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This application is a continuation of application Ser. No. 07/879,608, filed May 7, 1992, now abandoned.
FIELD OF THE INVENTION
The present invention relates to a method and apparatus for producing reducing gases having a high content of hydrogen and carbon monoxide, commonly known as synthesis gas (or syngas), from solid organic residues. More particularly the invention relates to a method and apparatus for gasifying industrial and domestic wastes of several types, including the non-metallic residues of automobile scrap, known as Auto Shredder Residues (ASR) also called "fluff", garbage, municipal waste, plastic wastes, tire chips, residues from the petrochemical, polymer and plastics industries, and in general wastes of organic compounds (including even liquids such as used motor oil), to produce a gas having a high content of hydrogen and carbon monoxide (typically more than 50%, or even well over 65% on a dry basis) which can be utilized as raw material in other industrial processes, for example, to reduce iron ores to metallic iron in the ironmaking processes known as Direct Reduction processes, or to be utilized as a source of energy to run an internal combustion engine or to produce steam and/or electricity. In its broader aspects the disclosed method can be used for devolatilization of coal or of other such non-waste complex molecular sources of carbon and/or hydrogen.
BACKGROUND OF THE INVENTION
In these days, and primarily in the industrialized countries, there is a deep concern about the safe disposal of domestic and industrial wastes which have acquired great ecological importance. These wastes often include a substantial proportion of organic content.
Many such wastes often contain toxic substances and are nonbiodegradable. They cannot therefore simply be disposed of in landfills due to contamination problems of air and water. Another alternative to dispose of these wastes is incineration. Normal and simple incineration however is not permitted if the product gases are not duly cleaned because it causes air pollution with toxic chemicals for example, chlorine compounds and nitrogen oxides. In some countries, environmental laws and regulations have been passed which prohibit burial or incineration of these types of wastes. Therefore these alternatives for disposal of such wastes are now subject to many restrictions.
A thorough description of the problems which the shredding industry is facing regarding disposal of fluff and some suggestions for utilization of the energy content of fluff, is found in a paper by M. R. Wolman, W. S. Hubble, I. G. Most and S. L. Natof, presented at the National Waste Processing Conference in Denver, Colo. held on Jun. 14, 1986, and published by ASME in the proceedings of said conference. This paper reports an investigation funded by the U.S. Department of Energy to develop a viable process to utilize the energy content of fluff. However, the process therein suggested is aimed to carry out a total incineration of the wastes, utilizing the heat from said incineration for steam production, while the present invention is addressed to producing from organic materials a high quality gas as an energy source.
It has also been proposed in the past to carry out a controlled combustion of the organic wastes and to utilize the heat or other values (such as process gases) released by such combustion. Such prior art processes typically gasify organic materials by one of two processes: pyrolysis, that is, thermal decomposition of the materials by indirect heating; or partial combustion of the materials with air or oxygen.
Energy consumption is one of the most important costs in ironmaking. Typical direct reduction processes consume from 2.5 to 3.5 Gigacalories (109 calories) per metric ton of product, known as sponge iron or direct reduced iron (DRI). Therefore, many processes have been proposed which utilize all types of available energy sources, such as coal, coke, liquid fuels, natural gas, reducing gases from biomass, nuclear energy and solar energy. Most of such proposals have not met practical success, sometimes because the materials and means needed are not yet available or because the relative costs for using such other energy sources are higher than for traditional fossil fuels.
Utilization of organic wastes as a source of energy for the ironmaking industry offers great economic advantages and solves environmental problems in those countries where large quantities of automobiles are scrapped or other wastes with high organic material content are generated. Metallic scrap is recycled for steelmaking. The nonmetallic residues of automobiles (fluff), however, had not been utilized to produce reducing gases useful in the production of iron or in other industrial processes.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a process and apparatus for producing reducing gases, also known as synthesis gas, preferably from low cost carbon/hydrogen sources such as garbage, or other organic containing wastes, which syngas can be utilized as raw materials in chemical processes and also as fuel.
Other objects of the invention will be described hereinbelow or will be evident to those readers skilled in the art.
The present invention comprises a process wherein gasification of organic materials is carried out by reaction of the thermally cracked complex hydrocarbons and gas evolved from said hot materials (preferably 650° to 800° C.), with carbon dioxide and water generated by combustion, preferably stoichiometric, of a fuel and oxygen at high flame temperature, typically at 2500° to 3000° C. (when using a tumbling reactor). The heat produced by the combustion of the fuel is transferred to the gasifiable materials not only by convection, but also by direct radiation from the flame and by tumbling contact with the glowing interior refractory lining of a rotary reactor. The burner(s) inside the reactor is balanced in positioning and capacity in such a way that it is capable of delivering the necessary heat for thermally decomposing the materials and also for carrying out the gaseous reactions of complex hydrocarbons with the water and carbon dioxide, as well as providing the necessary amount of H 2 O and CO 2 reactants for such reactions. These combustion products contact the evolved gases such that the resulting synthesis gas contains less than about two percent by volume of gases with a molecular structure having more than two carbon atoms. Another feature of the present invention is that a high quality gas is obtained in a single stage or reaction zone, while the prior art processes typically require two stages. Complex gases within the reaction zone(s) react by dissociation according to their thermal/chemical equilibrium composition and become substantially stable simple hydrocarbon gases at lower temperatures.
Since one of the advantages of this invention is to supply a high quality process gas at a cost competitive with traditional process gases (such as reformed natural gas), it may be necessary in practicing the invention in one of its broader aspects and under certain market conditions and with certain kinds of "fluff" or similar waste materials to use a slight excess of oxygen (or air) in the burner or to the reactor to reduce the amount of natural gas used in the burner relative to the amount of organic waste gasified. Not so much excess oxygen should be used as to result in substantial incomplete gasification or in the need for separate two-stage processing (at two significantly different temperatures, with the second stage being in the absence of the solid burden). This excess oxygen for example might be up to 10% more oxygen relative to the molar content of the fuel. Excessive oxygen makes control of the process difficult and is safer if minimized. Alternatively, as economics may dictate, a portion of the previously generated synthesis gas may replace an equivalent amount of natural gas in the burner, up to 100 percent replacement.
Regarding the rotary reactor disclosed in the present invention, it comprises some unique characteristics, namely: the rotary reactor is disposed substantially horizontally with respect to its axis of rotation, while known rotary reactors are inclined so that the materials tumbling inside are caused to move from their charge end to their discharge end. In the rotary reactor of the present invention solids move from the charge end to the discharge end of the reactor by the tumbling action of the rotating vessel, and by the volumetric displacement of reacted solid ash in the bed by unreacted material and inert solids contained in the feed material. The center of the reactor has a bulged shape to give the bed an adequate volume and burden retention time and to conform to the shape of the burner flame.
The process could be carried out in other apparatus such as a generally cylindrical horizontal stationary reactor having internal slightly-angled rotating paddles for tumbling the burden. The latter has some drawbacks such as possible obstruction of the preferred single flame within the reactor chamber and the engineering problems of the paddles and supporting moving parts being within the high temperature regions of the reactor.
Another important feature of the present invention is the unique structure of the high temperature seals which minimize seepage of outside air into the rotary reactor.
Because the primary process burner is driven by oxygen and fuel (natural gas, syngas, fuel oil, coal, etc.) the nitrogen content of the resulting product gas is normally limited to the nitrogen contained in the organic feed materials; thus, the nitrogen content of the product gas is normally less than ten percent by volume.
A significant aspect of this invention is the mixing of the evolved complex hydrocarbon gases and entrained soot-laden dust particles exiting the reactor into and through the high temperature CO 2 and H 2 O laden recirculating vortex created in the reactor's atmosphere by the counter-current burner gas stream(s). The flame of the primary process burner preferably enters the reactor from a counter-current direction relative to the movement of the burden material. The dust-laden gases generated by this process preferably pass out of the gasification reactor past the burner in a co-current direction relative to the movement of the bed of burden (ash plus gasifying materials).
