes 325 to central axle 350 . When the wind turns the turbine fan, the axle 300 will also turn, transmitting energy to a conventional electrical generator.
[0031] FIG. 7 shows an exploded view of the turbine blade assembly 32 0 above its housing 340 . The blade assembly fits down flush into the housing. The blades are configured to allow minimal loss of air leaking around, over, or underneath the blades. Cover 310 , not shown here, fits flush on top of the housing and blade assembly.
[0032] While each component may be constructed using lightweight, thin and otherwise flexible materials, when assembled the assembly creates a structurally rigid rotor.
[0033] FIG. 7 shows an exploded interior view of wind turbine assembly 300 in a preferred embodiment of the current invention. The assembly comprises a housing 310 , a turbine blade assembly 320 , and a power axle 350 . Turbine blade assembly 320 is designed to move in one direction only, counter-clockwise in the example shown in FIG. 7 . Wind comes in via aperture 360 , via conduit from the wind scoop and turntable assembly depicted in earlier figures. The wind forces the turbine blade assembly 320 to rotate around, thus in turn forcing axle 350 to move in the same direction. This moving power axle powers an electrical generator (not shown), which thus generates electricity. The air exits the wind turbine assembly to the outside atmosphere at aperture 370 .
[0034] FIG. 8 shows a plan view from above of the turbine assembly with cover removed.
[0035] FIG. 9 is intended to illustrate the progression of wind through the outlet, which allows expansion of the wind stream. This configuration is expected to result in lower pressure on the backside of the rotor blade and higher pressure on the front side of the rotor blade at all positions of the rotor. Wind enters at aperture 360 , circulates clockwise around housing 240 as shown via arrows, driving turbine blade assembly 320 . Wind exits from the turbine at aperture 370 .
[0036] FIG. 10 displays the various component elements of the turbine blade assembly 320 . These are assembled into the form of the final turbine blade assembly.
[0037] It should be noted that the rotor blades could be made in a different embodiment using a different geometry, such as a curved blade rather than an angled blade. The curved blade (shown in FIGS. 11-12 ) is similar in shape to a pipe split in half lengthwise. These have the advantage of lightweight, modular construction. At the same time, this embodiment allows wind to leak around the blades. The preferred embodiment of FIGS. 2-10 minimizes wind leakage. Wind leakage is undesirable, as energy collection efficiency is reduced thereby.
[0038] FIG. 13 displays details of the wind collection system. For obvious reasons, wind scoop 100 must be positioned above the roof. However, the entire system is closed except at the input end of wind scoop 100 , and the eventual air exit at aperture 370 . Therefore, it is entirely feasible to place the entire wind turbine assembly 300 in an indoor location, for instance in the attic of a residential house, or just underneath the roof.
[0039] The scoop is maneuvered, either by remote manual or automated means, into the position that faces the wind. The scoop funnels the air into an aperture in the top 210 . (Aperture 211 is obscured by the scoop 100 in the display of FIG. 13 .) Air will flow from scoop 100 via pipes 222 to the wind turbine assembly.
[0040] FIG. 14 displays a view of a magnified portion of the scoop assembly of a preferred embodiment of the present invention. Displayed in FIG. 2 is a portion of the wind collection feature of the current invention, with scoop 100 , and turret assembly 200 . Prominent in FIG. 2 is the scoop 100 , which is optionally open at its base to enable a close fit to a sloped roof.
[0041] An alternate embodiment of the current invention will encompass the capture of water energy. In this embodiment, the scoop will intake water from a supply, either natural, such as a river or stream, or an artificial source. Slight modifications to include water-tolerant materials of construction are contemplated. In general form, the scoop, turbine, and generator operate in exactly the same way as for the wind turbine. Water energy powers the turbine, thereby powering the generator to create electricity.
[0042] This alternate embodiment of the enclosed rotor concept comprises a smaller unit with round inlet and round outlet, fitted with standard plumbing couplings to be attached into the main waterline into houses and other buildings. The enclosure preferably is constructed of watertight construction, and contains either an inline turbine generator or a bladed/fenced rotor similar to the preferred wind embodiment, said rotor attached to an external generator. The turbine or generator in this alternative embodiment is matched in size and resistance to provide a similar reduction in water pressure as is achieved with water pressure regulators currently in use. Thus, this embodiment acts to draw electrical energy from current water pipe operation, without affecting the delivery or quality of the water being delivered.
[0043] While the invention has been described in connection with a preferred embodiment or embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
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A device to collect wind energy from the rooftop of a house or other building is described. The device encompasses a wind scoop, which can be moved in any direction to ‘catch’ the prevalent wind. The wind passes through conduits to a low-profile wind turbine, which is configured for maximum containment of wind and energy capture. The turbine powers a electricity generator to produce electricity. In an alternative embodiment, the turbine can be powered by moving water from ordinary municipal water lines or other sources.
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TECHNICAL FIELD
[0001] The invention relates to sealing devices for rotating shafts where sealed fluid is employed to generate hydrostatic and hydrodynamic lift-off forces between stationary and rotating sealing elements, thereby effecting their separation and providing non-contact operation.
BACKGROUND OF THE INVENTION
[0002] A sealing assembly of a non-contact type for rotating shafts is used in high speed and high pressure applications, where contacting type seals would experience overheating problems and failures caused by generation of excessive frictional heat. Contacting seals have pressure and speed limits depending primarily on whether the sealed fluid is liquid or gas. These limits are substantially lower with gas than with liquid, because as opposed to gas, liquid lubricates the opposed, rubbing surfaces of the sealing interface and can therefore expel a considerable amount of contact heat from said interface, hence permitting higher speeds and pressures.
[0003] Non-contact seals which are the subject to this invention, will also have speed and pressure limits. However, in the absence of contact, these limits are usually not because of frictional heat at the sealing interface, but moreover due to other factors such as material strength, viscous shear heat or permissible leakage value. The limits for non-contact seals are much higher than with contacting seals. Consequently, non-contact seals offer a preferred sealing solution for high speed, high pressure applications employed in centrifugal gas compressors, light-hydrocarbon pumps, boiler feed pumps, steam turbines and the like.
[0004] Non-contact seals are commonly more able to operate at elevated speeds and pressures regardless of whether the sealed fluid is a liquid, a gas or even a mixture of liquid and gas. Particularly, when sealed fluid change phase from gas to liquid and back, said seals offer an appreciable advantage. One of such non-contacting seals is of the face type, where one of the sealing surfaces is furnished with partial helical grooves as disclosed in U.S. Pat. No. 4,212,475, U.S. Pat. No. 3,704,019 or U.S. Pat. No. 3,499,653. This kind of seal has been applied to several sealing situations where not only high speeds and pressures were concerned but also in applications in which gas, liquid, or gas-liquid mixtures have been handled.
[0005] A disadvantage associated with sealing with non-contact seals is the effluvium which may be higher than the leakage expected when using a contacting seal in the same situation. This disadvantage becomes even more significant when the sealed fluid is either in liquid state of in a state of a liquid-gas mixture. This issue is associated with the fact that for the same volume of leakage, the density of liquid is several times higher than that of gas. Therefore the mass of amount leaked per unit of time will be much higher when leaking fluid is in liquid form rather than when it is in gaseous form. When sealing fluids at prominent pressure and speeds, the task is comparatively easier, if the sealed fluid is already in a gaseous state. If it is not and the sealed fluid is in liquid state, then there is always an inherent probability of high leakage.
[0006] From the above discussion, it could be concluded that vaporization at the seal faces of a contacting seal might offer a benefit since there would still be an abundance of liquid around the seal to entirely dissipate any frictional heat. However, in the prior art sealing arrangements it is not common to have the fluid change its phase from liquid to gas within the seal itself. As a matter of fact, gasification or vaporization at the sealing interface is though to be destructive to seal faces of liquid seals and it is therefore perpetually suppressed by the employment of flushing or cooling arrangements.
[0007] One such prior patent is U.S. Pat. No. 3,746,350 where a vortex type axial flow pumping device is employed to maintain an all liquid condition at the seal to extract frictional heat from the seal through liquid circulation. This heat removal lowers the temperature at the seal which then depresses the vapor pressure of the sealed liquid. Therewith, vapor pressure is kept safely below the pressure at the seal thus preventing liquid to vaporize. The pumping device operates by propelling liquid in an axial direction by vortex-forming threads shaped on the external surface of the rotatable part and on the internal surface of the surrounding non-rotatable part. The binary threads have opposite hands pending on direction of rotation, liquid will thereupon be urged in one of the two axial directions. Thread profile is optimized to achieve maximum flow rate of the liquid with given speeds of rotation.
[0008] A further prior patent is U.S. Pat. No. 4,243,230. Once more a pumping device is used to generate fluid pressure, which opposes loss of fluid from the housing during shaft rotation and which disengages the face seal to avoid loss of friction energy and to reduce wear. In this case, thread profile will not be optimized for maximum flow as in previously discussed patent, but instead will be optimized for maximum pressure differential toward the condition of zero or near zero flow, and this will normally result in a different thread profile.
STATEMENT OF THE INVENTION
[0009] In accordance with the invention, a seal arrangement is formed via combination of a non-contact seal and an axial flow pumping device. Said arrangement provides low-leakage performance of that of a gas seal even if sealed fluid is not a gas but rather a liquid or a gas-liquid mixture. This is accomplished by an axial flow pumping ring segment which is arranged to pump fluid away from the non-contact seal and back towards the source of said fluid. Thus without further replenishment of fluid flow through the axial flow pumping device will stall and a pressure drop is initiated. Subsequently, when fluid is stalled cooling is curbed and temperature of the fluid will rise. Both effects pressure drop and temperature rise cause vaporization of the fluid providing a non-contact gas seal with fluid in the preferred gaseous form for low leakage operation.
[0010] The prior patents discussed above present examples where pumping means inboard the sealing means are either employed to cool and circulate fluid or to seal fluid and disengage a contacting seal. The invention exploits pumping means inboard sealing means to resolve the problem of high leakage on elevated pressure and speed seals for liquids where vaporization occurs within pumping means rather than having vaporization at the sealing faces which is oftentimes destructive. In that way, sealing means will encounter only gaseous vapor for low leakage operation.
[0011] The basic differences between this invention and the prior patents are:
[0012] As opposed to U.S. Pat. No. 4,212,475, U.S. Pat. No. 3,704,019 or U.S. Pat. No. 3,499,653 the present invention will result in low leakage regardless of whether seal fluid is liquid, gas or a mixture of both, whereas the above prior art will result in low leakage only if sealed fluid is a gas with liquid or liquid-gas mixture leakage will be higher.
[0013] This invention enhances vaporization by restricting circulation of pumped liquid to heat it and depressurize it. On the other hand, working with liquid only the seal of U.S. Pat. No. 3,746,350 suppresses vaporization by minimizing restriction to pumped liquid flow and channeling this flow through a cooling system and back to the seal.
[0014] The present invention uses a pressure drop optimized pumping device to vaporize the liquid while prior art uses pressure drop optimized pumping device to move a sealing subassembly in axial direction.
[0015] These and many other features and attendant advantages of the invention will become apparent as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a side view in section of a selected tandem seal assembly;
[0017] [0017]FIG. 2 is a front view in elevation showing a sealing face detail;
[0018] [0018]FIG. 3 is a pressure-temperature chart showing a section of a typical vapor pressure curve of a fluid; and
[0019] [0019]FIG. 4 is a side view in section of another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring now to FIG. 1, a first embodiment of my invention comprises a shaft 10 , rotatable within the cylindrical bore 12 of a housing 14 . Bore 12 steps up concentrically within housing 14 to receive a non-rotatable pumping ring 16 and a seal retainer 18 . A cover plate 20 is secured to the housing 14 locking both the pumping ring 16 and the seal retainer 18 in axial position relative to the shaft 10 . The housing 14 may be mounted on a support (not shown). A stationary sealing ring 22 is urged against a rotatable sealing ring 24 by a spring disc 26 , pushed axially via a plurality of springs 28 . An O-ring 30 is positioned between the stationary sealing ring 22 and the spring disc 26 . The rotatable sealing ring 24 is seated in a drive sleeve 32 and locked by means of a clamp sleeve 34 . The drive sleeve 32 and the clamp sleeve 34 together form a rotating seal assembly prevented from rotation relative to shaft 10 by means of a key 38 . For non-contact, hydrodynamic operation the rotatable sealing ring 24 is provided with plurality of partial helical grooves 40 , shown in the sealing face shown on FIG. 2 with geometry differing depending on shaft rotation, sealed pressure and other variables. The drive sleeve 32 is provided with an external thread 42 which when optimized for maximum pressure differential will usually have a triangular shape in axial section.
[0021] The non-rotatable pumping ring 16 is provided with an internal thread 44 which is of the opposite hand to that of the thread 42 and also usually triangular for maximum pressure. Depending on the direction of rotation of the shaft 10 , one of these threads will have a right-hand direction while the other will have a left-hand direction. The section of drive sleeve 32 with thread 42 is concentrically positioned within the threaded section of thread 44 of the non-rotatable pumping ring 16 . Though both threads are separated by a small clearance, they are largely exaggerated for clarity on FIG. 1. The clearance is minimized for maximum pressure differential. During operation, the threads 42 and 44 propel liquid away from the sealing rings 22 and 24 and towards the source of liquid pressure at bore 12 to remove liquid from around the seal and leave said sealing rings surrounded by gaseous fluid for low leakage operation.
[0022] [0022]FIG. 2 illustrates the helical grooved end face of the rotatable sealing ring 24 in FIG. 1 showing the contour of grooves 40 , each of which starts at the outer circumference of the ring 24 extending inward and ending at a diameter larger than that of the inner circumference. All the helical grooves 40 are identical in their contours.
[0023] [0023]FIG. 3 is a graph of a section of the vapor pressure curve for a typical fluid with temperature bar on the horizontal axis and vapor pressure bar on the vertical axis. The curve 46 connects all points on the graph where fluid can be in either gas or liquid state. The region above curve 46 designated with the word “LIQUID” shows the region of pressure-temperature combination, where fluid can only be in liquid state. The region below curve 46 identified by the word “GAS” shows the region where fluid can only be in gaseous state.
[0024] Points A and B in FIG. 3 also appear on FIG. 1 and correspond to the pressure drop and temperature rise on the pumping device between threads 42 and 44 of FIG. 1 and illustrates the changes in the condition at respective axial ends of said threads from condition B of liquid state to condition A of gaseous state. It should be noted, that in order for liquid-gas state transition to take place, point B has to be sufficiently close to curvature 46 for the particular geometry of pumping threads and the rotational speed of the shaft, so that with given pressure drop and fluid heatup point A will remain in gaseous region of the chart and liquid will indeed vaporize.
[0025] [0025]FIG. 4 illustrates another embodiment of the invention similar to the one shown in FIG. 1 except for the pumping thread configuration. While the pumping device in FIG. 1 is based on a vortex-generating action, pumping device in FIG. 4 is based on viscosity effects and is utilized in sealing arrangements similar to those known as VISCOSEALS.
[0026] The sealing assembly of FIG. 4 uses a combination of smooth outer surface 48 of drive sleeve 32 and of a shallow rectangular thread profile 50 of non-rotatable pumping ring 16 , even though other profile configurations exist and are effective. Also shown in FIG. 4 is an optional inlet 54 for a gas such as air at atmospheric pressure through a one-way valve 52 . The purpose of this inlet is to prevent pressure on the seal from dropping below atmospheric pressure at conditions of start-up and before temperature reaches operating levels high enough to produce sufficient quantities of gas phase. Should seal fluid be such that mixing it with air is not permitted, the gas supplied at inlet 52 can be obtained from an external source.
[0027] It is to be realized that only preferred embodiments of the invention have been described and that numerous substitutions, modifications and alterations are permissible without departing from the spirit and scope of the invention as defined in the following claims.
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A sealing assembly for a rotatable shaft, comprising means to generate pressure differentials and temperature through pumping action and means to seal fluid, for example of the non-contact helical groove type. Sealing means are positioned outboard of pumping means. Fluid in liquid form is heated and depressurized on passage through pumping means of vortex or viscous shear type, thereby changed from liquid to gas. Gasified fluid is then sealed by sealing means for low leakage operation.
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FIELD OF INVENTION
[0001] The present disclosure relates to the field of portable toilets. More particularly, the present disclosure relates to portable toilets, which are foldable, collapsible and usable at any location.
BACKGROUND
[0002] In many underprivileged parts of the world, people are facing challenges on day-to-day basis due to scarcity of toilets or latrines. Still today, many undeveloped countries are facing sanitation problems. Many have to leave privacy of their shelters to perform one of the most basic human needs. They are conditioned to using unhygienic, often unsafe areas for their task.
[0003] In other scenarios, such as at construction and recreation sites portable toilets are often used which are normally made of metal sheets or a wooden material. These portable toilets are generally heavy due to which lot of transport difficulties arise during shifting from one place to another. Further, these toilets need septic tanks or a sewage pipe system to be fitted with them which results in increased operational and construction cost. Furthermore, there are no proper disposing solutions for the waste of these portable toilets, which results in increased danger of epidemics.
[0004] Sometimes, facilities available in public lavatories are unsanitary and one has to suffer if no other alternative is available. Conventionally, some disposable toilet seats, such as disposable covers are available however there are many disadvantages to these disposable covers.
[0005] Thus, there is felt a need to alleviate drawbacks associated with conventional disposable toilet facilities. There is a need to address the demand of toilets that can be cost effective, portable, easy to use and easily available.
SUMMARY
[0006] A portable toilet seat is disclosed. The portable toilet seat includes a foldable base configured in a shape of a conventional toilet seat, wherein the foldable base includes seat members defining an open center for excretion of waste therethrough. Each of the seat members includes a first end and a second end, wherein the seat members are connected with each other through a plurality of perforations provided at the first end and the second end of each of the seat members, to enable folding of the foldable base. The portable toilet seat further includes a receptacle removably connected to the seat members for covering operative back position of the open center, wherein the receptacle is configured to receive the waste through the open center.
[0007] A portable cabana is disclosed. The portable cabana includes an extendable hollow cylindrical body configured to be extended up to a predetermined height during operation. Further, an opening is provided at an operative top position and at an operative bottom position of the body to allow accommodation for a user within the body. Furthermore, the body is foldable into a predefined shape in an event the user is not accommodating within the body.
[0008] A portable toilet is disclosed. The portable toilet includes a portable toilet seat and a portable cabana. The portable toilet seat includes a foldable base in a shape of conventional toilet seat. The foldable base includes seat members defining an open center for excretion of waste therethrough. Further, the portable toilet seat includes a receptacle removably connected to the seat members for covering operative back position of the open center and to receive the waste excreted through the open center. The portable cabana includes an extendable hollow cylindrical body, which is extended up to a predetermined height during operation. Further, an opening is provided at an operative top position and at an operative bottom position of the body to allow accommodation of the portable toilet seat within the body.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0009] The novel features which are believed to be characteristic of the present disclosure, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. Embodiments of this disclosure will now be described by way of example in association with the accompanying drawings in which:
[0010] FIG. 1 illustrates a portable toilet seat in accordance with an embodiment of the present disclosure;
[0011] FIG. 2 illustrates a perspective view of the portable toilet seat during an operative condition, in accordance with an embodiment of the present disclosure;
[0012] FIG. 3 illustrates a perspective view of unfolding of the portable toilet in accordance with an embodiment of the present disclosure;
[0013] FIG. 4 illustrates a perspective view of a portable cabana in accordance with an embodiment of the present disclosure; and
[0014] FIG. 5 illustrates a perspective view of a collapsed portable cabana in accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION
[0015] The terminology used in the present disclosure is for the purpose of describing exemplary embodiments and is not intended to be limiting. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, operations, elements, and/or components, but do not exclude the presence other features, operations, elements, and/or components thereof. The method steps and processes described in the present disclosure are not to be construed as necessarily requiring their performance in the particular order illustrated, unless specifically identified as an order of performance.
[0016] In an event an element is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element, or intervening elements may be present. On the contrary, in an event an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element, there may be no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a like fashion. Further, the term “and/or” includes any and all combinations of one or more of the associated listed items.
[0017] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, and/or sections, these elements, components, regions, and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context.
[0018] The portable toilet of the present disclosure will now be described with reference to the accompanying drawings, which does not restrict the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
[0019] The portable toilet of the present disclosure includes a portable toilet seat and a portable cabana. In an embodiment, the present disclosure describes functioning of the portable seat in conjunction with the portable cabana however the functioning and use of the portable seat and the portable cabana are not limited to each other and both may also be utilized as individual units. The portable seat is foldable and the portable cabana is collapsible, due to which the portable toilet of the present disclosure is convenient to carry and helpful in emergency situations. The portable toilet of the present disclosure is quite useful in rural locations where common amenities are not available or a remote location where toilet facilities are not available. The portable toilet of the present disclosure may also find its utility in urban areas of the third world countries where women, men and/or children may perform their toilet activities in privacy using the portable toilet.
[0020] Referring to FIG. 1 , a portable seat 100 includes a base 102 and a receptacle 104 connected to the base 102 . The base 102 further includes two seat members 102 a and 102 b . For the purpose of description herein, number of seat members is restricted to two however the number of seat members may be increased for merely facilitating a design choice to a person ordinary skilled in the art. The placement of the seat members 102 a and 102 b defines an open center 116 which allows excretion of waste to the receptacle 104 placed underneath the open center 116 .
[0021] As illustrated in FIG. 1 , perforations 106 are provided at ends of the seat members 102 a and 102 b . Specifically, perforations 106 are provided at a first end 108 a and a second end 110 a of the first seat member 102 a . Further, perforations 106 are provided at a first end 112 b and at a second end 114 b of the second seat member 102 b . The perforations 106 may also be provided at other locations on the seat members 102 a and 102 b for merely facilitating a design choice to a person having ordinary skill in the art.
[0022] In an embodiment, the receptacle 104 is securely connected to the seat members 102 a and 102 b in such a manner to cover operative back position of the open center 116 , thereby conveniently receiving all the excreted waste. The receptacle 104 may be extended downwards about the perimeter of the open center 116 (as shown in FIG. 2 ) and may be securely engaged along the edges of the seat members 102 a and 102 b.
[0023] Referring to FIG. 2 , a sealed portable toilet seat 200 is illustrated. During operation, the receptacle 104 extends downward (as shown in FIG. 2 ) to receive waste being excreted by a user. The base 102 is foldable due to perforations 106 provided at the ends of the seat members 102 a and 102 b . The perforations 106 facilitate movement of the seat members 102 a and 102 b in a direction and a manner being desired by the user. Depending on a location of the perforations 106 on the seat members 102 a and 102 b , folding of the seat members 102 a and 102 b may be performed in different manners and styles (as indicated in FIG. 3 ), thereby rendering storage and carrying of the portable toilet seat 100 easy and convenient.
[0024] During operation, when the user is done with excretion of waste, the seat members 102 a and 102 b may be folded to get sealed with each other. In an embodiment, the seat members 102 a and 102 b may be sealed together (as shown in FIG. 2 ) through a sticker (not shown in figures) pasted on a glue panel (not shown in figures) present on a surface of the seat members 102 a and 102 b.
[0025] The portable toilet seat 100 is foldable due to presence of the foldable base 102 therein. Referring to FIG. 3 , the foldable base 102 of the portable toilet seat 100 may be folded to possess varying shapes and sizes as shown in FIG. 3 . In FIG. 3 , unfolding states of the portable toilet seat 100 has been shown. During operation, the user may unfold a first state 300 of the portable toilet seat to obtain a second state 400 of the portable toilet seat and subsequently may unfold the second state 400 of the portable toilet seat to obtain another intermediate state 500 of the portable toilet seat. The intermediate state 500 of the portable toilet seat may be unfolded to finally obtain the portable toilet seat 100 of FIG. 1 .
[0026] FIG. 4 illustrates a perspective view of a portable cabana 700 in accordance with an embodiment of the present disclosure. The portable cabana 700 includes a hollow cylindrically body 702 . The body 702 includes a first opening 704 at an operative top position and a second opening 706 at an operative bottom position. The first opening 704 and the second opening 706 enable a user to enter inside the body 702 . In an embodiment, the body 702 includes a room sufficient to accommodate the user sitting in a squat position. Typically, the body 702 is made of a flexible metal wire which may enable the user to increase the room inside the body 702 , if required. In another embodiment, height of the portable cabana 700 is adjustable due to flexible metallic wire body 702 . The user may adjust the height of the portable cabana 700 as per the requirement.
[0027] As illustrated in FIG. 4 , the portable cabana 700 further includes a structure 708 attached at an edge of the body 702 in such a manner to provide shade on the user sitting within the portable cabana 700 and/or to act as head covering for protection against external elements. The structure 708 may be attached removably with the body 702 . Due to the flexible metallic body 702 , the portable cabana 700 may be collapsed during non-operative conditions as shown in FIG. 5 .
[0028] Referring to FIG. 5 , the portable cabana 700 may be collapsed into an exemplary first collapsed state 800 which is a circular form or may be collapsed into another exemplary collapsed state 900 which is a “8” formation. Due to collapsible body 702 , it is easy to store and carry the portable cabana 700 .
[0029] In an embodiment, the receptacle 104 may be a bag or pouch made of a plastic, stiff paper or any other waterproof material. The foldable base 102 may be made of a cardboard or a stiff paper which makes the portable seat 100 bio-degradable, cost effective and easy to dispose.
[0030] In an embodiment, the portable toilet seat 100 may be used by a user while squatting within the portable cabana 700 or without the portable cabana 700 . In another embodiment, the portable toilet seat 100 may be placed on a conventional pedestal toilet seat.
[0031] In an embodiment, the portable toilet seat 100 may be painted with florescent colors which help in usage of the portable toilet seat 100 in absolute darkness conditions too.
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A portable toilet is disclosed. The portable toilet includes a portable toilet seat and a portable cabana. The portable toilet seat includes a foldable base in a shape of conventional toilet seat. The foldable base includes seat members defining an open center for excretion of waste therethrough. Further, the portable toilet seat includes a receptacle removably connected to the seat members for covering operative back position of the open center and to receive the waste excreted through the open center. The portable cabana includes an extendable hollow cylindrical body which is extended up to a predetermined height during operation. Further, an opening is provided at an operative top position and at an operative bottom position of the body to allow accommodation of the portable toilet seat within the body.
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BACKGROUND OF THE INVENTION
The present invention relates to an articulating joint for coupling members, such as tubular sections, of various assemblies where the members are capable of transmitting axial, torsional and bending stresses in their extended position, yet are foldable for collapsing into a more compact arrangement.
More particularly, the joint of the present invention is virtually completely contained inside a tubular section to which it is coupled when in the unfolded or concealed position, and facilitates a simple, flush appearance of two connected tubular sections.
One contemplated use of the joint of the present invention is in a folding ladder consisting of two or more sections which are pivotally interconnected. The sections are arranged to permit the ladder to fold or collapse to a reduced size on the order of one of its ladder section components for portability and/or storage.
The articulating joint of the present invention provides means for movement, as well as coupling, of tubular sections without the use of another element such as a sleeve or external linking part. Joints which require sleeves are disclosed in U.S. Pat. No. 3,235,038 to Nesslinger and U.S. Pat. No. 2,895,757 to Kaspar. Furthermore, the arrangement of the present invention allows tubular sections to be folded without having to axially rotate them or unscrew an internally contained bolt or sliding shaft (see, for example, the joint disclosed in U.S. Pat. No. 3,655,297 to Bolen, Jr., which does not permit the sections to be secured in a folded position and only facilitates, with the aid of an additional part (sleeve 24), the fixing of the two sections when the sections are disposed axially opposite one another).
OBJECTS OF THE INVENTION
It is therefore the primary object of the present invention to provide a simple, concealable articulating joint which overcomes the above-described deficiencies of the known related art.
Another object is to provide an articulating joint for connection between two tubular sections capable of sustaining substantial axial, transverse, torsional and bending loads.
Yet another object of the invention is to provide an articulating joint which can be combined with axially aligned tubular sections, which is easily disengaged from a concealed position (when the two sections abut) to permit angular movements of one or both of the joined sections relative to the other and the joint itself.
Still another object is to provide a fixing mechanism associated with the articulating joint for securing the tubular sections in either their aligned position or their angularly disposed position.
Still another object of the present invention is to provide an articulating joint having the abovementioned character and functions with economy of construction and simplicity in operation, whereupon it has widespread applications.
These objects are embodied in a novel articulating joint which is to be combined with the ends of tubular elements, so that the elements can function as a single united member, or as two folded, yet distinct and attached, elements.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages will become apparent to persons skilled in the art upon reading the detailed description which follows hereinafter when taken into consideration with the accompanying drawings forming a part of this specification and showing, for purposes of illustration, preferred forms of this invention, without limiting the claimed invention to such illustrative instances. These drawings include:
FIG. 1 which is a perspective view of a preferred embodiment of the invention showing tubular sections secured in an end-to-end position with the articulating joint concealed;
FIG. 2 which is a perspective view of the embodiment of FIG. 1 in an unengaged position with the tubular sections still in axial alignment;
FIG. 3 which is perspective view of the embodiment of FIG. 1 in its unengaged and folded position, the tubular sections each having been rotated 90° about the articulating joint into positions where both tubular sections are parallel;
FIG. 4 which is a view, partially in section, taken along line 4--4 of FIG. 5, with the tubular sections being in the position shown in FIG. 1.
FIG. 5 which is a partial sectional view taken along line 5--5 in FIG. 4;
FIG. 6 which is a partial sectional view of the two tubular sections in the position shown in FIG. 2;
FIG. 7 which is a partial sectional view of the two tubular sections in the position shown in FIG. 3;
FIG. 8 which is a view, partially in section, taken along line 8--8 in FIG. 7 of the two tubular sections in the position shown in FIG. 3;
FIG. 9 which is a cross-sectional view along line 9--9 in FIG. 4; and
FIG. 10 which is a top view of the ends of the tubular sections and the articulating joint in the position shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, FIG. 4, FIG. 5 and FIG. 9, the tubular element or section 10 may be considered the top end of a lower section tubular support member and the tubular element or section 12 may be considered the bottom end of an upper section tubular support member. Disposed within the top end of element 10 is a plug 14 consisting of two segments of a cylinder joined by a transverse pivot pin 14a, which is fixed (by any suitable means, such as a weld, screw, or the like) to the inside of the tubular section 10 so as to become an integral part with that section. In a similar manner, a plug 16 of the same construction as plug 14 is disposed within the bottom end of tubular section 12 as a reverse mirror-image of plug 14 and the two cylinder segments of plug 16 are joined together by a transverse pivot pin 16a (see FIG. 4). The radius of the curved surfaces of the cylindrical segments of each of plug 14 and 16 are desirably substantially equal to the interior radius of their respective tubular sections 10 and 12 so as to have the surfaces in direct contact with the interior walls of the tubular sections; however, it is sufficient if the exterior configuration of the segments of each plug are congruous with the interior configuration of the respective tubular sections. Disposed between, and coupling, the plugs 14 and 16 is a linking element 18 which preferably includes a central cylindrical portion 18a having a longitudinal axis and two identical linking flanges 18b, 18c each extending in a direction parallel to the axis and opposite from one another away from a respective one of the planar faces of cylindrical portion 18a. Each linking flange includes an elongated hole or slot (slot 20 in flange 18b; slot 22 in flange 18c), and transverse pivot pins 14a and 16a are positioned for passage through slots 20 and 22 on the sides thereof closest to the central cylindrical portion 18a. Flange 18b includes a partially circular (1/4 circle) edge 19 at one corner disposed opposite portion 18a and a squared notch 21 at the opposite corner. Similarly, flange 18c includes a partially circular (1/4 circle) edge 19' at one corner disposed opposite portion 18a and a squared notch 21' at the opposite corner. The linking flanges 18b, 18c of linking element 18 are each slidably supported in the space defined between the pair of cylindrical segments of plugs 14 and 16, respectively. The edge 18d of the flange between the notches is configured to fit into, and extend between, longitudinally extensive slots provided (e.g., by cutting) in radially aligned locations of tubular sections 10, 12. Each slot preferably has a width substantially equal to the width of the flange, and each slot is cut into the ends of the sections 10 and 12 adjacent the linking element 18. The flange edge 18d will lie flush with the outside surface of the tubular sections when the sections are disposed in the position shown in FIGS. 1 and 2, and when the sections are disposed in the folded position shown in FIG. 7, the flange surface 18e will lie flush (i.e., in the same plane) as the end faces of the respective tubular sections. In the linking flanges 18b, 18c, the radius of each of the 1/4 circle edges 19, 19' is equal to that of the interior of the tubular sections 10 and 12, and the length of the flange edge 18d between the squared notches is equal to the sum of two interior diameters d plus two thicknesses t. The cylindrical portion 18a of the linking element 18 preferably has a diameter d substantially equal to the interior diameter d of the tubular sections 10 and 12.
The plugs 14 and 16 thus provide a housing for the linking flanges 18b, 18c, and afford the tubular sections 10 and 12 with a reinforcing connection which restores any structural integrity which might be lost due to the cutting of the slots into the tubular sections.
For purposes of locking the tubular sections 10, 12 in an axially aligned, abutting position as shown in FIG. 1, the locking pins 24 and 26 normally pass through the slots of each linking flange 18b, 18c at the ends thereof furthest from the central cylindrical portion 18a of the linking element 18. From FIG. 5 it will be seen that the locking pins 24 and 26 each have a head 24b, 26b which protrudes outside of the respective tubular section 10, 12, and tapered convex ends 24c, 26c on the end of the respective pin opposite the heads 24b, 26b. The tapered ends are joined to the respective heads by a shaft. The shafts are housed within biasing springs 24a and 26a, which in turn are housed inside a passageway or hole in one of the cylindrical segments of each plug 14, 16. Each spring biases the tapered end 24c, 26c of each of the locking pins 24, 26 securely against tapered indentations 30 and 28, respectively, located in the flat surface of the other of the cylindrical segments. Each hole or indentation is configured with a female profile to accommodate the male profile of the tapered ends of the locking pins.
As shown in FIG. 4, when the linking element and plugs are completely contained within the tubular sections, the distance between the end of either one of the tubular sections (or transverse centerline of the linking element 18) and the centerlines of the transverse pivot housed within that tubular section is less than or equal to one half the interior diameter d of that tubular section. Similarly the distance between the centerlines of the transverse pivots 14a and 16a and the centerlines of the respective locking pins 24 and 26, as well as the distance between the outermost edge of a linking flange 18b or 18c and the respective locking pin 24 or 26, is equal to one half the interior diameter d of the tubular sections 10 and 12.
By pulling the respective protruding head 24b, 26b of the locking pin 24, 26 outwardly (away from the side of the respective tubular section), the biasing springs 24a and 26a are compressed and each respective tapered end 24c, 26c is drawn out of its indentation and into the associated passageway of its cylindrical segment in plug 14 or 16 until it has cleared the innermost edge of the slotted hole. Thereafter, the two tubular sections 10 and 12 will be unlocked from each other, and can be pulled apart. This will result in a displacement of each transverse pivot pin 14a or 16a in its respective slot 20, 22 outwardly in a direction away from the central portion 18a, whereupon the transverse pivot pin will assume the position shown in FIG. 6.
Looking more closely at FIG. 2 and FIG. 6, it can be seen that the linking element 18 is then visibly exposed, and that the transverse pivot pins 14a and 16a each now occupy the end of the slotted holes 20, 22 of respective linking flanges 18b, 18c previously occupied by the locking pins 24 and 26, respectively. The position of each transverse pivot pin 14a and 16a relative to the curved edge 19, 19' of the respective linking element flange portion 18b, 18c allows rotation of the tubular sction 10 in a counter-clockwise, and tubular section 12 in a clockwise, direction relative to the longitudinal axis of linking element 18 until each sectioin has moved 90 degrees into position. The distance between the centerline of the transverse pivot pins 14a and 16a and the edges of the linking element flange portion furthest from the central portion is equal to one half the interior diameter of the tubular sections 10 and 12.
Referring to FIG. 3 and FIG. 7 where the tubular sections 10 and 12 are shown disposed side-by-side and parallel to one another (in which the central portion of the linking element 18 and the ends of the plugs 14 and 16 are exposed to view), the tubular sections 10 and 12 are depicted as being held in position by the edge 18d of the element 18 abutting against the terminal edge of the slots in each tubular section. This abutment prevents the sections from further rotation about the respective transverse pivots 14a and 16a.
FIG. 8 illustrates the tapered head 24c of the locking pin 24 held against the indentation 32 on the locking flange 18b when the rotation of the tubular section 10 about pivot 14a brings the tapered head and the indentation into alignment. It is to be understood that the tapered head 26c has the same relationship with its corresponding indentation 34 as the parts 24c and 32. Both indentations 32 and 34 have a concave profile configured for mating receipt of the convex profile of the tapered heads of locking pins 24 and 26. By moving the locking pin 24 away from the interior of section 10 until the tapered head 24c has cleared the face of the linking flange 18b and is contained in the passageway of the segmented cylinder of plug 14, the tubular section 10 is once again free to rotate in the opposite direction.
FIG. 9 is a view of the tubular section 10 in a position where sections 10 and 12 are aligned as illustrated in FIG. 1, and shows the linking element 18, the plug 14 and the slot in the tubular section 10 all in an interlocked relationship, the entire cross-section of the assembly being solid with the exception of the slotted hole 14a of the linking flange 18d. This substantially solid arrangement of the interlocking parts gives the embodied articulation the requisite strength and structural integrity to allow the two tubular sections to behave as though they were one continuous section.
FIG. 10 depicts the distance from the centerline of each of the tubular sections 10 and 12 to the centerline of the linking element 18 as being equal to the interior diameter d of the tubular sections.
The foregoing description of the specific embodiments fully reveals the general nature of the invention so that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phrasiology or terminology employed herein is for the purpose of description and not of limitation.
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An articulation, or knuckle joint, which may be housed within two tubular sections to define a concealed fixing element enabling the sections to act as a single member, and which facilitates the folding or collapsing of the two sections by simply pulling them apart and rotating them about the articulation or knuckle joint.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method and arrangement for achieving load balance in washing machines provided with a drum operated by a variable speed electric motor, tachometer means for measuring the rotational speed of the motor and hence of the drum, or amperometer means for measuring the motor absorbed current or the motor control current, and electronic control means for controlling the motor speed so that between the end of the wash stage plus water discharge and the load spinning stage there is introduced a pre-spinning stage in which the motor accelerates to a speed less than the spinning speed.
2. Description of the Related Art
It is well known that if at the end of a wash cycle plus wash liquid discharge in an automatic washing machine the speed is increased to the spinning speed, the suspended machine masses, ie those relative to the clothes contained in the drum, the motor and the relative linkages connecting the drum to the motor, can undergo knocking and vibration which can compromise not only machine stability but also its operational integrity. The reason for such knocking and vibration lies in the fact that after discharging the free wash liquid (ie that not absorbed by the clothes), the clothes collect in the lowest part of the drum. Consequently when the drum speed increases, the clothes firstly "roll" randomly until they reach a critical speed (known as the orbital speed) at which the centrifugal force acting on the clothes equals the force of gravity and makes the clothes remain adhering to the inner surface of the drum in a substantially fixed position. However in many cases the clothes are not uniformly distributed within the drum at this orbital speed, with the result that further increase in speed with the load of clothes unbalanced can produce that vibration and knocking which are prejudicial to both machine stability and operational integrity, and cause the considerable noise generated by the washing machine when in this operating condition.
To remedy these drawbacks, certain methods and arrangements have been proposed involving measurement of the fluctuations in the current absorbed by the motor or of the variation in the motor speed (by a tachometer connected to the motor). If the range of this current fluctuation or voltage variation is large, this signifies that the load in the drum is unbalanced. The known or commonly used methods and/or arrangements for remedying this or for preventing this state of unbalance arising at the spinning stage involve a gradual increase in drum speed from the wash speed to the orbital speed, then checking the balance only when the orbital speed is attained, this speed then being maintained unaltered for a certain time, after which the state of the load is checked.
If after this certain time at the orbital speed it is ascertained that the load has attained a reasonably uniform distribution, the rotational speed is rapidly increased to the spinning speed. If however this check shows that at the orbital speed there is an intolerable load unbalance, the speed is reduced to the wash speed (with consequent separation of the clothes from the drum wall), after which it is again gradually increased to the orbital speed with the intention of achieving a different and more uniform distribution for the load. If this attempt also fails, it is followed by others. After a certain number of failed attempts the spinning speed is suitably reduced so as to reduce the effects of the unbalanced load. Such an arrangement is described for example in European patent 0071308.
In all cases the described action is taken after the load has been distributed, ie when the load is already at its orbital speed. This known arrangement comprising repetition of attempts involving remaining at the orbital speed results in a lengthening of the operating time of the washing machine, and in some cases represents an incomplete solution to the problems connected with drum instability.
SUMMARY OF THE INVENTION
The objects of the present invention are therefore to provide a method and arrangement which reduce the duration of the washing machine operating cycle while simultaneously statistically increasing the percentage of balanced loads obtainable during spinning, with consequent reduction in vibration and knocking and increased machine stability, and also the possibility of lightening the machine mechanical structure leading to cost reduction, while using components (tachometer, electronic control modules and microprocessors) already present in current washing machines, resulting in further reduction in the additional costs of its implementation and obtaining a reduction in those cases in which the washing machine generates further noise associated with load unbalance.
These and further objects which will be more apparent from the detailed description given hereinafter are attained by a method and arrangement, the inventive aspects of which are defined in the accompanying claims.
The inventive concept is such that after the final wash stage plus discharge of free wash liquid and before the complete orbital speed of the load is reached, a stage follows in which the washing machine is made to gradually increase the rotational speed of its drum, during which a physical quantity (for example the motor rotational speed, its absorbed current or the current controlling the static switch connected in series with the motor) is continuously monitored. This physical quantity is one which is indicative of the state of balance or unbalance of the drum, so that the initial moment in which the load is balanced in an acceptable form can be determined, to be followed by sudden increase in the motor speed up to for example spinning speed. In this respect it has been found that it is not in fact necessary to await the attaining of orbital speed (with the aforesaid drawbacks) before checking load distribution, it being sufficient to monitor it continuously beforehand, ie at lower speeds in that, as has been found in a statistically relevant number of cases, during this pre-spinning stage cases have been found with significant frequency in which at a given moment conditions exist in which the load although not being completely orbital is uniformly distributed within the drum and consequently balanced, such a load condition however not necessarily existing subsequently. Hence as stated, with the present invention, at the moment in which such a load balance state exists the speed is instantaneously increased with high acceleration to the spinning speed, whereas with the known method it can happen that such an instantaneous condition of balance no longer exists when the check is actually made, ie at the final orbital speed of the load. Consequently with the invention the moment of uniform load distribution during a stage prior to the attaining of complete orbital speed by the load is detected, and practically in that moment the speed is raised to spinning speed, so fixing the favourable and hence balanced load distribution. It has been found during statistically significant tests that using such a procedure a higher uniform load distribution percentage is achieved than in the aforedescribed known method.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more apparent from the detailed description of a preferred embodiment thereof given hereinafter by way of non-limiting example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic section through an automatic washing machine and the relative control means;
FIG. 2 is a block diagram of the control means; and
FIG. 3 is a time/speed diagram which further illustrates the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the reference numeral 1 indicates overall a washing machine of known structure. Of this, FIG. 1 shows only those parts required or may be required for a clear understanding of the invention, and which comprise: an outer tub 2 with a clothes loading and unloading aperture 3; a drum 4 with access mouth 5, mounted rotatable within the tub 2 and carrying the load; a shaft 6 rotatably supported by the tub 2 and torsionally rigid at one end with the drum 4; a first pulley 7 keyed onto the other end of said shaft; a transmission belt 8 cooperating with the first pulley 7; an electric motor 10 rigid with the tub 2; a second pulley 9 keyed onto the motor shaft 11 and cooperating with the transmission belt 8; a tachometer 12 operationally connected to the shaft 11 of the motor 10 to measure its speed; an electronic control module 14 controlling the motor with regard both to the absorbed current and hence power and to the relative r.p.m.; an interface 13 for converting the analog speed signal of the tachometer 12 into a digital signal accessible to the digital part of the control module; and an electronic timer 15 controlling all functions of the washing machine 1 and hence the wash, the distribution of the load 7A over the inner cylindrical wall of the drum 4, and the spinning.
As an alternative to or in combination with the use of the tachometer 12 and the relative interface 13, an amperometric sensor with relative interface can be used to measure the current absorbed by the motor or to measure the control current of a static switch connected in series with the motor.
In this configuration in both the aforesaid cases the electronic module 14 powers the motor 10 under the control of the timer 15 such that the operating conditions scheduled for each stage of the wash cycle are respected in relation to the particular state of the timer, as is well known to the expert of the art. For example, if during the wash cycle there is a stage in which the motor has to operate at a given speed and at predetermined time intervals, the timer 15 transmits the corresponding information to the electronic module 14, which via the feedback loop formed by the module and, for example, the tachometer 12 causes the motor to operate in a corresponding manner, independently of factors which tend to modify the predetermined conditions.
When the electronic module 14 has received the command from the timer 15 to implement the pre-spinning of the clothes contained in the drum 4, ie after the wash and the discharge of the free wash liquid, it firstly controls the r.p.m. and power of the motor 10 such that the motor r.p.m. increases gradually (see FIG. 3), for example from 55 r.p.m. to 120 r.p.m. within 10-30 seconds. During this acceleration the electronic module 14 receives signals from the tachometer 12 or amperometric sensor which indicate any fluctuations in the current dr in the motor r.p.m. consequent on load unbalance, these being continuously monitored, for example by conventional comparator circuits and logic gates. At a certain rotational speed, for example on reaching 80-90 r.p.m., ie a speed less than the orbital speed which in the present example is 120 r.p.m. (point Y of FIG. 3), the signal relative to the speed sensor or current sensor reaching the electronic module indicates that these fluctuations have been substantially reduced to an acceptable predetermined level (point X of FIG. 3) and that at that moment the load is distributed in a substantially balanced manner over the wall of the drum 4. A possible explanation of this phenomenon is that at this speed (for example 80-90 r.p.m.) the load has only partially orbited in that this speed is insufficiently high to overcome the force of gravity to which the clothes in the central part of the drum are subjected and which are only dragged by the rotation of the drum itself. These clothes dragged into rotation are however subjected to a centrifugal force which at certain moments (for example because by rolling, those clothes not in orbit become positioned in a region of the drum to which a smaller quantity of clothes adheres, hence in a region in which having a greater possibility of radial movement they are subjected to a greater centrifugal force) can overall determine the balanced load condition. On sensing this state of equilibrium the electronic module 14 passes this information to the timer 15 which, conversely, causes the electronic module 14 to feed maximum power to the motor 10, which undergoes the highest acceleration (sections P and Q of FIG. 3) provided for spinning, so orbiting the load. If balanced load distribution does not occur before the point of complete load orbiting, the spinning speed can be reduced in known manner. Alternatively one or more repetitions of the described attempt can be made, after which if balancing has still not been achieved the spinning speed is finally reduced.
It should be again noted that conventional arrangements do not take account of the fact that balanced distribution may be achieved just occasionally or only for brief periods (at the point X in the example of FIG. 3), before reaching the complete load orbiting speed (indicated by Y in FIG. 3), but instead check the state of the load only when orbiting is total, by checking for a certain period of time during this condition whether the load is balanced or not, then if the load is unbalanced repeating, possibly a number of times, the procedure involving moderate or low acceleration starting from the wash speed and rechecking the balance condition at the complete load orbiting speed, indicated by way of example as 120 r.p.m. (point Y).
According to the invention, at the end of the wash operations the timer 15 feeds to the electronic control module 14 a signal by which this latter causes the motor 10 to start rotating the drum at gradually increasing speed (pre-spinning).
The information which the electronic module 14 continuously receives via the feedback loop (FIG. 2) into which the sensor (12 and tachometer interface 13) is connected can represent either a balanced condition or an unbalanced condition for the load of clothes contained in the drum. The electronic module 14 continuously checks, by comparison with predetermined values present in the memory, whether this information corresponds to a balanced or an unbalanced load condition. If at a certain moment (for example at the point X of FIG. 2, after a time Δt 1 ) the information corresponds to a balanced load, the electronic module 14 causes the motor 10 to suddenly increase its speed (as shown by the section P of FIG. 3), so that the load 7A stabilizes in the balanced state and the spinning stage commences. If instead the information continues to show a load-unbalanced condition in relation to the reference values compared by the electronic module 14, this latter feeds a command to the motor 10 to continue to increase its speed only gradually, and consequently that of the drum containing the load.
If no load balance has been achieved up to the moment of complete load orbiting (point Y of FIG. 3), at which the entire load is immobilized against the peripheral wall of the drum, the motor 10 is set to a reduced spinning speed. Alternatively, the load distribution stage could be repeated by firstly reducing the speed (along the section from Y to I in FIG. 3 where I is the commencement point of the acceleration stage which follows the wash stage) and then repeating the already described balancing and monitoring procedure.
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A method for achieving load balance in washing machines provided with a rotary drum driven by an electric motor under the control of control means, and in which a circuit is provided for measuring a physical quantity associated with information relative to the state (balanced or unbalanced) of the load in the drum, the method comprising, after the wash stage, a stage in which the drum speed is gradually increased during which the physical quantity is continuously monitored to ascertain the state of load distribution within the drum, and a stage of rapid rotational speed increase at the moment in which a state of balanced load distribution within the drum is detected.
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This application is a continuation, of application Ser.No. 07/783,125 filed on Oct. 28, 1991, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to a pneumatic tire and more particularly an improvement in a tread reinforcing belt.
In general, a pneumatic tire is provided radially outside the carcass with a belt to reinforce the tread portion.
In a conventional belt structure, as shown in FIGS. 7 and 8, a belt ply (p) is formed by applying a strip (e) of rubberized parallel cords (b) around the carcass. A strip (e) of rubberized parallel cords (b) is made by cutting a sheet of tire fabric (d) at a bias angle (α). The ends (f) of the applied strip (e) are jointed by overlapping one upon the other by a certain width, and a joint running at the bias angle (α) is formed, and further two side edges with cord cut ends are formed. Therefore, due to the bias joint, steering stability and directional stability during straight running are liable to be disturbed. It is especially remarkable during high speed running. Further, durability is impaired due to the cord cut ends from which rubber separation failure arises.
In order to solve those problems, a jointless belt formed by spirally winding a continuous cord around the carcass at a small angle to the tire equator has been proposed in, for example, Japanese Utility-Model Publication No. 58-160805. However, due to the spiral cord arrangement, drifting toward a certain direction is liable to occur.
SUMMARY OF THE INVENTION
It is therefore, an object of the present invention to provide a pneumatic tire which can solve the problems of stability, durability and drifting.
According to one aspect of the present invention, a pneumatic tire comprises a carcass extending between beads, and a belt disposed radially outside the carcass and inside a tread and having opposite axial edges, wherein the belt comprises at least one cord continuously wound around the carcass while running zigzag between the edges of the belt to define cord segments extending between the edges of the belt, the cord segments including first cord segments and second cord segments, the first cord segments laid substantially parallel with each other, and the second cord segments laid substantially parallel with each other and crosswise to the first cord segments.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will now be described in detail in conjunction with the accompanying drawings, in which:
FIG. 1 is a cross sectional view of a tire according to the present invention;
FIG. 2 is a developed plan view of a belt and a carcass;
FIG. 3 is a perspective view of a ribbon of rubber used to form the belt;
FIG. 4 is a developed plan view showing a method of making the belt;
FIG. 5 is a developed plan view of another example of the belt;
FIG. 6 is a developed plan view of still another example of the belt;
FIG. 7 is a developed plan view of a carcass and conventional belt structure; and
FIG. 8 is a plan view of the tire fabric used to form the conventional belt.
DETAILED DESCRIPTION OF THE INVENTION
In the figures, pneumatic tire 1 has a tread portion 2, a pair of axially spaced bead portions 4, and a pair of sidewall portions 3 extending between the tread edges and the bead portions.
The tire 1 comprises a bead core 4A disposed in each bead portion 4, a toroidal carcass 5 extending between the bead portions 4 and turned up around the bead cores 4A, and an jointless belt 6 disposed radially outside the carcass 5 and inside the tread.
The carcass 5 in this embodiment comprises one ply of organic fiber cords, e.g. nylon, aromatic polyamide and the like, arranged radially at an angle of 60 to 90 degrees with respect to the tire equator C so as to provide a radial or a so called semiradial ply construction.
The belt 6 comprises at least one continuous cord which is wound at least once around the carcass while running zigzag from the one edge to the other edge of the belt, so that the or each belt cord has first parallel cord segments inclined at a bias angle (α) with respect to the tire equator and second parallel cord segments inclined at the same bias angle (α) but in a symmetrical direction with respect to the tire equator, wherein the cord segments mean substantially straight cord portions defined as extending from one edge to the other edge of the belt. By such arrangement of the cord segments, the first cord segments cross the second cord segments.
FIG. 2 shows a first example for the belt 6, in which several parallel cords 11 are wound together several times around the carcass. In this example, the first parallel cord segments 61 are located radially inside the second parallel cord segments 62.
FIG. 3 shows a ribbon 10 of rubber. In order to make the belt, such ribbon is used. In the ribbon, one belt cord or parallel belt cords 11 are embedded in coating rubber 12.
The number of the embedded cords 11 is set in the range of 1to 10. In the example shown in FIG. 3, the number is 7, and the cross sectional shape of the ribbon 10 is a flat rectangle.
Preferably, the width Wo of the ribbon 10 is set in the range of 5 to 15 mm.
For the belt cords 11, organic fiber cords, e.g. nylon, polyester, aromatic polyamide and the like or steel cords can be used. Preferably, aromatic polyamide fiber cords are used for their high modulus which corresponds to that of steel cords and light weight.
FIG. 4 shows a method of making the belt 6 shown in FIG. 2, wherein one ribbon 10 is wound plural times (n) as follows:
In the first winding, the ribbon extends at the angle (α) from a starting point S to the other left side belt edge F1;
A) at the other left side edge F1, the ribbon is folded back radially inwardly;
B) the ribbon extends at the angle (α) to the right side edge F2;
C) at the right side edge F2, the ribbon is folded back radially outwardly;
D) the ribbon extends at the angle (α) to the left side belt edge F1;
A) to D) are repeated until the ribbon returns to the imaginary starting point of the second winding which point S2fis adjacent to the previous starting point S.
In the subsequent second winding and third, fourth, through the last (n)th windings, the ribbon is wound in the same way as the first winding.
By winding the ribbon (n)-times, the belt becomes tight. In other words, no space is formed between the circumferentially adjacent ribbon segments (used in the same sense as the above-mentioned cord segments).
The zigzag pitch Pt in the circumferential direction of the tire is (n) times the the circumferential width P of the ribbon.
For the second through the last windings, each of the starting points therefor is located before the previous starting point. That is, the circumferential length of one winding is smaller than that of the belt, and the difference therebetween is the circumferential width P of the ribbon (P=Wo/sin(α)).
After the (n)-time winding of the ribbon, the terminal end thereof returns to the first starting point S and is jointed with the starting end.
As described above, in this example, the ribbon is always folded back from radially outward to inward at the left side edge F1 and from radially inward to outward at the right side edge F2. Accordingly, the ribbon is wound spirally and continuously around the thickness central plane of the belt while being wound around the carcass generally. This spiral-folding type belt is formed separately from the carcass, and thereafter they are assembled.
FIG. 5 shows a modification of the above-explained belt 6. In this belt 6a, the zigzag pitch Pt is equal to the circumferential width P of the ribbon, and accordingly the bias angle of the belt cords becomes larger, and the ribbon is wound once around the carcass.
FIG. 6 shows a modification of the belt 6a shown in FIG. 5. In this belt 6b, the folding-back directions of the ribbon at the belt edges are altered such that the ribbon is folded back from radially inside to outside at both the edges F1 and F2, which makes it possible to form the belt 6b directly on the carcass. It is however, also possible to form separately from the carcass.
Such one-way folding can be applied to the first example belt 6.
Further, in the belts in which the ribbon is wound a plurality of times around the carcass, for example the belt 6 and the belt 6 combined with the one-way folding, the circumferential length of one winding of the ribbon can be larger than that of the belt. The difference therebetween is set to be the circumferential width P of the ribbon. In other words, the imaginary starting points S2h for the second (exemplarily shown in FIG. 4) to last of the windings are positioned behind and adjacently to the respective previous starting points.
The above-mentioned bias angle (α) of the ribbon 10 or belt cords 11 Is in the range of 10 to 80 degrees with respect to the tire equator.
In the above-mentioned examples, the edges of the adjacent ribbon segments are not overlapped. However, they may be slightly overlapped.
In the, above-mentioned one-way folding, after one belt layer is formed, that is the ribbon returns to the first starting point, a further layer 20 can be formed successively thereon by continuously winding the ribbon therearound. In such a case, the axial extent W of the zigzag is preferably changed to be narrower or wider than the other layer. Such further layer 20 is shown by imaginary lines in FIG. 2.
Further, in the spiral folding explained in the first and second example belts 6 and 6a, after one belt layer is formed, a further layer can be formed successively by continuously winding the ribbon around the previously formed belt layer.
Furthermore, a belt layer (shown by imaginary lines in FIG. 2) made of a strip of conventional tire fabric can be combined with the above-mentioned zigzag cord belts 6, 6a and 6b. For example, a fabric belt layer 30 is disposed between the radially outer segments 62 and the radially inner segments 61 of the zigzag cord belt formed by spiral folding, or a fabric belt layer is disposed radially outside or inside the zigzag cord belt.
As described above, in the pneumatic tire according to the present invention, the belt is provided with an endless structure with respect to the circumferential direction of the tire, and there is no cord cut end at the edges, and further, the first cord segments cross the second cord segments. Therefore, belt edge looseness and rubber separation are effectively prevented, and durability of the tread portion is improved. The endless structure and cross structure provide a rigid and uniform reinforcement for the tread portion, and straight running performance and steering stability are improved.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A pneumatic tire which comprises a belt disposed radially outside a carcass and inside a tread and having opposite axial edges, the belt comprising a cord continuously wound around the carcass while running zigzag between the edges of the belt to defining cord segments extending between the edges of the belt, the cord segments including first cord segments and second cord segments, the first cord segments laid substantially parallel with each other, and the second cord segments laid substantially parallel with each other and crosswise to the first cord segments.
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BACKGROUND OF THE INVENTION
The invention relates generally to an arrangement which is variously known as a burner or jet, or blowing nozzle, for example for use in a metallurgical furnace, for injecting for example a fuel such as a fuel gas and one or more other gases, into the interior of the furnace. For the sake of simplicity of terminology in this specification, the term nozzle or nozzle assembly will be used to denote a burner or blowing nozzle.
German published specification (DE-AS) No 20 13 145 discloses a nozzle assembly for use in a metallurgical furnace such as an arc furnace, which in use is disposed above the level of the molten bath in the furnace. In the region of the tip of the nozzle assembly, that is to say, in the region of the discharge opening thereof, that arrangement has a change-over slide member which is displaceable by pneumatic or hydraulic means, for controlling the feed of fuel gas and one or more other gases to the discharge opening of the nozzle assembly.
When using nozzle assemblies which are sometimes referred to as jet burners for oil and oxygen or fuel gas and oxygen, in a metallurgical furnace, more specifically an electric arc furnace, the mouth opening of the nozzle assembly must be kept free of metal and slag which may be deposited in that area of the nozzle assembly as by splashing. The danger of the discharge opening of the nozzle assembly becoming fouled by slag or the like is very serious in particular during the periods of time when the nozzle assembly is not operating. Similar problems also occur in regard to nozzle assemblies forming blast nozzles for injecting oxygen or an oxygen-bearing gas into a furnace.
In order to avoid fouling and corrosion due to the deposit of slag on the burner arrangement, the burner arrangement must be drawn or pivoted out of its position in the wall of the furnace during the periods of time that the assembly is not operative, by using mechanical means. Such withdrawal means are expensive and also susceptible to breakdown or failure. They also require a large amount of maintenance. Furthermore, before the burner arrangement is refitted into position in the opening in the wall of the furnace, that opening must be properly checked and if necessary any slag deposited in that area must be removed.
Another method of keeping the mouth of the burner arrangement free involves blowing air through the burner during the periods when the burner is not in operation. The effectiveness of that mode of procedure is doubtful particularly when the burner is disposed in the wall of the furnace at a very low position, when slag reaches the openings. In addition, the costs involved in producing the flow of compressed air are high.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a new and improved burner or blow nozzle assembly for use in a metallurgical furnace.
Another object of the present invention is to provide a burner or nozzle assembly for a metallurgical furnace, such as to at least substantially reduce the accumulation of metal and/or slag at the discharge opening of the assembly or at the opening in the wall of the furnace which receives same.
Still another object of the present invention is to provide a burner or nozzle assembly with means adapted to remove spatter or splash of metal and/or slag on the assembly at or around the discharge opening thereof or at or around the opening through the wall of the furnace for receiving the burner or blow nozzle.
Yet another object of the present invention is to provide a burner or blow nozzle assembly which can be cleaned off in respect of metal or slag thereon, without removing or dismantling the burner or blow nozzle.
Yet a further object of the present invention is to provide a burner or blow nozzle for use in a metallurgical furnace, wherein spatters of metal or slag thereon can be readily removed by mechanical means and without the use of for example compressed air.
A still further object of the present invention is to provide a burner or blow nozzle which can be fixedly installed in the wall of a furnace in a low position, without operation of the burner or nozzle being disturbed by metal or slag adhering thereto in the region of its tip.
In accordance with the present invention, these and other objects are achieved by a burner or nozzle assembly for use in a metallurgical furnace such as an electric arc furnace, at a position above the level of the molten bath therein. The assembly comprises an injection duct or passage leading to a discharge opening for injecting for example oxygen or oxygen-bearing gas or fuel into the furnace. Disposed in the region of the discharge opening of the duct or passage and displaceable by means of an actuating means is a closure member which may be for example in the form of a piston. The closure member is thus adapted to be displaced by the actuating means into a closure position in which it blocks off the discharge opening.
When the assembly is fitted into the wall of a metallurgical furnace, above the level of the molten bath therein, with the wall having an opening which adjoins or is aligned with the discharge opening of the assembly, for the material injected by the assembly to pass through the wall opening into the furnace, the closure member may also be such that it can be displaced to a position in which it also closes or blocks off the opening in the wall of the furnace.
Therefore, it will be seen that, in the nozzle assembly according to the principles of the present invention, the discharge opening thereof, or also the opening in the wall of the furnace in which the nozzle assembly is fitted, can be closed off by means of the displaceable piston-like member. By virtue of the discharge opening being closed off in that way, during the periods when the nozzle assembly is not in operation, splashes of metal and/or slag can no longer penetrate into the mouth opening of the nozzle assembly and give rise to failures or interruptions in operation, but instead, such splashes impinge on the closure member in its position of closing off the discharge opening of the nozzle assembly and/or the opening in the wall of the furnace. In its region which is towards the interior of the furnace, the closure member is formed of scale-resistant material and is possibly coated with a material which is difficult to wet such as graphite, in order to make it difficult for splashes of metal and/or slag to adhere to the closure member. Preferably however, the piston-like closure member is also caused to oscillate in the region thereof which is towards the interior of the furnace, thereby to remove any splashes which may impinge thereon, as soon as they occur. In a particular form of that construction, when the closure member is of a piston-like configuration which is displaceable parallel to the longitudinal centre line of the burner or nozzle, longitudinal oscillations are particularly suitable for removing slag or metal. However, it is also possible to use transverse oscillations or mixed oscillations.
In an embodiment of the arrangement according to the present invention, the entire closure member may be caused to oscillate, in which case a mechanical oscillation generator, an electromechanical oscillator generator or a hydraulically or pneumatically actuated oscillation generator may be used to produce the oscillations. However, it will be appeciated that the important consideration is for the surface of the closure member on which the splashes of metal and/or slag may be deposited to be set oscillating. It is therefore sufficient for that surface portion to be caused to oscillate. That is a particularly important consideration when using ultrasonic oscillation generators in which the location of the amplitudes of the oscillations produced, within the closure member, is influenced by the configuration of the closure member. The oscillation amplitude should occur in the region of the surface on which the splashes of metal and/or slag impinge. Therefore, the shape and the distribution of mass of the closure member should desirably be such as to optimise the oscillation or sound field magnitude, in other words, the natural frequency of the piston-like member and the modes of oscillation within that member should be matched to the frequency of the oscillation generator.
Preferably, the displaceable piston-like member and the oscillation generator are matched to each other, in respect of design configuration and frequency, in particular to the sound and ultrasonic wave range, in such a way that sound waves or ultrasonic waves are irradiated from the surface of the closure member at such a high energy level that slag in the space in front of the closure member, in the direction of the interior of the furnace, is caused to oscillate to such an extent that it is thrown off or broken up.
The effect of removing particles of slag which adhere to the arrangement, or a layer of adhering slag in the region of or in front of the mouth opening of the nozzle assembly may also be achieved, possibly in combination with the generation of sound waves or ultrasonic waves, by the displaceable closure member being extended beyond the mouth opening of the nozzle assembly, by the means provided for actuating the displaceable closure member. During that thrust movement of the closure member inwardly of the furnace, any particles of metal or slag adhering to the nozzle assembly are mechanically removed, while if there is a layer of slag on the assembly, the closure member is pushed through that layer and thus causes it to be broken up and removed. In that case, the displaceable member acts in the manner of a ramming element or broaching tool for removing any foreign particles adhering to the nozzle assembly or the opening in the wall of the furnace in which the nozzle assembly is disposed. The removal operation by means of the broaching tool or ramming member may be carried out in each break in operation of the nozzle assembly automatically or in a controlled manner during operation of the assembly.
Further objects, features and advantages of the arrangement in accordance with the present invention will be more clearly apparent from the following detailed description of preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view in partial cross-section of a nozzle assembly such as a burner disposed in the side wall of a metallurgical furnace, in the operative condition of the nozzle assembly,
FIG. 2 shows the nozzle assembly of FIG. 1 but in the condition thereof that is assumed during a break in operation of the nozzle assembly,
FIG. 3 is a view similar to that shown in FIG. 2 of a second embodiment of a nozzle assembly such as a burner which has an electromagnetic oscillation generator instead of a hydraulic oscillation generator,
FIG. 4 is another view similar to that shown in FIG. 2 but showing a third embodiment using an ultrasonic oscillation generator,
and
FIG. 5 shows the arrangement of a nozzle assembly in the side wall of a metallurgical furnace, in which closure of the opening in the wall of the furnace is effected in the reverse direction to that used in the embodiments shown in FIGS. 1 through 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring firstly to FIG. 1, shown therein is a side wall structure 1 of a metallurgical furnace such as for example a Siemens Martin furnace, a converter, a melting gasifier, an electric arc furnace or the like, and a nozzle assembly indicated generally by reference numeral 2, such as a burner or blow nozzle, which is disposed in the side wall 1 of the furnace at such a position that it is above the level of the molten bath in the furnace. In the construction shown in FIG. 1, the nozzle assembly 2 is carried in a water cooling box 3 which in turn is fitted into the refractory lining of the furnace. Reference numeral 4 denotes the water feed for the water cooling box 3, while reference numeral 5 denotes the water return or discharge. The water cooling box 3 forms a part of the wall 1 of the metallurgical furnace and has an opening 6 through which the fuel mixture or the gases are discharged from the nozzle assembly 2 into the interior of the furnace. The nozzle assembly 2 is secured to the water cooling box 3 by means of a flange 7 in such a way that a discharge opening 8 of the nozzle assembly 2 is disposed directly adjoining the opening 6 in the wall 1. In the present case, the discharge opening 8 is of the same cross-section as the wall opening 6.
As can be seen from FIG. 1, the nozzle assembly or burner 2 illustrated therein comprises three concentric pipes 9, 10 and 11, thereby forming a central duct or passage 12 and first and second annular passages or ducts 13 and 14 which are disposed therearound. A fuel such as a fuel gas can be fed to the inner annular duct 13 by way of a feed connection 15 and an oxygen-bearing gas such as oxygen can be fed to the outer annular duct 14 by way of a feed connection 16. In the case of a known burner, the central duct 12 is usually also used for a feed of fuel gas or oxygen, while, in the case of a known blowing nozzle, oxygen is generally introduced through the central duct 12; a protective fluid is introduced through the annular ducts 13 and 14. In the nozzle assembly of the invention however, the duct 12 serves a different purpose, as will be described below.
In the construction illustrated in FIG. 1, associated with the nozzle 2 is a displaceable closure member 18 which is operatively connected to a suitable actuating means indicated generally by reference numeral 17, for displacing the member 18 in the lengthwise direction of the assembly 2. As will be clearly seen from FIG. 1, the member 18 is of a generally piston-like configuration and is disposed axially displaceably in the central duct 12 of the assembly 2. The cross-section of the central duct 12 approximately corresponds to the discharge opening 8 and the wall opening 6. The member 18 can be displaced by the actuating means 17 from the retracted or inoperative position shown in FIG. 1, into the first, extended position shown in solid lines in FIG. 2 and indicated by reference numeral 24, or into a second, further inwardly extended position shown by broken lines in FIG. 2 and indicated by reference numeral 19. In both the positions 19 and 24 shown in FIG. 2, the member 18 closes off the wall opening 6 and thus prevents splashes or spatter of metal or slag from being deposited in and adhering within the opening 6 in the wall 1 of the furnace. Any metal or slag which is already adhering to the structure in the opening 6 in the wall of the furnace is removed when the piston-like closure member 18 is extended from the retracted or inoperative position shown in FIG. 1 into the closure position shown in FIG. 2, as the external cross-section of the member 18 at its end at least substantially corresponds to the cross-section of the wall opening 6. It should be noted at this point however that the purpose of the member 18 is not to interrupt or cut off the supply of fuel or gas from the burner, that cut-off effect being produced by valves (not shown) in the conduits connecting to the connecting means 15 and 16. The purpose of the member 18 is to fill up the opening 6 in the wall of the furnace, in other words, to block up the opening 6 so as to prevent it from being accessible from the interior of the furnace, and to remove any slag or metal which has already been deposited in the wall opening 6 during the forward movement of the piston-like member 18, when it acts in the manner of a broaching tool. Any particles or pieces of slag or a layer of slag in front of the wall opening 6 can also be removed or pierced by the closure member 18 being extended further into the interior of the furnace, being the position indicated in broken lines at 19 in FIG. 2.
It will be noted that, in the construction shown in FIGS. 1 and 2, the two annular ducts 13 and 14 communicate with the central duct 12 upstream (in relation to the flow through the nozzle assembly) of the discharge opening 8 of the burner 2. By virtue of that arrangement, the respective discharge openings of the annular ducts 13 and 14 are brought together to form a single discharge opening 8 for the burner, and that discharge opening 8, like the wall opening 6, is closed when the closure member 18 is in the closed position. A design configuration of that kind appears to be desirable particularly when the mouth of the burner assembly 2 is directly exposed to the atmosphere within the furnace, so that the discharge opening 8 of the nozzle assembly 2 does not have a wall opening 6 of a water cooling box or the like, adjacent thereto, which would otherwise provide some measure of protection for the discharge opening 8 of the nozzle assembly.
In the embodiment illustrated in FIGS. 1 and 2, the actuating means 17 for displacing the piston-like member 18 lengthwise of the nozzle assembly 2 is in the form of a pneumatic double-acting thrust drive means, in other words, it causes the member 18 to be positively displaced both in its direction of extension and in its direction of retraction. For that purpose, disposed movably within a pneumatic cylinder unit 20 is a piston (not shown) which is connected to the member 18 by a piston rod 21. The pneumatic cylinder unit 20 has compressed air connections 22 and 23 which communicate with the interior of the pneumatic cylinder unit 20 on different sides of the piston therein. By virtue of this arrangement, the piston of the piston-cylinder unit 20 and thus the member 18 can be reciprocated between the positions shown in FIGS. 1 and 2 respectively. The further extended position 19 shown in broken lines in FIG. 2 may be provided either as an alternative to or in addition to the position indicated at 24 in solid lines. The pnematic cylinder unit 20 should be of such a size that, when the member 18 is extended from the retracted position of FIG. 1 into the closure position of FIG. 2, any metal or slag clinging to the arrangement is pushed off by the member 18, acting in the manner of a ramming tool, while when the member 18 is moved into the further extended position 19, it can pierce and thus break up any layer of slag which has been formed in front of the opening 6 in the wall of the furnace.
As, when the member 18 is in the closure position, a part of the surface thereof is exposed to the effect of splashes and spatters of metal and/or slag, it is advantageous to take steps to ensure that it is more difficult for such material to adhere to the member 18 in that part of its surface. In accordance with a preferred aspect of the invention, that is achieved in that the respective part of the member 18, that is to say, the surface thereof which, in the closure position of the member 18, is exposed to the possible effect of splashing of metal and/or slag, is set oscillating by means of an oscillation generator indicated diagrammatically by reference numeral 25. The surface of the member 18 which is directed inwardly of the furnace can be substantially or entirely kept free of slag or metal, by virtue of the form of oscillation and the frequency employed. Alternatively, or in order further to enhance that effect, the appropriate surface portion of the member 18 may also be made from or covered with a highly heat-resistant, scale-resistant material. That surface portion of the member 18 is deliberately not cooled so that it is heated up by the heat of the furnace to a high temperature, because at higher temperatures the slag runs off the member 18 more easily, by virtue of its viscosity being lower, or can be more easily thrown off the surface of the member 18 by virtue of the oscillation movement thereof. Suitable scale-resistant materials include chromium nickel steels, nickel alloys, ceramic materials or graphite. It is also advantageous for the surface of the member 18 which may be exposed to the effect of splashing of metal and/or slag to be coated with a material which is difficult to wet. Graphite is particularly suitable for that purpose. If there is a fear of possible overheating of the member 18, it may be desirable for the member 18 to be suitably cooled.
In the embodiment shown in FIGS. 1 and 2, the oscillation generator 25 is in the form of a pneumatic oscillation generator which, in this embodiment, operates at a frequency of 1 Hz, thereby causing the member 18 to oscillate axially with a stroke length of 15 mm. The piston rod 21 is of a hollow configuration so that the oscillation generator 25 can be supplied with the compressed air required for producing the oscillator movement. The central duct or passage of the piston rod 21 communicates with a connection 26 for the feed of compressed air.
The above-described burner assembly operates in the following manner:
During an interruption in the operation of the burner, the feed of fuel gas and oxygen to the connections 15 and 16 is interrupted, and the member 18 is in the position 24 shown in FIG. 2. It performs axial oscillatory movements about that position, which are produced by the pneumatic oscillation generator 25 which in turn is supplied with compressed air in a pulsating mode by way of the connection 2. When the burner assembly is set in operation, fuel gas and oxygen are supplied by way of the connections 15 and 16, and at the same time the pneumatic actuating means 17 is operated to retract the member 18 into the position shown in FIG. 1. The feed of compressed air to the oscillation generator 25 is also interrupted. Due to the high speed of the fuel gas oxygen mixture which issues from the mouth opening of the burner during operation thereof, the mouth opening is kept substantially free and open. If however particles or pieces of metal and/or slag should be deposited on and cling to the structure in the region of the wall opening 6 during operation of the burner, then such metal or slag may be removed again by the member 18 which acts as a ramming tool, when the member 18 is pushed into the extended position shown in FIG. 2, by the pneumatic thrust means 17. That operation is performed at the end of the period of operation of the burner assembly. However, such a displacement of the member 18 may also be produced during operation of the burner, in order to clean the discharge opening, but in that case the feed of fuel gases must be interrupted for the period of time for which the member 18 is in the advanced or extended position.
Particularly in operation of an electric arc furnace, it may occur that, during a break in operation of the burner, a larger amount of slag may splash or slop in front of the burner opening, that is to say, in the illustrated structure, in front of the wall opening 6. In that case, the opening may be closed off by a layer of slag which is of a generally bell-shaped configuration. The layer of slag formed in that way may be broken down and the opening 6 exposed again, by the member 18 being pushed out into the further inwardly extended position shown in broken lines at 19 in FIG. 2, by operation of the pneumatic actuating means. Another method of clearing the opening 6 in such a situation is for the layer of slag to be subjected to the action of a sound or ultrasonic oscillation so as to cause it to collapse. That may be achieved for example by means of the burner construction illustrated in FIG. 4, to which further reference will be made below.
Referring now generally to FIGS. 3 and 4, the nozzle assembly constructions illustrated therein differ from the construction shown in FIGS. 1 and 2, by virtue of the oscillation generator used in each of the constructions of FIGS. 3 and 4 being of a different kind. Thus, in the embodiment shown in FIG. 3, the fluid-operated oscillation generator 25 used in the embodiment of FIGS. 1 and 2 has been replaced by an electromagnetic oscillation generator 30. As will be seen from FIG. 3, secured in position within the central duct 12 of the nozzle assembly or burner 2a is a coil 31 with a connecting rod 32 extending therethrough, to the member 18. The connecting rod 32 has an armature 33 on the side of the coil 31 which is towards the actuating means 17. The armature 33 is connected to the piston rod 21a of the actuating means 17 by way of a resilient coupling 34. When the member 18 is in the closure position shown in FIG. 3, the armature 33 is disposed in the vicinity of the end of the coil 31 so that, when the coil 31 is supplied with alternating current, the armature 33 can be caused to oscillate, by magnetic attraction. The oscillatory movement is transmitted to the member 18, in the form of axial oscillations, and is substantially decoupled from the actuating means 17 by the resilient coupling 34. By virtue of the components which are to be caused to oscillate being of a suitable shape and mass distribution, it is possible for those components to be caused to oscillate in a resonance condition, at the required frequency. An important consideration in that respect is that the maximum oscillation amplitude should occur at the surface of the member 18, that is exposed to the atmosphere inside the furnace. However, the member 18 can also be caused to oscillate at a frequency other than its resonance frequency. When using an electromagnetic oscillation generator, it is desirable to make use of the mains frequency available, that is to say, the member 18 should desirably be oscillated at a frequency of 60 or 120 Hz.
In the case of the nozzle assembly or burner 2 shown in FIG. 4, the oscillation generator provided for oscillating the member 18 is in the form of an ultrasonic oscillator 40 which may be for example a quartz oscillator. The oscillator 40 causes the member 18b to oscillate in a longitudinal oscillation mode. An annular bearing member 41 is provided at the location of an oscillation node. In this construction also, the shape and mass distribution of the components to be oscillated are such that a maximum oscillation amplitude occurs at the surface of the member 18b which is towards the interior of the furnace. That oscillating surface acts at the same time as an ultrasonic emitter. Any layer of slag which is disposed in front of the oscillating member is caused to oscillate by the energy emitted by the oscillation generator, and is thus caused to break up. As in the case of the embodiment shown in FIG. 3, the oscillator in the FIG. 4 construction is decoupled from the actuating means 17 by a resilient coupling 34. Reference numeral 42 denotes a slide bearing ring for defining the position of the axially displaceable member 18b, in conjunction with the annular bearing member 41.
Reference will now be made to FIG. 5 showing an embodiment of the burner, indicated generally at 2c, in the form that is sometimes referred to as a trumpet-type burner. Such a burner construction is used when a wide but less deep region is to be heated. The burner assembly 2c is secured by means of a flange 7c to a water cooling box 3c which in turn is fitted into the side wall of a metallurgical furnace. The water cooling box 3c has a water feed connection 4c.