In the preferred embodiment the reactor rotates on a horizontal axis. On the charge end of the reactor the feed tube to the burden serves the following purposes: (1) as a raw material feed input, and (2) as an atmospheric seal.
Raw material/feed is force-fed by appropriate means such as by a method of extrusion into the gasification reactor by an auger which is of standard commercial design; however, the diameter, length, and taper of the extrusion tube from the auger into the reactor, and the exact position and clearance between the extrusion tube and the rotating reactor have been determined by practice and provide a support for the rotating slip-seal design on the feed-end of the reactor. Solid feed material in the auger serves as part of the atmospheric seal on the feed-end of the reactor. The auger can also serve a shredding function for oversized pieces of feed material.
Another method for feeding raw material into the reactor involves a hydraulic ram system in which two sets of hydraulic rams act to compact and force feed the material through a specially designed feed tube.
The nature of the carbonaceous feed material consumed in this process is such that some of the feed material has extremely low melting and volatilization temperatures; for example, plastics, rubber, and oil/grease. Therefore, it is important that the temperature of the feed material be controlled to prevent premature reactions before the material reaches the inside of the gasification reactor. The design of the feed extrusion tube and the receiving shaft, or tube through which the feed material is injected and through which the atmospheric seal must be maintained are important parts of the design of this invention.
The process temperature must be controlled to prevent ash materials in the bed from reaching their temperatures for incipient fusion; thus, preventing the formation of agglomerates in the bed and on the wall of the reactor. The critical ash fusion temperature has been determined by practice for various types of raw feed material(s). In the ideal practice of the art of this process it is important to maintain the highest possible bed temperature; however, the temperature of the bed should remain below the point of incipient fusion of the ash (hence the preferred 650°-800° C. range).
Non-reactive dust particles which become airborne pass out of the gasification reactor with the product gas into the hot gas discharge hood and then through hot ducts into a cyclone, venturi, or other appropriately adapted commercial equipment. The gas then passes through a packed-bed column where the acids are scrubbed from the gas and the wash water is adjusted to a Ph of about seven (7). The clean gas is then moved by compressor via pipeline to storage for use.
The design of the hot gas discharge hood is another important aspect of this invention. The hot gas discharge hood provides the port support structure for the process burner.
Secondary air/oxygen injector(s) may advantageously be located in the hot gas discharge hood and/or the hot cyclone for the purpose of adding air and/or oxygen to control the temperature of the product gas as it exits the hot gas discharge hood and/or to aid in "finishing" the gasification of any residual hydrocarbons or soot. In practice of this process it is important to maintain the temperature of the product gas at a sufficiently high level until the gas reaches the gas scrubber in order to avoid condensation of any remaining higher molecular weight gases exiting through the hood. The added residence time of the product gas in the hot gas discharge hood and the hot ducts and cyclone leading to the gas scrubber is such as to increase reaction efficiencies between gases and the carbonaceous portion of the dust.
By controlled additions of air and/or oxygen to the hot gas discharge hood, both the temperature and pressure in the discharge hood can be better managed. It has been found that by raising the temperature of the product gas to about 700° C. by the injection of about 5 percent by volume of oxygen, the residual complex hydrocarbon gases are predominantly decomposed into carbon monoxide and hydrogen. Ideally, such additions are minimized in order to maintain the quality of the synthesis gas. However, the differing types of burden require adjustments to give the required flexibility to the process. Where the type of burden is not standardized, such flexibility can be accomplished by adjusting the amount of air and/or oxygen additions. The amount of air and/or oxygen added in the hot gas discharge duct must also be controlled in view of the BTU requirements of the product gas being produced. For example: if the content of nitrogen in the product gas is not critical relative to the end use of the gas, air can be used exclusively to control the temperature and pressure in the hot gas discharge hood. However, if the content of nitrogen in the process gas must be maintained at a low level in order to meet the required BTU specifications for the gas, oxygen can be used instead of air.
Because the synthesis gas produced by this process is naturally high in particulate matter and acid gases, the sensible energy of the gas cannot be easily utilized by heat exchangers. On the other hand, the gas can be controlled to contain between about 1335 Kcal/m 3 and 3557 Kcal/m 3 (150 and 400 BTU/cubic foot) and can be easily scrubbed of particulate matter and acids.
Ash discharged directly from the reactor and from the hot cyclone is very low in leachable metals. This ash does not require further treatment to be disposed of in an environmentally safe manner. Dust remaining in the product gas following the hot cyclone is removed in a wet venturi scrubber and recovered from the wash water as a sludge. This sludge may be relatively high in leachable metals and therefore may require treatment for environmentally safe disposal.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partially schematic diagram of a preferred embodiment of the present invention useful for gasifying organic wastes to yield a synthesis gas and showing a number of exemplary end uses for such gas;
FIG. 2 shows a partially schematic vertical cross section in more detail of a rotary reactor of the type illustrated in FIG. 1; and
FIG. 3 shows a cross section of a rotary high temperature seal for the charge end of the reactor shown in FIG. 2.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A preferred embodiment of the invention as applied to the gasification of fluff will be described with reference to the appended drawings wherein common elements are designated by the same numerals in all the figures for easier reference. Referring to FIG. 1, showing a partially schematic diagram of the general process and apparatus, numeral 10 designates a charging hopper wherefrom fluff is introduced into the gasification reactor 18 by an auger feeder 20 having an auger 14 (shown in FIG. 2) driven by a motor 12.
Reactor 18 is of the rotary type and is provided with riding rings 22 and 24 which rest and roll on support rolls 26 and 28. Motor 30 causes reactor 18 to rotate about its horizontal axis by means of a suitable transmission device 32, for example of the type of chain and sprocket ring 34, in a manner known in the art.
The discharge end 35 of reactor 18 debouches into a gas collecting hood 36 having at its upper portion an emergency stack 38, through which the product gases can flow by safety valve 40, and a lower discharge section for collection of the solid residues or ash resulting from gasification of the fluff. Rotary valve(s) 42 is provided for regulation of solids discharge and contributes to prevent combustible gas from leaking to the outer atmosphere. Screw-type conveyor 44 driven by motor 46 cools the ash and transfers it into receiving bin 48 for disposal.
A burner 49 is positioned generally horizontally through hood 36 with its nozzle 50 reaching the interior of reactor 18 in the manner shown and described with reference to FIG. 2. Fuel gas and oxygen are fed to burner 49 through conduits 52 and 54.
From hood 36, the gases produced by reactor 18 are transferred through take off conduit 58 into a hot cyclone 60. The solid fine particles of fluff or soot 61 which may be entrained by the gases from reactor 18 are separated and are collected, cooled, and discharged into receiving bin 48.
A secondary burner 64, fed with oxygen/air and/or fuel gas, is positioned upstream of cyclone 60 for optional addition of air or oxygen to gasify any hydrocarbons or soot in the form of fine particles or gases which may reach that point. This "finishing" secondary gas stream from the secondary injector 64 is directed into the take off conduit 58 (which can be thus seen to function as a secondary reactor 58).
The raw product gas flows through conduit 70 into a wet venturi scrubber 72 where entrained dust particles are removed. The product gas then passes through packed bed tower 74 where acids are removed by water wash. Emergency pressure control valve 76 is provided at purge line 78 to relieve excess pressure in the system should upset conditions occur. Solids collected by scrubber 72 are sent into sludge tank 80 forming a sludge 82.
Clean and cool product gas flows to compressor 84 through pipe 86, connected to a flare stack 98 provided with valve 100 for disposal of excess gas surges.
The product gas can be utilized for a variety of purposes. For example, the high quality clean product gas can produce mechanical power as a fuel for an internal combustion engine 88, or can be stored in tank 90 for later use (e.g. to be burned for its heat content), or used to produce electricity in a gas turbine generator 92, or to produce steam in boiler 94 or to be used as a reducing gas in a direct reduction process 96.