In the embodiment illustrated in FIG. 5, the axis or centre line of the nozzle assembly 2c is inclined downwardly, in a direction inwardly of the furnace. The nozzle assembly 2c in this embodiment also is formed by three concentric pipes 9c, 10c and 11c, the outer pipe 9c in this embodiment performing the function of supporting the actuating means 17c for the member 18c which is disposed displaceably within the end of the nozzle assembly. The concentric pipes 10c and 11c define a central duct or passage 12c, for example for the feed of fuel gas, and an annular passage or duct 13c, for example for the feed of oxygen. The connections 15c and 16c for fuel gas and oxygen communicate with the central duct 12c and the annular duct 13c respectively.
Unlike the embodiments described with reference to FIGS. 1 through 4, in this embodiment it is not just the member 18c which is axially displaceable within the burner assembly, but rather the concentric pipes 10c and 11c are axially displaceable, together with the closure member 18c. The member 18c in the illustrated embodiment is of such a configuration that it spreads out the gas flowing therepast. The member 18c is fixed to the inner pipe 11c as by screwing while the inner pipe 11c is in turn fixed to the middle pipe 10c. The pipes 11c and 10c, together with the member 18c and the pipe connections 15c and 16c, are axially displaceable by means of the actuating rod 21c, by suitable operation of the actuating means 17c, more particularly, from the position shown in FIG. 5 towards the right therein until the member 18c closes off the wall opening 6c and thus protects the discharge opening 8c for the fuel gas and oxygen, from slag and/or metal. It should be clear from this embodiment which is illustrated by way of example that many modifications and alterations may be made without departing from the scope of the invention.
Although the above-described arrangements according to the invention were described with reference to nozzle assemblies or burners in which the fuel used is a fuel gas, it should be appreciated that the principles of the present invention can also be used in regard to nozzle assemblies which operate with a liquid fuel such as oil or a solid fuel in finely divided form, in suspension in a carrier gas. Oxygen-bearing gases such as air may be used in place of oxygen.
It will be seen therefore that the above-described burner or blowing nozzle for use in a metallurgical furnace can at least substantially reduce or remove any metal and/or slag that may accumulate at the discharge opening thereof, or at the opening in the wall of the furnace at which the nozzle assembly is disposed. Such accumulation of metal or slag may thus be removed, without the need to remove the nozzle assembly from the position of installation thereof, or without other dismantling of the nozzle assembly. The accumulated metal or slag is readily removed by a mechanical action, that is to say, by being engaged by the member 18, and is thus positively cleared away.
As mentioned, it will be appreciated that many other modifications and alterations may be made in the above-described assemblies, without thereby departing from the spirit and scope of the present invention.
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A nozzle assembly constituting a burner or blowing nozzle includes, in the region of the discharge opening thereof, a piston-like member which is displaceable by an actuating means into a position of blocking off the discharge opening thereby to prevent same from becoming clogged by slag or metal splashed thereon. When the assembly is mounted in the wall of a metallurgical furnace, the piston-like member may also be adapted to close off the opening in the wall, which communicates with the nozzle assembly, in order also to keep the wall opening open. At least a part of the piston-like member may be caused to oscillate or at least the part thereof which is towards the interior of the furnace may comprise or be coated with a scale-resistant material or may be coated with a material that is difficult to wet.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 14/134,092, filed Dec. 19, 2013, which is issuing as U.S. Pat. No. 9,120,014, which is a continuation of U.S. patent application Ser. No. 12/502,726, filed on Jul. 14, 2009, which issued as U.S. Pat. No. 8,622,795 on Jan. 7, 2014, which claims priority to U.S. Provisional Patent Application No. 61/119,915, filed Dec. 4, 2008, all of which are hereby incorporated by reference entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention relates generally to the field of analyzing motion data for translation to qualitative assessment, and more particularly, to systems and methods for the analysis and display of qualitative outcomes regarding object data in sports entertainment.
[0004] 2. Description of the Related Art
[0005] Many currently available data capture and analysis devices for athletes are intrusive to the athlete's performance. As a result, the devices may not be effectively used in an analysis during an event. In another scenario, the athlete may refuse to incorporate the device into his equipment or attire. A professional boxer, for example, wears footwear, boxer shorts, and boxing gloves during a boxing bout. Some amateur boxers can wear head gear and a vest, but a professional boxer does not. In another example, a soccer player wears footwear, shin guards, shorts, and a shirt. An athlete's uniform is designed for maximum mobility and protection, and should not impede the performance of the athlete. Thus, there is a need for a system and a method for data capture and analysis that does not interfere with an athlete's actions and abides by the rules of the sport.
SUMMARY
[0006] The systems and methods described herein attempt to provide data capture and analysis in a non-intrusive fashion. The captured data can be analyzed for qualitative conclusions regarding an object's actions.
[0007] In one embodiment, a computer-implemented method analyzes activity of an athlete to permit qualitative assessments of that activity using a processor. The method comprises receiving activity-related data from sensors on the athlete. A database stores the activity-related data. The processor compares the received activity-related data against a set of pre-identified discrete outcomes. The processor identifies by the processor one of the pre-identified outcomes as corresponding to the received activity-related data based on the comparison of the received activity-related data against the set of pre-identified outcomes. The identified pre-identified outcome is displayed.
[0008] In another embodiment, a system for analyzing activity of an athlete to permit qualitative assessments of that activity comprises a first processor to receive activity-related data from at least one sensor on the athlete. The at least one sensor has a first three-axis accelerometer coupled to the first processor and a first gyroscope coupled to the first processor. A first database stores the activity-related data from the at least one sensor. A second database contains pre-identified motion rules. A transmitter couples to the first processor to transmit the activity-related data to a second processor. A receiver couples to the second processor to receive the activity related data from the transmitter. The second processor compares the received activity-related data to the pre-identified motion rules, wherein the second processor identifies a pre-identified motion from the pre-identified motion rules that corresponds to the received activity-related data. A memory stores the identified pre-selected motion.
[0009] In another embodiment, a method analyzes hand activity of a boxer with an accelerometer and a gyroscope disposed on a hand of the boxer using a computer having a memory to permit qualitative assessments of the activity. The method comprises receiving by a computer hand activity-related accelerometer data from the accelerometer disposed on the hand of the boxer. A computer receives hand activity-related gyroscope data from the gyroscope disposed on the hand of the boxer. The memory stores the hand activity-related accelerometer and the hand activity-related gyroscope data. The computer detects a hand event and if a hand motion is detected, compares the received hand activity-related accelerometer data and hand activity-related gyroscope data against a motion profile. The computer identifies a hand motion corresponding to the received hand activity-related accelerometer and gyroscope data based on the comparison of the received hand activity-related accelerometer and gyroscope data against the motion profile.
[0010] In another embodiment, a computer program product has a computer usable medium having computer readable program code embodied therein for analyzing hand activity of a boxer with an accelerometer and a gyroscope disposed on a hand of the boxer. The computer readable program code in the computer program product has computer readable program code for receiving hand activity-related accelerometer data from the accelerometer disposed on the hand of the boxer. The computer readable program code has code for receiving hand activity-related gyroscope data from the gyroscope disposed on the hand of the boxer. The computer readable program code has code for storing the hand activity-related accelerometer and the hand activity-related gyroscope data in the memory. Additionally, there is computer readable program code for detecting a hand event. The computer readable program code has code for comparing the received hand activity-related accelerometer data and hand activity-related gyroscope data against a motion profile if the hand event is detected. The computer readable program code has code for identifying a hand motion corresponding to the received hand activity-related accelerometer and gyroscope data based on the comparison of the received hand activity-related accelerometer and gyroscope data against the motion profile.
[0011] In another embodiment, a computer program product has a computer usable medium that has computer readable program code embodied therein for analyzing activity of an athlete to permit qualitative assessments of that activity. The computer program product has code for receiving activity-related data from sensors on the athlete. The computer readable program code has code storing the activity-related data in a database. The computer readable program code has code for comparing by the received activity-related data against a set of pre-identified discrete outcomes. The computer readable program code has code for identifying by the processor one of the pre-identified outcomes as corresponding to the received activity-related data based on the comparison of the received activity-related data against the set of pre-identified outcomes. The computer readable program code for displaying the identified pre-identified outcome.
[0012] In another embodiment, a system analyzes punch activity of a boxer with an accelerometer and a gyroscope disposed on a hand of the boxer to permit qualitative assessments of the activity. The system has means for receiving hand activity-related accelerometer data from the accelerometer disposed on the hand of the boxer, a means for receiving hand activity-related gyroscope data from the gyroscope disposed on the hand of the boxer, a means for storing the hand activity-related accelerometer and the hand activity-related gyroscope data, a means for detecting a hand event, a means for comparing the received hand activity-related accelerometer data and hand activity-related gyroscope data against a motion profile if the hand event is detected, and a means for identifying a hand motion corresponding to the received hand activity-related accelerometer and gyroscope data based on the comparison of the received hand activity-related accelerometer and gyroscope data against the motion profile.
[0013] In another embodiment, a computer-implemented method displays qualitative hand assessment data of a boxer having an accelerometer and a gyroscope disposed on a hand of the boxer. The method has a computer that receives a real-time video data of the boxer. The computer receives data from a visualization engine, wherein the data comprises a real-time hand analysis data, and wherein the real-time hand analysis data comprises data identified by the analysis engine as one of a pre-identified outcome stored in a database corresponding to the data from the accelerometer and the gyroscope. The computer simultaneously displays the real-time video data and the real-time hand analysis data.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] In the Figures:
[0015] FIG. 1 shows an overall system design according to an exemplary embodiment;
[0016] FIG. 2 shows various available data sensors and locations on a boxer's body according to an exemplary embodiment;
[0017] FIG. 3 shows various available end uses according to an exemplary embodiment;
[0018] FIG. 4 shows a system for transmitting data from an item of athletic equipment to a computer according to an exemplary embodiment;
[0019] FIG. 5 shows a boxing glove cuff adapted to hold sensors according to an exemplary embodiment;
[0020] FIG. 6 shows a boxing glove adapted to hold sensors according to an exemplary embodiment;
[0021] FIGS. 7 a to 7 e show various perspective views of a soft switch assembly according to an exemplary embodiment.
[0022] FIG. 8 shows a system for collecting data from sensors according to an exemplary embodiment;
[0023] FIG. 9 shows an accelerometer according to an exemplary embodiment;
[0024] FIGS. 10 a to 10 d show jab and uppercut data in the form of graphs and corresponding punch depictions according to an exemplary embodiment;
[0025] FIG. 11 shows a flow diagram of a method to analyze and display data according to an exemplary embodiment;
[0026] FIG. 12 shows a screen shot of boxing display data and analysis according to an exemplary embodiment; and
[0027] FIG. 13 shows a 2-dimensional representation of location triangulation according to an exemplary embodiment.
DETAILED DESCRIPTION
[0028] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
[0029] FIG. 1 shows an exemplary system for capturing and analyzing activity-related data on an athlete 100 . The exemplary system 100 can include, among other components, at least one sensor 102 or other data capture device 104 , a signal strength monitor 105 , and a transmitter 106 connected to the sensor 102 or data capture device 104 . The sensor 102 can be positioned within equipment on the athlete to collect data regarding acceleration, force, orientation, or impact and transmit this data through the transmitter 106 to a data capture application 112 on a computer with a receiver (not shown). For example, in boxing, sensor data can be collected and analyzed for determining the speed and vector of a punch. The signal strength monitor 105 can judge the distance of the transmitter 106 or other radio device from the monitor using the strength of the signal. Data from multiple signal strength monitors 105 can be used to calculate the location of an athlete, or even parts of the athlete. The sensor 102 and/or data capture device 104 , such as a camera, can provide activity-related data that is transmitted from the athlete's equipment to the computer, where it can be stored in a database and analyzed.
[0030] The computer connected to the sensor 102 , data capture device 104 , signal strength monitor 105 , and/or transmitter 106 can execute a data capture application 112 , a server application 114 , analysis software 116 , a database platform 118 , and a visualization engine 120 . The data capture application 112 receives input data from data capture devices 104 and sensors 102 and stores them in a memory, such as RAM, a hard drive, a database, or flash memory. A server application 114 has access to the data stored by the data capture application 112 and coordinates the data with analysis software 116 , the database platform 118 , and the visualization engine 120 . The analysis software 116 compares the received data with historical data in the database. The analysis software then sends the results of its analysis to the server application 114 . The server application 114 sends the analysis results to a visualization engine 120 that displays the results. Each application can be on a single computer or on separate computers connected through a network or the internet.
[0031] FIG. 2 illustrates various sensors and data capture devices that can be positioned within the equipment and clothing of an athlete 200 . In one embodiment, an athlete can wear headgear 202 having a biometric sensor 204 , a motion capture surface 206 , and a force sensor 208 . The biometric sensor 204 , such as a temperature sensor, can be positioned between the headgear pads and the forehead of the athlete, monitoring the temperature of the athlete during an event. The motion capture surface 206 can be a surface coated with retro-reflective material to reflect light at a camera. A camera can be fitted with a filter so that only infrared light is sampled. Since the retroreflective material is more reflective than the rest of the materials used, the camera can effectively ignore the background. The force sensor 208 can also be positioned near the forehead on the headgear 202 to sense when and how forceful contact is made with the headgear 202 . The headgear 202 can also have a microprocessor and wireless transmitter board 210 to transmit the data captured by the sensors on the headgear 202 to a computer running a data capture application. The sensors 204 , 208 can be connected to the microprocessor through a wired transmitter 211 . The microprocessor is on the same printed circuit board as the wireless transmitter, which can transmit collected data to a computer.
[0032] The athlete 200 can wear a waist guard 212 having a force sensor 214 , a biometric sensor 216 , a motion capture surface 220 , a microprocessor and wireless transmitter board 222 , and a wired transmitter 218 connecting the sensors 214 , 216 to microprocessor. The sensors 214 , 216 and motion capture surface 220 on the waist guard 212 can be used similarly to the sensors 204 , 208 and motion capture surface 206 on the headgear 202 .
[0033] The athlete 200 can wear a glove 240 that has a motion capture surface 244 , a force sensor 242 , an accelerometer 248 , a gyroscope 249 , and a microprocessor and wireless transmitter board 246 . The motion capture surface 244 and force sensor 242 can be used similarly to the sensors on the headgear 202 and waist guard 212 . The accelerometer 248 can be used to sense motions of the glove 240 during an event. A three-axis accelerometer can collect data on the motions of the glove 240 in a three dimensional space. A gyroscope 249 can be used to collect data on the orientation of the glove 240 , allowing for the calculation of the rotation of the wrist and glove 240 . This data can be used in motion analysis of the glove 240 , for example, the type of punch thrown by a boxer. The sensors 242 , 248 , 249 can be connected to a microprocessor and wireless transmitter board 246 to transmit the data from the glove 240 to a computer.
[0034] The athlete 200 can also wear footwear 230 having a motion capture surface 232 and a sensor, microprocessor, and wireless transmitter board 234 . The motion capture surface 232 can be implemented like the headgear 202 and waist guard 212 . The sensors on the footwear 230 can include accelerometers to measure the motion of the athlete 200 . The data collected by the sensors can be transmitted to a computer and analyzed as discussed in the glove 240 embodiment.
[0035] The sensors and data capture devices depicted on any one article of the athlete's clothing can be similarly used on other articles of clothing. For example, an accelerometer can be positioned within headgear 202 to capture data about the athlete 200 . The sensors can also be positioned in different places within the gear or clothing. Further, the sensors can be placed on the same printed circuit board as the processor and transmitter or the transmitter can be separate from the processor.
[0036] FIG. 3 shows various aspects that can be implemented by the system in FIG. 1 . A visualization engine 302 can process information including enhanced statistics, interactive visualizations, real-time information for officials and advanced athletic training programs. The visualization engine 302 can interact with a television 304 to display live, on demand, pay per view, DVD, Blu-Ray, Interactive television, and gaming extras. Extras include enhanced statistics, interactive visualizations, and real-time information. The television display can interact live with the content of the visualization engine by sending signals to and from a cable box. The television display can interact with a visual storage medium such as a DVD or Blu-Ray Disc by embedding information about the athletic activity in the DVD or Blu-Ray Disc. The visualization engine 302 can interact with computers 306 for computer extras, virtualization and 3D rendering, gaming, and training programs. The visualization engine 302 can also interact with mobile devices 308 such as cell phones and smart phones to display mobile extras, virtualization and 3D rendering, mobile gaming, and create a mobile community with communication and networking.
[0037] The exemplary system 100 can also provide support for live events 310 . Similar to televisions, statistics and overlays can be displayed on a large scale display such as a Jumbotron screen at live events. The system can analyze data to detail how tired an athlete is by trending and/or tracking the speed and force of the athlete's motions. The system 100 can also interact with and display information for officials such as referees, judges, coaches, trainers, and doctors to monitor athletes at an event. Also, the system 100 can be used to display extras on monitors for on-site gambling and sweepstakes. The system 100 can also be used at a live event 310 for automated camera control.
[0038] In one exemplary embodiment, sensors and other data capture devices can be placed on a boxer. FIG. 4 illustrates how data can be transmitted from a piece of equipment on the boxer's hand or wrist, such as a boxing glove 400 or a cuff 402 to a computer 404 . The cuff 402 can be wrapped around the boxer's wrist and positioned over or under a cuff of the boxing glove 400 . The boxing glove 400 has the advantage of being capable of having more sensors, such as contact sensors, than the cuff 402 . The cuff 402 has the advantage of being used with multiple boxing gloves. A sensor and wireless radio board 406 can be a printed circuit board that can transmit the data captured from the sensors to a receiving board 408 connected to the computer 404 . The receiving board 408 can be a radio for receiving information from the sensor and wireless radio board 406 or can have additional functionality, such as data processing. The sensors are not required to be positioned on the same board as the wireless radio, but can be positioned on the same board to save space and weight.
[0039] As shown in FIG. 5 , a cuff 500 can have a wireless sensor board 502 connected to a battery 504 positioned within the cuff 500 . The cuff 500 can be constructed of foam material to protect the wireless sensor board 502 and battery 504 . Additional foam 506 can be folded over to create a cuff pouch that the wireless sensor board 502 and battery 504 can easily slip in and out of. The mobility of the wireless sensor board 502 and battery 504 helps with troubleshooting in the field because one board or battery can be replaced by another. Due to the miniature size of the wireless sensor board 502 and battery 504 , a boxer can comfortably wear the cuff 500 . The wireless sensor board 502 and battery 504 are also light for the convenience of the boxer.
[0040] In another embodiment, a battery and wireless sensor board 602 can be placed in a boxing glove 600 , as shown in FIG. 6 . A foam layer 604 around the wireless sensor board 602 can protect the board. With this protection, the wireless sensor board 602 can be slipped into a pocket 606 in the glove 600 . The wireless sensor board 602 is positioned on the on the forearm side of the boxing glove 600 so the board does not absorb a direct hit to the outside of the boxing glove 600 . The mobility of the wireless sensor board can allow for quick troubleshooting and replacement. The wireless sensor board 602 can also have inputs for sensors positioned within the glove 600 . The glove 600 can have internal sensors connected through a conductive ribbon or wire to the pocket 606 . As in the cuff 500 embodiment, the wireless sensor board 602 does not have to be a single unit.
[0041] In yet another embodiment, as shown in FIGS. 7 a to 7 e , a soft switch can be positioned within a boxing glove to indicate when an impact on the boxing glove has occurred. A soft switch can be constructed out of two layers of conductive fabric 702 separated by a non-conductive mesh 704 sewn into the punching face of the glove. FIGS. 7 a and 7 b show a plurality of non-conductive meshes with varying densities. A charge is applied to the conductive fabric 702 . When non-compressed, the mesh fabric 704 separates the two conductive fabrics so no current can flow between the two conductive layers. Current can only flow when the glove strikes a target with enough force to temporarily press the two pieces of conductive fabric 702 together through the holes in the mesh. When the face of the glove is compressed by the contact, the two conductive panels 702 touch through the mesh 704 , closing the switch and indicating an impact. A plurality soft switches can be used to determine what face of a glove made impact. Further, switches with different mesh density can be used to approximate force. By placing multiple soft-switches with varying mesh sensitivities in a glove, force can be coarsely approximated. A different amount of force would be required to compress soft-switches with different density meshes. The switch can be attached to a conductive ribbon that leads to the pocket 606 in the glove 600 . The conductive ribbon can be attached to the wireless sensor board 602 allowing for synchronization and transmission of the sensor data.
[0042] A property of any switch is bounce, which is multiple contacts of the switch in the space of a few milliseconds. Bounce leads to a false reading of the switch, as it may indicate multiple closures when only one effective closure occurred. A bounce can be corrected by circuitry using a capacitor and a resistor or by software to compensate for the bounce. According to known methods, the switch data can be processed to account for the bounce once transmitted from the wireless sensor board 602 to a computer, which could save battery life.
[0043] Various sensors can be placed on the wireless sensor board 800 to capture data of a boxer's punch, including accelerometers 802 and gyroscopes 804 . Accelerometers 802 can be positioned on the sensor board 800 to provide data on the acceleration of boxer's punch. Accelerometers 802 on the board 800 can have multiple axes. Three-axis accelerometers are available or can be built by using multiple single-axis or dual-axis accelerometers having the axes arranged orthogonal to each other together, thereby creating at least X, Y, and Z axes. Acceleration data can be measured on each of the axes and the data on the axes can be correlated to show movement of the wireless sensor board 800 in three dimensions.
[0044] Many currently available accelerometers have low range, high resolution capabilities or high range, low resolution capabilities. Accelerometers calculate acceleration, a common unit to measure acceleration is the acceleration due to gravity, g. 1 g=9.8 m/s 2 . A low range accelerometer may have the range of about 0 g to 6 g. This range would be insufficient to monitor the acceleration of a punch because the punch of a boxer can be in excess of about 100 g. Multiple accelerometers with varying ranges and resolutions can be used to collect more complete data on a boxer. For example, a low-range accelerometer with the range of about −3 g to +3 g can be used in conjunction with medium-range accelerometer with a range of about −18 g to +18 g, and a high-range accelerometer with a range of about −100 g to 100 g. The lower range accelerometers can generate more precise data during the initial acceleration and deceleration phases while the high-range accelerometer can be used to calculate maximum acceleration.
[0045] FIG. 9 shows how a 3-axis accelerometer 900 can be used to calculate orientation. The sensors generate data that about the instantaneous acceleration rates on all three axes. Correlation of this data on a sensor 902 yields tilt values in the form of pitch 906 and roll 908 by using earth's gravity as a reference point. Pitch 906 can be found by calculating the angular difference between the z-axis location and the force of gravity by correlating the force of gravity on the y-axis. Roll 908 can be found by calculating the angular difference between the z-axis location and the force of gravity by correlating the force of gravity on the x-axis.
[0046] A gyroscope 904 can also be placed on the sensor board to provide data on the angular motion of a fist as it moves through space. A gyroscope measures angular acceleration. A gyroscope can measure the orientation of an object independent of its acceleration. Yaw, pitch, and roll can all be determined by a gyroscope, a gyrometer, or an angular motion sensor. A gyroscope can sense angular rate change, for example at −500 degrees to +500 degrees each second. A multiple-axis gyroscope can be used to get complete angular motion data in a three dimensional space. Examples of a gyroscope are the InvenSense IDG-300 and IDG-600. One axis can be used to sense yaw, a second axis for pitch, and a third axis for roll.
[0047] The sensors can be either digital or analog. If the sensors are analog, an analog to digital converter may be necessary to convert the data into a digital signal to be used by a processor 906 . Many micro-controllers available today contain built-in analog to digital converters. The processor 906 can then format the data so it is suitable for transmission. The processor can store the data in its own memory or external memory until transmitted.
[0048] Data can be collected at one frequency and stored in the memory of the processor 906 . Then, the processor 906 can transmit the data through a Radio Frequency (RF) Transmitter 908 to an RF Receiver 910 connected to a computer 912 . The computer 912 can store the information in various ways, such as a database table. The computer 912 can analyze the data or send the data to another computer to analyze the data. Multiple transmitters used at the same time can be on different frequencies to minimize radio interference and possible data loss. Various transmitters and receivers can be used, including, but not limited to, Bluetooth, 802.11g, 802.11n, and other radios.
[0049] The collection of data by the processor 906 can be synchronized so that the data collected can be processed together. One way of synchronizing is by using a single clock signal for all sensor readings. Analysis software can then analyze the data in real time, with each data point on each sensor corresponding in time with the other sensors. Synchronization can also occur by timestamping the data to a common clock, thereby allowing for some of the data to be sensed at different frequencies. The timestamps also allow for synchronization by the analysis software of multiple sensor boards. This can be accomplished because the analysis software will have the data of the clock frequencies and time stamps of each of the boards. These boards can be synchronized prior to use so the analysis software can analyze data on multiple sensor boards at the same time.
[0050] In one embodiment, a thrown punch is detected and identified as a punch event within a stream of continuous data. A thresholding scheme combines the acceleration along all three axes to detect and identify the punch. When a value exceeds a preset threshold limit, the system can register a punch and begin analyzing the continuous data to determine the type, motion, and other statistical data of a punch. Complete analysis of a punch can take into account data that occurs before the threshold limit is passed.
[0051] The raw data collected by the accelerometers and gyroscopes can be used to calculate instantaneous measurements. Such measurements include the speed of each punch, the force of each punch, the duration of each punch, the distance covered by each punch, and other movements of the fist during a punch.
[0052] The speed and velocity of a punch can be determined by integrating the acceleration from a starting point using accelerometer data: v(t)=∫a(t)+v1. Because the acceleration data is in digital format when a computer processes it, discrete mathematics and a summation can be used for the calculation. The computer processing the data can accommodate for gravity by calculating the direction of gravity in relation to the axes of the accelerometers when the sensors sense approximately only the force of gravity (9.8 m/ŝ2). The processing computer can calculate the direction of the force of gravity during motions thereafter by correlating accelerometer and gyroscope data.
[0053] The distance covered by each punch can be determined over the time of the punch: d(t)=∫v(t). Acceleration starting at a fixed point can be integrated to calculate speed at a given time. The speed can be integrated to calculate distance.
[0054] Sensor data can be analyzed to determine the force of a punch. Force is equal to the product of mass times acceleration, or F=ma. Mass is how much matter is present in an object, while acceleration is the change in velocity over time. The force of a punch can be determined using the deceleration of the fist at the time of impact of the punch and the mass of a boxer's arm. The mass of a boxer's arm can be approximated by calibration. A boxer equipped with a sensor glove can punch a force sensor, like a force sensing resistor. The force sensor determines the force of a punch. The accelerometer determines the acceleration of the punch. Using those two data points, we can determine the approximate mass of the boxer's arm for that particular type of punch. The approximate mass of the boxer's arm for a particular type of punch can be used as a constant to approximate the force of a boxer's punch. The approximate mass of a boxer's arm can be profiled so that different types of punches by a particular boxer have different approximate masses. This is to account for how much of a boxer's body is used during a particular type of punch. Multiple profiling rules can be created for a boxer.
[0055] The duration of each punch can be found by using a clock to time a punch starting when acceleration starts and ending at hit, block, or miss. If a thresholding level is used as a cue that a punch has begun, analysis software can be used to determine when the punch actually started, not just when the threshold was met. A rule can be set so that a punch starts when a sharp acceleration begins. Deceleration data can be used to determine when the punch ended.
[0056] A sharp deceleration during a punch event can indicate a hit. For example, when an uppercut hits the abdomen of an opponent, the uppercut decelerates sharply due to the hit. A sharp deceleration is also seen when a jab hits the head of an opponent. In this case, though, the sharp deceleration is not the end of the movement, rather the sharp deceleration is part of the a complete follow through motion. Multiple rules can be set for when a punch event has ended and a hit is registered.
[0057] A block can be indicated by a lateral movement of the fist during the course of a punch revealed by an acceleration to the side with a forward deceleration. Additional information can be taken from an opponent's gloves registering a blocking motion at the same time as the punch event. The data from both boxers can be correlated to show both a punch and block. A block motion by the defender can be recorded as a lateral motion of the glove, as well as an inward motion by the glove at the time of an impact. The motion can be indicated during the punch event by the offensive opponent. Multiple rules can be set for when a punch event has ended and a block is registered. Data from both boxers can be profiled and rules set up for both individuals, as well as general rules.
[0058] A missed punch can be indicated by a slow forward deceleration along with a completed punch movement. A completed punch movement can be set as a rule. Accelerometer data not indicating a hit or block deceleration during the course of a punch event can be considered a miss outcome. Multiple rules can be set for when a punch event has ended and a miss is registered. Different punch types can have different miss endpoints. Other end outcomes can also be registered, such as a deflection.
[0059] Lateral and other movements of the fist during a punch can be identified through data on lateral acceleration. Lateral acceleration can be calculated by correlating accelerometer and gyroscope data. As a punch moves forward, lateral acceleration can be determined as being perpendicular with the forward acceleration and parallel to the ground. The acceleration in combination with orientation data can be used to determine lateral movements. Other movements can include guarding and blocking during the punch movement of the opponent.
[0060] Sensor data can be analyzed to determine the type of punch thrown. The type of punch can be determined by using gyroscopes, accelerometers, or both in combination. Vertical, outward, and forward acceleration as well as wrist movements can be determined by correlating gyroscope orientation data and accelerometer data. A computer can be programmed with a set of rules defining each type of punch. A punch can then be determined by comparing the live or recorded data with the set of rules. The rules can be in the form of pre-identified motions or outcomes.
[0061] FIG. 10 a depicts a jab motion along an x-axis. The motion can also be detected in three dimensions, but is simplified in this example to two axes. A jab starts from a block position 1002 a , then moves forward with a twisting of the wrist 1002 b and ends with the palm faced down and the arm extended 1002 c . Gyroscope data shows that a jab goes from a roughly vertical orientation 1002 a while in guard position, moves straight out from the leading shoulder 1002 b , and rotates approximately 90 degrees to finish with the palm facing downward 1002 c at the end of the punch. Accelerometer data shows that a jab is a fast acceleration from the leading hand in a direction away from the boxer's body. The data can be used to create a rule for a complete jab motion and the rule can be stored in a database. Pre-identified motion patterns can also be used to create the rule. A separate jab rule can be created for a jab that hits. The rule can include a sharp deceleration of the punch followed by a follow through on the motion. Different rules can be set up for different stages of completion of the punch before deceleration. Multiple rules for jabs can be created, some specifically calibrated to an individual boxer.
[0062] FIG. 10 b shows an uppercut motion occurring on a z-axis and an x-axis. The motion can also be detected in three dimensions, but is simplified in this example to two axes. An uppercut is a close proximity punch with vertical movement and a small forward motion. An uppercut can start from a guard position 1004 a , then the accelerometer data would show a vertical acceleration with a small forward component. The motion can be viewed as parabolic, with the motion being completed 1004 b as the boxing glove comes back towards the boxer. The boxer's wrist also twists so that the inside of the fist comes towards the boxer. A gyroscope will indicate the twisting of the wrist at roughly 45-90 degrees from the beginning of the punch to the end. The data can be used to create a rule for a complete uppercut motion and the rule can be stored in a database. Pre-identified motion patterns can also be used to create the rule. Separate rules can be created for when an uppercut that hits an opponent. Accelerometer data can indicate a hit by having a sharp deceleration in the forward and vertical movement. Different rules can be set up for different stages of completion of the punch before deceleration. Multiple rules for uppercuts can be created, some specifically calibrated to an individual boxer.
[0063] FIG. 10 c depicts a right hook on an x-axis and y-axis. The motion can also be detected in three dimensions, but is simplified in this example to two axes. A left or right hook is a punch with little vertical movement with a component of outward, forward, and inward motion. From a guard position, the punch can be seen as moving outward 1006 a . The punch moves forward and outward 1006 b , then begins to turn inward 1006 c . The hook is completed with the fist moving inward 1006 d towards an opponent. The accelerometers will show the movement as forward and outward, and then forward and inward. The gyroscope will show the twisting of the wrist with the palm facing downward at the end of the punch. Data can be used to create a rule for a complete hook motion and the rule can be stored in a database. Pre-identified motion patterns can also be used to create the rule. Separate rules can be created for when a hook hits an opponent. Accelerometer data can indicate a hit by having a sharp deceleration in the forward and inward movement. Different rules can be set up for different stages of completion of the punch before deceleration. Separate rules can be created for hooks, some specifically calibrated to an individual boxer.
[0064] A soft switch, described above, can be coupled to the accelerometers and gyroscopes to add an additional data point to complement acceleration data. The soft switch can help analyze the data by giving a time of impact. Impact can be used as a point for when a hit occurs, when a block might occur, and when a miss occurs. A hit or blocked punch can register data indicating the time of impact. With the time of impact as a reference, the follow through of a punch can be analyzed. A miss can occur when a punch is completed without any impact.
[0065] Motion and punch data can be profiled and stored in a database. A particular boxer's punches and motions can also be profiled to create a boxer specific motion profile. The profiles can go into even more detail and track changes in motions between different rounds of a boxing match. Profiles can include data and rules about pre-identified motions or outcomes. For example, one outcome can be a jab. As discussed, the timing, acceleration, and angular rate change data for this type of motion and outcome is different than that of an uppercut. FIG. 10 d graphically illustrates how sensors could read different data for the motion of a jab and the motion of an uppercut. The graphs show the X, Y, and Z axes of an accelerometer as well as the X and Y orientation of a gyroscope during the course of a jab and a subsequent uppercut. The accelerometer and/or gyroscope data can be used to identify a jab or uppercut. Similar analysis can be used to detect the outcome of a punch, whether a punch landed, missed, or was blocked. The orientation of the gloves and little acceleration of the fists can represent a profile for the automatic detection of a boxer's stance.
[0066] Analysis software can be used dynamically on the data collected by the sensors to qualitatively determine whether a punch has been thrown, and if so, what kind of punch was thrown. The software can be implemented on known devices such as a personal computer, laptop, a special purpose computer, a server, and various other devices with processors. This software can be stored on a computer readable medium and can execute programmable code on a general purpose computer. FIG. 11 illustrates an exemplary method to analyze the data dynamically.
[0067] A computer running analysis software 1102 receives activity-related sensor data. A transmitter can send data wirelessly from the sensors to a radio connected to the computer. The computer can process raw data into more usable data structures, such as a punch event. The computer can recognize a punch event as a data on an accelerometer accelerating past a threshold value.
[0068] Once a punch event has been detected, the punch can be analyzed. The computer obtains a motion profile from a profile database 1104 . The database can contain rules for different punch types and punch outcomes. The database can be on a different computer, accessed through a network, or be preloaded onto the computer running the analysis software.
[0069] In stage 1106 , the computer compares the activity-related data to the motion profile rules. Punch event data can be compared to general punch rules to narrow the type of punch into categories, such as a possible uppercut, hook, or jab. The categories are rules with broad punch data event possibilities. The rules can be construed at as a container for types of punches. The broader the rule, the more punch data that can fit within the container or category. The punch event data can then be compared to more specific rules within the general category.
[0070] In stage 1108 , the analysis software can identify a pre-identified motion or outcome in the motion profile corresponding to the activity-related data. The motion rules can be compared to the punch event data to determine what type of punch occurred. Analysis can be used to determine the broad category of the punch event as well as more descriptive categories. A more descriptive categories can include a jab with a follow through, an uppercut with no follow through, a missed jab, and a blocked right hook. If an unknown motion is discovered, the motion will be added to the database and a description for the motion can later be filed. Outcomes can be the motions described above or in the form of conclusions, such as a hit, block, or miss. Outcomes can be determined by comparing outcome profile rules to the punch event data. Punch event data can be in the form of a raw data stream or data patterns.
[0071] Stage 1110 shows the computer storing or displaying the identified pre-identified motions or outcomes. An example of displaying the identified pre-identified motions or outcomes is by overlaying the analysis on a live boxing screen, such as a Jumbotron screen at an event, a television, or a website. Information that a certain type of punch was registered can also be stored in a database for later statistical analysis. The information can also be used to update boxer-specific motion profiles, both generally and round-by-round.
[0072] Another feature is software to generate statistics and score a boxing match or sporting event. In boxing, the system can count the number and types of punches thrown, landed, and blocked as identified by the analysis software. The computer can act as an unbiased and impartial referee. The scoring can be overlaid on a large-scale display at a live event, a television, or via a website, or stored in a database for future use.
[0073] Along with scoring and statistics, another aspect is software to determine trending during the course of an event. Trending includes the number of punches during an event, decrease in punch speed over the course of an event, the current most powerful or fastest punch of the night, and the most powerful or fastest puncher. The number of punches for each athlete and each hand can be counted throughout the night. Decrease or increase in punch speed throughout the course of an event can be determined by tracking the calculated speed of each punch thrown during the night by an athlete. All of this information can be shown on an overlay during the course of a live event.
[0074] FIG. 12 exemplifies an embodiment where data gathered and statistics can be overlaid on a screen. The screen can be either interactive or non-interactive. In an interactive screen, there can be options to chat 1202 or buy merchandise 1204 . An interactive user can choose the overlaid information boxes 1206 , 1208 to view information about an event and the athletes. A non-interactive user can see rotating information boxes.
[0075] An exemplary system can also use the wireless radios on articles of clothing or equipment to triangulate the position of an athletes during an event. The signal strength of a radio on the athlete can be used to approximate the distance between a signal strength monitor and the radio. The signal strength monitor can also be a receiver. Distance from a signal strength monitor can be calculated using the inverse square law, signal strength=1/distance squared. The signal strength monitor can also be calibrated to ensure proper functionality. Calculating distance from a radio signal can be accomplished using existing technology. FIG. 13 shows a two-dimensional example of location tracking through triangulation. Using the distance as a radius, the location of the signal is narrowed to be on the perimeter 1302 of a circle. Location can be triangulated using multiple signal strength monitors. Adding a second fixed point of reference narrows the position of the radio signal to two points, 1304 and 1306 . Adding a third fixed point of reference leaves one location point 1308 in two dimensions. Adding a fourth fixed point of reference allows for three dimensional tracking of the signals, using the surface of a sphere instead of a circle for tracking More than four signal strength monitors can be used. The signal strength monitors can be placed in the corners of a boxing ring. Four monitors with known heights and locations can be used to create a three-dimensional virtual boxing ring to track the motion of the boxers. In an alternative embodiment, eight signal strength monitors fixed around a boxing ring can be used to track the motion of a boxer or the locations of radios on the boxer. For example, four signal strength monitors can be fixed at high locations and four can be fixed at lower locations, e.g., the base of the boxing ring.
[0076] In another embodiment, one or more cameras can be used to track the position of boxers during a boxing match. A single camera can be used to track athletes in two dimensions. A camera can be placed directly above the boxing ring. A high-resolution camera can distinguish the boxers as distinct from the floor of the ring. A computer can analyze the camera data frame by frame to track boxers. The data can be analyzed by a computer to show how a boxer is controlling the ring over the course of a round or fight, such as by counting the number of punches thrown, blocks used, position within the ring, or other collected data.
[0077] In another embodiment, multiple cameras can be used to capture the motions of the boxer's body. The motion capture can be accomplished using existing technology. Retro-reflective markers or motion capture surfaces can be placed on the body so the cameras can clearly distinguish between the body and the background. Placement of markers on the joints would allow for more detail, but markers on athletic clothing would interference less with a boxer. The images from the cameras can be used to create a virtual three-dimensional model or representation of the boxers in a space.
[0078] Retro-reflective markers may interfere with normal television camera operation. Therefore, an alternative to track the body instead of relying on retro-reflective markers is to use UV markers, UV illuminators, and cameras capable of capturing the UV spectrum. Athletes could be coated with sun block to reflect the UV light, which can be used to distinguish the athletes from the background. Normal television cameras can be fitted with UV filters to filter out any interference. The use of UV illuminators is not necessarily recommended due to the possibility that the illuminators may be hazardous to the health of the athletes and audience.
[0079] A thermal imaging camera can be used to detect the surface temperature changes of a boxer. The thermal camera can be used to both track the surface temperature of an athlete and as a way to distinguish between the athletes and other objects. Points of an athlete, identified by temperature, can be marked by a computer and followed throughout an event.
[0080] Data from cameras can be analyzed by connecting the cameras to an analysis system. A computer can analyze camera data to detect punch types. From above, punches can be seen in two dimensions, the x-axis and y-axis. Other cameras can be set on the sides of an event to give an x-axis and z-axis view, and a y-axis and z-axis view. The computer can mark identifiable portions of a boxer's body by differentiating those portions from background objects. Portions that can be marked include a boxing glove and a boxer's elbow. Once portions of a boxer's body are marked, discrete data can be generated from video captured by the cameras. The generated data can be analyzed to determine the type of punch thrown. Similar methods to analyzing acceleration data can be used on the video data. For example, from above, a left hook can be analyzed as an outward forward motion followed by an inward forward motion. A high resolution camera can even record the twisting of the forearm during a punch. From the point of view of a camera, a jab goes from a roughly vertical orientation while in guard position, quickly moves straight out from the leading shoulder and rotates approximately 90 degrees to finish with the palm facing downward at the end of the punch. The camera can isolate that movement using markers. Data could be correlated with data from an accelerometer and gyroscope to increase the reliability of the analysis.
[0081] Data from cameras can also be analyzed to determine uppercuts, left and right hooks, and other punches. A left hook can be seen by a camera connected to a computer as moving outward from the side of a boxer and then moving forward, with little vertical movement. An uppercut can be seen by the computer as having a good amount of vertical movement by the glove, with little horizontal movement. Once again, this data can be correlated with data from accelerometer, gyroscope, and impact sensors to increase the reliability of the analysis.
[0082] In yet another embodiment, the system can have a camera pointing at the triangulated position of the boxers for automatic camera movement. A computer can be programmed to create a three-dimensional grid of the boxing ring. The computer can then triangulate the positions of the boxers using distance information from multiple radios placed on each boxer. The camera can be equipped to be moved autonomously or semi-autonomously by computer. The computer can track the movements of the boxers in three dimensions through triangulation and signal the camera to move.
[0083] Once a camera detects the gloves, the body, and the heads of two boxers, a computer can determine where a punch hits with some accuracy. Multiple cameras can be used to capture data from multiple angles. The head of each boxer can be marked by the computer, along with the torso and boxing gloves. When a boxer's punch is thrown, the computer can analyze the glove's location compared to the head and body of the opponent. Camera data can be correlated with accelerometer and gyroscope data to coordinate when a punch is thrown, its impact, and its location. For example, a punch event can be recognized using accelerometer data. The type of punch can be deduced by comparing accelerometer and gyroscope data to motion profile rules. An impact time can be calculated using deceleration rules or an impact sensor. A camera can determine where the punch glove was as compared to the other boxer at the time of impact.
[0084] In another embodiment, the system can be used for training. The system can obtain raw data and analyze it while an athlete is training Analysis software can display faults of an athlete's movements while training. For instance, if an amateur boxer is sparring with a professional boxer, both using a system to monitor their movements, the amateur boxer can compare the way he holds his hands as compared to the professional in order to improve in the future. The computer can even give the trainee instructions on how to improve. A trainee can also use the information to improve the force of his punch. Further, for training, additional sensors can be used that would normally not be used in a live event, such as piezoelectric sensors to sense force and heart rate monitors.
[0085] Though many of the embodiments discussed are examples of boxing, the systems and methods described can be applied to various physical environments. For instance, martial arts and other physical activities can use this technology for training, keeping statistics, scoring, and adding entertainment value. In one example, sensors can be placed in footwear for kickboxing and soccer. In another example, motion profiling techniques can be used to determine what motions occurred by using motion rules and profiles. Outcomes can be determined for a variety of motions and movements for different activities. Event data can be triggered by different thresholds to correspond with different sports. In ice skating, an event can begin when a certain threshold angular acceleration is begun. For example, an event can be started for calculating the rotational speed of a lutz and other jumps. In wrestling, moves, such as a suplex, body slam, or a chop, can be determined outcomes from data gathered through data capture devices. Other uses can include, without limitation, kicking a ball in soccer or football, gymnastics judging, free style skiing judging, diving judging, and the swinging of a golf club. Additionally, an outcome can be a foul or misstep, such as a step outside of a boundary or a punch below belt. Such outcomes can be used in judging to penalize an athlete or reduce an athlete's point total.
[0086] The above-described technology can be implemented on known devices such as a personal computer, a special purpose computer, cellular telephone, personal digital assistant (PDA), a programmed microprocessor or microcontroller and peripheral integrated circuit element(s), and ASIC or other integrated circuit, a digital signal processor, a hard-wired electronic or logic circuit such as a discrete element circuit, a programmable logic device such as a PLD, PLA, FPGA, PAL, or the like. In general, any device capable of implementing the processes described herein can be used to implement the systems and techniques according to this invention.
[0087] It is to be appreciated that the various components of the technology can be located at distant portions of a distributed network and/or the Internet, or within a dedicated secure, unsecured and/or encrypted system. Thus, it should be appreciated that the components of the system can be combined into one or more devices or co-located on a particular node of a distributed network, such as a telecommunications network.
[0088] Furthermore, it should be appreciated that the various links connecting the elements can be wired or wireless links, or any combination thereof, or any other known or later developed element(s) that is capable of supplying and/or communicating data to and from the connected elements. Programmable code can be embodied in a module including hardware, software, firmware, or combination thereof that is capable of performing the functionality associated with that code. The terms determine, calculate and compute, and variations thereof, as used herein are used interchangeably and include any type of methodology, process, mathematical operation or technique.
[0089] Moreover, the disclosed methods may be readily implemented in software, e.g., as a computer program product, executed on a programmed general purpose computer, cellular telephone, PDA, a special purpose computer, a microprocessor, or the like. In these instances, the systems and methods of this invention can be implemented as a program embedded on a personal computer such as a JAVA®, CGI or Perl script, as a resource residing on a server or graphics workstation, as a routine embedded in a dedicated image system, or the like. The systems and methods of this invention can also be implemented by physically incorporating this system and method into a software and/or hardware system, such as the hardware and software systems of a computer. Such computer program products and systems can be distributed and employ a client-server architecture.
[0090] The embodiments described above are intended to be exemplary. One skilled in the art recognizes that numerous alternative components and embodiments may be substituted for the particular examples described herein and still fall within the scope of the invention.
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The systems and methods described herein attempt to provide data capture and analysis in a non-intrusive fashion. The captured data can be analyzed for qualitative conclusions regarding an object's actions. For example, a system for analyzing activity of an athlete to permit qualitative assessments of that activity comprises a first processor to receive activity-related data from sensors on the athlete. A first database stores the activity-related data. A second database contains pre-identified motion rules. A second processor compares the received activity-related data to the pre-identified motion rules, wherein the second processor identifies a pre-identified motion from the pre-identified motion rules that corresponds to the received activity-related data. A memory stores the identified pre-selected motion.
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FIELD OF INVENTION
This invention relates to water curable silane containing polymers wherein the silane group is introduced onto the polymer by reaction of the polymer with a combination of an azido silane and a monovalently olefinically unsaturated silicon compound. Such a combination provides for the use of less of the expensive azide compound without sacrificing physical property improvements of the polymer associated with the use of the azide compound alone.
BACKGROUND OF THE INVENTION
The crosslinking of polymers by various methods to achieve certain improved physical properties is well known in the art. The particular method of modifying polymers by azidosilanes and further crosslinking is known as for example in U.S. Pat. No. 3,697,551 to Thomson. Furthermore, the crosslinking of particular polymers such as polyethylene and polyethylenebutene copolymers after exposure to sulfonylazides and, subsequently, moisture is known as for example in U.S. Pat. No. 4,551,504 to Barnabeo. In addition, the subsequent moisture crosslinking of polymers previously exposed to a monovalently olefinically unsaturated silane and a peroxide have been disclosed as, for example, in U.S. Pat. No. 3,646,155 and U.S. Pat. No. 4,247,667.
Also, a method which describes polymers which have been modified with γ-methacryloxypropyltrimethoxysilane in the presence of peroxides has been disclosed in U.S. Pat. No. 4,032,592. And polyolefin blends which contain a polyolefin which has been modified with an olefinically unsaturated silane and a peroxide have been disclosed in U.S. Pat. No. 4,533,602.
Furthermore, polyethylenes which have been grafted with trimethoxyvinylsilane and a peroxide to give gel contents of about 23% to 78% and which are used to produce foams in the presence of 0.2 to 30 percent of a foaming agent such as azidocarbonamide based materials have been disclosed in U.S. Pat. No. 4,413,066. And polyolefin resins which are modified by trimethylvinylsilane with peroxide and are foamed by, and reacted with, water are disclosed in U.S. Pat. No. 4,591,606.
Also, polyolefin precoat compositions containing azidosilane crosslinking compounds have been described in U.S. Pat. No. 4,552,794.
SUMMARY OF THE INVENTION
Now, in accordance with this invention, it has been found that thermoplastic polymers such as polyolefins, even those which degrade upon exposure to peroxides such as polypropylene, and engineering thermoplastics can be modified with a combination of azidosilane and a monovalently olefinically unsaturated silicon compound and subsequently crosslinked with moisture. An engineering thermoplastic for purposes of this invention is a thermoplastic polymer which requires temperatures greater than about 170° C. to process. Because the monovalently olefinically unsaturated silicon compound can be used with the azidosilane, lower levels of the expensive azidosilane can be used than if azidosilane was used alone to achieve the same degree of physical property modification.
In this invention a thermoplastic polymer having a number average molecular weight greater than 20,000 is treated with a combination of an azidosilane of the formula (I): ##STR1## where R may be an organic radical, X may be selected from halo, alkoxy or aryloxy; T may be selected from alkyl, cycloalkyl, aryl, alkaryl, and aralkyl radicals; a is an integer from 1 to 3; b is an integer from 0 to 2; c is an integer from 1 to 10; d is an integer from 1 to 3, and a+b+d equals 4; and Z may be selected from ##STR2## and a monovalently olefinically unsaturated silicon compound of of formula (II) ##STR3## where n is an integer from 0 to 4 and where R 2 , R 3 , R 4 , R 5 , R 6 , and R 7 are lower alkyl, monovalently olefinically unsaturated (alkenyl), aryl, aralkyl, or lower alkoxy and may be the same or different provided one is a monovalent olefinically unsaturated hydrocarbon radical. The resulting azidosilane and monovalently olefinically unsaturated vinyl silicon compound and polymer combination is then heated to a temperature to decompose the azide. Generally, this is in an apparatus with mechanical blending of the polymer such as in a Brabender mixer, Banbury mixer or an extruder. The reacted thermoplastic polymers are then crosslinked or cured by exposure to moisture to give a thermoset polymer. The crosslinking or curing may be carried out (1) by reaction with moisture in the atmosphere at room temperature, (2) by immersion in hot water or (3) by exposure to steam until about greater than ninety percent of the silane groups have been reacted with water.
DETAILED DESCRIPTION OF THE INVENTION
Azidosilanes useful in this invention are described by the azidosilanes of formula (I). In formula (I) R is generally selected from the group consisting of hydrocarbon, halo-substituted hydrocarbon, hydrocarbon-oxyhydrocarbon, hydrocarbon-thiocarbon, and hydrocarbonsulfonyl-hydrocarbon divalent radicals. In preferred embodiments R will be a divalent radical selected from the group consisting of alkylene radicals such as the straight chain and branched C 1 to C 20 alkenyl radicals which include, for instance, the methylene, ethylene, trimethylene, tetramethylene, pentamethylene, hexamethylene, octamethylene, decamethylene, dodecamethylene, octadecamthylene, and the like radicals; cycloalkylene radicals such as the C 3 to C 20 cycloalkylene radicals which include, for instance, the cyclohexylene, cyclopentylene, cyclooctylene, cyclobutylene, and the like radicals; arylene radicals suchas o-, m- and p-phenylene, naphthylene, biphenylene, and the like radicals; arylene-dialkylene radicals, such as o-, m- and p-xylylene diethylene, o-, m- and p-phenylene diethylene, and the like radicals; alkylene-diarylene radicals such as methylene bis (o-, m-, and p-phenylene), ethylene bis (o-, m-, and p-phenylene and the like radicals; cycloalkylenedialkylene radicals such as, 1,2-, 1,3- and 1,4-cyclohexanedimethylene, 1,2- and 1,3-cyclopentane dimethylene, and the like radicals; and the alkylene-oxy-alkylene radicals, arylene-oxy-arylene radicals, alkarylene-oxyarylene radicals, alkyarylene-oxyalkarylene radicals, aralkylene-oxyalkylene radicals, aralkylene-oxyoaralkylene radicals and the like as well as the corresponding thio and sulfonyl radicals, specific examples of which include ethylene-oxyethylene, propylene-oxybutylene, phenylene-oxyphenylene, methylenephenylene-oxy-phenylene-methylene, phenylene-methylene-oxymethylenephenylene, ethylene-thio-ethylene, phenylene-thio-phenyllene, phenylene-methylene-thiomethylene-phenylene, butylene-sulfonyl-butylene, and the like radicals. It will, of course, be obvious to those skilled in the art that R can contain other functional groups which are substantially inert to the reactions in which these compounds are used, such as esters, sulfonate esters, amides, sulfonamides, urethanes and the like. In general X can be a hydrolyzable radical. Typical hydrolyzable radicals are the halo radicals which include, for instance, the fluoro, chloro, bromo, and iodo, radicals; the alkoxy radicals including the C 1 to C 20 straight and branched chain alkoxy radicals such as methoxy, ethyoxy, propoxy, butoxy, isobutoxy, octadecyloxy and the like; the aryloxy radicals such as phenoxy, and the like; the organo oxycarbonyl radicals including the aliphatic oxycarbonyl radicals such as acetoxy, propionyloxy, stearoyl oxy, and the like; the cycloaliphatic oxycarbonyl radicals such as cyclohexylcarbonyloxy, and the like; the aromatic oxycarbonyl radicals such as benxoyloxy, xylyloxy, and the like. Generally T will be a radical selected from the group consisting of alkyl, cycloalkyl, aryl, alkaryl, aralkyl radicals such as methyl, ethyl, propyl, isopropyl, butyl, hexyl, cyclohexyl, cycloheptyl, phenyl, tolyl, benxyl, xylyl, and the like. An especially preferred azidosilane for use in this invention is triethoxysilylhexane sulfonyl azide.
The monovalently olefinically unsaturated silicon compound useful in this invention are described as shown by the structure of formula (II). Examples of monovalently olefinically unsaturated hydrocarbon radicals are vinyl, allyl, butenyl, cyclohexenyl, cyclopentadienyl, cyclohexadienyl, methacryloxyalkl, acryloxyalkyl, and vinylphenoxy radicals. Examples of alkyl are methyl, ethyl, propyl, and the like radicals. Examples of alkoxy are methoxy, ethoxy, propoxy, and the like. Examples of aryl are phenyl and naphthyl. Examples of aralkyl are benzyl, ethylphenyl, and the like. An especially preferred vinyl silane useful in this invention is vinyltriethoxysilane.
Exemplary thermoplastic polymers which are useful in this invention are polyethylene, polypropylene, poly(4-methylpentene-1), polybutene-1, polystyrene, styrene-butadiene rubber, butyl rubber, natural rubber, polybutadiene, polyisobutylene ethylene-propylene copolymer, cis-1,4-polyisoprene, ethylene-propylene-dicyclopentadiene terpolymer and the like, and blends of these polymers with each other; bisphenol A polymers such as polysulfone; the polyamides such as nylon, Perlon®-L (nylon 6 polyamide), aromatic polyamides and the like; and poly(vinyl alkyl ethers) such as poly(vinyl methyl ether), polyoxymethylene and the like; vinyl chloride polymers such as poly(vinylchloride), vinyl chloride-vinyl acetate copolymers, vinylchloride-vinylidene chloride copolymers, vinylchloride-maleic anhydride copolymers, vinyl chloride-fumaric acid copolymers, vinyl chloride-vinyl acetal copolymers such as the vinyl chloride-vinyl butyral copolymers, vinyl chloride-vinylidene chloride-acrylonitile terpolymers, and the like. Especially useful polymers which are modified by this invention are ultra high molecular weight polyethylene (i.e., a polyethylene of number average molecular weight greater than about 500,000), polypropylene, polysulfone, and polyoxymethylene.
Polymer compositions of the azidosilane and monovalently olefinically unsaturated silicon compound can be achieved by directly treating the polymer powder or pellet with the azidosilane and monovalently olefinically unsaturated combination. Generally it is preferred to conduct the treatment with the azidosilane and monovalently olefinically unsaturated combination in solution or liquid form. Since some of the azidosilane and monovalently olefinically unsaturated combinations are solid, solvents are generally used. However, where the combination is liquid and especially where heating is involved, the polymer may be treated without the use of a solvent. The preferred solvents to use when solvents are necessary are low boiling organic solvents such as chloroform, methylene chloride, diethyl ether, tetrahydrofuran, and the like. Alternatively, the azidosilane and monovalently olefinically unsaturated silicon compound mixture can be blended into the polymer by initially treating a filler with a solvent solution of the azidosilane and monovalently olefinically unsaturated silicon compound combination and then mixing the filler with the polymer and subsequently heating. The filler may be any inorganic or organic material which is used in thermoplastic polymers. Especially useful fillers are mica, glass, talc, Wollasonite, asbestos, sand, clay, cement, stone, brick, and ceramic materials.
The amount of azidosilane and monovalently olefinically unsaturated silicon compound used will vary with the molecular weight of the polymer from about 0.1 to about 4 weight percent of each component. Generally, for polymers with a molecular weight greater than about 500,000, the preferred range of azidosilane is about 0.1 to 1.0 percent to about 0.1 to about 1 percent of the monovalently olefinically unsaturated silicon compound. When the polymer molecular weight is between about 20,000 and 500,000, the preferable amount of azidosilane is about 1 to about 2 weight percent and about 1 to about 2 weight percent of the monovalently olefinically unsaturated silicon compound. Generally it is preferred to use an equal amount of azidosilane to monovalently olefinically unsaturated silicon compound in the combination. However, it is possible to use differing amounts of azidosilane to monovalently olefinically unsaturated silane in the combination. Generally this range will be about 0.25 to 4 parts of azidosilane to about 1 part of monovalently olefinically unsaturated silicon compound.
Reaction of the azidosilane and monovalently olefinically unsaturated silicon compound with the polymer can be accomplished by heating the azidosilane and monovalently olefinically unsaturated silicon compound and polymer combination while mixing. This may be accomplished in a Brabender mixer, a Banbury mixer or an extruder. The temperature of heating will depend on the type of azide or polymer used. Generally, the temperature will be from about 120° C. to about 400° C. for a time sufficient to cause the reaction of at least 90 percent of the azidosilane and unsaturated silane reactive groups, i.e., azide and vinyl groups, in the combination.
It is generally believed that the thermal decomposition of azidosilanes of the type used in this invention form upon heating a triplet or singlet nitrene. If a singlet nitrene is formed, then presumably insertion of the silylnitrene into a C--C or preferably a C--H bond takes place as shown in equation (III). If, on the other hand, a triplet nitrene is formed, then hydrogen abstration presumably initially takes place and the formed silylamine radical or an unsaturated silane can add to the formed polymer radical as shown in equation (IV). If the unsaturated silane adds to the radical as shown in equation (IV), polymerization of the monovalently olefinically silicon compound with other monovalently olefinically unsaturated silicon compound can proceed until chain termination occurs by a variety of mechanisms which can include coupling with the formed silylamine radical. If the monovalently olefinically unsaturated silicon compound is coupled to the azidosilane through --Si--O--Si-- bonds before heating, then chemical crosslinking can occur. The mechanisms of equations (III) and (IV) are not meant to limit the invention but merely to provide a description of the type of reaction which occurs while carrying out the invention. ##STR4##
The moisture curing or crosslinking of the azidosilane and monovalently olefinically unsaturated silicon compound modified polymer is effected by exposing the polymer to moisture. This can be accomplished in a number of ways. The polymer may be exposed to the moisture in the air. Or it may be immersed in heated water. Or it may be exposed to steam. The rate of reaction will depend on the temperature, the thickness of the sample and the transmission rate of moisture in the polymer. Thus, the time of exposure to moisture to convert the thermoplastic material to a thermoset material will depend on these factors, (1) temperature of reaction with moisture, (2) thickness of sample and (3) type of polymer and its molecular weight. In the preferred embodiment of this invention, it is desirable to expose the formed polymer whether it be a fiber, or film or shaped article to steam at about a temperature of 70° C. to 120° C. until about 90 percent of the silyl groups have been reacted with water to form the particularly desired --Si--O--Si-- bonds.
In the following examples, which are illustrative of the present invention, triethoxysilylhexane sulfonylazide was used in combination with triethoxyvinylsilane. The triethoxysilylhexane sulfonylazide was prepared by hydrosilation of hexene with trichlorosilane, followed by sulfochlorination, followed by ethoxylation, and finally reaction with sodium azide. This procedure is given in detail in Example 1. The vinyl triethoxysilane was used as received from Petrach Systems. Insoluble gel means the amount of polymer which does not dissolve in a particular solvent at its boiling point after 24 hours. The percent gel is determined by weighing the dried "gel" and comparing that amount to the weight of the starting sample.
EXAMPLE 1
(A) Preparation of Triethoxysilylhexane Sulfonylazide
1-hexene (38 g, 1 eq) is added dropwise to a stirred, refluxing (35° C.) mixture of trichlorosilane (67 g) and dichlorobis (benzonitrile) platinum II (0.00337 g). The heat source is removed and the temperature continues to rise during the addition, reaching 65° C. After the addition is complete and the temperature drops to 50° C., a vacuum of 15 mm is applied for thirty minutes. The product is a water white liquid of 83.6 g of trichlorosilylhexane. Gas chromatographic analysis shows it to be 95% pure.
The trichlorosilylhexane (80 g) in methylene chloride (640 g) is added to a pyrex reaction flask and it is sparged with nitrogen for 15 minutes and cooled to 5°-10° C. The reaction mixture is saturated with sulfur dioxide and a 125 watt Hanovia mercury lamp placed as close to the flask as possible is turned on. Sulfur dioxide and chlorine gas in a 1:2 ratio are bubbled in until about 1 equivalent of sulfur dioxide and chlorine are added. A nitrogen purge is bubbled into the reaction mixture for 15 minutes with the light on. The solvent and sulfuryl chloride are distilled off at about 15 mm and at a pot temperature of 70° C., then distilled at about 1 mm. The unreacted trichlorosilylhexane is distilled off at about 1 mm and 70°-90° C.
Trichlorosilylhexane sulfonyl chloride (32 g) are added to methylene chloride (100 g) in a reaction flask fitted with a stirrer and condenser and heated to reflux under a nitrogen purge. When at reflux, dry ethanol (14 g, 3.1 equivalents) is added dropwise and the mixture is stirred and refluxed under nitrogen for one hour. After cooling to room temperature, the water condenser is replaced with a dry ice condenser, propylene oxide (6 g, 1 equivalent) is added and the mixture and stirred at room temperature for thirty minutes. The mixture is evaporated at 50° C. under water aspirator vacuum to give 34 g of triethoxysilylhexane sulfonyl chloride.
Sodium azide (1.5 equivalent) in 4 ml of sodium hydrogen phosphate and hydrogen chloride buffer (14.4 g or Na 2 HPO 4 to 4.4 mil conc HCl in 1 liter of distilled water) per gram of azide is added dropwise to a stirred 50 percent solution of triethoxysilylhexane sulfonyl chloride in methylene chloride containing 1 percent Aliquat 336. The mixture is stirred at room temperature for thirty minutes after the addition is complete. The layers are separated. The methylene chloride layer is washed with a saturated salt solution, dried over magnesium sulfate and the methylene chloride is evaporated. Ninety percent solids of a light yellow liquid triethoxysilylhexane sulfonyl azide of about 90 percent purity are obtained.
(B) Preparation of Modified Polymer
A mixture of 1.0 weight percent of triethoxysilylhexane sulfonyl azide and 1.0 weight percent triethoxyvinylsilane is mixed with high density polyethylene of number average molecular weight of about 150,000 for five minutes in a Waring blender. The samples are then masticated using a Brabender Plastograph for five minutes at 200° C. under a nitrogen blanket and are subsequently compression molded into 6"×6"×25 mil plaques at 240° C. using an Elmes press. The resulting plaques are then steamed for 24 hours in a pressure cooker at about thirty psi. Insoluble gel determinations are made by refluxing 1 gram of sample in 200 ml of decalin for 24 hours. The percent gel of this sample was 95%.
EXAMPLE 2
A mixture of 2 weight percent of triethoxysilylhexane sulfonyl azide and 1 weight percent of triethoxyvinylsilane is mixed with Pro-fax® 6501 polypropylene of number average molecular weight of about 50,000 for five minutes in a Waring blender. The sample is then masticated by a Brabender Plastograph for five minutes at 200° C. under a blanket of nitrogen and subsequently compression molded into 6"×6"×25 mil plaques at 240° C. using an Elmes press. The resulting plaques are then steamed for 26 hours at about 120° C. followed by overnight drying in a steam heated oven. Insoluble gel determination are made by refluxing 1 gram of sample in 200 ml of xylene for 24 hours. Percent gel of this sample was 63 percent.
EXAMPLE 3
A mixture of 0.5 weight percent of triethoxysilylhexane sulfonylazide and 0.5 weight percent of triethoxyvinylsilane is mixed with ultrahigh molecular weight polyethylene of number average molecular weight of 500,000 or greater for five minutes in a Waring blender. The sample is then extruded at about 240° C. The resulting strands are then steamed for 24 hours in a pressure cooker at about 30 psi. Insoluble gel determination is made by refluxing 1 gram of sample in 200 ml of decalin for 24 hours. Percent gel of this sample is 90 percent.
EXAMPLE 4
A mixture of 1.5 weight percent of triethoxysilylhexane sulfonylazide and 1.5 weight percent of triethoxyvinylsilane is mixed with Udel® polysulfone of number average molecular weight of about 50,000 for five minutes in a Waring blender. The sample is subsequently extruded at about 350° C. and the resulting strands are then steamed for 24 hours at about 120° C. followed by overnight drying in a steam oven. Insoluble gel determination is made by refluxing 1 gram of sample in 200 ml of xylene for 24 hours. Percent gel of this sample is 75 percent.
EXAMPLE 5
A mixture of two weight percent of triethoxysilylhexane sulfonyl azide and two weight percent of triethoxyvinylsilane is mixed with polyoxymethylene of number average molecular weight of about 50,000 for five minutes in a Waring blender. The sample is then extruded at about 400° C. and the resulting strands are steamed for 24 hours at about 120° C. followed by overnight drying in a steam heated oven. Insoluble gel determinations are made by refluxing 1 gram of sample in 200 ml oc xylene for 24 hours. The percent gel of this sample is 95 percent.
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The modification of thermoplastic polymers with a combination of azidosilanes and monolefinically unsaturated monomers and subsequent crosslinking by moisture.
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FIELD OF THE INVENTION
The present invention relates generally to vacuum cleaners and, more particularly, to a handle for a vacuum cleaner.
BACKGROUND OF THE INVENTION
It has long been known to provide a vacuum cleaner with a moveable cleaning head for movement over a floor to clean the floor surface. For convenience of movement, an extended handle is attached to the cleaning head so that the user may stand more or less erect while moving the cleaner head over the floor.
In most standard cleaner head designs, the cleaner head is a planar member with wheels. The handle member is centrally mounted thereon and pivotally connected to the cleaner head. This arrangement is standard for all types of vacuum cleaner heads, including upright vacuum cleaners, canister vacuums and central vacuum cleaning systems. To use the cleaner head, the user holds the end of the handle in one hand and moves the cleaner head about the floor in front of the user by extending an arm outwardly to move the cleaner head away from the user's body, and then bringing their arm back to the user's side to move the cleaner head back towards the user.
The difficulty with centrally mounting the handle on the cleaner head is that, when the user brings their arm back to the user's side, eg., to clean the floor in front of the user's feet, a portion of the cleaner head is directly in front of the user's feet. This can make it difficult for the user to walk forward while cleaning the floor because the user is in danger of stepping on the cleaner head. Further, the interference between the user's feet and the cleaner head limits the amount of carpet which can be cleaned by the user in a single stroke.
In order to overcome this difficulty, the user could position the cleaner head to be displaced to one side of the user so that the cleaner head would contact a portion of the surface to be cleaned that is laterally displaced from the portion over which the user moved. The difficulty with this approach is that the user would have to extend their arm outwardly from their side to hold the handle of the vacuum cleaner. This is not an ergonomic position and can result in the user becoming tired before they have finished using the vacuum cleaner.
Accordingly, there is a need for an improved vacuum cleaner handle design providing enhanced ergonomic comfort and convenience for the user.
SUMMARY OF THE INVENTION
In accordance with the instant invention, the handle of a vacuum cleaner has a hand grip portion which is laterally displaced from the centre line of the vacuum cleaner. Thus the handle is positioned so that it my be easily grasped by the user. Surprisingly, not only does this positioning of the hand grip portion provide improved comfort for the user, but even with the hand grip portion displaced from the centre of the cleaner head, the user may still easily control the cleaner head to move in a straight line.
In accordance with the instant invention, there is provided vacuum cleaner comprising a longitudinally extending cleaner head having an upper surface, a lower surface, transversely spaced apart opposed sides and a longitudinally extending axis centrally positioned between the opposed sides, and a handle having an upper portion positioned to one side of the longitudinally extending axis, the handle drivingly connected to the cleaner head for moving the cleaner head in response to a force applied to the upper portion.
In one embodiment, the vacuum cleaner further comprises an upper casing rotatably attached to the cleaner head and the handle is attached to the upper casing.
In another embodiment, the handle is attached to the cleaner head.
In another embodiment, the upper portion is positioned adjacent one of the opposed sides.
In another embodiment, the handle has a portion which is mounted to the vacuum cleaner to one side of the longitudinally extending axis.
In another embodiment, the handle further comprises a lower portion which is mounted to the vacuum cleaner to one side of the longitudinally extending axis and a portion extending laterally between the lower portion and the upper portion of the handle.
In another embodiment, the cleaner head has a centre line plane substantially parallel to the longitudinally extending axis and the handle has a the lower portion which is mounted to the vacuum cleaner at a position adjacent the centre line plane, the handle having a portion extending laterally between the lower portion and the upper portion of the handle.
In another embodiment, the upper portion has a hand grip portion that is angled to extend rearwardly and laterally.
In another embodiment, the upper portion has a hand grip portion which is lockingly rotatably mounted to handle.
In another embodiment, the upper portion has a hand grip portion which is ergonomically configured so as to be positioned adjacent the side of a person when they are using the vacuum cleaner.
In accordance with another embodiment, of the instant invention, there is provided a vacuum cleaner comprising cleaner head means moveable over a surface in a direction of travel, the cleaner head means having a centre line plane substantially parallel to the direction of travel and perpendicular to the surface when the cleaner head is positioned on the surface, and handle means for moving the cleaner head in response to a force applied to the handle means, the handle means having a portion positioned to one side of the centre line plane.
In one embodiment, the vacuum cleaner further comprises an upper casing including means for separating entrained dirt from dirty air entering the vacuum cleaner and the handle means is attached to the upper casing.
In another embodiment, the handle means is attached to the cleaner head.
In another embodiment, the handle means has an upper portion which is positioned adjacent a lateral side of the vacuum cleaner.
In another embodiment, the handle has a lower portion which is mounted to the vacuum cleaner at a position spaced from the centre line plane. All of the handle means maybe spaced from the centre line plane.
In another embodiment, the handle means further comprises a lower portion which is mounted to the vacuum cleaner at a position spaced from the centre line plane and a portion extending laterally between the lower portion and the portion positioned to one side of the centre line plane.
In another embodiment, the handle means has a portion which extends laterally.
In another embodiment, the upper portion has a hand grip portion that is angled to extend rearwardly and laterally.
In another embodiment, the upper portion has a hand grip portion which is lockingly rotatably mounted to handle.
In another embodiment, the handle means is ergonomically configured so as to be positioned adjacent the side of a person when they are using the vacuum cleaner.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example to the accompanying drawings of a preferred embodiment of the vacuum cleaner in which:
FIG. 1 is a front elevational view of an upright vacuum cleaner having an offset handle according to the present invention;
FIG. 2 is a top plan view of the upright vacuum cleaner of FIG. 1;
FIG. 3 is a front elevational view of an alternate embodiment of an upright vacuum cleaner according to the present invention wherein the handle has a rotatable hand grip;
FIG. 4 is a top plan view of the upright vacuum cleaner of FIG. 1;
FIGS. 5 and 6 are rear elevational views of alternate embodiments of an upright vacuum cleaner according to the present invention wherein the handle is mounted to the upper casing of the vacuum cleaner;
FIGS. 7-9 are rear elevational views of alternate embodiments of an upright vacuum cleaner according to the present invention wherein the handle is mounted to the cleaner head and,
FIG. 10 is an exploded view of a handle according to another embodiment of the instant invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-6, handle 10 according to the instant invention is shown is use with an upright vacuum cleaner 12. Upright vacuum cleaner 12 may be of any design know in the art. Accordingly, upright vacuum cleaner 12 may have a cleaner head 14, means for movably supporting cleaner head 14 on the floor (eg. wheels 16), and a main or upper casing 18. Cleaner head 14 and casing 18 house a dirty air inlet, a dust separation mechanism and motor of any type known in the art for use in vacuum cleaning devices.
The handle of the instant invention may be used with any vacuum cleaner. For example, handle 10 may be used with a canister vacuum cleaner or a central vacuum cleaning system. In such appliances, the user moves a cleaner head across a surface (i.e. there is no upper casing pivotally mounted to the cleaner head). In such cases, handle 10 may be affixed to cleaner head 14 (see for example FIGS. 7-9).
Cleaner head 14 may be of any design known in the art. Cleaner head 14 has an upper surface 40, a lower surface 42 and transversely spaced apart opposed sides 44. In any design, cleaner head 14 has a longitudinally extending axis 22 centrally positioned within cleaner head 14 to thereby bisect cleaner head 14 (see FIG. 2) into two opposed lateral portions. Axis 22 extends in the direction of travel 22 of cleaner head 14. The vacuum cleaner has a centre line plane 20 which is substantially parallel to longitudinally extending axis 22.
According to the present invention handle 10 has an upper portion (eg. grip 32) positioned to one side of longitudinally extending axis 22. By positioning grip 32 towards one lateral side 44 of cleaner head 14, grip 32 may be positioned adjacent to the side of the user when they are using the vacuum cleaner. Accordingly, the user will not have to extend their hand outwardly from their side to control the vacuum cleaner when cleaner head 14 is positioned to the side of the user (i.e. outside the walking path of the user when they are using the vacuum cleaner). Handle 10 may be affixed to the vacuum cleaner (either upper casing 18 or cleaner head 14) by any means known in the art to drivingly connected to the cleaner head for moving the cleaner head in response to a force applied to the upper portion of the handle.
Referring to FIGS. 1 and 2, handle 10 has a shaft 30 and a grip 32. Shaft 30 is affixed to upper surface 40 of cleaner head 14 and is preferably pivotally mounted thereto. It will be appreciated that upper casing 18 may be supported by mounting it to shaft 30. In an alternate embodiment, it will be appreciated that shaft 30 may be affixed to upper casing 18 and upper casing 18 is pivotally mounted to cleaner head 14 (see FIGS. 5 and 6).
According to the present invention, grip 32 is offset laterally (i.e. in a direction perpendicular to the travel access) from longitudinally extending axis 22. The offset distance D may be any amount, but is preferably approximately equal to one half of the width W of cleaner head 14. This results in a reduction in the possibility of interference between a user's feet and cleaner head 14 during normal use.
Although FIGS. 1 and 2 show shaft 30 substantially aligned with grip 32, it will be understood by one skilled in the art that the position of shaft 30 is not important to the present invention provided that handle 10 is mounted to the vacuum cleaner so that a user may move cleaner head 14 in response to a force applied by the user to handle 10. Thus, referring to FIGS. 1-4, shaft 30 may be a generally straight member and grip 32 may be positioned in line with shaft 30. This configuration may also be used if shaft 30 is connected directly to cleaner head 14 (see FIG. 9). Alternately, as shown in FIG. 5, shaft 30 may comprise angled portion 34 and lower portion 36. Lower portion 36 is affixed to main casing 18. Angled portion 34 extends laterally between lower portion 36 and grip 32 so that grip 32 of handle 10 is offset from centre line plane 20. Referring to FIG. 6, it will be appreciated that shaft 30 may consist only of angled portion 34. In this embodiment, angled portion 34 serves two purposes namely to provide a spacing means to offset grip 32 from centre line plane 20 and to affix handle 10 to upper casing 18. If handle 10 is affixed directly to cleaner head 14, shaft 30 may also have an angled portion 34 and a lower portion 36. Lower portion 36 may be positioned adjacent centre line plane 20 (see FIG. 7) or to one side of centre line plane 20 (see FIG. 8).
It will be appreciated that shaft 30 may be of any design known in the art. Angled portion 34 may extend at any angle from lower portion 36 or from upper casing 18 if angled portion 34 is directly mounted too upper casing 18. Thus, angled portion 34 may extend both laterally and rearwardly. Further, angled portion 34 may be curved.
It will be appreciated that grip 32 may be of any design known in the art. Grip 32 may extend at any angle from shaft 30. For example, grip 32 may extend rearwardly and upwardly from shaft 30 as is typical of the art (see for example FIGS. 1 and 2). It will be appreciated that grip 32 may itself also extend laterally (see for example FIG. 6 wherein grip 32' comprises an extension of angled portion 34). Further, grip 32 may be curved.
It will be appreciated that grip 32 may be positioned either to the right or to the left of axis 22 (when viewed from the rear of cleaner head 14). If cleaner head 14 is to be used by a right handed person, then grip 32 is preferably mounted to the left of axis 22. However, if cleaner head 14 is to be used by a left handed person, then grip 32 is preferably mounted to the right of axis 22 (when viewed from the rear).
In order to increase the flexibility of the vacuum cleaner, according to another aspect of the present invention, grip 32 is preferably rotatably mounted to shaft 30 such as at rotational point 38 (see FIG. 3). Any rotational mounting means known in the art may be used, such as a bearing or using a self lubricating nylon washer). Rotation point 38 permits grip 32 to be rotated around shaft 30 to a position which yields a comfortable hand orientation for the user. For a right-handed user using the vacuum cleaner, the angle of rotation α to a comfortable position is preferably about 10 to 50°, more preferably about 20 to 40° and most preferably the angle is about 30° clockwise from the straight back position (see the position in dotted outline in FIG. 4). It will also be appreciated that by rotating grip 32 in the counterclockwise direction by an angle of rotation β of preferably about 10 to 50°, more preferably about 20 to 40° and most preferably the angle is about 30° (as shown in solid outline in FIG. 4) the vacuum cleaner may be used by a left handed person. In this later case, a longer grip 32 may be used so that distal end 46 of grip 32 extends beyond centre line plane 20. To this end, grip 32 may be removably mounted to shaft 30 by any means known in the art.
Handle 10 may be provided with a locking means so that grip 32 may be locked at any desired angle of rotation. Any means for locking one member to another to prevent the rotation of one member with respect to the other may be used. For example, if grip 32 has a lower portion which is rotatably received in shaft 30, shaft 30 may be provided with a threaded opening for receiving butterfly set screw 48 for lockingly engaging the lower end of grip 32. Thus, the user may simply rotate butterfly set screw 48 to enable grip 32 to be rotated and, when grip 32 is in the desired position, then butterfly set screw 48 may be rotated to fix grip 32 at a desired angle of rotation.
Alternately, grip 32 may be rotatably mounted about shaft 30 through a plurality of preferred positions in which it may be locked, with respect to shaft 30, so that grip 32 is prevented from easily rotating out of the desired position during normal use. These preferred positions may be provided by any means known in the art, such as a retractable detent means, twist-locking means, or other position-holding means. For example, referring to FIG. 10, shaft 30 comprises a hollow cylindrical member for receiving lower end 50 of hand grip portion 32. Lower end 50 has an annular detent member 52 positioned thereon. The inner portion of shaft 30 is provided with an annular detent member 54 shown in dotted outline in FIG. 10. When hand grip 32 is inserted into shaft 30, annular detent member 52 cams along upper surface 56 of annular detent member 54 and extends through annular detent member 54 so that upper surface 58 of annular detent member 52 is positioned below lower surface 60 of annular detent member 54. The abutment of upper surface 58 against lower surface 60 maintains hand grip portion 32 within shaft 30 and allows it to freely rotate with respect to shaft 30. Hand grip 32 is provided with first engagement member 62 having a plurality of recesses (not shown) on lower surface 64 thereof. Shaft 30 is provided with second engagement member 66 having a plurality of detent members 68 on upper surface 70 thereof. Annular detent members 52, 54 maintain engagement members 62, 66 in contact and therefore cause detent members 68 to mate with a respective recess on lower surface 64. Detent members 68 define preset positions in which hand grip 32 may be locked.
The advantages of the rotatable grip portion can equally be realized on a conventional, centre-mounted handle as well. For example, in FIG. 3, shaft 30' may be centrally positioned and adapted for rotatably receiving grip 32.
Accordingly the offset handle according to the present invention provides an increased ergonomic convenience to the user in moving a cleaner head about the floor by minimizing interference between cleaner head 14 and the user's body. Also, according to the angled handle of the present invention, a more ergonomic handle position is provided.
While the above description constitutes the preferred embodiments, it will be appreciated that the present invention is susceptible to modification and change without departing from the fair meaning of the proper scope of the accompanying claims. Further, it will be appreciated that handle 10 may also be constructed to function as a cleaning wand as is known in the art.
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A vacuum cleaner handle is provided which offers improved ergonomic characteristics by providing a grip portion which is offset from the center line axis of the cleaner head.
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BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The present invention relates to a volume control system for a compressor unit of the type wherein it is not permissible that the ratio of delivery pressure relative to intake pressure during a partly loaded operation, i.e., pressure ratio, is considerably differentiated from the pressure ratio during normal loaded operation. An example of this type of compressor is a screw compressor of the dry type.
2. DESCRIPTION OF THE PRIOR ART
The dry type screw compressor comprises a pair of screw rotors disposed in a housing in non-contact relationship with each other. No oil is fed into the housing during operation. In this type of compressor, if the compressor is controlled such that the intake flow is throttled while the compressor is subjected to the same delivery pressure, as is in an oil-injection type screw compressor, the intake pressure becomes close to a partial vacuum with a result that the pressure ratio is extraordinarily increased. In addition, the dry type screw compressors are not sufficiently cooled to avoid undue rise of the delivery temperature, which would cause accidental contact or sticking between screw rotors themselves or between the rotors and the housing due to the thermal expansion of the rotors. Thus, a volume control method has been employed for the dry type screw compressor, wherein the intake flow is throttled and simultaneously the delivery port is open to the atmosphere so as to eliminate the increase of the pressure ratio.
However, if the intake flow is completely stopped, the pressure ratio will become unduly high. Thus, another control has been proposed wherein the intake flow is not completely stopped but a small amount of gas is admitted into a compressor to restrain the increase of pressure ratio as much as possible. Such a control method and a system used to carry out the method are disclosed in U.S. Pat. No. 3,367,562. The control system disclosed in the U.S. Pat. has problems which will be discussed hereunder.
A hydraulic actuator comprising a housing (27) and a diaphragm (26) is employed to open a throttle valve (6) and close a pressure relief valve (22) and to keep these valves in these positions.
In loaded operating condition of the compressor unit, the pressure relief valve (22) is subjected to the delivery pressure of the high-pressure compressor (3) through a conduit (17). The force produced by this delivery pressure is of a considerable magnitude. This force could be reduced by reducing the diameter of the pressure relief valve (22). However, if the valve diameter were reduced, the resistance to the flow of the gas through a valve seat of a correspondingly reduced diameter will be correspondingly increased, so that the power to drive the compressors (2) and (3) cannot be reduced even during unloaded operation.
The diaphragm (26) divides the interior of the housing (27) into two chambers (28) and (29). The maximum pressure in the second chamber (29) will be equal to the delivery pressure of the high-pressure compressor (3) (with the compressor unit disclosed in U.S. Pat. No. 3,367,562, the pressure in the second chamber is equal to the delivery pressure of the low-pressure compressor (2). Considering the fact that leakage through the pressure relief valve (22) when in its closed position, i.e., during loaded operation of the compressor unit, must be avoided, the inner diameter of the housing (27) of the hydraulic valve actuator must be at least as large as from 2 to 3 times of the diameter of the valve (22). Thus, a large-sized valve actuator is required.
The use of a fluid pressure to operate the throttle valve (6) and the pressure relief valve (22) disadvantageously involves a substantial time delay from the moment when a pressure-sensitive switch actuator (77) associated with a gas reservoir or tank (14) emits a signal to the moment when the throttle valve (6) is open and the pressure relief valve (22) is closed or vice versa. Accordingly, the pressure in the tank (14) will be considerably varied from a level below a predetermined lower limit set by the switch actuator (77) to a level above a predetermined upper limit set by the actuator. The compressor unit control system disclosed in the U.S. Patent, therefore, fails to provide a good response and thus causes an unduly high power consumption.
The throttle valve (6) and the pressure relief valve (22) are linked by a rod (24). Thus, the pressure relief valve (22) is required to be disposed at a place near to the throttle valve. Consequently, the length of the pressure relief pipe (17) is increased with a resultant increase in the resistance of the pipe to the flow of the pressurized gas discharged therethrough during an unloaded operation of the compressor unit. The increase in the length of the pressure relief pipe (17) also has direct and indirect problems that the choice of the places at which a silencer and cooler (19), an intercooler (9), an after cooler (13), the air tank (14), etc. of the compressor unit is considerably limited.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a volume control system for a compressor unit in which intake throttle valve and pressure relief valve can be opened and closed in an extremely shortened time period.
It is another object of the present invention to provide a volume control system of the class specified above and which requires a reduced amount of power consumption.
It is a further object of the present invention to provide a volume control of the class specified above and in which the places of machine components can be substantially freely selected.
It is a still further object of the present invention to provide a volume control system for a compressor unit which has a simplified structure and achieves the objects pointed out above.
The improved volume control system for a compressor unit according to the present invention is characterized by a first spring means operative to bias a throttle valve toward its closed position, a first solenoid means operative when energized to move the throttle valve to its fully open position against the first spring means, link means between the throttle valve and the first solenoid means, a second spring means operative to bias a pressure relief valve toward its fully open position, a second solenoid means operative when energized to move the pressure relief valve to its closed position against the second spring means, an electric circuit for the second solenoid, an electric switch in the electric circuit, and a switch actuator means responsive to change-over of the positions of the throttle valve to actuate the electric switch, the arrangement being such that, when the throttle valve is moved to its closed position, the pressure relief valve is opened, and such that, when the throttle valve is moved to its open position, the pressure relief valve is closed.
The above and other object, features and advantages of the present invention will become more apparent from the following description with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 are partly sectional diagrammatic illustrations of first to third embodiments of a volume control system for a compressor unit according to the present invention, respectively.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring first to FIG. 1 showing a first embodiment of the invention, a low-pressure compressor 2 and a high-pressure compressor 3, both of which are screw compressors, are mounted on a casing 1. These compressors 2 and 3 are driven by a common shaft (not shown) mounted in the casing 1. An intake throttle valve 6 having an orifice 7 formed therein is disposed in an air intake pipe 4 connected to an intake port of the low-pressure compressor 2 and divides the intake pipe 4 into an upstream section 4' and a downstream section 5. When the throttle valve 6 is in its closed position, air flows from the upstream section 4' into the downstream section 5 through a gap 32 between the inner peripheral surface of the intake pipe 4 and the outer peripheral edge of the throttle valve 6 and through the orifice 7. However, when the throttle valve 6 is in its open position, air can freely flow from the upstream section 4' to the downstream section 5.
A delivery port of the low-pressure compressor 2 is connected to an intake port of the high-pressure compressor 3 through a pipe 8, an intercooler 9 and a pipe 10. To a delivery port of the high-pressure compressor 3 is connected a delivery pipe 11 which in turn is connected to a second delivery pipe 12. The delivery pipe 12 in turn is connected to an air tank 14 through an aftercooler 13.
The air delivered from the low-pressure compressor 2 at an intermediate pressure is introduced into the intercooler 9 through the pipe 8 and then into the high-pressure compressor 3 through the pipe 10. The compressed air discharged from the high-pressure compressor 3 is delivered to the tank 14 through the delivery pipes 11 and 12 and through the aftercooler 13.
At the junction between the delivery pipes 11 and 12 is disposed a check valve 15 which is adapted to interrupt the communication between the delivery pipes 11 and 12 when the valve 15 is closed thereby to prevent the compressed air in the tank 14 from flowing therefrom back toward the compressor 3 when the compressors 2 and 3 are stopped or unloaded.
A pressure relief pipe 16 is connected to the delivery pipe 11 and communicated with a valve chamber 18 which in turn is connected to a downstream relief pipe 17 open to the atmosphere. A pressure relief valve 19 is provided in the valve chamber 18 to control the communication between the upstream and downstream relief pipes 16 and 17.
The throttle valve 6 is connected through a member 21 to one end of a rod 20 the other end of which is connected to an iron core 33 surrounded by a first solenoid 27. A spring 24 is provided around the rod 20 to bias the latter in a direction to close the throttle valve 6.
The relief valve 19 is connected through a rod 38 and a lever 37 to one end of a rod 36 which in turn is connected at the other end to a second iron core 34 which is surrounded by a second solenoid 28. The electric circuit for the solenoid 28 includes therein a switch 31 adapted to be opened and closed by link members 30 and 35 which are operatively connected to the rod 20. A spring 29 is so asssociated with the rod 38 as to bias the latter in a direction to open the relief valve 19.
The tank 14 is provided with a pressure-sensitive switch actuator 22 which is adapted to open and close a switch 23 disposed between electric conductors 25 and 26. The solenoid 27 is connected in series to the switch 23 through the electric conductor 25.
In operation, a conventional timer relay 50 keeps the electric conductors electrically cut off from the power supply source until the speed of the motor (not shown) for the compressors 2 and 3 is increased up to a predetermined full speed. In this state, the throttle valve 6 and the relief valve 19 are positioned in their closed position and open position as shown in FIG. 1, respectively, due to the biasing forces of the springs 24 and 29, so that the compressors are driven in unloaded conditions. After the electric conductors 25 and 26 are supplied with electric current, if the pressure in the tank 14 is lower than a level which is predetermined by the pressure-sensitive switch actuator 22, the switch 23 is closed by the actuator 22. Consequently, the solenoid 27 is energized to move the iron core 33 and, thus, the rod 20 leftward against the force of the spring 24 thereby to rotate the throttle valve 6 toward its fully-open position. When the throttle valve 6 is rotated almost to its fully-open position by the leftward movement of the rod 20, the switch 31 is closed by the members 30 and 35, so that the solenoid 28 is energized to lift the iron core 34 together with the member 36. As a result, the lever 37 is rotated clockwise to lower the rod 38 against the biasing force of the spring 29. Consequently, the relief valve 19 is closed to render the compressors 2 and 3 loaded.
When the pressure in the tank 14 rises up to the upper limit set by the switch actuator 22, the switch 23 is opened to deenergize the solenoid 27, so that the rod 20 is moved rightward by the force of the spring 24 thereby to move the throttle valve 6 to the closed position. As the rightward movement of the rod 20 is commenced, the switch 31 is also opened to deenergize the solenoid 28, so that the spring 29 moves the relief valve 19 to its open position whereby the compressors 2 and 3 are unloaded.
In the illustrated embodiment of the invention, a relatively small magnitude of power will be sufficient to operate the throttle valve 6 due to the presence of the gap 32 around the valve 6. Therefore, the solenoid 27 is required only to exert a small magnitude of force which is necessary and sufficient to overcome the biasing force of the spring 24. In addition, a commercially available solenoid valve of the type that is closed when electrically energized can conveniently be used as an assembly of the solenoid 28 and the relief valve 19.
A second embodiment of the invention is illustrated in FIG. 2 wherein parts similar to those of the first embodiment are designated by similar reference numerals. The difference only will be discussed hereinafter. The switch 31 for opening and closing the electric circuit for the solenoid 28 is actuated by a differential pressure sensitive switch actuator 39 which is sensitive to a difference in pressure between the upstream and downstream sections 4' and 5 of the intake pipe 4. The switch actuator 39 is pneumatically connected to the upstream and downstream sections 4' and 5 of the intake pipe 4 by pressure transmitting conduits 39' and 39", respectively. The switch actuator 39 is arranged such that, when the throttle valve 6 is in the fully-opened position with the pressure differential across the throttle valve 6 being substantially zero (0), the switch 31 is kept closed , and such that, when the throttle valve 6 is slightly moved from the fully-open position to a partly closed position to produce a pressure differential across the throttle valve, the switch 31 is opened.
In operation, the throttle valve 6 and the relief valve 19 are in the illustrated positions when the compressors 2 and 3 are just started. After the electric conductors 25 and 26 are supplied with electric current, the volume control of the compressors is carried out in accordance with the pressure in the tank 14. More specifically, if the pressure in the tank 14 is at a level below a lower limit of the pressure level determined by the switch actuator 22, the switch 23 is closed to cause the solenoid 27 to be energized, so that the throttle valve 6 is opened. When the throttle valve 6 is opened, the actuator 39 operates to close the switch 31, so that the solenoid 28 is energized to close the relief valve 19, whereby the compressors 2 and 3 are brought into loaded operations thereby to charge the tank 14 with compressed gas.
When the upper limit of the pressure determined by the pressure sensitive switch actuator 22 is reached in the tank 14, the actuator 22 operates to open the switch 23 to close the throttle valve 6. The differential pressure sensitive switch actuator 39 operates in response to a pressure difference produced across the closed throttle valve 6 to open the switch 31, so that the relief valve 19 is opened to render the compressors 2 and 3 unloaded.
In the embodiment shown in FIG. 2, the switch 31 is opened and closed by the differential pressure sensitive switch actuator 39. However, the actuator for the switch 31 is not limited to the differential pressure sensitive type and may be replaced by another type of switch actuator. For instance, in the case where the pressure in the intake pipe 4 upstream of the throttle valve 6 is kept at a substantially constant level, as in the case in which the upstream section 4' of the intake pipe 4 is open directly to the atmosphere, the electric circuit for the solenoid 28 may be opened and closed by a pressure-sensitive type switch actuator 40 which is shown in FIG. 3 and operative in response to a variation in pressure in the downstream section 5 of the intake pipe 4. The rest of the embodiment shown in FIG. 3 is identical to those of the embodiment shown in FIG. 2.
The volume control system of the present invention described above provides the following advantages:
Due to the use of the solenoids 27 and 28 as the actuators for the throttle valve 6 and the relief valve 19, the structure of the whole control system is greatly simplified and much inexpensive as compared with the control system in which a fluid pressure is used to operate such valves. In addition, since these solenoids can operate in quite a short time, the opening of the throttle valve 6 and the closing of the relief valve 19 can be finished almost instantaneously, so that the range of variation of the pressure in the tank 14 can be maintained substantially as small as the range set by the pressure-sensitive switch actuator 22. This assures not only a substantially constant pressure of compressed air at the delivery port of the tank 14 but also a reduced loss of power supply to the compressors 2 and 3.
Further, since the relief valve 19 and the throttle valve 6 are connected electrically only, the relief valve 19 can be located in the vicinity of the delivery pipe 11, so that the length of the pressure relief pipe 16 can considerably be reduced with a result that the flow resistance of the relief pipe 16 is remarkably reduced and that the volume of the relief pipe 16 is reduced. Accordingly, the air in the delivery pipe 11 and in the relief pipe 16 can be discharged through the relief valve 19 promptly when the latter is opened, so that the pressure in the delivery pipe 11 is immediately lowered to render the compressors 2 and 3 unloaded in a shortened time period. The reduced volumes of the relief pipe 16 and the delivery pipe 11 reduce the time required for the compressors to be rendered loaded when the relief valve 19 is closed, thereby to assure a prompt rise of the delivery pressure of the compressor 3. This also contributes to the reduction of loss of power supply to the compressors.
The prior art volume control system had a disadvantage that, when the operation of an associated compressor unit was changed over from a loaded operation to an unloaded operation, i.e., when the throttle valve is closed and the relief valve is opened, an unduly high pressure ratio is momentarily established between the low-pressure compressor and the high-pressure compressor 3 with a resultant rise of the temperature of the compressed air up to as high as some hundreds' degrees of centigrade thermometer because the air in the pipe 8, intercooler 9 and in the pipe 11 and relief pipe 16 is not quickly discharged. According to the control system of the invention, however, such a temperature rise can be avoided because the throttle and relief valves 6 and 19 are quickly operated to cause air in the relief pipe 16, delivery pipe 11, intercooler 9 and pipes 8 and 10 to be promptly discharged therefrom into the atmosphere and because the relief pipe 16 can be shortened to cause the volume of the relief pipe 16 and the delivery pipe 11 to be minimized.
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In a compressor unit of a type wherein the ratio of delivery pressure relative to intake pressure, i.e., pressure ratio, is required to be as uniform as possible during unloaded and loaded operating conditions, as is in screw compressors of dry type, solenoids are used to drive an intake throttle valve and a pressure relief valve in such a manner that, when the throttle valve is closed, the pressure relief valve is opened to avoid an increase of the pressure ratio. When signals are produced to close the throttle valve and open the pressure relief valve, the solenoids are instantanously operative to close the throttle valve and open the pressure relief valve.
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BACKGROUND OF THE INVENTION
The present invention relates to an appliance for affixing surgical or ligating clips and more particularly to an appliance for rapidly employing several clips at a surgical site. There are many different designs for surgical clip applicators for a variety of surgical procedures including laproscopy in which a clipping appliance fits through a trocar tube into a body cavity where the clips are applied.
This invention provides a repeating multi-clip applier having a simplified mechanism for applying clips which mechanism is suitable for the full spectrum of clip appliers including laparoscopy. The applier mechanism is particularly adaptable to the disposable cartridge/fixed handle design. The simplified mechanism reduces tooling and assembly requirements, provides high operating reliability at lower product cost.
SUMMARY OF THE INVENTION
A surgical clip applicator according to the invention comprises an operating handle and clip applying mechanism having an operating cycle in which operating levers are squeezed together and released. In this cycle, a clip is applied in surgery and the clip applicator is reloaded from a clip supply channel for clip application in the next cycle.
The applicator provides a moveable clip supply channel containing a line of clips that are released seriatim. The supply channel integrates a clip pusher and an escapement or clip stop spring in a single stamped unit.
Clip crimping jaws apply a clip with a rearward movement of a camming member thereby allowing the functions of clip loading and jaw closure to be coordinated and operated by a single sliding bar moving reciprocally to load and fire clips.
A preferred embodiment of the clip actuating mechanism includes a combined actuating rod and in-line clip supply channel together with clip indexing mechanisms arranged so that with a squeeze of the operating levers, the actuating rod moves rearward in the appliance to apply a clip in surgery, capture the next in-line clip, indexes a line of clips rearward away from the clip jaws, and that with release of the operating levers, the jaws open, the next in-line clip is loaded into the jaws, the second next in-line clip is separated from the line, and the clip indexing movement is reset for the next cycle.
The clip applicator provides a novel mechanism with minimal complexity especially suited to disposable cartridge for fixed handle appliances.
A clip applicator according to the invention employs low operating force without recoil, a clip counter, jaw lockout after the last clip and is adaptable for use as a quick snap-in disposable cartridge with a fixed non-disposable operating handle. An operating handle that provides linear reciprocating motion including scissors-type or pistol grip may be used in the invention.
OBJECTS OF THE INVENTION
An object of the invention is to provide a novel clip applicator with minimum complexity and with adaptability to a complete range of clip applicators including laproscopic use.
Another object of the invention is to provide a clip applicator adaptable for use with a replaceable cartridge.
Another object of the invention is to provide a clip applicator in which clip feed and applying mechanisms are driven by an actuator having a linear reciprocating motion generated by operating handles.
Another object of the invention is to provide a surgical clip applier useful with a variety of operating handle designs.
Other and further objects of the invention will become apparent with an understanding of the following detailed description of the invention or upon employment of the invention in practice.
A preferred embodiment of the invention has been chosen for detailed description to enable those having ordinary skill in the art to which the invention appertains to readily understand how to construct and use the invention and is shown in the accompanying drawing in which:
FIG. 1 is a plan view of a surgical clip applicator according to the invention.
FIG. 2 is an exploded perspective view of the components of a preferred embodiment of surgical clip applicator.
FIGS. 3 a - 3 c are sequential fragmentary perspective views of a surgical clip applicating mechanism according to the invention.
FIGS. 4 a - 4 b are sequential plan views of a preferred embodiment clip applicator jaws in open and closed positions, respectively.
FIGS. 5 a - 5 b are sequential plan views of a modified embodiment clip applicator jaws in open and closed positions, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawing, a preferred embodiment of the repeating multi-clip applier 10 comprises handle 12 and clip applicator 14 .
The handle 12 (FIG. 2) includes a central casing 16 formed of upper 16 a and lower 16 b shells each having aligned confronting journal pin guiding slots 16 c. The shells are joined to each other along edges 16 d to define an enclosure 16 e for receiving handle components 18 including actuating levers 18 a-b pivotally mounted on adjacent posts 18 c-d, links 18 e-f joined to each other by journal pin 18 g and connected by pivot pins 18 h-i to levers 18 a-b, and compression spring 20 .
In assembly, the compression spring is mounted on actuating rod 30 with one spring end 20 a abutting rod shoulders 30 s and the other spring end 20 b abutting a rear face 20 c of a spring housing 20 d. The end 30 a of the actuating rod extends through the spring for connection to links 18 e-f by means of journal pin 18 g. The exposed ends of the journal pin fit into the guiding slots 16 c which define the axial excursion of the actuating rod. When assembled, the spring urges the actuating rod forward in a straight line and (by means of actuating rod connection at 30 a to the journal pin 18 g and links 18 e-f ) urges the actuating levers 18 a-b to pivot outward from the casing to normal position. In use, the levers with finger loops are moved together (inward) against the spring for the purpose of applying a clip and moved apart (outward) to reload the applicator jaws with a clip.
It is to be understood that the links-actuating rod journal pin 18 g moves in a rearward then forward linear excursion within the guiding slots for each inward-to-outward cycle of the operating levers. This reciprocating linear motion serves to operate the clip applicator 14 by means of the actuating rod 30 .
In practice the clip applicator 14 can be used with any suitable handle that provides linear reciprocating motion. The description of a scissors-type handle is illustrative.
The clip applicator 14 comprises an applicator housing 22 including cover 24 and base 26 connected to the forward end 16 f of the handle casing with the applicator housing enclosing and forming part of a clip applicator mechanism 28 . In the following description, the applicator housing cover and base are regarded as stationary in relation to movement of the applicator mechanism components.
The applicator housing base 26 is an elongate open ended channel secured at its rear end 26 a to the operating handle casing and having an anchor pin 26 b affixed to the channel base 26 c.
The elongate actuating rod 30 is located in the applicator base channel 26 c with the rod connected at its rear end 30 a to the handle link journal 18 g for receiving linear reciprocating motion with respect to the stationary base channel 26 c for each cycle of the handle operating levers. The actuating rod at its front end includes upstanding cooperating cam members 30 c-d for closing and opening clip applicator jaws 32 . The actuating rod also includes an anchor pin slot 30 e to accommodate reciprocal movement of the rod in the base channel and a circular hole 30 f to receive a retaining pin 38 a fitted to the clip supply channel as described below.
Clip applying jaws 32 comprising spring biased arms 32 a-b (FIGS. 2, 4 a-b ) are mounted at hole 32 c to anchor pin 26 b on the applicator base with the jaws 32 d-e projecting from the front end of the channel.
The applicator jaws are affixed to the base channel so that as the actuator rod reciprocates, cam means 30 c-d (FIGS. 2, 4 a-b ) forming part of the actuating rod ride along cam surfaces 32 f-g of the applicator jaws for closing the jaws to apply a clip and for opening the jaws to receive another clip. The normal position for the actuating rod and jaws occurs with the actuating rod at the forward end of linear excursion, with the jaws open and with the actuating rod cam means in an inactive position with respect to applicator jaws.
Preferred and modified applicator jaws are illustrated in FIGS. 4 a-b and 5 a-b.
FIGS. 4 a-b illustrate spring biased applicator jaws 32 affixed at a rear point 32 c to the applicator housing anchor pin 26 b with spring biased arms able to move from open-to-closed-to-open positions in applying a clip. The inner surfaces 32 h-i of the jaws are recessed to form cooperating channels for movement of each clip into the jaws. The outer surfaces of the jaws have aligned recesses 32 f-g defining cam surfaces cooperating with aligned cam members 30 c-d affixed to the actuating rod 30 for the purpose of closing the jaws for each rearward excursion of the actuating rod (FIG. 4 b ). The jaws are released to spring open on the forward excursion of the actuating rod placing the cam members within the recesses (FIG. 4 a ).
FIGS. 5 a-b illustrate pivoted applicator jaws 34 with pivot arms 34 a-b affixed at aligned central pivot points 34 c-d to the applicator housing base 26 c. The rearward inner surfaces of the jaws have aligned recesses defining cam surfaces 34 e-f cooperating with cam member 30 g affixed to the actuating rod 30 for the purpose of closing the jaws for each rearward excursion of the actuating rod (FIG. 5 b ). The jaw arms move from open-to-closed-to-open positions in applying a clip. The jaws are moved to normally open position by means of a spring (not shown) or by a positive displacement cam means. The forward inner surfaces 34 g-h of the jaws are recessed to form cooperating channels for holding each clip in the jaws as the jaws close. The jaws move open on the forward excursion of the actuating rod and cam member 30 g (FIG. 5 a ). A sinuous interface 34 i of the jaw arms ensures true rocking or pivoting movement of the jaw arms from open to closed positions.
The applicator mechanism 28 also includes a clip supply channel 38 (FIGS. 2, 3 a-c ) which is affixed to and reciprocates with the actuating rod 30 by means of an anchor pin 38 a at the underside the channel which fits into hole 30 f in the actuating rod. The supply channel 38 includes an elongate base plate 38 b with upstanding sides 38 c to define a central channel 38 d and includes flanges 38 e defining inwardly directed side channels 38 f-g for receiving and retaining a line of clips C. The clip supply channel has an integral forwardly extending pusher plate 38 h preferably with notched front edge conforming to clip contour for the purpose of pushing each clip into the jaws as it leaves the supply channel. A clip stop spring 38 m with vertical tip 38 n is formed integral in the base plate 38 b for gripping the leading clip C L at midpoint. The clip stop spring has a “spring set” wherein the spring is normally positioned or biased below the surface of base plate 38 c with the spring being accommodated in a slotted cam plate 39 located underneath the channel.
The cam plate 39 (FIG. 2) is fixed to the stationary housing by means of tabs 39 t or mounted at hole 39 a to anchor pin 26 b, so that the back edge of the slot 39 b acts as a cam to urge the clip stop spring and its tip 38 n upward into the path of clips C when the clip cartridge 38 moves rearward with the actuating rod 30 . A slot 39 c in the cam plate accommodates reciprocal movement of the clip cartridge/actuating rod connecting pin 38 a.
The housing cover 24 has an elongate transparent slot 24 a (FIG. 1) through which a user can see the supply of clips. The cover may also have count marks 24 b indicating the number of clips remaining in the applicator. The cover (FIGS. 3 a-c ) also has on its inner surface a clip block 24 c, a clip capture spring 36 and a guide ramp 24 d for positioning clips for movement into clip applying jaws as more fully described below. The underside surface of the cover may also have a set of longitudinally extending ratchet teeth 24 e (FIG. 3 b ) forming a part of a clip advancing mechanism described below.
A clip advancing mechanism 40 (FIG. 3 b ) is positioned and retained in the clip supply channel 38 d and side channels 38 f-g in engagement with the last clip C Z for advancing the line of clips along the supply channel. The clip advancing mechanism includes a clip follower 40 a with forwardly directed fingers 40 b-c for engaging clip shoulders for constantly maintaining a force on the line of clips, a sinuous compression spring 40 d, and a ratchet head 40 e. The ratchet head is provided with upper 40 f and lower 40 g tangs or spring biased ratchet pawls for engagement, respectively, with ratchet edges or teeth 24 e in the under side of the housing cover and ratchet openings 38 p in the supply channel base plate 38 b.
The ratchet head, the clip follower and follower spring by their design and operation, and in cooperation with the movable clip stop spring 38 m, regulate step-by-step or indexing movement of a line of clips through the supply channel toward the applicator jaws.
In normal (or forward) position of the actuating rod 30 and supply channel 38 (which are affixed to each other), the bias spring 40 d, clip follower 40 a and ratchet head 40 e maintain contact and force on the clip line urging the line toward the clip stop spring 38 m by means of upper pawl 40 f engagement with ratchet teeth 24 e in the housing cover and by means of lower pawl 40 g engagement with ratchet openings 38 p in the supply channel base plate while the clips are at rest in the supply channel.
The clip advance mechanism, the bias spring and clip follower, the cover ratchet teeth, the base plate ratchet openings, and the clip stop spring act together for step-by-step or indexed movement of the clips down the supply channel as now described.
With the actuating rod and supply channel in forward or normal position, the upper pawl and compression spring hold the clip line stationary against the clip stop spring 38 m. When the actuating rod 30 and supply channel 38 move rearward with squeeze of the operating levers, the ratchet head and upper pawl remain stationary while the compression spring accommodates rearward movement of the clip stop spring and the contiguous line of clips. The rearwardly moving supply channel slips over the lower pawl 40 g bringing the next forward ratchet opening 38 p into contact with the lower pawl thereby indexing forward by one step the relative position of the ratchet head and the supply channel.
Next the actuating rod and supply channel and line of clips move forward as a unit into normal position. During this forward movement, the upper pawl 40 f slips one notch along the under side of the housing cover into engagement with the next ratchet tooth 24 e.
In lieu of the clip advancing mechanism 40 , an elongate compression spring 41 (FIG. 2) may be employed for advancing clips in the clip supply channel. As shown, a compression spring attached to a channel back wall 38 r and to a spring head 41 a lies in the clip channel for engaging and moving a line of clips C in the channel by spring force.
Referring to FIGS. 3 a-c , with forward movement of the supply channel and coherent line of clips, a first in line of clips C F comes to rest against the clip block 24 c. The capture spring 36 straddles the clip block and separates clip C F . The capture spring 36 is stationary in that it is affixed to the under side of the housing cover in position to capture and hold the lead clip at the end of the forward excursion of the actuating rod and supply channel. The capture spring takes and separates the lead clip from the clip line in preparation for movement of the lead clip into the applicator jaws on a subsequent applicator cycle.
The capture spring in preferred form is generally U-shaped with front tabs 36 a-b affixed to the cover, with spaced shoulders 36 e-f, and with inclined rear end 36 g. The spring captures clip C F by reaction as the inclined end rides up on forwardly moving clip C F and snaps down as the clip passes the shoulders. Such clip capture occurs as the actuating rod and supply channel reciprocate during operation of the applicator, as detailed below.
At the end of rearward excursion of the supply channel (FIG. 3 b ), the capture spring 36 pushes clip C F downward and out of engagement with the clip block 24 c and into the path of the pusher plate 38 h. The pusher plate then engages the rear of captured clip C F with its contoured edge to advance clip C F into the applicator jaws on forward movement of actuating rod and supply channel. The guide ramp 24 d on the cover guides clip C F into the jaws.
The operation of the applicator is as follows. Referring to FIGS. 1, 3 a and 4 a, the housing cover and base are stationary with respect to movements of the component parts of the actuating mechanism. At the beginning of an operating cycle (or normal position), the handle actuating levers are positioned apart, the actuating rod and supply channel are in forward position, the jaws are open holding a clip in position for surgical application, jaw actuating cam means are in inactive position, the lead clip in the capture position, the pusher plate lies under the lead clip, the clip stop spring is inactive and lies in the cam plate recess below the surface of the pusher plate, and the clip follower engages the last in line clip, the spring biased line of clips is in contact with lead clip C F , the lower pawl engages a corresponding supply channel ratchet edge, and the upper pawl engages a cover ratchet tooth.
By squeezing the handle levers together (FIGS. 3 b and 4 b ), the actuating rod and supply channel move rearward relative to the stationary cover and base to accomplish:
a. retraction of the actuating rod cam means along the jaws cam surfaces to close the jaws and apply a clip;
b. movement of the pusher plate relative to the cam plate whereby the stop spring is cammed up so its tip grips the next in line clip C L and by rearward movement the stop spring separates the clip stack from the lead clip C F ;
c. the captured clip C F is held in place under the capture spring;
d. movement of the pusher plate from underneath into position behind the captured clip C F ;
e. the upper pawl of the ratchet head is in engagement with a ratchet tooth of the housing cover as the clip follower and follower spring maintain back pressure on the clip line in the supply channel thereby holding the ratchet head stationary with respect to the upper housing cover as the staple supply channel moves rearward with the actuating rod,
f. indexing the lower pawl one step of relative movement between the ratchet head and the supply channel;
and by releasing the handle levers to move apart, the actuating rod and supply channel move forward in relative movement to the stationary cover and base to accomplish:
g. movement of the pusher plate to advance the captured clip C F into the jaws;
h. movement of the actuating rod cam means along the jaws cam surfaces into inactive position opening the jaws;
i. with the lower pawl in engagement with a ratchet edge of the supply channel advance the ratchet head and the clip line and the supply channel for moving the clip line and the lead clip C L toward capture position;
j. indexing the upper pawl one step along the cover ratchet teeth; and
k. the pusher plate and stop spring moving relative to the cam plate with the stop spring reentering is slot in the cam plate out of the path of the clip line so as to permit the next in line clip C L to advance along the surface of the pusher plate to deflect the capture spring and be captured as C F .
The invention provides that the clip applicator of FIG. 2 of the drawing can be made as a disposable cartridge to be inserted into a non-disposable handle with the cartridge removed from the handle and discarded after its clips are consumed. In a cartridge arrangement both the cartridge housing and rear end of the actuating rod have plug-in connections to the handle housing and link journal respectively.
Various changes may be made to the structure embodying the principles of the invention. The foregoing embodiments are set forth in an illustrative and not in a limiting sense. The scope of the invention is defined by the claims appended hereto.
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A repeating multi-clip applier for surgery with scissor-type or pistol grip operating handles, and a clip feeding and applying mechanism actuated by linear reciprocating movement generated by the handles. A unitary linear actuating rod and clip supply channel together with clip feed mechanisms reciprocate rearward-to-forward as the handles move for applying a clip in surgery and for advancing clips into the applying jaws.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is an U.S. national phase application under 35 U.S.C. §371 based upon co-pending International Application No. PCT/DE2008/001365 filed on Aug. 19, 2008. Additionally, this U.S. national phase application claims the benefit of priority of co-pending International Application No. PCT/DE2008/001365 filed on Aug. 19, 2008 and German Application No. 10 2007 039 399.9 filed on Aug. 21, 2007. The entire disclosures of the prior applications are incorporated herein by reference. The international application was published on Feb. 26, 2009 under Publication No. WO 2009/024138.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a gripper mechanism for machines, robots and handling equipment with at least one movable gripping finger which is driven by at least one driveshaft, crank, gear wheel, tooth belt or chain sprocket shaft, wherein the driveshaft, crank, gear wheel, tooth belt or chain sprocket shaft is of multiple-section design and is axially and radially mounted in the structure on both sides by a “fixed-loose”—or a journal bearing in such manner that at least one of the bearing journals on both sides of the driveshaft is formed as a separate neck bearing on a gripping finger and/or on a connecting bar of the gripper mechanism which drives the gripping finger, and the centering of the components of the sections of the driveshaft in relation to one another as well as the transmission of the torque from the driveshaft to the gripping fingers or other elements of the gripper mechanism takes place by way of an end-faced axial tooth intermeshing or axial pin connection of the portions in relation to one another.
2. Description of the Prior Art
Gripper mechanisms, the gripping fingers of which are set into rotary motion by a crank or a tooth gear, as a rule, comprise a crank or tooth gear shaft with bearing journals on both sides as an integral unit, the shaft ends of which, for purposes of torque transmission, project from the transmission and transmit the torque by means of known shaft-hub-connections onto other members of the gripper mechanism. For assembly reasons the casing of such gripper mechanisms is composed of a plurality of parts which are bolted together. Their manufacture is cumbersome and their assembly is particularly cumbersome. When work pieces are gripped, the flow of forces passes from the gripping finger by way of the fastener elements of the casing components and endeavors to force these apart. Moreover, the fixation and the transmission of the torque between the crank or tooth gear shaft, being an integral unit, and the other members of the gripper mechanism is tied in an unchangeable manner to a specific position of the driveshaft.
SUMMARY OF THE INVENTION
Against this background, the invention is based on the object to manufacture the casing, including its forces- and torque-transmitting parts to be resistant to bending and torque and also in a favorable manner assembly- and cost-wise from an integral work piece and, moreover, to provide the connection between the driving member, crank, tooth gear, chain or belt pulley and the driven member of the gripper mechanism simply, reliably and, as regards its twisting angle, rigid yet variable in order to permit the broadest possible usability of this particular gripper mechanism.
This object is attained according to the invention by means of the features set out in claim 1 .
The subsidiary claims represent advantageous further modifications of the invention.
Because of the splitting of the driveshaft or rotary axle into a plurality of at least two separate sections of which the two outermost sections each comprise a bearing, the assembly of the driveshaft or rotary axle with the gripper members fitted thereto is made possible without dividing the casing. Preferably, the driveshaft is divided into three sections, a driven central section in the form of a crank or tooth gear, chain pulley or belt pulley with axial tooth intermeshing on both sides as well as with or without axial bearing surfaces for a journal bearing support in X-configuration and two separate bearing journals in the form of neck bearings in separate parts of the gripper mechanism with axial tooth intermeshing as well as with or without axial bearing surfaces as an alternative to a journal bearing support of the driveshaft in O-configuration.
The axial tooth intermeshing of the sections which may also be provided in the form of a stub tooth intermeshing by means of bores and pins, takes care of the positive inter-engagement and centering of the sections in relation to one another and provides the torsionally rigid transmission of the torque from one section to another section of the driveshaft, yet allowing for a variable twisting angle.
The bearing journals of the driveshaft on both sides may also include axial bores therethrough, which serve for the passage of the pins from the bores of the central section of the driveshaft all the way into the bores of the driven gripping finger or the connecting bar which drives the gripping finger. Thus, the driveshaft may be composed of two sections, (a central drive section together with a bearing journal and on one side a gripping finger, together with a neck bearing), or of up to five sections, (a first gripping finger half, a first bearing journal, a central drive section, a second bearing journal and a second gripping finger half), all of which are interconnected by axial pin connections, preferably by continuous long pins.
The connection of the sections of the multi-sectional driveshaft or the multi-sectional rotary axle to one another may also be brought about by frictional interengagement with the aid of conically-shaped shaft and hub connections. The advantage of a frictional engagement resides, on the one hand, in that the sections can be interconnected in relation to one another infinitely variably, and, on the other hand, this kind of connection, in the event of an accidental collision when in use, acts as a kind of frictional clutch and protects the components against breakage.
In its most simple embodiment, a gripper mechanism according to the invention comprises on one side or both sides a movable gripping finger fitted to the multiple-section-designed driveshaft, crank shaft, tooth gear shaft, belt pulley shaft or chain pulley shaft, which, serving as a clamping device, operates in opposition to a fixed gripper or machine component. In the event that the gripper mechanism comprises a gripping finger fitted on one side to the driveshaft, at least the one neck bearing with or without axial bearing surface is provided on this gripping finger. The second neck bearing forms a free-wheeling simple swivel part serving as an end support bearing with axial intermeshing with or without axial bearing surface. Both neck bearings, finger bearings and end support bearings have a common axis and form the axis of rotation of the driveshaft.
In the event that the gripper mechanism has a gripping finger fitted to both sides of the driveshaft, both radial bearings with end-facing axial tooth intermeshing, with or without axial bearing surface, are accommodated as neck bearings in the two finger halves or in driven connecting bar members which drive the gripping finger.
The casing of a so designed gripper mechanism may be machined from the solid or be cast in one integral piece. It comprises two interconnected cavities for the accommodation of the actuating unit, such as e.g. a piston and piston rod for the pneumatic operation on the one hand, and for the accommodation of the driveshaft of a toothed shaft or of the entire transmission unit in the event of articulated linkage systems on the other hand. After fitting the actuating unit and the introduction of the transmission unit without neck bearings into the cavities provided therefor, the cavities are closed using appropriate covers and fastening elements or stoppers. Finally, the gripping fingers or the driven connecting bar components with the neck bearings provided thereon on both sides or on one side, with end support bearings on the other side are inserted into the bores of the casing from the outside and are fitted axially to the other section or other sections of the driveshaft in form-fitting or frictional engagement. At this stage finally the driveshaft and jointly therewith the transmission unit is completely mounted in its bearings. The transmission space is closed hermetically by means of a cover or a stopper. In the event of the gripping finger on one side only, a free-wheeling thrust bearing serving as an end support bearing forms the second bearing journal of the driveshaft. By the pitch of the axial tooth intermeshing or bores and pins of the neck bearings and the central section of the driveshaft it is possible to vary the positioning of the gripping fingers and that of the driven connecting bars in relation to the driving unit. In this manner, the opening and closing position of the gripping fingers becomes variable.
When using as axial bearings journal-type radial bearings with a bearing collar, the end face sides of the central section of the driveshaft are designed as axial bearings for a journal bearing support of the X-configuration. They find support against the bearing collar of the sliding bearing inserted into the casing from inside. In the case of the O-configuration of the axial journal bearing support of the driveshaft or of the rotary axle, the axial bearing surfaces thereof are located at the outwardly positioned end face sides of the bearing journals of the neck bearings and end support bearings on both sides. Where a finger is provided on one side only, the entire torque of the driveshaft is transmitted from one side onto the gripping finger. The end support bearing revolves torquelessly.
For applications where a relatively broad jaw is required, a second gripping finger half or connecting bar half in mirror-image relationship to the first one is fitted instead of the end support bearing to the internal sections of the driveshaft and is fixed outside of the gripper casing to the gripping finger by way of an intermediate member serving as a jaw mounting means, or by way of an articulation. Both finger or connecting bar members, jointly with the jaw mounting means or gripping finger on the one side and at the central section or components of the driveshaft or the rotary axle on the other side result in an integrated gripping finger or finger mechanism which resists bending and torsional deformation. In that case, the driveshaft is loaded symmetrically on both sides. Half of the torque is applied to each of the two sides.
For use in dusty environments and applications where protection against explosion is needed, flat axial seals are employed at the end of the neck bearings and end support bearings outside of the bearing areas, but below the gripping finger or the connecting bar and the head of the end support bearing.
In all cases the positions of the gripping fingers or of the driven connecting bars serving as driven members, in relation to the central section of the driveshaft serving as the driving member, may be varied as desired or required in respect of the end face intermeshing tooth pitch or the pitch of the pin bores in order to adapt the gripping range of individual gripping fingers to the particular application.
In the case of a gripper mechanism having two or more gripping fingers, a corresponding number of multiple-section drive shafts and/or rotary axles according to the invention are provided which are placed concentrically about the actuating unit and, with a single drive means, are necessarily operated synchronously.
A further advantageous embodiment of the invention provides gripper mechanisms, each comprising two driven drive shafts per moving gripping finger.
The gripper members, also referred to as connecting bars, connected on one side or both sides to the multiple-section drive shafts, together with the neck bearings, guide at their free ends the gripping finger as a coupler of an articulated linkage system. Whereas the first connecting bar connected to the first driveshaft is connected pivotally to the gripping finger, the second connecting bar connected to the second driveshaft is connected by way of a sliding linkage or by way of a smaller connecting bar, a binary member, pivotally to the gripping finger.
The sliding linkage may be provided in the gripping finger or in the connecting bar, connected to the driveshaft. It may adopt optional trajectory configurations in order to additionally swing the gripping finger during its movement within certain limits.
A thus designed gripper mechanism, comprising two synchronously driven shafts per gripping finger, guides the gripping finger as a coupling of a multiple-member articulated linkage system even through and beyond the extended and final position of the gripping finger together with the driven connecting bars, securely and unambiguously without tilting over or jamming. This allows a range of movement to be achieved which may go far beyond the conventional 90° swiveling per gripping finger.
Accordingly, the gripping fingers may thus, even in the case of parallel movement, swing backwardly out of the space ahead of the gripping body by more than 180° to render the space ahead of the gripper available for other purposes. In the case of parallel finger movement, where both connecting bars, guiding the gripping finger, are of equal length and parallel to one another, the sliding linkage guide may be dispensed with entirely. In that case the second connecting bar, driven by the second driveshaft, guides the gripping finger likewise by way of a simple hinge joint. If the linkage quadrangle, comprising the gripping finger, connecting member of the two drive shafts as well as both connecting bars driven by the drive shafts, is not required to move beyond its extended and final position, it is possible for one of the two drive shafts to be dispensed with and that one to be replaced by a co-revolving rotary axle.
BRIEF DESCRIPTION OF THE DRAWINGS
In detail there is shown in:
FIG. 1 the longitudinal section through the casing of the gripper mechanism according to the invention, comprising two pneumatically driven drive shafts of multiple-section design.
FIG. 2 the cross-section through a crank shaft in three sections serving as driveshaft of a gripping mechanism according to the invention with finger means provided on one side only.
FIG. 3 the longitudinal section through the casing of a gripper mechanism according to the invention, comprising a gear wheel or pinion shaft designed in at least two sections, serving as driveshaft and a tooth rack connected to a cylinder-piston-unit serving as a drive unit.
FIG. 4 the cross-section through a crank shaft in three sections serving as a driveshaft of a gripper mechanism according to the invention, comprising fingers arranged on both sides and a jaw mounting member designed as a connecting member between the two finger halves.
FIG. 5 the front elevation into the transmission cavity of a gripper mechanism according to the invention, comprising four drive shafts, each designed in three sections, for four gripping fingers provided on both sides.
FIG. 6 a longitudinal section through a gripper mechanism according to the invention, comprising for each gripping finger two crank shafts of multiple-section design serving as drive shafts.
FIG. 7 a longitudinal section through a gripper mechanism according to the invention, comprising for each gripping finger two gear wheel shafts of multiple-section design serving as drive shafts.
Identical components are denoted by identical reference numbers or identical reference letters. Indices denote different regions, different designs or multiple uses of one and the same element.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with FIG. 1 the gripper mechanism comprises a casing ( 1 ) having two coaxial cavities ( 2 a , 2 b ). In the cylindrical cavity ( 2 a ) a piston and piston rod unit ( 3 ) is accommodated as an actuating unit and is sealed in by the cover ( 11 a ). In the transmission cavity ( 2 b ) the transmission unit, comprising at least one slider-crank mechanism or at least one gear wheel and tooth rack unit or one worm and worm wheel unit is accommodated. The piston rod, by means of a slider ( 4 a ) and a coupler member ( 5 ), drives the central section of the driveshaft ( 6 ), composed of three sections, acting as a crank shaft. The torque is transmitted by the central section acting as crank of the driveshaft ( 6 ), by way of tooth intermeshing on the end face side brought about by bores and pins ( 8 ), onto the gripping finger ( 10 ). The central section of the driveshaft ( 6 ) on both sides has two plane surfaces comprising the bores for accommodating the pins ( 8 ) and can accordingly be inserted through the opening on one side of the gripper casing into the transmission cavity ( 2 b ). Portions of these plane surfaces may serve as axial bearings for the driveshaft ( 6 ). The transmission cavity ( 2 b ) may also be represented by a simple bore in which a toothed shaft serving as the driveshaft ( 6 ) is accommodated and is driven by a toothed piston rod.
According to FIG. 2 the driveshaft ( 6 ) comprises three sections ( 6 a , 6 b , 6 c ) and is supported by a journal bearing of the X-configuration. The central section of the driveshaft, the crank ( 6 a ), is provided on both sides with two surfaces ( 7 a , 7 b ) serving as axial bearing surfaces of the journal bearing support. In the center of these bearing surfaces, bores are provided on both sides which accommodate the neck bearing ( 6 b ) of the gripping finger and of the end support bearing ( 6 c ) by means of pins ( 8 ), to center it and by way of these pins or by means of other kinds of tooth-meshing transmit the torque of the driveshaft ( 6 ) to the gripping finger ( 10 ). The radial bearing of the driveshaft ( 6 ) in the gripper casing ( 1 ) is fitted on one side as a neck bearing ( 6 b ) to the gripping finger ( 10 ) and on the other side as a separate end support bearing ( 6 c ). This permits the pre assembled transmission, comprising the slider ( 4 a ), couplers ( 5 ) and cranks ( 6 a ) to be inserted through the front aperture in the gripper casing ( 1 ), to be connected to the piston rod of the actuating unit ( 3 ), followed by sealing of the cavity by means of the cover ( 11 b ). After the insertion of the gripping finger ( 10 ) with the axial sealing ring ( 9 ) and the neck bearing ( 6 b ) provided on the gripping finger ( 1 ) from the one side and the end support bearing ( 6 c ) with the axial sealing ring ( 9 ) from the other and their axial fixation by means of screws ( 12 a , 12 b ) through the hollow center, the driveshaft ( 6 ) including its bearing mountings is completely assembled. The journal bearing mounting of the driveshaft may also be brought about in an O-configuration. In that case, the axial bearing surfaces are provided on the neck of the gripping finger ( 10 ) and of the end support bearing ( 6 c ) outside of the casing within the axial sealing rings ( 9 ).
In accordance with FIG. 3 the gripping fingers ( 10 ) are each driven by a driveshaft ( 6 d ) provided in two or three sections, carrying tooth formations, forming a gear wheel shaft. At the end of the piston-piston rod unit ( 3 ) a tooth rack ( 4 b ) provided in the form of a slider which drives the driveshaft ( 6 d ) having tooth formations and by means thereof drives the gripping finger ( 10 ). The tooth rack ( 4 b ) and the toothed driveshaft ( 6 d ) may also be replaced by a worm and a worm wheel in order to impart a rotary actuation, e.g. by way of an electric motor. In this case as well the toothed driveshaft ( 6 d ) is mounted at both ends axially and radially in the gripper casing ( 1 ), the neck bearing ( 6 b ) being provided as a component of the gripping finger ( 10 ) on the latter and the end support bearing ( 6 c ) being provided separately on the opposite side of the gripping finger. Where the toothed driveshaft ( 6 d ) is designed in two sections, the toothed central section is provided either on the neck bearing ( 6 b ) or on the end support bearing ( 6 c ). The pitch of the toothed driveshaft may in the case of a spur toothing be brought about within the region of the tooth formations, such that the tooth intermeshing is composed of two halves which are axially connected to one another by pins or are otherwise fixed. Where the toothed driveshaft ( 6 d ) is divided in two, the neck bearing ( 6 b ) and/or the end support bearing ( 6 c ) is of larger diameter than the circular head diameter of the tooth formations. In that case, the transmission cavity ( 2 b ) is formed exclusively by bores for the tooth rack of the drive unit ( 3 ) as well as the drive shafts ( 6 ).
In accordance with FIG. 4 the gripping finger is composed of two halves ( 10 a , 10 b ) provided on opposite sides of the casing and interconnected in a releasable manner outside the range of the casing by means of the jaw mounting member ( 10 c ). Each gripping finger half ( 10 a , 10 b ) comprises a neck bearing ( 6 b ) of the driveshaft, crank or gear wheel shaft, an axial sealing ring ( 9 ) and, in the case of an O-configuration, also an axial bearing surface of the journal bearing support. The central section ( 6 a ) of the driveshaft forms jointly with the finger members ( 10 a , 10 b ) and the jaw mounting member ( 10 c ) a closed unit which resists bending and torsional deformation. The gripping finger halves ( 10 a , 10 b ) with the aid of their integrated neck bearings ( 6 b ) and their pins ( 8 ) or axial tooth formations support and center the central section ( 6 a ) of the driveshaft and form by means of its axial bearing surfaces ( 7 ) and the jaw mounting member ( 10 c ) a completely closed gripping finger which resists bending and torsional deformation and which in relation to its driveshaft, crank or gear wheel shaft is angularly adjustable within the range of pitching of the pins ( 8 ).
In accordance with FIG. 5 a plurality of gripping fingers ( 10 ) may be provided around the central actuating unit ( 3 ), all of these being driven with the aid of a single centrally located slider ( 4 c ) and a crank or gear wheel shaft pneumatically, hydraulically or by electric motor synchronously.
In accordance with FIG. 6 two drive shafts ( 6 ) composed of multiple sections, in this case designed as crank shafts, each actuate a connecting bar ( 10 d ) to the ends of which a gripping finger ( 14 a ) has been hinged. Whereas one of the connecting bars is connected to the gripping finger by a pivoting joint, the second connecting bar has a linkage pin by means of which it engages into a sliding linkage ( 13 a ) of the gripping finger ( 14 a ). This allows the connecting bars ( 10 d ) to be of different lengths or the cranks ( 6 a ) to perform different swiveling angles in order to lend to the gripping finger ( 14 a ) an additional rotation during the opening or closing procedure. The trajectory configuration of the sliding linkage ( 13 a ) as well may permit the gripping finger to perform additional movement, that is to say for each gripping finger a different movement if the handling task so requires. The sliding linkage ( 13 a ) may alternatively be provided on one of the two connecting bars ( 10 d ), in which case the gripping finger ( 14 a ) will merely comprise two pivoting joints. If the two connecting bars ( 10 d ) are parallel and of equal length, the sliding linkage on the gripping finger ( 14 a ) or on the connecting bar ( 10 d ) may be dispensed with. When dispensing with the sliding linkage ( 13 a ) the external drive of one of the two connecting bar ( 10 d ) may likewise be dispensed with, for as long as the thus resulting articulated quadrangle ( 1 , 10 d , 14 a , 10 d ) does not move into its final or extended position. The gripping finger ( 14 a ) driven by two connecting bars ( 10 d ) is able even in its extended or final position in relation to the connecting bars ( 10 d ) to move onwards unambiguously and securely and transmit forces and torque onto the gripped object while doing so.
The linear actuating unit ( 4 d ) may be driven pneumatically, hydraulically or electro-motorically. It drives the cranks ( 6 a ) of the drive shafts ( 6 ) by way of the coupler member ( 5 ) and may be divided into two separate drives in tandem or coaxial arrangement and coupled to one another by positive or non-positive or frictional interengagement in order to drive the two connecting bars ( 10 d ) partly jointly and partly separately from one another. The cover ( 11 c ) closes the transmission cavity hermetically so that the entire gripper mechanism is completely sealed.
According to FIG. 7 the linearly driven slider ( 4 e ) with its tooth rack ( 4 b ) imparts rotary movement to two drive shafts ( 6 d ) of multi-sectional and toothed design. The radial bearings of the toothed drive shafts ( 6 d ) are provided in the form of neck bearings ( 6 b ) on the connecting bars ( 10 d , 10 e ) and are connected angularly adjustable with the aid of bores and pins ( 8 ) to the toothed portion of the driveshaft. The connecting bar ( 10 d ) engages at its end the gripping finger ( 14 b ) by way of an articulation. The connecting bar ( 10 e ) is provided at its end with a sliding linkage ( 13 b ) into which the linkage pin of the gripping finger ( 14 b ) engages. The sliding linkage ( 13 b ) may be replaced by a binary member, comprising a small connecting bar with rotary linkage on both sides, not illustrated. Kinematically, this gripper mechanism performs in a similar manner to what has been described in FIG. 6 . Here as well the drive by the second driveshaft may be dispensed with under the same conditions as described with reference to FIG. 6 .
The actuation of the second driveshaft may also be performed by a toothed belt or a chain by way of the first driveshaft.
The features of the invention disclosed in the description, the drawings and the claims may individually as well as in optional combination be of importance for practicing the invention.
All disclosed features are important to the invention.
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A gripper mechanism for machines, robots and manipulation devices, comprising at least one moving gripping finger, driven by a driveshaft of multiple parts, a crank, belt or gear shaft, wherein the centering of the parts relative to each other and the transmission of the torque from a driving part to the next part, up to the gripping finger, is achieved by means of axial toothing, preferably a pinion gearing with pins and drillings. The driveshaft is preferably provided with a carrying support bearing. As a result of the splitting of the driveshaft, it is possible to cast the housing in one piece with two cavities for housing the operating unit and the transmission. The gripping finger or the lever driving the gripping finger are externally fixed to the driveshaft in an axial manner.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the U.S. national stage of PCT/EP2014/059535 filed May 9, 2014, which claims priority of German Patent Application 10 2013 104 866.8 filed May 11, 2013.
FIELD OF THE INVENTION
The invention relates to a container having a first element and at least a second element movable relative to the first element between a closed position and an open position, as well as a drive device for moving the second element. The container can be a piece of furniture, a household appliance, as for example a kitchen appliance or built-in kitchen appliance, or a vending machine.
BACKGROUND OF THE INVENTION
A piece of furniture of the above named type is known from WO 2008/141348 A2. The piece of furniture has a first element in form of a furniture shell and a second element in form of a movable flap. By means of the drive device, the flap can be automatically transferred into an open or a closed position. For actuating, i.e. switching-on the drive device, a switching element is provided. The switching element is arranged and formed such, that by a movement of the flap caused by a user, the drive device is actuated. In this case, the flap is arranged in its closed position such, that it covers the switching element and abuts the same. Because of a pressure loading onto the flap in direction towards the piece of furniture a pressure switch of the switching element is switched and the drive device is actuated. In this case, a sufficient large compression path has to be provided for the pressure switch and thus for the flap, which compression path has to be provided between the flap and the piece of furniture. This can, for example, be ensured by a spring buffer. It can be disadvantageous, that with each pressure application onto the flap the drive device is actuated and the flap is transferred into the open position, even when the flap was pushed accidentally. WO 2008/141348 A2 proposes alternatively to provide a position measuring device, by means of which also the velocity and acceleration of the movement of the flap can be calculated. This allows, that driving of the flap by means of the drive device is carried out in dependency of the determined sizes of the flap. In this case, also a corresponding pushing path has to be provided via spring buffers. A further alternative, which is proposed in WO 2008/141348 A2, are capacitive switching elements, which operate free of contact.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a container of the above named type, in which it is possible to realise that for actuating the drive device, an as small as possible path, which preferably is not noticeable for the user, can be achieved for actuating an actuating device.
The object is met according to the invention by a container, which comprises a first element and at least one second element movable relative to the first element between a closed position and an open position as well as a drive device for moving the second element, wherein at least one deformation measuring unit is provided with a deformation sensor on one of the elements for detecting a force exerted on one of the elements, and wherein a control unit is provided for receiving and evaluating a deformation signal transmitted by the deformation measuring unit and for actuating the drive device.
A deformation sensor has several advantages compared to commonly used switching elements. The deformation sensor detects the deformation of a component and transmits it as a deformation signal, wherein the course of the deformation changes can be read. This means, that not a digital/binary signal is transmitted, as this is the case in a switching element, but makes an analog course of deformation or a deformation change available as deformation signal. The term “analog” does not mean, that the deformation signal cannot be scanned digitally and can be transmitted as a digital signal. It is, rather, meant, that not only two conditions of a measuring value, as this is the case in a switching signal (on/off), can be determined, but an analog signal or a digitally determined signal of a course of measuring values with an accuracy depending on the digital resolution.
This has the advantage, that assembly tolerances of the two element towards each other and the deformation measuring unit have no influence, when the drive device is actuated. Commonly used switching elements have a precise switching point, when reaching it or exceeding it, the switch is switched from one condition to another condition. Thus, it is clearly set, in which position of the switching element the drive device is actuated. The position of this switching point depends on the assembly tolerances. Especially then, when the drive device is actuated by a force exerted on an element of the container, i.e. the switching element is switched indirectly, e.g. via a flap of the container, the switching point is pre-set by the assembly tolerances. This is not the case, when using a deformation sensor. In this case, only an initial initialization has to take place, so that the control unit is taught such, that it knows at given assembly conditions the deformation signal, existing in the closed position, as a reference point and starting from this reference value can process relative deformation changes.
Preferably, the container is a piece of furniture or a household appliance, especially a fully integrated kitchen appliance. The first element can be a furniture shell and the second element can be an element held movable relative to the shell, especially a lid, a flap, a drawer or a door.
The deformation sensor is preferably a sensor for recording a relative deformation change, especially a piezo element with a piezo crystal or a strain gauge. Piezo elements and strain gauges have the advantage, that they enable deformation signals, which can already be evaluated during deformations, which are not noticed by a user.
The second element can be supported via the deformation measuring unit on the first element. The deformation measuring unit can, for example, be arranged on a first element in form of a shell of a piece of furniture, wherein the second element, for example in shape of a flap or a lid, is supported on the deformation measuring unit. The deformation measuring unit can be incorporated in a side wall of the shell such, that the deformation sensor projects slightly over the front edge of the side wall, so that the flap can come into abutment with the deformation sensor. In this case, the flap completely covers in the closed position the deformation measuring unit, so that it is not visible to the user. By of a force exerted from the outside onto the flap in direction towards the shell of the piece of furniture and, thus, towards the deformation sensor, the deformation signal thus produced is changed, whereby an actuation of the drive device can be triggered. Especially, when the deformation sensor is a piezo element with a piezo crystal, the necessary path or the necessary deformation is so small, that it is not noticed by a user, which leads to a pleasant haptical feeling during the actuation of the flap or of the drive device. Furthermore, such a deformation measuring unit can also be used in containers, in which sealing elements are provided between the shell of the piece of furniture and the flap or the first element and the second element, which only have to be deformed by a very small amount, to actuate the drive device.
The deformation measuring unit can have an accommodation element accommodating the deformation sensor, wherein the accommodation element is mounted in or on the first element. In this case, the second element is supported on the deformation sensor.
Furthermore, in the accommodation element an additional switch for actuating the drive device can be integrated. This can, especially, be of advantage, when the container is a wall unit with a flap moving upwards. By means of a pressure application onto the flap arranged in the closed position, the drive device can, as described above, be actuated, as the flap is supported via the deformation measuring unit on the shell. As soon as the flap is in the open position, a further device has to be provided, to move the flap again back into the closed position. This is achieved by a switch, which is preferably arranged in the accommodation element of the deformation measuring unit. Thus, no separate switching unit has to be provided. The present deformation measuring unit can be used, which then represents a single component with the deformation sensor and switches.
The deformation measuring unit can also be arranged on a component, especially a front of one of the elements. The deformation measuring unit does not have to be arranged between the two elements. The deformation can for example be detected by means of a strain gauge on a front of the second element. It is also possible, that the deformation measuring unit is arranged on the first element, for example on or in a shell, wherein even during a force loading on the second element, the deformation can be determined in the first element, insofar as the second element is supported on the first element. Thus, the deformation measuring unit can be arranged such, that it is not visible to a user.
Preferably, one of the elements, for example the second element, includes a first component and a second component, wherein the deformation measuring unit is arranged between the two components. Thus, a deformation or displacement of the two components relative to each other can be determined.
In this case, the first component of the second element can be represented in form of a front and the second component in the form of a support element, wherein the support element is, for example, a frame, which is displaceable within the first element and supports the front.
In a preferred embodiment the deformation sensor is formed like a plate and is arranged such, that it is bent during a force loading on the first component. Alternative, also a deformation sensor can be provided, which is stressed by compression.
In the preferred embodiment, the deformation measuring unit has an accommodation element accommodating the deformation sensor. The accommodation element is supported on the first component and on the second component.
In this case, the accommodation element can be formed with a pressure portion supporting the first component. The accommodation element has then preferably two support portions supporting the accommodation element on the second component. The deformation sensor is supported on a first side on the pressure portion and on a second side, facing away from the first side, on the support portions. Thus, during a displacement of the pressure portion relative to the two support portions, a deformation of the deformation sensor takes place.
As the deformation sensor records relative deformation changes, it can be provided, that the deformation sensor is held prestressed between the pressure portion and the support portions. Thus, always a deformation signal is provided, even when no deformation of the two components to each other or of one of the components has taken place. Thus, an existing play, which would lead to a measuring inaccuracy, is removed.
The pressure portion can have an attachment portion, wherein attachment projections of the second component are clamped between the attachment portion and the support portions. A deformation of the accommodation element is achieved during a force loading in the area between the two support portions, which can be detected by the deformation sensor.
Furthermore, the object is met by a method for actuating a drive device of a container according to the above type, wherein the course of the relative deformation change is evaluated by using of the deformation signal and by actuating the drive device when specific conditions are met. In this case, the deformation signal is evaluated such, that an unintended actuation of the drive device is prevented. Depending on the force loading, a specific course of the deformation signal is achieved, wherein by means of the course of the deformation signal it can be differentiated between different force loadings. The force loading onto the deformation measuring unit for example during a switching movement of a person can clearly be distinguished, from the course of the deformation signal during an unintended hitting or leaning against the second element.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments are described in detail in the following using the figures and herein it shows:
FIG. 1 a perspective representation of a cabinet having a shell and a lid in its closed position;
FIG. 2 a cabinet of FIG. 1 having a lid in its open position;
FIG. 3 a perspective representation of a deformation measuring unit of FIGS. 1 and 2 ;
FIG. 4 an internal view of the cabinet having the deformation measuring unit of FIG. 3 ;
FIG. 5 a second embodiment of a cabinet with a shell and a pullout/drawer;
FIG. 6 a perspective view of a deformation measuring unit for the application in a cabinet of FIG. 5 ;
FIG. 7 a cross-sectional view along the intersection line VII-VII of FIG. 6 and
FIG. 8 a cross-sectional view through a part of the pullout/drawer of the cabinet of FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 and 2 show a first embodiment of a container according to the invention, wherein the container is formed as a cabinet 1 and comprises a first element in form of a shell 2 and a second element in form of a lid 3 . The lid 3 is connected via a drive device 5 in form of a lid opener to the shell 2 and can be moved relative to the shell 2 from the closed position shown in FIG. 1 to the open position shown in FIG. 2 . The drive device 5 includes, in this case, an electric drive (e.g. an electric motor), which enables an automatic displacement of the lid 3 .
The shell 2 has a side wall 4 , into which a deformation measuring unit 6 is incorporated. The deformation measuring unit 6 is shown in detail in FIGS. 3 and 4 . FIG. 4 shows a partial cross-sectional view through the cabinet 1 of FIG. 1 with the lid 3 in its closed position. Furthermore, the deformation measuring unit 6 is shown schematically in a longitudinal sectional view.
The deformation measuring unit 6 includes an accommodation element in form of a housing 7 . The housing 7 is received in a recess 8 of the side wall 4 . The recess 8 starts from an end face 10 as well as from an inner face 14 of the side wall 4 . The end face 10 is facing the lid 3 , wherein the lid 3 covers the end face 10 in the closed position. The deformation measuring unit 6 comprises a sensing arm 9 , which is, in the present example, formed integrally with the housing 7 and is arranged deformably relative thereto. Preferably, the housing 7 is manufactured from plastic, so that the sensing arm 9 is connected via a film hinge 16 to the housing 7 and is elastically movable. In this case, the sensing arm 9 projects over a front face 13 of the housing 7 and over the end face 10 of the side wall 4 . The lid 3 is, as can be seen in FIG. 4 , supported in its closed position via the sensing arm 9 on the deformation measuring unit 6 and, thus, indirectly on the shell 2 .
In the inner of the housing 7 , a piezo element 11 is arranged, which is schematically shown in FIG. 4 . By means of a force loading on the sensing arm 9 in direction of the piezo element 11 , a force is thus acting on the piezo element 11 , which comprises a piezo crystal, so that a deformation signal is produced by the piezo element 11 . The deformation signal is transmitted to a control unit 12 , which is an integral component of the deformation measuring unit 6 or is provided as a separate unit, which is connected via a common data connection, for example a radio link or a cable connection, to the deformation measuring unit 6 . The control unit 12 is, furthermore, connected via common data connections to the drive device 5 , so that during a force loading on the lid 3 via the sensing arm 9 onto the piezo element 11 , an actuation of the drive device 5 is possible.
On the side of the deformation measuring unit 6 , which projects from the side wall 14 out of the recess 8 , a separate switch 15 is provided. The switch 15 can be actuated manually, so that when the lid 3 is open, the lid 3 can be transferred by means of the easy reachable switch 15 from its open position again into its closed position. For this the switch 15 is also connected to the control unit 12 via a data connection.
In FIGS. 5 to 8 , a second embodiment of a container according to the invention is shown in the form of a cabinet 30 , having a first element in form of a shell 31 and a second element in the form of a pullout/drawer 32 . In FIG. 5 the shell 31 is shown schematically by indication of the outer edges. The pullout 32 includes a front 33 ( FIG. 8 ) and a support element 34 . The support element 34 is arranged linearly displaceable within the shell 31 and is driven electrically by a drive device 35 , so that by actuating the drive device 35 the pullout 32 can be driven out and again back into the shell 31 . A solution may also be considered, in which the pullout is only expelled a bit from the shell 31 and the further movement is achieved by free-wheeling or manually. Several shelves 36 are arranged on the support element 34 for storing objects. Between the front 33 and the support element 34 , a deformation measuring unit 37 is provided, which actuates the drive device 35 .
The deformation measuring unit 37 is shown in detail in FIGS. 6 to 8 . The deformation measuring unit 37 comprises a deformation sensor 38 , formed plate-like. The deformation sensor 38 is not shown in FIG. 6 for clarity. The deformation measuring unit 37 includes further an accommodation element 39 , formed frame-like. The deformation sensor 38 is mounted on the accommodation element 39 . The accommodation element 39 has a fixing portion 40 with a circular through opening 41 . Towards one side, the through opening 41 has an annular fixing recess 42 , into which the deformation sensor 38 can be inserted. A pressure arm 56 with a central pressure projection 59 projects radially from the edge of the through opening 41 up to the center of the through opening 41 . The deformation sensor 38 is arranged between the pressure arm 56 and the fixing recess 42 or is held by the pressure arm 56 . The pressure arm is supported with a pressure projection 59 on the deformation sensor 38 , in the fixing recess 42 . Thus, the deformation sensor 38 is fixed on the accommodation element 39 .
The accommodation element 39 has further a pressure portion 43 , which is arranged centrally to a longitudinal axis L of the accommodation element 39 . The pressure portion 43 has an attachment portion 44 , which comprises two tabs 45 , 46 , projecting respectively from one side of the longitudinal axis L.
Two support portions 47 , 48 of the accommodation element 39 are provided on both sides of the longitudinal axis L.
For attaching the accommodation element 39 , the support element 34 has a vertically extending pillar 49 with an also vertically extending attachment groove 50 . The attachment groove 50 is facing the front 33 . The attachment groove 50 is flanked along its longitudinal extension direction at both sides by plate-like attachment projections 51 , 52 , which form together with the attachment groove 50 respectively an undercut. The accommodation element 39 is inserted with the attachment portion 44 into the attachment groove 50 such, that the tabs 45 , 46 engage behind the attachment projections 51 , 52 , wherein the tabs 45 , 46 are supported on the latter on the side of the attachment projections 51 , 52 facing the attachment groove 50 . The support portions 47 , 48 are supported on the side of the attachment projections 51 , 52 facing away from the tabs 45 , 46 on the pillar 49 . The accommodation element 39 is, in this case, preferably dimensioned such, that the attachment projections 51 , 52 are clamped with bias between the tabs 45 , 46 and the support portions 47 , 48 .
In this case, the accommodation element 39 is arranged between the pillar 49 of the support element 34 and the front 33 , so that a loading force is introduced in the force introduction direction P. The accommodation element 39 is deformed via the pressure portion 43 . The accommodation element 39 is supported on the front 33 , wherein this deformation is transferred to the deformation sensor 38 . During a deformation in force introduction direction P, the attachment portion 44 is pushed deeper into the attachment groove 50 , wherein the tabs 45 , 46 lift off the attachment projections 51 , 52 . To facilitate this deformation, the support portions 47 , 48 have support projections 53 , 53 ′, 54 , 54 ′, which project in direction towards the pillar 59 from the support portions 47 , 48 and by means of which the support portions 47 , 48 are supported on the pillar 49 . The support projections 53 , 53 ′, 54 , 54 ′ are formed burled and form thus points of rotation, around which the accommodation element 49 can pivot during deformation.
The attachment portion 44 comprises further a bore 55 , which is aligned with the attachment groove 50 and extends starting therefrom in direction to the front 33 . The attachment portion 44 can be rigidly screwed to the front 33 via the bore 55 or can be connected in any other way. Thus, also a force in opposition to the force introduction direction P can be achieved, wherein in this direction, the tabs 45 , 46 are supported on the attachment projections 51 , 52 and no deformation of the accommodation element 39 is produced. Thus, the deformation measuring unit 47 can also be used for pullouts 32 , which have a drawbar on the side of the front 33 facing away from the pillar 49 . The deformation measuring unit 47 behaves elastically, thus, when a force is produced in an opposite direction to the force introduction direction P and is rigid against the force introduction direction P.
The pressure arm 56 on the pressure portion 43 serves also for the better transmission of the deformations of the accommodation element 39 onto the plate-like deformation sensor 38 . The pressure arm 56 projects radially into the through opening 41 and is supported centrally on the deformation sensor 38 . Thus, a pressure force, which acts in the force introduction direction P onto the front, is transmitted centrally onto the deformation sensor 38 and ensures a sufficient deformation of the deformation sensor 38 also at low pressures.
The accommodation element 39 has a web 57 , on which end a control unit 58 is mounted. The control unit 58 receives via a common data connection the deformation signal of the deformation sensor 38 and processes this. Furthermore, the control unit 58 is connected to the drive device 35 via a data connection, like for example a cable connection or a radio link, to be able to actuate the drive device 35 .
REFERENCE NUMERALS LIST
1 cabinet
2 shell
3 lid
4 side wall
5 drive device
6 deformation measuring unit
7 housing
8 recess
9 sensing arm
10 front face
11 piezo element
12 control unit
13 end face
14 inner face
15 switch
16 film hinge
30 cabinet
31 shell
32 pullout/drawer
33 front
34 support element
35 drive device
36 shelf
37 deformation measuring unit
38 deformation sensor
39 accommodation element
40 fixing portion
41 through opening
42 fixing recess
43 pressure portion
44 attachment portion
45 tab
46 tab
47 support portion
48 support portion
49 pillar
50 attachment groove
51 attachment projection
52 attachment projection
53 support projection
54 support projection
55 bore
56 pressure arm
57 web
58 control unit
59 pressure projection
L longitudinal axis
P direction of the force introduction
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Container comprising
a first element 2 and at least a second element 3 movable relative to the first element 2 between a closed position and an open position, and a drive device 5 for moving the second element 3, wherein at least one deformation measuring unit 6 is provided with a deformation sensor 11 on at least one of the elements 2, 3 for detecting a force exerted on one of the elements 2, 3 and wherein a control unit 12 is provided for receiving and evaluating a deformation signal transmitted by the deformation measuring unit 6 and is provided for actuating the drive device 5.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an error correcting and detecting decoder and, more particularly, to an error correcting and detecting decoder that performs predetermined processes on digital data read from a recording medium in accordance with an error correction code and error detection code included in digital data.
2. Description of the Related Art
In compact disc read only memory (CD-ROM) systems, a digital audio compact disc (CD) is used as a read only memory (ROM) for digital data. To improve the reliability of digital data read from a CD, error correction is performed on the digital data twice. The first error correction is executed by a digital signal processor which is common to both an audio system and a CD-ROM system, and the second error correction is executed by a CD-ROM decoder of the CD-ROM system.
FIG. 1 is a block diagram of a CD-ROM system. The CD-ROM system includes a pickup 1, a pickup controller 3, an analog signal processor 4, a digital signal processor 5, a CD-ROM decoder 6, a buffer random access memory (RAM) 7 and a control microcomputer 8.
The pickup 1 irradiates light on a disk 2 to generate a voltage signal proportional to the intensity of the reflected light. The pickup controller 3 controls the read position of the pickup 1 with respect to the disk 2 so that the pickup 1 reads data from the disk 2 in the correct order. Servo control to turn the disk 2 at a predetermined velocity is performed in accordance with the position control of the pickup 1. The servo control keeps the linear velocity of tracks on the disk 2 constant.
The analog signal processor 4 receives the voltage signal from the pickup 1 and generates one frame of an Eight to Fourteen Modulation (EFM) data signal consisting of 588 bits. As shown in FIG. 2, EFM data includes a 24-bit sync signal assigned to the beginning of each frame, 3-bit connection bit fields and 14-bit data bit fields which are alternately provided in each frame after the sync signal.
The digital signal processor 5 receives the EFM signal from the analog signal processor 4 and performs EFM demodulation on the signal for conversion to 8 bits from 14 bits. In this EFM demodulation, 8-bit subcode data is produced from the first data bit field following the sync signal, and 32-byte symbol data is produced from the remaining thirty-two pieces of data bit fields. Further, the 32-byte symbol data is subjected to Cross-Interleave Reed-Solomon Code (CIRC) demodulation to yield one frame of CD-ROM data consisting of 24 bytes. The first error correcting process is completed with this CIRC demodulation.
The CD-ROM data is handled in a block by block manner, each block of data consisting of 2352 bytes (24 bytes×98 frames). As shown in FIG. 3, normally (in mode 1), one block of data includes a sync signal (12 bytes), a header (4 bytes), user data (2048 bytes), an error detection code (EDC) (4 bytes) and an error correction code (ECC) (276 bytes). In one block of data, 2340 bytes of data excluding the 12-byte sync signal has previously undergone a scrambling process and is reproduced by a descrambling process.
The CD-ROM decoder 6 receives the CD-ROM data from the digital signal processor 5 and performs error correction in accordance with the ECC and error detection in accordance with the EDC to provide the processed CD-ROM data to a host computer. Normally, therefore, after an error in data is corrected in accordance with the ECC, it is checked in accordance with the EDC to determine if the error was properly corrected. When the error has not been corrected properly, error correction is carried out again in accordance with the ECC, or an error flag is affixed to the CD-ROM data containing the error code.
The buffer RAM 7 is connected to the CD-ROM decoder 6 and temporarily stores CD-ROM data in a block by block manner. Since the ECC and EDC are included in one block of CD-ROM data, the CD-ROM decoder 6 requires at least one block of CD-ROM data. Therefore, the buffer RAM 7 stores one block of CD-ROM data for the CD-ROM decoder 6.
The control microcomputer 8 can be a one-chip microcomputer that incorporates an internal ROM and an internal RAM. The control microcomputer 8 controls the operation of the CD-ROM decoder 6 in accordance with a control program stored in the ROM. At the same time, the control microcomputer 8 receives command data from the host computer and subcode data from the digital signal processor 5 and temporarily stores those data in the internal RAM. The control microcomputer 8 controls the operations of the individual circuits in accordance with the command data (i.e., commands from the host computer) so that the host computer can receive the desired CD-ROM data from the CD-ROM decoder 6.
The CD-ROM decoder 6 performs the reception of the CD-ROM data from the digital signal processor 5 and the sending of the CD-ROM data to the host computer in parallel. In accordance with the input and output of data, writing and reading the CD-ROM data into and from the buffer RAM 7 are repeated. Normally, the CD-ROM decoder 6, in a time-sharing manner, accesses the buffer RAM 7 in a unit of byte or a unit of code for each input or output.
In general, the CD-ROM decoder 6 is configured such that error correction and detection for one block of CD-ROM data is completed within a predetermined period (hereinafter called "one block period") in accordance with a reference system clock. If a predetermined process cannot be accomplished within one block period for some reason, CD-ROM data is consecutively written in the buffer RAM 7. As a result, unprocessed CD-ROM data remains in the buffer RAM 7. As such a state continues, the buffer RAM 7 overflows. This overflow forces the CD-ROM decoder 6 to temporarily interrupt the reception of CD-ROM data.