Referring now to the more detailed drawing of the gasification reactor 18 shown in FIG. 2, the bed of material 102 to be gasified is formed in this primary reactor 18, and solids are caused to move from the charge end 103 to the discharge end 35 by tumbling action induced by rotation of reactor 18 and by the volumetric displacement of reacted solid ash in the bed 102 by unreacted and inert solids contained in the feed material delivered by auger feeder 20. The tumbling and mixing action of hot reacted and inert ash with fresh unreacted solids in the feed material greatly increases the rate of heat transfer in the bed 102 and thus enhances the rate and completeness of gasification of the raw feed material.
The depth of bed 102, and the retention time for feed material in reactor 18, are determined by the diameter and length of the reaction zone and are also relative to the length, diameter, and the angle of the slope of reactor 18 leading to discharge end 35.
A horizontal rotation axis is preferred among other reasons because the seals 120 and 122, located at the periphery of reactor 18 generally at its charge end 103 and discharge end 35, do not have to withstand excessive thrust or strain due to uneven distribution of the center of gravity of reactor 18. This also applies to the support rolls 26 and 28, which are of a simpler design and easier to maintain if reactor 18 rotates horizontally.
In one of the preferred embodiments, the shape of the primary reactor 18 is an important feature of this invention because the hot volatile gases which evolve from the bed of material 102 must be brought immediately into contact with the extremely hot products of combustion (CO 2 +H 2 O) from burner 49, in order to more directly absorb the high temperature energy of the flame via the endothermic reactions of complex gases to form gases of simpler compounds. The shape and length of the flame from burner 49 is such that volatile gases which evolve from the bed 102, and over the entire length of reactor 18, react with the high temperature products of the combustion from burner 49. These combustion products contact the evolved gases such that the resulting synthesis gas contains less than about two percent by volume of gases with a molecular structure having more than two carbon atoms.
Reactor 18 is provided with refractory lining 108 in the manner known in the art. Refractory lining 108 contributes to a uniform and efficient heating of bed 102 because the exposed portion of refractory lining 108 receives heat from the flame by radiation and also by convection. The lining 108 includes a typical intermediate insulation layer 107 (shown in FIG. 3) as a thermal protection to the metallic shell 109 of the reactor 18. Uniform and efficient absorption of the high temperature energy from burner 49 by bed 102 also depends upon the rotation speed of reactor 18 and is necessary to prevent overheating of areas of bed 102 which are exposed directly to the heat of the flame, as well as to prevent overheating refractory lining 108. If uncontrolled overheating of bed 102 and/or refractory lining 108 should occur, fusion and/or melting and agglomeration of ash-to-ash and/or ash-to-refractory lining 108 could result in damage to refractory lining 108.
A second burner 51 has been shown in dashed lines to illustrate an alternative embodiment having a plurality of burners. However, in the preferred embodiment only a single burner 49 is used.
Adjustable positioning of nozzle 50 of burner 49, shown in solid and dotted lines, inside reactor 18 is an important feature for optimal operation of the process. The preferred position of nozzle 50 will be such that an effective reaction between the gases evolved from bed 102 and the oxidants produced by the flame of burner 49 is accomplished. The flame causes a vortex near the discharge end 35 of reactor 18 and the gases evolving from bed 102 must pass by or through the influence zone of the flame. This arrangement results in the production of a high quality gas in a single reaction zone.
The discharge end 35 of reactor 18 is provided with a foraminous cylinder 110 for screening of fine and coarse solid particles of ash discharged from reactor 18. The fine particles 116 and coarse particles 118 are collected through conduits 112 and 114, respectively, for disposal or further processing.
Burner 49 in this preferred embodiment is operated stoichiometrically to minimize the direct oxidation of the material in bed 102 inside reactor 18.
Seals 120 and 122 are provided to substantially prevent uncontrolled introduction of atmospheric air into reactor 18. The design of seals 120 and 122 will be better appreciated with reference to FIG. 3. The design of reactor 18, (shape, length and horizontal axis rotation), results in minimal thermal expansion, both axial and radial. Seals 120 and 122 are specifically designed to absorb both axial and radial expansion, as well as normal machine irregularities, without damage while maintaining a secure seal.
The seals comprise a static U-shaped ring 130 seen in cross section supported by annular disk plate 132 which closes off the end of the reactor space 138 and in turn is attached by flange 134 to the outer housing structure of the auger feeder 20. A fixed packing 136 is provided to ensure that no gas leaks from space 138 which communicates with the interior of reactor 18 through annular space 140.
Two independent annular rings 142 and 144, made of stainless steel, are forced to contact the static U-shaped ring 130, by a plurality of springs 146. Rings 142 and 144 are fastened to supporting annular plate 148 to form an effective seal between ring 142 and plate 148 by conventional fasteners 150. Supporting plate 148 is securely attached to member 152 which forms part of or is fixed to the outer shell of reactor 18.
Springs 146 maintain the sealing surfaces of rings 142 and 144 against the surface of static ring 130, in spite of temperature deformations or wear.
EXAMPLE NO. 1
A pilot plant incorporating the present invention was operated during many trial runs. The rotating kiln reactor is on the order of 4.3 meters long by 2.4 meters wide (14×8 feet) at its widest point and is shaped generally and has accessory equipment as illustrated in FIG. 1. The following data was obtained: Auto shredder waste from a shredder plant was fed to a rotary reactor as described in the present specification.
Typical analysis of the ASR material, (also called "fluff") which is the material remaining after metallic articles, such as auto bodies, appliances and sheet metal, are shredded and the metals are removed, is in weight percent as follows:
______________________________________Fiber 26.6% Metals 3.3%Fabric 1.9% Foam 1.4%Paper 3.7% Plastics 12.5%Glass 2.4% Tar 3.6%Wood Splinters 1.4% Wiring 1.3%Elastomers 3.3% Dirt/Other 38.6% TOTAL = 100.0%______________________________________
It should be understood, however, that actual analyses vary in a wide range due to the nature and origin of this material. Depending on the shredding process, fluff contains a variable weight percentage of noncombustible (ash). Bulk density of fluff is approximately 448 kg/m 3 (28 lb/ft 3 ). In general, noncombustibles account for about 50% by weight and combustible or organic materials account for about 50%.
About 907 kg/hr (2000 lb/hr) of fluff were fed to the rotary furnace by means of the auger-type feeder after a period of heat-up of the reactor, so that its interior temperature reached above 650° C. (1202° F.). During stable operation, the temperature in the reactor was more or less homogeneous and near 700° C. (1292° F.). Although the temperature of the flame may reach about 3000° C. (5432° F.), the endothermic reactions between the gases evolved from the hot fluff and the oxidants (CO 2 and H 2 O) produced by the burner cause the interior reactor temperature in the bed and adjacent internal atmosphere to stabilize at about 700° C. (1292° F.) .
The reactor was set to rotate at about 1 r.p.m. The burner was operated stoichiometrically using about 64.3 NCMH (2271 NCFH) of natural gas and 129 NCMH (4555 NCFH) of oxygen. A rate of 573 NCMH (20,235 NCFH) of good quality synthesis gas was obtained.
Typical analysis of the synthesis gas produced is:
______________________________________ % Volume (dry basis)______________________________________H.sub.2 33.50CO 34.00CH.sub.4 8.50CO.sub.2 13.50N.sub.2 5.50C.sub.2 H.sub.2 0.75C.sub.2 H.sub.4 3.50C.sub.2 H.sub.6 0.75TOTAL: 100.00______________________________________
As can be readily observed, the product gas obtained contained 67.5% of reducing agents (H 2 and CO) and 13.5% of hydrocarbons which in some applications for this gas, for example, in the direct reduction of iron ores, may undergo reformation in the direct reduction process and produce more reducing components (H 2 +CO).
The heating value (HHV) of the product gas was about 3,417 Kcal/m 3 (384 BTU/ft 3 ), which corresponds to a medium BTU gas and may be used for example to fuel an internal combustion machine, and certainly can be burned to produce steam or for any other heating purpose. As a comparison, the gas effluents from blast furnaces have a heating value of about 801 TO 1068 Kcal/m 3 (90 to 120 BTU/ft 3 ) and even so are utilized for heating purposes in steel plants.