For fast reproduction like ×2 reproduction, the CD-ROM system increases the playback speed of the disk 2 without changing the frequency of the reference system clock that is supplied to each circuit. The increased playback speed decreases the number of clock cycles supplied in one block period. In other words, the duration of one block period for error correction and detection is shortened and becomes insufficient. The reduction in the number of clock cycles makes it difficult to complete a predetermined process in one block period.
For fast transfer of CD-ROM data to the host computer, the frequency of data reading from the buffer RAM 7 can be increased. However, when such fast transfer is provided, the time available for reading and writing CD-ROM data from and into the buffer RAM 7 decreases. As a result, the error correction and detection is often delayed, thus making it difficult to accomplish a predetermined process in one block period.
The above-mentioned problems also arise in a digital video disc read only memory (DVD-ROM) system which uses a DVD or a high-density recording medium as a ROM. A DVD has approximately seven times the recording capacity of a CD. Therefore, there is a greater demand for a faster playback speed in a DVD-ROM system than for a CD-ROM system.
Therefore, there is a need to improve not only the data transfer speed but also the speed of the decode process performed by an error correction/detecting decoder.
SUMMARY OF THE INVENTION
The present invention relates to an error correcting and detecting decoder that executes a decode process at high speed. The present invention can be implemented in numerous ways including as an apparatus, a system and a method.
As an error correcting and detecting apparatus for receiving digital data including an error correction code and an error detection code and performing error correction and error detection on the digital data in accordance with the error correction code and error detection code, one embodiment of the invention includes: an input interface for receiving the digital data from a recording medium and writing the digital data into a memory device; an error correction decoder for receiving the digital data from the memory device and performing error correction on the digital data in accordance with the error correction code; an error detection decoder for receiving the digital data from the memory device and performing error detection on the digital data in accordance with the error detection code; and an output interface for reading digital data from the memory device and outputting the read digital data, the read digital data having undergone the error correction and error detection. The error correction by the error correction decoder and the error detection by the error detection decoder are performed in parallel.
As a computer system, an embodiment of the invention includes: a disk recording medium; a disk read circuit that reads digital data from the disk recording medium; an error correcting apparatus that corrects errors in the digital data read from the disk recording medium by the disk read circuit. The error correcting apparatus includes: an input interface for receiving the digital data from the disk read circuit and writing the digital data into a memory device; an error correction decoder for receiving the digital data from the memory device and performing error correction on the digital data in accordance with the error correction code; an error detection decoder for receiving the digital data from the memory device and performing error detection on the digital data in accordance with the error detection code; and an output interface for reading digital data from the memory device and outputting the read digital data, the read digital data having undergone the error correction and error detection. The error correction by the error correction decoder and the error detection by the error detection decoder are performed in parallel.
Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
FIG. 1 is a block diagram illustrating a conventional CD-ROM system;
FIG. 2 shows the format of data produced in each circuit of a CD-ROM system as CD-ROM data is produced from data read from a disk;
FIG. 3 shows the format of CD-ROM data produced by the CD-ROM system in FIG. 1;
FIG. 4 is a block diagram illustrating an error correcting and detecting decoder according to one embodiment of the invention;
FIG. 5 shows the exchange of CD-ROM data between the error correcting and detecting decoder and a buffer RAM as shown in FIG. 4;
FIG. 6 is a timing chart exemplifying the process of the error correcting and detecting decoder;
FIG. 7A illustrates access states in data writing, error correction, error detection and data reading according to the embodiment; and
FIG. 7B illustrates access states in data writing, error correction, error detection and data reading according to a prior art example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to an error correcting and detecting decoder that executes a decode process at high speed. An error correcting and detecting decoder according to one embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 4 is a block diagram illustrating a CD-ROM decoder 10 according to one embodiment of the invention. The CD-ROM decoder 10 includes a DSP interface circuit 11, an error correcting and detecting circuit 12, a host interface circuit 13 and a memory controller 14 all connected to a buffer RAM 20. The DSP interface circuit 11 includes an input interface 11a, a write controller 11b and a sync detector 11c.
The input interface 11a, provided for interface with a digital signal processor 30, receives CD-ROM data of a predetermined format which has undergone digital signal processing and supplies it to the write controller 11b. The CD-ROM data is handled in a block by block manner consisting of 98 frames (2352 bytes) as shown in FIG. 3. Data in each block excluding a sync signal is scrambled. The input interface 11a descrambles 2340-byte data in one block of CD-ROM data excluding the 12-byte sync signal and sends the CD-ROM data including the descrambled data to the write controller 11b.
The write controller 11b writes the CD-ROM data in the buffer RAM 20 at a predetermined address under the control of the memory controller 14. At this time, the write controller 11b operates so the CD-ROM data is stored in the buffer RAM 20 within a predetermined period (one block period) for processing one block.
The buffer RAM 20 stores CD-ROM data in a block by block manner. The buffer RAM 20 has sufficient capacity to store at least four blocks of CD-ROM data, namely one block of CD-ROM data for the DSP interface circuit 11, two blocks of CD-ROM data for the error correcting and detecting circuit 12, and one block of CD-ROM data for the host interface circuit 13.
The sync detector 11c acquires the sync signal from the CD-ROM data and produces a block sync signal indicating the head timing of each block. This block sync signal is supplied to the error correcting and detecting circuit 12 for the timing control for error correction and detection.
The error correcting and detecting circuit 12 includes an ECC decoder 12a, an EDC decoder 12b, an ECC controller 12c and an EDC controller 12d. The ECC decoder 12a reads one block of CD-ROM data from the buffer RAM 20 under the control of the memory controller 14 and performs error correction thereon in accordance with the error correction code (ECC). This error correction employs, for example, an interleave system using a Reed-Solomon code. In this system, an error contained in data is detected and the detected error is corrected. Then the CD-ROM data (as corrected) is written in the buffer RAM 20 so that erred data is replaced with error-corrected data.
The ECC decoder 12a receives the first block of CD-ROM data from the DSP interface circuit 11 and performs error correction of the first block of CD-ROM data. The first block of CD-ROM data is then stored in the buffer RAM 20. The ECC decoder 12a further receives the second block of CD-ROM data from the DSP interface circuit 11 after one block period. In other words, after error correction of the first block of CD-ROM data is completed in one block period, the second block of CD-ROM data is initially written in the buffer RAM 20.
The EDC decoder 12b receives one block of CD-ROM data from the buffer RAM 20 and performs error detection thereon in accordance with the error detection code (EDC). This error detection is carried out in accordance with a code, such as Cyclic Redundancy Code (CRC) which has a higher detection precision than the error detection by the ECC decoder 12a.
Specifically, the EDC decoder 12b receives the first block of CD-ROM data from the buffer RAM 20 and performs error detection. This error detection is performed one block period before the processing of the second block of CD-ROM data by the ECC decoder 12a. That is, after error correction of the first block of CD-ROM data is completed in one block period, the second block of CD-ROM data is written in the buffer RAM 20. Alternatively, the error detection is performed two block periods before the writing of the second block of CD-ROM data by the DSP interface circuit 11. In other words, after error correction and error detection of the first block of CD-ROM data are completed in two block periods, the second block of CD-ROM data is written in the buffer RAM 20.
The ECC controller 12c receives the block sync signal from the sync detector 11c and activates the ECC decoder 12a in accordance with the block sync signal. The EDC controller 12d also receives the block sync signal from the sync detector 11c and activates the EDC decoder 12b in accordance with the block sync signal.
When the sync signal representing the head of the second block of CD-ROM data is detected, the first block of CD-ROM data that directly precedes the second block of CD-ROM data has already been written in the buffer RAM 20. When the sync signal of the second block of CD-ROM data is detected, therefore, the ECC and EDC controllers 12c and 12d respectively control the ECC decoder 12a and the EDC decoder 12b so that the decoders 12a and 12b start the processing of the first block of CD-ROM data.
The ECC controller 12c and the EDC controller 12d designate read addresses in the buffer RAM 20 so that the first block of CD-ROM data for the ECC decoder 12a and the second block of CD-ROM data for the EDC decoder 12b are shifted from each other by one block. In other words, the ECC controller 12c and the EDC controller 12d designate read addresses in the buffer RAM 20 so that the first block of CD-ROM data for the ECC decoder 12a and the second block of CD-ROM data for the EDC decoder 12b do not overlap each other. Accordingly, the ECC decoder 12a and the EDC decoder 12b execute their processes in parallel at predetermined timings.
The host interface circuit 13 includes a read controller 13a and an output interface 13b. The read controller 13a reads the CD-ROM data, which has undergone a predetermined process by the error correcting and detecting circuit 12, from the buffer RAM 20 under the control of the memory controller 14. The read controller 13a supplies the CD-ROM data to the output interface 13b.
The output interface 13b serves as an interface with a host computer 40. The output interface 13b supplies CD-ROM data, read from the buffer RAM 20 via the memory controller 14 and the read controller 13a, to the host computer 40. The output interface 13b receives various control commands from the host computer 40 and supplies those commands to a control microcomputer 50. The CD-ROM decoder 10 may also be provided with a write circuit which receives various control commands from the host computer 40 and temporarily stores those commands in the buffer RAM 20.
The memory controller 14 is connected between the buffer RAM 20 and the DSP input interface 11, the error correcting and detecting circuit 12 and the host interface circuit 13. The memory controller 14 controls the exchange of CD-ROM data between the individual circuits 11, 12 and 13 and the buffer RAM 20 in a block by block manner. The DSP interface circuit 11, the error correcting and detecting circuit 12 and the host interface circuit 13 respectively handle different blocks of CD-ROM data. Specifically, the DSP interface circuit 11 writes one block of CD-ROM data in the buffer RAM 20. The error correcting and detecting circuit 12 reads and writes one block of CD-ROM data from and into the buffer RAM 20. The host interface circuit 13 reads one block of CD-ROM data from the buffer RAM 20. Therefore, the memory controller 14 is configured such that the individual circuits 11, 12 and 13 access the buffer RAM 20 so that different blocks of CD-ROM data are independently written into or read from the buffer RAM 20. This structure allows the individual circuits 11, 12 and 13 to concurrently access different blocks of CD-ROM data in the buffer RAM 20 in a block by block manner.
FIG. 5 shows the writing and reading of CD-ROM data into and from the buffer RAM 20 which are executed by the memory controller 14. FIG. 6 is a timing chart exemplifying the processes of the individual circuits 11, 12 and 13 in the CD-ROM decoder 10. In FIG. 5, consecutive (n-3)-th to n-th blocks of CD-ROM data B(n-3) to B(n) are stored in first to fourth areas 20a to 20d in the buffer RAM 20.
The CD-ROM data B(n) written in the first area 20a is the CD-ROM data that is currently supplied to the buffer RAM 20 from the DSP interface circuit 11. The CD-ROM data B(n-1) written in the second area 20b is the CD-ROM data that has been written in the buffer RAM 20 one block before the CD-ROM data B(n). The CD-ROM data B(n-2) written in the third area 20c is the CD-ROM data that has been written in the buffer RAM 20 one block before the CD-ROM data B(n-1) and has undergone error correction. The CD-ROM data B(n-3) written in the fourth area 20d is the CD-ROM data that has been written in the buffer RAM 20 one block before the CD-ROM data B(n-2) and has undergone error correction and error detection.
FIG. 6 is a timing chart exemplifying the processing by the CD-ROM decoder 10. For the error correction by the ECC decoder 12a, the reading and writing (rewriting) of the (n-1)-th block of CD-ROM data B(n-1) are executed in parallel to the writing of the CD-ROM data B(n). For the error detection by the EDC decoder 12b, the reading of the (n-2)-th block of CD-ROM data B(n-2) is executed in parallel to the writing of the CD-ROM data B(n). For data supply to the host interface circuit 13, the (n-3)-th block of CD-ROM data B(n-3) is read in response to an interrupt instruction from the host computer 40.
As described above, the memory controller 14 operates so that different blocks of CD-ROM data, shifted from one another by one block, are written into and read from the buffer RAM 20 in accordance with the operational statuses of the DSP interface circuit 11, the ECC decoder 12a, the EDC decoder 12b and the host interface circuit 13. That is, the memory controller 14 operates so that different blocks of CD-ROM data are read from the buffer RAM 20 in accordance with addresses designated by the ECC controller 12c and the EDC controller 12d. The ECC decoder 12a and the EDC decoder 12b can therefore perform their operations in parallel. This improves the processing speed of the error correcting and detecting circuit 12 without changing the frequency of the operational clock to each circuit.
Access to the buffer RAM 20 is time-divisionally executed with respect to individual blocks. As shown in FIG. 7A, for example, the writing of data from the DSP interface circuit 11 and the reading of data into the host interface circuit 13 are time-divisionally executed. The DSP interface circuit 11 accesses the buffer RAM 20 in synchronism with the input of the CD-ROM data. This access is therefore performed in an approximately constant cycle. By contrast, the host interface circuit 13 accesses the buffer RAM 20 in accordance with the processing status of the host computer 40 connected to the host interface circuit 13. This access is thus carried out irregularly. The memory controller 14 and the control microcomputer 50 monitor those accesses. In accordance with such monitoring, the memory controller 14 and the control microcomputer 50 assign an interval between the accesses as the period for accessing the buffer RAM 20 by the error correcting and detecting circuit 12.
According to this embodiment, when a transfer request from the host computer 40 and access to the buffer RAM 20 for error correction are not made, memory access for error detection, which is performed in parallel with the error correction, is executed. The duration of time in which there is no access to the buffer RAM 20 is reduced, thus improving the access efficiency of the buffer RAM 20.
The conventional CD-ROM decoder 6 shown in FIG. 1 consecutively performs the ECC decoding process and the EDC decoding process. As shown in FIG. 7B, therefore, there is a large free time to access the buffer RAM 7. When there is no transfer request for CD-ROM data from the host computer, no access is made to the buffer RAM 7 while the position of an error and the number of errors are computed in the error correcting process. This inevitably produces a time period in which no access is made to the buffer RAM 7 before and after the ECC/EDC process in the interval between accesses by the host computer.
According to the embodiment of the invention, the amount of CD-ROM data to be stored in the buffer RAM 20 is increased by one block as compared with the ECC/EDC process of the conventional CD-ROM decoder 6. As the buffer RAM according to the embodiment has a sufficient memory capacity to store more CD-ROM data than necessary while securing the operational margin, however, nothing undesirable or critical to data storage occurs.
It should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. Particularly, it should be understood that this invention may also be embodied in a data reading system which uses a recording medium like a CD. One example of such a system is a DVD (Digital Video Disc) system. Therefore, the present examples and embodiment are to be considered as illustrative and not restrictive and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalence of the appended claims.
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The present invention relates to an error correcting and detecting apparatus that executes a decode process at high speed. The error correcting and detecting apparatus receives digital data including an error correction code and an error detection code and performs error correction and error detection on the digital data. In one embodiment, the apparatus includes: an input interface for receiving the digital data from a recording medium and writing the digital data into a memory device; an error correction decoder for receiving the digital data from the memory device and performing error correction on the digital data in accordance with error correction codes; an error detection decoder for receiving the digital data from the memory device and performing error detection on the digital data in accordance with error detection codes; and an output interface for reading digital data from the memory device and outputting the read digital data, the read digital data having undergone the error correction and error detection. The error correction by the error correction decoder and the error detection by the error detection decoder are performed in parallel.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to secure processors and to secure software execution thereon, such as for example to secure processors capable of secure execution of application software.
[0003] 2. Related Art
[0004] In known computing systems, the availability of processing capability, such as provided by microprocessors and other processing devices, is no longer a significant limit when considering the value of the computing system. Availability of application software and multimedia content, or more precisely, authorization to use that application software and multimedia content, for execution by those processors (and for presentation by those processors) has become a substantial limit. One effect of this is that a substantial value to many computing systems is the application software and multimedia content that executes on the device or platform. Both application software and multimedia content have become more easily distributed, such as for example using a communication network or by distribution using inexpensive CD-ROM media, with the effect that protecting against unauthorized copying and distribution (sometimes called “software piracy”) has become an economically important concern. Accordingly, one problem in the known art is to assure that such application software and multimedia content, being valuable, are only used on processors when the right to do so has been authorized, such as for example when that right has been properly paid for, or the integrity of the content verified with respect to information from a trusted content publishing entity.
[0005] Another problem in the known art is that, while it is desired to provide application software and multimedia content with the property that such application software and multimedia content cannot be used on processors without authorization or alteration, it is not desirable to redesign or re-author the application software or multimedia content to provide this property. There is a sufficient set of application software and multimedia content available, and the value of that application software and multimedia content is sufficiently large, that the approach of altering that application software or that multimedia content would likely be expensive, unreliable, and unwieldy.
[0006] Accordingly, it would be advantageous to restrict application software and multimedia content to those processors for which that application software and multimedia content is authorized, without having to substantially alter the original application software or multimedia content.
SUMMARY OF THE INVENTION
[0007] The invention provides a secure processor, and a method and system for using that secure processor, capable of assuring that application software is executed securely, and capable of assuring that only authorized application software is executed and only authorized multimedia content is presented. Further, it is also important to ensure that the authorized content can be played only on the device on which rights or permission for the content have been purchased and can be verified. The secure processor includes two modes of operation, a monitored mode and a secure mode. The former executes application software transparently to that application software. The latter verifies that execution of the application software (and presentation of the multimedia content) is authorized, and performs any extraordinary services required by the application software. The secure processor appears hardware-identical, to the application software, to an ordinary processor, with the effect that application software written for ordinary processors can be executed on the secure processor without substantial change. The secure processor needs only a minimal degree of additional hardware over and above those portions that appear hardware-identical to an ordinary processor, with the effect that the secure processor can operate without substantial reduction in speed or other resources available to the application software. In one embodiment, a portion of the secure processor is substantially identical to a semiconductor die for an original ordinary processor (except for using different die size or manufacturing technology), with the effect that there is substantial assurance that the application software will execute identically on the secure processor as it would have on the original ordinary processor.
[0008] In one embodiment, the secure processor initiates execution at power-on in secure mode. In this initial operation phase, the secure processor executes secure code in secure mode. The secure code is maintained in a persistent memory internal to the secure processor chip and therefore trustable. The secure code loads additional source code from one or more trusted sources, verifying both the trustworthiness of the sources and the authenticity of the additional source code, with reference to security information also maintained in the persistent memory internal to the secure processor chip and therefore trustable. The security information might include, but is not necessarily limited to, encryption keys, secure hash values, or other data for verification of the trusted sources and authentication of the additional source code.
[0009] Once loaded, the additional secure code causes the secure processor to request application software from trusted sources, verifies that the secure processor has authorization to execute the requested application software, verifies that the application software has been correctly loaded, and checks the integrity of that application software. In the context of the invention, there is no particular requirement that either the persistent memory or the trusted source have the particular implementation described herein. For one example, not intended to be limiting in any way, either the persistent memory, or one or more of the trusted sources, might be replaced or supplemented with a hardware device coupled to the secure processor (such as by a user). In this example, the secure processor would verify the integrity of the coupling and verify the authenticity and correct operation of the hardware device before trusting any code loaded from that source.
[0010] The secure processor is able to exit secure mode and execute the application software that has been correctly loaded in monitored mode. Application software executes without substantial change in original code for that application software, with the effect that the application software sees a processor environment that is not substantially different from an ordinary processor. When the application software needs services the secure processor oversees, the application software generates an interrupt, causing the secure mode to be re-entered, the services to be delivered to the application software, and the secure mode to be exited, with the effect that the application software can continue to execute in monitored mode. For one example, not limiting in any way, the application software might request additional application software modules to be requested, loaded, and executed. Among other services, the secure processor might oversee I/O operations, which the application software might request using an API (application programming interface) provided to secure code executable by the secure processor.
[0011] The secure processor is also able to interrupt the application software using a timer, enter secure mode, perform any desired steps, and re-enter monitored mode. Where secure mode might be entered by more than one technique, the secure processor is able to determine by which technique secure mode is entered. The secure processor is also able to record accesses to external memory, with the effect of being able to verify correct execution by the application software. Among other features, the secure processor might have the capability of overseeing (that is, reviewing and confirming the propriety of) I/O operations, or the secure processor might have the capability of performing (preferably, after reviewing and confirming the propriety of) secure operations at the request of application software.
[0012] For one example, not intended to be limiting in any way, the secure processor is able to examine those locations in external memory the application software attempts to access. If the application software attempts to access any locations outside a range of locations permitted by the secure processor, the secure processor might determine in response thereto that the application software is acting improperly. For example, not intended to be limiting in any way, in such cases the application software might have a software error, might include a software virus, or might be designed to be actively malicious. In response thereto, the secure processor might take appropriate action to limit any such improper effect. For example, again not intended to be limiting in any way, in such cases the secure processor might take action to limit access by the application software to those external memory locations, might take action to halt operation by the application software, or might take action to perform a software virus check or software virus clean-up of the application software.
[0013] The secure processor is also able to perform encryption or decryption on behalf of application software, with the effect that the application software need not be aware that encryption or decryption, or other security features, are being performed with regard to its ordinary operations. For a first example, not intended to be limiting in any way, the application software might perform a check for authenticity on additional code or on multimedia content loaded from a server, from external mass storage, or from external memory, without having access to the unique ID or private keys for the secure processor, but still using the full power of the security features of the secure processor. For a second example, again not intended to be limiting in any way, the application software might encrypt or decrypt secure information it communicates with external entities, again without having access to the unique ID or encryption or decryption keys for the secure processor, but still using the full power of the security features of the secure processor.
[0014] In one embodiment, the secure processor includes a unique ID, and is capable of using that unique ID (and unique encryption or decryption keys associated with that unique ID) to uniquely identify the particular instance of the secure processor. In such embodiments, when performing encryption or decryption on behalf of application software, the secure processor uses the unique ID and unique encryption or decryption keys. For example, not intended to be limiting in any way, the secure processor might perform encryption or decryption on behalf of application software, and thus use the unique ID and unique encryption or decryption keys, when communicating with external entities. In one such example, the secure processor might perform communication with external entities to confirm, exchange, or obtain DRM (digital rights management) information.
[0015] The secure processor maintains the unique ID, code signatures or cryptographic hashes, and unique encryption or decryption keys, as well as any other information specific to the particular instance of the secure processor, in a non-volatile memory (such as for example an NVROM). The NVROM includes a non-bonded pin used during manufacture or configuration of the secure processor to record information specific to the particular instance of the secure processor, which is left non-bonded after manufacture or configuration, with the effect that the NVROM cannot be written a second time.
[0016] Having a unique ID (and unique encryption or decryption keys) provides systems including the secure processor with several advantages:
[0017] Use of the secure processor to communicate with servers is traceable, so that users making unauthorized attempts to download application software or multimedia content can be called to account.
[0018] Securely embedding the unique ID and unique encryption or decryption keys allows servers to trust the secure processor without having to verify or trust the portion of the secure processor, such as its secure boot code, which attempts to download application software or multimedia content. The server need only trust the manufacturer to securely embed the unique ID and unique encryption or decryption keys.
[0019] Systems including the secure processor are resistant to tampering by users attempting to intercept signals to and from the secure processor, or otherwise present in the system, because sensitive data communicated with the secure processor can be encrypted for security. Attempting to compromise sensitive data would otherwise involve difficult deconstruction of the secure processor chip.
[0020] In the secure processor, the CPU that executes application software or presents multimedia content is substantially identical to an original non-secure processor, so attempts to disable the security features of the secure processor would also disable desired functionality of that CPU.
[0021] The secure processor can securely verify rights by the CPU to execute application software or to present multimedia content. For example, not intended to be limiting in any way, a trusted server (or other trusted entity, such as a certification authority) might issue a secure digital purchase receipt for which authenticity can be verified by the secure processor, such as using the unique ID and unique encryption or decryption keys. In such examples, the secure digital purchase receipt might uniquely identify the specific device (or class of device) having the right to execute application software or to present multimedia content.
[0022] The secure processor can enforce copy prevention and copy protection of application software and multimedia content. For example, not intended to be limiting in any way, such content might include (1) a set of purchased application software the CPU is permitted to execute, or purchased multimedia content the CPU is permitted to present, (2) digital rights to enable such execution or presentation, (3) information for use between the CPU and another device, such as for example a peer-to-peer message, intended to be limited to a specific device (or class of devices).
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] [0023]FIG. 1 shows a block diagram of a system including a secure processor capable of secure execution.
[0024] [0024]FIGS. 2 a and 2 b show a process flow diagram of a method of operating a secure processor capable of secure execution.
[0025] [0025]FIG. 3 shows a block diagram of a circuit including a device for programming a non-volatile memory in a substantially non-erasable way.
[0026] [0026]FIG. 4 shows a process flow diagram of a method of operating a circuit including a device for programming a non-volatile memory in a substantially non-erasable way.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] In the description herein, a preferred embodiment of the invention is described, including preferred process steps and data structures. Those skilled in the art would realize, after perusal of this application, that embodiments of the invention might be implemented using a variety of other techniques not specifically described, without undue experimentation or further invention, and that such other techniques would be within the scope and spirit of the invention.
[0028] Lexicography
[0029] The following terms relate or refer to aspects of the invention or its embodiments. The general meaning of each of these terms is intended to be illustrative and in no way limiting.
[0030] The phrase “secure processor” describes a device having the capability of assuring that only trusted software is executed on a subunit, the subunit including a “processor” or “processing unit,” (herein sometimes referred to as a “CPU”). Within the secure processor, the concept of a processor or processing unit is broad, and is intended to include at least the following: a general-purpose processor having a general instruction set, a special purpose processor having a limited instruction set, a set of special purpose circuitry capable of executing or interpreting program instructions, a set of firmware program instructions capable of emulating a secure processor of any type, any reasonable generalization thereof, and the like.
[0031] The phrase “application software” describes a set of instructions or parameters capable of being executed or interpreted by a processor. As noted herein, the concept of application software is broad, and is intended to include at least the following: software or firmware program instructions, software or firmware program parameter values, source code capable of being compiled by a programming language compiler or interpreted by a programming language interpreter, macro definitions for a compiled or interpreted programming language, commands or requests to be received and acted upon by an application program, any reasonable generalization thereof, and the like.
[0032] The phrase “multimedia content” describes a set of information or parameters capable of being presented to a user. As noted herein, the concept of multimedia content is broad, and is intended to include at least the following: animation, audiovisual movies, still pictures, or sound, whether embedded in data for interpretation and presentation by software or firmware program instructions; embedded in software or firmware program instructions for producing such data themselves; embedded in a markup language for multimedia content, such as DHTML, SGML, VRML, Macromedia Flash, and the like; commands or requests to be received and acted upon by an application program; any reasonable generalization thereof; and the like.
[0033] The phrases “monitored mode” and “secure mode” describe possible operational states of the secure processor. As noted herein, the concepts of monitored mode and secure mode are broad, and are intended to include at least the following: any distinguishable states in which instructions executed or interpreted by the secure processor have distinguishable degrees of access to capabilities of the processor, and in which the secure processor when in secure mode is capable of performing any type of monitoring or restriction of the secure processor when in monitored mode, and the like.
[0034] The concepts of transparent execution (of application software by the secure processor) and apparent hardware identity (of the secure processor to the application software) describe the capability of the secure processor to execute application software, in the view of that application software, as if that application software were executing on an ordinary processor. This has the effect that the secure processor can execute that application software without any need for modification of that application software, but is still capable of maintaining security features as described herein. For just one example, not limiting in any way, a portion of the secure might be substantially identical to a semiconductor die for an original ordinary processor, with the effect that there is substantial assurance that the application software will execute identically on the secure processor as it would have on an original ordinary processor.
[0035] The phrase “power on” describes an initial operation phase of a processing unit, whether occurring after an actual change in power supply, a reset signal, or any other substantial initialization in state for the secure processor. As noted herein, the concept of power-on is broad, and is intended to include any initial operational state described herein, as well as generalizations thereof.
[0036] The phrases “secure code” and “secure boot loader code” describe program instructions, interpretable or executable by the secure processor, and known to the secure processor to be trustable. Secure code might, for example, not limiting in any way, be known to be trustable by virtue of having been maintained in persistent memory in the secure processor chip. Starting from such trustable secure code, additional source code can be established as “secure code” by virtue of having been received from a trusted source and authenticated to be accurate by previously established “secure code” or “secure boot loader code”. As noted herein, the concept of secure code is broad, and is intended to include any program code for which the secure processor can trust that code, including for example, to perform security functions.
[0037] The phrases “security functions” and “security kernel software” describe program instructions, interpretable or executable by the secure processor, known to the secure processor to be verifiable, and capable of implementing functions relating to security, authentication, or verification. For example, not intended to be limiting in any way, functions including digital signatures, encryption and decryption, verification of digital signatures, and the like, might be implemented by security functions or security kernel software. In one embodiment, such security functions or security kernel software might be made available for use by application software using an API (application programming interface). In one embodiment, the security kernel software is loaded by the secure boot loader code and verified for integrity and/or authenticity before execution. That portion of software related to security, having been authenticated and maintained in (possibly volatile) memory within the secure processor chip, is included within the concept of “secure code”.
[0038] The phrase “secure processor chip” (herein sometimes referred to as the “chip”) describes the physical hardware on which the secure processor is implemented. As described herein, the secure processor chip includes hardware structure and program instructions, known to the secure processor to be trustable, and difficult for others to interfere with or to breach the security of.
[0039] The scope and spirit of the invention is not limited to any of these definitions, or to specific examples mentioned therein, but is intended to include the most general concepts embodied by these and other terms.
[0040] System Elements
[0041] [0041]FIG. 1 shows a block diagram of a system including a secure processor capable of secure execution.
[0042] A system 100 includes a secure processor 110 , a communication link 120 , and at least one software or content publisher 130 . Optionally, the software or content publisher 130 (herein sometimes called the trusted server 130 ) might include a trusted server capable of online or offline additional content delivery to the secure processor 110 or to devices controlled by the secure processor 110 .
[0043] In one embodiment, the system 100 also includes an application device 140 , including at least one input device 141 and at least one output device 142 , operating under control of application software 143 executed by the secure processor 110 .
[0044] The application device 140 might perform any application desired when the secure processor operates in monitored mode. For one example, not limiting in any way, the application device 140 might include a device for playing or participating in a real-time audiovisual game, such as might be installed in an arcade or at a personal computer. However, there is no particular requirement in the context of the invention that the application device 140 is so specific. Rather, the application device 140 may generally include a gaming device; a personal computer or personal workstation; any hand-carried device, such as a pager, a PDA (personal digital assistant) or other hand-held computer, a notebook or laptop computer, a telephone, a watch, a location or condition sensor, a biometric sensing or reporting device, a pacemaker, a telemetry device, or a remote homing device.
[0045] More generally, so long as the secure processor 110 is able to perform the functions described herein, the application device 140 may include any device following a computing paradigm.
[0046] For additional delivery of authentic applications or content to the chip, the communication link 120 might include a communication path from the trusted server 130 to the secure processor 110 . For example, not intended to be limiting in any way, the communication link 120 might include a communication path using the Internet or a portion thereof, either in real time, or using one or more store and forward devices, or using one or more intermediate caching devices, or physical delivery through storage media. However, in alternative embodiments, the communication link 120 may include a communication path to a private or public switched telephone network, a leased line or other private communication link, a radio transceiver, a microwave transceiver, a wireless or wireline modem, or any other device or system capable of communication with the trusted server 130 on behalf of the secure processor 110 . More generally, the communication link 120 might include any conceivable technique for delivery of content, such as for example storage media (such as a CD-ROM) physically shipped and delivered from the trusted server 130 .
[0047] The trusted server 130 includes a content publishing, delivery, or serving entity, such as for example as part of an electronic distribution system. In one embodiment, the trusted server 130 is (optionally) capable of generating a digital signature for any content it distributes, such as for example application software or multimedia content, with the effect that the secure processor 110 is capable of verifying the authenticity of that content. In one embodiment, that digital signature might be generated using a digital signature technique used with a public key cryptosystem, a system of a like nature, or another type of system capable of generating information from which the content can be verified for authenticity.
[0048] In alternative embodiments, the trusted server 130 may include a logically remote device capable of receiving messages including requests for information, and generating messages including responses to those requests for information. For example, not intended to be limiting in any way, the trusted server 130 might include an internet server including a high-end PC or workstation. Although in one embodiment the trusted server 130 includes a stand-alone server, there is no particular requirement in the context of the invention that the trusted server 130 is so specific. Rather, the trusted server 130 may generally include any device capable of acting as described herein, and may include either hardware components or software components or both. Moreover, there is no particular requirement in the context of the invention that the trusted server 130 includes any particular combination of components, or even that the trusted server 130 is a single device or even that it includes the whole of any particular device. Rather, the trusted server 130 may generally include one or more portions of another device, and may generally include more than one device (or portions thereof) operating in conjunction or cooperation. More generally, as described above, the trusted server 130 might include any conceivable device for creation or encapsulation of content for delivery, such as for example a device for writing storage media (such as a CD-ROM) to be physically shipped and delivered to the secure processor 110 .
[0049] As noted above, more generally, the trusted server 130 might include any conceivable technique for delivery of content. In the context of the invention, there is no particular requirement for any actual online content delivery, or even for any live or real-time link between the secure processor 110 and the trusted server 130 . For one example, not intended to be limiting in any way, application software or multimedia content might be delivered from the trusted server 130 to the secure processor 110 by any of the following techniques, or some combination or conjunction thereof:
[0050] The application software or multimedia content might be delivered using an interactive or switched communication system.
[0051] The application software or multimedia content might be delivered using physical storage media.
[0052] The application software or multimedia content might be delivered, by any technique, from a third party, in an encoded or encrypted form, and a key for decoding or decryption might be delivered, by any technique, from the trusted server 130 .
[0053] The application software or multimedia content might be delivered, by any technique, from a third party, and a certificate or other guarantee of authenticity might be delivered, by any technique, from the trusted server 130 .
[0054] The application software or multimedia content might be delivered, by any technique, using intermediate storage devices or other types of caching devices, using the Internet or any other distribution technique.
[0055] The secure processor 110 includes a monitored processor 111 , a set of security logic 112 , and a set of security information 113 . The secure processor 110 can operate in either a monitored mode or a secure mode. When operating in the monitored mode, the secure processor 110 uses circuitry including the monitored processor 111 . When operating in the secure mode, the secure processor 110 uses circuitry including the monitored processor 111 and the security logic 112 , and also uses data including the security information 113 .
[0056] 1. Monitored Processor
[0057] The monitored processor 111 includes an internal bus 114 , a CPU A 100 , a CPU memory interface A 103 , a mass storage interface A 135 , a memory interface A 140 , a set of application-specific circuitry A 145 , a mass storage device A 150 , a set of RAM A 155 .
[0058] The internal bus 114 is capable of communicating signals, including requests for data and responses including data, among portions of the monitored processor 111 . The internal bus 114 is coupled to the CPU memory interface A 103 , the mass storage interface A 135 , the memory interface A 140 , the application-specific circuitry A 145 , and the mass storage device A 150 .
[0059] The CPU A 100 might include any general-purpose processor or special purpose processor capable of carrying out the functions described herein. For example, the CPU A 100 might include a general-purpose processor such as those made by AMD or Intel, or a special purpose processor such as a DSP or an embedded micro-controller.
[0060] The CPU memory interface A 103 is coupled to the CPU A 100 . The CPU memory interface A 103 receives memory access requests from the CPU A 100 and records accesses by the CPU A 100 to RAM A 155 . Although in one embodiment the CPU memory interface A 103 records all such accesses, in alternative embodiments the CPU memory interface A 103 may choose to record only some of such accesses, such as only those accesses specified in a selected set of memory locations specified by the security logic 112 or the security information 113 .
[0061] The mass storage interface A 135 performs appropriate interface functions with the mass storage device A 150 . The mass storage device A 150 might include a hard disk, floppy disk, tape, or other types of mass storage.
[0062] The memory interface A 140 performs appropriate interface functions with the external memory (that is, the RAM A 155 ). The RAM A 155 includes all forms of random access memory, whether writable or not, and if writable, whether writable more than once or only once.
[0063] The application-specific circuitry A 145 performs any other functions specific to the particular monitored processor 111 , not already performed by the CPU A 100 . The CPU A 100 and the application-specific circuitry A 145 might perform selected functions in conjunction or cooperation.
[0064] 2. Security Logic
[0065] The security logic 112 includes a secure mode switch circuit A 105 , a secure timer circuit A 110 , a set of secure boot code A 115 , an access control circuit A 133 , a secure mode active signal A 160 , a set of access control signals A 163 , a NMI (non-maskable interrupt) signal A 165 , and a port A 171 for receiving an external reset signal A 170 . In addition, a set of secure code A 120 that assists with security functions might be maintained in mass storage A 150 .
[0066] The secure processor 110 is capable of responding to the external reset signal A 170 . In response to the reset signal A 170 , the CPU A 100 transfers control to (that is, begins execution of instructions at a new location) a pre-selected reset location in the secure boot code A 115 . Neither the pre-selected reset location nor the secure boot code A 115 is alterable by the CPU A 100 or any application software.
[0067] In response to the reset signal A 170 , the secure mode switch circuit A 105 generates the secure mode active signal A 160 , which sets up access rights so that the CPU A 100 is allowed to access the secure boot code A 115 , execute its instructions, and read and write data using the security information 113 . On reset, the secure processor 110 transfers control to the reset location and executes the secure boot code A 115 , and (the secure mode active signal A 160 being logical TRUE) allows the CPU A 100 to access restricted secure portions of the chip. In one embodiment, the secure boot code A 115 is maintained in a separate non-volatile memory A 115 , and neither its location nor its contents are alterable by any application software.
[0068] The secure boot code A 115 locates and loads any additional software and security functions included in the secure kernel code A 120 from external mass store A 150 and into internal RAM A 120 , after performing any necessary security checks.
[0069] After locating and loading any additional secure code A 120 , the CPU A 100 transfers control to, and begins execution of, that secure code A 120 . The secure code A 120 causes the CPU A 100 to prepare to authenticate and execute the application code 143 . Once the preparation to execute the application code 143 is complete, the secure code A 120 causes the secure processor 110 to exit secure mode.
[0070] The secure processor 110 is also capable of responding to an NMI signal A 165 . The NMI signal A 165 might for example be generated by application code 143 (such as for example by a program instruction executable by the CPU A 100 ) to request a service to be performed in secure mode. An example of such a service might be to perform a secure function or another function that only the secure code A 120 has authority to perform. To request such a service, the application code 143 sets selected bits in the security logic 112 . The secure mode logic sets the secure mode active signal A 160 to be logical TRUE, which enables the CPU A 100 to have access to secure parts of the secure processor 110 . Simultaneously the security logic 112 sends the NMI signal A 165 to the CPU A 100 , causing the CPU A 100 to transfer control to the secure boot code A 115 internal to the chip. The secure boot code 115 performs services for the application, renders the results to some shared memory locations in RAM A 155 , and exits to the monitored mode using the security logic 112 . The pre-selected NMI handler location, the secure boot code A 120 , and the technique by which the security kernel software is loaded and authenticated, are not alterable by the CPU A 100 or by any application software.
[0071] As described herein, the secure kernel code A 120 is maintained in internal memory (either non-volatile memory, or in a volatile memory, in which case it is loaded from external storage and authenticated). The secure mode switch circuit A 105 generates the secure mode active signal A 160 , which enables the CPU A 100 to access the non-volatile memory C 100 including the secure boot code A 115 , so that the CPU A 100 can execute its instructions, and read and write data using the security information 113 .
[0072] The secure timer circuit A 110 is capable of generating a timer interrupt signal for the CPU A 100 , in response to parameters set by the secure mode switch circuit A 105 . The security logic 112 can also generate an NMI signal A 165 to the CPU A 100 in response to a timeout from a secure timer. In response, the CPU A 100 transfers control to a pre-selected timer interrupt handler location in the secure kernel code A 120 . Neither the pre-selected timer interrupt location nor the secure kernel code A 120 is alterable by the CPU A 100 or any application software (or any other software maintained in the external storage A 150 ).
[0073] In response to the timer interrupt signal A 165 , and similar to other methods of entering secure mode, the secure processor 110 sets the secure mode active signal A 160 to be logical TRUE, with the effect of enabling access to secure portions of the secure chip.
[0074] The access control circuit A 133 controls access to elements of the secure processor 110 in response to the secure mode active signal A 160 , by generating the access control signals A 163 , which are coupled to each element of the secure process 110 for which access control is performed. When the secure mode active signal A 160 indicates that the secure processor 110 is in a secure mode, the access control circuit A 133 allows the CPU A 100 to access all elements of the secure processor 110 . When the secure mode active signal A 160 indicates that the secure processor 110 is in a monitored mode, the access control circuit A 133 allows the CPU A 100 to only access backward-compatible monitored-mode portions of the secure processor 110 . In a preferred embodiment, these backward-compatible monitored-mode portions exclude the security logic 112 (except for indicating entry into secure mode) and the security data 113 .
[0075] More specifically, when the secure mode active signal A 160 indicates that the secure processor 110 is in a monitored mode, the access control circuit A 133 prevents the CPU A 100 from accessing the secure mode switch circuit A 105 (except for indicating entry into secure mode), the secure timer circuit A 110 , the secure boot code A 115 , the secure kernel code A 120 , the access control circuit A 133 itself, the secure mode active signal A 160 , the access control signals A 163 , the read-only secure data A 125 , the R/W volatile secure state value A 130 , the encryption/decryption keys B 101 , and the licensing information B 102 .
[0076] 3. Security Information
[0077] The security information 113 includes a set of read-only secure data A 125 , a R/W volatile secure state value A 130 , a set of private (such as from a public key cryptosystem), a set of encryption/decryption keys, a set of optional unique IDs and a set of signature information B 101 .
[0078] The read-only secure data A 125 includes a set of secure code, as described herein, such as code available to be executed by the CPU A 100 in response to the reset signal A 170 , optionally in response to the NMI signal A 165 , in response to the timer interrupt signal A 165 , or otherwise when the secure mode is entered.
[0079] In one embodiment, the read-only secure data A 125 includes a set of one or more private keys, and a set of encryption/decryption keys B 101 , preferably unique to the individual secure processor 110 . In such embodiments, the secure processor 110 uses the encryption/decryption keys B 101 for decrypting messages from trusted sources using a public-key cryptosystem (such as for example by using a private key of a private/public key pair in a public-key cryptosystem). Alternatively, the secure processor 110 might have another set of code signatures B 103 , differing from the encryption/decryption keys B 101 , with which to authenticate trusted sources using other techniques for authentication. Similarly, in such embodiments, the secure processor 110 uses the code signatures B 101 for verifying the accuracy of additional secure code to be loaded into memory, such as by noting the correctness of a digital signature or secure hash associated with that additional secure code when received from authenticated trusted sources.
[0080] In one embodiment, the read-only secure data A 125 also includes a set of key information B 102 , by which the individual secure processor 110 is able to authenticate sources and verify that the individual secure processor 110 has the right to receive and perform relevant application software. For example, the licensing information B 102 might include a signed certificate from a trusted authority, indicating that the individual secure processor 110 is licensed to perform the relevant application software. In such embodiments, in response to the licensing information B 102 , the authenticated trusted sources provide the relevant capabilities for the secure processor 110 to load and execute application software. In one embodiment, these capabilities include either the application software itself, or a DRM (digital rights management) certificate authorizing the secure processor 110 to load and execute the application software.
[0081] The R/W volatile secure state value A 130 includes any read/write volatile memory the secure processor 110 needs to execute the secure code. In one embodiment, the secure processor 110 maintains all of its volatile state in the R/W volatile secure state value A 130 , with the effect that application code cannot access any of the state information used by the secure code. The secure processor 110 also includes, in the secure kernel code A 120 , instructions performable by the CPU A 100 to make relevant authentication and validity checks for any software to be executed by the CPU A 100 . Maintaining all of the volatile state for the secure processor 110 in the R/W volatile secure state value A 130 also has the effect of increasing the work factor for users to attempt to read that state and violate the security of secure mode operation for the secure processor 110 . However, in alternative embodiments, the secure processor 110 may maintain at least some of its volatile state in ordinary memory, with the effect that it may be possible for application code to access some of the values associated with that state.
[0082] Method of Operation
[0083] [0083]FIG. 2 shows a process flow diagram of a method of operating a secure processor capable of secure execution.
[0084] A method 200 is performed by the system 100 . Although the method 200 is described serially, the flow points and steps of the method 200 can be performed by separate elements in conjunction or in parallel, whether asynchronously or synchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 200 must be performed in the same order in which this description lists flow points or steps, except where explicitly so indicated.
[0085] 1. Power On
[0086] At a flow point 210 , the secure processor 110 is ready for power on.
[0087] At a step 211 , the secure processor 110 is powered on.
[0088] At a step 212 , the reset signal A 170 is asserted, with the effect of indicating that the secure processor 110 has just been reset. When the secure processor 110 is reset, the secure mode active signal A 160 is asserted (that is, set to logical TRUE) and the CPU A 100 jumps to (that is, transfers execution control to) the secure boot code A 115 .
[0089] At a step 213 , the secure mode switch circuit A 105 asserts the secure mode active signal A 160 , which indicates to the non-volatile memory C 100 (FIG. 3) that the CPU A 100 is allowed to access the secure boot code A 115 , execute its instructions, and read and write data using the security information 113 . The CPU A 100 then transfers control to a pre-selected reset location in the secure boot code A 115 .
[0090] At a step 214 , the CPU A 100 executes instructions from the secure boot code A 115 .
[0091] At a step 215 , the CPU A 100 executes the secure boot code A 115 .
[0092] In one embodiment, the following illustrative implementation on a MIPS or MIPS compatible processor results in the entry into secure mode upon reset. This illustrative implementation begins at a flow point 250 , and includes actions that would be included in the step 214 and the step 215 .
[0093] At a step 251 , the reset signal causes a request to enter secure mode.
[0094] At a step 252 , the security logic 112 prepares to set the secure mode signal A 165 to logical TRUE, if and only if a subsequent uncached read to the reset location 0×1fbc0000 is made.
[0095] At a step 253 , the CPU A 100 interrupts normal execution to respond to the reset signal.
[0096] At a step 254 , the CPU A 100 attempts to fetch the next instruction from location 0×1fbc0000, with the effect of invoking a reset interrupt handler or NMI interrupt handler.
[0097] At a step 255 , the security logic 112 sets the secure mode signal A 165 to logical TRUE, with the effect of enabling access for secure parts of the chip and the execution of boot secure code.
[0098] At a step 256 , the CPU A 100 proceeds to execute the reset interrupt handler or NMI interrupt handler in the secure boot code A 120 .
[0099] After the execution of the secure boot code A 120 , the following steps load the security kernel or security functions, if any, from mass storage A 150 .
[0100] The secure boot code A 115 reads the security information 113 , receives additional cryptographically signed or verifiable instructions, and records those additional instructions in the internal RAM A 155 . To perform this step, the CPU A 100 performs the following sub-steps:
[0101] At a sub-step 215 , the CPU A 100 , operating in secure mode executes software (possibly obtained from a server device) from external mass storage A 150 , after having been loaded and authenticated by secure boot code A 120 . In one embodiment, the message is encrypted using encryption/decryption keys B 101 from the read-only secure data A 125 , accessible only by the CPU A 100 while operating in secure mode.
[0102] Although in one embodiment the CPU A 100 obtains the additional instructions using the communication link 120 , in alternative embodiments the system 100 may obtain additional instructions (either some or all of them) by other means. Some examples, not intended to be limiting in any way, are described herein, including the possibilities of obtaining such additional instructions either (1) by means of physical media, or (2) from a third party, with a DRM (digital rights management) certificate or other capability being obtained from a server device.
[0103] Moreover, although in one embodiment the additional instructions are sent in an encrypted form, in alternative embodiments the system 100 may obtain such additional instructions (either some or all of them) in a non-encrypted form, with enforcement of the right to use those additional instructions being managed using a DRM certificate, other capability, or other technique.
[0104] At a sub-step 216 , the CPU A 100 , operating in secure mode, also authenticates the software and verifies its integrity with respect to secure information either from within the chip or verified with respect to messages from trusted servers whose trust has in turn been already established by secure software or data. In one embodiment, the CPU A 100 performs this authentication sub-step using a public key cryptosystem, including encryption keys or code signatures B 101 from the read-only secure data A 125 , and using information about the trusted server 130 (such as for example a public key for the trusted server 130 ) included in the encryption/decryption keys B 101 or other read-only secure data A 125 .
[0105] At a sub-step 216 , the trusted server optionally 130 verifies that the secure processor 110 is authorized to receive application software or other additional instructions from the trusted server 130 . In one embodiment, the CPU A 100 performs this verification sub-step using a public key cryptosystem, using encryption/decryption keys B 101 from the read-only secure data A 125 , and using licensing information B 102 or other information from the read-only secure data A 125 .
[0106] Those of ordinary skill in the art will recognize, after perusal of this application, that many other techniques might be used to authenticate software or data from a server using cryptographic signatures and trusted root keys. Moreover, there is no particular requirement that such authentication need be for only the trusted server 130 . In alternative embodiments, it may be that both server and client authenticate each other.
[0107] At a sub-step 217 , the CPU A 100 , operating in secure mode, receives the application software or other additional instructions from the trusted server 130 , and verifies the accuracy of that application software or those other additional instructions. In one embodiment, the CPU A 100 performs this verification sub-step using a public key cryptosystem, using encryption/decryption keys B 101 from the read-only secure data A 125 , or using a secure hash for the application software or other additional instructions from the read-only secure data A 125 .
[0108] At a sub-step 218 , the CPU A 100 , operating in secure mode, records the application software or other additional instructions in RAM A 155 . A result of this sub-step is that the application software or other additional instructions are ready to be executed by the CPU A 100 .
[0109] Although one example method is described herein for authenticating and loading application software, other and further techniques are also possible for doing so. As described above, in the context of the invention, there is no requirement that authentication of the application software involves any particular technique, and in particular, there is no requirement that authentication of the application software involves interactive communication with the trusted server 130 .
[0110] In one embodiment, at least some portions of the secure kernel code A 120 itself are obtained by the secure processor 110 as such additional instructions. In one embodiment, the following technique might be used:
[0111] At start-up (either power-on or upon receipt of the reset signal), the CPU A 100 is forced to perform the secure kernel code A 120 , which is verified to be correct and secure by secure boot code.
[0112] The CPU A 100 performs the secure kernel code A 120 , after loading program code by a bootstrap loader, with the effect of locating and copying code for performing security functions from mass storage A 150 , or other external devices, to an internal memory. In one embodiment, the internal memory is an on-chip volatile memory, such as for example an SRAM memory.
[0113] The non-volatile write-once memory C 110 (FIG. 3) is initialized, at the time of manufacture of the secure processor chip, with a cryptographically-strong signature value, such as for example a 160-bit secure hash or digest value. In one embodiment, the secure hash or digest value might include an SHA1 secure hash or other known cryptographically-strong signature values. As described herein, construction and initialization of the non-volatile write-once memory prevents it from being modified by application software after manufacture of the secure processor chip.
[0114] The bootstrap loader portion of the secure kernel code A 120 computes a signature of the newly loaded program code, and compares that computed signature with a pre-computed signature already internally stored in the non-volatile memory C 110 . If the computed signature and the pre-computed signature match, the bootstrap loader portion of the secure kernel code A 120 concludes that the newly loaded program code is accurate and trustworthy. Upon this conclusion, the CPU A 100 is permitted to execute the newly loaded program code in secure mode.
[0115] In one embodiment, the CPU A 100 re-verifies the newly loaded program code as being accurate and trustworthy each time it attempts to load additional software intended to be executed in secure mode. For example, not limiting in any way, these cases might include (1) each time a portion of the secure kernel code A 120 is loaded from RAM A 155 , mass storage A 150 , or any other external device, (2) each time additional software is desired to be loaded and added to the secure kernel code A 120 , such as for example a new security function or a new function to be provided by the secure kernel code A 120 .
[0116] As noted herein, in one embodiment, the CPU A 100 separately verifies each module of the newly loaded program code as being accurate and trustworthy. For example, not limiting in any way, these cases might include (1) maintaining a separately pre-computed signature for each module, when multiple modules are loaded from RAM A 155 , mass storage A 150 , or any other external device, (2) locating a new pre-computed signature in each module for a next such module, when additional software is desired to be loaded in a sequence of modules, (3) maintaining both a separately pre-computed signature for each module, and a pre-computed signature for a set of such modules.
[0117] At a step 219 , the secure processor 110 exits from the secure mode to the monitored mode. A general illustrative method of exit from secure mode is outlined later herein.
[0118] 2. Requests for Services
[0119] At a flow point 220 , the secure processor 110 is executing application software in monitored mode. The secure mode is ready to receive a request for services from the application software.
[0120] At a step 221 , the application software presents a request for services to the secure processor 110 .
[0121] At a step 222 , in one embodiment, the application software places parameters for the request for services in a set of selected registers in the secure mode logic.
[0122] At a step 223 , the secure mode logic 112 sets the secure mode signal A 160 to logical TRUE.
[0123] At a step 224 , the secure mode logic 112 generates the NMI interrupt signal A 165 to the CPU A 100 , with the effect that the CPU A 100 transfers control to the secure kernel code A 120 to satisfy the request for services.
[0124] At a step 225 , similar to the step 213 , the CPU A 100 jumps to a pre-selected interrupt handler location in the secure code. The secure mode switch circuit is responsible for A 105 asserting the secure mode active signal A 160 , which enables the CPU A 100 to access the secure code, execute its instructions, and read and write data using the security information 113 .
[0125] At a step 226 , similar to the step 214 , the CPU A 100 executes instructions from the secure code. The secure code handles the NMI interrupt.
[0126] In one embodiment, the following illustrative implementation on a MIPS or MIPS compatible processor results in the entry into secure mode at the request of the application code 143 . This illustrative implementation begins at a flow point 250 .
[0127] The application performs an uncached read to a register in secure mode logic. This “arms” the secure mode logic to conditionally enter secure mode if and only if it encounters a subsequent read from NMI reset location 0×1bfc0000.
[0128] At a step 252 , the security logic 112 prepares to set the secure mode signal A 165 to logical TRUE, if and only if a subsequent uncached read to the reset location 0×1fbc0000 is made.
[0129] At a step 253 , the security logic 112 causes an NMI signal to be asserted to the CPU A 100 .
[0130] At a step 254 , the CPU A 100 attempts to fetch the next instruction from location 0×1fbc0000, with the effect of invoking a reset interrupt handler or NMI interrupt handler.
[0131] At a step 255 , the security logic 112 sets the secure mode signal A 165 to logical TRUE, with the effect of enabling access for secure parts of the chip and the execution of boot secure code.
[0132] At a step 256 , the CPU A 100 proceeds to execute the reset interrupt handler or NMI interrupt handler in the secure code A 120 .
[0133] In one embodiment, a register in the secure mode logic is reserved to indicate the reason for entry into secure mode; for example, due to a reset, due to a request from the application code, and the like.
[0134] The secure kernel determines the cause of entry to secure mode and performs the services requested by the application by possibly reading restricted areas of the chip, and returns the result to a memory area shared with the application.
[0135] After performing the requested operation, the secure kernel triggers a defined exit sequence (as described below) through the secure mode logic and returns to the application code 143 .
[0136] At a step 227 , the secure processor 110 saves a result of the requested operation in a shared memory, such as the RAM A 155 .
[0137] In one embodiment, the request for services presented by the application software might include a request to perform an I/O operation. In such embodiments, the secure processor 110 reserves at least some I/O operations to be performed in secure mode, with the effect that the application software cannot perform those I/O operations without assistance from secure code.
[0138] The application software presents a request for services, indicating by the parameters associated with the request that the requested service is an I/O operation. The parameters associated with the request follow an API (application programming interface) selected for the secure processor 110 by its designers, preferably to operate in cooperation with the application software without substantial change in the application software.
[0139] In one embodiment, the request for services presented by the application software might include a request to load additional software. In such embodiments, the secure processor 110 performs steps similar to the step 214 and its sub-steps. Accordingly, in the system 100 , in sub-steps similar to those of the step 214 , the CPU A 100 authenticates the server device as a trusted server 130 , the CPU A 100 receives or loads the additional software, either from mass storage A 150 from the trusted server 130 , and the CPU A 100 records the additional software in RAM A 155 after verifying the authenticity and integrity of such software.
[0140] Error traps or I/O emulation can be handled by the same illustrative mechanism above through the secure mode logic. The secure mode logic forces the CPU to enter secure mode in those cases and execute pre-authenticated software to handle error traps or I/O requests as necessary.
[0141] At a step 228 , the secure processor 110 exits from the secure mode to the monitored mode. A general illustrative method of exit from secure mode is outlined later herein.
[0142] 3. Timer Interrupts
[0143] At a flow point 230 , the secure processor 110 has set a timer that might interrupt application software executing in monitored mode, and the timer is ready to go off.
[0144] At a step 231 , similar to the step 221 , the timer goes off, and the application software is interrupted.
[0145] At a step 232 , similar to the step 222 , the timer interrupt signal A 165 is asserted, with the effect of indicating that processing on the secure processor 110 has just been interrupted.
[0146] One illustrative method of the implementation of the secure timer trap on a MIPS or MIPS compatible processor is as follows. This illustrative method is similar to the steps beginning with the flow point 250 .
[0147] The secure timer is programmed in the CPU reset secure boot software to count down to zero and reset to a value that determines the periodicity of the secure time trap. This mechanism is not maskable or interruptible by any application software, and runs continuously while the application continues to execute.
[0148] The timer counts down from the programmed setting and upon reaching zero, triggers an NMI signal A 165 to the CPU (which interrupts its execution path), and arms the secure mode logic to conditionally assert the secure mode active signal if an only if a subsequent uncached read request is made to the NMI routine location.
[0149] The CPU jumps to execute the NMI routine where the secure kernel resides to perform the desired action upon timer interrupt.
[0150] The secure mode logic, upon acknowledging the read to the NMI location, sets secure mode active signal to true and permits access to secure regions of the chip.
[0151] The secure kernel routine responsible for handling the timer trap performs its operation and finally exits secure mode again through the secure mode logic.
[0152] At a step 236 , the CPU A 100 exits the secure code, and returns to the application software execution point. The secure mode switch circuit A 105 de-asserts the secure mode active signal A 160 , with the effect of indicating that the CPU A 100 is no longer allowed to access the secure code, execute its instructions, or read and write data using the security information 113 .
[0153] 4. Monitored Memory Access
[0154] At a flow point 240 , the secure processor 110 is ready to record accesses to external memory by application software executing in monitored mode.
[0155] At a step 241 , the CPU A 100 attempts to read from or write to RAM A 155 . To perform this step, the CPU A 100 sends a memory address to the CPU memory interface A 103 .
[0156] At a step 242 , the CPU memory interface A 103 couples that memory address to the internal bus 114 , which couples that memory address to the memory interface A 140 and to the security logic 112 .
[0157] At a step 243 , the security logic 112 , including the access control circuit A 133 , determines if the CPU A 100 should be allowed to access that memory address in the RAM A 155 . In one embodiment, the CPU A 100 is generally always allowed to access any memory address in the RAM A 155 . However, in alternative embodiments, the access control circuit A 133 might restrict the CPU A 100 from accessing selected memory addresses, with the effect of isolating selected portions of the RAM A 155 from when the CPU A 100 is operating in monitored mode.
[0158] At a step 244 , the security logic 112 , including the access control circuit A 133 , records the attempt to access that memory address in the RAM A 155 by the CPU A 100 . In one embodiment, the CPU A 100 records only selected such memory addresses. For one example, not limiting in any way, the access control circuit A 133 might select one or more portions of the RAM A 155 for which to record accesses when the CPU A 100 is operating in monitored mode. However, in alternative embodiments, the access control circuit A 133 may attempt to record all such memory accesses, may attempt to record memory accesses in response to a pattern thereof, or may attempt to record memory accesses in response to some other criteria selected by the CPU A 100 operating in secure mode. The application specific restriction information could be loaded by the security software during application launch with the usual authentication checks on the restrictions.
[0159] In one embodiment, a method of implementation of the exit from secure mode in any of the above mechanisms.
[0160] The register indicating the reason for entry into secure mode is cleared.
[0161] The software clears all caches or internal memory regions used to execute secure kernel software.
[0162] The secure kernel software returns from NMI routine.
[0163] Non-Volatile Memory
[0164] [0164]FIG. 3 shows a block diagram of a circuit including a device for programming a non-volatile memory in a substantially non-erasable way.
[0165] A circuit 300 includes a non-volatile memory C 100 , a disable logic circuit C 110 , an external program logic circuit C 120 , a non-bonded pin C 130 , and a set of external programming pins 340 .
[0166] In one embodiment, the non-volatile memory C 100 includes a flash memory or other memory capable of being electrically programmed, and capable of being read, with the effect that the circuit 300 can determine whether the non-volatile memory C 100 has been programmed with data or not. In the context of the invention, there is no particular requirement that the non-volatile memory C 100 includes any particular memory technology, so long as it can perform the functions described herein.
[0167] The disable logic circuit C 110 is coupled to the external program logic circuit C 120 , with the effect that when the program enable signal from the disable logic circuit C 110 is turned off, inputs to the external program logic circuit C 120 are disabled and the non-volatile memory C 100 cannot be electrically programmed from the external programming pins.
[0168] The disable logic circuit C 110 is also coupled to the non-volatile memory C 100 , and is capable of reading values from the non-volatile memory C 100 and comparing those values with a program enable signature value, with the effect that the disable logic circuit C 110 can determine if the non-volatile memory C 100 has been initially programmed or not. If the non-volatile memory C 100 has been initially programmed with a program enable signature value, the disable logic circuit C 110 causes inputs to the external program logic circuit C 120 to be enabled, with the effect that the non-volatile memory C 100 can be electrically programmed. If the program enable signature value is not present the program enable output from the disable logic C 110 will be disabled.
[0169] The non-bonded pin C 130 includes an electrically conducting pad, located on the secure processor chip die and capable of being probed before the die is packaged, but not bonded to any external wiring or packaging. This has the effect that the non-bonded pin C 130 can be electrically coupled to external circuitry when the secure processor chip is manufactured, but that after manufacture and packaging, the non-bonded pin C 130 is substantially unable to be electrically coupled to any external circuitry. Thus, after manufacture and before packaging of the secure processor chip, the non-bonded pin C 130 is available for use when programming the non-volatile memory C 100 , but when manufacture and packaging are completed, the non-bonded pin C 130 is no longer available for use when programming the non-volatile memory C 100 , with the effect that the non-volatile memory C 100 cannot be externally programmed.
[0170] On wafer test after manufacture, the non-bonded pin C 130 is coupled to a selected voltage (logic “0”), with the effect that the external program logic circuit C 120 is enabled and the non-volatile memory C 100 can be electrically programmed, regard-less of the state of the program enable output from the disable logic C 110 .
[0171] Method of Recording Unique Information
[0172] [0172]FIG. 4 shows a process flow diagram of a method of operating a circuit including a device for programming a non-volatile memory in a substantially non-erasable way.
[0173] A method 400 is performed with regard to the circuit 300 when constructing the secure processor 110 . Although the method 400 is described serially, the flow points and steps of the method 400 can be performed by separate elements in conjunction or in parallel, whether asynchronously or synchronously, in a pipelined manner, or otherwise. There is no particular requirement that the method 400 must be performed in the same order in which this description lists flow points or steps, except where explicitly so indicated.
[0174] At a flow point 410 , the non-volatile memory C 100 in the secure processor 110 is ready to be programmed. In one embodiment, a result of the method is to cause security information unique to that particular secure processor 110 to be recorded in a non-volatile memory.
[0175] At a step 411 , the non-bonded pin C 130 is coupled to a selected voltage (logic “0”), with the effect that the external program logic circuit C 120 is enabled and the non-volatile memory C 100 can be electrically programmed.
[0176] At a step 412 , the non-volatile memory C 100 is electrically programmed with an initial program enable signature value (disposed in its last memory location), with the effect that the non-volatile memory C 100 is ready to be further programmed.
[0177] At a step 413 , the circuit 300 is packaged, with the effect that the non-bonded pin C 130 is no longer available for coupling to external circuitry.
[0178] At a step 414 , the non-volatile memory C 100 is electrically programmed.
[0179] In one embodiment, when this step is performed, security information 113 unique to the particular instance of the secure processor 110 is recorded in the non-volatile memory C 100 . This has the effect that the particular instance of the secure processor 110 becomes uniquely distinguishable from each other instance of the secure processor 110 , and can uniquely identify itself to trusted servers 130 .
[0180] At a step 415 , the non-volatile memory C 100 is further electrically programmed to erase the program enable signature value. When the program enable signature value is no longer present, the disable logic circuit C 110 determines that the non-volatile memory C 100 is no longer available for programming, and causes the external program logic circuit C 120 to be disabled. This has the effect that the non-volatile memory C 100 can no longer be further electrically programmed from the external programming pins.
[0181] At a flow point 420 , the non-volatile memory C 100 no longer includes the program enable signature value, the disable logic circuit C 110 determines that the non-volatile memory C 100 is no longer available for programming, and the disable logic circuit C 110 causes the external program logic circuit C 120 to be disabled. On power-up for the secure processor 110 , the non-volatile memory C 100 can no longer be further electrically programmed from the external programming pins.
[0182] Alternative Embodiments
[0183] Although preferred embodiments are disclosed herein, many variations are possible which remain within the concept, scope, and spirit of the invention. These variations would become clear to those skilled in the art after perusal of this application.
[0184] There is no particular requirement that all executable code, or even all secure code, need be present on the chip on which the secure processor 110 is integrated. In alternative embodiments, the secure processor 110 may involve secure code or other executable code maintained in the external RAM A 155 , in the mass storage A 150 , or in other external devices.
[0185] There is no particular requirement that the secure processor 110 need be implemented as a single integrated chip. In alternative embodiments, the secure processor 110 may include multiple devices, coupled using signals that are either encrypted or otherwise secured against snooping or tampering.
[0186] There is no particular requirement that all secure code need be loaded all at once. In alternative embodiments, the secure processor 110 may involve multiple segments of secure code, which are loaded and verified at different times, such as in a sequence, or such as on an on-demand basis. For a first example, not intended to be limiting in any way, the secure kernel code A 120 might include signatures of one or more modules of additional software to be loaded and integrated into the instructions performed by the CPU A 100 when operating in secure mode. For a second example, not intended to be limiting in any way, the secure kernel code A 120 might include signatures of one or more modules of additional software to be loaded, each of which itself includes signatures of one or more modules of additional software to be loaded.
[0187] Memory and mass storage access checks might be performed in response to selected events. For a first example, not intended to be limiting in any way, these selected events might include any request for encryption/decryption services, I/O services, or secure signature or verification services by the application software. For a second example, not intended to be limiting in any way, these selected events might include periodic intercepts of memory of mass storage access (such as every N th access, for a selected value of N), periodic timer interrupts, and the like.
[0188] Authentication and verification checks might be performed in response to selected events, similar to memory or mass storage access checks. For a first example, not intended to be limiting in any way, these selected events might include any request for encryption/decryption services, I/O services, or secure signature or verification services by the application software. For a second example, not intended to be limiting in any way, these selected events might include periodic intercepts of memory of mass storage access (such as every N th access, for a selected value of N), periodic timer interrupts, and the like.
[0189] The secure kernel code A 120 might offer additional security services, besides those mentioned herein above, to the application software. For example, not intended to be limiting in any way, these additional services might include authentication and verification of messages from servers (other than the trusted server 130 , which is already described above) and other messaging partners (such as in peer-to-peer protocols and such as in protocols in which the application software has the role of a server), encryption/decryption of messages exchanged with servers (other than the trusted server 130 , which is already described above) and other messaging partners, public-key signature of messages exchanged with servers (other than the trusted server 130 , which is already described above) and other messaging partners, authentication and verification of further additional software to load and execute from secondary trusted servers 130 , management of DRM licensing information, periodic (or in response to selected events, as noted above) authentication and verification of software loaded for execution by the CPU A 100 , and the like.
[0190] The secure kernel code A 120 might offer additional services other than those related to security, besides those mentioned herein above, to the application software. For example, not intended to be limiting in any way, these additional services might include specific device drivers or operation of specific hardware for which the application software is licensed to operates, and the like.
[0191] Those skilled in the art will recognize, after perusal of this application, that these alternative embodiments and variations are illustrative and are intended to be in no way limiting.
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A secure processor assuring application software is executed securely, and assuring only authorized software is executed, monitored modes and secure modes of operation. The former executes application software transparently to that software. The latter verifies execution of the application software is authorized, performs any extraordinary services required by the application software, and verifies the processor has obtained rights to execute the content. The secure processor (1) appears hardware-identical to an ordinary processor, with the effect that application software written for ordinary processors can be executed on the secure processor without substantial change, (2) needs only a minimal degree of additional hardware over and above those portions appearing hardware-identical to an ordinary processor. The secure processor operates without substantial reduction in speed or other resources available to the application software. Functions operating in secure mode might reside in an on-chip non-volatile memory, or might be loaded from external storage with authentication.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 13/294,885, filed Nov. 11, 2011 and entitled Electronically Conductive Polymer Binder for Lithium-Ion Battery Electrode, now issued as U.S. Pat. No. 8,852,461, which is a continuation of PCT Application No. PCT/US2010/035120, filed May 17, 2010 and entitled Electronically Conductive Polymer Binder for Lithium-Ion Battery Electrode; which claims priority to U.S. Provisional Application Ser. No. 61/179,258 filed May 18, 2009, and U.S. Provisional Application Ser. No. 61/243,076 filed Sep. 16, 2009, both entitled Electronically Conductive Polymer Binder for Lithium-Ion Battery Electrode, Liu et al. inventors; each of which applications is incorporated herein by reference as if fully set forth in their entirety.
STATEMENT OF GOVERNMENTAL SUPPORT
The invention described and claimed herein was made in part utilizing funds supplied by the U.S. Department of Energy under Contract No. DE-AC02-05CH11231. The government has certain rights in this invention.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates generally to lithium ion batteries, and more specifically to an improved polymeric binder for forming silicon electrodes resulting in battery electrodes of increased charge density.
Background of the Invention
Lithium-ion batteries are a type of rechargeable battery in which lithium ions move between the negative and positive electrode. The lithium ion moves through an electrolyte from the negative to the positive during discharge, and in reverse, from the positive to the negative, during recharge. Most commonly the negative electrode is made of graphite, which material is particularly preferred due to its stability during charge and discharge cycles as it forms solid electrolyte interface (SEI) layers with very small volume change.
Lithium ion batteries and finding ever increasing acceptance as power sources for portable electronics such as mobile phones and laptop computers that require high energy density and long lifetime. Such batteries are also finding application as power sources for automobiles, where recharge cycle capability and energy density are key requirements. In this regard, research is being conducted in the area of improved electrolytes, and improved electrodes. High-capacity electrodes for lithium-ion batteries have yet to be developed in order to meet the 40-mile plug-in hybrid electric vehicle energy density needs that are currently targeted.
One approach is to replace graphite as the negative electrode with silicon. Notably graphite electrodes are rated at 372 mAh/g (milliamp hours per gram) at LiC 6 , while silicon electrodes are rated more than tenfold better at 4,200 mAh/g at Li 4.4 Si. However, numerous issues prevent this material from being used as a negative electrode material in lithium-ion batteries. Full capacity cycling of Si results in significant capacity fade due to a large volume change during Li insertion (lithiation) and removal (de-lithiation). This volumetric change during reasonable cycling rates induces significant amounts of stress in micron size particles, causing the particles to fracture. Thus an electrode made with micron-size Si particles has to be cycled in a limited voltage range to minimize volume change.
Decreasing the particle size to nanometer scale can be an effective means of accommodating the volume change. However, the repeated volume change during cycling can also lead to repositioning of the particles in the electrode matrix and result in particle dislocation from the conductive matrix. This dislocation of particles causes the rapid fade of the electrode capacity during cycling, even though the Si particles are not fractured. Novel nano-fabrication strategies have been used to address some of the issues seen in the Si electrode, with some degree of success. However, these processes incur significantly higher manufacturing costs, as some of the approaches are not compatible with current Li ion manufacture technology. Thus, there remains the need for a simple, efficient and cost effective means for improving the stability and cycle-ability of silicon electrodes for use in Lithium ion batteries.
SUMMARY OF INVENTION
By way of this invention, a new class of binder materials has been designed and synthesized to be used in the fabrication of silicon containing electrodes. These new binders, which become conductive on first charge, provide improved binding force to the Si surface to help maintain good electronic connectivity throughout the electrode, to thus promote the flow of current through the electrode. The electrodes made with these binders have significantly improved the cycling capability of Si, due in part to their elasticity and ability to bind with the silicon particles used in the fabrication of the electrode.
More particularly, we have found that a novel class of conductive polymers can be used as conductive binders for the anode electrode. These polymers include poly 9,9-dioctylfluorene and 9-fluorenone copolymer. The polyfluorene polymer can be reduced around 1.0 V (vs. lithium metal potential) and becomes very conductive from 0-1.0 V. Since negative electrodes (such as Si) operate within a 0-1.0 V window, this allows polyfluorene to be used as an anode binder in the lithium ion battery to provide both mechanical binding and electric pathways. As a unique feature of this polymer, by modifying the side chain of the polyfluorene conductive polymer with functional groups such as —COOH that will bond with Si nanocrystals, significantly improved adhesion can be realized.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing aspects and others will be readily appreciated by the skilled artisan from the following description of illustrative embodiments when read in conjunction with the accompanying drawings.
FIG. 1 depicts a generic chemical formula of a conductive polymer binder according to an embodiment of the present invention.
FIG. 2 is a plot of electrode capacity vs. cycle number for a Si anode made with the conductive binder of FIG. 1 according to one embodiment of the invention, wherein R 1 =R 2 =(CH 2 ) 7 CH 3 , R 5 =COOCH3, R 6 =H and x=0.5, x′=0, y=0.175 and z=0.325.
FIG. 3 is a plot of Coulombic Efficiency (%) vs. Cycle Number for the same Si anode/conductive binder electrode of FIG. 2 .
FIG. 4 shows the voltage profile of the electrode of FIG. 2 in the first several cycles of lithium insertion and removal.
FIG. 5 shows the de-lithiation performance of the same electrode at different charge-rates.
FIG. 6 is a plot of Si electrode cycling behavior at fixed capacity for the electrode of FIG. 2 . When the lithiation is limited to a selected capacity, the de-lithiation capacities are stable in 100 cycles as shown.
FIG. 7 is a plot of cycling results for a PFFOMB (poly(9,9-dioctylfluorene-co-fluorenone-co-methylbenzoic acid)) binder used in combination with an electrolyte comprising LiPF 6 in EC/DEC+10% FEC.
DETAILED DESCRIPTION
According to this invention the conductive polymers developed herein act as a binder for the silicon particles used for the construction of the negative anode. They are mixed with the silicon nano sized silicon parties in a slurry process, then coated on a substrate such as copper or aluminum and thereafter allowed to dry to form the film electrode. Though the silicon particles can range from micron to nano size, the use of nano sized particles is preferred as such results in an electrode material that can better accommodate volume changes.
A fabrication method for the synthesis of one embodiment of the binder polymer of this invention is as set forth below. First presented is a means for preparing one of the monomers used in polymer formation, i.e. 2,5-dibromo-1,4-benzenedicarboxylic acid, a reaction scheme for preparing this monomer is illustrated immediately below.
When the benzenedicarboxylic acid staring material has only one CH 3 group, the reaction will end up with only one R=COOCH 3 group in the final product.
A. Synthesis of Polymeric PFFO (poly(9,9-dioctylfluorene-co-fluorenone))
Exemplary of a method for forming one of the polymers of this invention is provided with respect to one embodiment, according to the reaction scheme set forth below. A mixture of 9,9-dioctylfluorene-2,7-diboronic acid bis(1,3-propanediol) ester (0.83 g, 1.5 mmol) commercially available from Sigma-Aldrich Company, 2,7-dibromo-9-fluorenone (0.50 g, 1.5 mmol), (PPh 3 ) 4 Pd(0) (0.085 g, 0.07 mmol) and several drops of aliquat 336 in a mixture of 10 mL of THF (tetrahydrofuran) and 4.5 mL of 2 M Na 2 CO 3 solution was refluxed with vigorous stirring for 72 hours under an argon atmosphere. During the polymerization, a brownish solid precipitated out of solution. The solid was collected and purified by Soxhlet extraction with acetone as solvent for two days with a yield of 86%.
B. Synthesis of PFFOMB (poly(9,9-dioctylfluorene-co-fluorenone-co-methylbenzoic acid))
A mixture of 9,9-dioctylfluorene-2,7-diboronic acid bis(1,3-propanediol) ester (0.80 g, 1.43 mmol), 2,7-dibromo-9-fluorenone (0.24 g, 0.72 mmol), methyl 2,5-dibromobenzoate (0.21 g, 0.72 mmol), (PPh 3 ) 4 Pd(0) (0.082 g, 0.072 mmol) and several drops of Aliquat 336 in a mixture of 13 mL of THF (tetrahydrofuran) and 5 mL of 2 M Na 2 CO 3 solution was refluxed with vigorous stirring for 72 h under an argon atmosphere. After reaction stopped, the solution was concentrated by vacuum evaporation and the polymer was precipitated from methanol. The resulting polymer was further purified by precipitating from methanol twice. The final polymer was collected by suction filtration and dried under vacuum with a yield of 87%.
C. Synthesis of PFFOBA (poly(9,9-dioctylfluorene-co-fluorenone-co-benzoic acid))
A mixture of PFFOMB (0.36 g) and KOH (2 g, 35 mmol) in 20 mL of THF and 2 mL of H 2 O was refluxed for 48 h under an argon atmosphere. After reaction stopped, the solution was concentrated by vacuum evaporation and polymer was precipitated from methanol. The resulting polymer was suspended in 10 mL of concentrated H 2 SO 4 with vigorous stirring for 12 hours. The final product was filtered, washed with water and dried with a yield of 96%.
Reaction scheme for forming conductive polymer with —COOCH 3 (PFFOMB) and —COOH (PFFOBA) groups on the side chains.
It has been found that the presence of —COOH groups serves to increase the bindability of the polymer to the silicon particles of the electrode. In particular, one can position carboxylic acid groups in connection with the 9 th position of fluorene backbone. The below formula depicts the general structure of this type of polymer.
Wherein x=0, x′ and y=>0, and z<=1, and x′+y+z=1, R 3 and R 4 can be (CH 2 ) n COOH, n=0-8, and R 5 and R 6 can be any combination of H, COOH and COOCH 3 .
Another variation is to adjust the number of COOH groups by copolymerizing x monomer into the main chains as illustrated in the formula shown below. By adjusting the ratio of x:x′, the number of —COOH groups can be controlled without changing the electronic properties of the conductive binders. Exemplary of such a composition is as illustrated below by the following formula.
wherein, x, x′, y>0, and z<=1, with x+x′+y+z=1. R 1 and R 2 can be (CH 2 ) n CH 3 , n=0-8. R 3 and R 4 can be (CH 2 ) n COOH, n=0-8. R 5 and R 6 can be any combination of H, COOH and COOCH 3 ; and the “x, x′” unit is fluorene with either alkyl or alkylcarboxylic acid at the 9, 9′ positions; the “y” unit is fluorenone, The H positions of the back bone of fluorenon and fluorene also can be substituted with functional groups such as COOH, F, Cl, Br, SO 3 H, etc.