The amount of dry ash discharged from the reactor amounts to about 397 kg/hr (875 lb/hr) and additionally about 57 kg/hr (125 lbs/hr) were collected as sludge from the gas cleaning equipment.
The hot ashes collected directly from the reactor discharge port and from the hot cyclone are very low in "leachable" heavy metals, and consistently pass the TCLP tests without treatment. These ashes contain between eight and twelve percent recyclable metals, including iron, copper, and aluminum. The hot ashes are composed of iron oxides, silica, alumina, calcium oxide, magnesium oxide, carbon, and lesser amounts of other matter.
After removal of oversize metal pieces by screening, the remaining dry ash is environmentally safe for land-filling without further treatment. The toxicity analysis of the concentration of the eight RCRA metals in an extract obtained by TCLP tests is illustrated in the following table.
______________________________________ Regulatory *TCLP Test Concentrations ResultsMetals (mg/L) (mg/L)______________________________________Silver 5.0 <0.01Arsenic 5.0 <0.05Barium 100.0 5.30Cadmium 1.0 <0.01Chromium 5.0 <0.05Mercury 0.2 <0.001Lead 5.0 <0.02Selenium 1.0 <0.05______________________________________ *Toxicity Characteristics Leachate Procedure (per Resource Conservation & Recovery Act).
Dust solids collected from the gas scrubbing system are recovered as sludge and have been analyzed for the eight RCRA metals as illustrated in the following table:
______________________________________ Regulatory TCLP Test Concentrations ResultsMetals (mg/L) (mg/L)______________________________________Silver 5.0 <0.01Arsenic 5.0 0.06Barium 100.0 3.2Cadmium 1.0 0.78Chromium 5.0 <0.05Mercury 0.2 <0.001Lead 5.0 4.87Selenium 1.0 <0.07______________________________________
Several TCLP tests have been made and in each case the sludge materials have passed the test without additional treatment.
EXAMPLE NO. 2
The effectiveness of the seals which are described and claimed in this application, constituting an important feature of the present invention, can be seen comparing the results of two trial runs of the pilot plant (the first with a commercial seal installed and the other with a seal made as shown in FIG. 3).
__________________________________________________________________________ COMMERCIAL SEAL FIG. 3 SEAL SCMH (SCFH) SCMH (SCFH)__________________________________________________________________________Gases Produced 574 (20,279) 64% 606 (21,408) 94%(except N.sub.2)Nitrogen 333 (11,753) 36% 36 (1,263) 6%TOTAL Gas Produced 907 (32,032) 100% 642 (22,671) 100%__________________________________________________________________________
Although it has been found that about 3 percent of the nitrogen content in the final product gas is originated from the fluff material, it can be seen that an important decrease in the nitrogen content of the produced synthesis gas was made by the unique construction of the inventive seals, which contribute to gas produced having a higher quality and value.
EXAMPLE NO. 3
In order to assess the suitability of the synthesis gases produced according to this invention for the chemical reduction of iron ores, the following material balance was carried out running a computer simulation program specifically devised for said purpose.
The basis for calculations was 1 metric ton of metallic iron produced.
Although the reducing gas produced according to the present invention can be utilized by any of the known direct reduction processes. The material balance was calculated as applied to the HYL III process invented by employees of one of the Co-assignees of this application. Examples of this process are disclosed in U.S. Pat. Nos. 3,765,872; 4,584,016; 4,556,417 and 4,834,792.
For an understanding of this example, reference can be made to FIG. 1 where one of the applications shown is the direct reduction of iron ores, and to Table 1 showing the material balance.
926 Kg (2042 lb.) of fluff are gasified in reactor 18.
95 NCM (3354 NCF) of natural gas are fed to burner 49 along with 190 NCM (6709 NCF) of oxygen. Gasification of this amount of fluff produces 1,000 NCM (35,310 NCF) of raw hot reducing gas (F 1 ) which after cleaning and cooling will reduce to 785 NCM (27,718 NCF) with the composition identified as F 2 .
The thus clean reducing gas then is combined with about 1,400 NCM (49,434 NCF) of recycled gas effluent from the reduction reactor after being cooled by quench cooler 124 and divided as composition F 7 .
The mixture of fresh reducing gas F 2 and recycled gas F 7 is then passed through a CO 2 removal unit 126, which can be of the type of packed bed absorption towers using alkanolamines resulting in 1,876 NCM (66,242 NCF) with the composition of F 3 , which clearly is a gas with high reductant potential, of the type normally used in Direct Reduction processes. By means of unit 126, 297 NCM (10,487 NCF) of CO 2 are removed from the system as gas stream F 10 . The resulting gas stream F 3 is then heated by heater 110 to about 950° C. (1742° F.) and is fed to the reduction reactor 104 as gas stream F 4 to carry out the reduction reactions of hydrogen and carbon monoxide with iron oxides to produce metallic iron.
The gas stream effluent F 5 from said reduction reactor 104 has consequently an increased content of CO 2 and H 2 O as a result of reactions of H 2 and CO with the oxygen of the iron ore, therefore the effluent gas F 5 is dewatered by cooling it in a direct contact water quench cooler 124 to give 1687 NCM (59,568 NCF) of a gas F 6 . From gas F 6 a purge F 8 of 287 NCM (10,134 NCF) is split out and removed from the system to eliminate inerts (e.g. N 2 ) from building up in the system and also for pressure control. The rest of the gas is recycled as described above as gas stream F 7 (being combined with F 2 , stripped of CO 2 , and then fed to the reduction reactor as gas stream F 3 having the composition shown in Table 1).
Optionally a cooling gas, preferably natural gas, can be circulated in the lower portion of the reactor in order to cool down the direct reduced iron (DRI) before discharging it.
To this end, about 50 NCM (1766 NCF) of natural gas F 9 are fed to a cooling gas loop and circulated through the lower portion of the reduction reactor 104. The gas stream effluent from the cooling zone of said reactor is cooled and cleaned at quench cooler 106 and recirculated within said cooling loop.
TABLE 1__________________________________________________________________________Material Balance of the HYL III D.R. Process (of Example 3)Using Synthesis Gas From Gasification of ASR Materials F.sub.1 F.sub.2 F.sub.3 F.sub.4 F.sub.5 F.sub.6 F.sub.7 F.sub.8 F.sub.9 F.sub.10__________________________________________________________________________H.sub.2 % vol. 28 35 44 44 33 40 40 40 0.4CO 26 33 26 26 14 16 16 16 0.1CO.sub.2 11 14 0 0 11 13 13 13 0.4 100CH.sub.4 7 10 16 16 13 16 16 16 93.7N.sub.2 4 5 12 12 11 14 14 14 0.5C.sub.3 H.sub.8 0 4.6C.sub.4 H.sub.10 0 0.3H.sub.2 O 24 3 2 2 18 1 1 1Flowrate 1,000 785 1,876 1,876 2,023 1,687 1,400 287 50 297(NCM)Ton FeTemperature 500 30 40 950 639 30 30 30 25 30(°C.)__________________________________________________________________________ | A process and apparatus for gasification of organic materials (typically incorporated in domestic and industrial wastes, including auto shredder residues) to produce useful synthesis gas (primarily CO & H 2 ) with effectively non-toxic ash residue by means of a preferably stoichiometric burner directed into a single stage reactor containing a tumbling charge thus heated to 650° to 800° C. (below the incipient fusion temperature of the charge) resulting in thermally cracking and gasifying the organic materials in the charge and reacting the complex hydrocarbons and gas evolved with the CO 2 and H 2 O generated by the burner by combustion of a fuel and oxygen-containing gas at a high flame temperature, typically 2500° to 3000° C. | 2 |
BACKGROUND
[0001] The present invention is directed to improvements to cylinder locks.