In still another embodiment, one can increase the flexibility of the polymer by introducing a flexible section between repeating units. This is illustrated as shown below where a flexible chain section such as alkyl or polyethylene can be used to connect A sections together to further improve elasticity, the structure illustrated by the below formula:
where n>=0, and the A sections are defined as follows:
wherein
0<=x, x′, y and z<=1 and x+x′+y+z=1. R 1 and R 2 can be (CH 2 ) n CH 3 , n=0-8, R 3 and R 4 can be (CH 2 ) n COOH, n=0-8, R 5 and R 6 can be any combination of H, COOH and COOCH 3 .
Most of the highly conjugated conductive polymers have rigid backbones, and the elasticity of the polymers is low. In order to accommodate volume expansion incurred during the Li interacalation and de-intercalation in the alloys, it is important that the conductive polymer binders have certain degree of elasticity. One method to increase flexibility is to synthetically introduce flexible units (n) into the polymer system as show above. Unit n is a flexible alkyl or polyethylene portion. This flexible unit (n) can be one or many of —CH 2 units depending upon the requirements for a particular alloy system, or could be other types of liner units depending on the ease of synthesis. Both x, x′, y and z units could be one or many fluorene or fluorenone units. One possible structure is of a random copolymer with a few percent of flexible units distributed along the fluorene main chain. The R 1 -R 6 units could be either one of the choices, and it is not necessary they be all the same in a polymer chain. Increasing the length of the side chains may also have an effect on the flexibility of the polymer binder. Therefore, the number of units in R 1 -R 6 is also subject to change during an optimization process. One may change the number of units of the R 1 -R 6 , and look for improved cell cycling performance as indication of optimization.
Another issue is the stability and impedance of the interface between the active cathode material and electrolyte. The binder may cover (that is, over-coat) all the active materials at higher binder loadings. Such over-coverage will modify the interface stability and impedance. Varying the number of units in R 1 -R 6 will play a significant role in optimizing the charge transfer impedance at the interface.
Current polymer structures that have been synthesized and tested in lithium ion battery are shown as illustrated by the below.
Once the conductive polymers have been synthesized they can be mixed with the silicon particles, and coated onto a substrate such as copper and allowed to dry to form the electrode material. A more detailed discussion of electrode preparation is presented below. An advantage of the use of these conductive polymers of the present invention is that they are easily compatible with current slurry processes for making electrodes, thus requiring no special steps or equipment.
Process for Making Slurry of Conductive Polymer
Si/conductive polymer mixtures were made by dissolving 0.09 g of the conductive polymer of FIG. 1 (i.e., PFFOBA, wherein R 1 =R 2 =(CH 2 ) 7 CH 3 , R 5 =COOCH 3 , R 6 =H, and x=0.5, x′=0, y=0.175 and z=0.325)) in 2.6 g of chlorobenzene. 0.18 g of Si was dispersed in the polymer solution to meet the desired Si:polymer ratios at 2:1. To ensure the thorough mixing of the Si nanoparticles into the polymer solution, a Branson 450 sonicator equipped with a solid horn was used. The sonication power was set at 70%. A continuous sequence of 10 second pulses followed by 30 second rests was used. The sonic dispersion process took about 30 min. All of the mixing processes were performed in Ar-filled glove boxes.
Process for Making Conductive Glue of AB/PVDF
By way of comparison to the conductive polymers of this invention, illustrated in FIGS. 2 and 3 , slurries of AB:PVDF (acetylene black/polyvinylidene fluoride) at 0.2:1 ratios by weight were made by dissolving 5 g of PVDF in to 95 g of NMP to make a 5% PVDF in NMP solution. Proper amounts of AB were dispersed in the PVDF solution to meet the desired AB:PVDF ratios. To ensure the thorough mixing of the AB nanoparticles into the PVDF solution, the Branson 450 sonicator equipped with a solid horn was used. The sonication power was set at 70%. A continuous sequence of 10 s pulses followed by 30 s rests was used. The sonic dispersion process took ca. 30 min. All of the mixing processes were performed in Ar-filled glove boxes.
Process for Making Slurry of Si/AB/PVDF
0.86 g Si was mixed with 7.16 g of the conductive glue (PVDF:AB=1:0.2 by weight in 95% PVDF NMP solution). To ensure the thorough mixing of the Si nanoparticles into the glue solution, the Branson 450 sonicator equipped with a solid horn was used. The sonication power was set at 70%. A continuous sequence of 10 s pulses followed by 30 s rests was used. The sonic dispersion process took about 30 min. All of the mixing processes were performed in Ar-filled glove boxes.
Process for Making the Electrode
All electrode laminates were cast onto a 20 μm thick battery-grade Cu sheet using a Mitutoyo doctor blade and a Yoshimitsu Seiki vacuum drawdown coater to roughly the same loading per unit area of active material. The films and laminates were first dried under infrared lamps for 1 h until most of the solvent was evaporated and they appeared dried. The films and laminates were further dried at 120° C. under 10 −2 Torr dynamic vacuum for 24 h. The film and laminate thicknesses were measured with a Mitutoyo micrometer with an accuracy of ±1 μm. The typical thickness of film is about 20 μm. The electrodes were compressed to 35% porosity before coin cell assembly using a calender machine from International Rolling Mill equipped with a continuously adjustable gap.
Process for Fabricating Coin Cell
Coin cell assembly was performed using standard 2325 coin cell hardware. A 1.47 cm diameter disk was punched out from the laminate for use in the coin cell assembly as a working electrode. Lithium foil was used in making the counter electrode. The counter electrodes were cut to 1.5 cm diameter disks. The working electrode was placed in the center of the outer shell of the coin cell assembly and two drops of 1 M LiPF 6 in EC:DEC (1:1 weight ratio) electrolyte purchased from Ferro Inc. were added to wet the electrode. A 2 cm diameter of Celgard 2400 porous polyethylene separator was placed on top of the working electrode. Three more drops of the electrolyte were added to the separator. The counter electrode was placed on the top of the separator. Special care was taken to align the counter electrode symmetrically above the working electrode. A stainless steel spacer and a Belleville spring were placed on top of the counter electrode. A plastic grommet was placed on top of the outer edge of the electrode assembly and crimp closed with a custom-built crimping machine manufactured by National Research Council of Canada. The entire cell fabrication procedure was done in an Ar-atmosphere glove box.
Process for Testing Coin Cell
The coin cell performance was evaluated in a thermal chamber at 30° C. with a Maccor Series 4000 Battery Test System. The cycling voltage limits were set at 1.0 V at the top of the charge and 0.01 V at the end of the discharge.
Chemicals
All the starting chemical materials for synthesis of the conductive polymer were purchased from Sigma-Aldrich. Battery-grade AB with an average particle size of 40 nm, a specific surface area of 60.4 m 2 /g, and a material density of 1.95 g/cm 3 was acquired from Denka Singapore Private Ltd. PVDF KF1100 binder with a material density of 1.78 g/cm 3 was supplied by Kureha, Japan Anhydrous N-methylpyrrolidone NMP with 50 ppm of water content was purchased from Aldrich Chemical Co.
As described above, the conductive polymers of this invention can be used as electrically conductive binders for Si nanoparticles electrodes. The electron withdrawing units lowering the LUMO level of the conductive polymer make it prone to reduction around 1 V against a lithium reference, and the carboxylic acid groups provide covalent bonding with OH groups on the Si surface by forming ester bonds. The alkyls in the main chain provide flexibility for the binder.
Results of the various tests that were conducted are as reported in the various plots of FIGS. 2-7 . FIG. 2 shows the new conductive polymer binder in combination with Si nanoparticles much improving the capacity retention compared to conventional acetylene black (AB) and polyvinylidene difluride (PVDF) conductive additive and binder as a control. FIG. 3 illustrates the improved coulombic efficiency of the conductive binder/Si electrode of the invention compared with the conventional AB/PVDF approach. FIG. 4 illustrates results showing very similar voltage profiles of the conductive polymer/Si electrode to the pure Si film type of electrode. FIG. 5 plots the rate performance of the conductive polymer/Si electrode of the invention, showing good results. Evan at a 10 C rate, there is still more than half of the capacity retention. FIG. 6 illustrates cycleability of the silicon electrode made with the copolymer binder of the invention, which is very good at limited capacity range. There is no capacity fade in 100 cycles at 1200 mAh/g and 600 mAh/g fixed capacity cycling. FIG. 7 illustrates cycling results for a PFFOMB binder using an electrolyte comprising 1.2 M LiPF6 in EC/DEC (ethylene carbonate and diethylene carbonate) plus 10% FEC (fluoroethylene carbonate or fluorinated ethylene carbonate), the FEC additive serving as a stabilizer.
This invention has been described herein in considerable detail to provide those skilled in the art with information relevant 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 different equipment, materials 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.
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A family of carboxylic acid group containing fluorene/fluorenon copolymers is disclosed as binders of silicon particles in the fabrication of negative electrodes for use with lithium ion batteries. These binders enable the use of silicon as an electrode material as they significantly improve the cycle-ability of silicon by preventing electrode degradation over time. In particular, these polymers, which become conductive on first charge, bind to the silicon particles of the electrode, are flexible so as to better accommodate the expansion and contraction of the electrode during charge/discharge, and being conductive promote the flow battery current.
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FIELD OF THE INVENTION
[0001] The invention relates to a valve assembly for fluids, in particular for liquids, and includes a housing, which has an elastic valve membrane mounted in the housing and a valve body held in the elastic valve membrane. The valve assembly includes an inlet for the fluid, opening into a chamber, and an outlet leading out from the chamber, it being possible to bring the valve body into contact with the elastic valve membrane to close the fluid passage portion of the valve.
[0002] The valve is preferably used in a mechanically operated liquid pump, particularly in a liquid pump provided for medical and nutrient liquids, and for liquids in the biological and laboratory sector. It is also conceivable to use the valve for gases, particularly those that have to be delivered in the context of laboratory tests. The main field of application of the valve is in the delivery of a liquid.
BACKGROUND OF THE INVENTION
[0003] Many different types of liquid pumps are used to deliver liquids. Pumps that are not operated electrically, such as mechanical infusion pumps, have the disadvantage that they generate different pressures during the period of use. This means that the initial pressure is generally higher than the end pressure. The flow rate is controlled using capillary hoses or glass capillary tubes. These solutions with capillaries give rise to flow rate fluctuations of up to 70% within the period of use. This is a major problem for patients with tolerance difficulties, e.g. allergy sufferers, since excessively high dosing rates may lead to adverse side effects and intolerance phenomena.
[0004] A valve of the type mentioned at the outset, and used for liquids, is known from EP 1 321 156 A1. There, the housing has a chamber, an inlet channel in flow communication with the chamber, and an outlet channel in flow communication with the chamber. A stiff valve body for regulating the flow of the liquid through the chamber is arranged within the chamber. The valve body is connected to a valve membrane clamped in the housing in the area of the circumferential edge, with the valve body being moved according to the movement of the valve membrane. The housing accommodates an annular elastic element concentric to the inlet channel. To close the inlet channel, the valve body can be moved against the elastic element. Because of the dimensions of this valve, and of the flow restrictor assigned to the outlet channel, the resistance against the liquid flowing out of the housing is greater than the resistance made to the liquid flowing into the valve. As the liquid flows into the housing, a hydrostatic pressure arises in the liquid-filled chamber and acts on the valve body and the valve membrane. When spacer parts of the valve body bear without pressure on the elastic element, the liquid channel extending through the latter is not closed, and liquid can flow from the inlet channel into the chamber and from there into the outlet channel. The elasticity of the elastic element has the result that, when a force acts in its direction, and the pressure of the liquid present in the chamber changes, the valve membrane is curved slightly away from the chamber interior, and the valve body is moved in this direction, with the spacer parts of the valve body being pressed into the elastic element. This reduces the gap between the sealing surfaces. The volumetric flow passing through the valve thus decreases. If the force is sufficiently great, the valve body closes the gap, such that liquid present in the inlet channel can no longer penetrate into the chamber. Consequently, the pressure in the chamber decreases. As the pressure decreases, the restoring force of the deflected valve membrane causes the valve body to be lifted from the elastic element, such that the gap forms again between the sealing surfaces. This valve therefore operates in the manner of a pressure reducer, specifically as a function of the developing inlet pressure. With this valve, it is not adequately possible to keep the pressure substantially constant.
[0005] U.S. Pat. No. 5,616,127 describes a device for delivering a medical liquid to a patient. It comprises a valve for regulating the flow of the liquid medicament. The valve has a housing with a conically arranged valve seat, and a valve body which is displaceable relative to the latter and which likewise has a conical valve seat. The valve body is connected to the valve housing via an elastic intermediate member in the shape of a bellows. The space enclosed by the bellows forms a chamber, which is provided with an outlet channel. The inlet channel is routed through the valve housing. When the pressure in the chamber increases, the bellows expands, as a result of which the valve body reduces the cross section of passage of the valve body until, at a maximum pressure, the inlet channel of the valve housing is closed by means of the valve body. If the valve is free of pressure, the bellows ensures, by virtue of its restoring forces, that the valve body is moved against a further valve seat of the housing and, in this state, also blocks the flow through the valve.
[0006] U.S. Pat. No. 4,852,605 discloses a valve in which a valve housing has a valve seat, and a valve body designed as a ball interacts with the valve seat. This ball is held in a bearing, which in turn is mounted in a valve membrane. When an increased pressure is present in an inlet channel of the housing, the ball lifts from the valve seat. Depending on the pressure increase, a greater or lesser cross section of flow for the liquid from the inlet channel is obtained.
[0007] DE 44 36 540 A1 describes an infusion system for continuous dispensing of a liquid medicament under pressure. A piston is provided there in a state of equilibrium. If too high a volumetric flow is applied by a medicament delivery device, this leads to a displacement of the piston and, depending on the displacement travel of the piston, to a greater or lesser reduction of an inlet channel for the medicament.
[0008] U.S. Pat. No. 3,511,472 describes a valve with an elastic valve membrane for closing the seat of a valve housing. The cross section of flow through the valve can be regulated in a stepless manner by an adjustable screw that supports the valve body.
SUMMARY OF THE INVENTION
[0009] The object of the present invention is to develop a valve of the type mentioned at the outset, in such a way as to guarantee that the flow of liquid is kept substantially constant, and thus that the flow of liquid is kept constant within a narrow tolerance range.
[0010] The object is achieved by a valve of the type mentioned at the outset, characterized by the following features:
the elastic element is the elastic valve membrane, a stop is used to limit the extent to which the valve membrane curves outward during an increase in pressure of the fluid, the stop moving the elastic element against the valve body and closing the fluid passage of the valve.
[0013] It is a particular advantage of the valve according to the invention that the flow of liquid can be kept substantially constant, irrespective of how great the inlet pressure is on the valve. This is possible because of the fact that a pressure arising at the outlet causes the valve membrane to curve outward from its starting position, with the result that the valve membrane is moved against the stop and in this way experiences a deformation, which leads to the closure of the valve body. The relatively high pressure in the area of the outlet, which is of course lower than the pressure in the area of the inlet, is ensured by the flow restrictor.
[0014] In a particularly advantageous embodiment of the valve from the point of view of its construction, the inlet is routed through the valve membrane and the valve body to the chamber. This in particular entails interconnected channels.
[0015] The valve membrane and the valve body are in particular separate structural parts. The valve body is designed in particular as a valve core. This expression is intended to signify that this structural part is arranged in a central area of the valve and in particular is held in the described manner in the valve membrane.
[0016] The valve body is preferably a rigid structural part. It is held in the valve membrane in such a way that it cannot be moved relative to the latter in the direction of movement of the valve body, or in its transverse direction, and, in particular, can also not be rotated with respect to the valve membrane. This ensures that the inlet channels of valve membrane and valve body are aligned in each operating state and, in addition, ensures a defined position of the valve body to the valve membrane, particularly in the area in which the valve body is intended to be closed by the valve membrane. The valve membrane is preferably held in the area of a circumferential edge between two parts of the housing, and in particular is held there by clamping. This affords the possibility of the valve membrane, starting from the edge areas, being able to bulge out sufficiently under the effect of the respective fluid pressure. The valve membrane is preferably profiled in cross section, and a central area of the valve membrane serves to receive the valve body. This central area has a pot-shaped configuration in particular.
[0017] A special configuration of the valve membrane is preferably provided. Accordingly, a closure element is a component part of the valve membrane. The stop moves the closure element against the valve body and in doing so closes the fluid outlet of the valve.
[0018] The outlet of the valve can be designed in different ways. It is conceivable to route the outlet directly from the chamber to the housing and from there via a channel to an outlet conduit connected to the housing. In a modified configuration, it is possible, corresponding to the routing of the inlet channel through the valve membrane, to also provide an outlet channel that is routed through the valve membrane.
[0019] The valve can be simply constructed, particularly in the area of the valve membrane and of the valve body, wherein the valve membrane has a radial inlet channel and the valve body has a radial inlet channel adjoining the latter inlet channel. The inlet channel of the valve body empties into an axial inlet channel of the valve body that can be closed by means of the valve membrane. An outlet channel, starting from the chamber, is preferably formed between the valve body and the valve membrane.
[0020] According to a particular embodiment of the invention, the stop is designed as an adjustable stop. It is designed in particular as an adjusting screw that is screwed into the housing. The further the screw frees the adjustment path of the valve membrane, the greater is the secondary pressure in the valve.
[0021] With the valve according to the invention, the flow of the fluid is regulated in relation to the maximum pressure. The valve membrane is preferably configured with respect to the pressure level to be regulated. This means that the regulation can be effected entirely by means of the elastic valve membrane. According to a development of the invention, however, a spring is provided for resetting the valve membrane to the open position of the valve. This spring assists the resetting movement of the valve membrane.
[0022] The spring is preferably designed as a compression spring supported on the housing and on the valve membrane, and, in particular, the valve membrane can be reset against a stop on the housing side. This stop limits the resetting movement of the valve membrane.
[0023] The outlet of the valve preferably includes a flow restrictor. The latter thus forms a component part of the valve.
[0024] Further features of the invention are set forth in the dependent claims, in the description of the figures, and in the figures themselves. It will be noted that all the individual features and all combinations of the individual features are part of the invention.
[0025] The invention is depicted in the figures on the basis of a mechanically operated liquid pump that is provided with the valve, without being limited to this illustrative embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 shows an exploded view of a mechanically operated liquid pump using the valve according to the invention,
[0027] FIG. 2 shows a vertical longitudinal midsection through the pump shown in FIG. 1 , in particular to illustrate the drive mechanism of the pump, with a balloon bearing on a core,
[0028] FIG. 3 shows a section according to FIG. 2 , with the balloon filled with liquid,
[0029] FIG. 4 shows a vertical longitudinal section through the pump shown in FIG. 1 , at a distance from the longitudinal center axis of the pump, in the area of a valve of the pump,
[0030] FIG. 5 shows a section, cut transversely through the pump illustrated in FIG. 1 , in the area of the valve,
[0031] FIG. 6 shows a horizontal longitudinal midsection through the pump shown in FIG. 1 , with the balloon bearing on the core,
[0032] FIG. 7 shows a section according to FIG. 6 , with the balloon filled with liquid,
[0033] FIG. 8 shows a section through the pump, cut transversely in the area where the core is supported,
[0034] FIG. 9 shows a section through the pump, cut transversely in the area of the unsupported portion of the core and of the liquid-filled balloon,
[0035] FIG. 10 shows an enlarged sectional view of core, balloon and clamping ring for connection of balloon and core, with the balloon bearing on the core,
[0036] FIG. 11 shows a section, cut transversely to the longitudinal extent of the core, through the core and the balloon, with the balloon bearing on the core,
[0037] FIG. 12 shows a sectional view according to FIG. 11 for a modified cross-sectional configuration of the balloon,
[0038] FIG. 13 shows an enlarged sectional view of the valve shown in FIG. 4 , and
[0039] FIG. 14 shows a diagram illustrating the operating principle of the mechanically operated liquid pump, and indicating physical parameters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] For purposes of description herein, the terms “upper”, “lower”, “right”, “left”, “rear”, “front”, “vertical”, “horizontal” and derivatives thereof shall relate to the invention as oriented in FIG. 1 . However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
[0041] The mechanically operated liquid pump 1 illustrated in FIG. 1 is used in particular for administering medical or nutrient liquids, for example for administering a liquid medicament.
[0042] The pump 1 has a multi-component housing 2 formed by a middle part 3 , by an upper part 4 and a lower part 5 that interact with said middle part 3 , by an upper shell 6 interacting with the upper part, and by a lower shell 7 interacting with the lower part 5 .
[0043] The middle part 3 is provided on its upper face with a recess 8 that is open to the free edge of the middle part 3 and that has a semicircular cross section, and the upper part 4 is provided on its lower face, and in the corresponding edge area, with a corresponding semicircular recess 9 . With the upper part 4 connected to the middle part 3 , the two recesses 8 and 9 form a circular cross section for receiving a conically widened end area 10 of a core 11 . Except at its end area 10 , the core 11 has a constant external diameter. This cylindrical portion of the core 11 is designated by reference number 12 . A channel 13 (see FIG. 2 ) extends through the core 11 along its longitudinal center axis, and several channels 14 extending radially through the core 11 branch off from the channel 13 in the area of the portion 12 ( FIG. 6 ). In the area of the outer circumference of the core 10 , the radial channels 14 open into circumferential grooves 15 of the core 11 .
[0044] An elastic element interacts with the core 11 and is designed as a silicone balloon 16 . The latter is produced by injection molding. The balloon has a conically widened end area 17 with opening 17 a, corresponding to the end area 10 of the core 11 , and it has a portion 18 which corresponds to the outer shape of the portion 12 of the core 11 and which merges into the end area 19 , closed on account of the balloon design and remote from the end area 17 .
[0045] The dimensions of core 11 and balloon 16 are such that, as can be seen from FIG. 2 , the balloon fitted onto the core 11 bears completely on the core 11 , such that the end area 17 of the balloon contacts the end area 10 of the core, and the portion 18 of the balloon 16 contacts the portion 12 of the core 11 , and, finally, the end area 19 of the balloon 16 bears on the free end of the core 11 . The dimensions of the balloon 16 in relation to the core 11 are chosen here such that the balloon 16 bears on the core 11 with relatively little pretensioning, in other words in a relatively unstressed state.
[0046] In order to fasten the end area 17 of the balloon 16 on the core 11 , at the end area 10 of the latter, a clamping ring 20 is provided, which is fitted externally onto the balloon 16 at the end area 17 thereof. The structure thus formed is inserted with the clamping ring 20 into the recess 8 of the middle part 3 , and the upper part 4 is then connected to the middle part 3 , as a result of which the clamping ring 20 and therefore the core 11 and balloon 16 are held secure in the recesses 8 and 9 of middle part 3 and upper part 4 . For the clamping ring 20 , the recesses 8 and 9 have a seat that widens conically in the direction away from the respective free edge of the middle part 3 and upper part 4 , in order to ensure a secure hold of the clamping ring 20 .
[0047] The middle part 3 , the upper part 4 and the lower part 5 serve to receive further operating elements of the pump 1 :
[0048] A Luer check valve or lock valve 21 connected to the upper part 4 passes through an opening 22 in the upper part 4 , and, as is explained in the following description of FIG. 2 , has a Luer lock valve housing 23 and a Luer lock valve core 24 . By way of a channel 25 , the Luer lock valve 21 is in communication with a channel 26 , which is formed between the upper part 4 and the middle part 3 and which communicates with the channel 13 extending through the core 11 .
[0049] The pump is filled with liquid by way of the Luer lock valve 21 and the channels 25 , 26 and 13 . Starting from the unfilled state shown in FIG. 2 , and with increasing delivery of liquid, the balloon 16 expands in that area not clamped by the clamping ring 20 , and, when completely filled, adopts the final shape illustrated in FIG. 3 . The space occupied by the liquid is designated there by reference number 27 . It will be seen from FIGS. 2 , 3 and 6 to 12 that, as it fills with liquid, starting from its initial state bearing on the core 11 , the balloon 16 changes shape both in the longitudinal direction of the core and also in transverse directions thereof, i.e. in a first transverse direction and in a second transverse direction perpendicular thereto.
[0050] The upper part 4 and the lower part 5 are provided with locking projections 28 , which serve to receive a cap 29 that is approximately kidney-shaped in cross section. As can be seen from FIG. 9 , this cap has an extension in its direction of width that is substantially greater than that in the direction of its height. The width-to-height ratio is 2:1, for example. As can be seen from FIG. 2 for example, the length-to-height ratio of the cap 29 is approximately 2.5:1. The cap 29 is preferably clipped non-releasably onto the housing 2 . When the balloon 16 is filled completely with liquid, it takes up as much as possible of the internal space in the cap 29 .
[0051] This is achieved by the fact that, as can be seen from the view in FIG. 11 showing the balloon 16 bearing on the core 11 , the balloon 16 has relatively thick wall portions 30 in a first direction of extent X perpendicular to the longitudinal axis of the core 11 , and it has relatively thin wall portions 31 in a second direction of extent Y perpendicular to the longitudinal axis of the core 11 and perpendicular to the first direction of extent X. Thus, when liquid is introduced into its space 27 , the balloon 16 seeks to expand preferably in the direction of extent X, thereby resulting in the expanded oval cross-sectional shape illustrated in the view in FIG. 9 . Overall, the pump 1 is presented as a flat functional component that can be easily worn on the body, and the balloon 16 , in the state when filled with liquid, likewise adopts a flat shape adapted to the outer contour of the pump 1 .
[0052] The channels 26 and 13 serve not only to deliver the liquid from the Luer lock valve 21 into the balloon 16 , but also to dispense the liquid from the interior of the balloon 16 to the patient. Thus, the channel 26 is continued past the inlet point of the channel 25 to a valve 32 that is mounted in the middle part 3 and upper part 4 and that restricts the volumetric flow of liquid discharged from the balloon 16 . This valve 32 is formed by an elastic valve membrane 33 held at the edge between middle part 3 and upper part 4 , by a valve core 34 that interacts with the valve membrane 33 , by a compression spring 35 supported on the valve membrane 33 and the upper part 4 , and by an adjusting screw 36 , which is mounted in a thread of the upper part 4 and can be brought into operative connection with the valve membrane 33 .
[0053] As can be seen from the detailed view in FIG. 13 , the channel 26 opens into a radially extending channel 37 of the valve membrane 33 and from there into a radial channel 38 of the valve body 34 , which opens into an axial channel 39 of the valve core 34 . This channel 39 is open in the area of its end directed toward a reinforced portion 40 of the valve membrane 33 . A stop designed as an adjusting screw 36 is arranged on that side of the portion 40 directed away from the channel 39 , which portion 40 has the function of a closure element. In principle, this stop could also be stationary. Between the projections 41 of the valve membrane 33 , the valve core 34 is held so as to be axially immovable relative to the valve membrane 33 and also non-rotatable relative to the latter.
[0054] The valve 32 is used to stop the volumetric flow in the event of too high a pressure. Two separate chambers 42 and 43 are formed in the valve and are connected to each other via a channel 44 , which extends through the valve core 34 and is arranged parallel to the channel 40 . The chamber 42 , which lies in the direction of flow to the inlet, and therefore to the channel 26 , serves as a blocking chamber. The chamber 43 lies in the direction of flow to the outlet 45 . To filter the liquid dispensed through the valve 32 , a filter 46 is provided which is clamped at the edge between the middle part 3 and the lower part 5 . Starting from the chamber 43 and the outlet 45 , the liquid passes to a channel 47 ( FIG. 5 ) in flow communication with the outlet 45 , and from there to a Luer lock attachment 48 held between the middle part 3 and the lower part 5 . A Luer lock connector 49 , provided with a hose 50 leading to the patient, can be connected to the Luer lock attachment 48 .
[0055] As can be seen from the view in FIG. 5 , a glass capillary 53 is fitted into the channel 47 . This glass capillary constitutes a flow restrictor, which is able to restrict the volumetric flow passing through the channel 47 out of the pump, since the flow restrictor has a smaller cross section than the channel 37 lying in the inlet. By selecting various flow restrictors, it is possible to set various constant flow rates, as long as the pressure at the inlet does not drop below a defined value. In principle, the cross-sectional area of flow of the inlet is greater than the cross-sectional area of flow of the outlet. Of course, the flow restrictor can be designed other than in the form of a glass capillary. For example, it is entirely conceivable to provide downstream of the valve, in the outlet of the pump, a meander chip that restricts the through-flow.
[0056] Because of the stated diameters of the channels that connect the space 27 of the balloon to the valve 32 , and the diameter of the channels arranged behind the valve 32 with the flow restrictor 53 , the resistance that the channel 47 with flow restrictor 53 sets against the outflow of liquid from the housing 2 is greater than the resistance made to the liquid flowing into the valve 32 .
[0057] In an initial state, the valve membrane 33 is located in the position shown in FIG. 13 , in which the valve membrane 33 bears largely on the middle part 3 , without requiring any action of the compression spring 35 . Because of the positioning of the valve core 34 relative to the portion 40 of the valve membrane 33 , a small gap is provided between the portion 40 and an encircling and therefore annular projection 54 of the valve core 34 . This projection 54 encloses the channel 43 . Accordingly, liquid flows through the channel 13 of the core 11 and through the adjoining housing channel 26 into the channel 37 of the valve membrane 33 and from there into the channels 38 and 39 of the valve core 34 . From the channel 39 of the valve core 34 , the liquid flows through the gap formed between the projection 54 and the portion 40 of the valve membrane 33 , and into the chamber 42 located there, and from the chamber 42 through the channel 44 between valve membrane 33 and valve core 34 to the chamber 43 , passes the filter 46 and travels through the outlet 45 to the channel 47 with the flow restrictor 53 . If a higher liquid pressure is established in the inlet, thus also in the channel 39 , without a greater volumetric flow being able to issue from the pump as a result of the flow restrictor 43 , this has the result that the valve membrane 33 , which is clamped in the edge area between the middle part 3 and the upper part 4 , deforms in the central area in the direction of the adjusting screw 36 with the stop function, specifically counter to the force of the compression spring 35 . When the valve membrane 34 with its portion 40 comes up against the projection 55 of the adjusting screw 36 directed toward the portion 40 , the portion 40 makes contact there with the adjusting screw 36 , such that, since the valve membrane 33 cannot move any farther up in the direction of the upper shell, the portion 40 is pressed against the projection 54 of the valve core 34 and thus closes the flow through the channel 39 . As the liquid flows out through the flow restrictor 53 , the pressure in the chamber 43 decreases, with the result that the membrane, by virtue of its own elasticity, moves back again in the direction of its initial state according to FIG. 13 , such that the portion 40 disengages from its contact with the adjusting screw 36 , and the flow gap between the projection 54 and the portion 40 is again freed. Depending on the pressure prevailing in the balloon 16 , this state can be obtained only when the initial position of the valve membrane 33 is reached, as shown in FIG. 13 , or even earlier, in other words with the valve membrane 33 still deflected. The adjusting screw 36 serves to modify the opening and closing behavior of the valve 32 . The further the screw frees the adjustment path of the valve membrane, the greater is the secondary pressure in the valve. In principle, it is not necessary to provide the compression spring 35 . It is of advantage when greater pressures are intended to be dealt with by the pump 1 and, accordingly, the elastic restoring behavior of the valve membrane 33 is not sufficient to move it into the initial position according to FIG. 13 .
[0058] With the valve 32 , the volumetric flow of liquid is therefore restricted as a function of the pressure prevailing in the balloon 16 , and the volumetric flow of liquid is maintained substantially constant via the flow restrictor 53 . In principle, the liquid pump could be modified by providing only a device for maintaining substantially constant the volumetric flow of liquid dispensed from the elastic element, or only a device for restricting the volumetric flow of liquid dispensed from the elastic element.
[0059] Before using the mechanically operated liquid pump, liquid is delivered through the Luer lock valve 21 , as a result of which the liquid passes into the balloon 16 , and the filling level of the balloon can be read off through the transparent cap 29 on the basis of the markings 51 which are arranged in the transverse direction of the cap and which are a reference for the transverse expansion of the balloon as a function of its state of filling. After the pump 1 has been filled and the pump has been attached to the patient via the hose 50 , liquid is dispensed out of the pump through the valve 32 , with elastic pretensioning of the expanded balloon 16 , and this is done until the balloon has been completely emptied and bears on the core 11 .
[0060] The particularly simple design of the described liquid pump allows it to be used in a variety of different ways. The user is able to operate the pump anywhere, and immediately, without long start-up times. It can be used carried around by the user, or used in one place, specifically in all normal life situations in or outside the field of medicine. The pump can be used in a sterile state and requires minimal operating/handling effort. Because of the simple construction of the small number of component parts, the pump is inexpensive to produce. This is a condition for its being able to be used particularly in outpatient care, and in financially weak markets. The low weight of the pump permits its use in accident and emergency situations, in field hospitals and in disaster areas. Some or all of the functional elements of the pump are exchangeable. The pump is suitable for short or long dispensing times, for example in the case of a balloon with a capacity of 25 ml, for a flow rate of 2.5 ml per hour, that is to say a running time of 10 hours. It is of course possible to use other balloons with other volumes, for example 10 ml, 50 ml, 100 ml or 150 ml. The running time can be much longer, for example up to 24 hours. Although flow rates of >1000 ml per hour are entirely possible, a flow rate of 0.5 to 10 ml per hour is considered the preferred option.
[0061] According to the illustrative embodiment, a balloon is described which is produced by injection molding and serves as a container for the medicament solution and as a pressure reservoir. The balloon has a defined contour in cross section and in expansion, for filling flat housing spaces and for avoiding pressure peaks. It is radially and/or axially pretensioned on a one-part or multi-part core, in order to increase the restoring forces. One end of the balloon is sealed off in an airtight manner over the core and fixed in position by a clamping ring with a form fit. The balloon is freely movable in the axial and radial directions during filling and emptying, being elastically deformable and able to move in a manner free from friction inside the cap.
[0062] The pump 1 can additionally be provided with a bolus reservoir. In FIG. 1 , the provision of such a bolus is indicated by reference number 52 . The pump can be converted to this extent, as and when required.
[0063] FIG. 14 is a diagram illustrating how the above-described mechanically operated pump works and showing the physical parameters. The contour of the pump is indicated by the dot-and-dash line.
[0064] In the foregoing description, 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 herein. Such modifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
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The invention relates to a valve ( 32 ) for a fluid, in particular for a liquid, with a housing ( 3, 4 ), which has a flexible valve membrane ( 33 ) mounted in the housing and a valve body ( 34 ) held therein, and with an access point ( 26, 37, 38, 39 ) for the fluid, which opens into a chamber ( 42, 43, 44 ), and an outlet ( 45 ) leading out of the chamber, it being possible to bring the valve body into contact with a flexible element ( 33 ) in order to close the fluid passage of the valve. According to the invention, in a valve of that kind the flexible element is the flexible valve membrane ( 33 ) and a stop ( 36, 55 ) is used to limit the extent to which the valve membrane curves outwards during an increase in pressure in the fluid, the stop moving the flexible element ( 33 ) against the valve body ( 34 ) and closing the fluid passage of the valve.
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BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to a method of preparing promoted vanadium antimony oxide catalysts useful in catalytic hydrocarbon ammoxidation to α, β-unsaturated mononitriles; i.e., acrylonitrile and methacrylonitrile, catalytic oxidation, and NO x reduction. In particular, the process of the present invention provides promoted VSbO x catalysts useful in the ammoxidation of propane to acrylonitrile.
Because of the price differential between propylene and propane an economic incentive exists for the development of a viable catalytic process for conversion of propane to acrylonitrile.
Earlier attempts in the prior art to develop an efficient process for the ammoxidation of propane to acrylonitrile produced either insufficient yields or processes that necessitated adding halogen promoters to the feed. The latter procedure would require not only reactors made of special corrosion resistant materials, but also the quantitative recovery of the promoter. The added costs thus eliminated the advantage of the propane/propylene price differential.
In U.S. Pat. No. 3,860,534 there are disclosed catalysts for the ammoxidation of propane (or other alkanes) using an excess of propane to both ammonia and molecular oxygen wherein the ranges of the paraffin to NH 3 and to O 2 overlap the ranges of the present process. The catalyst may be mixed with particles of an inert and refractory material, or applied as a layer on the surface of an inert support. Except for such inert materials, the catalyst contains only V, Sb and oxygen. The catalyst is calcined at 350° to 950° C., preferably 700° to 900° C., and particularly 750° to 870° C., and most desirably 790° to 850° C. The essence of the invention is that before use the catalyst is water-washed for long periods in water.
Earlier (earlier filed in the priority country) British patent specification No. 1,336,135, having a common assignee and a common inventor with the aforesaid U.S. patent, discloses inter alia the use of catalysts containing only V and Sb in oxidic form in the ammoxidation of paraffins such as propane at the same alkane to NH 3 and O 2 ratios, the catalysts being calcined at 300©to 950° C., preferably 600° to 850° C. However, the calcined catalysts are not water-washed. The earlier specification also discloses that the catalysts can contain V and Sb and only one other metal. The sole third component disclosed for addition to a V, Sb catalyst is tin, and this is only by way of specific Example III.
U.S. Pat. No. 4,746,641, Guttmann et al. discloses ammoxidation of paraffins including propane and isobutane at ratios of reactants different than the present claims using catalysts that can contain Sn in addition to V and Sb.
British Patent No. 1,336,136, another earlier patent to the common assignee and to a sole inventor who is the common inventor in British Patent No. 1,336,135 and U.S. Pat. No. 3,860,534 is much the same as British Patent No. 1,336,135 but more narrow. Thus, all of the catalysts contain V and Sb in oxidic form with or without only one other metal. The only such other metal identified is tin, which is in Example III, identical to Example III of British No. 1,336,135, already discussed.
Canadian patent No. 901,006 also relates to ammoxidation of propane and isobutane using catalysts of seven different categories. The only pertinent category uses exactly three metals in oxidic form in combination, exclusive of the combination V-Sb-Sn. The three are chosen from Sb, Sn, Ti, V and U. No proportions are suggested, except in specific examples. No specific suggestion of, or specific example of, a catalyst having V, Sb and Ti is disclosed.
Recent U.S. Pat. Nos. 4,784,929, 4,879,264, 5,008,427 and 5,094,989, all assigned to the assignee of the instant application disclosed various procedures for preparation of VSbO x catalyst or VSbO x promoted catalyst useful in the ammoxidation of propane to acrylonitrile.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved process for the manufacture of VSbO x promoted catalysts.
It is a further object of the present invention to provide an improved catalytic ammoxidation process for making unsaturated mononitriles from lower paraffins.
Other objects, as well as aspects, features and advantages, of the present invention will become apparent from a study of the accompanying disclosure and the claims.
According to one aspect of the present invention, the process of manufacturing a catalyst having the following empirical formula:
VSb.sub.m A.sub.a D.sub.d O.sub.x
where A is one or more of Ti, Sn, Fe, Cr, Ga, Li, Mg, Ca,
Sr, Ba, Co, Ni, Zn, Ge, Nb, Zr, Mo, W, Cu, Te, Ta, Se, Bi, Ce, In, As, B and Mn, preferably Ti, Sn, Fe, Cr, and Ge, most preferably Ti and Sn,
D is one or more of Li, Ag, Fe, Co, Cu, Cr, Mn, (VO) 2+ , (PW 12 O 40 ) 3- and (PMo 12 O 40 ) 3-
m is from about 0.5 to 10
a is 0.01 to 10
d is 0. 0001 to 2.0, preferably 0. 0001 to 0.1;
x=number of oxygen ions necessary to satisfy the valency requirement
comprises forming a catalyst precursor having the formula VSb m A a O x wherein m, A, a and x are defined above, adding said one or more D elements to the surface of said catalyst precursor and calcining the surface modified catalyst precursor to produce said catalyst.
The catalyst precursor may be prepared by any method known in the art for synthesis of mixed metal oxides. The synthesis methods of U.S. Pat. Nos. 4,784,979 and 4,879,264 are preferred and are herein incorporated by reference. The catalyst precursor may be unsupported or may be supported on any suitable carrier. The catalysts of the present invention can be used in fixed bed, fluid bed, or transport line reactors or in any other suitable reactor configuration.
Elements D are added to the surface of the catalyst at any stage after the basic VSb m A a O x precursor has been synthesized, e.g., after drying and calcination and before or after the precursor has been washed using water, isobutanol, methanol or other solvents after any of the calcination steps (preferably after washing step). Addition of the D element(s) to the catalyst surface is carried out by one or more of the following methods:
(i) Ion-exchange using water or any other suitable solvent as the medium for the exchange reaction between the catalyst matrix and the soluble reagent(s) or solid(s) (organic and/or inorganic) containing the desired element(s).
(ii) Solvothermal treatment at high temperature (100° to 450° C.) and pressure (>1 atm) using water or any other solvent as the medium for the interaction of the catalyst matrix and the reagent(s) containing the desired element.
(iii) Incipient wetness and/or impregnation using water or any other suitable solvent as the medium for the deposition of the reagent(s) containing the desired element(s) on the surface of the catalyst matrix.
The materials obtained by any of the above methods may then be calcined for their activation in the temperature range of 100° to 1200° C. under an appropriate atmosphere (inert, oxidizing or reducing, under static or dynamic conditions). The materials obtained after calcination may then be used as prepared or further washed with water, isobutanol, methanol, acidic solutions, liquid ammonia, or any other suitable washing medium as disclosed in U.S. Pat. Nos. 3,860,534 and 5,094,989, herein incorporated by reference.
The catalyst is useful for the oxidation and ammoxidation of paraffins, olefins, and aromatic compounds, including propane ammoxidation to acrylonitrile, propylene ammoxidation to acrylonitrile, methylpyridine ammoxidation to cyanopyridine, and m-xylene ammoxidation to isophthalonitrile.
In particular, the catalysts prepared by these methods have been found to provide superior performance in propane ammoxidation to acrylonitrile. Said ammoxidation process using the catalysts disclosed herein is the same as that described in U.S. Pat. No. 5,008,427, herein incorporated by reference.
DETAILED DESCRIPTION OF THE INVENTION
The following examples illustrate the advantages of increased selectivity and/or yield when the instant invention is applied to catalysts for the ammoxidation of propane to acrylonitrile (AN). The examples are illustrative only and are not to be considered in any way limiting.
Ion-Exchange Treatment:
Surface promotion of propane ammoxidation catalysts by Ion-Exchange (IE) was carried out as follows. An aqueous solution of an appropriate compound of the promoting element D at the desired atomic ratio of D element in solution to vanadium in the catalyst (D/V) is placed in a beaker. The appropriate amount of washed precursor catalyst (catalyst prepared in accordance with U.S. Pat. No. 4,784,979 or U.S. Ser. No. 112,027 filed Aug. 26, 1993, and then washed in accordance with the procedure set forth in U.S. Pat. No. 5,094,989, each assigned to the assignee of the instant application and incorporated herein by reference) is added to this solution and the slurry is kept under stirring for at least 1 hour. After the end of this period, the catalyst is separated from the solution and rinsed with deionized water. In the case of multiple ion-exchange, this same procedure is repeated once or twice more. After the ion-exchange procedure is completed, the rinsed catalyst is placed in an oven at 120° C. to dry overnight. The dried catalyst is then calcined in air at the desired temperature for a period of 3 hours. Finally, the catalyst is washed with isobutanol, and placed in an oven at 120° C. to dry overnight. Catalysts prepared by this method were tested in a fluid-bed 60cc unit or in fixed-bed reactor under propane ammoxidation conditions. Results of these tests are summarized in Tables 1 and 2, below.
Table 1A below further demonstrates the results obtained with catalyst prepared according to the process of the present invention. The results set forth in Table 1A are obtained with fixed-bed catalyst where the ion exchange procedure has been performed twice followed by calcination after the second ion exchange procedure. The ion exchange procedure and calcination procedure are performed as described above.
TABLE 1__________________________________________________________________________Ion-Exchange TreatmentFluid-Bed CatalystsExper-iment Precursor Initial Feed Ratios Calcina- ContactNum- Catalyst D Com- D/V in C.sub.3 H.sub.8 /NH.sub.3 / tion Temp. Time, % C.sub.3 H.sub.8 % Propane Selectivity to:ber Composition pound Solution O.sub.2 /N.sub.2 °C. sec conv. AN Acet HCN CO CO.sub.2 C.sub.3 H.sub.6__________________________________________________________________________1 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 None None 5/1.07/2.87/ none 3.7 15.77 59.40 2.70 11.80 11.20 9.90 3.00Com- Ti.sub.0.1 O.sub.x 8.24para-tive2 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 0.004 5/1.06/3.10/ 650 3.0 15.00 62.90 2.50 10.80 10.50 9.40 2.40 Ti.sub.0.1 O.sub.x COO).sub.2 8.623 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 FeCl.sub.2 0.012 5/1.06/3.05/ 600 4.5 14.32 63.30 2.00 10.30 11.30 9.60 2.40 Ti.sub. 0.1 O.sub.x 8.524 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 None None 5/1.0/2.75/ none 2.3 16.01 55.30 2.40 8.30 17.10 14.40 1.10Com- Ti.sub.0.1 O.sub.x 7.82para-tive5 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 0.0024 5/1.07/10/ 650 2.2 16.25 59.20 2.30 9.40 14.50 12.30 1.10 Ti.sub.0.1 O.sub.x COO).sub.2 8.716 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 None None 3/1.03/2.69/ none 5.4 29.29 46.00 1.60 8.60 23.50 19.40 0.40Com- Ti.sub.0.1 O.sub.x 6.9para-tive7 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 0.0024 3/1.04/2.81/ 650 5.6 27.73 49.90 1.60 9.70 20.90 16.70 0.60 Ti.sub.0.1 O.sub.x COO).sub.2 7.28 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 None None 5/0.96/2.99/ none 4.0 15.97 60.60 2.00 10.10 13.70 11.80 0.90Com- Ti.sub.0.1 Co.sub.0.014 O.sub.x 8.36para-tive9 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 CO(CH.sub.3 0.0024 5/1.14/2.96/ 650 3.8 15.62 62.30 2.20 10.80 11.70 11.10 1.20 Ti.sub.0.1 Co.sub.0.014 O.sub.x COO).sub.2 8.5910 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 None None 3/1.07/2.94/ none 7.8 31.58 51.00 1.30 9.20 20.80 16.80 0.30Com- Ti.sub.0.1 Co.sub.0.014 O.sub.x 10.41para-tive11 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 0.0024 3/1.08/2.82/ 650 8.3 31.05 53.30 1.30 9.10 18.50 17.00 0.40 Ti.sub.0.1 Co.sub.0.014 O.sub.x COO).sub.2 10.38__________________________________________________________________________ Pressure = 15 psig Reaction Temp. = 460° C.
TABLE 1A__________________________________________________________________________Ion-Exchange TreatmentFixed-Bed Catalysts After Calcination Precursor Calcination ContactExperiment Catalyst D Initial D/V Temp. after Time, % C.sub.3 H.sub.8 % Propane Selectivity to:Number Composition Compound in Solution IE, °C. sec conv. AN HCN CO C.sub.3 H.sub.6__________________________________________________________________________12 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 3.70 30.92 55.59 10.54 31.31 1.32Comparative Ti.sub.0.1 O.sub.x13 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 COO).sub.2 0.01 650 3.94 29.60 57.99 10.52 29.38 0.90 Ti.sub.0.1 O.sub.x14 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 3.77 30.03 56.11 10.61 31.13 0.94 Ti.sub.0.1 O.sub.x15 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 COO).sub.2 0.01 650 4.02 29.85 58.21 10.74 29.25 0.61 Ti.sub.0.1 O.sub.x16 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 3.55 30.68 56.53 10.40 31.35 0.59 Ti.sub.0.1 O.sub.x17 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 COO).sub.2 0.01 650 3.34 29.78 57.95 10.32 29.74 0.79 Ti.sub.0.1 O.sub.x__________________________________________________________________________ Reaction Conditions: 480° C.; 1 atm; 3.0 C.sub.3 H.sub.8 /1.16 NH.sub.3 /2.88 O.sub.2 /10.31 N.sub.2 /1.94 H.sub.2 O IE = Twice ionexchanged in an aqueous solution having an initial atomic ratio of D element to vanadium in solution (D/V) at 23° C. for at least 1 hour; dried catalyst then calcined in air for 3 hours at indicate temperature. Precursor for ionexchange = V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Ti.sub.0.1 O.sub.x (after second calcination at 650° C. and isobutanol wash)
TABLE 2__________________________________________________________________________Ion-Exchange TreatmentFixed-Bed CatalystsExperiment Catalyst Initial D/V Calcination Contact % C.sub.3 H.sub.8 % Propane Selectivity to:Number Composition D Compound in Solution Temp, °C. Time, sec conv. AN HCN CO C.sub.3 H.sub.6__________________________________________________________________________18 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 1.70 14.70 60.90 11.00 22.60 1.50Comparative Ti.sub.0.1 O.sub.x19 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Co(CH.sub.3 COO).sub.2 0.016 650 2.60 14.70 65.90 9.90 19.40 1.50 Ti.sub.0.1 O.sub.x20 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Li(CH.sub.3 COO) 0.016 650 2.80 14.20 65.10 10.00 20.10 1.40 Ti.sub.0.1 O.sub.x21 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Cu(CH.sub.3 COO).sub.2 0.016 650 3.00 15.20 64.50 10.30 20.90 1.40 Ti.sub.0.1 O.sub.x22 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Cu(CH.sub.3 COO).sub.2 0.016 500 2.10 14.70 61.20 9.90 24.50 1.00 Ti.sub.0.1 O.sub.x23 V.sub.1.0 Sb.sub. 1.4 Sn.sub.0.2 Mn(CH.sub.3 COO).sub.2 0.016 650 3.30 15.80 62.30 10.50 23.00 1.20 Ti.sub.0.1 O.sub.x24 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Cr(CH.sub.3 COO).sub.3 0.016 650 2.90 15.90 64.00 10.20 21.60 1.20 Ti.sub.0.1 O.sub.x25 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 COO).sub.2 0.016 650 2.70 16.00 64.70 10.40 20.70 1.40 Ti.sub.0.1 O.sub.x26 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 VO(CH.sub.3 COO).sub.2 0.016 650 1.40 15.50 60.90 10.40 22.00 2.30 Ti.sub.0.1 O.sub.x27 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 VO(CH.sub.3 COO).sub.2 0.016 500 1.90 15.90 61.40 10.10 23.80 1.30 Ti.sub.0.1 O.sub.x28 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 H.sub.3 (PW.sub.12 O.sub.40) 0.081 500 1.70 14.10 62.00 10.80 21.80 1.70 Ti.sub.0.1 O.sub.x29 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 H.sub.3 (PMo.sub.12 O.sub.40) 0.081 650 1.30 14.40 61.40 10.70 22.20 2.60 Ti.sub.0.1 O.sub.x__________________________________________________________________________ Reaction Conditions: 460° C.; 1 atm; 5.0 C.sub.3 H.sub.8 /1.0 NH.sub.3 /2.8 O.sub.2 /1.0 H.sub.2 O IE = IonExchange Treatment in aqueous solution having a nominal element t vanadium (D/V) ratio at 23° C. for at least 1 hour.
Solvothermal Treatment:
Surface promotion of propane ammoxidation catalysts by HydroThermal Treatment (HTT) was carried out as follows. An aqueous solution of an appropriate compound of the promoting D element at the desired atomic ratio of D element in solution to vanadium in the catalyst (D/V) is placed in the Teflon cup of a Parr Digestion Bomb. The appropriate amount of washed precursor catalyst (catalyst prepared in accordance with U.S. Pat. No. 4,784,979 or U.S. Ser. No. 112,027 filed Aug. 26, 1993 and then washed in accordance with the procedure set forth in U.S. Pat. No. 5,094,989, each assigned to the assignee of the instant application and incorporated herein by reference) is added to this solution, the bomb is closed and placed in an oven at 180° C. for 16 hours. After cooling back to room temperature, the bomb is opened, the catalyst is separated from the solution, rinsed with deionized water and placed in an oven at 120° C. to dry overnight. The dried catalyst is then calcined in air at the desired temperature for a period of 3 hours. Finally, the catalyst is washed with isobutanol and placed in an oven at 120° C. to dry overnight. Catalysts prepared by this method were tested in a fixed-bed micro-reactor under propane ammoxidation conditions. Results of these tests are summarized in Table 3.
TABLE 3__________________________________________________________________________Solvothermal TreatmentFixed-Bed CatalystsExperiment Catalyst Initial D/V Calcination Contact % C.sub.3 H.sub.8 % Propane Selectivity to:Number Composition D Compound in Solution Temp, °C. Time, sec conv. AN HCN CO C.sub.3 H.sub.6__________________________________________________________________________30 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 2.40 14.50 61.40 10.00 22.10 3.40Comparative Ti.sub.0.1 O.sub.x31 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 H.sub.2 O only none none 2.70 14.90 60.80 9.30 25.30 1.90 Ti.sub.0.1 O.sub.x32 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 LiOH 0.001 650 2.60 14.40 62.80 9.90 22.10 2.40 Ti.sub.0.1 O.sub.x33 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 LiOH 0.001 650 2.70 14.50 63.70 8.40 23.40 1.50 Ti.sub.0.1 O.sub.x34 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 LiOH 0.001 700 3.10 13.40 63.50 10.00 23.20 0.30 Ti.sub.0.1 O.sub.x35 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 AgNO.sub.3 0.001 650 2.80 14.20 63.40 10.60 22.00 1.20 Ti.sub.0.1 O.sub.x36 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 CO(NO.sub.3).sub.2 0.001 650 2.80 14.80 63.40 8.50 24.40 0.90 Ti.sub.0.1 O.sub.x37 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 2.20 15.70 61.80 8.00 25.90 1.50Comparative Ti.sub.0.1 O.sub.x38 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 H.sub.2 O only none 650 3.10 15.20 62.40 8.00 26.70 0.30Comparative Ti.sub.0.1 O.sub.x39 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 COO).sub.2 0.001 650 2.70 15.10 65.10 9.60 22.60 0.00 Ti.sub.0.1 O.sub.x40 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 COO).sub.2 0.0005 650 3.10 15.20 64.30 8.90 23.90 0.40 Ti.sub.0.1 O.sub.x41 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Cr(CH.sub.3 COO).sub.3 0.001 650 3.20 15.60 62.50 8.10 26.60 0.30 Ti.sub.0.1 O.sub.x42 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Mn(CH.sub.3 COO).sub.2 0.001 650 3.20 15.30 62.40 8.30 26.20 0.60 Ti.sub.0.1 O.sub.x__________________________________________________________________________ Reaction Conditions: 460° C.; 1 atm; 5.0 C.sub.3 H.sub.8 /1.0 NH.sub.3 /2.8 O.sub.2 /1.0 H.sub.2 O HTT = Hydro Thermal Treatment in aqueous solution having a nominal D element to vanadium (D/V) ratio at 180° C. for 16 hours.
Impregnation Treatment:
Surface promotion of propane ammoxidation catalysts by Impregnation (IMP) was carried out as follows. An aqueous solution of an appropriate compound of the D promoting element at the desired atomic ratio of D element in solution to vanadium in the catalyst (D/V) is placed in a Pyrex flask. The appropriate amount of washed catalyst precursor (prepared in accordance with the procedure set forth previously) is added to this solution. The flask containing the slurry is attached to a Rotoevaporator. The slurry in the flask is then evaporated to dryness by rotating the flask in a water bath at 55° C. under a slight vacuum for at least 3 hours. After the end of this period, the catalyst is removed from the flask and placed in an oven at 120° C. to dry overnight. The dried catalyst is then calcined in air at the desired temperature for a period of 3 hours. In the final step the catalyst is washed with isobutanol and placed in an oven at 120° C. to dry overnight. Catalysts prepared by this method were tested in a fixed-bed micro-reactor under propane ammoxidation conditions. Results of these tests are summarized in Table 4.
TABLE 4__________________________________________________________________________Impregnation TreatmentFixed-Bed CatalystsExperiment Catalyst Initial D/V Calcination Contact % C.sub.3 H.sub.8 % Propane Selectivity to:Number Composition D Compound in Solution Temp, °C. Time, sec conv. AN HCN CO C.sub.3 H.sub.6__________________________________________________________________________43 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 2.40 14.50 61.40 10.00 22.10 3.40Comparative Ti.sub.0.1 O.sub.x44 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 LiOH 0.001 650 4.60 14.40 62.70 8.60 23.70 2.30 Ti.sub.0.1 O.sub.x45 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 none none none 2.20 15.70 61.80 8.00 25.90 1.50Comparative Ti.sub.0.1 O.sub.x46 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 COO).sub.2 0.001 650 4.20 15.40 63.50 8.50 24.80 0.90 Ti.sub.0.1 O.sub.x47 V.sub.1.0 Sb.sub.1.4 Sn.sub.0.2 Fe(CH.sub.3 COO).sub.2 0.001 700 4.10 14.60 63.90 8.90 24.50 0.20 Ti.sub.0.1 O.sub.x__________________________________________________________________________ Reaction Conditions: 460° C.; 1 atm; 5.0 C.sub.3 H.sub.8 /1.0 NH.sub.3 /2.8 O.sub.2 /1.0 H.sub.2 O IMP = Impregnation Treatment in aqueous solution having a nominal D element to vanadium (E/V) ratio at 55° C. for at least 3 hours.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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The process of manufacturing a catalyst having the following empirical formula:
VSb.sub.m A.sub.a D.sub.d O.sub.x
where A is one or more of Ti, Sn, Fe, Cr, Ga, Li, Mg, Ca, Sr, Ba, Co, Ni, Zn, Ge, Nb, Zr, Mo, W, Cu, Te, Ta, Se, Bi, Ce, In, As, B and Mn,
D is one or more of Li, Ag, Fe, Co, Cu, Cr, Mn, (VO) 2+ , (PW 12 O 40 ) 3- and (PMo 12 O 40 ) 3-
m is from about 0.5 to 10
a is 0.01 to 10
d is 0.0001 to 2.0, preferably 0.0001 to 0.1;
x=number of oxygen ions necessary to satisfy the valency requirement
comprising forming a catalyst precursor having the formula VSbmAaOx wherein m, A, a and x are defined above, adding at least one D element to the surface of said catalyst precursor and calcining the surface modified catalyst precursor to produce said catalyst.
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This is a division of application Ser. No. 07/753,302 filed Aug. 30, 1991.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present application relates to medical diagnostic apparatus for introducing a high intensity light beam into a fiber optic cable.
2. Description of Related Art
Fiber optic cable illumination apparatus is used for medical diagnostic purposes wherein a focused lamp supplies light to an optic cable interface. Such devices operate most efficiently when the proper lamp is properly focused. However, present units permit improper lamps to be substituted during lamp replacement. Additionally, present illumination apparatus requires manual electrical connections be made during lamp replacement necessitating a higher degree of skill by the operator than is desirable.
Fiber optic systems are known to have inefficient light introduction interfaces due to the spaces between the fibers which contribute little to the interface when the light source impinges directly upon them. Also, due to the contour of the light beam impinging on the flat, planar fiber ends, an effect known as Newtonian ring interference causes rings of color light to appear at the cable output which reduces the illumination quality of the cable bundle. Known illumination apparatus have not effectively overcome this phenomenon.
OBJECTS OF THE INVENTION
In view of the foregoing deficiencies of medical illumination apparatus, it is an object of the invention to provide a more powerful and efficient high intensity light source for the transmission of light by means of fiber-optical cables.
A further object of the invention is to provide an essentially pure white light for fiber-optical cable transmission and to provide a more efficient application of light to a fiber optical cable interface.
Yet another object of the invention is to provide a method of preventing electrical shock to personnel servicing the lamp assembly when the lamp supporting drawer is extended and to insure proper electrical connection to the lamp assembly before energizing the lamp electrical connections.
A further object of the invention is to provide a lamp replacement system for medical diagnostic apparatus which substantially eliminates the likelihood of improper lamps being installed through the use of an electrical interlock which completes the circuit to the lamp only upon the proper lamp being properly positioned with respect to the optical cable interface.
SUMMARY OF THE INVENTION
These objects are accomplished, in part, through the novel use of an internally focused metal halide arc lamp as a light source for medical diagnostic illumination apparatus. The halide arc lamp provides a significantly greater light intensity than a comparable wattage incandescent lamp. Additionally, the halide arc lamp provides light of a multi-color spectra through a differential reflector focusing configuration such that the light quality at the focal beam is adjusted to achieve an exceptionally intense white light which is superior for purpose of illumination in the medical field wherein the light source is distributed through fiber optic cables.
It has been found that among the problems attendant with fiber optic light transmission technology is the inefficient transmission of light into the cables through the fiber optic cable interface and the presence of Newtonian interference rings at the cable output. The invention employs a metal halide arc light having a focused output beam having an axis, the focal point of the beam is directed to impact at the fiber optic cable interface and the beam axis is at an angle of about 10° relative to the cable interface axis. This angle increases the amount of light carried through the cable through enhancement of the acceptance angle of the converging beam to the end of the cable bundle while also minimizing the Newtonian ring interference at the light output.
In order to avoid potential shock hazard, the circuit to the bulb power receptacles located in the housing and the bulb connectors mounted on a slidable drawer supporting the lamp is interrupted when the drawer is opened to expose the lamp for replacement purposes. The electrical circuit to the lamp is automatically restored when the drawer is closed.
Further, the apparatus includes an interlock feature located on a bracket directly attached to the proper lamp and when a proper lamp and bracket are installed, an interlock tab defined on the lamp mounting bracket closes an electrical interlock switch when the bracket is properly positioned which completes the circuit to the bulb power receptacles. This unique tab interlock is such that improper lamps placed within the bracket cannot activate the unit, nor can the electrical interlock switch be inadvertently activated through other means.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be clearly understood, it will now be described, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of medical diagnostic illumination apparatus in accord with the invention having a lamp supporting drawer partially extended from its cabinet enclosure,
FIG. 2 is an enlarged detail cut-away perspective view of the cabinet and drawer as viewed from the drawer outer side,
FIG. 3 is an enlarged plan detail cut-away view showing the lamp bracket interlock switch assembly,
FIG. 4 is a elevational detail view, partly in cross-section, showing the bracket interlock tab engaging the interlock switch, the insulator columns being omitted for purposes of illustration,
FIG. 5 is a front elevational view of the lamp bracket, per se,
FIG. 6 is a rear elevational view of the lamp bracket partially inserted into the lamp bracket holder per se, the insulator columns not being illustrated,
FIG. 7 is a elevational detail side view, partially in cross-section of the heat sink and lamp assembly, the insulator columns and lamp bracket holder being omitted for purpose of illustration,
FIG. 8 is a detail plan view, partially in section, of the drawer face and lamp assembly, the lamp bracket holder being omitted for purpose of clarity,
FIG. 9 is a detail plan view of the lamp assembly lamp plugs in engagement with the floating receptacle bracket when the drawer is closed,
FIG. 10 is an elevational detail sectional view of the connector system showing lamp plug engagement with the floating receptacle bracket when the drawer is closed, the lamp components and the lamp bracket holder being omitted for purpose of illustration
FIG. 11 is an elevational view of the lamp assembly and bracket, per se, the insulator columns being omitted for purpose of illustration,
FIG. 12 is an enlarged detail elevational view of the floating lamp connector, partially in section, and
FIG. 13 is an elevational view of the floating receptacle connector member as taken along 13--13 of FIG. 10.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A medical diagnostic fiber optic light source apparatus for the supplying of light for illumination to a fiber optic cable interface utilizing the invention is generally indicated at 10 of FIG. 1, and the light source apparatus includes a cabinet housing 12 with a slidingly insertable drawer 14 adapted to facilitate component maintenance. Inside the housing 12 is a standard power supply, not shown, which provides electrical power to the drawer circuitry.
When the drawer 14 is extended from the cabinet front opening compartment 16, the resulting exposed, energized electrical surfaces pose an electrical shock hazard which is avoided in the invention by using a separating connector system, as illustrated in FIG. 10, which automatically electrically disconnects an installed 250 watt focused beam metal halide arc lamp 18, as the drawer is withdrawn from the cabinet.
The separating connector system comprises two power connector pins 20 on standoff insulators 22 which horizontally extend from a vertically mounted lamp bracket 24 with a bridging insulative spacing member 26 between them. Electrical connection between the pins 20 and the metal halide arc lamp 18 are made by wires 28 extending from a lamp base connector 30 and a second lamp terminal 31 to solder pads on the spacing member 26 in electrical connection with the power connector pins 20. These rigidly extending pins 20 make connection with two complementary aligned, longitudinally spaced radially floating sleeve connectors 32 mounted upon and through an opposing insulated cabinet mounted receptacle bracket 34 when the lamp bracket 24 is correctly seated in the lamp bracket holder 36 which is fixed to the drawer 14.
The cabinet receptacle bracket 34 is fabricated of a durable insulating material such as nylon secured by screws 38 to a contiguous cabinet mounting plate 40, FIG. 2. While the preferred embodiment employs enlarged sleeve connector mounting holes 33 in the bracket 34 which cooperate with floating sleeves connectors 32 and their associated connector nuts 42 which are secured in a spaced relationship to the bracket 34, it is anticipated that other locations and connector types may be substituted for the configuration of the preferred embodiment without departing from the inventive concepts. The space 44 between the bracket and the floating sleeve connectors allows the sleeve connectors 32 to axially pivot thereby facilitating alignment with the pins 20 which enables the drawer to be closed and the electrical connections made in spite of any relatively minor pin and sleeve connector misalignment which may exist. Electrical connection is made to the sleeve connectors 32 by means of a ring lug connector terminated wire 46 which is secured between the two connector nuts 42 and to which electrical current is supplied by the power supply, not shown.
An interlock switch 48 prevents power supply energization unless the arc lamp bracket 24 is properly in place as is sensed by the cooperation of a lamp bracket interlock tab 50 with the interlock switch plunger 52. The lamp bracket lower edge 54 engages the lamp bracket holder bottom flange 56 when the bracket 24 is fully inserted, as illustrated in FIG. 2. As seen in FIG. 6, the lamp bracket side edges 58 slidingly engage spaced lamp bracket holder guide tabs 60, homogeneously formed of the bracket holder material, thereby assuring proper lamp bracket alignment as the bracket 24 is inserted into the guide tabs 60 for parallel mounting upon holder 36. Should improper bulb installation occur, the power connector pins 20 will not align with and engage the cabinet floating sleeve connectors 32 thereby preventing power from being applied to the lamp 18. Furthermore, the bracket interlock tab 50, an extension of the lamp bracket 24, will ensure that the floating sleeve connectors 32 will be activated only if the lamp 18 is correctly in place prior to closing the lamp drawer 14. The tab construction is such that other bulbs placed within the unit cannot activate the unit, nor can the unit be activated by another means. When the lamp bracket 24 is properly fully seated in the lamp bracket holder 36, the interlock tab 50 extends downward through a drawer interlock hole 62, FIG. 4, which is mounted on the drawer bottom surface 64 adjacent and beneath the lamp bracket holder.
The interlock switch 48 is mounted to the lower surface to the drawer bottom 64 in a longitudinal orientation. The plunger 52 longitudinally extends from the interlock switch 48 to a position beneath the drawer interlock hole 62 and the plunger end is beveled to provide a cam surface engageable by tab 50 which axially displaces the plunger when the lamp bracket 24 is correctly and fully seated. The interlock switch 48 interrupts the electrical power to the cabinet power supply if the arc lamp 18 is not installed or is improperly installed thereby assuring safe operation.
The mounting alignment and location of metal halide lamps is critical for the proper application of highly focused light onto the associated fiber optic bundle. By using an interlock tab 50 in conjunction with the square lamp bracket holder 36 and bracket holder guide tabs 60, the lamp assembly is not only positioned laterally, but is also maintained in the preferred square, vertical position by the engagement of the lamp bracket top flange 70 and the bracket holder top edge 55.
The employment of an internally focused beam high intensity metallic halide arc lamp in accord with the invention provides a white light for illumination which is less prone to affect target color appearance than one of a yellow hue, and to the inventors' knowledge, such lamps have not been used previously with medical diagnostic apparatus. The light output of a metal halide arc lamp is a consequence of the process by which a differential reflector focusing technique is applied to the light of multiple color spectra such that the light quality at the focal beam is adjusted to achieve white light. Furthermore, the lamp provides significantly greater light intensity for a given wattage bulb than that which can be attained with an incandescent lamp.
The invention anticipates that in order to use a metal halide arc lamp a special configuration must be employed in order to provide enhanced performance, acceptable service life and economical construction. One of the critical factors associated with the very high intensity of metal halide lamps is the characteristically great amount of lamp heat generated by the lamp's operation, and specifically present in the light beam at its focal point 72, FIGS. 7 and 8. In order to safely dissipate the arc lamp heat and minimize thermal stresses to the system components, three techniques are used.
First, by employing a member interposed between the arc lamp 18 and bracket 24 which will allow for thermal expansion of the lamp and components coming in contact with it, mechanical stresses to the components can be minimized thereby increasing service life. Such a member's effectiveness in minimizing stresses can be further enhanced if it has good insulative qualities. In the preferred invention, spacers 74 are interposed between an annular circumferential ceramic halide arc lamp collar 76 and the lamp bracket 24. The halide arc lamp collar 76 is interposed adjacent to the lamp face 78 and spaced from the lamp bracket 24 to minimize drawer face heating. The spacers 74 in this configuration serve several purposes: a) they remove the lamp face from the bracket; b) they provide a means of adjustment for lamps having diverse focal points; and c) by using spacers of diverse selected lengths, the focused lamp beam axis and bundle interface angle can be varied to enhance the bundle interface angle of acceptance.
The support of the halide arc lamp on the bracket 24 is completed by fixing the halide lamp intermediate the collar spacers 74 and four washers 86 mounted on spaced standoff insulators 82. Each standoff insulator 82 is mounted upon and extends from the lamp bracket 24 alongside the lamp collar 76 and is secured with a screw 84 to securely clamp the arc lamp 18 into place between a spacer 74 and a washer 86 as can be appreciated by reference to FIG. 9.
Secondly, a vaned heat sink 88 is placed intermediate the lamp bracket holder 36 and the drawer face 90, which has a central aperture 92 for passage of the lamp light beam 94 through the heat sink 88 to the fiber optic bundle interface 80, FIG. 8. Air is constantly forced over the heat sink 88 by a fan within cabinet 12 discharging air through port 95, FIG. 1, thereby keeping drawer face 90 temperatures within an acceptable range.
Thirdly, the drawer face heating due to arc lamp radiation is also minimized by the orientation of the lamp beam axis at an approximately 10° horizontal angle relative to the face plane and bundle central axis 96, as seen in FIG. 8, which allows proper application of the light to the fiber optic interface yet minimizes the heat applied to the forward face of the drawer and the enclosure.
The most important benefit of angling the arc lamp to the optic bundle axis is an increased efficiency of light transferred to the bundle from the beam focal point 72 at the bundle interface 80. In using metal halide arc lamps in conjunction with fiber optic cables, it has been found that by directing the light to the bundle interface at an angle, rather than in alignment with the bundle axis, a more efficient transfer of light results due to enhancement of the acceptance angle of the converging beam to the end of the bundle, consequently, more light is transferred to and carried through the bundle. It has been determined that by deviating the lamp beam axis between 8° and 12° from the optic fiber bundle axis optimum improved results are achieved, and preferably, a 10° angle deviation is employed.
Newtonian ring interference patterns normally occur which degrade the output light quality from fiber optic cables. Newtonian rings are caused by light interference from the contact of the conical light wave's spherical front when it contacts the planar fiber optic fiber interface. The invention's significant advancement to the art of angling the arc lamp as previously described improves the quality of light at the bundle output by the minimization of Newtonian ring interference patterns.
A turret assembly 98 is located on the drawer face 90 which is rotatable and selectively aligns the fiber optic interface of one of several sizes of fiber optic cables with the aperture 92, the appropriate size of cable may be inserted in the correspondingly sized connection sleeve 102. The cables are secured by set screws 106 installed on each of the several turret connection sleeves 102.
It is appreciated that various modifications to the inventive concepts may be apparent to those skilled in the art without departing from the spirit and scope of the invention.
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The invention pertains to a fiber optic lamp system such as those employed in medical diagnostic systems using a cabinet containing a power supply having a front extendible drawer containing a 250 watt focused beam metal halide arc lamp mounted in a removable bracket which includes a sensing tab extension. The bracket sensing tab operates an electrical interlock switch when the proper lamp is properly installed. The interlock switch controls power to the system whose circuit includes pin and floating sleeve electrical connectors which automatically directly completes the circuit to the arc lamp upon the drawer being closed. The amount of light transferred to the fiber optic cable is optimized by offsetting the axis of focused light with respect to the optic cable axis at the cable interface.
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FIELD OF INVENTION
The present invention relates to new and useful mine strata support structure and components thereof and, more particularly, presents a bracket, generally a mine roof bracket, that is provided a bearing plate and a depending body having a rearward pocket indentation. A connector, generally in the form of a U-configured stirrup, inter-engages with the bracket, the bracket being supplied with a stop or travel delimiting structure, generally spaced from the body, whereby to deter excessive rearward travel of the stirrup that would chance decoupling of the stirrup from the bracket.
DESCRIPTION OF PRIOR ART
A number of different types of trussing structures, whether useful in active or passive mode, or both, has previously been devised and extensively used in underground mines. A variety of brackets and connectors of prior design have been employed for achieving the trussing and/or support function desired.
One such prior structure is disclosed in the inventor's prior U.S. Pat. No. 5,026,217, issued Jun. 25, 1991 and entitled MINE ROOF SUPPORT TRUSS AND COMPONENTS. Other structures are shown an another of the inventor's patents, see U.S. Pat. No. 5,176,473, issued Jan. 5, 1993 and entitled MINE ROOF TRUSS AND COMPONENTS. The disclosures of both of these patents are fully incorporated herein by way of reference. In connection with the truss system shown in these patents as well as trussing systems shown in other literature, there may occur the problem of "bumps" or minor earthquakes in the mine strata, which infrequently can occur, owing to a shift or cleavage in the mine roof strata. Indeed, there can occur a situation wherein the trussing system will experience, momentarily, considerable slack, on account of which the connector such as a stirrup will travel rearwardly relative to the bracket pocket so as to chance disengagement altogether of the stirrup or other connector with the bracket. In such event, the stirrup and the tie rod structure associated therewith may chance to fall downwardly, thus negating the truss effect and actually constitute a safety hazard to mine personnel.
BRIEF DESCRIPTION OF INVENTION
According to the present invention, the truss system includes mine brackets and connectors, e. g. stirrups, wherein structural design facilitates selective engagement and also disengagement of a stirrup from the bracket, but wherein component structures are dimensioned so as to preclude the inadvertent disengagement of the stirrup from the bracket during instances of strata-shock when temporary slack is experienced by the truss. In one form of the invention the respective mine brackets include a depending vertical protuberance which is generally integral with the bearing plate of the respective bracket. This depending protuberance or projection serves as a travel stop to delimit the rearward travel of the stirrup or other connector such that the stirrup cannot become disengaged from the body of the mine bracket once the struss is operationally installed; yet, the depending protrusion is positioned relative to the bracket body, for example, so as to supply sufficient space for the stirrup to be preliminarily inserted, as through a structurally formed passageway, such that the stirrup can be installed and also disassembled relative to the body of the bracket.
The bracket itself, in one form of the invention, may have a body provided with a rearwardly extending portion having an upper periphery formed as a cradle, i.e. with the lower portion having in this regard an upstanding lip. Accordingly, for portage of the bracket and its stirrup, the latter may hang vertically from the cradle of the bracket so that a workman can easily carry the combination to a desired point for bracket securement. Alternatively, the lower portion of the body of the bracket may include laterally extending, essentially horizontal ears or projections which serve to keep the stirrup from becoming disengaged relative to the bracket. In either or both instances, in the present invention the depending stop-projection, depending from the bearing plate of the mine roof bracket, is spaced rearwardly, in one form of the invention, from the rearward terminal of the lower portion of the bracket body so as to provide a vertical passageway whereby the stirrup can be easily slipped into the passageway and later rotated and positioned in place for engagement with the bracket body at its reward indentation. However, the lower portion of the bracket body will be configured, whether by ears, lip, or otherwise, or structural components are constructed, dimensioned and arranged, such that when a strata "bump" occurs, the stirrup's travel rearwardly is delimited by the downward projection or stop, above described, such that for normal operating conditions of the truss, the stirrup will in nowise become disengaged from the bracket body. Generally speaking, and in one form of the invention, there will be an overlap and thus an interference as between the rear curved portion of the stirrup and the lower portion of the bracket body. The stirrup is likewise designed for ease of fabrication and satisfactory performance for tie rods of enlarged diameter. In the larger view, the invention herein comprehends all bracket-connector structures where a stop is provided, relative to the connector, e. g. stirrup, so as to preserve bracket-connector connection even during periods of the existence of structural slack.
OBJECTS
Accordingly, a principle object of the present invention is to provide new and improved truss structure.
The further object is to provide, in one form of the invention, a mine bracket having a bearing plate and body extending therefrom and integral therewith, the bracket also including a depending protrusion proximate to but spaced from the rearmost area of the bracket body, whereby to delimit connector travel in the event of slack being developed in a truss incorporating the bracket.
A further object is to provide a bracket equipped with one of several types of structure, whereby the bracket is useful for vertical portage of a stirrup cradled thereby and, most importantly, wherein a vertical stop projection depends from the bearing plate of the bracket and is spacedly disposed, relative to a receiving indentation, forming a reaction surface, of the bracket whereby vertical travel of a stirrup, mounted over the bracket body is delimited in extent, the lower portion of the bracket being configured so as to overlap or interfere with any inadvertent downward travel or dropping off of the rearward portion of the stirrup for all operating conditions of the truss within which the stirrup and bracket are employed.
An additional object is to provide and improved stirrup connector for mine trusses.
A further object is to provide an improved mine bracket, useful particularly in mine roofs although not delimited in such usage, wherein the same incorporates restraining structures so as to delimit a connector movement relative to the bracket during periods of mine strata shock and/or stratashift.
A further object of the present invention is to provide new and improved mine truss components, whether the truss be of active or passive nature.
An additional object is to provide a new and improved mine bracket.
A further object is to provide a new and improved stirrup structure for use in mining structures.
An additional object is to provide an improved combination of stirrup and mine roof bracket wherein the components are dimensioned and configured such that the stirrup will not become disengaged inadvertently from the bracket once the combination of the stirrup and bracket are installed and a truss containing the same is operationally disposed in place.
A further object is to provide a mine roof bracket having depending projection disposed rearwardly of the bracket body and mutually spaced therefrom so as to provide a travel path for a stirrup to be installed on the bracket body, yet delimit the rearward travel of such stirrup so that the stirrup does not become inadvertently disengaged from the bracket body.
A further object is to provide a mine bracket having a bearing plate and a body integral and depending therefrom, the body including a rearward reaction surface and a lower portion, such lower portion being configured, whether by upstanding lip, lateral ears, or otherwise, to accommodate both portage of a stirrup when in vertical hanging position and also, owing to the vertical projection inclusion, accommodating passageway insertion of the stirrup for mounting purposes, yet delimiting rearward travel of such stirrup during truss installation and operation whereby to maintain bracket-stirrup inter-engagement.
IN THE DRAWINGS
The present invention may best be understood by reference to the following detailed description, taken in connection with the following drawings in which:
FIG. 1 is a side elevation, partially in section, of a portion of a mine roof truss installed against the roof of mine strata, the truss incorporating the mine roof bracket and stirrup or connector of the present invention.
FIG. 2 is a bottom view, looking upwardly, of the bracket and stirrup of FIG. 1, the phantom lines representing an extension of the stirrup illustrating that rearward travel of the stirrup is delimited, owing to one or more depending stop-abutments or projections disposed rearwardly of the bracket body.
FIG. 3 is an end view of the right end of the structure of FIG. 2
FIGS. 4 and 5 are each respectively similar to FIG. 2, but with a single depending projection being employed, and illustrate that when the stirrup and mine roof bracket are aligned in quadrature or 90 degree relationship, the stirrup can be advanced from the position shown in FIG. 4 to the position seen in FIG. 5, whereby a leg of the stirrup comes up through the travel path proved between the depending projection and the lower portion of the bracket body.
FIG. 6 is a detail of the structure to the left side of FIG. 1 illustrating that, upon successive rotations, the central curved portion of the stirrup can be advanced rearwardly and downwardly for obtaining stirrup release; alternatively, the stirrup can be installed or re-installed in similar manner, the direction of the arrows of course being reversed as to direction.
FIG. 7 is similar to FIG. 1, is in reduced scale, and illustrates an alternate bracket configurement.
FIG. 8 is a bottom view looking up at the structure of FIG. 7, illustrating the overlap or interference of ears supplied the lower portion of the bracket body, even when the stirrup travels rearwardly, whereby to keep the stirrup in engagement with the bracket even though, through strata shift, slack is developed in the truss so as to produce a rearward travel of the stirrup; in FIG. 8 the phantom line, which is essentially horizontal, illustrates the quadrature relationship of the stirrup and mine roof bracket whereby the stirrup intentionally can be removed from or installed upon such bracket.
FIG. 9 is similar to FIG. 2 but illustrates an embodiment wherein the structure is foreshortened, whereby the structure presents a self-contained stop, of whatever form and constituted by whatever components, so as to delimit rearward sturrup travel relative to the mine roof bracket body.
FIG. 10 is a perspective view of a mine bracket having plural body portion extensions provided with plural stirrup-travel-delimiting stop projections.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 mine roof strata 10 includes a roof surface 11 and also roof bolt admittance aperture 12. Mine bracket 13, generally a mine roof bracket, is secured in place by anchor bolt or roof bolt 14, anchored in aperture 12 as by conventional epoxy, point anchor, etc., in a customary manner, and provided with tightening nut 15 threaded thereon. Threads 16 are provided the bolt 14 to accommodate nut 15. Mine bracket 13 in FIGS. 1 and 2 is shown to included a bearing plate 17 and also a body 18 which is integral and/or fixedly disposed therewith and secured thereto. Where the mine bracket is cast, then bearing plate 17 and body 18 will comprises respective portions thereof. Body 18 includes a forward canted surface 19 which is provided with aperture 20. Aperture 20 is in line with aperture 21 of bearing plate 17, forming a composite aperture 20B (see FIG. 6) and thus is aligned with the aperture 12 of the mine roof strata. Body 18 includes a horizontal rearwardly oriented and extending lower portion 22 which, in the embodiment shown in FIGS. 1 and 2, is provided with an upstanding lip 23 in part forming cradle 24. Cradle 24 in turn is contiguous with a rearward indentation 25 that serves as a seat or stirrup mount reaction surface 25A for curved portion 26 of U-configured member 27. U-configured member 27 forms the principal part of a stirrup 28, the latter having an end fitting 29. End fitting 29, see FIG. 3, is preferably formed of a face-to-face disposed pair of curved, aperture forming elements 30 and 31. Elements 30 and 31 are welded together at W and also to the ends or extremities 32 and 33 of legs 34 and 35. Legs 34 and 35, with interconnecting medial portion 26, comprise the stirrup principal member or U-configured member 27 of stirrup 28. Stirrup 28 is brought into tension by the employment of a threaded tie rod 36 having threads 37 accommodating securement nut 38 which is threaded thereon. The remainder of truss T, comprised of the tie rod 36, bracket 13, and stirrup 28, is not shown (to the right of tie rod 36), but can comprise similar structure to that shown. Stirrup 28, with or without the inclusion of tie rod 36, may be thought of as a connector that loops around body 18 of mine bracket 13. In this regard, indentation 25 comprises a rearward pocket constituted by reaction surface 25A which is preferably concave in a vertical plane but arcutely convex in a horizontal plane; the edge surface thereof, therefore, is preferably convex to cooperate with the curved nature of medial portion 26 of stirrup 28.
Of special importance is the inclusion of a depending stop member or projection 39. The same projects downwardly and it is mutually spaced downwardly from the rearward indentation 25 or body 18 and also is spaced from upstanding lip 23. Thus, there is a passageway P which is provided for the selective reception and also disengagement of the stirrup 28 relative to the body 18 of the bracket 13. The contour and dimensions of medial portion 26 of the stirrup and the placement and extent of depending projection 39 are chosen such that, in the normal operating condition, there will be no disengagement of the stirrup 28 from body 18 of mine bracket 13 whatever the condition, intermittent shock or "bump" experienced by the mine strata. This is to say, if there is a strata shift or other strata disturbance tending to produce slack in the truss at T, yet the rearward movement of the stirrup 28 will be delimited by the positioning of and engagement with the stirrup of projection 39 so that there will be an overlap of portions of the lower portion 22 of body 18 relative to medial portion 26 of the stirrup. See in this regard FIG. 2, wherein it is clearly seen that when the stirrup advances to the phantom line condition shown at 28', a point at which the stirrup engages the depending stop member or projection 39, the lower portion will be of sufficient lateral dimension so as to be in interference with the dropping down of the stirrup 28 when the same assumes its position at 28'. FIG. 4 illustrates that in the situation wherein a decoupled stirrup 28 is to be removed from the bracket, it is simply advanced to the left to the position indicated in FIG. 5, wherein the right leg 34 is lifted upwardly and the user simply pulls toward himself the stirrup such that leg 35 advances out of passageway P. Assuming the reverse situation wherein the stirrup 28 is to be installed, the plane of the stirrup will be disposed normal to the surface S of bearing plate 17 and it is simply slipped downwardly, relative to FIG. 4, and then manipulated to a horizontal position, whereat, and owing to the rearward indentation 25, see FIG. 1, the stirrup can be twisted about a vertical axis 90 degrees to assume the position shown in FIGS. 1 and 2.
It is important to note that the vertically depending projection or stop at 39, in the embodiment shown in FIG. 2, is disposed rearwardly of reaction surface 25A of the body of the mine roof bracket 13. This is preferred and contributes to ease of designing the cooperating structures so that the stop serves to preclude unwanted disengagement of the stirrup 28 relative to body 18 during operative conditions of slack in the truss system. However, one or more projections 39B depending from the bearing plate 17 or associated structure can be employed, with or without projection 39, which need not be disposed rearwardly of lip 23 or reaction surface 25A, so long as the stop function is retained; i.e., there is an engagement of the stirrup relative to such stop structure for delimiting stirrup rearward travel whereby the inter-coupling of the stirrup with the bracket body is retained while the truss is installed and regardless of "bumps" or other stress experienced by the mine roof strata. Whatever and wherever the nature of the stops, however, they should be so placed and the complementary structure designed such as to provide for preliminary installation, and also desired intentional manual removal of the stirrup relative to the bracket body.
FIG. 6 illustrates that the mine bracket 13, generally comprising a mine roof bracket, includes a canted composite aperture 20B comprised of aligned apertures 20 and 28 relative to body 18 and bearing plate 17. Nut 15 in FIG. 6 secures the bracket 13 to and against bearing surface 11 of mine roof strata 10 in FIG. 1. Should it be desired to manipulate the stirrup 28 into a disengaged position relative to bracket 13, then the medial portion 26 of the stirrup is advanced in the direction of the arrows to the rearward position, thus abutting projection 36 as seen at 31, and then be dropped downwardly from A1 to the position shown at A2. The reverse case is also clearly possible. Thus, whether the mine bracket is mounted or is in a dismount condition, the medial portion, or even a leg 34, 35 of the stirrup can be advanced into passageway P and advanced from a position A2 to position A1 and thereafter turned and rotated so as to assume the normal installed position relative to stirrup 28.
A connector or tie rod receiving aperture 40 is formed by the curved, aperture-forming elements 30 and 31 in FIG. 3, to provide access for the threaded tie rod 36 in FIG. 1 and the securement thereof in place by means of nut 38.
FIGS. 7 and 8 illustrate an additional embodiment of the invention wherein the body, now 18A, of mine roof bracket 13A corresponding to mine roof bracket 13 in FIGS. 1 and 2, takes a slightly different form but does include aperture 20A. The stirrup 28 in its design can be essentially identical, the same incorporating the threaded tie rod 36 which is secured to other structure, not shown. End fitting 29 is of course welded as before to the U-configured member 27. As to the new bracket in FIGS. 7 and 8, namely bracket 13A, the same includes a bearing plate 17A and, depending therefrom, body 18A which is provided with rearwardly extending lower portion 22A. This time, the lower portion 22A, corresponding to lower portion 22 in FIG. 1, includes laterally extending ears or projections 41 and 42. The purpose for these projections will become clear upon reference to FIG. 8. Thus, should a jarring or "bump" occur effecting the mine strata so as to tend to produce slack in the mine truss, the rearward advancement of stirrup of 28 will be delimited by the inclusion of the stop 39A which corresponds to the stop or projection 39 in FIG. 1. It is noted that at this point the curved medial portion 26 will have advanced to 26A in FIG. 8. However, at this point the ears or extensions 41 and 42 will operate as an interference or retainer such that the stirrup in its customary orientation will be unable to drop out of pathway PA corresponding to passageway P in FIG. 1. Thus, there is no chance for the stirrup to become inadvertently disengaged relative to the mine bracket 13A. Of course, when the user desired either to assemble the stirrup onto the mine roof bracket or, alternatively, to remove the stirrup from the bracket, then the workman needs only to advance rearwardly stirrup 28 and then twist the same to the right or to the left relative to FIG. 8 and advance one of the legs upwardly to 90 degree orientation relative to the bearing plate 17A so that a leg can slip out of the passageway PA. Hence, at all events the passageway PA will be larger than that portion of the stirrup which is to be accommodated by it.
The phantom line configurement at 28A in FIG. 8, see also FIG. 7, illustrates the vertical orientation of the stirrup whereby the same can be slipped easily out of the path or passageway PA such that the stirrup can be either disengaged from or, alternatively, engaged with respect to the body 18A of mine roof bracket 13A.
FIG. 9 is another embodiment, similar to that shown in FIG. 2, but illustrates that the depending protrusions 39, 39B of FIG. 2 can conceivably be eliminated and, for example, the stirrup at 28B be foreshortened relative to stirrup 28 in FIG. 2 such that rearward travel of the stirrup is delimited by engagement of structure associated with said stirrup, i.e. see (in FIG. 9) 28B, 38, and end of connector 36, and structure associated with mine roof bracket 13B, 13, i.e. 14, 15, 18, and 19 (FIG. 1), which now has bearing plate 17B and lower portion 22B. According, and merely by way of example, when the nut 38 advances forward to engage a part of the structure associated with the bracket, then the outward travel of stirrup 28B is constrained as to maximum travel thereof to the position shown at the phantom lines above lower portion 22B in FIG. 4, thereby retaining an interference or stop relationship as between lower portion 22B of the mine roof bracket and portions of the curved portion of stirrup 28B. The embodiment discussed in this paragraph is feasible; however, other embodiments as shown and described are deem preferable from construction and operational standpoints.
The present invention likewise comprehends mine brackets having bearing plates with multiple, mutually spaced, depending body portions as in the various embodiments shown in prior U.S. Pat. No. 5,176,473. FIG. 10 herein illustrates, by way of example, the FIG. 9 embodiment of the above referenced patent--which is fully incorporated herein by way of reference--, but which now includes one or more depending stop projections cooperative with the depending body portions of the bracket. In FIG. 10, optional mine bracket 43 includes bearing plate 44 having depending body portions 45 integral therewith or secured thereto. The depending body portions are oppositely facing and include respective reaction surfaces 46 and upturned lips 47. The bearing plate is shown to include a central mounting aperture 49, and also depending stop projections 50 and 51, corresponding and operating in the same manner as stop projection 39 in FIG. 1. Other types of stirrup travel delimiting structures can be employed in lieu of or in addition to stop projections 50 and 51. In operation, stirrups 52 and 53, corresponding to stirrup 28 in FIG. 2, engage the respective body portions 45, and stirrup travel is constrained, i.e. by stop projections 50 and 51, to avoid inadvertent disengagement of the stirrups from such body portions. This invention of course comprehends all types of mine brackets having either singular or plural, lateral or depending body portions and provided stirrup travel delimiting structure.
As the above description reveals, therein here in the invention a particular method of providing trussing structure for stabilizing mine strata, comprising the steps of: (a) providing a mine bracket having a bearing plate portion and a body portion, provided a reaction surface indentation, extending laterally from said bearing plate; (b) mounting said mine bracket against desired mine strata; (c) providing and dimensioning a stirrup connector for encompassing said body portion and reactively engaging said body portion when in operative condition; and (d) providing at least one stop projection for said mine bracket, spaced from said reaction surface, whereby to admit the installation of said stirrup connector of about said body but abuttingly engaging said stirrup connector for delimiting rearward travel thereof, whereby to deter inadvertent disengagement of said stirrup with said bracket for operative condition of said trussing structure.
While particular embodiments of the present invention have been shown and described, it will be obvious to all those skilled in the art that various modifications and changes may be made in the invention without departing from the essential aspects thereof, and therefore the aim of appended claim is to cover all such changes and modifications as fall within the true spirit and scope of the invention.
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Mine strata support structure and components in a mine truss and including a mine bracket and a connector, the latter preferably being in the form of an elongated stirrup; the mine bracket, stirrup and associated structure are constructed and dimensioned such that the stirrup may be brought into retentive engagement with the bracket and not slip inadvertently out of engagement; this can be produced through the employment of a depending projection which vertically depends from the bearing plate of the bracket, such projection serving with the body of the bracket to supply an access path for stirrup installation, the projection deterring excess rearward travel of the stirrup whereby to maintain bracket-stirrup inter-engagement, and thus truss-integrity, even during conditions of mine strata shock.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a national stage application under 35 U.S.C. §371(c) of prior filed, copending PCT application serial number PCT/GB2014/051235, filed on Apr. 22, 2014, which claims priority to Great Britain Patent Application Serial No. 1307447.1 filed Apr. 25, 2013 and titled DATA COMMUNICATIONS SYSTEM. The above-listed applications are herein incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] Embodiments of the invention relate to data transmission to and from down hole equipment and in particular, though not exclusively, to a data communication system and a method of data transmission through a sucker rod string between the sub-surface and a surface location of a well bore.
[0003] In the exploration and production of oil and gas wells, well bores are drilled from the surface to a subsurface location to access the reserves. The well bore is typically ‘cased’ with tubing to prevent collapse. A string can be run into the well bore to position down hole equipment at a sub-surface location. Down hole equipment is understood to refer to any tool, equipment or instrument that is used in a well bore.
[0004] Data needs to be transmitted between down hole equipment and the surface for various reasons. For example, monitoring performance of motors/pumps; transmission of control signals for control of valves; measuring device orientation and position, and making physical measurements. Power may also need to be transmitted to the down hole monitoring equipment. Due to the complexity of construction and the depths which wells are drilled, the data is sent to surface without installing dedicated cables and power for the down hole instrumentation is also sent without adding wires to the well equipment.
[0005] Telemetry systems are known which use the casing to transmit electromagnetic and acoustic data signals from a sub-surface location to a surface location. Such systems typically cannot achieve transmission of power from surface to sub-surface.
[0006] An embodiment of the present invention provides an alternative wireless system and method of data transmission when an electrical cable is not present in the well bore. In an embodiment of the present invention an alternative system and method of power transfer is also described.
SUMMARY OF THE INVENTION
[0007] According to a first aspect of the present invention there is provided a data communications system for transmitting data over a string between a surface location and a sub-surface location in a well bore, the data communications system comprising a sub-surface system module including load varying means to vary mechanical load on the string to be indicative of the data and a surface system module including load measuring apparatus to monitor the mechanical load on the string and a processor for determining the data from variation in the load.
[0008] In this way, the data is coupled onto the string by varying the mechanical load on the string using a force modulating device. The variation in mechanical load is applied in a way that can be read as information at the surface. The system therefore provides wireless transmission of data between the surface and sub-surface.
[0009] In an embodiment, the string is a sucker rod string. In this way data can be transmitted from surface driven down hole equipment, such as a PCP, plunger pump, or sucker rod pump system. In this embodiment, the sub surface module alters the mechanical force required to operate the pump in such a way as to convey measured sub surface data, and the surface module measures and decodes this mechanical load change. The effect of the mechanical pumping system on the data signal integrity can be minimised.
[0010] In an embodiment, the load varying means comprises a power generator module which is used to alter the mechanical loading on the string. The load varying means is an electrical generator with a variable electrical load which alters the mechanical loading of the string. The electrical generator may be a linear or rotary electrical generator. Alternatively, the load varying means may comprise a mechanical or hydraulic brake with a control mechanism. The brake may be a linear or rotary roller wheel with variable friction. Alternatively, the brake may be a linear stroking hydraulic piston with variable chokes on the hydraulic fluid feed or outlet which vary the force and thus the mechanical load on the string. Optionally, the brake may be a rotary acting hydraulic piston or motor with variable chokes on the hydraulic fluid feed or outlet which varies the force required to rotate the assembly.
[0011] In an embodiment, the load varying means varies the load in a ‘high-low’ pattern to form bits representative of single bit data. The ‘high-low’ pattern may be an ‘on-off’ pattern. In this way, the data is sent as single bit data. Alternatively, the data may be sent in binary bit strings using NRZ or any other encoding scheme. Where the data is sent in binary bit strings, which may be encoded, the binary bit strings are also configured as PN sequences to improve signal to noise ratio.
[0012] In an embodiment, the load varying means is mounted above a pump assembly being assembled and installed in the same way as the pump assembly. In this way, the sub-surface module can be fitted to any standard pump assembly using sucker rod mechanical drive from surface.
[0013] In an embodiment, the load measuring apparatus comprises a detection system at surface to measure the changes in the mechanical loading created by the sub-surface module. The detection system may be a load cell, pressure sensing device, bending beam, or use the current sense from the pump drive motor.
[0014] In an embodiment, the sub-surface module includes one or more gauges to make down hole measurements. More particularly, the load varying means is used to power at least one electronics module in the one or more gauges. In an embodiment, the one or more gauges have a power module. The power module may derive power from the load generator and store and regulate this power sufficient to run the at least one electronics module in the one or more gauges. Power can thus be maintained on the down hole monitoring instrumentation if the main sucker rod drive has stopped, which provides essential information in the event of pump shut downs or other major events in the well.
[0015] In an embodiment, the load varying means may be directly dependent on temperature or pressure. In this way, the mechanical load on the string is directly affected by pressure or temperature so providing a simple direct method of measuring the down hole environment.
[0016] According to a second aspect of the present invention there is provided a method of transmitting data on a string between a surface location and a sub-surface location in a well bore, comprising altering a mechanical load on the string at the subsurface location, the load being altered to convey data, monitoring the change in mechanical load on the string at the surface and decoding the data.
[0017] In this way, data signals are be transmitted from the sub-surface to the surface via the string.
[0018] In an embodiment, the method includes the step of sending the data as a single bit data stream. Alternatively, the data may be sent in binary bit strings using NRZ or any other encoding scheme. Where the data is sent in binary bit strings, which may be encoded, the binary bit strings are also configured as PN sequences to improve signal to noise ratio.
[0019] In this way, data signals can be transmitted from the sub-surface to the surface through the string via a wireless alternating load transmitter.
[0020] In an embodiment, the data is transmitted over a sucker rod string in a mechanical pump drive. The method includes the step of applying a change in the mechanical load during a selected part of the pump cycle. In this way, the time period where the load changes are applied is easier to detect.
[0021] The selected part of the pump cycle is when the load from the pump drive action is steady. In this way, changes to the mechanical load can be more easily seen. The selected part of the pump cycle is when the load on the sucker rod string is lowest. In this way, the changes will appear larger as compared to the background loads.
[0022] The method includes the step of varying the load during the down stroke on a sucker rod pump. This will improve the signal to noise ratio.
[0023] Optionally, the method includes the step of varying the load during the upstroke. In this way, rod string buckling is prevented.
[0024] The method includes the step of varying the load at a relatively high frequency. In this way, the data signal transmission can be differentiated more readily from background pump noise.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0026] FIG. 1 shows a typical set up of down hole equipment in a well, in the form of a rod pump completion;
[0027] FIG. 2 shows a schematic block diagram of a data communication system according to a first embodiment of the present invention;
[0028] FIG. 3 shows an illustration of a down hole pump assembly including a data transmission system according to an embodiment of the present invention;
[0029] FIGS. 4( a ) and 4 ( b ) are graphs illustrating a transmitted binary signal in the form of a ‘1’, FIG. 4( a ), and a ‘0’, FIG. 4( b ), according to an embodiment of the present invention;
[0030] FIGS. 5( a )-( c ) illustrate data transmission systems, with FIG. 5( a ) being the data transmission system of FIG. 3 ; FIG. 5( b ) being a further embodiment of a data transmission system; and FIG. 3( c ) being a yet further embodiment of a data transmission system; and
[0031] FIGS. 6( a ) and 6 ( b ) show configurations of data transmission systems to provide fluid flow in a well bore according to embodiments of the present invention
DETAILED DESCRIPTION
[0032] Reference is initially made to FIG. 1 of the drawings which illustrates a data transmission system, generally indicated by reference numeral 10 , located within a well 12 , to transmit data from a sub-surface location 14 to a surface location 16 through a string 18 located in the well 12 , according to an embodiment of the present invention.
[0033] Well 12 is a typical oil, gas or water well in which a well bore 20 is drilled and lined with casing 22 held in place by cement 24 . Tubing 26 is inserted in the casing 22 , providing an annulus 28 therebetween. Oil 30 from an oil bearing zone or reservoir 32 in the sub-surface 14 , enters the tubing 26 through perforations 34 in the casing, to travel to the surface 12 . When the reservoir pressure is insufficient to lift the oil 30 to the surface 16 , it is common to provide down hole equipment in the form of an artificial lift system. Types of artificial lift systems include hydraulic pumps, Rod pumps, Electric Submersible Pumps (ESPs), Jet Pumps, Progressing-Cavity pumps (PCPs) and gas lift. FIG. 1 of the drawings illustrates a typical rod pump completion 36 in a well bore 20 .
[0034] The completion 36 consists of a down hole pump assembly 38 in the oil producing section of the reservoir 32 . This pump 38 is deployed on a tubing string 26 and driven mechanically by a sucker rod string 18 . A rod pump completion 36 provides a reciprocating pump 38 driven from the surface 16 by drive units which move a polished rod 18 through a stuffing box 40 . A main walking beam 42 is pivotally mounted on a Samson post 44 with one end providing a horse head 46 with a bridle 48 attached to the polished rod 18 . The opposing end is connected to a pitman arm 50 and crank 52 which are coupled to a motor drive and gearbox assembly 54 to reciprocate the walking beam 42 .
[0035] On reciprocation of the walking beam 42 , the rod string 18 is stroked up and down through the stuffing box 40 . At the end of the rod 18 , arranged at the perforations 34 , is a pump barrel 56 including a standing valve 58 and a travelling valve 60 connected to the end of the rod 18 . Each stroke lifts the oil into the tubing 26 . At the surface 16 , the lifted oil and gas can be siphoned off via a gas line 62 and an oil line 64 from a tee 66 .
[0036] While a rod pump completion 36 can be considered as relatively simple technology, they are expensive to maintain and repair. Consequently, monitoring is required in order to ensure correct operation and, most importantly, avoid a pump off condition. This occurs when an insufficient amount of fluid enters the pump barrel 56 on a downstoke. On the next downstroke, the travelling valve 60 and rod 18 impact the fluid in the pump barrel 56 , sending shock waves through the assembly 38 causing damage. Additionally, it is beneficial if the motor and drive unit 54 can be controlled so that the rod 18 reciprocates and drives the pump at maximum efficiency. The majority of current control systems are limited to monitoring the position of the polished rod 18 in the stuffing box 40 to infer conditions at the pump barrel 56 .
[0037] In an embodiment of the present invention, one or more down hole gauges are mounted sub-surface 14 in the vicinity of the pump barrel 56 and the data from these gauges is transmitted to surface 16 via a data transmission system 10 .
[0038] Referring now to FIG. 2 of the drawings there is illustrated a functional block diagram of a data transmission system 10 . Located sub-surface 14 is a measurement module 68 which measures any required parameter of the pumping system 38 , such as pressures temperatures, vibration and fluid presence. The measurement module 68 is powered by a power regulator module 70 , which also transmits the measured data to a load modulating device 72 , all located sub-surface 14 . There is a mechanical transmission in the form of a string 18 , between sub-surface 14 and surface 16 . The load modulating device 72 acts on the string 18 in response to the data. Located at the surface 16 is a measurement device 74 which senses the variation in the mechanical load on the string 18 . The measurement device 74 may be a load cell, pressure gauge or optical sensing device. A processor 76 decodes the sensed load variations and generates readings of the data measured in the measurement module 68 . There may be an optional display or computer logging system 78 where the information system is presented to an operator and/or stored for future review.
[0039] Reference is now made to FIG. 3 of the drawings which illustrates the sub-surface components of a data transmission system 10 fitted to a down hole pump assembly 38 . Mounted in the tubing 26 above the down hole pump assembly 38 is a load modulating device 72 . Device 72 has a substantially cylindrical housing 80 with an outer diameter in an embodiment no greater than that of the pump 38 . Within the housing 80 there is arranged a stator 82 . Stator 82 is a cylindrical arrangement of static windings 84 providing a bore 86 therethrough. The stator 82 is attached to the body 80 as described herein after with reference to FIGS. 6( a ) and ( b ). Located upon the rod string 18 in the vicinity of the stator 82 is an actuator 88 in the form of a magnetic core. The magnetic core comprises multiple magnets 132 arranged around and along the rod 18 . A down hole electronics module 90 is also arranged on the tubing 26 between the load modulating device 72 and the down hole pump assembly 38 . The tubing 26 has a narrower diameter in this region to accommodate the down hole electronics module 90 in a manner as is known in the art. The down hole electronics module 90 contains the measurement module 68 and the power regulator module 70 .
[0040] In use, device 72 and the electronics module 90 are arranged on the tubing 26 when the tubing 26 is run in the well bore 20 to locate the down hole pump assembly 38 at the reservoir 32 . The actuator 88 is located in the sucker rod string 18 . With the data transmission system 10 in place, the pump assembly 38 can be operated as normal. When measurements are required, the measurement module 68 operates gauges and/or other sensors to record the desired parameters such as temperature, pressure, vibration and fluid presence. Recorded data is transferred into bits and the signal transmitted to the power regulator module 70 . The power regulating module 70 then controls the load modulating device 72 to vary the force between the stator 82 and actuator 88 such that the mechanical load on the rod 18 varies in response to the data signal. Thus an increase in load may signify a bit equal to ‘one’ and a decrease in load may signify a bit equal to ‘zero’. At the surface 16 , the measurement device 74 will monitor the change in load and the processor 76 will decode the load variations and reconstruct the data signal from the measurement module 68 . Data signals from different gauges may be sent in series by this method.
[0041] This provides transmission of a single bit data stream. However, the data may be sent in binary bit strings using NRZ or any other encoding scheme. Also, where the data is sent in binary bit strings, which may be encoded, the binary bit strings may also be configured as PN sequences to improve the signal to noise ratio.
[0042] The electronics module 90 may monitor the pump cycle and transmit the data at a selected part of the pump cycle so that the time period where the load changes are applied is easier to detect at the surface 16 . Choosing the selected part of the pump cycle to be when the load from the pump drive action is steady will give changes to the mechanical load which can be more easily seen. Taking the selected part of the pump cycle when the load on the sucker rod string is lowest ensures that the changes will appear larger as compared to the background loads. Transmitting data by varying the load during the down stroke on a sucker rod pump will improve the signal to noise ratio. Conversely, transmitting data by varying the load during the upstroke will prevent rod string buckling.
[0043] Additionally, if the load is varied at a relatively high frequency compared to the stroke frequency, the data signal transmission can be differentiated more readily from background pump noise.
[0044] Reference is now made to FIGS. 4( a ) and ( b ) which illustrate the data decoding from the load measurement. In FIG. 4( a ), the force or load 92 on the string 18 is measured against time on the stroke 94 . The trace 96 shows an increase 90 , which begins at a selected time in the pump cycle, is held for a period of time 100 , before decreasing 102 back to its starting level 104 . This can be considered as transmission of a ‘one’ in binary code. Similarly the inverse can be performed to provide transmission of a binary sequence. In FIG. 4( b ), transmission of a ‘zero’ can be achieved by decreasing 106 the load at a preselected time in the cycle period, for a period of time 108 , before increasing 110 back to its starting level 112 . Clearly depending on the physical size of the pumping system and the depth it may be possible to send more than one bit of information per pump stroke, so the data speed can be anywhere from a single bit as illustrated to many bytes per pump stroke.
[0045] It is also realised that in passing the actuator 88 through the bore 86 of the stator 82 , the effect of passing a magnetic field through a set of electromagnetic windings 84 can generate an electric current. This current is transmitted to the power regulator module 72 where it can be stored and used to power the gauges and sensors in the measurement module 68 . With the ability to store power down hole, the measurement gauges and sensors can operate when the pump when the main sucker rod drive 54 has stopped which provides essential information in the event of pump shut downs or other major well events.
[0046] Referring now to FIGS. 5( a ) to ( c ), there is shown embodiments of load varying devices. Those skilled in the art will recognise that these do not form an exhaustive list but are merely illustrative of the types of devices available. FIG. 5( a ) shows a load varying device, generally indicated by reference numeral 114 , being an electromagnetic linear generator according to the embodiment of a data transmission system as presented and described with reference to FIG. 3 . Actuator 88 provides a magnetic core on the rod 18 which is stroked within a static electromagnetic winding 84 allowing power to be drawn from the load varying device 114 . Also, by altering the electrical loading, the force required to operate the pump (not shown) can be altered.
[0047] FIG. 5( b ) shows a load varying device, generally indicated by reference numeral 116 , based on a mechanical brake according to the embodiment of a data transmission system. Body 80 has the same outer diameter as the device 114 . On an inner surface 118 of the body 80 , there are arranged roller contacts 120 . The roller contacts 120 are arranged to make frictional contact with the rod 18 as it passes through the body 80 . The body 80 can be considered as a central bearing tube with a mechanism for altering the force which the roller contacts 120 apply to the shaft of the rod 18 . Altering the force will vary the load upon the rod 18 which can be decoded at the surface 16 . In this way data is transmitted to the surface 16 . The device 116 can also contain a mechanically driven power generator to allow electrical power to be used for local electronics down hole.
[0048] FIG. 5( c ) shows a load varying device, generally indicated by reference numeral 122 , based on a hydraulic brake according to the embodiment of a data transmission system. In this device 122 , hydraulic or pneumatic pistons 124 are used to provide a load. The sucker rod 18 is latched onto this system through a mechanical latch 126 allowing the pistons 124 to act directly on the rod string 18 . Thus by varying the pistons 124 position, the load is varied upon the string 18 . If data is coupled onto the pistons 124 by varying their position, this load variation can be read at surface 16 and decoded to derive the data. Power can be generated by using a small linear generator in the same outline as one of the pistons, or by adding a small turbine generator to the hydraulic or pneumatic circuit of one or all of the pistons.
[0049] It will be realised that the load varying devices 114 , 116 , 122 require to operate in the tubing 26 without restricting the flow of fluid from the pump assembly 38 which is being lifted to the surface 16 . Thus fluid must be able to flow past each device 114 , 116 , 122 . Additionally, a compromise between clearance and wear must be made as while a smaller clearance between the actuator and stator will increase the power transfer, it will also increase the chances of sticking and wear. Referring now to FIGS. 6( a ) and ( b ) there are illustrated schematic cross-sectional views through load varying devices according to further embodiments of a data transmission system which achieve the required fluid bypass.
[0050] Referring initially to FIG. 6( a ), the outer stator 82 is shown as an annular tube which is static. The actuator 88 provides a moving magnetic or mechanical centre piece 128 . The centre piece 128 has an annular outer wall 130 upon which is arranged the active parts such as magnets 132 or roller contacts 120 . These active parts are designed to occupy a space outside the nominal bore 134 of the production tubing 136 , and inside the static section 82 of the device 114 , 116 , 122 . A central support 138 connects into the rod 18 having support spindles 140 to the outer wall 130 . Spaces 142 between the spindles 140 allow the fluid to flow freely through the centre of the device 114 , 116 , 122 while maintaining a small clearance between the outer wall 130 and the stator 82 for good power transfer. This structure would also allow wiper seals to be used between the stroking part 88 and the static section 82 to assist in preventing debris from getting into the moving surfaces.
[0051] An alternative arrangement is shown in FIG. 6( b ). In this Figure the stator 82 remains the same. The central support 138 now has a larger diameter which can accommodate parts of the actuator 88 if required. The active parts are now located in wings 144 located around the edge of the central support 138 . Bypass channels 146 are present between the wings 144 to provide for fluid flow through the device 114 , 116 , 122 . The outer edge 150 of each wing 144 is arranged to be rounded and provide a small clearance with the stator 82 to give good power transfer.
[0052] In a yet further embodiment the load varying device is formed from a material sensitive to temperature or pressure so that the load on the string is directly dependent on temperature or pressure which the device is exposed to. In this way temperature or pressure can be read at the surface without requiring any power generator down hole.
[0053] An embodiment of the present invention provides a system and method of data transfer between sub-surface and a surface location of a well bore using the already present string in the well bore.
[0054] An embodiment of the present invention provides a wireless system and method of data transfer between sub-surface and a surface location in a well bore.
[0055] An embodiment of the present invention provides a wireless system and method of power transfer to down hole equipment in a well bore.
[0056] It will be apparent to those skilled in the art that various modifications may be made to the invention herein described without departing from the scope thereof. For example, other load varying devices may be considered as may the system and method be applied to other instrumentation on a string within a well bore. Additionally, though the string in the present invention has been described as a tubular string, coiled tubing and wireline strings may also be considered.
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A data communications system and method for transmitting data over a string between a surface location and a sub-surface location in a well bore in which a load varying device at the sub-surface varies the mechanical load on the string to be indicative of the data and a load measuring apparatus at surface monitors the mechanical load on the string and decodes the data. Data transmission is described from a pump assembly through a sucker rod string. Embodiments of load varying devices using electrical generators, friction rollers and hydraulic and pneumatic brakes are also described.
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BACKGROUND OF THE INVENTION
This invention concerns in die tapping devices which are used to tap holes in workpieces being formed by dies installed in presses.
Such tapping devices have often been operated by the motion of the press, as described in U.S. Pat. No. 6,547,496. Since the tap drive is dependent on the sinusoidal press motion, significant limitations on tapping speed results, increasing the cycle time for the process.
Thus, electrical servo motor drives have been developed for in-die tapping units in which servo motors mounted to the tapping unit are used to drive the tap, as described in copending U.S. application Ser. No. 10/417,428, filed on Apr. 15, 2003.
The tap drive is made independent of the press motion by the use of servo motors, and this allows driving of the tap at maximum speed to reduce cycle times.
A significant problem is created by mounting a servo motor to a tapping unit in that the servo motor is thereby subjected to shock loading when the stripper plate impacts the workpiece and fixture, and suddenly decelerates the servo motor, shortening the service life of the motor.
Typically, spring mounted stripper plates carry the tapping units and the stripper plate springs have been relied on to reduce the shock loading of servo motors.
However, the stripper plates comprise a separately supplied component from the tapping unit, and the stripper plate springs are not designed specifically to adequately attenuate shock loading of the associated servo motor in this application.
The user of this equipment must therefore attempt to design proper stripper springs to reduce shock loading of the motors to acceptable. This necessity is often neglected to the detriment of the service life of the servo motors.
According, it is an object of the present invention to provide an effective shock protection for servo motor driven die tapping units which does not rely on stripper plate springs to reduce shock or require a special design of the stripper plate springs to provide shock protection.
SUMMARY OF THE INVENTION
The above object and other objects which will become apparent upon a reading of the following specification and claims are achieved by providing built in shock protection combined with the servo motor tapping unit itself. In a first embodiment, a shock plate to which the tapping unit is fixed, extends horizontally over an aligned parallel base structure attached to an associated stripper plate, the shock plate floatingly mounted to the base structure by opposing resiliently deflectable elements.
A series of upwardly projecting guide pins are fixed at one end to the base structure and slidably received in the shock plate to guide relative vertical movement of the shock plate and tapping unit.
Two sets of opposed compression springs act to resiliently position the shock plate closely spaced above the base plate, the spring rates and spacing of the shock plate set to reduce the maximum shock loading to a predetermined acceptable level. This floating mount allows limited relative movement between shock and base plates when impacting of a stripper plate occurs during press cycling. This attenuates the shock loading of the tapping unit mounted on the shock plate to a level where damage to the servo motor is avoided.
In a second, vertically oriented motor embodiment, the servo motor is attached to a shock plate. A tooling housing is located spaced beneath the shock plate and is directly attached to a stripper plate. A series of pins guide movement of the shock plate relative to the tooling housing, which mounts a tap drive and holder assembly.
A first set of compression springs are interposed between the shock plate and housing recessed in pockets in the shock plate, compliantly resisting downward movement of the shock plate.
A second set of compression springs are received in a respective bore in the shock plate and are each compressed beneath a washer secured by a machine screw to the base structure engaged against a rim at the bottom of a respective shock plate bore. The second set of springs compliantly resists upward movement of the shock plate, such that the shock loading when the stripper impacts the workpiece and/or fixture and when the stripper reverses direction, is greatly attenuated.
In a third embodiment, a housing comprising the base structure has a portion which extends alongside the servo motor axis and a tool drive and holder assembly is mounted to be offset to the servo motor axis. A shock plate is interposed between the motor and one end of the housing.
In all of these embodiments, the spring rates, number of springs and shock plate spacing from the base are designed for mass of the particular tapping unit to properly attenuate the shock loading to a predetermined safe maximum level.
The assembly of the tapping unit, shock plate base structure, and springs is installed as an assembly onto the stripper plate to minimize the burden on the user and to insure proper protection for the servo motor.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial view of a first embodiment of a tapping unit having built in shock protection assembly installed onto a stripper plate, with press platens and a workpiece also shown.
FIG. 2 is an enlarge pictorial view of the tapping unit shock plate assembly shown in FIG. 1 .
FIG. 3 is a side elevational view of the tapping unit shown in FIGS. 1 and 2 .
FIG. 4 is a fragmentary view of the tapping unit shown in FIG. 3 showing the internal details of the tap drive and holder components.
FIG. 5 is a pictorial view of a second embodiment of a tapping unit according to the present invention, also showing in phantom lines the outline of press platens and a stripper plate.
FIG. 6 is a partially sectional elevation view of the second embodiment shown in FIG. 5 .
FIG. 7 is a pictorial enlarged view of the second embodiment with the shock plate and transmission housing shown in phantom lines to reveal the springs and guide pins mounting the shock plate to the transmission housing.
FIG. 8 is an elevational view of the components shown in FIG. 7 .
FIG. 9 is a pictorial view of a third embodiment of a tapping unit according to the invention.
FIG. 10 is a vertical sectional view through the lower part of the tapping unit shown in FIG. 9 .
FIG. 11 is an end view of the shock plate and transmission housing components of the tapping unit shown in FIGS. 9 and 10 .
FIG. 12 is a view of the section 12 - 12 taken in FIG. 11 .
FIG. 13 is a view of the section 13 - 13 taken in FIG. 11 .
FIG. 14 is a view of the section 14 - 14 taken in FIG. 11 .
DETAILED DESCRIPTION
In the following detailed description, certain specific terminology will be employed for the sake of clarity and a particular embodiment described in accordance with the requirements of 35 USC 112, but it is to be understood that the same is not intended to be limiting and should not be so construed inasmuch as the invention is capable of taking many forms and variations within the scope of the appended claims.
Referring to the drawings and particularly FIGS. 1-4 , an upper platen 10 and lower platen 12 of a press is shown with a workpiece 14 , such as an elongated strip formed with holes to be tapped, extending across a fixture 16 installed on the lower platen 12 .
A tapping unit 18 for tapping the holes formed in the workpiece 14 is mounted together with shock plate 30 and base structure 32 on a stripper plate 20 movably suspended on supports 22 with gas springs 24 urging the plate 20 to a down position on the supports 22 .
After the press is operated to bring the stripper plate 20 against the workpiece 14 on the fixture 16 , the tapping unit 18 is operated to advance and rotate the tap in a hole in the workpiece 14 in the well known manner.
As seen in FIG. 2 , the tapping unit 18 is comprised of a horizontally oriented servo motor 26 having a transmission housing 28 attached at one end, which motor and housing in turn is mounted to a horizontally extending shock plate 30 underlying the motor 26 and housing 28 which is fixed to the shock plate 30 with suitable fasteners (not shown).
The shock plate 30 in turn is floatingly mounted on a base structure comprising a plate 32 to form a tapping unit with built in shock protection. This assembly is affixed to the stripper plate 20 with screws 21 when being installed in a press.
The shock plate 30 is floatingly mounted at a predetermined space above the base plate 32 by opposing resiliently deflectable elements comprising two opposing sets of four springs each.
The springs 34 in an upper set are received in a respective counterbore pockets 36 and compressed therein by a washer 38 and machine screw 40 received in base plate 32 to urge the shock plate 30 downwardly.
The opposing springs 42 of a lower set are received in respective lower counterbore pockets 44 and engaged with the undersurface of shock plate 30 to urge the same upwardly, counteracting the springs 34 so that the shock plate 30 thus floats above the base plate 32 with a predetermined gap between the shock plate 30 and base plate 32 .
A set of four dowel pins 46 are press fit into holes in the base plate 32 and extending vertically and slidably received into bushing sleeves 48 fit in holes in the shock plate 30 . This guides the vertical motion of the shock plate 30 induced by shocks experienced by the tapping unit assembly during press operation.
The transmission housing 28 contains bevel gears 50 A, 50 B driven by the output shaft 52 of the servo motor 26 . A polygon drive shaft 54 is rotated by gear 50 B which in turn drives a lead screw 60 threaded into a bushing 56 nonrotatably held in a bore 58 in the housing 28 by a key 59 . The lead screw 60 mounts a tap holder 62 releasably holding a tap 64 . The lead screw 60 advances axially when rotated to advance and rotate the tap 64 when tapping a hole in the well known manner. A safety spring 66 allows the bushing 56 to be retracted if the tap 64 is blocked from advancing, as could happen if the hole to be tapped is not formed properly or is absent. A nose piece 65 holds tap holder 62 to transmission housing 28 , and serves as a pilot registration for concentric alignment of tap 64 to the hole to be tapped in the workpiece 14 .
Thus, excessive shock loading of the servo motor 26 is prevented by being mounted to the floating shock plate 30 which is spaced above the base plate 32 by the springs 34 , 42 . The springs 34 , 42 are matched to the mass of the tapping unit, and the tapping unit, shock plate and base plate installed as a single package with built in shock prevention so as to not require any shock prevention measures to be undertaken by the user.
The following formulas have been used to insure that a predetermined maximum deceleration is not exceeded:
Δ
x
=
mV
2
(
N
B
+
N
T
)
K
(
1
)
a
=
V
2
mV
2
(
N
B
+
N
T
)
4
K
(
2
)
a
=
V
2
2
(
Δ
x
)
(
3
)
m=Mass of motor
V=Velocity of press
N B =Number of springs on bottom
NT=Number of springs on top
K=Spring stiffness
Δx=Gap between bottom of shock plate and base structure
a=Acceleration
The number of springs and their rate and the gap between the shock plate and base can be varied to insure that the maximum deceleration will not exceed a predetermined maximum value, usually under 5 g's.
In one example, four springs in each set having a spring rate of 143 pounds per inch, a press speed of 12 inches/second, and a gap of 0.06 inches produced a deceleration of less than 4 g's for the servo motor used.
FIGS. 5-8 show a second embodiment of the invention featuring a servo tapping unit 68 in which a servo motor 70 is vertically oriented within a press, mounted on a stripper plate 72 suspended from the press upper platen 10 as in the first described embodiment.
A base structure comprising a housing 74 is attached to the stripper plate 72 which supports the servo motor 70 with an interposed shock plate 76 .
The interposed shock plate 76 is floatingly supported at a spaced location above the base housing 74 by two opposing sets of four springs each. A first set of springs 78 are each received in a respective upwardly facing counterbore 80 in the shock plate 76 , compressed beneath a headed screw 82 threaded into a hole in the top of the base 74 to act to urge the shock plate 76 downwardly.
A second set of four springs 84 are each received in a downwardly facing counterbore 86 in the shock plate 76 compressed against the upper surface of the base housing 74 to urge the shock plate upwardly.
A set of dowels 88 are press fit in holes in the base housing 74 and slidably received in bushing sleeves 90 . This guides any movement of the shock plate 76 due to shock loading by press operation causing impacting of the stripper plate 72 on the workpiece 14 and fixture 16 .
Suitable tap holder and drive components 94 as shown are mounted within the base housing 74 .
These include a polygonal drive element 93 having a square drive end received in a square hole in a tap holder plug 95 threaded in a lead screw sleeve 97 keyed to be nonrotatable but able to axially advance against the force of safety spring 99 if the tap 64 cannot advance.
A nose piece 92 holds a tap holder to base housing 74 , and serves as a pilot registration for the concentric alignment of tap 64 to the hole to be tapped in workpiece 14 .
FIGS. 9-14 show a third embodiment of a tapping unit with shock protection according to the invention.
In this embodiment, a vertically oriented servo motor 96 is mounted on a base structure comprising a housing 98 with a floating interposed shock plate 100 .
A tap holder and drive housing 101 is mounted on a housing section offset horizontally from the axis of the servo motor 96 .
The shock plate 100 is resiliently float mounted above the housing 98 as in the other embodiments with two opposing sets of four springs. A first set of four springs 102 are received in respective upward facing counterbores 104 . The springs 102 are compressed against end walls at the bottom of counterbores 104 by the heads of screws 106 threaded into the base housing 98 to urge the shock plate 100 downwardly. A set of spacer-bushings 108 limit the extent of compression of the springs 102 .
A second opposing set of four springs 110 are received in downwardly facing bores 112 in the shock plate 100 compressed against the upper surface of the base housing 98 to urge the shock plate 100 upwardly, balancing the effect of the springs 102 so that the shock plate 100 with the servo motor 96 floats above the base housing 98 .
A set of four dowel pins 114 are press fit into holes in the base housing 98 at their lower ends projecting up and slidable in bushings 116 carried in bores in the shock plate 100 . This guides the vertical movement of the shock plate and servo motor 96 induced by shock loading when the press is operated, as in the above described first and second embodiments.
The base housing 98 contains a gear 118 driven by the servo motor output shaft 120 which drives an idler gear 122 , driving a gear hub 124 . Gear hub 124 rotates a tap holder assembly 126 housed within a cover 128 and annular extension 129 fixed onto the base housing 98 with bolts 131 .
An outer sleeve 136 has a threaded engagement with internal threads 138 of the cap 128 . A keyway 140 and key 142 establish a rotational connection with the gear hub 124 while allowing axial movement.
This causes downward advance of the tap holder assembly 126 and a tap 130 secured therein with an included tap holder 132 carrier by an inner sleeve 144 .
A safety spring 134 is interposed between the outer sleeve 136 and inner sleeve 144 to allow the outer sleeve 136 to move down even if the inner sleeve 144 cannot advance for some reason.
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A servo motor in die tapping unit provides built in shock protection for the motor by fixing a shock plate to the servo motor and floatingly mounting the shock plate to a base structure attachable to a stripper plate in a press. Sets of opposing springs allow movement of the shock plate relative the base plate to relieve shock loads when the press is operated, the shock plate guided on dowel pins fixed to the base structure. The shock plate, and tapping unit and base structure form a self contained assembly for mounting together in the press.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 020,985, filed Mar. 16, 1979, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is an emulsion polymer of water-compatible alkyd resins with vinyl monomers, formed via an emulsion polymerization process in an aqueous alkyd resin solution, which retains the water-compatible and gloss properties of the alkyd and the fast dry and surface-protective properties of the vinyl polymer.
2. Prior Art
Japanese Pat. No. 102,390 of 1977 discloses the formation of vinyl colloid emulsions in a dispersion of a post-maleated high oil-modified alkyd resin neutralized with a tertiary organic amine as a dispersion stabilizer. This patent also discloses standard procedures and materials for preparing alkyds and emulsions.
DESCRIPTION OF THE INVENTION
It is desirable for environmental and other reasons to reduce or eliminate the use of volatile organic solvents in the coating industry. Water-borne materials such as some alkyds thus become attractive. In practice, however, the alkyds develop film hardness slowly. Emulsion polymers exhibit good drying properties but film appearance is poor. Mixtures of emulsions and water-borne alkyds do improve the drying properties of the latter, but these mixtures are unstable and poor in appearance.
It has been found that the drying properties of alkyds can be improved without deleterious effects on gloss by a process in which: (1) a water-dispersible alkyd resin is formed by conventional procedures; (2) the aqueous suspension of the alkyd is neutralized to about pH 7.5 (6-9) with ammonia or volatile amine, readily forming a soap; and (3) a vinyl emulsion polymer is produced directly in the thus-neutralized suspension by substantially conventional emulsion polymerization methods. The weight ratio of alkyd/vinyl monomers in the solids content of the resulting emulsion is preferably about 1/1, varying from about 80/20 to 20/80. The total solids content of the emulsion is about 30-50% by weight.
In addition, it has been unexpectedly found that if a small amount of a free radical-generating catalyst, e.g., a peroxide such as benzoyl peroxide, is added during the emulsion polymerization step, films of the alkyd-latex product dry without an induction period, that is, oxygen-induced hydroperoxide is formed without marked delay.
As noted, the alkyd resins of this invention are formed from conventional materials, i.e., polyhydric alcohols, polybasic acids and drying oils or fatty acids. The basic ingredients of the preferred alkyd are trimethylol propane, soya fatty acids, isophthalic acid, trimellitic anhydride and maleic anhydride. Acid number of the product alkyd is also important, about 50 being preferred. An acid number much above 50 results in water-sensitive films while much below 50 results in gelation. The procedure for the preparation of the alkyd is entirely conventional, the desired materials merely being brought together and refluxed until the appropriate acid number is reached.
Although any volatile alkali may be used, ammonia is the preferred neutralization agent because it is the most volatile alkali and the one least likely to cause complications. Neutralization is carried out to a pH of about 6-9, 7.5 being preferred. A pH much above about 7.5 may retard polymerization while one much below requires more solvent to maintain stability. Volatile primary or secondary amines, e.g., methyl amine, dimethyl amine, ethyl amine, ethanolamine, etc., can be substituted for ammonia if desired.
The monomers used for the emulsion polymerization with the neutralized alkyd suspension may be any of those normally used for emulsion polymerization. Preferred are hydrophobic, or "hard" monomers, i.e., those giving nonplasticized products, such as methyl methacrylate, ethyl methacrylate, butyl methacrylate, styrene, α-methylstyrene, vinyl toluene, etc. A plurality of monomers in conventional fashion are preferred. Most preferred monomers are methyl methacrylate, butyl methacrylate, and vinyl toluene, all three of which result in clear, glossy and tough films. Conventional "soft" monomers such as ethyl acrylate, butyl acrylate, octyl acrylate, etc., can be included but are not needed since the alkyd soap itself functions as a plasticizer. It may be noted that acrylic monomers do not react as readily with the alkyd as do methacrylate monomers and vinyl toluene.
Emulsion polymerization in the neutralized alkyd suspension can be carried out at reflux, but a lower temperature, e.g., 30°-70° C., is preferred. Higher temperatures and higher pH's accelerate alkyd hydrolysis.
Addition of the selected monomers to the neutralized alkyd is carried out slowly, either continuously or incrementally, because bulk addition results in resin swelling and excessive initial viscosity. For the same reason, agitation of the reacting mixture at all times is essential. Otherwise, the emulsion polymerization is entirely conventional.
In practice and in order to destroy residual monomers in the product, a small amount of benzoyl peroxide was dissolved in the monomers and activated by raising the temperature briefly from 60°-90° C., i.e., above the critical decomposition temperature for this peroxide. Surprisingly, when the product alkyd-latex was used in film forming, it was found to dry, initially and after about 5 months' aging, without an induction period. Generally, conventional aqueous alkyds may require an induction period of as much as 28 hours. As a possible explanation of this phenomenon, and one to which I do not propose to be bound, it is suggested that, during polymerization, the emulsion polymer particles capture and encapsulate free radicals and/or unreacted peroxides. These become operative during paint film formation. The peroxides then collaborate with the cobalt drier used in the oxidative phase to initiate oxidative crosslinking. It is assumed that these "frozen" radicals are isolated in the polymer particle until film formation occurs. At that time, they mix in the film and react with the cobalt to form the classical cobalt-peroxide initiator.
Any solvent-soluble conventional peroxide catalyst with a critical temperatures of 40° C. or more may be used, e.g., t-butyl hydroperoxide, cumene peroxide, dicumyl peroxide, lauroyl peroxide, methyl ethyl ketone peroxide, etc., and can be activated by exposure to the conventional alkyd driers and oxygen in the air. The quantity of peroxide employed is not critical but may conveniently comprise 0.1-2.0% by weight of latex solids in the product. It is found that, on storage, the peroxide remains stable for at least 4-5 months.
There follow some examples illustrating the invention in more detail. In these examples, parts and percentages are by weight and temperatures are in degrees centigrade unless otherwise specified.
EXAMPLE 1
Methacrylate Latex-Modified Alkyd
A. Alkyd. In a typical glass resin reaction flask equipped with stirrer, thermometer, nitrogen inlet and condenser having a Dean-Stark water collector, the following were combined:
______________________________________Ingredient Parts______________________________________Soya fatty acids 3452.5Trimethylol propane 3260.0Isophthalic acid 2718.5Xylene (azeotroping solvent)______________________________________
During 10 hours of reflux in the range 190°-220°, 858 ml of water was removed. The acid number of the product was 7.6, and the solids content was 93.4%.
To achieve alkali solubility, 1384.5 g of the above product was combined with 140.1 parts of trimellitic anhydride and 12.75 parts of maleic anhydride in an apparatus similar to that above. The mixture was brought to a temperature of 200° and held to an acid number of 49, 20 ml of water being collected. The alkyd product was dissolved in methyl ethyl ketone (MEK) to a solids content of 74%. The Gardner-Holdt viscosity was X.
B. Latex. In a flask equipped with stirrer, thermometer, nitrogen inlet, separatory funnel and reflux condenser were mixed the following:
______________________________________Ingredient Parts______________________________________Alkyd MEK solution from A 810.8Water 1280.0Ammonia (to pH = 7.5)______________________________________
The above mixture was heated to 60° and maintained at that temperature.
The following monomer mix was separately prepared and transferred to a funnel:
______________________________________Ingredient Parts______________________________________Methyl methacrylate 270.0Butyl methacrylate 30.0Vinyl toluene 100.0Benzoyl peroxide 0.4______________________________________
10% of the monomer mixture was added to the alkyd mixture at 60° along with 4 parts of ammonium persulfate, and 2 parts of sodium sulfite dissolved in 25 parts of water.
The remainder of the monomer mixture was then added dropwise to the alkyd over 2-3 hours. At the end of the addition, 1 part of ammonium persulfate and 0.5 part of sodium sulfite in 10 parts of water were added. The mixture was held at 60° for approximately 1 hour and then at 90° for 30 minutes more. The modified alkyd mixture was cooled to room temperature and the pH adjusted to 7.5. Constants of this latex-modified product were as follows:
______________________________________Particle size = uniform, spherical (ca. 0.1μ in diameter)Alkyd/monomer ratio = 60/40Appearance = milky white dispersionFinal solids = 36.3%Final pH = 7.6%Theoretical conversion = 99+% (trace BMA odor)______________________________________
C. Film. The latex-modified product from B was catalyzed with 0.1% cobalt metal via a 6% cobalt naphthenate solution. A thin film was prepared by spreading the product on glass with a doctor blade. A 1.5 mil dry film became gasoline- and water-resistant after an overnight dry.
EXAMPLE 2
Paint
A. Millbase. To a mixture of:
______________________________________ Ingredient Parts______________________________________Alkyd from Example 1A 18.5Water 13.6Ethylene glycol monobutyl ether (EGME) 8.8Ammonia (28%) in water (to pH - 7.5)______________________________________
was added titanium dioxide (2 parts), ferrite yellow (10 parts), chrome yellow (37 parts) and molybdate orange (1 part). The resultant composition was mixed and dispersed through a sand mill.
B. Paint Preparation. A mixture was made up from:
______________________________________ Ingredient Parts______________________________________EGME 15.0Methyl ethyl ketoxime 0.212% zirconium drier 1.96% calcium drier 2.54/1 water/EGME 25.00______________________________________
To this mixture was added 135.4 parts of the millbase prepared above. These ingredients were mixed well and 212.7 parts of latex from Example 1B and 2.5 parts of a 6% cobalt drier solution were added thereto to complete the paint. Paint constants were: P/B=65/100; Viscosity=60 sec on Zahn #2 cup; Co/Ca/Zr drier ratio=0.15/0.15/0.225.
C. Cure. The paint prepared above was sprayed over a steel panel to achieve a 1.5-mil dry film, then allowed to stand overnight. The paint was dry within 1 hour. The following properties were achieved overnight:
______________________________________ Overnight pencil hardness = HBWater resistance = SatisfactoryGasoline resistance = SatisfactoryAdhesion to glass = 100%60° gloss = 65______________________________________
Dry was good, with a tack-free state reached within 30-45 minutes at 25° F. and 50% relative humidity. Fast dry, good gloss and film properties characteristic of alkyds were thus attained. Stability is comparable to that of the conventional water-borne alkyds.
EXAMPLE 3
Vinyl Latex-Modified Alkyd
This shows the preparation of a very high gloss enamel.
A. Alkyd.
______________________________________ Materials Parts by Weight______________________________________Linseed oil fatty acids 456Trimethylol propane 277Isophthalic acid 264Trimellitic anhydride 87 1084Water removed -84 1000______________________________________
The linseed oil fatty acids, trimethylol propane, and isophthalic acid were charged into a resin reaction kettle equipped with agitator, thermometer and inert gas sparge. The kettle was heated to melt the charge and agitation begun. The charge was heated to 250°, held there until an acid number of about 10 was reached, and cooled to 193°. The trimellitic anhydride was added and the temperature was held at about 193° until an acid number of 60 was reached. The temperature was lowered below 160°, EGME was added to reduce nonvolatiles to 80% and the charge was filtered. Overall processing time was about 8-10 hours.
The resulting alkyd had: acid number (solids), 53; nonvolatiles, 80%; Gardner-Holdt viscosity, Z 7 +.
B. Latex. In flask equipped with stirrer, nitrogen inlet, separatory funnel and reflux condenser were mixed the following:
______________________________________ Ingredient Parts______________________________________Alkyd solution above 250Water 550Ammonia (to pH - 7.5)______________________________________
The above mixture was heated to 60° and maintained.
The following mixture was transferred to a funnel:
______________________________________Ingredient Parts______________________________________Vinyl toluene 200Benzoyl peroxide 0.2______________________________________
10% of the above was added along with 2 parts of ammonium persulfate, and 1 part of sodium sulfite dissolved in 25 parts of water. The remainder was added dropwise over 2-3 hours. At the end of the addition, 1 part of ammonium persulfate and 0.5 parts of sodium sulfite in 10 parts of water was added. The mixture was held at 60° C. for approximately 1 hour and then at 90° C. for 30 minutes more. The mixture was cooled and the pH adjusted to 7.5.
A millbase of the above alkyd was made by mixing in a sand mill the following:
______________________________________ Ingredient Parts______________________________________Above alkyd 18.5Water 13.6EGME 8.8Titanium dioxide 50.______________________________________
The following paint was made:
______________________________________ Ingredient Parts______________________________________Millbase 138Above latex 2236.0% cobalt naphthenate 2.5MEK oxime 0.6______________________________________
This paint was spread with a doctor blade on glass. It dried within 1 hour to a 6B pencil hardness, overnight to a B hardness. The 60° gloss was 95+, the 20° gloss was 77. The film was resistant to water but was spotted by high-test gasoline overnight.
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Stable coating compositions are made from an aqueous dispersion of an alkyd resin (20-80% by weight of solids) neutralized to a pH of about 7.5 with ammonia or a volatile amine by forming therein an emulsion polymer (80-20% by weight of solids) of one or more vinyl monomers. When coated on a substrate, the compositions dry readily like vinyl emulsion polymers but with a glossy and durable finish like the relatively cheap alkyds. Free radical catalysts, e.g., peroxides, may be encapsulated during the emulsion polymerization and remain stable until evaporation of water.
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CROSS REFERENCE TO RELATED CASES
[0001] The present patent application is based upon and claims the benefit of U.S. Provisional Patent Application Ser. No. 60/467,773, filed on Apr. 30, 2003, entitled “Wind Turbine” by Ronald J. Taylor and Scott J. Taylor, which is hereby specifically incorporated herein by reference for all that it discloses and teaches.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains generally to wind turbines and more specifically to crossflow wind turbines having a plurality of stationary airfoils positioned about a rotor having a plurality of blades.
[0004] 2. Description of the Background
[0005] Radial flow windmills that harness wind energy using a plurality of exposed blades have been used both privately and commercially for some time. These machines often have a high initial cost and have limited efficiency. Further, the exposed blades are hazardous to certain wildlife such as birds. In addition, radial windmills cannot normally be operated in very high wind conditions, as they often lack sufficient structural integrity and are not mechanically designed to prevent over-speeding.
[0006] Crossflow turbine wind machines, such as described in U.S. Pat. Nos. 6,015,258 to Taylor and 5,391,926 to Staley, et al., have been developed to address some of the limitations of the radial flow wind turbines. The crossflow turbine wind machine comprises a set of fixed stators that direct wind into a rotating turbine. One of the advantages to the crossflow turbine machine is the higher efficiencies that can be achieved, and they are less dangerous. Further, the structural integrity of the machine and the serviceability of the moving components are superior to that of a radial flow windmill.
SUMMARY OF THE INVENTION
[0007] The present invention overcomes the disadvantages and limitations of the prior art by providing a crossflow wind turbine that uses various airfoil and rotor configurations and orientations, including a rotor that has gaps near the leading edges and ground airfoils to increase efficiency.
[0008] The present invention may therefore comprise a crossflow wind turbine that generates mechanical energy from wind comprising: a rotor having a plurality of rotor blades that are symmetrically disposed around an axis, the rotor blades disposed in the rotor so that a gap is formed between leading edges of the rotor blades; a rotor space formed in a volume that is swept out by the rotor blades, the rotor space having a drive portion in which the rotors are driven by the wind and a return portion in which the rotors return to the drive portion; a plurality of airfoils that direct wind into the drive portion and direct wind away from the return portion to cause the rotor to turn and generate the mechanical energy.
[0009] The present invention may further comprise a method of generating mechanical energy from wind comprising: providing a crossflow wind turbine having airfoils and a rotor that sweeps out a rotor space, the rotor space having a drive portion and a return portion; symmetrically placing a plurality of rotor blades in the rotor that form a gap between leading edges of the rotor blades; placing the airfoils around the rotor to direct the wind into the drive portion of the rotor space so that the wind drives the rotor blades in the drive portion, and to block the wind from entering the return portion of the rotor space so that the rotor blades return to the drive portion to generate the mechanical energy.
[0010] The present invention may further comprise a crossflow wind turbine that generates mechanical energy from wind comprising: a rotor having a plurality of rotor blades that are symmetrically disposed around an axis, the rotor blades disposed in the rotor so that a gap is not formed between leading edges of the rotor blades; a rotor space formed in a volume that is swept out by the rotor blades, the rotor space having a drive portion in which the rotors are driven by the wind and a return portion in which the rotors return to the drive portion and a plurality of airfoils that direct wind into the drive portion and direct wind away from the return portion to cause the rotor to turn and generate the mechanical energy.
[0011] Advantages of various embodiments of the present invention include the ability to harness wind energy with an economical wind turbine that is safe and visually appealing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings,
[0013] [0013]FIG. 1 is an illustration of a perspective view of one embodiment of the present invention of a wind turbine.
[0014] [0014]FIG. 2 is an illustration of a perspective view of another embodiment of the present invention of a wind turbine.
[0015] [0015]FIG. 3 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0016] [0016]FIG. 4 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0017] [0017]FIG. 5 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0018] [0018]FIG. 6 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0019] [0019]FIG. 7 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0020] [0020]FIG. 8 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0021] [0021]FIG. 9 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0022] [0022]FIG. 10 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0023] [0023]FIG. 11 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0024] [0024]FIG. 12 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
[0025] [0025]FIG. 13 is an illustration of a cross-sectional view of another embodiment of the present invention of a wind turbine.
DETAILED DESCRIPTION OF THE INVENTION
[0026] [0026]FIG. 1 is a perspective view of a first embodiment of a crossflow wind turbine 100 . Crossflow wind turbines differ from propeller type (radial flow) turbines in that the wind generally flows across the axis of rotation in crossflow turbines, rather than generally along the axis of rotation in propeller type turbines. As shown in FIG. 1, a vertical rotor 102 is propelled by the wind and is mechanically coupled to an electrical generator located in the base 108 . The rotor 102 is generally disposed with a vertical axis, but can have other orientations as desired. Three airfoils 104 , 106 , and one not visible behind the rotor 102 , serve to support the upper portion of the rotor 102 and also to direct the wind into a drive portion of a rotor space 118 of the rotor 102 for increased efficiency and to block wind from a return portion of the rotor space 118 . The rotor space 118 is the volume that is swept out by the rotor blades of rotor 102 , such as rotor blades 120 , 122 , during the rotation of rotor 102 . A ground airfoil portion 110 of airfoil 104 extends across the base 108 , and functions to direct additional wind into the rotor 102 . Airfoil 106 similarly has a ground airfoil 112 . An optional vent hole 14 may be present in the top of the wind turbine.
[0027] The wind turbine 100 may be over 210 feet tall in some embodiments. The distance from the tip of the ground airfoil 110 to the tip of ground airfoil 112 may be over 200 feet in such embodiments. Such an embodiment may be suitable for a large wind farm application of a permanent power generation facility. In other embodiments, such as a portable wind turbine generator, the entire height of the turbine 100 may be only three or six feet. The general concepts embodied in the present invention are scalable to wind turbines of many different sizes, as is appreciated by those skilled in the arts.
[0028] The rotor 102 may be composed of several sections that are connected at joints such as the flange joint 116 . Such embodiments may allow the rotor sections to be fabricated in sections that may be shipped to a wind turbine site for assembly. The rotor 102 , in the embodiment of FIG. 1, is comprised of three blades. In some embodiments, the rotor blades may be individually manufactured and assembled in sections.
[0029] The rotor blades may be manufactured from a variety of materials, using a variety of methods. For example, the rotor blades may be fabricated from sheet metal, such as steel or aluminum, using fasteners or welded connections. In other embodiments, the rotor blades may be constructed of reinforced composite material using a variety of manufacturing techniques, including hand laid-up and autoclave cured fiberglass, or graphite composite, or any automated or semi-automated composite manufacturing technique desired. In still other embodiments, the rotor blades may be manufactured of molded or formed plastic. An advantage of lighter weight rotors is that less wind speed may be required to start the rotational motion of the rotor. In yet other embodiments, the rotor blades may be constructed with a sail cloth or another engineered fabric exterior over a structural frame. Carbon fiber may also be used. In fact, any suitable material or manufacturing technique may be used by those skilled in the arts while keeping within the spirit and intent of the present invention.
[0030] The airfoils, such as airfoil 104 , may be manufactured by a variety of techniques. For example, the airfoil 104 may be a poured concrete slab that is lifted into place in a fashion similar to conventional ‘tip up’ building construction techniques. In such an example, the airfoils may be fabricated on-site and lifted into place. In another example, the airfoils may be continuously poured in a vertical manner using techniques common to the construction trade. In still other examples, the airfoils may be constructed of metal or other suitable material such as carbon fiber, fiberglass, etc. Some embodiments for airfoils may incorporate a rigid framework over which sail cloth is placed, or another engineered fabric or plastic type material, that forms an air-directing airfoil. Such a framework may be constructed of metal, concrete, or any other suitable material.
[0031] In some embodiments, the airfoils may be constructed of a combination of manufacturing techniques. For example, a steel column may support panels of concrete, sail cloth, metal, or other materials. In another example, a prestressed concrete post may have panels of various sorts attached thereto. Those skilled in the art may construct an embodiment of the present invention using any suitable materials while keeping within the spirit and intent of the present invention.
[0032] The base 108 may be used to house various components such as gearboxes, generators, control equipment and the like. The base 108 may be constructed above ground as shown or may be constructed below grade in other embodiments. In still other embodiments, the mechanical and electrical equipment for the wind turbine 100 may be located partially below grade. In embodiments with the base 108 above ground, the walls of the base 108 may be slanted to direct airflow into the rotor 102 .
[0033] [0033]FIG. 2 illustrates a perspective view of another embodiment of a wind turbine 200 . The rotor 202 comprises eight blades while six airfoils 204 support the rotor 202 and direct airflow into the rotor 202 . A mechanical enclosure 206 may contain a generator and other electrical and mechanical equipment. The mechanical energy may be used directly in pumps or other mechanical devices including reverse osmosis desalination, or with generators/alternators that produce electrical energy that can be used for various purposes. The ground airfoils 208 may direct airflow into the drive portion of the rotor space.
[0034] The rotor 202 may contain a plurality of stiffening ribs 210 disposed between the various blades of the rotor 202 . The ribs 210 may help disperse the loads seen by the blades of the rotor 202 during high wind conditions. In some embodiments, the rotor blades may be stiff enough to not require the ribs 210 . In other embodiments, the ribs 210 may be used to lower the weight of the blades while giving the same overall structural integrity. Such tradeoffs may be made by those skilled in the arts in mechanical and structural design.
[0035] [0035]FIG. 3 illustrates a cross-sectional view of an embodiment of a wind turbine 300 . The incoming airflow is represented by arrow 301 which shows wind blowing from the left. Airfoils 302 , 304 , and 306 are symmetrically disposed about the embodiment 300 . Three rotor blades 308 , 310 , and 312 have a slight curve. A center axis shaft 314 is present in the embodiment 300 that may be used to support the rotor blades 308 , 310 and 312 along the length of the rotor blades. A gap 316 is also present between the leading edge of each blade. The gap 316 has been shown through computational fluid dynamics models to reduce the drag on the rotor and thereby increase efficiency under certain conditions. Different configurations of rotor blades that are shown in the various embodiments disclosed below can be used with the airfoil configuration of FIG. 3 and other airfoil configurations disclosed herein. Similarly, the various airfoil configurations disclosed herein can be used with the various rotor configurations to achieve desired results.
[0036] As also shown in FIG. 3, the rotor blades 308 , 310 , 312 sweep out a volume that is generally shown by the circle 320 which is the rotor space. The rotor space has two different portions, a drive portion 316 and a return portion 318 . The drive portion 316 is the portion of the rotor space 320 in which the rotor blades are driven by the wind flowing from direction 301 . The return portion 318 is the portion where the rotor blades return to the drive portion 316 . As shown in FIG. 3, airfoil 302 blocks wind flowing from direction 301 from substantially entering the return portion 318 . In addition, airfoil 302 directs wind into the drive portion 316 . Airfoil 306 also directs wind into the drive portion 316 . The drive portion 316 may vary in accordance with the magnitude of the flow 301 , i.e., the magnitude of the wind speed. For example, high wind flowing from direction 301 may be guided by airfoil 306 so that the drive portion 316 extends into part of the return portion 318 at the right side of the rotor space 320 where the rotor blade 310 is disposed. In other words, the division between the drive portion 316 and the return portion 318 may not be exactly as shown in FIG. 3 or any of the figures and may vary in accordance with the wind speed. Further, the direction of flow 301 to the wind may greatly affect the operability and efficiency of the device of FIG. 3. As shown in FIG. 3, the wind flow 301 is from the 9 o'clock position and is able to produce high efficiency because the wind flow 301 is guided by airfoil 302 into the drive portion 316 and away from the return portion 318 . Similar efficiencies occur when the wind comes from the 1 o'clock position and the 5 o'clock position. Of course, as the direction of the flow 301 changes, the drive portion and the return portion of the rotor space 320 also change.
[0037] As set forth above, a gap 316 is formed between the leading edges of each of the rotor blades 308 , 310 , 312 . As shown in FIG. 3, the leading edges of the rotor blades 308 , 310 and 312 are not overlapping. The curvature of the rotor blade 308 , 310 , 312 functions to assist in capturing wind flowing from direction 301 in the drive portion 316 and reducing resistance in the return portion 318 . The curvature of the rotor blades 308 , 310 , 312 also causes wind to flow across the surface of the rotor blades, such as rotor blade 308 , and direct wind into the return portion 318 to drive another rotor blade, such as rotor blade 310 . This process further increases the efficiency of the embodiment of FIG. 3. Hence, the gaps cause the wind to flow across the rotor blades through the gap and into the return portion 318 for the purpose of driving additional rotor blades in the return portion 318 , which increases efficiencies under certain conditions.
[0038] [0038]FIG. 4 illustrates a cross-sectional view of another embodiment of a wind turbine 400 that is similar to the embodiment of FIG. 3, but has smaller gaps between the leading edges of the rotor blades 408 , 410 and 412 . The incoming airflow is represented by arrow 401 from the left side of FIG. 3. Airfoils 402 , 404 , and 406 are also symmetrically disposed about the embodiment 400 . Three rotor blades 408 , 410 , and 412 also have a slight curve. A center axis shaft 414 is present in the embodiment 400 . A gap 416 is present between the leading edge of each of the rotor blades 408 , 410 , 412 . The gap 416 is smaller than the gap 316 of embodiment 300 , which provides higher efficiencies in some conditions. The gap 416 increases the performance of the wind turbine 400 under some conditions for the same reasons as set forth above in the explanation of the embodiment of FIG. 3. The size of the gap in the position of the rotor blades 408 , 410 , 412 with respect to the other blades and the axis 414 controls the manner in which the wind flows across the rotor blade and is directed from the drive portion 416 into the return portion 418 of the rotor space 420 . As such, the efficiency in operation of the device is affected by these matters. As shown in FIG. 4, the rotor blades are capable of directing wind from the drive portion 416 into the return portion 418 to drive other rotor blades in the return portion 418 through the gap 416 . Again, FIG. 4 shows the leading edges of the rotor blades 408 , 410 , 412 as non-overlapping rotor blades.
[0039] [0039]FIG. 5 illustrates a cross-sectional view of another embodiment of a wind turbine 500 . The incoming airflow is represented by arrow 501 from the left. Airfoils 502 , 504 , and 506 are symmetrically disposed about the embodiment 500 . Three rotor blades 508 , 510 , and 512 have a slight curve. The rotor blades are supported at the ends so that no center axis shaft is necessary in embodiment 500 . The leading edges of the rotor blades 508 , 510 , 512 form a gap around the axis of rotation. As shown in FIG. 5, the rotor blades are overlapping. The overlapping blades function to further channel the flow of wind across the rotor blade and onto the surface of another rotor blade. This process functions to further increase the efficiency of the device under certain conditions by creating multiple driving surfaces formed from multiple rotor blades. For example, wind captured by rotor blade 508 may flow across the surface of rotor blade 508 and be directed onto the surface of rotor blade 510 so as to drive multiple rotor blades. Airfoil 502 directs wind away from the return portion 520 and into the drive portion 518 of the rotor space 522 . The trailing edge 516 of the rotor blade 508 has an angled fin to further assist in capturing wind.
[0040] [0040]FIG. 6 is a cross-sectional view of another embodiment of a wind turbine 600 . The incoming airflow is represented by arrow 601 from the left side of FIG. 6. Airfoils 602 and 604 are asymmetrically disposed about the embodiment 600 . Airfoil 602 blocks the wind from the return portion 620 of rotor space 622 . Airfoil 604 guides the wind into the drive portion 618 of the rotor space 622 . Three rotor blades 608 , 610 , and 612 have a slight curve and are overlapping in a fashion similar to rotor blades 508 , 510 , 512 of FIG. 5. As such, rotor blades 608 , 610 , 612 operate in a fashion similar to rotor blades 508 , 510 , 512 . No center axis shaft is present in embodiment 600 , and the rotor blades 608 , 610 , 612 can be supported in various ways such as top and bottom plates. The gap formed between the leading edges provides increased efficiencies for the same reasons as set forth above. The trailing edge 616 of the rotor blade 608 has an angled fin which further aids in capturing wind and holding the wind as the wind falls off of the rotor blades during rotation of the rotor blades through the drive portion 618 .
[0041] The asymmetrical design of the embodiment 600 may be beneficial in locations where the wind is predominately from one direction, which is often the case in locations of high wind. Such embodiments may have the benefit of lower costs, since fewer structural components may be needed to construct the wind turbine. Further, the asymmetric nature of the wind turbine may be optimized for increased performance in the direction of the prevailing wind.
[0042] [0042]FIG. 7 illustrates a cross-sectional view of another embodiment of a wind turbine 700 . The incoming airflow is represented by arrow 701 from the left side of FIG. 7. Airfoils 702 , 704 , 706 , and 708 are disposed symmetrically on two sides of the rotor space 720 . Three rotor blades 710 , 712 , and 714 are similar in design to those of embodiment 600 .
[0043] Airfoils 702 , 704 , 706 , 708 are disposed in a symmetric design that is capable of capturing wind from two opposing directions. Airfoils 702 , 704 , 706 , 708 are arranged in a manner that provides optimized performance from wind flowing from direction 701 as well as wind flowing from the opposite direction 703 . In many locations with high prevailing wind, the wind direction may often be from a primary direction 701 . In such locations, the secondary direction is often opposite from the primary direction 701 . The embodiment 700 may take advantage of such a phenomena by being oriented to perform at maximum efficiency in the two main wind directions. As shown in FIG. 7, airfoil 702 blocks wind flowing from direction 701 from entering the return portion 718 of the rotor space 720 . Airfoil 706 assists in guiding wind flowing from direction 701 into the drive portion 716 . Similarly, airfoil 708 blocks wind flowing from direction 703 from the drive portion 716 , which becomes the return portion. Airfoil 704 guides wind flowing from direction 703 into the return portion 718 , which becomes the drive portion of the rotor space 720 .
[0044] [0044]FIG. 8 illustrates a cross-sectional view of another embodiment of a wind turbine 800 . The incoming airflow is represented by arrow 801 from the left side of FIG. 8. Airfoils 802 , 804 , and 806 are symmetrically disposed about the rotor space 820 . Two rotor blades 808 and 810 are barrel-shaped and are separated at the center by a gap between leading edges 812 and 814 . The leading edges are not overlapping. The shape of the rotor blades 808 , 810 together with the gap provided between the leading edges 812 , 814 , respectively, allows wind to be channeled from one rotor blade to another. In other words, when a rotor blade is in a position to catch the wind flowing from direction 801 in the drive portion 816 , the wind will move along the surface of the rotor blade and be transferred to the other rotor blade through the gap between the leading edges 812 , 814 . In this fashion, driving forces can be generated in both the drive portion 816 and return portion 818 of the rotor space 820 .
[0045] The embodiment 800 illustrates the use of two rotor blades and three airfoils. Many different combinations of rotor blades and airfoils may be used while keeping within the spirit and intent of the present invention. Further, the embodiment 800 illustrates the use of different shapes of rotor blades. The rotor blades 808 and 810 are shown as lines. However, in practice the blades 808 and 810 will have some thickness and shape such as an airfoil design. Those skilled in the arts will appreciate that a line may represent the general shape of an airfoil design. However, the rotor blade may require some thickness for structural integrity and the thickness may be constructed in an aerodynamic airfoil shape to further enhance efficiency of the wind turbine.