[0002] Cylinder locks consist of a stator or housing which is also known as a block, having a barrel for a rotor or cylinder (also known as plug) that rotates within the barrel. The lock is provided with tumblers which are pin-like elements that sit within a part of a radial bore hole that extends from the keyway in the rotor, crossing the rotor into the stator. The tumbler is positioned proximally to the keyway. The bore extends into the stator, and there is a second pin like element within the stator, that is biased towards the tumbler by a biasing spring that is held in place by a plug that blocks the distal end of the bore.
[0003] The perimeter of the cylinder, where it contacts the barrel is known as the shear line. To rotate the cylinder, none of the tumblers or driver pins may bridge the shear line. The features of the correct key within the keyway position the tumblers and drivers in the correct positions so that none bridge the shear line, enabling the key to be rotated, rotating the cylinder with it.
[0004] Rotating the cylinder with respect to the stator unlocks the lock and typically allows the retraction of one or more latches or bolts, allowing a door to be opened. This can only happen if all the tumbler pins are within the rotor and all the driver pins are within the stator such that no part of any pin bridges the divide between the stator and the cylinder. This is achieved by the proximal element or pin lying fully within the cylinder and the distal element or pin lying fully within the bore in the stator.
[0005] The cylinder is provided with a key way into which a corresponding key may be inserted. The corresponding key has protrusions or indentations that toggle the tumblers and align their ends with the shear line, i.e. the perimeter between the stator and cylinder to allow the cylinder to be rotated.
[0006] In general, the more tumblers that are provided, the better the lock and the more difficult it is to force since the number of key options increases exponentially with the number of tumblers.
[0007] The key may have a jagged edge, as common in Yale® locks, a cylindrical shank as common in Chub® locks, or a flat key with indentions as is common in Rav Bareach® locks.
[0008] Rav Bareach® have a well deserved reputation for their quality locks. The Rav Bareach® lock is a cylinder lock that is opened using a flat blade dimpled key. Each dimple engages and toggles a different tumbler. The depth and position of the dimples provides different key-lock combinations. In high security locks, the shape of the depressions may also vary.
[0009] Mul-T-lock has developed the so-called 3 in 1 system wherein a lock is provided with three color coded keys, typically red, yellow and green. The green key is the basic one for opening the lock as provided. Insertion and turning of a yellow coded key causes the end of one or more pins to break and changes the configuration of the lock so that the red key will no longer open it, with the yellow key becoming the key for the lock. This provides a convenient way to change the configuration of a lock twice, without having to remove and change the lock cylinder.
[0010] There are various improvements and variations to this type of lock-key combination. For example, USSN 2012/0055212 to Nicoara provides a further layer of sophistication to Rav Bariach's lock and key combinations, by providing flat blade keys mutually compressible actuating elements, that are essentially telescopic studs that align with and compress the pins of a tumbler and which make duplicating the key more difficult. The pins used are compound pins that include an inner pin and an outer pin housing. Both pin and outer pin housing have beveled edges that enable them to slide up and down as the key is inserted into the keyway.
[0011] There is an ongoing need to provide additional security features, and there is value in enabling locks to be reconfigured using a key, without having to change cylinders.
[0012] The tumblers that are pushed up into the bores of the stator by the key are sometimes known as pins. This term is appropriate if the element is a simple cylinder. In some locks, more sophisticated elements are provided. For example, in German Utility Design DE 202004015051 titled “Locking cylinder for door lock comprises a housing pin having a first pin part and a second pin part which slide into each other and a spring acting between the first and second pin parts for moving the pin parts”, an element consisting of male and female components around a spring is shown—see FIG. 3 thereof. Insertion of the key causes the male component to be squeezed into the female component, compressing the spring. On removal of the key, the spring causes the male component to move with respect to the female component, restoring the overall length.
[0013] European patent number EP0763639 titled “Pin tumbler and lock cylinder with such a pin tumbler” also show a compressible element (referred to as a bolt) with an internal spring. The compressible element has a male component or shaft with a protruding ring referred to as a shaped outer ridge around the shaft, that can be moved in and out of a cylindrical housing or female component referred to therein as a mounting bore, with the protruding ring configured to slide within a circumferential indention referred to therein as a widened section, that keeps the male part (shaft) locked within the female part (mounting bore), but allowed the overall element to be compressed by applying a force that overcomes the resilience of the spring. On releasing the compressive force, the spring expands, forcing the male element (shaft) to slide outwards to assume its outer configuration, the protrusion being stopped by the end of the circumferential indentation. Sometimes these compressible elements are referred to as pins, but this is somewhat confusing.
[0014] https://www.reporteditor.com/reports/report/bc8b718491be21b8/publication1 titled “Key Operated Locks” describes a method of changing the effective lengths of the tumblers of a Yale™ type lock, using a special reconfiguring keys. The effective lengths of the tumblers may be shortened or lengthened.
[0015] U.S. Pat. No. 3,589,153 titled “Key Operated Lock” describes a key operated lock including a housing having a cylindrical bore therethrough in which a plug is rotatably mounted. Apertures extend radially outwardly in the housing from the bore and each slideably receives a driver. Each driver is aligned, in one position of the lock, with a tumbler assembly movably positioned in an aperture in the plug. The tumbler assembly—receiving apertures communicate with a main key slot in the plug, and insertion of a main key in this slot biases the several tumbler assemblies to a lock opening position in which the tumbler assemblies contact the drivers along a shear line lying in the interface between the plug and body. The tumbler assemblies are adjustable in their dimensions so that they may be altered to permit a new key to be made operative for opening the lock. Each tumbler assembly includes two relatively moveable parts which are interlocked by a locking pin until it is desired to alter the assembly's dimension for key changing purposes. The locking pins are cammed to the interlocking positions by cam plates. These cam plates pine up with the driver apertures when the plug is rotated to a key changing position, and in this position, a change key can be inserted in a change key slot in the plug to bias each locking pin to a position in which the two relatively movable parts of each tumbler assembly are disengaged. The tumbler assemblies can then automatically accommodate their dimensions to an entirely different main key inserted in the main key slot. Thus a second key is required in a second key slot to reconfigure the main key.
[0016] U.S. Pat. No. 8,347,678 titled “Rekeyable Lock Cylinder Assembly” describes a rekeyable lock cylinder assembly includes at least one lock cylinder and a mortise lock adapter. Each lock cylinder includes a cylinder body with a longitudinal axis. A locking bar is disposed in the cylinder body for movement transverse to, and rotationally about, the longitudinal axis. A plug assembly having a tool receiving aperture is disposed in the cylinder body and is rotatable about the longitudinal axis. A plurality of pins and a corresponding plurality of racks are disposed in the plug assembly. A first member is moveable in response to application of a force by a tool received through the aperture to simultaneously disengage all of the plurality of racks from the plurality of pins. The mortise lock adapter includes a housing configured for receiving the cylinder body of the lock cylinder. A mortise lock actuator is coupled to the plug assembly of the lock cylinder.
[0017] U.S. Pat. No. 7,634,931 titled “Rekeyable Lock Cylinder Assembly With Adjustable Pin Lengths” describes a rekeyable lock cylinder includes a plug body and a backing rack that cooperate to define a plurality of pin chambers within the lock cylinder, with each of the pin chambers housing a corresponding pin. Movement of the backing rack changes the configuration of the pin chambers, thereby allowing the corresponding pins to change configuration to match the bitting on a valid key.
[0018] U.S. Pat. No. 4,732,023 titled “Modifiable Cylinder” describes a modifiable cylinder which comprises a plug and a cylinder body. The plug fits into the cylinder body and has a keyway and a plurality of bottom pin holes which are disposed above and perpendicular to the keyway. Each of the bottom pin holes has a bottom pin. The cylinder body comprises a main chamber housing and a subchamber housing. The main chamber housing has a plurality of top pin holes, each of which has a spring and a top pin. In open position, the top in hoes are aligned with the bottom pin holes. The subchamber housing has a plurality of top pin holes, each of which has a spring, a top pin and several discs. When the plug is turned to the modifying position, the top pin holes are aligned with the bottom pin holes so that the discs can be moved into the bottom pin holes so as to modify the inner combination of the cylinder.