[0046] [0046]FIG. 9 illustrates a cross-sectional view of another embodiment of a wind turbine 900 . The incoming airflow is represented by arrow 901 from the left side of FIG. 9. Airfoils 902 , 904 , and 906 are symmetrically disposed about the embodiment 900 . Two rotor blades 908 and 910 are barrel-shaped and are separated at the center by a gap between leading edges 912 and 914 . The rotor blades 908 , 910 are shaped to provide a large overlapping area between the rotor blades. This allows wind flowing from direction 901 to be easily transferred from one rotor blade in the drive portion 916 to another rotor blade in return portion 918 of the rotor space 920 . Again, this design provides driving forces in both the drive portion 916 and the return portion 918 .
[0047] [0047]FIG. 10 illustrates a cross-sectional view of another embodiment of a wind turbine 1000 . The incoming airflow is represented by arrow 1001 from the left side of FIG. 10. Airfoils 1002 , 1004 , and 1006 are symmetrically disposed about the embodiment 1000 . Two rotor blades 1008 and 1010 are straight and are separated at the center by a gap between leading edges 1012 and 1014 . Wind flowing from direction 1001 drives the rotor blade in the drive portion 1016 and transfers wind to the other rotor blade in the return portion 1018 of the rotor space 1020 . The trailing edge 1016 has a large fin that catches exiting wind.
[0048] [0048]FIG. 11 illustrates a cross-sectional view of another embodiment of a wind turbine 1100 . The incoming airflow is represented by arrow 1101 from the left side of FIG. 11. Airfoils 1102 , 1104 , and 1106 are symmetrically disposed about the embodiment 1100 . Two rotor blades 1108 and 1110 are substantially straight with a curved portion near the leading edges 1012 and 1014 . The trailing edge 1116 has a large fin. Again, wind flowing from the direction 1101 drives the rotor blade in the drive portion 1118 and transfers wind to the other rotor blade in the return portion 1120 of the rotor space 1022 . The large fins at the end help to catch wind and drive the rotor blades.
[0049] [0049]FIG. 12 illustrates a cross-sectional view of another embodiment of a wind turbine 1200 that does not have gaps and that has increased efficiency. The incoming airflow is represented by arrow 1201 from the left side of FIG. 12. Airfoils 1202 , 1204 , and 1206 are symmetrically disposed about the embodiment 1200 . Two rotor blades 1208 and 1210 are curved and join at the center axis shaft 1212 so that no gap is formed. In this manner, air is trapped by the rotor blades and continues to force the rotor blade around its axis, rather than being exhausted through a gap. This increases efficiencies under certain conditions. Air flowing from direction 1201 is substantially blocked from entering the return portion 1216 by airfoil 1202 . This allows the rotor blade 1210 to return in the return portion 1216 with minimal force from the airflow 1201 . Rotor blade 1208 is driven by the wind in the drive portion 1214 of the rotor space 1218 as described above.
[0050] [0050]FIG. 13 illustrates a cross-sectional view of another embodiment of a wind turbine 1300 . The incoming airflow is represented by arrow 1301 from the left side of FIG. 13 that also does not have a central gap. Airfoils 1302 , 1304 , 1306 , and 1308 are symmetrically disposed about the embodiment 1300 . Two rotor blades 1310 and 1312 are curved and are joined at the center in the same manner as the embodiment of FIG. 12, which results in increased efficiencies for the same reasons as set forth above. As shown in FIG. 13, airfoil 1302 blocks the wind from entering the return portion 1316 while airfoil 1308 directs the airflow into the drive portion 1314 of the rotor space 1318 . When the wind flows from the opposite direction, airfoil 1306 performs the same function as airfoil 1302 , while airfoil 1304 performs the same function as airfoil 1308 . Similarly, wind can flow from the top of FIG. 13, or the bottom of FIG. 13, and the airfoils operate in substantially the same fashion. In this manner, the device of FIG. 13 can operate with wind coming primarily from four different directions.
[0051] The present invention therefore provides a unique system of both blocking wind in a return portion of a rotor space and directing wind to rotor blades in a drive portion of a rotor space. Various configurations of airfoils and rotors can be used to achieve these results. A gap formed between leading edges of rotor blades can function to allow wind to flow across the rotor blades in a drive portion and be channeled through a gap between the leading edges and into a return portion of the rotor space to drive another rotor blade. This channeling of the wind through the central gaps allows multiple rotor blades to be driven by wind coming from a single direction. Other embodiments do not provide a central gap, which increases efficiencies in certain conditions. While certain embodiments are specifically adapted to operate with wind coming primarily from a predetermined direction, other embodiments are arranged to operate efficiently with wind coming from two or more directions. In this manner, the particular airfoil and rotor design for any particular environment can be achieved based upon prevailing winds in the area. In addition, airfoils can be used near the bottom portion of a vertically oriented wind turbine to direct ground winds or low winds up into the wind turbine in an efficient manner.
[0052] The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.
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A wind turbine device of increased efficiency is comprised of a set of fixed airfoils that direct wind into a rotor having a plurality of blades. The fixed airfoils may extend to the ground to increase the amount of wind directed into the rotor and may be manufactured from concrete. The rotor blades have a vented portion near the axis of rotation that has been found to increase efficiency for certain blade geometries. For other blade geometries, increased efficiency is observed with no gap at the axis of rotation. The rotor may also be manufactured from composite materials to increase strength while decreasing the moment of inertia for the rotor.
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FIELD OF INVENTION
The present invention relates to the technological field of axial-throughflow turbomachines. It refers to a rotor for an axial-throughflow turbomachine and to a moving blade for such a rotor.
BACKGROUND
Stationary gas turbines with a high power output have long been an essential component of power stations, especially combined-cycle power stations. FIG. 1 shows a perspective, partially sectional view of an example of such a gas turbine which is supplied by the Assignee of the present invention and is known by the type designation GT26®.
The gas turbine 10 of FIG. 1 is equipped with what is known as sequential combustion. It comprises a multistage compressor 12 which sucks in air via an air inlet 15 and compresses it. The compressed air is used, in a following first annular combustion chamber 14 a , partially for the combustion of an injected fuel. The hot gas occurring flows through a first turbine 13 a and then enters into a second combustion chamber 14 b where the remaining air is employed for the combustion of a fuel which again is injected. The hot gas stream coming from the second combustion chamber 14 b is expanded in a second turbine 13 b so as to perform work and emerges from the gas turbine 10 through an exhaust gas outlet 16 , in order to be discharged outward or, in a combined-cycle power station, in order to be used for the generation of steam.
The compressor 12 and the two turbines 13 a , 13 b have sets of moving blades which rotate about the axis 30 and which, together with guide vanes fastened to the surrounding stator, form the blading of the machine. All the moving blades are arranged on a common rotor 11 rotatable about the axis and are fastened releasably to the rotor shaft by means of rotor grooves provided for this purpose. Special attention is in this case devoted to the last stages 12 a of the compressor 12 where the compressed air reaches temperatures of several hundred degrees Celsius.
It is known from the prior art (see, for example, WO-A1-2005/054682), according to FIG. 2 , to provide the moving blades 12 of the last stages 12 a of the compressor 12 with a blade root 18 designed as a hammerhead root and to push them with the blade root 18 into a rotor groove 19 extending about the axis and hold them there. The blade root 18 is supported on radial stop faces 25 of the rotor groove 19 which lie further outward in the radial direction, against centrifugal forces which act on the moving blade 17 . Said blade root is likewise supported on axial stop faces 20 lying further inward in the radial direction, against axial forces which act on the moving blade 17 . An undercut is in this case provided between each of the radial stop faces 25 and each of the axial stop faces 20 . A spring 22 is provided at the bottom of the rotor groove 19 and fixes the moving blade 17 in the radial direction during assembly.
In the course of ongoing discussions about energy and the environment, there is the persistent desire to increase the power, efficiency, combustion temperature and/or mass throughflow of machines of this type. An increase in the power output can be achieved, inter alia, by improving the compressor.
An improvement in the gas turbine entails an increase in the mass throughflow through the compressor which leads to a higher gas temperature in the last compressor stages 12 a . The up-to-date, progressive aerodynamic design of the blade leaves for the compressor requires greater axial chord lengths, this leading to a greater distance between the rotor grooves 19 .
The two together give rise to markedly increased thermal stresses in the notches at the bottom of the rotor grooves in the rear compressor stages when the machine is being started, because the center of the rotor body is still at a low temperature (T 1 in FIG. 2 ), whereas the outer region is already exposed to the high full-load temperature (T 2 in FIG. 2 ), and therefore high thermal stresses occur in the material.
In another context, to be precise in moving blades of gas turbines with a dovetail-shaped blade root which bears against oblique stop faces in the rotor groove and because of the friction exerts shear forces on the side walls of the groove, it has been proposed to introduce fillets into the rotor groove below the stop faces in order to break down the friction-induced stresses (see U.S. Pat. No. 5,141,401). Here, however, thermal stresses do not play any part.
In connection with measures for reducing the stresses in the region of the rotor groove, EP-A1-1703080 repeats the critical influence of the cross-sectional contour of the groove upon the stress profile in the rotor. It is suggested there, in this connection, that the groove bottom be given an elliptical cross-sectional contour.
A rotor groove designed in this way has at its bottom, in order to reduce thermal stresses, an axially and radially widened bottom region 23 with a continuously curved cross-sectional contour which is distinguished by a large radius of curvature in the region of the mid-plane 33 and is designed to be mirror-symmetrical with respect to the mid-plane 33 .
Should the design of the rotor root 18 of the moving blade 17 be preserved in the case of a rotor groove geometry modified in this way, the hammerhead of the blade root 18 according to FIG. 3 would have to be enlarged by the amount of the additional volume 24 illustrated by hatching, and this would lead to a marked increase in the mass of the moving blade 17 and therefore to a rise in the centrifugal forces acting on the rotor groove 21 .
SUMMARY
In a first embodiment, the present disclosure is directed to a rotor for an axial-throughflow turbo machine. The rotor carries a plurality of moving blades which are pushed, in each case, with a blade root into a rotor groove extending about an axis and are held there. The blade root includes a hammer root with a hammerhead and is supported on radial stop faces of the rotor groove which lie further out in the radial direction, against centrifugal forces which act on the plurality of moving blades, and is supported on axial stop faces lying further inward in the radial direction, against axial forces which act on the plurality of moving blades. The rotor groove having at a bottom portion, in order to reduce thermal stresses, an axially and radially widened bottom region with a continuously curved cross-sectional contour. The blade root of the plurality of moving blades is adapted to the widened bottom region in a radial direction.
In another embodiment, the disclosure is directed to a moving blade ( 26 ) for the above rotor. The moving blade includes a blade root designed as a hammer root with a hammerhead. The blade root is extended in the radial direction below the hammerhead in order to bridge the radial widening of the widened bottom region of the rotor groove.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail below by means of exemplary embodiments in conjunction with the drawing, in which
FIG. 1 shows a perspective, partially sectional view of a gas turbine with sequential combustion, such as is suitable for implementing the invention;
FIG. 2 shows the longitudinal section through the rotor of a known gas turbine in the region of the last stages of the compressor with the associated fastening of the moving blades;
FIG. 3 shows two adjacent identical rotor grooves with a widened bottom region and a continuously curved cross-sectional contour in an enlarged illustration with the associated dimensions;
FIG. 4 shows a possible adaptation of the blade root to the modified rotor groove geometry;
FIG. 5 shows the illustration of an adapted moving blade for the changed rotor groove geometry from FIG. 3 according to an exemplary embodiment of the invention;
FIG. 6 shows the adapted moving blade from FIG. 5 inserted into the rotor groove from FIG. 3 ; and
FIG. 7 shows an illustration of an adapted moving blade for the changed rotor groove geometry from FIG. 3 in a type of design alternative to that of FIG. 5 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Introduction to the Embodiments
The object of the invention, therefore, is to design the rotor or the moving blades used on the rotor, such that the advantages of a rotor groove geometry with a widened bottom region and large radius of curvature can be exploited, preferably without disadvantages of any kind.
The object is achieved by the whole of the features as set forth in the appended claims. In the embodiments of the invention, the rotor groove has at its bottom, in order to reduce thermal stresses, an axially and radially widened bottom region with a continuously curved cross-sectional contour, and the blade root of the moving blades is adapted in the radial direction to the widened bottom region.
According to one embodiment of the invention, the widened bottom region is formed mirror-symmetrically to a mid-plane passing through a rotor groove and standing perpendicularly to the axis, and the radius of curvature of the cross-sectional contour of the bottom region in this case decreases from the mid-plane towards the margin.
Another embodiment of the invention is distinguished in that the widened bottom region has a predetermined maximum width in the axial direction, in that the radial stop faces have a predetermined minimum spacing in the axial direction, and in that the ratio of the minimum spacing to the maximum width amounts to between 0.1 and 0.6, that is to say 0.1<d 5 /d 1 <0.6.
It is in this case advantageous if the widened bottom region has a predetermined first maximum depth in relation to the radial stop faces, the widened bottom region has a predetermined second maximum depth in relation to the inner edges of the axial stop faces, and the ratio of the second maximum depth to the first maximum depth amounts to between 0.4 and 0.9, that is to say 0.4<d 3 /d 4 <0.9.
It is especially beneficial if a plurality of identical rotor grooves are provided, offset at a predetermined distance, in the axial direction, and the ratio of the maximum width to the distance amounts to between 0.5 and 0.8, that is to say 0.5<d 1 /d 2 <0.8.
According to a further embodiment of the invention, the blade root is lengthened in the radial direction below the hammerhead in order to bridge the radial widening of the widened bottom region.
Preferably, to lengthen the blade root, a lengthening bolt extending radially is provided. The comparatively slender lengthening bolt bridges the distance, without any mass being needlessly added to the moving blade.
It is in this case advantageous in production terms if the lengthening bolt is integrally formed on the hammerhead.
Furthermore, it is advantageous if a curved transitional face is provided at the transition between the lengthening bolt and the hammerhead in order to ensure a continuous transition.
Alternatively, there may be provision for producing the lengthening bolt as a separate part and for connecting this to the hammerhead.
It is proved advantageous, in this case, to fasten the lengthening bolt to the hammerhead by screwing or welding.
Furthermore, the mass of the moving blade may be further reduced if mass-reducing recesses are provided in the blade root.
Preferably, the recesses extend over the hammerhead and the lengthening bolt.
Although preferably running in the circumferential direction, these recesses may also extend in another, for example radial direction.
In a refinement of the rotor according to the invention, an interspace remains free between the lower end of the lengthening bolt and the bottom of the widened bottom region, and the free interspace has arranged in it a spring which presses the moving blade with the blade root against the radial stop faces in the radial direction.
In another refinement, the hammerhead has a predetermined height, the lengthening bolt has a predetermined radial length, and the ratio of height to length is between 0.2 and 0.8, that is to say 0.2<d 2 /d 1 <0.8.
A further refinement is distinguished in that the hammerhead has a predetermined first axial width, in that the lengthening bolt has a predetermined second axial width, and in that the ratio of the second to the first axial width is between 0.2 and 0.6, that is to say 0.2<d 4 /d 3 <0.6.
DETAILED DESCRIPTION
FIG. 4 shows the longitudinal section, comparable to FIG. 2 , through the rotor 11 of a gas turbine in the region of the last stages of the compressor according to the invention. A comparison of FIGS. 2 and 4 shows that the upper portion of the rotor groove 21 remains unchanged, as compared with the known rotor groove geometry from FIG. 2 . The radial and axial stop faces 25 and 20 correspondingly remain virtually unchanged. Consequently, the proven design can be adopted in this region.
What is novel, however, is the widened bottom region 23 of the rotor groove 21 . In the widened bottom region, a cross-sectional contour of the bottom region 23 is continuously curved, and the radius of curvature of the cross-sectional contour of the bottom region 23 is very large in the region of the mid-plane and decreases sharply from the mid-plane towards the margin. The cross-sectional contour is mirror-symmetrical to the mid-plane.
The widened bottom region 23 widens directly below the axial stop faces 20 , on both sides, in the axial direction in the manner of a relief. It has, as shown in FIG. 3 , a predetermined maximum width d 1 in the axial direction, while the radial stop faces 25 have a predetermined minimum spacing d 5 in the axial direction. It is especially beneficial if the ratio of the minimum spacing d 5 to the maximum width d 1 amounts to between 0.1 and 0.6, that is to say the inequality 0.1<d 5 /d 1 <0.6 is true.
The widened bottom region 23 has a predetermined first maximum depth d 4 in relation to the radial stop faces 25 . It has a predetermined second maximum depth d 3 in relation to the inner edges of the axial stop faces 20 . It is especially beneficial if the ratio of the second maximum depth d 3 to the first maximum depth d 4 amounts to between 0.4 and 0.9, that is to say if the inequality 0.4<d 3 /d 4 <0.9 is true.
A further inequality relates to the offset of the rotor grooves with respect to one another. If a plurality of identical rotor grooves 21 are provided, offset at a predetermined distance d 2 with respect to one another, in the axial direction, it is advantageous if the ratio of the maximum width d 1 to the distance d 2 amounts to between 0.5 and 0.8, that is to say the inequality 0.5<d 1 /d 2 <0.8 is true.
Basically, the previous moving blades with their blade roots 18 can be taken over unchanged and used in the widened rotor grooves 21 . However, because of the widened bottom region 23 , the blade root 18 would then have to be provided with an additional volume 24 , as shown in FIG. 4 , which would lead to undesirable secondary effects.
An adaptation of the blade root to the changed rotor groove geometry is therefore preferred, this being reproduced by way of example in FIGS. 5 , 6 and 7 . The moving blade 26 of FIGS. 5 and 6 has a blade root 27 which in the upper portion, which reaches as far as the axial stop faces, is designed in essentially the same way as the blade root 18 from FIG. 2 . However, by contrast differs in the radial downward prolongation, starting at the hammerhead 32 , by means of a lengthening bolt 29 which is integrally formed onto the hammerhead 32 and which is narrower (width d 9 ) than the hammerhead 32 (width d 8 ). The radial length (d 6 ) of the lengthening bolt ( 29 ) is markedly greater than the height (d 7 ) of the hammerhead 32 .
If the lengthening bolt 29 is integrally formed directly on the hammerhead 32 , a curved transitional face 28 is preferably provided at a transition between the lengthening bolt 29 and the hammerhead 32 in order to ensure a continuous transition.
As a cost-effective alternative for the axial lengthening of the blade root 18 , it is appropriate to produce the lengthening bolt 29 as a separate part and to connect it to the hammerhead 32 . Screwing or welding has in this case proved to be a method of connection which satisfies the requirements of practical operation. Thus, the hammerhead 32 may be equipped on the bottom 34 , in the region of the mid-plane 33 , with a threaded bore 35 . With the aid of an integrally formed threaded bolt 36 , the lengthening bolt 29 is screwed into the blade root 18 , as outlined by way of example in FIG. 7 .
Furthermore, one or more mass-reducing recesses 31 are provided in the blade root 18 , 27 and may be designed as a circular, elliptical or otherwise shaped hole or slot in a single or multiple version. The recess or recesses 31 extends or extend in the radial direction preferably over the hammerhead 32 and the lengthening bolt 29 . In this case, this recess or these recesses 31 preferably, but not necessarily, runs or run in the circumferential direction, as illustrated in FIGS. 5 , 6 and 7 . Other suitable directional runs and embodiments of mass-reducing recesses 31 may likewise be envisaged, however, such as, for example, in the form of bores introduced radially into the blade root 27 .
The ratio of the height (d 7 ) of the hammerhead 32 to the length (d 6 ) of the lengthening bolt 29 is preferably between 0.2 and 0.8, that is to say the inequality 0.2<d 7 /d 6 <0.8 is applicable.
The ratio of the axial width (d 9 ) of the lengthening bolt 29 to the axial width (d 8 ) of the hammerhead 32 is preferably between 0.2 and 0.6, that is to say the inequality 0.2<d 9 /d 8 <0.6 is applicable.
The invention includes the following features and advantages: The blade root comprises as a radial prolongation a lengthening bolt having the dimensions 0.2<d 7 /d 6 <0.8 and 0.2<d 9 /d 8 <0.6, so that the spring 22 can be used for assembly. The lengthening bolt 29 may be chamfered at the margins in order to save additional weight. The transitional faces between the lengthening bolt and the hammerhead are preferably curved in order to reduce mechanical stresses. In the region of the hammerhead and of the lengthening bolt, recesses, in particular holes or slots are provided, in order to reduce the weight or mass.
LIST OF REFERENCE SYMBOLS
10 Gas turbine
11 Rotor
12 Compressor
12 a Last compressor stages
13 a , 13 b Turbine (HP, LP)
14 a , 14 b Combustion chamber
15 Air inlet
16 Exhaust gas outlet
17 , 26 Moving blade, moving blade leaf
18 , 27 Blade root
19 , 21 Rotor groove
20 Stop face (axial)
22 Spring
23 Bottom region (widened)
24 Additional volume
25 Stop face (radial)
28 Transitional face (curved)
29 Lengthening bolt
30 Rotor axis
31 Recess
32 Hammerhead
33 Mid-plane
34 Blade root bottom
35 Threaded bore
36 Threaded bolt
d 1 , . . . , d 4 Distance
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A rotor is provided for an axial-throughflow turbo machine, which carries a plurality of moving blades which are each pushed with a blade root into a rotor groove extending about the axis and are held. The blade root includes a hammer root with a hammerhead and is supported on radial stop faces of the rotor groove which lie further outward in the radial direction, against centrifugal forces acting on the moving blades, and are supported on axial stop faces lying further inward in the radial direction, against axial forces which act on the moving blade. The rotor groove has at its bottom, to reduce thermal stresses, an axially and radially widened bottom region with a continuously curved cross-sectional contour. In such a rotor, an advantageous adaptation of the blading is achieved by the blade root of the moving blades being adapted to the widened bottom region in the radial direction.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present invention generally relates to cutting mechanisms and, particularly, to a cutting mechanism for cutting elements formed by injection molding.
[0003] 2. Discussion of Related Art
[0004] Injection molding is a process that injecting melted modeling material into molds to mold elements having predetermined shapes. Injection molding is widely used in ceramic and polymer products as having advantages of low cost, high efficiency, and high precision.
[0005] Generally, the semi-manufactured products formed by injection molding usually have different structures due to molds with different runners, for example, correctitude runners or side runners. Referring to FIG. 5 , a semi-manufactured product 20 molded by molds having correctitude runners includes a sprue portion 200 , a plurality of runner portions 202 and a plurality of lenses 204 respectively connected to the plurality of runner portions 202 . The runner portions 202 are connected to the sprue portion 200 and form a radial-distribution around the sprue portion 200 . Each of the lenses 204 is correspondingly formed at a distal end of the runner portions 202 and on an axial direction extending from the center axis AA′ of the runner portions 202 . Referring to FIG. 6 , a semi-manufactured product 30 molded by molds having side runners similarly includes a sprue portion 300 , a plurality of runner portions 302 and lenses 304 . The difference between the semi-manufactured product 30 and the semi-manufactured product 20 is that, each of the lenses 304 is formed on a side of a direction extending from the center axis BB′ of the runner portions 302 . Due to different structure relationship between the lenses and runner portions, different cutting blades are needed in cutting process. Accordingly, a corresponding cutting mechanism is needed in the cutting process.
[0006] Therefore, what is needed is a new cutting mechanism in order to overcome the above described shortcomings.
SUMMARY
[0007] A cutting mechanism, in accordance with a present embodiment, is provided. The cutting mechanism includes a first main body and a second main body. The first main body includes a first base, a plurality of first cutter holders and a plurality of first cutters. The first cutters are mounted on the respective first cutter holders. The first cutter holders are movably engaged with the first base in a manner that the first cutters mounted thereon are adjustably movable toward and away from the first base. The first cutters are rotatable relative to the respective first cutter holders about parallel first axes, and each of the first cutters has a first blade substantially parallel to the respective first axis. The second main body includes a second base, a plurality of second cutter holders and a plurality of second cutters. The second cutter holders are movably engaged with the second base in a manner that the second cutters mounted thereon are adjustably movable toward and away from the second base. The second cutters are rotatable relative to the respective second cutter holders about parallel second axes, and each of the second cutters has a second blade substantially parallel to the respective second axis.
[0008] Detailed features of the present cutting mechanism will become more apparent from the following detailed description and claims, and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Many aspects of the present cutting mechanism can be better understood with reference to the following drawing. The components in the drawing are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present cutting mechanism. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, wherein:
[0010] FIG. 1 is a schematic view of a cutting mechanism, according to an exemplary embodiment;
[0011] FIG. 2 is an exploded view of a first main body of the cutting mechanism illustrated in FIG. 1 ;
[0012] FIG. 3 is a schematic view of the cutting mechanism used to cut a semi-manufactured injection molding product with correctitude runners;
[0013] FIG. 4 is a schematic view of the cutting mechanism used to cut a semi-manufactured injection molding product with side runners;
[0014] FIG. 5 is a schematic view of a typical semi-manufactured injection molding product with correctitude runners; and
[0015] FIG. 6 is a schematic view of a typical semi-manufactured injection molding product with side runners.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Reference will now be made to the drawing to describe the embodiments of the present cutting mechanism, in detail.
[0017] Referring to FIG. 1 , a cutting mechanism 10 , according to an exemplary embodiment, is shown. The cutting mechanism 10 includes a first main body 11 and a second main body 12 .
[0018] Referring to FIG. 2 , the first main body 11 includes a base 110 , a plurality of cutter holders 112 and a plurality of cutters 114 corresponding to the cutter holders 112 . Each cutter 114 is assembled in the corresponding cutter holder 112 . In this exemplary embodiment, the first main body 11 includes eight cutter holders 112 and eight cutters 114 .
[0019] The base 110 includes a supporting portion 1102 , a plurality of receiving recesses 1104 , a plurality of positioning holes 1106 and a plurality of fasteners 1108 . The supporting portion 1102 is configured for supporting semi-manufactured products formed by injection molding. The receiving recesses 1104 are respectively defined at side portions of the base 110 and configured for receiving end portions of the cutter holders 112 therein. The fasteners 1108 penetrate through the positioning holes 1106 and thereby fix the cutter holders 112 onto the base 110 respectively. The positioning holes 1106 communicate with the corresponding receiving recesses 1104 respectively. The positioning holes 1106 can be screw thread holes and the fasteners 1108 can be screws matching with the positioning holes 1106 . The positioning holes 1106 can also be through holes with smooth inner walls, and the fasteners 1108 can be nuts and bolts matching with the nuts.
[0020] The cutter holders 112 extend radially and outwardly from the first base 110 . Each of the cutter holders 112 includes a first end portion 1120 and a second end portion 1122 . The second end portion 1122 includes a receiving slot 1124 and a pivot hole 1126 . The receiving slot 1124 is configured for receiving the cutter 114 . The pivot hole 1126 communicates with the receiving slot 1124 . The pivot hole 1126 can be a screw thread hole. The pivot hole 1126 and a pivot member 1128 cooperatively pivot the cutter 114 with the second portion 1122 . As such, the cutters 114 are detachably pivoted on the second end portions 1122 of the cutter holders 112 . The pivot members 1128 can be screws engaging with the screw threads of pivot holes 1126 . The pivot holes 1126 can also be through holes with smooth inner walls, and the pivot members 1128 can be nuts and bolts matching with each other.
[0021] The cutters 114 each includes a cutting portion 1140 and a pivot portion 1142 . The cutting portion 1140 and the pivot portion 1142 are approximately perpendicular to each other. The cutting portion 1140 includes a blade 1144 . The pivot portion 1142 includes a pivot slot 1146 . The pivot portion 1142 is received in the receiving slot 1124 of the cutter holder 112 . The pivot member 1128 penetrate through the pivot hole 1126 and the pivot slot 1146 , thereby pivot and fix the pivot portion 1142 at the second end portion 1122 of the cutter holder 112 .
[0022] Since the first end portion 1120 of the cutter holder 112 is received in the receiving recesse 1104 of the base 110 and fixed by by engagement of the fastener 1108 in the positioning holes 1106 , the cutter holder 112 can be moved back and forth when the fastener 1108 is loosened. Thereby, the position of the cutter holder 112 can be adjusted, and thereafter be fixed again by the fastener 1108 .
[0023] Similarly, the cutter 114 can also be moved back and forth when the pivot member 1128 is loosened. Additionally, since the pivot portion 1142 of the cutter 114 is pivoted with the second end portion 1122 of the cutter holder 112 cooperatively by the pivot member 1128 and the pivot hole 1126 , the cutter 114 can be rotated around the pivot member 1128 when the pivot member 1128 is loosened. Thereby, the cutter 114 can be adjusted to have a predetermined angle with the cutter holder 112 , and thereafter be fixed again by the pivot member 1128 .
[0024] The second main body 12 has a configuration approximately as same as the first main body 11 . The second main body 12 includes a base 120 , a plurality of cutter holders 122 , and a plurality of cutters 124 arranged at end portions of the cutter holders 122 . The base 120 includes a plurality of receiving recesses 1204 , a plurality of positioning holes 1206 and a plurality of fasteners 1208 . The cutter holders 122 are radially arranged around the first base 110 . Each of the cutter holders 122 has an end portion received in the receiving recess 1204 .ln the present embodiment, there are eight cutters 124 detachably pivoted on the other end portions of the cutter holders 122 . The difference between the first main body 11 and the second main body 12 is that, the second main body 12 does not include a base instead, it has a receiving hole/chamber configured for receiving sprue portions 200 /or 300 (as shown in FIGS. 3 & 4 ). As such, the first and second main body 11 , 12 can move relative to each other, thereby facilitating cutting function of the semi-manufactured products formed by injection molding.
[0025] Referring to FIG. 3 , The semi-manufactured product 20 is disposed on the supporting portion 1102 of the first main body 11 , with the runner portions 202 respectively arranged directly above the cutter holders 112 . A plurality of lenses 204 are connected respectively connected to the runner portions 202 . When the cutting mechanism 10 is used to cut the semi-manufactured product 20 having correctitude runners, the cutters 114 and 124 are respectively located at distal ends of the cutter holders 112 and 122 correspond with lenses 204 . Thereby, the semi-manufactured product 20 will be cut as the first main body 11 and the second main body 12 moving towards each other.
[0026] Referring to FIG. 4 , the semi-manufactured product 30 is disposed on the supporting portion 1102 of the first main body 11 , with the runner portions 302 respectively arranged directly above the cutter holders 112 . A plurality of lenses 304 are respectively connected to the runner portions 302 . When the cutting mechanism 10 is used to cut the semi-manufactured product 30 having side runners, the pivot members 1128 are loosened, and thereby the cutters 114 can be rotated corresponds to the location of the semi-manufactured product 30 disposed on the supporting portion 1102 of the cutter holders 112 . Thereafter, the pivot members 1128 will be fastened to fix the cutters 114 to the cutter holders 112 . Then, the cutters 124 are rotated facing the cutters 114 . The cutters 114 , 124 are respectively located on sides of the cutter holders 112 , 122 and correspond with lenses 304 on sides of the runner portions of 302 . Thereby, the semi-manufactured product 30 will be cut as the first main body 11 and the second main body 12 moving towards each other.
[0027] It is to be understood that, the number of cutter holders and cutters of the cutting mechanism 10 can also be one, two, three, four, six, or more and not limited to be eight. The cutter holders and the base can also be integrative. The distribution of the cutter holders is not limited to be radially arranged around the base, as long as it is the same with the distribution of the runner portions of the semi-manufactured products. The pivot slots of the cutters can also be replaced by through holes in the pivot portions of the cutters, the through holes can have smooth inner walls or be screw thread hole. Accordingly the pivot members can be nuts and bolts or screws matching the screw thread holes.
[0028] In sum, due to the cutting mechanism 10 being equipped with cutters 114 , 124 detachably pivoted on end portions of the first cutter holders 112 and second cutter holders 122 , thereby the cutters 114 , 124 can be adjusted to have a predetermined orientation as same as that of the runner portions 200 , 302 , as such the cutting mechanism 10 is applicable for cutting semi-manufactured injection molding products having runners different orientations.
[0029] Finally, it is to be understood that the above-described embodiments are intended to illustrate rather than limit the invention. Variations may be made to the embodiments without departing from the spirit of the invention as claimed. The above-described embodiment illustrates the scope of the invention but do not restrict the scope of the invention.
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A cutting mechanism includes a first main body and a second main body. The first main body includes a first base, a plurality of first cutter holders, and a plurality of first cutters. The first cutters are mounted on the respective first cutter holders. The first cutter holders are movably engaged with the first base in a manner that the first cutters mounted thereon are adjustably movable toward and away from the first base. The first cutters are rotatable relative to the respective first cutter holders about parallel first axes, and each of the first cutters has a first blade substantially parallel to the respective first axis. The second main body has a similar configuration as the first main body.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the delivery of antimicrobial functions or agents from the surface of coatings, particularly the release of antimicrobial functions or agents from the surface of medical devices, especially medical devices that have been inserted or implanted into patients. The invention particularly relates to the controlled or controllable delivery of such functions or agents.
[0003] 2. Background of the Art
[0004] It has become common to treat a variety of medical conditions by introducing or implanting a temporary or permanent medical device partly or completely into a patient. These devices may be inserted or implanted (the term “implanted” shall be used herein to reflect both short term insertion and long term implantation) into many different organs and glands such as the heart, brain, esophagus, stomach, trachea, colon, biliary tract, urinary tract, vascular system or other location within a human or veterinary patient. These implants may be in the form of a device such as a pump, delivery system, sensing system, stent, catheter, balloon, wire guide, cannula, electrical pulsing or pacing system or the like. However, when such a device is introduced into and manipulated through the vascular system or implanted at a selected site, the tissue or vascular walls can be disturbed or injured. Clot formation or thrombosis, bacterial collection and infection and other adverse events can occur at the injured site or implantation site, causing acute or chronic injury or infection at the sire. Moreover, if the medical device is left within the patient for an extended period of time, thrombus and infections may often form on the device itself, again causing serious potential for damage and illness. As a result, the patient is placed at risk of a variety of complications, including heart attack, pulmonary embolism, stroke, site infection, sepsis, implant rejection, and the like. Thus, the use of such a medical device can entail the risk of causing problems as serious or worse than the problems that the device's use was intended to ameliorate.
[0005] Another way in which blood vessels undergo stenosis is through disease. Probably the most common disease causing stenosis of blood vessels is atherosclerosis. Atherosclerosis is a condition which commonly affects the coronary arteries, the aorta, the iliofemoral arteries and the carotid arteries. Atherosclerotic plaques of lipids, fibroblasts, and fibrin proliferate and cause obstruction of an artery or arteries. As the obstruction increases, a critical level of stenosis is reached, to the point where the flow of blood past the obstruction is insufficient to meet the metabolic needs of the tissue distal to (downstream of) the obstruction. The result is ischemia.
[0006] Many medical devices and therapeutic methods are known for the treatment of atherosclerotic disease. One particularly useful therapy for certain atherosclerotic lesions is percutaneous transluminal angioplasty (PTA). During PTA, a balloon-tipped catheter is inserted in a patient's artery, the balloon being deflated. The tip of the catheter is advanced to the site of the atherosclerotic plaque to be dilated. The balloon is placed within or across the stenotic segment of the artery, and then inflated. Inflation of the balloon “cracks” the atherosclerotic plaque and expands the vessel, thereby relieving the stenosis, at least in part.
[0007] While PTA presently enjoys wide use, it suffers from two major problems. First, the blood vessel may suffer acute occlusion immediately after or within the initial hours after the dilation procedure. Such occlusion is referred to as “abrupt closure.” Abrupt closure occurs in perhaps five percent or so of the cases in which PTA is employed, and can result in myocardial infarction and death if blood flow is not restored promptly. The primary mechanisms of abrupt closures are believed to be elastic recoil, arterial dissection and/or thrombosis. It has been postulated that the delivery of an appropriate agent (such as an antithrombic) directly into the arterial wall at the time of angioplasty could reduce the incidence of thrombotic acute closure, but the results of attempts to do so have been mixed.
[0008] A second major problem encountered in PTA is the re-narrowing of an artery after an initially successful angioplasty. This re-narrowing is referred to as “restenosis” and typically occurs within the first six months after angioplasty. Restenosis is believed to arise through the proliferation and migration of cellular components from the arterial wall, as well as through geometric changes in the arterial wall referred to as “remodeling.” It has similarly been postulated that the delivery of appropriate agents directly into the arterial wall could interrupt the cellular and/or remodeling events leading to restenosis. However, like the attempts to prevent thrombotic acute closure, the results of attempts to prevent restenosis in this manner have been mixed.
[0009] Non-atherosclerotic vascular stenosis may also be treated by PTA. For example, Takayasu arteritis or neurofibromatosis may cause stenosis by fibrotic thickening of the arterial wall. Restenosis of these lesions occurs at a high rate following angioplasty, however, due to the fibrotic nature of the diseases. Medical therapies to treat or obviate them have been similarly disappointing.
[0010] A device such as an intravascular stent can be a useful adjunct to PTA, particularly in the case of either acute or threatened closure after angioplasty. The stent is placed in the dilated segment of the artery to mechanically prevent abrupt closure and restenosis. Unfortunately, even when the implantation of the stent is accompanied by aggressive and precise antiplatelet and anticoagulation therapy (typically by systemic administration), the incidence of thrombotic vessel closure or other thrombotic complication remains significant, and the prevention of restenosis is not as successful as desired. Furthermore, an undesirable side effect of the systemic antiplatelet and anticoagulation therapy is an increased incidence of bleeding complications, most often at the percutaneous entry site.
[0011] Other conditions and diseases are treatable with stents, catheters, cannulae, pacemakers, defibrilators, pumps, eluent drug delivery systems and other devices inserted into organs such as the heart, the brain, the esophagus, the trachea, the colon, biliary tract, urinary tract and other locations in the body, or with orthopedic devices, implants, or replacements. It would be desirable to develop devices and methods for reliably delivering suitable agents, drugs or bioactive materials directly into a body portion during or following a medical procedure, so as to treat or prevent such conditions and diseases, for example, to prevent site infection, either from short term insertion or long term implantation of the device. As a particular example, it would be desirable to have devices and methods which can deliver an antibacterial agent or other medication to the region of implantation, where the release of the antibacterial agent can be externally controlled, rather than relying on predetermination of a release rate. Additionally, the release rate should not be dependent upon external reading of the device or regular sampling of the blood stream to determine when release rates of a medical pump should be modified to adjust to altering patient conditions. The antibacterial delivery system should also be minimally additive in size or volume to the device being implanted. It would also be desirable that such devices would controllably deliver their agents over both the short term (that is, the initial hours and days after treatment) and the long term (the weeks and months after treatment). It would also be desirable to provide relatively precise control over the delivery rate for the agents, drugs or bioactive materials, and to limit invasive control in effecting that delivery. This would be particularly advantageous in therapies involving the delivery of a chemotherapeutic agent to a particular organ or site without requiring reinsertion or additional insertion to the patient through an intravenous catheter (which itself has the advantage of reducing the amount of agent needed for successful treatment). This would reduce the trauma to the patient and reduce additional invasion of the patient. A wide variety of therapies can be similarly improved by the practice of this methodology. Of course, it would also be desirable to avoid degradation of the agent, drug or bioactive material during its incorporation on or into any such device.
[0012] Problems experienced with the use of pumps, structural implants, pacemakers, defibrillators, and catheters, particularly catheters designed for urinary tract infections or indwelling vascular catheters such as those used in patients receiving long term chemotherapy for malignancies or antimicrobials for persistent infections present a significant risk in patients with an indwelling catheter. Although many such infections are asymptomatic, they are sometimes serious and can result in prolonging the length of stay and increasing the cost of hospital care. Bacteria are believed to gain access to the catheterized bladder either by migration from the collection bag and/or catheter or by ascending the periurethral space outside the catheter. It has been found that by coating catheters with silver or silver oxide reduced the incidence of catheter associated bacteriuria. Silver is known to possess antibacterial properties and is used topically either as a metal or as silver salts. It is not absorbed to any great extent and the main problem associated with the metal is argyria, a general gray discoloration. Although silver is an effective topical antibacterial agent, it tends to act only on bacteria in direct contact with the surface and is subject to chemical reactions such as oxidation, which reduce its long term effectiveness.
[0013] Additionally, where release of the antibacterial agent from a coating is solely by mass transfer release by elution or migration out of a coating, drug is unnecessarily released during movement to the implantation site. At a minimum, this drug is wasted during implantation, or in the case of highly active agents, it is released to a region where that drug is not needed.
[0014] U.S. Pat. No 5,418,130 describes a method for inactivating viral and/or bacterial contamination in blood cellular matter, such as erythrocytes and platelets, or protein fractions. The cells or protein fractions are mixed with chemical sensitizers and irradiated with, for example, WV, visible, gamma or X-ray radiation. In particular, quaternary ammonium or phosphonium substituted, halo-psoralen compounds are described as being useful. This system is for use on solutions or dispersions of cells or the like and is not described for application on medical devices.
[0015] A typical drug delivery system with a biodegradable release layer is shown by U.S. Pat. No. 6,342,250. U.S. Pat. No. 6,251,136 describes a method of forming a release catheter comprising a method for coating a stent, comprising the steps of: providing a stent; applying a base layer of sticky material to selected surfaces of said stent; applying pharmacological agent in micronized, dry form to selected surfaces coated by said base layer; and applying a membrane forming polymer coating through which said pharmacological agent is able to diffuse to all surfaces of said stent.
[0016] U.S. Pat. No. 4,723,950 by Lee relates to a microbicidal tube which may be incorporated into the outlet tube of a urine drainage bag. The microbicidal tube is manufactured from polymeric materials capable of absorbing and releasing anti-microbial substances in a controllable sustained time release mechanism, activated upon contact with droplets of urine, thereby preventing the retrograde migration of infectious organisms into the drainage bag. The microbicidal tube may be produced by one of three processes: (1) a porous material, such as polypropylene, is impregnated with at least one microbicidal agent, and then coated with a hydrophilic polymer which swells upon contact with urine, causing the leaching out of the microbicidal agent; (2) a porous material, such as high density polyethylene, is impregnated with a hydrophilic polymer and at least one microbicidal agent; and (3) a polymer, such as silicone, is compounded and co-extruded with at least one microbicidal agent, and then coated with a hydrophilic polymer. A broad range of microbicidal agents are disclosed, including chlorhexidine and triclosan, and combinations thereof. The purpose of Lee's device is to allow the leaching out of microbicidal agents into urine contained in the drainage bag; similar leaching of microbicidal agents into the bloodstream of a patient may be undesirable.
[0017] U.S. Pat. No. 6,168,601 shows a system utilizing the eutectic forming ability of related drugs to control release. Biologically active materials are provided in a cylindrical carrier medium with better control over the rate of delivery and length of time of delivery by providing a carrier having dissolved or dispersed therein at least two compounds having a common biologically active nucleus, but with different solubility parameters. The combination of the two different variants of the same drug with different solubility parameters provides the material with control over the rate of release of the compounds (by varying the proportions of the variants) and most importantly, extending the useful life of the device by enabling release of effective levels of the compounds over a longer period of time. The cylindrical carrier medium, comprised of silicone, further includes a tail, a skirt, or a rate-limiting membrane.
[0018] U.S. Pat. No. 5,091,442 by Milner relates to tubular articles, such as condoms and catheters, which are rendered antimicrobially effective by the incorporation of a non-ionic sparingly soluble antimicrobial agent, such as triclosan, The tubular articles are made of materials which include natural rubber, polyvinyl chloride and polyurethane. Antimicrobial agent may be distributed throughout the article, or in a coating thereon. A condom prepared from natural rubber latex containing 1% by weight of triclosan, then dipped in an aqueous solution of chlorhexidine, is disclosed. U.S. Pat. Nos. 5,180,605 and 5,261,421, both by Milner, relate to similar technology applied to gloves.
[0019] U.S. Pat. No. 6,224,579 discloses a method of producing a non-infecting medical article by imbuing the device in a solution containing synergistic amounts of two antibiotics. That article comprises a medical article prepared by exposing a polymer-containing medical article, for an effective period of time, to a treatment solution comprising between about 0.3 and 1.5 percent of a silver salt and between about 0.1 and 20 percent triclosan, where the treatment solution and the medical article do not contain chlorhexidine or a chlorhexidine salt.
[0020] Improved coatings and control of drug delivery is desired for medical devices.
SUMMARY OF THE INVENTION
[0021] The present invention relates to medical devices that are inserted or implanted into patients and that have antimicrobial coatings that controllably release free radicals into the vicinity of the device. These devices may have coatings that alter their rate of flow release or elution release of an antibacterial agent from a coating on the device upon immediate, local or external stimulation or external activation. By immediate is meant that the coating or element is itself heatable or responsive to radiation (e.g., Infrared responsive, RF responsive, etc.), local means that an adjacent element may generate the heat or accept radiation emission and convey the energy to the layer or element to stimulate the release of the free radical, and external activation includes a signal from a distal control to mechanically alter the size of an opening, or cause a stretching of elongation of the element to open pores or holes. The coating should therefore be responsive to immediate, local or external control such as by heating (e.g., by electrical resistance where an external wire is present on the device) or responsive to external RF [radio frequency] stimulus, sonic control [e.g., to disrupt a coating or to activate a battery driven circuit in the system], local radiation stimulation or activation and the like. By having control of the release rate, and in some structures without invasion of the patient by mechanical means in addition to the device itself, the release rate can be in response to need at the implant site. The class of compounds to be released are free radical compounds, compounds that release free radicals upon immersion or stimulation, the free radicals acting as the antibacterial agent. Semiconductor materials capable of emitting radiation (e.g., UV radiation that can be generated internally from the semiconductor to activate free radicals) may be used to control release of free radicals in a layer responsive to the emissions or temperatures that can be generated by the semiconductor.
BRIEF DESCRIPTION OF THE FIGURE
[0022] [0022]FIG. 1 shows a cutaway view of a catheter providing free radicals according to an aspect of the invention
DETAILED DESCRIPTION OF THE INVENTION
[0023] Over the past few years, free radicals have been implicated in all sorts of diseases. Every health supplement and face cream seems to include some protection against them—but what are they and, more importantly, what do they do? We first need to go back to basic level chemistry to understand what a free radical is. The chemical bonds that hold atoms together to make molecules contain pairs of electrons. For example, there are two electrons in each of the bonds holding the hydrogens of water to the oxygen. The two electrons act to stabilize the bond between the atoms. However, some molecules, especially those containing oxygen, can easily gain an extra one of these bonding electrons. As this electron is not paired with any other electrons, it makes the molecule very reactive. In a sense this molecule or atom with the extra, available electron is a molecule with a free chemical bond. This is essentially what a free radical is—a molecule containing unpaired electrons. This molecule will steal electrons from other molecules in order to pair its lone electron. In stealing this electron the structure of the electron-donating molecule may be changed or even turned into a free radical itself. Free radicals are generated by all sorts of different processes in the body. Approximately 5% of the oxygen that our cells use to burn sugars to release energy is lost as oxygen free radicals. UV light, cigarette smoke, and various other agents generate free radicals. White blood cells deliberately produce free radicals to kill invading bacteria. Free radicals can destroy enzymes, make proteins brittle, make cells leaky, cause cholesterol to become stuck in arteries and mutate DNA. Much of the process of ageing appears to be due to a very slow but steady wearing out of the body by free radical damage.
[0024] The body deals with free radicals either by using antioxidant enzymes, which degrade the radicals back to harmless water and oxygen, or with chemicals called antioxidants, which react with and neutralize the radicals. Vitamin C and vitamin E are the two most important antioxidants within the body. Vitamin E neutralizes radicals in the fats and oils of our body while vitamin C protects the water-soluble biomolecules.
[0025] Free radicals are relatively free from controversy in the medical field with respect to their toxicity, effectiveness, and long term effects. Although free radicals in solution are recognized as fighting or killing bacteria or viruses, much literature addresses the presence of free radicals in the body as unhealthy, contributing to cell deterioration, especially skin and tissue aging. A great deal of commercial literature focuses on the increase of antioxidants in diets to reduce the amount of free radicals in human blood streams to reduce aging effects. There is still incontrovertible evidence that free radicals in solution have a direct and immediate effect on disabling or killing bacteria and viruses. However, except for ozonation, there appears to be little effort that has been made in the direction of finding any useful method for applying free radicals to human therapy, except for the natural free radical generations effected by the body as part of its immune response.
[0026] Free radicals are atoms or groups of atoms with an unpaired valence electron. Free radicals can be produced by photolysis or pyrolysis in which a bond is broken without forming ions (e.g., hemolytic fission). The presence of the unpaired electrons causes free radicals to be highly active. Free radical generating compounds, especially those that are responsive to light and/or heat to generate the free radicals are especially well known in the photocatalytic art. Among the many types of free radical generating initiators known in the polymer art are triazines, s-triazines, quaternary ammonium compounds and salts; halogen releasing compounds; diazonimum salts, iodonium salts (especially diary iodonium salts), phosphonium salts (especially triaryl phosphonium salts), sulfonium salts (especially triaryl sulfonium salts), biimidazoles, benzophenones, and the like. Some of these materials are quite stable in aqueous environments, generating the free radicals only upon thermal or photoinitiation. Other classes of free radical generating compounds more typically known in the medical environment as a treatment for in vitro liquid supplies are fibrates (e.g., fenofibrate); NSAIDS such as benoxaprofen, carprofen, ketoprofen, naproxen, suprofen, Tiaprofenic acid; Germicides such as Bithionol, buclosamide, fenticlor, hexachlorophene, tetrachlorosalicylanilide, and triclosane; tetracyclines such as demeclocycline, doxycycline and tetracycline; quinolones such as cyprofloxacin, fleroxacin, lomefloxacin, nalidixic acid, and ofloxacin; psoralens such as bergamot oil, 5hydroxypsoralen, isopsoralen, 5-methoxypsoralen, 8-methoxypsoralen, and trimethylpsoralen; diphenhydramine, thiazides, sulfonylureas; azines such as chlorpromazine, and promethiazine. The use of brominated or halogenated psoralens is particularly useful in activation in the practice of the invention, either as pure coatings or dissolved or dispersed in polymeric coatings. Other types of intercalators may be utilized besides the psoralens and substituted psoralens such as those listed below. These intercalators may be used to target viruses or other blood contaminants, or cancer cells. Thus, halogenated or metal atom-substituted derivatives of the following compounds may be utilized as sensitizers: dihematoporphyrin esters, hematoporphyrin derivatives, benzoporphyrin derivatives, hydrodibenzoporphyrin dimaleimade, hydrodibenzoporhyrin, dicyano disulfone, tetracarbethoxy hydrodibenzoporhyrin, tetracarbethoxy hydrodibenzoporhyrin dipropionamide; and the like. The above compounds in their non-halogenated or non-metal atom substituted forms are disclosed in U.S. Pat. Nos. 4,649,151, 4,866,168, 4,883,790, 5,053,423 and 5,059,619, incorporated by reference herein. When modified with halogen atoms or metal atoms, the above-identified classes of compounds may be sensitized with electromagnetic radiation, including visible light. Semiconductors such as titanium dioxide and zinc oxide also produce free radicals upon UV and visible light exposure, and are preferred sources of free radicals in compositions used in the present invention.
[0027] Polymeric compositions are often used as coatings on medical devices, such as catheters or stents, as shown in U.S. Pat. No. 5,964,705, either as the structural material for the device or as an insulating or protective coating. Such medical devices, where the polymer is formed by a free radical polymerization process, may have residual free radical polymerization catalyst present in the polymer coating. The concentration of such free radical catalysts in polymers is typically on the order of 1-3% by weight. Literature citing extreme ranges of free radical catalysts may indicate levels as high as 10% by weight, but these are truly unrealistic amounts added to provide broad ranges of protection for purposes of legal disclosure. Even at those levels, and particularly where the inclusion in the polymer does not provide them in an active state or enable them to be come active, such low levels of free radical polymerization catalysts would not be a sufficiently high concentration of materials to maximize antibacterial activity according to the practice of the invention, and such activity has never been reported in the literature.
[0028] The invention encompasses various devices, including a medical device for insertion into a patient, the device having a surface with a coating thereon or containing within its outermost layer, an antimicrobial amount of at least one compound that provides microbe suppressing free radicals into an aqueous environment in contact with the device upon external stimulation of the coating, layer or compound. The device may provide the coating releases an amount of free radicals upon heating that increases in a rate of release from the coating to an aqueous environment by at least 20% when heated from 37° C. to 50° C. The device may have the coating release an amount of free radicals upon sonication that increases in a rate of release from the coating to an aqueous environment by at least 20%. The device may be designed with the coating comprising at least 0.0001% by weight of compounds that release free radicals when in contact with an aqueous environment. The device may have the coating comprise at least 0.005% by weight of compounds that release an antimicrobially active amount of free radicals when in contact with an aqueous environment. The device may alternatively have the coating comprise at least 0.1% by weight of compounds that release an antimicrobially active amount of free radicals when in contact with an aqueous environment. The device may have the compound generate free radicals upon stimulation by electromagnetic radiation. The device may have the coating comprises at least 1.0% or at least 1.5% by weight of the compounds. The free radical releasing compound may comprise a quaternary salt or a compound that releases halogen free radicals. The coating or outer layer may comprise at least 0.005% by weight of compounds that release an antimicrobially active amount of free radicals when stimulated by heat or electromagnetic radiation. There may be an electromagnetic receiver that initiates heat generation in the device to elevate the temperature of the coating. A battery may electrically attached to said device to power heat generation, or a transmitting wire is electrically attached to said device to power heat generation from an outside power source.
[0029] The invention may be alternatively described as medical device for insertion into a to patient, the device having a containing within its outermost layer an antibacterial amount of at least one compound that provides microbial-suppressing free radicals into an aqueous environment in contact with the device upon external stimulation. It ius preferred that the compound comprises TiO 2 , ZnO, SiO, and other metal oxides either alone or in combination. The stimulation is preferably provided by infrared radiation, ultraviolet radiation or visible light. The antimicrobial agent may also be a photoactive compound.
[0030] In the practice of the present invention, coatings with free radical generating or free radical providing compositions should be present in the coatings on medical devices of the present invention as at least 0.0001% by weight of the coating because of the high activity of free radical materials. The coatings or compound contained within the coating on the device might make up only a fraction of the weight—possible as little as 0.0001%, at least 0.0005%, 0.001%, 0.005%, 0.01%, 0.05%, 0.1%, 0.5%, 1.0%, 2%, 5% by weight, at least 10% by weight, at least 12% by weight, at least 15% by weight, at least 20% by weight, at lest 25% by weight at least 30% by weight, up to solid coatings of 100% by weight of the free radical generator. Solid coatings are preferred but water immiscible oil-based coating may also be provided, although these can be rubbed off during insertion.
[0031] Coatings may be applied to the surfaces of the medical devices by any convenient method, including but not limited to dip coating, spray coating, iontopheresis, deposition coating, manual application, and the like. As the activity of the free radicals tends to be a surface phenomenon, or at least material is released from the surface, the coatings do not have to be thick to provide effective results. Coating of less than 0.5 microns can provide some significant activity, and layers thicker than 100 microns do not provide significantly additional effectiveness, although the thicker layers would provide a greater life and endurance. Therefore, the nominal thickness of 0.5 to 100 microns is merely a general range, and not exclusive of other thicknesses. Generally preferred ranges would be from 0.5 to 50 microns, 1.0 to 50 microns, 1 to 30 microns, 2 to 30 microns, or 2 to 25 microns.
[0032] The use of normal migration of free radical providing materials out of the coating is one method of providing local free radical antimicrobic activity. Providing thermally responsive or photoresponsive free radical generators requires some more substantive structure. For example, FIG. 1 shows a side view of a catheter 2 . The catheter 2 has a drug delivery port 4 with a drug delivery tube 6 , and narrowing tip 8 . The catheter 2 is shown as layered, with layers 35 , 37 and 39 to contain the structural elements of the catheter 2 . As an example of a structure with embodiments of the invention, this FIG. 1 will be described.
[0033] Layer 35 is a structural support layer in the catheter 2 , supporting layer 37 that contains coils 12 , 16 , 18 and 32 . Those coils 12 , 16 , 18 and 32 are powered through wires 36 and 38 . These types of coils are traditionally used as RF responsive microcoils for generating a field of view under MRI (magnetic resonance imaging), but here with appropriate thickness, they can also be used as resistive wires. When sufficient current is passed through the coils 12 , 16 , 18 and 32 , those coils would generate heat that could trigger free radical release in layers 39 and/or 40 , either or both of which may comprise the free radical generating composition. Tubes 24 , 24 a, 26 , 26 a , 28 , 28 a , 30 and 30 a represent microcatheters, light pipes, material delivery tubes and the like as designed into the structure. The figure shows microcatheters 24 and 30 as material 25 delivery ports. These material delivery ports 24 and 30 may deliver drugs locally during primary catheter treatment procedures and then be used to deliver ingredients that would actively cause release of free radicals in layer 40 . Microcatheters 26 and 28 could be light pipes to deliver radiation towards layers 39 and/or 40 to cause photoinitiated release of free radicals from those layers 39 and/or 40 . The release could be from the surface of layer 40 or from an interior wall of layer 39 so that free radicals are released into delivery tube 4 to diffuse out of that tube or to be forced out of the delivery tube 4 . Component 22 may be a preamplifier, battery, RF receiving system, sonar-receiving system, or the like to control liquid flow through delivery tubes 26 and/or 28 , or to control electrical flow into wire 20 and into the coils 16 , 18 , 10 and 32 . Individual coils 13 , 15 , and 17 are shown, as is the spacing B and 19 between sets of coils. The coils are shown as two ( 32 ) or three ( 34 ) windings.
[0034] Coatings of materials can be provided in many variants and forms that can be externally activated. By the term “externally activated” it is meant that direction must be given from an outside source to initiate increased rates of release of the free radicals, and that even if there is some level of free radical release from the implanted or inserted structure, that rate may be increased upon an initiating signal from outside the patient or even with a sensor signaling function in the patient and communicatively attached to the device. The free radical materials are provided as a coating on at least a portion of the implanted device. The coating may have an initial release capacity for the free radicals of the coating composition and/or may have an additional and alternative antibacterial or anticlotting or other medically active compound that is released spontaneously during dwell of the implanted or inserted device. The free radical material must be deliverable by a signal function, as explained above. The coating may therefore be associated with a heating element, such as a resist heating element, a light emitting heating element (e.g., infrared emitter, or other radiation emitter with an absorber/thermal converter thermally connected to the free radical releasing layer), mass conductive heating element, or the like. The free radical providing layer may also be solvent activatable, where the introduction of a particular class of solvents or solutions to the region will leech and/or activate free radical materials from the coating. Alternatively, radiation projection onto the coating may cause release of free radicals as is the case with TiO2, free radical photonitiators, and coatings whose solubility change to release more dissolved or dispersed material when photoinitiated. Such release functions are well known in the photoimaging, printing and lithographic arts.
Prophetic Examples
[0035] A stent comprising an array of Titano® bars and cross-bars providing flexibility and elastic memory that can undergo compression and expansion is dip coated into a solution comprising a bioinert polysiloxane polymeric binder and trial sulfonium tetrafluoroborate in a weight ratio of 10:90 in an organic solvent. The coating would be applied in an amount that upon drying would provide a 10 micron thick coating. A nickel/cadmium battery is electrically connected to the bars, with an intermediate RF receiver with switching capacity. The RF receiver is programmed to response to a preprogrammed signal so that upon receipt of the signal, a circuit is closed for a specified period of time (e.g., 1 minute) during which the battery heats the stent and the coating, the heat stimulating release of free radicals from the coating.
[0036] An alternative design places an ultraviolet radiation-emitting semiconductor underneath the coating and over the stent bars and cross-bars. The battery is electrically connected to the semiconductor so that upon being powered up, the semiconductor emits UV radiation, photoinitiating release of the free radicals.
[0037] A catheter is coated with TiO 2 and a UV emitting fiber optic is placed into the catheter at the skin's surface and fed down the catheter. The light source is turned on causing a photoinduced release of free radicals from the TiO 2 . Alternatively, the catheter itself (with transparency through the structural material of the catheter (as in a radiation transparent window) can be used to transmit the light from an external source to the region of the free radical releasing composition.
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The present invention relates to medical devices that are inserted or implanted into patients and that have antimicrobial coatings that release free radicals into the vicinity of the device. These devices may have coatings that alter their rate of flow release or elution release of an antibacterial agent from a coating on the device upon external stimulation. The coating should therefore be responsive to external control such as by heating, external RF stimulus, sonic control, visible or ultraviolet light exposure and the like. By having control of the release rate, and in some structures without invasion of the patient by mechanical means in addition to the device itself, the release rate can be in response to need at the implant site. The class of compounds to be released are free radical generating or initiating compounds, or compounds that release free radicals upon immersion or stimulation, the free radicals acting as the antimicrobial agent.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for inspecting the thread of any threaded member, and particularly the threads on a bolt or screw. Specifically, the present invention relates to an apparatus and method for performing a functional test by a thread inspection device having a parts feeder and transfer means for sequentially transferring threaded members through a predetermined transfer path while maintaining the threaded members in a predetermined orientation for functional testing of the thread and subsequent sorting of the non-functional threaded members from the functional threaded members.
2. Description of the Prior Art
Heretofore, one of the principal costs in the production of threaded fasteners has been the manual and visual inspection and sorting of dimensionally defective threaded fasteners from the large volume automatic-machine production of such threaded fasteners. Threaded fasteners such as threaded bolts are normally made on high volume, high speed automatic cold heading machines. Production is often at the rate of several thousand pieces per hour. Initially, in order to select from such high volume production, those threaded fasteners which contain dimensional defects including failure to tap or thread the shaft, severely deformed threads resulting from any number of manufacturing problems, or for any other reason wherein the threaded shaft is unduly or unusually misshapened or is of improper dimensional characteristics, manual and personal inspection is required and the associated costs constitutes a substantial part of the cost of production. In addition, personal or manual inspection is not only cost prohibitive but not always reliable, particularly as required for and by the large volume users of threaded fasteners such as manufacturers in the automotive industry. To accommodate these requirements, sampling programs were implemented with reasonable success for monitoring the quality of the production volume of threaded fasteners. However, recent zero defect demands of very high quality control for threaded fasteners constitute a major requirement by the end user and have resulted in the requirement that the supplier inspect 100 percent of every threaded fastener prior to shipping to the end user. Such requirements have clearly superseded the sampling techniques that were prevalent in the industry and demanded that provisions be made for 100 percent inspection of threaded fasteners utilized in critical components such as engine components as well as transmission and drive train components.
These and other factors have resulted in a vital and increasing need to enable evaluation of all critical dimensional criteria of individual threaded fasteners by the supplier to ensure defective threaded fasteners are removed before shipment. Statistical sampling is no longer an acceptable testing technique.
To attempt to provide 100 percent inspection of threaded fasteners, numerous systems based on optics and acoustics were developed and are presently known for dimensionally qualifying each and every threaded fastener produced. Typically, a plurality of threaded fasteners are advanced along the fabrication line by means of physically engaging the extended flanges of a headed portion and a gripping mechanism and sequentially feeding the threaded fasteners through an examination station, whereby each threaded fastener is subjected to a dimensional qualification. After the threaded fastener is examined, it is subsequently discharged from the machine in either a "reject" receptacle, or, if conforming, into an "accept" receptacle.
Various non-contact inspection systems are also known using various techniques. For example, ultrasonic inspection systems examine reflective sound waves as a means of characterizing a component. Various systems based on a video image of a part are also known. In addition, laser gaging systems are used in which specific dimensional measurements can be obtained. Inducing eddy currents to characterize dimensional characteristics is also a known prior art gaging system for the examination of threaded fasteners.
In general, however, although known non-contact inspection systems are extremely useful, they all have certain limitations. Many of the available non-contact gaging systems are complex data processing approaches which impose expensive hardware requirements and can limit the speed with which evaluations can be accomplished. Preferably, evaluation of a workpiece can be conducted in a rapid enough fashion that the parts can be directly sorted into qualified or disqualified part streams. Prior art systems also tend not to be easily adapted to various part configurations or for evaluating different features of a part. Moreover, many of the currently available non-contact inspection systems have limitations in terms of the number of parameters which can be effectively examined during the inspection process. Another disadvantage of some known systems is their limitation in terms of types of parameters which can be considered. For example, often fine details of thread profiles of threaded fasteners are required to be inspected. Moreover, many prior art systems, although performing adequately in laboratory settings, are not sufficiently rugged for production environments where temperature variations, dust, dirt, cutting fluids, etc. are encountered.
Further, the many defects as characterized by dimensional characteristics of what seems to be a rather simple item combined with the speed at which these threaded fasteners are produced in production presents a challenging problem to ensure 100 percent inspection. For example, a threaded fastener such as a threaded bolt is instructive to consider in this regard. The length of the bolt head and of the cylindrical shank on which threads are formed are each important characteristics which on given designs may, for example, need to be within a minimum and maximum dimension. If the bolt has a hex head, the presence of properly defined corners on that head are important to enable the use of a wrench with that threaded fastener. Some designs incorporate a punched out void area in the center of the head, for use with socket or similar interior wrench devices. These voids need to be cleared of waste metal to ensure usefulness of the threaded fastener; an incomplete void may prevent the bolt from being installed in its intended location. Additionally, head diameter, shoulder thickness, length of thread, etc. are but some of the dimensions that must meet certain prequalified tolerance requirements. Further, damaged threads due to handling or incomplete production processing are defects which may occur even if the bolt is otherwise completely within all dimensional tolerances.
In all of the prior art applications and specifically with respect to gaging of threaded members, none of the known gage inspection or gaging systems provide any information with respect to detail defects within the thread profile. That is, threads may become damaged as a result of handling especially since such threaded fasteners are handled in bulk containers. Therefore, many threaded fasteners which are passed by the so called 100 percent inspection systems often have nicks within the thread which go undetected through the inspection system and are reported as an acceptable part, when in fact the nick in the thread will prevent the threaded bolt from being assembled to a complementary threaded nut. The reason that such defects are undetectable by the sophisticated prior art laser systems is because most of the systems verify dimensional checks such as outside diameters, shaft diameter, shoulder location relative to an end, head height, overall length etc. Notwithstanding the correctness of all of these dimensional characteristics, none of the prior art systems ensure that the thread has not been damaged so that it will properly function with a complementary threaded hole or threaded nut.
In U.S. Pat. No. 3,743,091, there is proposed an apparatus and method for automating the final inspection as to the pitch diameter of the thread so that screws with two or more different threads can be separated and properly sorted from a batch of mixed parts. This inspection is accomplished by presetting the mixed parts in seriatim at a separating station and alternatively moving the parts past at least two gage heads serving as a go/no-go gage. If the thread of the screw matches with the contour of the first gage head, then the screw will be ejected by the kicker to a first receiving bin. If there is a no-go condition (no match) at the first gage head, then the part is redirected and urged for movement past a second gage head whereby the part is deposited in a second receiving bin. In the event that neither gage head corresponds to the threads of the screw being tested, the screw may, in accordance with one embodiment of the invention, be removed from the gaging station along a separate path so that the sorting operation may continue unimpeded.
In spite of the fact that the teachings of U.S. Pat. No. 3,743,091 are concerned with testing for pitch diameter, so as to enable sorting of mixed threaded parts, it can be noted from FIG. 5 that such testing is limited strictly to a cross-sectional outline of the threaded part being matched with the gage head of the testing device. Accordingly, again, any nicks or damage within the thread may not necessarily be caught and a thread which properly meets the condition of the go/no-go gage of the invention may still be unable to be utilized in conjunction with a complementary threaded bore or threaded nut for which it is intended.
Accordingly, there has been a long felt need in the art for a machine that would automatically functionally check the screw thread of a threaded shaft to ensure that when that screw thread was matched with a corresponding hole in an engine block or in the alternative, a threaded nut, there will be no question that the two will properly be allowed to mate and perform the intended function. No solution currently exists for solving the above-identified problem. Accordingly, what is needed is a 100 percent mechanized inspection device which will ensure the functionality of a thread found on a threaded shaft with a complementary female thread in the bore of a hole or in a nut such that the threaded fastener may serve its intended purpose.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method and apparatus for functionally testing and sorting threaded members during the fabricating process is provided. The apparatus of the invention is formed as a single inspection device in which production parts are continuously supplied and serially moved into a test station wherein the threaded profiles of the production parts are functionally tested. Further, a plurality of laser sensors are disposed along the transfer path through the inspection device to perform predetermined measurements of specified dimensional characteristics of the production parts. The output of the functional test as well as from the laser sensors is compared with a predetermined tolerance limit so that a predetermined acceptance/unacceptance signal is generated in the form of a sorting signal and communicated to a sorting device disposed closest to the end of the transfer path through the device to separate defective parts from nondefective parts.
In a preferred embodiment of the method and apparatus for sorting threaded members, a frame support is mounted to a base member. A slotted input rail receives threaded members from a supply container and delivers a plurality of threaded members to a first rotatable transfer or escapement wheel attached to the frame in order to advance the threaded members one at a time from one end of the inlet area and rotatably transfer each of the members one at a time to a predetermined drop-off area. A second rotatable transfer wheel or regulator wheel is attached to the frame support and spaced relative to the escapement wheel such that the threaded fasteners carried by the first rotatable transfer wheel are conveyed to the drop-off area and transferred to the second rotatable transfer wheel. The second rotatable transfer wheel holds the fastener magnetically along its peripheral edge and carries the threaded fastener to a test station. At the test station, the threaded fastener is tested for selective dimensional characteristics as well as for functionally operating according to its intended purpose. While the threaded fastener is in the test station, designated lasers are placed surrounding the test station in order to check dimensional characteristics such as length, head height, flange diameter, etc. as well as to functionally test the thread profile of the production fastener. The functional test of the threaded fastener is accomplished by providing a slide mechanism which carries a master thread gage. A second slide mechanism carries a plurality of guide rollers. As the threaded fastener is moved by the regulator wheel to the test position, an appropriately placed sensor signifies to the slide mechanism that a threaded fastener is incoming to the test station whereupon the second slide mechanism containing the guide rollers is moved towards the regulator wheel in order to allow the fastener to abut the rollers. The threaded fastener can no longer move circumferentially upon abutting the guide rollers so that the fastener begins to roll or rotate about its longitudinal axis along the peripheral edge to the regulator wheel while under the magnetic influence of the regulator wheel. Subsequently, the first slide mechanism having a master thread gage at the front thereof is moved in the direction toward the threaded fastener so as to allow the guide rollers and master thread gage as well as the regulator wheel to provide a nest for the threaded fastener in the test station. The master thread gage is an identical thread to that found on the threaded fastener but manufactured to very close dimensional tolerances so that dimensionally all dimensions are at a mean condition of the part print dimensions. Therefore, the pitch diameter of the threaded profile on the master thread gage is at its mean dimension and after engaging the profile of the part to be tested any deviation in the thread profile of the threaded fastener is detected by a laser sensor which is calibrated from a datum position and takes into account the allowable tolerance in pitch diameter as depicted on the part print.
Since the regulator wheel rotates at a constant speed, the threaded fastener is caused to rotate at a constant speed in the test station. After engagement, the thread profile of the master thread gage is forced to follow the thread profile of the threaded fastener for its full length. In following the thread profile of the threaded fastener for its entire length, the tolerance variation of the pitch diameter of the thread profile of the fastener will be reflected by the in and out movement of the thread profile of the master thread gage, that is, as the tolerances of the thread profile of each of the threaded fasteners differs the master thread gage will engage each threaded fastener at a different point. Accordingly, by providing a mean start position or datum point an upper and lower limit (the part print tolerance) for the permissible movement of the master thread gage with respect to the mean dimension can be determined. Any movement outside of these limits is evidence of a defect, i.e. nick, gouge, burr, etc. or some type of a deformity in the thread. Accordingly, proper complementary engagement of the complementary thread profiles between the threaded fastener and the master thread gage will not be possible and such arrangement is considered an unacceptable part. If the movement of the master thread gage is outside of the tolerance limits a signal will be generated to reject such a part. Following the residence of the threaded fastener in the test station for a predetermined amount of time, a signal is generated indicating whether such part is acceptable or unacceptable. Thereafter, both the guide rollers and master thread gage are retracted by their respective slide mechanisms and the magnetic regulator wheel will carry the threaded fastener to a discharge location. At the discharge location an indexing stripper removes the threaded fastener from the regulator wheel and indexes the threaded fastener to a position near the inlet of a slotted discharge rail. A solenoid operated rotatable door for sorting the acceptable threaded fasteners from the unacceptable threaded fasteners is mounted along the slotted discharge rail. The rotatable door moves into the traveling path of the threaded fastener discharged along the slotted discharge rail to allow the threaded fastener to be sorted into a reject receptacle upon receiving the appropriate reject signal from the testing station. If there is no reject signal, the threaded fastener is allowed to travel down the slotted discharge rail into a storage bin which represents acceptable threaded fasteners.
The apparatus of the invention is adapted to sort acceptable and unacceptable threaded parts by a method that includes the steps of:
serially placing the plurality of threaded members one at a time at a predetermined pick-up area on a first rotatable transfer wheel carried by the frame support which is mounted to a base member;
transferring each of the threaded members from the predetermined pick-up area to a second rotatable transfer wheel mounted to the frame support for serially moving each of the threaded members to at least one test station;
functionally testing the threaded profile of each of the threaded members by rotating each threaded member while located in the test station in complementary engagement with a master thread gage;
monitoring the master thread gage for movement while the master thread gage is engaged with the threaded portion of the threaded member to generate a control signal indicative of the accuracy of the thread of each threaded member as compared to the master thread gage;
discharging the threaded member from the second rotatable transfer wheel into a discharge rail at a predetermined discharge area; and
sorting each defective threaded member discharged on the discharge rail from the nondefective threaded members upon receiving the control signal from the monitoring device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the inspection device;
FIG. 2 is a partial offset cross-sectional view taken along lines 2--2 of FIG. 1;
FIG. 3 is a perspective view of the discharge or unloading component assembly;
FIG. 4 is a partial view of the slotted discharge rail and solenoid operated door assembly; and
FIG. 5 is a plan view of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIGS. 1 through 5 there is shown an inspection device 10 for functionally and dimensionally testing threaded members and, specifically, in the preferred embodiment, production threaded fasteners T wherein a continuous path is established for the threaded fastener to follow. While along this path the threaded fastener encounters a test station for functionally testing the helical thread thereon as well as for inspecting various dimensional characteristics, if required. The device lends itself to checking dimensional characteristics of the threaded fastener at any convenient place along the path which the threaded fastener T travels in the inspection device.
The inspection device 10 is an assembly of three basic structural component assemblies mounted to a frame support 28 on a base 20. A threaded fastener delivery system for conveying threaded fasteners to a functional test station 45; a test station component for functionally and, if desired, dimensionally checking the threaded fasteners while they are located in the test station; and a discharge or unloading component for discharging the threaded fasteners as a function of the functional test performed while the threaded fastener is in the test station or, in addition, based on the results of any dimensional testing which may occur while the threaded fastener travels along the path through the inspection device. The functional test compares a master thread gage 70 with the actual production thread profile fabricated while the dimensional characteristics of the threaded fastener are compared to an allowable tolerance variation as specified on the part print for the specific threaded fastener T tested.
The inspection assembly 10 consists of a supply container (not shown), whose construction is known from the prior art, and which contains the bulk threaded members or, as in the preferred embodiment, a threaded fastener T formed with a head, shank and a thread form thereon. The supply container may be located adjacent the inspection assembly or can be directly mounted to the base 20. The threaded fasteners T are discharged in seriatim onto a slotted inlet rail 24 from which the threaded fasteners are suspended. Because the head diameter is larger than the width of a slot 25 of the slotted inlet rail, the fasteners slide along the rail with the underside shoulder of the head portion while the shank of the threaded fastener is guided by the slot 25 in the rail. The slotted inlet rail 24 is inclined downwardly so as to permit gravity to impart a substantially constant rectilinear movement in the direction of transportation. Note that there is realistically no limit as to the length of the threaded fastener which can be transported by the slotted inlet rail 24 since the overall length of the shank is only limited by the height of the frame support 28 mounted on the base 20. The slotted inlet rail 24 terminates near an escapement or transfer wheel 30 which is mounted to the frame support 28 located on the base 20. The escapement wheel 30 is attached to an upright shaft (not shown) having an opposite end driven by a motor through a gear box (not shown) all of which are mounted on the frame support 28. The escapement wheel 30 has on its outermost periphery, formed in a generally circular configuration, a plurality of cog-like indentations 32 at equally spaced locations along the outer periphery of the escapement wheel. The cog-like indentations 32 are for the purpose of receiving the threaded fasteners T from the slotted inlet rail 24 and rotatably transferring the threaded fasteners along a circular slotted guide 34 (similar to the slotted inlet rail 24) provided between the escapement wheel 30 and a portion of the frame support 28 so as to move the threaded fastener T from the slotted-inlet rail 24 to a position adjacent a rotatable transfer or regulator wheel 40 which in the preferred embodiment is magnetic so that the threaded fastener T can be magnetically held along a peripheral edge 42 of the regulator wheel 40 for a reason to be explained hereinafter.
The regulator wheel 40 is mounted to the frame support 28 adjacent the escapement wheel 30 to permit the transfer of the threaded fastener, as it is rotated by the escapement wheel 30 through the circular slot 34 and in the proximity of the regulator wheel. The magnetic force of the regulator wheel 40 pulls or unloads the threaded fastener from the escapement wheel 30 and positively locates the threaded fastener T along the peripheral edge 42 of the regulator wheel 40. The regulator wheel 40 rotates at a constant speed in a direction opposite to that of the rotation of the escapement wheel 30 and the unloading of the threaded fastener T from the escapement wheel 30 is facilitated by the cog-like indentations 32 along the peripheral edge of the escapement wheel 30. The driving force for the regulator wheel is a motor and gear box (not shown) mounted to the frame support 28 in a manner well known to a person ordinarily skilled in the art. The mass of the threaded fastener T and the speed at which the threaded fastener is moved through the inspection device may, in the alternative, dictate the use of a pressure wiper device (not shown). If the threaded fastener, as it is carried by the escapement wheel 30 exhibits any tendency for movement as a result of any vibrations, the positioning of the threaded fastener T on the regulator wheel 40 can be positively established by the use of a pressure wiper which is mounted above the regulator wheel 40 at a location where the threaded fastener is magnetically transferred to the regulator wheel 40. The pressure wiper ensures positive location of the threaded fastener on the regulator wheel 40 by placing a slight pressure on the top side of the head of the threaded fastener T in a downward direction, towards the regulator wheel, so that a firm contact is established by the underside of the head portion of the threaded fastener with the top side of the regulator wheel 40. The magnetic holding force will maintain such location as the threaded fastener continues along its transfer path. The regulator wheel continuously rotates at a preselected constant speed opposite to the rotation of the escapement wheel 30 in order to ensure the smooth transition of the threaded fasteners from the escapement wheel 30 to the regulator wheel 40 as well as in order to provide rotatable motion necessary to functionally check the threaded profile on the threaded fastener as will be explained hereinafter.