[0019] European Patent Number EP 2,184,426 titled “Lock Cylinder, In Particular for a Door Lock” describes a lock wherein the closing cylinder has a housing containing a first spring acting on a housing pin and a core rotating in a cavity. A second spring is fitted between the first pin part and the second pin part. This spring is stressed in the direction of the core. The first pin part is in the form of a shell, and the second one has a widened end facing the core.
[0020] U.S. Pat. No. 3,802,234 titled “Pick-Resistant Lock Construction Including Jamming Feature” describes a keyed, pin tumbler type lock that has one or a series of jamming pin members in the casing intermediate the path of rotation of the lock cylinder between locked and unlocked positions. Attempted rotation of the lock cylinder from locked toward unlocked position without use of the key permits the jamming pin members to move inwardly partially into the lock cylinder jamming it against further rotation to the unlocked position. The jamming pin members are axially split pins outwardly axially abutted by spring urged wedge members which force the split pins partially into the lock cylinder pin openings while radially separating the split pins to engage them axially outward with casing shoulders, thereby permanently positioning the jamming pins in lock cylinder jamming position.
SUMMARY OF THE INVENTION
[0021] A first aspect is directed to a tumbler for positioning in a bore extending radially from a keyway in a lock for selectively engaging a feature of a key within the keyway, said tumbler comprising a male part that interlocks with a female part about a compressed spring; the male part having retaining teeth for selectively engaging an inner notch or an outer notch on inner surface of the female part, such that when said retaining teeth engage the outer notch, the lock component has a first configuration with an uncompressed overall length and on compression assumes a second configuration wherein the teeth of the male part engage the inner notch in the inner surface of the female section, so that the overall length of the tumbler is reduced, such that the reduction in length of the tumbler is irreversible.
[0022] In some embodiments, a plurality of inner notches are provided, and the tumbler is able to assume a plurality of shortened lengths.
[0023] The retaining teeth are locking such that the tumbler may be compacted, but once compacted, the tumbler may not be extended again.
[0024] Typically, the male and female parts each have a flat surface parallel to the keyway.
[0025] Typically, the male and female parts further comprise beveled edges around said flat surfaces.
[0026] Alternatively, the male and female parts have dome shaped outer surfaces.
[0027] Optionally, the tumbler further comprises an inner pin having a length equal to the combined length of the interlocked male and female parts when the teeth of the male part engage the inner notch of the female part and the lock component is compacted.
[0028] Optionally, the tumbler further comprises a filling disk such that the filling disk and the inner pin have a combined length equal to the combined length of the male and female parts when the teeth of the male part engage the outer notch of the female part and the lock component is not compacted.
[0029] A second embodiment is directed to a tumbler assembly comprising a tumbler, a driver, a spring and a plug within a bore; the tumbler for positioning in a bore perpendicular to a keyway in the lock for selectively engaging a feature of a key within the keyway, said tumbler comprising a male part that interlocks with a female part about a compressed spring; the male part having retaining teeth for selectively engaging an inner notch or an outer notch on inner surface of the female part, such that when said retaining teeth engage the outer notch, the lock component has a first configuration with an uncompressed overall length and on compression assumes a second configuration wherein the teeth of the male part engage the inner notch in the female section so that the overall length of the tumbler is reduced.
[0030] Typically, the male and female parts each have a flat surface parallel to the keyway and beveled edges around said flat surfaces.
[0031] Alternatively, the male and female parts each have dome shaped ends.
[0032] Typically, the male part is fabricated from a resilient, elastic material.
[0033] Typically, the resilient, elastic material is a metal alloy.
[0034] Optionally, the teeth of the male part have outer tapered surfaces and lower flat surfaces and the metal or alloy of the male part has a Young's modulus such that the teeth may be forced inwards to enable the tumbler to be compacted, but the compaction is irreversible.
[0035] In one embodiment, the tumbler comprises an inner pin having a length equal to the combined length of the interlocked male and female parts when the teeth of the male part engage the inner notch of the female part and the lock component is compacted.
[0036] Optionally, the tumbler assembly further comprises a filling disk such that the filling disk and the inner pin have a combined length equal to the combined length of the male and female parts when the teeth of the male part engage the outer notch of the female part and the lock component is not compacted, but on compacting, the filling disk is expelled out of the lock component into the bore.
[0037] A third aspect is directed to a lock comprising a cylinder configured to rotate within a barrel, and provided with a tumbler assembly, comprising a tumbler, a driver, a spring and a plug within a bore extending radially from a keyway in a lock for selectively engaging a feature of a key within the keyway, said tumbler comprising a male part that interlocks with a female part about a compressed spring; the male part having retaining teeth for selectively engaging an inner notch or an outer notch of the female part, such that when said retaining teeth engage the outer notch, the tumbler for assuming a first configuration with an uncompressed overall length and on compression assuming a second configuration wherein the teeth of the male part engage the inner notch in the female section so that the overall length of the tumbler is reduced, wherein the reduction in overall length of the tumbler is irreversible.
[0038] Optionally, the male and female parts each have a flat surface parallel to the keyway and beveled edges around said flat surfaces.
[0039] Alternatively, the male and female parts each have domed ends.
[0040] Optionally, the tumbler further comprises an inner pin having a length equal to the combined length of the interlocked male and female parts when the teeth of the male part engage the inner notch of the female part and the lock component is compacted; a filling disk such that the filling disk and the inner pin have a combined length equal to the combined length of the male and female parts when the teeth of the male part engage the outer notch of the female part and the lock component is not compacted, but on compacting, the filling disk is expelled out of the lock component into the bore, such that inserting a key having a shallow dimple into the keyway and rotating causes the beveled surfaces to press against barrel lock component to assume a compacted state and to expel the filling disk out of the lock component and into the bore.
[0041] In some embodiments, the lock further comprises a socket on opposite side of cylinder from tumbler bore, such that rotation of cylinder through a preset angle, causes the filling disk to be ejected out of the bore by the spring, and into the socket.
[0042] The preset angle may be 180°.
[0043] It will be appreciated that the lock may further comprise additional tumblers.
[0044] A fourth aspect is directed to a method of changing a key and lock combination of a lock comprising a cylinder configured to rotate within a barrel, by providing a tumbler within a bore extending radially from a keyway in a lock for selectively engaging a feature of a key within the keyway, said tumbler comprising a male part that interlocks with a female part about a compressed spring; the male part having retaining teeth for selectively engaging an inner notch or an outer notch of the female part, such that when the retaining teeth engage the outer notch, the lock component has a first configuration with an uncompressed overall length and on compression assumes a second configuration wherein the teeth of the male part engage the inner notch in the female section so that the overall length of the lock component is reduced, wherein the reduction in length of the tumbler is irreversible.
[0045] Optionally, the tumbler has a plurality of inner notches and may assume a plurality of reduced lengths.
[0046] Optionally, the male and female parts each have a flat surface parallel to the keyway and beveled edges around said flat surfaces.
[0047] Alternatively, at least one of the male and female parts has a domed end.
[0048] In some embodiments, the tumbler further comprises an inner pin having a length equal to the combined length of the interlocked male and female parts when the teeth of the male part engage the inner notch of the female part and the lock component is compacted.
[0049] Typically, the radially extending bore further includes a driver, a spring and a plug.
[0050] Optionally, the radially extending bore further comprises a filling disk such that the filling disk and the inner pin have a combined length equal to the combined length of the male and female parts when the teeth of the male part engage the outer notch of the female part and the lock component is not compacted, but on compacting, the filling disk is expelled out of the lock component into the bore.
[0051] The method of changing the key comprises inserting a key having at least one shallow dimple corresponding to a tumbler having a first lock component into the keyway and rotating the key to compact the first lock component, thereby ejecting the filling disk into the bore, such that on rotating the cylinder through the preset angle, the filling disk is transferred to the socket.