As stated above, the threaded fastener T is magnetically held to the regulator wheel 40 as the wheel rotates to move the threaded fastener to the test station 45. To ensure the correct orientation of the threaded fastener as well as to ensure that longer threaded fasteners T are positively held in place magnetically during their conveyance through the test station and the functional thread check, the regulator wheel 40 consists of an upper wheel assembly 40a and a lower wheel assembly 40b (as shown in FIG. 2) so as to support the threaded fastener T along opposing ends of the shank length while the threaded fastener is moved from the escapement wheel 30, where it is unloaded, to the regulator wheel 40 to its ultimate test position. As the regulator wheel 40 rotates and thereby carries the threaded fastener on its periphery to bring the threaded fastener to the test station, the threaded fastener encounters a set of idling rollers 50. The idling rollers 50 are carried by a solenoid operated slide mechanism 54 located opposite the regulator wheel 40. The slide mechanism 54 allows for linear adjustment in the direction towards and away from the regulator wheel 40 as well as in a direction transverse thereto. The idling rollers 50 are adjustable in an up and down direction in order to accommodate different lengths of threaded fasteners.
Before the threaded fastener arrives at the test station 45 the adjustable slide mechanism 54 is activated to move the idling rollers 50 in a position nearby the peripheral edge 42 of the regulator wheel 40. The distance between a peripheral edge 52 of the rollers and the peripheral edge 42 of the regulator wheel 40 must be less than the diameter of the threaded fasteners T since upon arrival of the threaded fastener at the test position the outer peripheral edge 52 of the roller must engage the outer diameter of the shank of the threaded fastener T to stop the threaded fastener from being further conveyed rotatably by the regulator wheel 40 beyond the test position. As the idling rollers 50 abut the threaded fastener T and stop its peripheral rotating travel, the threaded fastener cannot move further circumferentially and, therefore, begins to rotate about its longitudinal axis while located on the outer peripheral edge of the regulator wheel 40 while under the influence of the magnetic attraction of the regulator wheel 40 in the test station 45.
Since the regulator wheel 40 rotates at a constant speed, the threaded fastener T also rotates in the test station at a constant speed. As the circumferential translation of the threaded fastener is stopped and the threaded fastener begins to rotate in place, a second solenoid operated slide mechanism 60 is actuated to move towards the regulator wheel 40. The second slide mechanism 60, like the first slide mechanism 54, moves in a linear direction towards and away from the regulator wheel 40 as well as transverse thereto.
The second slide mechanism 60 has at the forward end thereof a yoke member 62 with a precision spindle 64 mounted between the opposing ends of the yoke member as more clearly shown in FIG. 2. Mounted to the precision spindle is the master thread gage 70. The master thread gage 70 is fabricated with close tolerances to the mean dimensions of the thread profile intended to be inspected and the inner diameter 72 thereof, which mounts to the precision spindle 64, is fabricated for a sliding fit so that the master thread gage 70 can slide along the precision spindle 64 in an up and down direction.
As the second slide mechanism 60 moves towards the regulator wheel 40, the master thread gage 70 engages the thread form of the threaded fastener T and since the threaded fastener T is rotating about its longitudinal axis when the master thread gage 70 engages the thread profile of the thread fastener, the master threaded gage 70 will begin to rotate about its longitudinal axis on the precision spindle 64. As rotation is imparted to the master thread gage 70, the master thread gage 70 is caused to follow the thread form of the threaded fastener in the test station and, therefore, begins to slide up or down the precision spindle 64. The magnetic attraction between the regulator wheel 40 and the threaded fastener T is sufficiently strong to prevent any movement of the threaded fastener along its longitudinal axis. The master thread gage 70 continues to slide along the precision spindle 64 as long as the master thread gage 70 engages the thread profile of the threaded fastener T. During the engagement of the master thread gage 70 with the thread profile on the threaded fastener a complete 360° physical meshing of the opposing threaded profiles occur. Therefore, any defect in the thread profile along the complete longitudinal length of the thread profile on the threaded fastener T will prevent the master thread gage 70 from a mutually complementary engagement of the master thread gage 70 with the threaded fastener.
To detect a defect in the thread profile of the threaded fastener, a laser measuring device 75 is attached to the frame support 28 at a preselected location. The laser sensing or measuring device 75 is calibrated to read on a preselected datum point on the solenoid actuated second slide mechanism 60. This preselected datum position is representative of the mean dimension of the pitch diameter of the respective thread profile on the threaded fastener T being tested.
From this datum point the laser measuring device 75 can read/detect movements of the second slide mechanism 60 in a linear direction either towards or away from the regulator wheel 40. This movement is caused by the interrelationship of the pitch diameters of the two threads (one on the threaded fastener and one on the master thread gage) as they rotate in place in the test station 45. The degree of linear movement is monitored by the laser sensing device 75 and a certain degree of movement on either side of the datum position (a maximum deviation range about either side of the mean datum position) is expected and tolerable since some dimensional deviation in the pitch diameter of the thread profile is allowable as per the part print dimensioning. A threaded fastener T staying within the allowable deviation range of the pitch diameter of the thread profile is considered acceptable. However, if the laser sensing device 75 senses linear movement of the second slide mechanism 60 in excess of the preselected or preprogrammed acceptable tolerance deviation range, such threaded fastener will generate a reject signal and send this signal to the discharge component of the inspection device to separate the rejected threaded fastener from the acceptable threaded fasteners as is hereinafter discussed.
It is readily understood by a person skilled in the art that any defect, i.e. burr, malformation, flaw, etc., within the profile of the thread on the threaded fastener T will cause the master thread gage 70 to be moved outward in a direction away from the regulator wheel 40 resulting in a movement outside of the acceptable deviation range for the pitch diameter dimension which will trigger a reject signal.
After the threaded fastener T has resided in the test station 45 for a predetermined period to ensure adequate functional testing of the mutually engaged thread profiles of the threaded fastener T and the master thread gage 70, and a signal (acceptable or unacceptable) has been generated by the laser sensing device 75, the first solenoid operated slide mechanism 54 carrying the idling rollers 50 at the front thereof is actuated and retracted in a direction away from the regulator wheel 40. As the idling rollers 50 retract with the movement of the first slide mechanism 54 and the abutment condition between the idling rollers 50 and the threaded fastener T magnetically held along the peripheral edge of the regulator wheel 40 disappears, the threaded fastener T will stop rotating along its longitudinal axis and under the influence of the magnetic attraction of the regulator wheel 40 begin to continue to move circumferentially with the regulator wheel 40.
Located adjacent the regulator wheel 40 is an indexing stripper arm mechanism 80 having three equally spaced semi-circular index fingers 82. The index fingers 82 are in the form of an upper and lower finger so that the upper and lower fingers can straddle the regulator wheel in order to act on the threaded fastener T and overcome the magnetic attractive force between the threaded fastener and the magnetized regulator wheel 40 and strip the threaded fastener from the peripheral edge 42 of the regulator wheel 40. The indexing stripper arm mechanism 80 is driven by air activated drive cylinders 90 mounted to the frame support 28. The stripper arm mechanism 80 is mounted to the frame support 28 in spaced relationship to the regulator wheel 40 to ensure easy access by the index fingers 82 to the threaded fastener T to thereby remove the threaded fastener from the peripheral edge 42 of the regulator wheel 40. To facilitate such removal, each of the fingers has a semi-circular depression 84 which forms about the shank of the threaded fastener to "pull" the threaded fastener T and overcome the attractive force between the threaded fastener and the magnetic regulator wheel 40. The threaded fastener is supported on the indexable stripper arm mechanism 80 similar to the support provided by the slotted inlet rail 24 or the circular slotted guide 34 between the frame support 28 and the escapement wheel 30. The underside of the head portion of the threaded fastener rests on the top surface of the index fingers 82 of the stripper arm while the stripper arm indexes the threaded fastener to a position in line with a slotted discharge rail 95 located adjacent and in alignment with the fingers 82 of the stripper arm mechanism 80. The stripper arm rotates to move the threaded fastener T into the slot 96 of the slotted discharge rail 95. The action of stopping the stripper arm mechanism 80 in an aligned position with the slotted rail 95 and the momentum of the threaded fastener T normally results in the threaded fastener being removed from the fingers 82 and placed onto the slotted rail 95. To ensure removal of the threaded fastener from the fingers 82 of the stripper arm mechanism 80 when the stripper arm mechanism 80 is aligned with the slotted discharge rail 95, a small air jet (not shown) is mounted near the discharge slotted rail 95 so that when the finger 82 of the indexing stripper arm mechanism 80 moves the threaded fastener in alignment with the slotted discharge rail 95 the air jet is directed on the threaded fastener to ensure removal of the threaded fastener T from the stripper arm mechanism 80. The slotted discharge rail 95, like the slotted inlet rail 24, is oriented at an angular position with respect to the horizontal so that the gravitational force of the threaded fastener causes the threaded fastener to slide along the slotted discharge rail 95 in a downward direction as clearly seen in FIG. 4.
Along the slotted discharge rail 95 is positioned a solenoid operated rotatable door mechanism 100 having a forward or peripheral portion 105 which constitutes part of the slotted discharge rail 95. Upon receiving a signal from the laser detection device 75 the door mechanism 100 rotates such that the forward portion 105 thereof interferes and interrupts the slotted discharge rail 95 to divert the threaded fastener T moving in a downward direction. Such action is instigated by a reject signal received from the laser sensing device 75 and communicated to a solenoid 102 of a rotary door 104 of the rotatable door mechanism. Therefore, the threaded fastener delivered by the fingers 82 of the indexing stripper arm mechanism 80 to the slotted discharge rail 95 will be redirected off of the slotted discharge rail 95 by the peripheral portion 105 of the rotary door mechanism 100 if the solenoid 102 receives a signal from the laser sensing device 75 that the next threaded fastener T being inspected and carried by the stripper arm mechanism 80 to the slotted discharge rail 95 is a reject. The rotary door mechanism 100 moves the peripheral portion 105 into the slot 96 of the slotted discharge rail 95 to redirect rejected threaded fasteners to a collection bin 108 standing nearby. If the rotary door mechanism 100 is not actuated by any signal from the laser sensing mechanism 75, the threaded fastener T is allowed to travel the complete length of the slotted discharge rail 95 to a second storage bin 110 located at the end of the slotted discharge rail 95 to collect threaded fasteners whose threads have been functionally found to be acceptable in the test station 45 of the inspection device 10.
While the threaded fastener T is in the test position, additional dimensional characteristics may be selectively checked using additional laser sensing devices. For example, laser sensing devices to check the overall length of the threaded fastener, the head diameter, the location of the shoulder relative to either end of the bolt, etc., can easily be placed along the path of the threaded fastener to monitor dimensional characteristics. Upon finding an out of tolerance dimension a reject signal (like the reject signal of the functional test station) is generated and communicated to the rotatable door mechanism 100 so it may actuate to interfere with the fastener travelling down the slotted discharge rail and reject same if any one of these dimensional characteristics is not within the acceptable tolerance range as determined by the part print. Accordingly, each of these detecting devices are able to generate a signal to the rotatable door mechanism 100 mounted in the slotted discharge rail 95 in order to separate rejects from acceptable parts. Such additional dimensional checks are intended to be combined with the functional testing of the thread profile in order to provide a threaded member to the end user which completely complies with the end user's requirements.
The invention also contemplates the use of appropriate proximity sensors to ensure the existence of a continuous supply of threaded fasteners. Any interruption in the continuous flow of fasteners is sensed by these proximity sensors and an appropriate signal is generated to stop the device so that corrective action may be initiated.
While an operable embodiment of the invention has been described and illustrated, it will be understood that the invention is not limited thereto, since many modifications may be made and will become apparent to those skilled in the art. The reject mechanism has been described and associated with a preferred embodiment of the functional testing device. However, it is apparent that detection circuits operating differently can be used with the rejection scheme that has been described above and which is claimed in the claims.
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An inspection device for inspecting production threaded members wherein the threaded members are routed to a test station to functionally inspect the thread profile of each threaded member to ensure that when the threaded member is matched with a corresponding threaded hole in an engine block or, in the alternative, a threaded nut, the threaded member will mate properly to serve its intended purpose.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of commonly owned U.S. application Ser. No. 10/927,547, filed Aug. 26, 2004. The '547 application is a continuation-in-part of PCT Application No. PCT/US2004/009549 filed 29 Mar. 2004, which designates the United States. The PCT Application claims priority from commonly owned, copending U.S. Provisional Application Ser. No. 60/458,487, filed 28 Mar. 2003. The disclosures of these applications are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention provides an ultrasonic spray coating system that represents an improvement over the ultrasonic spray systems described in U.S. Pat. Nos. 5,409,163, 5,540,384, 5,582,348 and 5,622,752, the disclosures of which are hereby incorporated herein by reference. The ultrasonic spray coating system of the present invention can be used in the methods taught in these patents, and can also be used as described herein.
SUMMARY OF THE INVENTION
[0003] The ultrasonic spray head with integrated fluid delivery system (IFDS) consists of an ultrasonic transducer with a spray forming tip, an ultrasonic generator, an external liquid applicator, a precision liquid delivery system and air directors.
[0004] The coating liquid is delivered to the spray forming tip on the ultrasonic transducer from an external liquid applicator. The liquid is stored in a pressurized reservoir and fed to the liquid applicator by a precision liquid delivery system. The ultrasonic vibrations of the spray forming tip break up the liquid into small droplets and propel them from the tip in the form of a spray. The spray produced with ultrasonic energy alone is a very narrow “sheet-like” pattern. The width of the spray pattern produced is equal to the width of the spray forming tip (2 mm to 4 mm).
[0005] Air directors are used to produce air streams to further shape and accelerate the ultrasonically produced spray. Air directors can be used to produce three distinct spray patterns, based upon the nature and placement of the air stream—narrow mode spray pattern; wide mode spray pattern; or side mode spray pattern.
[0006] An air shaping ring in the IFDS assembly is used for the narrow mode spray pattern operation of the spray head. The air shaping ring entrains the ultrasonically produced spray without mixing with it and produces a coating segment about 5 mm wide with well-defined edges from a distance of about 25 mm between the spray head and the substrate.
[0007] An air director in the IFDS assembly is used to produce the wide mode spray pattern operation of the spray head. The air director impinges a jet of air on the tip of the spray head opposite the liquid feed side. The resulting airflow entrains and expands the ultrasonically produced spray to form a flat (rectilinear) pattern up to five times (5×) the width of the pattern produced by in the narrow mode. The width of the spray pattern is proportional to the distance between the spray head tip and the substrate.
[0008] An air director in the IFDS assembly is also used to produce the side mode spray pattern operation of the spray head. Here the air director impinges a jet of air on the tip of the spray head opposite the liquid feed side, and the spray head tip is offset to the side of the substrate so that the spray is directed to coat a vertical side of the substrate.
[0009] Since the spray is produced with ultrasonic energy rather than pressure and because a low velocity air stream is used only to shape or guide the spray pattern, the transfer efficiency is in the range of 95 to 99 percent. In other words, very little coating is wasted due to overspray. All process parameters for the spray head with the integrated fluid delivery system are controlled electronically, including liquid flow rate, air pressure, spray mode, head height and head speed.
[0010] The method used to deliver the coating liquid to the liquid applicator on the ultrasonic spray head is based upon the properties of the coating material. The coating material is stored in a sealed reservoir and then precisely metered to the liquid applicator. Liquid metering methods include pressurizing the coating reservoir; activating liquid flow with a solenoid valve and delivering the liquid to the applicator through a precision orifice; pressurizing the coating reservoir and delivering the liquid to the applicator with a rapidly pulsing solenoid valve; delivering the liquid to the applicator with a motorized positive displacement piston type pump; or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 , which includes two parts ( 1 A and 1 B) the device of the present invention. FIG. 1A shows the ultrasonic power generator attached to the spray unit, with the ultrasonic spray head. FIG. 1B shows additional details including the liquid metering device, ultrasonic transducer, IFDS, air directors, liquid applicator and the spray forming tip.
[0012] FIG. 2 is an exploded view of the component parts showing the relationships between the ultrasonic spray head with IFDS and the pulsed liquid delivery system of the present invention.
[0013] FIG. 3 , which includes eight parts ( 3 A, 3 B, 3 C, 3 D, 3 E, 3 F, 3 G and 3 H) illustrates the spray head of the present invention.
[0014] FIG. 4 , which includes four parts ( 4 A, 4 B, 4 C, 4 D and 4 E) illustrates the Air Shaping Ring of the Integrated Fluid Delivery System (IFDS) employed in the spray head of the present invention.
[0015] FIG. 5 , which includes seven parts ( 5 A, 5 B, 5 C, 5 D, 5 E, 5 F and 5 G) illustrates the Integrated Fluid Delivery System (IFDS) employed in the spray head of the present invention.
[0016] FIG. 6 , which includes five parts ( 6 A, 6 B, 6 C, 6 D and 6 E) illustrates details of the liquid applicator and the air director system.
[0017] FIG. 7 is a graph illustrating dispense volume per pulse vs. pressure, illustrating the accurate flow control available in the spray head of the present invention.
[0018] FIG. 8 is a circuit diagram of the high-speed driver circuit used to operate the solenoid valve for flow control in the spray head of the present invention.
[0019] FIG. 9 is a graphic representation of Voltage vs. Valve-on Time illustrating the spike voltage for rapid opening of the solenoid valve and the hold voltage used to keep the valve open as desired.
[0020] FIG. 10 illustrates the solenoid valve controls ( 1 , 2 , 3 ) used to control the three spray patterns available from the device—narrow mode spray pattern; wide mode spray pattern; and side mode spray pattern.
[0021] FIG. 11 , which has two parts ( 11 A and 11 B), illustrates the operation of the spray head of the present invention and shows one example of a precise narrow spray pattern obtained therefrom.
[0022] FIG. 12 illustrates the operation of the spray head of the present invention and shows one example of a precise wide mode spray pattern obtained therefrom.
[0023] FIG. 13 illustrates the operation of the spray head of the present invention and shows one example of a precise side mode spray pattern obtained therefrom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] The present invention is an ultrasonic spray coating system comprising an ultrasonic converter with spray head, integrated fluid delivery device with air and liquid supply passage ways, support brackets and an ultrasonic power generator. See FIGS. 1A , 1 B, 10 , 11 and 12 .
[0025] This invention preferably comprises an ultrasonic spray coating system with an integrated fluid applicator. In one preferred embodiment, the system is capable of spraying liquids onto substrates in narrow (2 mm to 5 mm wide), well-defined patterns at a distance of up to 1.75 inches from the substrate.
[0026] In addition to the directed air stream produced by the air-shaping ring to focus the spray the following additional embodiments have been made:
1) An air director and mounting ring. 2) A pneumatically actuated air director positioner for the air director. 3) Two additional solenoid valves to activate air flow to the air director and to the air director positioner.
[0030] These improvements enable the spray head to operate in any one of the following three-modes (or combinations thereof):
1) Narrow mode—where the airflow is directed through the air-shaping ring to focus the ultrasonically produced spray. See FIGS. 10 and 11 . 2) Wide mode—where the airflow is directed through the air director to expand the ultrasonically produced spray. Impinging the directed air stream on the flat surface of the spray-forming tip expands the spray. The directed air stream is impinged on the opposite surface to the liquid feed surface. See FIGS. 10 and 12 . 3) Side mode—where the air director positioner is actuated, moving the air director to the lower position and airflow is directed through the air director to direct the ultrasonically produced spray at an oblique angle from the spray forming tip. The purpose of directing the spray at an oblique angle is to coat a vertical surface, such as the side of a tall component that would not otherwise be coated if the spray were directed in the normal vertical path. See FIGS. 10 and 13 .
[0034] In many coating applications, such as the application of conformal coatings to printed circuit boards, there are various size areas that require a uniform coating. Due to production volume, the time available to apply the coating may be limited. It is critical to have the ability to accurately apply coatings to small areas without applying coating to adjacent areas or components (keep out areas). This can be achieved with a narrow, focused spray pattern. However, if a larger area needs to be coated, many passes will be required with the narrow width spray. This may exceed time limitations imposed by production volume. A wider spray pattern will enable larger areas to be coated more quickly. Additionally, coating may need to be applied to the side surfaces of taller components. A spray applicator that is able to deliver a narrow pattern for small areas, a wider pattern for larger areas as well as the ability to apply coating to the side surfaces of taller components would meet these requirements.
[0035] Thus, the improved spray head of the present invention provides the following benefits:
1) The ability to apply a narrow coating pattern and a wider coating pattern with the same spray head. 2) The ability to apply a narrow coating pattern, a wider coating pattern and a sideways coating pattern with the same spray head. 3) The ability to change between the three modes of operation without manual adjustments. Pattern changes are initiated through the coating system software and control components. 4) The ability to expand the narrow coating pattern by a multiple of up to 5 times the narrow pattern width. For example, from a narrow pattern width of 5 mm, to a wide pattern width of 25 mm. 5) The ability to significantly reduce the time to coat a substrate with both small areas and large areas to be coated.
[0041] Referring in detail to FIGS. 1A and 1B , the ultrasonic converter transforms high frequency electrical energy into high frequency mechanical energy. The converter has a resonant frequency. A spray head is coupled to the converter and is resonant at the same resonant frequency of the converter. The spray head has a spray-forming tip and concentrates the vibrations of the converter at the spray-forming tip.
[0042] The integrated fluid applicator contains separate passageways for liquid and air, a liquid output surface, an air output annulus and an air-shaping ring. The fluid applicator has separate ports for air and liquid. The air inlet port is connected to a ring shaped annulus. The inlet port for liquid is connected to the output surface of the applicator. The air-shaping ring attaches to the bottom of the fluid applicator to enclose the air annulus to form an air passageway to supply air to the holes in the air-shaping ring. The angle of the holes in the air-shaping ring can be set to achieve a specific focal point of the liquid spray, thus producing the desired spray pattern size.
[0043] Referring in detail to FIGS. 2 and 3 , the spraying end of the system contains the necessary elements to produce the desired spray pattern: 1) atomizing surface of the spray head, 2) liquid applicator output surface and 3) air shaping ring. These elements are arranged in a manner that allows spraying end to be contained within a small in area (less than 19 mm×18 mm). This small envelope allows the spray system to be positioned in tight areas for spray coating between objects protruding from the substrate (e.g., components attached to a printed wiring board).
[0000] Ultrasonic Spray Head with IFDS and Pulsed Liquid Delivery System
[0044] Referring in detail to FIG. 2 , the ultrasonic spray head with IFDS and pulsed liquid delivery system has thirteen components:
1 . Ultrasonic transducer/converter 2 . Micro flow control valve 3 . Air flow control valve 4 . Liquid feed tube 5 . Integrated fluid applicator 6 . Spray head mounting bracket 7 . Mounting thumb screw 8 . Fluids applicator mounting bracket 9 . Cam adjuster 10 . Micro flow control bracket 11 . Filter bracket 12 . Fluid filter 13 . Liquid spray tube
[0058] The IFDS is fixed in position relative to the spray forming tip with a precision bracket system that allows the IFDS to be adjusted in the “Z” direction and the “X” direction. The mounting surface of the IFDS attaches to the fork shaped end of the IFDS bracket with two machine screws. The IFDS mounting holes in the bracket are slotted to allow the IFDS to be positioned in the “X” axis relative to the spray forming tip. The IFDS bracket attaches to the slots in the “tee” shaped leg of the spray head bracket with two machine screws and wave washers. The barrel of the adjuster cam mounts in a hole in the spray head bracket underneath the IFDS bracket. The slotted end of the adjuster cam protrudes from the backside of the tee leg to allow the cam to be rotated with a screwdriver. The eccentric pin portion of the adjuster cam mates with a slot in the IFDS bracket. When the cam adjuster is rotated the eccentric pin moves the IFDS bracket up and down to provide the “Z” adjustment of the IFDS relative to the spray forming tip.
[0059] The spray head is clamped in the spray head bracket. The spray head is “keyed” to the bracket to orient the spray forming tip to the IFDS.
Spray Head Description
[0060] Referring in detail to FIG. 3 , the ultrasonic spray head is comprised of an input end, a body and a spray forming tip. The spray forming tip or output end contains a feed blade and an atomizing surface. The spray head has a resonant frequency (fsh) and has a length equal to one-half wavelength (λ/2) of the resonant frequency. The wavelength for a particular spray head is defined by:
λ=Cm/fsh
Where:
[0000]
λ=Wavelength (inches)
Cm=material's speed of sound (inches/second)
fsh=resonant frequency (Hertz or 1 cycle/second)
[0065] The practical resonant frequencies range from 20 kHz to 120 kHz for atomizing liquids (20 kHz≧fsh≦120 kHz). The spray head is constructed of metal, either 6Al-4V titanium or 7075-T6 aluminum; titanium is preferred because of its strength and corrosion resistance properties.
[0066] The input end is comprised of a coupling surface and a coupling screw. The input end of the spray head is connected to an ultrasonic converter. The input must be flat and smooth for optimal mechanical coupling to the converter. The ultrasonic converter has a resonant frequency (fc) that is matched to the resonant frequency of the spray head (fsh) or fc=fsh.
[0067] The body connects the input end to the output end and is formed to concentrate ultrasonic vibrations on the output end. To achieve ultrasonic amplification through the body, the input end must be larger than the output end. The profile of the body can be stepped, linear, exponential or Catenoid. The Catenoid shape is preferred because it provides the largest amplification of the sound wave through the body to the output end, which in turn, provides maximum atomizing capability. Preferable ratios of output end diameter (d 2 ) to input end diameter (d 1 ) are:
[0000] 4≧( d 1 / d 2 )≦8
[0000] The Catenoid shape is described by the catenoidal equation:
[0000] Y=Yo*cosh [m ( X−Xo )]
Where:
[0000]
X→X coordinate
Y→Y coordinate at X
Xo→X coordinate of the lowest point on Catenoid
Yo→Y coordinate of the lowers point on Catenoid
Cosh→hyperbolic cosine
M→Constant (depends on the end points of the catenoid)
[0074] The spray forming tip has two main features: 1) an atomizing surface that provides concentrated ultrasonic vibrations with sufficient energy to atomize a flowing liquid, 2) a feed blade that allows a liquid that is applied to it to flow to the atomizing surface.
[0075] The spray forming tip is preferably rectangular but it can be round or square. The shape of the spray forming tip influences the shape of the spray that forms on the atomizing surface. A round tip produces a more or less round spray, a square tip produces a more or less square spray and a rectangular tip produces a more or less rectangular spray.
[0076] The purpose of the feed blade is to direct all of the liquid flow towards and onto the atomizing surface. The feed blade shape can be convex (round), concave or flat. With a round or convex feed blade the liquid streams to the atomizing surface but some also flows around the spray forming tip before finally reaching the atomizing surface. The flat feed blade performs better with most of the liquid going to the atomizing surface, however some liquid still flows onto the sides of the feed blade before going to the atomizing surface. This spurious liquid flow causes the spray pattern to become erratic resulting in ragged, ill defined edges on the coating pattern.
[0077] Referring in detail to FIGS. 3G and 3H , a concave feed blade performs best because the dish shaped surface helps to contain the flow to the feed blade causing all of the liquid to flow directly to the atomizing surface. The concave feed blade eliminates spurious liquid flow and therefore facilitates a coating pattern with well defined edges.
[0078] The present invention comprises an ultrasonic spray coating system having a converter mechanism for converting high frequency electrical energy into high frequency mechanical energy to thereby produce vibrations. The converter mechanism is designed to have one resonant frequency. A spray head is coupled to the converter mechanism and is resonant at the same resonant frequency. The spray head has a spray forming tip and concentrates the vibrations of the converter at the spray forming tip. The spray forming tip has a feed blade and an atomizing surface. The spray forming tip concentrates a surface wave on the feed blade and a displacement wave on the atomizing surface from the vibrations of the converter. A high frequency alternating mechanism is electrically connected to the converter mechanism to produce a controllable level of electrical energy at the proper operating frequency of the spray head/converter mechanism such that the spray forming tip is vibrated ultrasonically with a surface wave concentrated on the feed blade and a displacement wave concentrated on the atomizing surface.
[0079] As shown in FIG. 3H , a liquid supplier is provided having a liquid applicator in close proximity with the feed blade of the spray forming tip and spaced therefrom. The liquid applicator includes an output surface having an orifice therein. The output surface is in close proximity with the feed blade of the spray forming tip and spaced therefrom. The output surface of the liquid applicator and the feed blade of the spray forming tip are at substantially right angles to each other such that liquid supplied from the liquid applicator forms a bead or meniscus between the output orifice of the liquid applicator and the feed blade of the spray forming tip. The meniscus is formed and sustained by the flow of liquid from the output orifice of the liquid applicator and the ultrasonic surface wave that exists on the feed blade of the spray forming tip. The ultrasonic surface wave enables the liquid to ‘wet-out’ and adhere to the feed blade of the spray forming tip. The surface tension of the liquid allows the meniscus to form and constant flow of liquid sustains the meniscus. The longitudinal displacement wave (that displaces the atomizing surface) pumps the liquid from the feed blade to the atomizing surface located on the end of the spray forming tip. The opposite side of the spray forming tip is the air impingement surface. A film of liquid then forms on the atomizing surface and that liquid is transformed into small drops and propelled from the atomizing surface by air directed against the impingement surface, thereby forming a rectilinear spray. A controllable gas entrainment mechanism is associated with the spray head for affecting and controlling the velocity and pattern of the resultant spray.
Integrated Fluid Delivery System (IFDS)
[0080] Referring in detail to FIGS. 4 , 5 and 6 , the IFDS provides the liquid delivery means and air delivery means to facilitate a narrow, well defined spray pattern on a substrate. The IFDS: 1) provides the means to apply a flowing liquid to the feed blade of the spray head and 2) provides a directed air stream in the direction of the atomized coating to “focus” the resulting spray pattern onto a substrate. The IFDS is sized to fit the nominal diameter of the spray head. Referring in detail to FIGS. 5A-5G , an IFDS consists of nine components:
( 1 ) Liquid Applicator ( 2 ) Fluids Applicator Body ( 3 ) Air Shaping Ring ( 4 ) Air Shaping Ring Retainer ( 5 ) Air Diffuser ( 6 ) Inner Gasket ( 7 ) Outer Gasket ( 8 ) Air Shroud ( 9 ) Air Inlet
[0090] First, the Liquid Applicator attaches through a cutout feature in the side of the Applicator Body Second, the Air Diffuser mounts concentrically to a seating surface in the bottom of the Applicator Body. A “disk shaped” annulus is formed between the applicator body and the air diffuser disk. Next, the Inner and Outer Gaskets mount concentrically to seating surfaces on top of the Air Diffuser. Then, the Air Shaping Ring mounts against the Inner and Outer Gasket's surface. A “disk shaped” air passageway is formed between the Air Diffuser and Air Shaping Ring with spacing equal to the thickness of the gaskets. After that, the Air Shroud is pressed into the Air Shaping Ring. Last, the Air Shaping Ring retainer is threaded to the bottom of the Applicator Body pushing the Air Shaping Ring against the gaskets to form a sealed air passageway.
[0091] Air flows from the Air Inlet to the annulus in the Applicator Body, through the diffuser into the air passageway formed by the gaskets and inside surface of the Air Shaping Ring out through the holes in the Air Shaping Ring. The Air Diffuser evenly distributes the air to the holes in the Air Shaping Ring from the air supply port in the Applicator Body. The Air Shroud prevents the air curtain from curling inward towards the spray forming tip and interfering with the ultrasonic atomizing process. The resulting air curtain entrains and focuses the ultrasonically produced spray without mixing with it, thus controlling the shape of the coating pattern.
[0092] The Air Shaping Ring is used to control the 1) width of the spray pattern, 2) quality of the edges of the coating pattern and 3) to facilitate high quality coating patterns at a distance of more than 20 mm from the substrate. Control over coating width is important to facilitate coating patterns as small as 1 mm (e.g., applying liquid solder flux to solder balls on a semiconductor package) up to 20 mm (e.g., applying conformal coating between components on a printed circuit assembly).
[0093] Controlling the quality of the coating edges is important to minimize coating going onto areas where it is not wanted. Applying the coating from at least 20 mm away from the substrate is important to avoid objects protruding from the substrate (i.e., avoiding circuit components on a printed circuit assembly).
[0094] Referring in detail to FIGS. 4A-4D , the Air Shaping Ring delivers a conically shaped air curtain to entrain the atomized liquid flowing from the Spray Forming Tip to create a well-defined coating pattern on a substrate. The width of the spray pattern “w” is determined by the angle (θ) of the air passageway holes the Air Shaping Ring. In general, when θ is zero the spray pattern is widest and there is minimal control over the quality of the edges of the coating. This is because the air curtain does not intersect with the column of atomized coating. It has been found through experimentation the θ must be between 5 degrees and 15 degrees, depending on the diameter of the hole pattern in the Air Shaping Ring, for optimal coating pattern quality.
[0095] Referring to FIGS. 5A-5G , the Liquid Applicator is comprised of 1) a liquid applicator block 12 and 2) a liquid applicator feed tube 13 . The liquid applicator block contains a liquid inlet port 14 , a liquid passageway and outlet port 15 . The liquid inlet port is a threaded port that will accept the liquid supply tube. The liquid passageway is a concentric hole that in turn connects to an outlet port. The outlet port provides the mounting means for the liquid applicator feed tube. The liquid applicator feed tube is formed from stainless steel hypodermic tubing and has a straight portion that is the inlet end has a bent portion that is the outlet end. The outlet end of the liquid feed tube is the liquid output surface from which liquid is delivered to the spray forming tip. The inlet end of the liquid applicator feed tube is connected coaxially to the outlet port of the liquid applicator block. The Liquid Applicator is mounted to the Applicator Body such that the inlet port and outlet port are at a 22 degree angle with respect to the centerline of the Applicator Body and so that the outlet end of the feed tube is at a 90 degree angle to the centerline of the Applicator Body. The Liquid Applicator is detachable from the Applicator Body for maintenance purposes. The liquid applicator is constructed from stainless steel or engineering thermoplastic such as PPS or PEEK.
[0096] As shown in FIGS. 5C and 5D , the Applicator Body has an outside diameter (OD) and an inside diameter (ID) and a height (h). The inside diameter provides clearance for the spray head and ranges from 6 mm to 10 mm. The outside diameter is a small as practical but large enough to contain the air passageways for the Air Shaping Ring and cutout feature for the Liquid Applicator. The outside diameter ranges from 17.5 mm to 25 mm. The height of the Applicator Body is 14.5 mm. The applicator body has a top surface and a bottom surface that are parallel to each other and perpendicular to the OD and ID. The top surface has two chamfered features that are opposite each other about the centerline axis; the first chamfer starts at the centerline and is cut at a 9 degree angle to the OD of the part, the second chamfer is offset from the centerline and is cut at a 22 degree angle to the OD of the part, 180 degrees opposite the first chamfer. The first chamfer provides a surface for the air inlet port. The second chamfer is to match the angle of the Applicator Block inlet port surface.
[0097] The Applicator Body has an air inlet port connected to an air passageway. The air inlet port is perpendicular to the first chamfered surface in the top of the Applicator Body and connects coaxially with an air passageway that goes through to the bottom surface of the Applicator Body.
[0098] The Applicator Body has a cutout pocket feature to hold the Liquid Applicator. This feature starts from the top surface and OD of the part and goes 10 mm from the top surface into the applicator body and intersects the ID. The width of the cutout matches the width of the Liquid Applicator and is centered on the centerline of the part, 180 degrees opposite the air inlet port.
[0099] The bottom surface of the Applicator Body has an air annulus, seating surfaces for the Air Diffuser, Inner and Outer Gaskets and Air Shaping Ring and a threaded feature that the Air Shaping Ring retainer threads onto. The threads are cut into the OD of the Applicator Body over a 3 mm length from the bottom surface. A seating surface is bored into the part to a 2 mm depth from the bottom surface. An annulus for air is cut into the seating surface 3 mm wide and 1 mm deep such that the air passageway intersects the center of the annulus.
[0100] The Air Diffuser distributes the air flowing from one relatively large air supply port in the Applicator Body over many smaller holes to provide an even flow distribution to the air ports in the Air Shaping Ring. The Air Diffuser is a thin disk (0.076 mm thick) with an OD and ID such that it mounts concentric to the ID of the Applicator Body and against the seating surface. The diffuser is made up of one hundred and eight (108) holes arranged in an array of three concentric rings. The inner and outer diameters of the array of holes match the annulus in the Applicator Body so that the array of holes is aligned to the annulus. Each ring has thirty six holes evenly spaced over the diameter. The each hole in each ring is offset by 5 degrees to the hole in the adjacent ring. The effective area of the array of holes should be twice the area of the air supply hole in the Applicator Body.
[0101] The Inner and Outer Gaskets provide an air tight seal between the Air Diffuser and the inside surface of the Air Shaping Ring. The annulus between the gaskets and the Air Shaping Ring form the air passageway that supplies air to the holes in the Air Shaping Ring. The gaskets are constructed of a rubber-like material such as a perfluoroelastomer for maximum chemical resistance. The gaskets are 0.75 mm thick. The ID of the inner gasket matches the ID of the Applicator Body and the OD of the Inner Gasket matches the OD of the air annulus. The OD of the Outer Gasket matches the diameter of the seating surface bore and the ID of the Outer Gasket matches the OD of the air annulus.
[0102] The Air Shaping Ring is a disk that has an inlet side and an outlet side and is 2 mm thick. The OD of the ring matches the OD bore of the seating surface in the Applicator Body. The ID of the ring matches the ID of the seating surface bore. The inlet side has an air annulus that is 0.25 mm deep and that matches the annulus formed by the inner and outer gaskets. An array of between six (6) and twelve (12) through holes is machined in the annulus at an angle between 5 and 15 degrees with respect to the longitudinal axis of the ring. The diameters of the holes are the same and range from 0.3 mm to 0.5 mm. A counter bore is formed into the outlet side of the Air Shaping Ring to accept the Air Shroud. The Air Shaping Ring is constructed from either stainless steel or an engineering thermoplastic that is chemically resistant, such as PPS or PEEK.
[0103] The Air Shroud is a cylindrical shaped device that shields the atomization process on the spray forming tip from the air issuing from the Air Shaping Ring. Without the Air Shroud atomized coating is pulled back into the IFDS by the Air Shaping Ring air causing coating material to build up in the IFDS and drip off. Coating material dripping from the IFDS causes defects in the spray pattern and also causes coating to be deposited in unwanted areas. It has been found through experimentation that the Air Shroud should protrude from the outlet surface of the Air Shaping Ring 1.6 mm.
Liquid Applicator
[0104] FIGS. 6A-6E illustrate additional details of the liquid applicator and air director assembly. As shown in FIG. 6A , the device includes the following components:
1 liquid applicator 2 air director assembly 3 fluids applicator body 4 air shaping ring 5 air shaping ring retainer 6 air diffuser 7 inner gasket 8 outer gasket 9 air shroud 11 air inlet 12 liquid applicator block 13 liquid feed tube 14 liquid inlet port 15 wide mode air director inlet port 16 wide mode air deflector tube 17 liquid outlet port
[0121] FIGS. 6B , 6 C and 6 D show additional details. FIG. 6B shows the liquid supply tube, the ring air supply tube, the air director supply tube, the air director wide mode position, the liquid applicator output surface, the feed blade, the impingement surface and the atomizing surface of the spray tip. FIG. 6C shows the air director assembly ( 1 ) and the fluids applicator assembly ( 2 ). FIG. 6D shows the air director tube ( 1 ), the air director ( 2 ) and the air director clamp ( 3 ).
[0122] FIG. 6E shows the following component parts in and exploded view:
1 liquid applicator 3 fluids applicator body 4 air shaping ring 5 air shaping ring 6 air diffuser 7 inner gasket 8 outer gasket 9 air shroud 11 air inlet 12 liquid applicator block
Ultrasonic Generator Description
[0133] A voltage generator drives the spray head at the proper ultrasonic operating frequency. The circuitry is designed to include the spray head in the frequency control path and to adjust power according to system demand. The operating frequency (f o ) generated is between the resonant frequency (f r ) and the anti-resonant frequency (f a ) of the spray head—as shown in FIG. 13 , such that a proper ultrasonic wave system is established in the spray forming tip. The ultrasonic generator is designed to generate and maintain the required operating frequency during changing environments such as ambient temperature. Additionally, the amplitude of the ultrasonic output from the generator is adjustable to accommodate the flow rate requirements of various situations.
[0134] The power generator features a unique full bridge power output circuit configuration with a frequency driven pulse mode driver. The high frequency alternating voltage generator utilizes MOSFET power transistors in a bridge type, transformer-coupled configuration (no shown) to provide power to the ultrasonic converter. The DC supply voltage to the bridge circuit is varied to control the level of voltage delivered to the ultrasonic converter.
Pulsed Liquid Delivery
[0135] A precision liquid delivery system controls liquid flow to the spray forming tip. The liquid delivery system consists of a high-speed miniature solenoid valve and a high-speed driver circuit. The valve is commercially available from The Lee Company, USA. The solenoid valve is chemically inert, has a response time of less than 0.25 milliseconds and operates at speeds up to 1200 Hz. The valve has an open flow capacity, with water, of 20 cc/min at 20-PSI pressure.
[0136] Referring in detail to FIG. 7 , the dispense volume per pulse is determined by the ON time (Ton) of the valve and the type fluid dispensed. The effective flow rate is calculated by multiplying the number of pulses per second (or operating frequency) of the valve. The ON time of the valve can be varied between 0.2 milliseconds and 0.5 milliseconds. The operating frequency of the valve can be varied from 10 Hz to 1200 Hz. This system can accurately control flow from 0.5 μLiters/second to 800 μLiters/second (based on water at standard temperature and pressure).
[0137] Referring in detail to FIGS. 8 and 9 , the high-speed driver circuit is used to operate the solenoid valve. This circuit applies a high voltage level to the valve (called the “spike voltage”) to quickly open the valve, and then applies a lower voltage (called the “hold” voltage”) to keep the valve open. The length of time the spike voltage is applied is set via potentiometer P 3 . The total time the valve is to be kept open is set either by potentiometer P 1 , or via a 0-5V signal applied to the “On Time” terminal. The range of time that the valve is held open is set via potentiometer P 2 . Momentarily switching the “Trigger” terminal to ground via and external controller activates the circuit. The switching time of the external controller set the valve operating frequency.
[0138] Thin, precisely defined coating patterns are achievable using the ultrasonic spray system with the precision liquid delivery system.
Coating Segment Shape
[0139] FIG. 10 illustrates the three solenoid valves (# 1 , # 2 , # 3 ) used to control the spray patterns of the spray head.
[0140] Referring in detail to FIG. 11 , the ultrasonic spray head with IFDS and precision liquid delivery system produces a coating segment with a shape. The width of the coating segment is proportional to the 1) ID of the liquid feed tube in the IFDS; 2) the liquid flow rate; and 3) the speed of the spray head relative to the substrate. The coating segment width is directly proportional to the ID of the liquid feed tube—the smaller the ID of the liquid feed tube, the narrower the coating segment width. The coating segment width is directly proportional to the liquid flow rate—the lower the flow rate, the narrower the coating segment width. The coating segment width is inversely proportional to the head speed—the faster the speed of the head, the narrower the coating segment width.
[0141] The precision liquid delivery system enables accurate control over the shape of a coating segment. Precisely metering the liquid flow to the spray forming tip provides a smooth transition from a flow “off” to a flow “on” condition and vice versa. The rapid on/off metering of the liquid flow eliminates heavy (wide) sections at the beginning and end of spray segments that would normally result if a conventional solenoid valve or pneumatically actuated needle valve were used. Additionally, the precision liquid delivery system allows the liquid flow rate to be changed electronically with the system control software. Thus, the coating thickness and coating segment width can be changed independent of coating head speed providing a more versatile, fully programmable selective coating system.
[0142] Referring in detail to FIGS. 11 , 12 and 13 , in addition to the directed air stream produced by the air-shaping ring described above, the following additional improvements in the spray head have been made:
1) An air director and mounting ring. 2) A pneumatically actuated air director positioner for the air director. 3) Two additional solenoid valves to activate air flow to the air director and to the air director positioner.
[0146] These improvements enable the spray head to operate in any one of the following three-modes (or combinations thereof):
1) Narrow mode—where the airflow is directed through the air ring to focus the ultrasonically produced spray (i.e., as described above). See FIG. 11 . 2) Wide mode—where the airflow is directed through the air director to expand the ultrasonically produced spray. Impinging the directed air stream on the flat surface of the spray-forming tip expands the spray. The directed air stream is impinged on the opposite surface to the liquid feed surface. See FIG. 12 . 3) Side mode—where the air director positioner is actuated, moving the air director to the lower position and airflow is directed through the air director to direct the ultrasonically produced spray at an oblique angle from the spray forming tip. The purpose of directing the spray at an oblique angle is to coat a vertical surface, such as the side of a tall component that would not otherwise be coated if the spray were directed in the normal vertical path. See FIG. 13 .
[0150] Referring in detail to FIGS. 10-13 , the ultrasonic spray head with IFDS, precision liquid delivery system, air director positioner, air director and air director mounting ring produces a coating segment with a shape. When solenoid valve # 1 is activated, airflow is directed to the air-shaping ring producing a narrow pattern as described previously. When solenoid valve # 2 is activated, airflow is directed through the air director, which impinges the air stream on the flat surface of the spray-forming tip on the opposite side to the liquid feed tube. The impinged air stream expands the ultrasonically produced spray emanating from the spray-forming tip producing a wide pattern up to five times the width of the narrow mode pattern. When solenoid valve # 3 is activated the air director positioner is actuated to move the air director to position in which the air stream through the air director (activated by solenoid # 2 ) is directed directly into the ultrasonically produced spray emanating from the spray-forming tip. The resulting spray pattern from the simultaneous activation of solenoid valves # 2 and # 3 produces a sideways spray in which coating is applied to a vertical surface.
[0151] Referring in detail to FIG. 12 , solenoid valve # 2 is activated, directing the airflow through the air director to impinge upon the side surface of the spray-forming tip. The impinged air expands the ultrasonically produced spray to a width up to five times the narrow mode width ( FIG. 11 )
[0152] Referring in detail to FIG. 13 , solenoid vales # 2 and # 3 are activated, moving the air director to direct the air stream into the ultrasonically produced spray. The spray is directed to the side (vertical) surface of a component.
[0153] As described above, the ultrasonic spray head assembly consists of two major components: 1) an ultrasonic converter with spray head and 2) an integrated fluid applicator. This system is constructed in the same manner, and from the same materials, as are the prior art ultrasonic spray systems defined in the patents recited above. The prior art systems are commercially available from Ultrasonic Systems, Inc. of Haverhill, Mass., the assignee of the present invention.
[0154] This invention can be used for applying thin, uniform coatings to virtually any substrate. In particular, this device can be used to apply conformal coatings to printed circuit board assemblies, either to cover the entire board assembly or to apply the coating selectively to the board. The advantages that this device provides over conventional spray devices include:
(1) Improved transfer efficiency—over 90% of the sprayed coating is transferred to the board vs. 40% to 60% for air assisted spray nozzles; (2) Smooth, defect free coatings—since the primary mechanism for atomization is ultrasonic, the applied coating appears smooth and is free of bubbles and pin-holes. Conventional air assisted spray nozzles use compressed air to atomize the coating, which results in a coating that has an “orange peel” like appearance and can have bubbles and pin holes due to the atomizing air pressure. To overcome these “defects” air assisted nozzle coatings are applied in higher volume resulting in a thicker coating—typically between 125 microns to 250 microns. (3) Thinner coatings—since this device provides a uniform, defect free coating the resulting coating thickness is typically between 10 microns to 250 microns. The thinner, defect free coating applied at a higher transfer efficiency results in coating material savings. (4) In certain embodiments, finer, more narrow spray patterns—the air shaping ring, as part of the integrated fluid applicator allow the spray pattern to be focused and to allow superior “edge definition” at a greater distance from the substrate allowing for greater flexibility in positioning the spray device for selectively coating a populated circuit board. (5) More precise control over coating deposition—since the liquid is applied externally to the vibrating spray forming tip, precise amounts of liquid can be applied to the tip and dispersed as a spray to the substrate providing precise coating deposition control.
[0160] This device can also be used to apply proprietary liquid coatings to green tape used in the production of fuel cells. Other applications include applying: “micro volume” liquid coatings to semiconductors devices (e.g., flux to solder balls (C4 technology) for flip chips), polymer coatings (drug coatings) for stents, conductive inks on ceramic substrates and many more. Many of the advantages listed above over existing spray nozzle technology are applicable to these applications.
[0161] This device will typically be attached to an end effector that is part of an X, Y, Z programmable robot that controls the position and speed of the device relative to the substrate, thereby, allowing the user to apply coatings of any desired pattern to the substrate.
[0162] The present invention has been described in detail, including the preferred embodiments thereof. However, it will be appreciated that those skilled in the art, upon consideration of the present disclosure, may make modifications and/or improvements on this invention and still be within the scope of this invention as set forth in the following claims.
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Disclosed is an ultrasonic spray coating system comprising an ultrasonic spray head with integrated fluid delivery system (IFDS), which consists of an ultrasonic transducer with a spray forming tip, an ultrasonic generator, an external liquid applicator, a precision liquid delivery system and air directors. The coating liquid is delivered to the spray forming tip on the ultrasonic transducer from an external liquid applicator. The liquid is stored in a pressurized reservoir and fed to the liquid applicator by a precision liquid delivery system. The ultrasonic vibrations of the spray forming tip break up the liquid into small droplets and propel them from the tip in the form of a spray. The spray produced with ultrasonic energy alone is a very narrow “sheet-like” pattern. The width of the spray pattern produced is equal to the width of the spray forming tip (2 mm to 4 mm). Air directors are used to produce air streams to further shape and accelerate the ultrasonically produced spray. Air directors can be used to produce three distinct spray patterns, based upon the nature and placement of the air stream—narrow mode spray pattern; wide mode spray pattern; or side mode spray pattern.
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CLAIM OF PRIORITY
Priority is claimed based on Provisional Application Serial No. 60/042,080 filed Mar. 28, 1997.
DESCRIPTION OF RELATED ART
Prior art rail car truck bowl liners come in several categories. Early liners were made of hard metal alloys such as manganese steel, however these need to be lubricated periodically, which is burdensome and expensive. Certain recent liners are composed of an ultra high molecular weight polymer, which eliminated the need for lubrication. However, such liners needed to have separate grounding apparatus added since the liner is nonconductive.
A third category is a hybridized composite liner that utilizes metal reinforcement in a polymer matrix. The metal provides some conductivity, but not necessarily at a desired level. Finally, a molded polyurethane bowl liner using entrained carbon fiber is known, but the proportions are specifically different and a for the purpose of ablation of the carbon fiber as the polyurethane wears, to provide lubrication. These properties are different from, and are specifically avoided in, the present invention which relies primarily on the self-lubricating properties of the polyethylene.
SUMMARY OF THE INVENTION
This invention relates to a grounding product for railroad car center plate assembly bowl liners of the all polymeric type, and more particularly providing for effective grounding without the use of conductive plates, clips or shunts attached to the liner, as disclosed in Wulff U.S. Pat. No. 4,241,667, granted on Dec. 30, 1980. The liner material used herein has similar mechanical properties to the liner as disclosed in Chierici and Murphy U.S. Pat. No. 4,075,951, granted on Feb. 28, 1978, but has improved electrical properties. The disclosures in Wulff U.S. Pat. No. 4,241,667 and Chierici and Murphy U.S. Pat. No. 4,075,951, are incorporated by reference.
Railroad cars are commonly in the form of a body resting on and swivelly connected to a pair of trucks adjacent each end of the car. The swivel connection involved in each truck is generally formed by the car body bolster center plate resting on the truck bolster bowl, with these parts being pivotally connected by a center pin assembly. The reason for the swivel connection is to accommodate motion such as occurs during the car rounding turns and shakes imposed on the railroad car such as caused by track discontinuities while doing minimal damage to the car itself and cargo. Such cars commonly had a manganese steel liner captured between the center plate and the truck bolster bowl. A disadvantage of the manganese steel liner between the two components that has been recognized is that frequent lubrication is necessary. If a car with this old style all metal liner went unlubricated, the swiveling motion would be inhibited and could possibly cause a derailment. At a minimum, excess wear would be caused to the car center plate, the truck center bowl, or both.
The Chierici and Murphy patent referred to above discloses a special truck bolster bowl liner that was devised to replace the conventional and troublesome manganese steel liner. The Chierici and Murphy liner is in the form of a bowl shaped member or body formed from an ultra high molecular weight polymer of dry self lubricating characteristics. An ultra high molecular weight polyethylene (UHMW-PE) is preferred, and the bowl member is shaped to define a floor portion and an upstanding side wall portion which is in circumambient relation about the bowl liner floor portion.
The bowl liner side wall is proportioned to space the car body bolster center plate from the truck bolster bowl side wall, about the circumference of these components, and hold the body bolster center plate in such spaced relation against end of car impacts, whereby such impact forces transmitted between the car body bolster center plate and the truck bolster bowl side wall are spread over 180 degrees of the bolster components involved thereby avoiding overstressing of these components. In the flat horizontal liner, these side loads are borne by a separate liner, usually of steel, held in place in the truck bolster bowl. The problem with the previously disclosed liners are that they are nonconductive, necessitating the addition of some grounding apparatus such as that disclosed in the Wulff patent.
Several alternative embodiments are also present to this bowl liner configuration, which can be adapted to the static dissipative characteristics of the instant invention. One option is to use a UHMW-PE flat horizontal disk formed liner to bear the car bolster center plate. In this embodiment, sidewards loads on the bolster assembly are borne by a metal liner or wear ring welded to the truck bolster, filling the space between the center plate and truck bolster bowl. This embodiment is referred to as a flat horizontal liner. In addition, additional configurations for a top edge seal on an all plastic bolster bowl liner are also possible.
The Chierici and Murphy all plastic bowl liner of said patent establishes two slip surfaces in the center plate assembly, one on either side of the bowl liner, that insures adequate truck swiveling action even under severe operating contingencies, and further provides for a wear resisting resurfacing of the bolster surfaces engaged by the bowl liner whereby the center plate assemblies involved become effectively resistant against further wear, as disclosed in said patent.
The American Association of Railroads requires that railroad car center plate assemblies be arranged so that the body bolster center plate will be sufficiently grounded to the truck bolster bowl. Standards for static electricity conductivity, in other industries such as ANSI/NFPA77 make it desirable to form and arrange the center plate assembly so that it will offer no more than about 1×10 6 ohms (100 Kohms) resistance to electrical current flow therethrough. The invention here exceeds the NFPA standards by an order of magnitude, there being no quantitative AAR standard. The purpose is to assure that any electric charge that might tend to build up in the car body or be induced in same will be discharged through the car trucks to the track rails.
Where the car body center plate acts directly on the bolster bowl, or where the commonly employed manganese steel liner is employed between the two, the metal to metal contact involved has been considered adequate to meet static dissipation standards. While the grounding standard is met, there remains the wear and damage problem in the center plate assembly area of the car.
Railroad cars having their center plate assemblies equipped in accordance with said Chierici and Murphy patent have the benefits described in said patent. However, as the polymeric material from which the liner is formed is electrically insulating or dielectric in nature, the car body bolster center plate and the truck bolster bowl have been considered to require grounding therebetween, at least for certain types of cars, even though the bolster center pin may provide a measure of electrical conductivity to the trucks.
Cars using a liner as disclosed in Chierici et al also had to incorporate grounding apparatus, as disclosed in the Wulff patent. Grounding methods such as the one disclosed in Wulff all use some form of conductive shunt clip and metal rivets to provide an artificial path between the car body center plate to the truck bolster bowl. These methods are disadvantageous in that they are subject to wear and tear, and after extended use the conductors can be recessed below the surface area of the liner to a point where they have a less effective contact area.
As the grounding clip or shunt exists for the purpose of providing unlubricated metal to metal contact, it also provides increased friction over that provided by the Chierici et al all UHMW-PE liner. The previous grounding method is also disadvantageous in that periodic inspection of the grounding clips may be necessary, requiring costly disassembly of the center plate assembly. Wear of the grounding clip, present for the purpose of providing metal to metal contact, can result in the frictional wearing of the clip sufficient that it becomes dismembered and therefore the electrical contact is, in any event, broken. There are also potential difficulties in the fact that the shunt or clip provides for contact in a relatively small portion of the total bearing surface. As a car rolls or pitches there is the risk of intermittent contact if the orientation of the shunt is not roughly perpendicular to the axis of the aforesaid pitching or rolling movement.
The present invention is concerned with providing a liner with all the benefits as disclosed in the Chierici et al patent and in addition being conductive, thereby eliminating the need for any additional grounding apparatus.
The liner is composed of a base ultra high molecular weight polyethylene (UHMW-PE) material with a conductive material additive. The preferred composition is UHMW-PE specially mixed with 2.0% carbon black. The conductive material, such as carbon black sold on the market as Monarch 700 anti-static agent, can be added as a particulate to UHMW-PE in particulate or powder form and then the mixture heated under mold pressure for thermoforming. With other plastics, or other molding or forming methods, the conductive material may be added as described above with UHMW-PE or possibly mixed with a plastic in its solid pelletized form or the conductive carbon black material may be added while the plastic is liquified for thermoforming. It is also possible that an appropriate thermosetting plastic could be used as the self-lubricating matrix with conductive material mixed therein and the liquified thermosetting plastic cured to form a liner having the requisite mechanical and electrical properties.
It will be noted that other plastics can be formed as ultra high molecular weight material. At the present time, polyethylene is preferred both for performance and economic reasons. However, other polymers would prove to be suitable and applicants do not wish to be limited only to the invention as claimed.
This improved liner still has all of the same properties that make the liner as disclosed in Chierici et al so beneficial, with the additional benefit that the liner is now conductive. Any electrical charge built up in the car body will be discharged through the liner into the car trucks and discharged into the track rails.
BRIEF DESCRIPTION OF THE DRAWINGS
The following drawings, in which like reference characters indicate like parts, are illustrative of embodiments of the invention and are not intended to limit the scope of the invention in any manner whatsoever, as encompassed by the claims forming a part hereof.
FIG. 1 is a diagrammatic transverse cross-sectional view through a railroad car body underframe at one of its body bolsters, showing some parts of same and the supporting truck bolster in elevation, with the truck wheels being shown in phantom and the truck side frames omitted for ease of illustration;
FIG. 2 is a fragmental vertical cross-sectional view through the center plate assembly shown in FIG. 1 illustrating one arrangement of the center plate components and self lubricating liner in accordance with this invention;
FIG. 3 is a perspective view of the liner;
FIG. 4 is a fragmental vertical sectional view of the liner of FIG. 3 showing same as separated from the center plate assembly.
FIG. 5 is a top plan view of the flat horizontal embodiment of the static dissipative liner.
FIG. 6 is a fragmental vertical sectional view of the flat horizontal embodiment of the static dissipative liner of FIG. 5.
FIG. 7 is a top plan view of an alternative embodiment of the bowl liner in accordance with this invention.
FIG. 8 is a fragmental vertical sectional view of the liner of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference numeral 10 generally indicates a railroad car in diagrammatically illustrated form and shown to comprise car body underframe 12 having a car body bolster 14 resting on and swivelly connected to truck bolster 16 of railroad car truck 18. The truck 18 and its bolster 16 are of any conventional type and thus are only diagrammatically illustrated.
The connection of the car body bolster 14 to the truck bolster 16 is effected utilizing center plate assembly 20, which in accordance with the present invention comprises truck bolster bowl 22 (see FIG. 2) that is integral with the bolster 16 and defines upstanding side wall 24 and floor wall 26, in which is received body bolster center plate 28 that in the form shown is integral with center filler 30 suitably fixed to the underframe center sill 32 for forming the "center plate" of body bolster 14. As is conventional, the truck bolster bowl floor 26 and center plate 28 are apertured as indicated at 34 and 36, respectively, to receive the conventional kingpin 37 (only a fragment is shown) that swivelably connects these components together. Bowl 22 and center plate 28 are of standard shaping, and thus bowl wall 24 is shown to include the usual recessed edge 35 that normally functions to retain the conventional manganese steel liner in the bowl 22.
The body bolster center plate 28 comprises an upstanding side wall 40 that is integral with planar wall portion 42 that seats within the bolster bowl 22. As is well known in the art, the center plate 28 may be a separate component, or part of a separate component suitably fixed to the center sill 32 and/or the body bolster 14, or plate 28 may be an integral part of bolster 14 or parts of same.
In accordance with the present invention, a liner 44 of special characteristics is interposed between the body bolster center plate 28 and the side wall 24 and floor 26 of the bolster bowl. Liner 44 is formed of dry self lubricating material to eliminate the need for applying separate lubricating materials to the center plate assembly 20, which in turn permits the center plate and bowl area of the car to be free of wet type lubricants that are customarily used for this lubrication, but also accumulate wear inducing foreign matter.
In the form of FIGS. 2-4, the liner 44 is of dished, bowl like configuration, and comprises a floor or disc portion 46 of rounded configuration that is apertured at 48 to receive the aforementioned conventional kingpin. The liner 44 about the outer margin 50 of its floor disc portion 46 includes upstanding side wall 52 that is in circumambient relation thereabout and that is continuous and uninterrupted about its circumference, as indicated in FIG. 3.
The liner 44, in accordance with the invention, is defined by a high density polymer of dry self lubricating characteristics that is pliable but non-stretchable and is thus free from distending or stretching characteristics and that is sufficiently compaction resistant to resist any substantial compaction under compressive forces up to its elastic limit, and has a high degree of elastic memory for full return to original shape after being stressed, up to its elastic limit. The liner is also conductive, made from ultra high molecular weight polyethylene specially mixed with a conductive material such as 2% carbon black. This carbon black is known on the market as Monarch 700 anti-static agent.
While the use of carbon black mixed with plastics is known, this combination of materials has not heretofore been found useful in the unique application of a self-lubricating rail car center bowl liner. A combination of mechanical, chemical and electrical traits need to be optimized for a center bowl liner to be designed to meet all these competing needs. A standard carbon black mixture with carbon black mixed with ultra high molecular weight polyethylene is 1% carbon black. The particulate carbon black 54 is shown in FIG., 4. The distribution is shown here diagrammatically and the distribution is not to be considered to be shown quantitatively in this Figure. As is discussed, the carbon black particles 54 are in a proportion of about 2% to the UHMW-PE matrix material into which particles 54 are mixed for substantially uniform distribution. It is also possible that other particulates may be suitably mixable in the proportions and having the properties claimed herein.
It will be noted that rail car center bowls are designed to withstand loads imposed by cars having a mass bearing on each center bowl on the order of 25,000 to 122,000 pounds depending on the specific cars' contents and construction standards. These loads are imposed by both static and dynamic forces although the dynamic forces can sometimes exceed the 122,000 lbs described above. It is critical to maximize the properties of the liner material in both the chemical and mechanical areas to preserve the self lubricating feature as well as wear resistance and resistance to compression, deterioration and disintegration. Accordingly, standard carbon black UHMW-PE mixtures may have been made for other applications, such as coloration of plastic, at the 1% carbon black percentage.
It is also expected that the load placed on the liner by the weight carried in the car has beneficial effects on the properties of the liner with the disclosed proportion of entrained carbon black conductive material in that the liner is compressed under load. As the distance between the particles decreases, as at high tare weights, then conductivity increases as a static charge has a smaller distance to travel. Thus, there would be an increase in conductivity in a car, such as a railroad tank car, which is fully loaded, when compared to an unloaded car, which in this instance will correspond to the time for the most desirable increase in conductivity, as the car is being loaded.
Another advantage provided by the instant invention, using the carbon black in the proportion described herein is that as described in the Chierici et al patent, there is a polishing and wear hardening that occurs using the all UHMW-PE liner. Because the carbon black conductive material is uniformly contained with in the UHMW-PE matrix, as that matrix undergoes ablation by this wear process, new carbon black particulates are exposed as the matrix wears. Thus, while as explained below, the walls of the liner are arranged to minimize contamination of the self-lubricating surfaces of the liner from the exterior, to the extent contamination occurs, there would be more carbon black material exposed as the UHMW-PE matrix wears or ablates.
Including too much carbon black mixed with the plastic interferes with the self-lubricating properties of the UHMW-PE. In the Rudibaugh U.S. Pat. No. 5,443,015 prior art patent, 5% carbon black was mixed with castable thermoset urethane for the purpose (the opposite of that desired here) of ablating a sufficient amount of carbon so that the lubricating properties of the carbon will be effective in lubricating the urethane wear plate. Because the instant invention relies on the advantages of the self-lubricating UHMW-PE material, the 5% limit for the urethane wear plates provides substantiation for the upper limit of applicants' range of carbon black. It is not, however, an absolute upper limit because of the different properties of the urethane and self-lubricating UHMW-PE.
The full bowl liner embodiments of the invention contemplate that the liner side wall 52 and floor portion 46 are proportioned to fully fill the space between the truck bolster bowl and the body bolster center plate that would not permit any lost motion movement of the center plate 28 relative to bowl 22 in the plane of these components. Thus, the side wall 52 of liner 44 is proportioned to fill the space between the bowl side wall 24 and the body bolster center plate side wall 40 to the extent that bowl wall 24 holds the liner 44 against movement in the plane of bowl 22, and liner 44 holds center plate 28 against movement in the same plane. Of course, the liner 44 is not closed across the aperture 48 so as to permit application of a conventional kingpin, and, as indicated in FIG. 2, liner 44 need not have the inner surfacing along floor 46 or wall 52 fully complement the normal tapered external surfacing of center plate 28 at the lower portion of its wall 40. It is only necessary that the liner wall 52 have a thickness such that at the upper level of bowl wall 24, just below recess 35, the liner wall 52 fully fills the space between center plate wall 40 and bowl wall 24, so as to preclude movement of the center plate 28, relative to bowl 22, in the plane of center plate assembly 20.
In FIGS. 5 and 6, the preferred flat horizontal disk 146 is provided with aperture 148 through which kingpin 36 (FIG. 1) and related assemblies may pass. Outer or peripheral edge 150 is sized such that disk 146 will fit inside a metal collar style wear liner fitted to a truck bolster, in the manner described in the background of the invention and as is known in the field. In the sectional view FIG. 6, the flat configuration of disk 146 is shown as is wall 152 which defines aperture 148.
FIGS. 7 and 8 show another approach, using a full bowl liner 244 having a floor or disk portion 246 with kingpin aperture 248 and upstanding wall 252 terminating in flange 264. There are mechanical and electrical conductivity improvements in this embodiment. Disk portion 246 has two major subdivisions, a conductive ring 270 which has the disclosed 2% to about 5% conductive material molded or entrained in the plastic and an outer ring 272 composed of the structural self-lubricating plastic, preferably UHMW-PE. This can be molded using known plastic molding techniques such as compression molding. Preferably known plastic molding techniques can be used to partially mold the outer ring 272, wall 252 and flange 264 as a unit and then placing the solid particulate plastic and conductive material mix in position to form ring 270 and then reheating the entire unit under pressure to form a substantially unitary disk portion 244 simply with a concentration of conductive material in a preselected location.
Flange 264 includes a horizontal portion 274 with an internally conical bevel 276 which will fit closely against the car bolster as shown in FIG. 1. Exterior radiused ring portion 278 provides for better support of flange 264 and potentially improved sealing against the truck bolster.
The mechanical features of the UHMW-PE bowl liner include the configuration to fit in the space between the truck bolster bowl 22 and the body bolster center plate 28 to limit lost motion movement of the center plate 28 relative to wall 52 of bowl 22 in the plane of these components and also to provide vertical support for center plate 28 in bowl 22. Liner 44's preferred UHMW-PE material resists distension or stretching, and any substantial compaction due to compression (up to its elastic limit). Liner 44 holds these components firmly spaced apart and against forces, and especially impact forces. The UHMW-PE material disperses loads, is itself highly resilient to such loads, particularly when captured between main load bearing components like center plate 28 within bowl 22 and has the beneficial self-lubricating properties as described in greater detail in the cited patents which are incorporated by reference.
The configuration of liner 44 is much like the older steel liner. As disclosed in the earlier patents, liner wall 52 does not seat in any way on the top surfacing 60 of the bowl 22 or its recess 35, rising straight out of the bowl interior for firm engagement with the neck portion 62 of center plate wall 40, 360 degrees thereabout. This effects a seal about the center plate neck portion 62 that precludes entry of foreign material between the liner 44 and center plate 28.
Flange 64 extends outwardly from bevelled portion 66, itself at the top of wall 52 at an approximately 90 degree angle. This provides a level of line sealing contact with the center plate neck portion 62. The precise dimensions and proportions can be adapted to particular center bowl needs. This configuration, building on the teachings of Chierici and Murphy is not required in order to practice the invention according to the teachings herein.
Liner 44 freely carried in its captured location between bowl 28 and center plate 28. This embodiment forms two slip surfaces with the center plate assembly 20 to insure the needed swivelling action of the car trucks 18 with respect to the car body 12.
It is expected that the configuration shown in FIG. 7 and FIG. 8 may be preferred over this older configuration.
The flat disk of FIGS. 5 and 6 could also be made pursuant to either the uniform distribution of conductive material embodiment or with a more concentrated inner conductive ring, as described above. Of course the flat disk version of FIGS. 5 and 6 provides the flat slip surfaces in a car that has a partial metal liner.
The primary slip surface is between the upper surface 72 of the liner 44 and the body bolster center plate 28's lower surface or planar wall 42. Liner 44 also forms a secondary contingency slip surface 70, the lower surface of the liner 44 and the truck bolster floor 26.
The liner 44, 146, in accordance with this invention, can both meet the from 0.15 to 0.20 coefficient of friction of the all UHMW-PE liner (Chierici et al and Murphy) relative to the surfaces of the body bolster center plate 28 and bolster bowl 22 and also meet the electrical conductivity standards of 1×10 5 ohms (100 Kohms), although coefficient of friction under load can temporarily be higher. As such, it is an improvement over both the all UHMW-PE liner, which has a high resistance, and the clip or shunt grounded version (Wulff) which has an inconsistent coefficient of friction due to the interference of the shunt or clip with the uniform contact of surfaces 70, 72.
As many and varied modifications of the subject matter of this invention will become apparent to those skilled in the art from the detailed description given hereinabove, it will be understood that the present invention is limited only as provided in the claims appended hereto.
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A conductive center bearing liner for railroad car center plate assemblies comprising a bowl shaped or flat round horizontal member formed from a cross-linked ultra high molecular weight polymer specially mixed with a conductive material shaped to define a floor portion and alternative embodiments with an upstanding side wall. Another embodiment concentrates the conductive material in a selected sector of the disk portion of the liner. The conductive liner eliminates the need to incorporate special apparatus to ground the car body center plate to the truck bolster bowl. This grounding method eliminates the wear and erosion that occurs by grounding using conventional methods.
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This application is a division of application Ser. No. 07/988,474 filed Dec. 10, 1992, now U.S. Pat. No. 5,393,684.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for forming thin oxide regions particularly in electrically erasable and programmable read-only memory cells.
2. Discussion of the Related Art
In conventional electrically erasable and programmable read-only memory cells, technically known as EEPROMs, it is advantageous to delimit an oxide portion in which it is possible to grow a thinner oxide, so that the electric writing and erasure of the cell can occur through such portion.
One of the problems encountered with these EEPROM devices is caused by the lithographic process. As is known to those skilled in the art, the dimensional limit for a given technology is set by the photolithographic method employed, through which it is possible to define structures whose dimensions exceed a given value.
Furthermore, radiation-induced damage due to so-called "dry etching" often occurs in these devices. This type of etching does not allow removal of the gate oxide from a surface portion which is greater than the desired tunnel dimensions.
In addition to the problem which arises from the type of etching, it is also very difficult to etch the oxide on limited areas, because one must work at the limit of what is technologically feasible.
Another problem associated with conventional EEPROM cells is related to controlling the dimensions of the tunnel portion, whose variability affects the capacitive coupling of the cell and thus its electric performance.
SUMMARY OF THE INVENTION
Accordingly, an aim of the present invention is to substantially eliminate or substantially reduce the problems described above in connection with conventional EEPROM cells.
Another aim is to provide a method for producing thin oxide structures for applications in EEPROM cells which substantially reduces, and possibly eliminates, the problems related to the limits of the photolithographic process.
Within the scope of the above aims, an object of the present invention is to provide a method which improves efficiency in controlling the area of the thin oxide element.
Another object of the present invention is to provide a method which is highly reliable, relatively easy to perform and can be performed at competitive costs.
This aim, the objects mentioned and others which will become apparent hereinafter to those skilled in the art are achieved by a method for producing tunnel structures in EEPROM cells. The method includes the following steps: defining an active area on a doped silicon substratum by growing gate oxide regions; generating protective portions of a first layer of radiation-sensitive material on the active area and gate oxide regions; heavily doping the active area; removing the protective portions of the first layer of radiation-sensitive material; growing a first oxide layer on the active area; generating protective portions of a second layer of radiation sensitive-material which surround an opening in the active area; lightly doping the active area; removing a portion of the first oxide layer within the opening; removing the protective portions of the second layer of radiation-sensitive material: and growing a second oxide layer on the active area.
Further characteristics and advantages of the invention will become apparent from a reading of the description of a preferred but not exclusive embodiment of a method for producing tunnel structures in electrically erasable and programmable read-only memory cells, in the particular example, with a single polysilicon level, illustrated only by way of a non-limiting example in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a to 1k are cross-sectional views of a structure showing the steps of a conventional prior art method; and
FIGS. 2a to 2l are cross-sectional views of a structure showing the steps of the method according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the term "to mask" or "masking" defines the conventional photolithographic process by means of which the radiation-sensitive material is made soluble or insoluble by exposure to a source of radiation which is controlled and filtered by a mask which bears the layout of the individual layer. In most practical cases, the radiation-sensitive material is constituted by light-sensitive resin, technically termed photoresist, whereas the radiation source is usually an electromagnetic radiation source, generally in the visible-light range. The term "etching" defines the chemical incision of the layers of a calibration structure. The term "doping" defines the introduction of impurities by means of high-energy implantation, by means of gaseous diffusion or other equivalent implantation processes.
With reference to FIGS. 1a to 1k, a conventional method for producing a tunnel structure includes the following steps: A preparation step, shown in FIG. 1a, wherein an active area 2 is delimited in EEPROM cells on a doped silicon substratum S by growing gate oxide regions 1;
A first deposition step, shown in FIG. 1b, wherein a layer 3 of radiation-sensitive material is deposited on the device: the layer 3 is subsequently masked and its soluble portions are removed, leaving protective portions 3 on the gate oxide regions 1 which limit each EEPROM cell;
A first doping step, shown in FIG. 1c, wherein a light n-doping is performed on the active area 2 of the EEPROM cells.
A first cleaning step, shown in FIG. 1d, wherein the protective portions 3 of radiation-sensitive material are removed from the gate oxide regions 1;
A diffusion step, shown in FIG. 1e, wherein the lightly doped drains are diffused;
A first growth step, shown in FIG. 1f, wherein a layer 4 of gate oxide is grown on the active area 2;
A second deposition step, shown in FIG. 1g, wherein a layer 5 of radiation-sensitive material is deposited on the device and is subsequently masked; soluble portions thereof are then removed, leaving open a central portion 10 of the active area 2 of the cell;
An etching step, shown in FIG. 1h, wherein the gate oxide 4 is removed from the open portion 10 exposed during the second deposition step;
A second cleaning step, shown in FIG. 1i, wherein the protective portions 5 of radiation-sensitive material are removed;
A second growth step, shown in FIG. 1j, wherein another layer of oxide 6 is grown on the active area 2; and
A third deposition step, shown in FIG. 1k, wherein a layer 7 of polysilicon is deposited on the device and subsequently masked and partially removed by etching yielding the floating gate electrode.
With reference to FIGS. 2a to 2l, wherein like reference characters denote similar features to those of FIGS. 1a-1k, a method for producing tunnel structures according to the present invention includes the following steps:
A preparation step (FIG. 2a) wherein an active area 2 is delimited on a doped silicon substratum S, by growing gate oxide regions 1, in the EEPROM cells;
A first deposition step (FIG. 2b) wherein a layer 3 of radiation-sensitive material is deposited on the device and is subsequently masked; the soluble portions thereof are then removed, leaving protective portions 3 on the active area 2 and on the gate oxide regions 1, limiting each EEPROM cell;
A first doping step (FIG. 2c) wherein heavy doping is performed on the actives area 2 of the EEPROM cells;
A first cleaning step (FIG. 2d) wherein the protective portions 3 of radiation-sensitive material are removed from the active area 2 and from the gate oxide regions 1;
A diffusion step (FIG. 2e) wherein the heavily doped drains are diffused;
A first growth step (FIG. 2f) wherein a gate oxide layer 4 is grown on the active area 2;
A second deposition step (FIG. 2g) wherein a layer 5 of radiation-sensitive material is deposited on the device and is subsequently masked; soluble portions thereof are then removed, leaving open a central portion 10 of the active area 2 of the cell;
A second doping step (FIG. 2h) wherein light doping is performed on the active area 2 of each memory cell;
An etching step (FIG. 2i) wherein the gate oxide 4 is removed from the central portion 10 exposed during the second deposition step;
A second cleaning step (FIG. 2j) wherein the protective portions 5 of radiation-sensitive material are removed;
A second growth step (FIG. 2k) wherein a further oxide layer 6 is grown on the active area 2; and
A third deposition step (FIG. 2l) wherein a layer 7 of polysilicon is deposited on the device and is subsequently masked and partially removed by etching, yielding the floating gate electrode.
In this manner a tunnel oxide portion 13 is obtained whose dimensions are smaller than the resolution of the photolithographic method used.
The so-called "enhanced oxidation effect", is exploited during the definition of the tunnel oxide portion 13, i.e. the phenomenon by virtue of which greater oxidation occurs where substratum doping is higher. Accordingly, the gate oxide 14 which grows above the more heavily doped portions n+ is thicker than the oxide 15 grown upon the less heavily doped portions. The thickness of approximately 15 nanometers makes the oxide 14 grown in this manner an excellent insulator.
The high thickness of the gate oxide 14 above the more heavily doped portions n+ is achieved in the two following steps which are ensured by two different and easily controllable effects: the first step, which is the first doping step (FIG. 2c), wherein lateral diffusion of the heavy doping occurs; and the second step (FIG. 2k), which uses the enhanced oxidation effect wherein the oxide thickness is different above the heavily doped portions than above the portions with less heavy n- doping implantation.
The electrical operating characteristics of the cell produced by the method of the present invention are better than those of a conventional cell.
Advantageously, the tunnel oxide portions obtained with the method according to the invention have dimensions which are smaller than the resolution of the photolithographic method employed.
The provision of a tunnel with such dimensions also leads to a benefit in the capacitive couplings of the cell, allowing a reduction in the overall dimensions of said cell.
With the method of the present invention, silicon oxide etchings can be performed with a wet process, using known substances, such as, for example, hydrofluoric acid (HF:H 2 O) or any other substance which can etch the oxide without damaging the surface of the device. These etchings allow removal of the gate oxide from a surface which is larger than the final dimensions of the tunnel portion.
These results conveniently lead to a degree of manufacturing freedom which is absent in conventional cells.
Practical tests have shown that the present invention achieves the intended aim and objects, including providing a method for defining thin oxide portions particularly for EEPROM cells with dimensions which are smaller than the resolution of the photolithographic method used.
The method according to the present invention can have numerous modifications and variations and remain within the scope of the inventive concept. All of the details may be replaced with other technically equivalent elements as will be apparent to those skilled in the art. In practice, the materials employed, as well as the dimensions, may be any according to the particular requirements in specific applications.
Having thus described one particular embodiment of the invention, various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements as are made obvious by this disclosure are intended to be part of this disclosure though not expressly stated herein, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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A method for forming thin oxide portions in electrically erasable and programmable read-only memory cells, including the use of the enhanced oxidation effect and the lateral diffusion of heavy doping, for obtaining a tunnel portion whose dimensions are smaller than the resolution of the photolithographic method used.
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