BRIEF DESCRIPTION OF FIGURES
[0052] For a better understanding of the invention and to show how it may be carried into effect, reference will now be made, purely by way of example, to the accompanying drawings.
[0053] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only, and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention; the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice. In the accompanying drawings:
[0054] FIG. 1 is a schematic representation of a lock housing or stator, having a pair of cylinders, each within a barrel, and corresponding keys.
[0055] FIG. 2 is a sectional view of a compactable tumbler in its extended state;
[0056] FIG. 3 is a sectional view of the compactable tumbler of FIG. 2 in a compacted state;
[0057] FIG. 4 is a sectional view of a lock showing a cylinder (also known as rotor, or plug) in the barrel of a stator (housing), and a tumbler system that includes the compactable tumbler. Also shown is part of a key in the keyway, such that a dimple is aligned with the compactable tumbler and receives the end of the compactable lock element, resulting in the cylinder being able to turn within the barrel;
[0058] FIG. 5 shows a sectional view of the lock of FIG. 4 , wherein a key with a shallow dimple is inserted into the keyway, causing the compactable tumbler to extend into the bore within the stator of the lock;
[0059] FIG. 6 shows a modified compactable tumbler its extended state, the modified tumbler having an inner pin. Also shown is a filling disk;
[0060] FIG. 7 shows the modified compactable tumbler of FIG. 6 , in its compacted state, ejecting the filling disk;
[0061] FIG. 8 shows the modified compactable tumbler of FIG. 7 within the cylinder of a lock, with a key in the keyway, the key having a shallow dimple, such that the filling disk is transferred from the compactable tumbler to the bore extending into the barrel, and remains within the barrel as the cylinder is turned by the key;
[0062] FIG. 9 is a section through a lock and key showing the modified compactable tumbler in its non-compacted state with the filing disk within the tumbler, with a key having a deep dimple, and
[0063] FIG. 10 is a section through a lock and key showing the modified compactable tumbler in its compacted state, with a key having a deep dimple causing the modified compactable tumbler to compact, ejecting the filling disk from the modified compacted tumbler into the bore.
DESCRIPTION OF EMBODIMENTS
[0064] With reference to FIG. 1 , a cylinder block 2 is shown. The cylinder block 2 contains a pair of cylinder plugs 3 that each rotate within a barrel 4 . There is a keyway 6 within the cylinder plug for a key. The barrel 4 is part of the stator 5 . Rotating the key 8 causes the cylinder plug 3 to rotate within the barrel 4 and to turn a transmission element 9 that transfers the torque of the key to retract the latch or bolt of the lock (not shown).
[0065] Within the stator 5 or housing, are various bores that include pin like elements known as tumblers and driver pins. The key aligns the tumblers pins and drivers such that the joining edges thereof are aligned with the shear line between the cylinder and the barrel, allowing the cylinder plug 3 to rotate.
[0066] The present invention is directed to a novel type of lock component, known hereinbelow as a compactable tumbler.
[0067] With reference to FIG. 2 a sectional view of a compactable tumbler 10 1 is shown. Tumbler 10 1 is generally cylindrically shaped, and so its section, as shown is generally rectangular. Tumbler 10 1 consists of a first element 12 and a second element 14 coupled around a spring 16 . One of the first element 12 and the second element 14 is provided with teeth 18 that engage a notch 20 in the other of the first element 12 and the second element 14 . As shown, the lower element 14 is provided with teeth 18 and the upper element 12 is provided with a notch 20 . It will be appreciated however, that compactable tumbler 10 1 is reversible, and the male element 14 with the teeth 18 may be provided on the top, and the female element 12 with the notch 20 may be provided on the bottom. As shown, the base 24 of the bottom element 14 is flat, and it is provided with a beveled edge 22 . Similarly, the top element 12 has a flat base 24 ′ surrounded with a beveled edge 22 ′. Alternatively, one or more of the flat base and beveled edge may be replaced with domed ends.
[0068] The overall length of the compactable tumbler 10 1 shown in FIG. 2 , is X 1 . On application of a compressive force to the compactable tumbler 10 1 , distal component 12 is rammed into proximal component 14 , and teeth 18 engage a second notch 26 . The compactable tumbler 10 1 then assumes a compacted configuration 10 2 shown in FIG. 3 , and has an overall length X 2 such that X 2 <X 1 .
[0069] Although shown with male, toothed component 14 on the lower element, and a female component 12 with notches 20 , 26 as the upper element, it will be appreciated that compactable tumbler 10 1 may be inserted into a bore such that either element 12 , 14 is proximal to the keyway. The male, toothed component 14 and its teeth 18 are generally fabricated from a resilient material, typically a metal or alloy such as brass, but possibly a ceramic or plastic having an appropriate degree of stiffness and resilience. The distal surface of the teeth 18 are beveled but the upper surface of the teeth 18 are flat. This configuration enables the teeth 18 to deform under compacting pressure so that they disengage an outer notch 20 and then engage an inner notch 26 such that the overall length of the tumbler is reduced. This reduction is irreversible. The shape of the teeth do not allow the shortened tumblers to revert to their extended non compacted configurations. In some embodiments, not shown, there are more than one inner notches 26 . In such embodiments, the tumbler may assume more than one compacted length.
[0070] Unlike the components in prior art DE 202004015051 and European patent number EP0763639 described hereinabove, which describe compressible tumblers, the compactable lock component 10 1 is designed such that application of a compacting force causes the overall length of the compactable tumbler 10 1 to change, such that the tumbler assumes a shortened configuration and is locked into this configuration. The distal component 12 and proximal component 14 may be fabricated from any suitable resilient metal, such as brass, for example, where the Young's modulus enables the teeth 18 to be bent inwards slightly to allow the pin to be compacted, but on compaction, the teeth 18 spring out into the inner notch 26 , and lock in place.
[0071] With reference to FIG. 4 , a section through a lock 28 showing a cylinder or cylinder 32 in the barrel 34 of a stator (housing) 35 , and a bore 37 that includes a tumbler 10 1 within the cylinder part, a distal driver pin 36 substantially within the part of the bore extending into the stator, a resilient spring 38 and a plug 40 . to enable the cylinder to turn within the barrel, the tumbler and driver pin must be aligned such that the connecting edge between them is at the shear line between the cylinder and barrel.
[0072] Also shown is part of a key 30 in the keyway 31 , such that a dimple A is aligned with the compactable lock element 10 1 and receives one end 24 of the compactable tumbler 10 1 . The length X 1 of the compactable tumbler 10 1 is such, that the other end 24 ′ of the compactable tumbler 10 1 is aligned with the shear line, i.e. the join between cylinder 32 and barrel 34 , with the distal lock element, i.e. the driver pin 36 is wholly within the housing 35 . The retaining spring 38 is held in place by the plug 40 and supports the compactable tumbler 10 1 and driver pin 36 , such that the compactable tumbler 10 1 is pushed against the key 30 . The dimple A in key 30 is aligned with the compactable driver 10 1 and receives one end 24 of the compactable driver 10 1 , resulting in the tumbler 10 1 lying completely within the cylinder 32 , and since neither tumbler 10 1 nor driver 36 span across the shear line, i.e. the outer edge of the cylinder 40 , the cylinder 40 is able to turn within the barrel 34 .
[0073] With reference to FIG. 5 , a section through the lock 28 is shown, mutatis mutantis, wherein a key 30 ′ having a shallower dimple B is provided. Consequently, the proximal end 24 of the compactable tumbler 10 1 does not sit so high up in the keyway 31 , and the distal end 24 ′ of the compactable tumbler 10 1 protrudes beyond the cylinder 32 into the barrel 34 of the stator, pushing the distal driver pin 36 against the compressed spring 38 supported by the plug 40 .
[0074] In FIG. 5 , due to the shallower dimple B of key 30 ′ not allowing the proximal end 24 of the compactable tumbler 10 1 to sit so highly in the keyway 31 , the distal end 24 ′ of the compactable tumbler 10 1 extends beyond the cylinder 32 , into the cylinder block 34 . Consequently, the cylinder 32 is prevented from rotating in barrel 34 by the protruding distal end 24 ′ of the compactable tumbler 10 1 .
[0075] With reference to FIG. 6 , a modification of compactable tumbler 10 1 is shown. Modified compactable tumbler 110 1 consists of an upper part 112 and a lower part 114 that are coupled together around a compressed spring 116 . One of the upper part 112 and lower part 114 is provided with teeth 118 and the other of upper part 112 and lower part 114 is provided with a notch 120 . The teeth 118 engage notch 120 . As shown, the teeth 118 are provided as integral with lower part 114 and the notch 120 with the upper part 112 , i.e. the lower part 114 is the male part and the upper part 112 is the female part. It will be appreciated, however, that the teeth 118 could be provided on the upper part 112 , and the notch 120 on the lower part 114 .
[0076] Modified compactable tumbler 110 1 is an outer pin or sleeve, having an inner pin 125 or insert. Inner pin 125 is shorter than modified compactable tumbler 110 1 and a filling disk 127 is provided.
[0077] With reference to FIG. 7 , the modified compactable tumbler 110 is shown in its compacted state 110 2 . The lower part 114 is squeezed into the upper part 112 such that teeth 118 of lower part 114 engage an inner notch 122 on the upper part 112 . Thus modified compactable lock element 110 in its compacted state 110 2 is shorter than in its non compacted state 110 1 . Overall length of compacted modified compactable tumbler 110 2 is the same as the length of the inner pin 125 , so squeezing the compactable tumbler 110 1 ejects the filling disk 127 .
[0078] With reference to FIG. 8 , if a key 30 ′ with a shallow dimple B is inserted into key way 31 of the modified compactable tumbler 110 and rotated slightly, the beveled edge 22 of the lower section 114 presses against the barrel 34 , and the lower section 114 is pushed into the upper section 12 , such that the compactable tumbler 110 moves from its non compacted state 110 1 to its compacted state 110 2 , with teeth 118 engaging inner notch 122 .
[0079] In this manner, with reference to FIG. 9 , the lock with compactable tumbler 110 1 is compatible with a key 30 with a deep dimple A, and can be used to open and close the lock in a normal fashion. However, referring to FIG. 10 , if a key 30 ′ with a shallow dimple B is inserted in the keyway 31 , the filling disk 127 is ejected into the bore, and rotating the key causes the compactable tumbler 110 1 to compact, assuming the compacted configuration 110 2 . Rotating the key 30 through 180° rotates the cylinder 32 through an appropriate preset angle, such as 180° which is the angle shown, and brings a socket 50 into alignment with the bore 37 of the tumbler. The compressed spring 38 forces the filling disk 127 into the socket 50 .
[0080] In this manner, the tumbler of the lock 28 shown is reconfigured from one that is openable by a deep dimple A, to one that may be opened by a shallow dimple B. In other words, the key that opens the lock 28 is changed.
[0081] It will be appreciated that a lock may have any number of tumbler assemblies and typically has from 2 to 10 tumbler assemblies, each in its own bore. Any or all of these may be configured with a compactable tumbler 110 1 that enables the key required to open the lock to be changed.
[0082] Thus the lock and key combination of a lock including one or more compactable tumblers 110 1 may be changed one or more times by changing the key and turning it, without requiring additional tools, or specialist lock skills, simply by changing the key.
[0083] Although described for a dimpled key, it will be appreciated that the compactable lock element described hereinabove and the corresponding method of changing the lock and cylinder combination may be adapted for a jagged flat key or for a key with a cylindrical shaft.
[0084] Several embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
[0085] Thus persons skilled in the art will appreciate that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention is defined by the appended claims and includes both combinations and sub combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
[0086] In the claims, the word “comprise”, and variations thereof such as “comprises”, “comprising” and the like indicate that the components listed are included, but not generally to the exclusion of other components. | A tumbler for positioning in a bore perpendicular to a keyway in a lock for selectively engaging a feature of a key within the keyway, said tumbler comprising a male part that interlocks with a female part about a compressed spring; the male part having retaining teeth for selectively engaging an inner notch or an outer notch of the female part, such that when said retaining teeth engage the outer notch, the tumbler has a first configuration with an uncompressed overall length and on compression assumes a second configuration wherein the teeth of the male part engage the inner notch in the female section so that the overall length of the lock component is reduced, the change being irreversible. | 4 |
This is a divisional of co-pending application Ser. No. 716,853 filed on Mar. 28, 1985 and now U.S. Pat. No. 4,973,209.
BACKGROUND OF THE INVENTION
This invention relates generally to locking screws, and more particularly to a screw for use with a pre-tapped mating nut or other threaded hole and wherein good resistance to vibrational loosening is required.
The present invention is particularly applicable to a screw for use with a pre-tapped nut or like threaded member and wherein the pre-tapped thread is likely to be partially coated with paint or other contaminants. Permanently attached nuts on automobiles or other vehicles or tapped holes for containers are typical examples of the pre-tapped threads which are likely to be contaminated and with which the screw of the present invention is intended to be used.
Various types of screws are known for use with pre-tapped holes. Generally speaking those screws have a substantially circular cross-section and are free running provided the nut threads are clean. If resistance to vibrational loosening is required these screws of circular cross-sections can be modified by the addition of plastic (such as nylon) or other non-metallic patches over a portion of their length. If the pre-tapped nut or female thread is contaminated with paint or other hardened material, difficulty is sometimes encountered in using screws of the type which are of a circular cross-section with or without the addition of non-metallic or plastic patches.
Another known type of screw for use with a pre-tapped hole has a trilobular cross-section but wherein the thread includes a double angle profile. In this type of thread profile the flanks of the thread from the root of the thread outwardly past the pitch circle are at the normal flank angle. However, at the crest portion of the thread the flank angle is reduced which causes an interference between the thread on the screw and the thread in the hole. For example, in one known arrangement the flanks are at the normal 60 degree angle from the root of the thread outwardly a certain distance past the pitch circle, but at the crest region of the thread, the flank angle is about 30 degrees. In a trilobular screw of the type having the 60 degree-30 degree double angle profile the screw creates a resistance to vibrational loosening.
Also known are several types of screws designed for removing female thread contamination as they are inserted. However, none of these screws are intended to provide a locking arrangement which resists vibrational loosening.
In another known arrangement an otherwise known trilobular screw was modified by having its entry portion almost triangular in configuration. It was intended that the triangular entry portion would create a scraping effect while at the same time providing a clearance space for contaminants scraped off of the female thread. Such an arrangement was found to be successful in cases where there were small amounts of fairly soft contamination material. In recent years, however, automobile paints have become much harder and much thicker in order to protect the vehicle against corrosion. Where the threaded hole is contaminated by such coatings and a locking screw of the double angle type is used, the extra surface pressures generated by the hard contaminants can cause excessive and objectionable noise levels as the screws are driven into the contaminated holes. Moreover, the contaminant adversely effects the torque-tension relationships in driving the screw into the hole, and in extreme cases might possibly cause failure of the screw.
OBJECTS AND SUMMARY OF THE INVENTION
An object of this invention is to provide an improved screw for the use stated and which will eliminate or significantly reduce the installation noise levels.
It is a further object of this invention to provide a screw of the type stated that maintains a more constant torque-tension relationship while threading the screw into the workpiece.
It is yet another object of this invention to provide a screw of the type stated which will retain substantial vibration resistance when threaded into place even when the mating female threads are sufficiently contaminated by thick hard paint and like extraneous coatings.
In accordance with the invention there is provided a hardened steel screw, having a head at one end, a three-part entry portion at the other end, and a trilobular threaded shank portion between the head and the entry portion and extending from the entry portion toward the head. The threaded shank portion is characterized by a double-angle profile of the thread which is symmetrical about an axis perpendicular to the longitudinal axis of the screw, and by a helix angle equal to that of conventional circular-section machine screws. The threaded shank portion may extend from the entry portion to a position closely adjacent to the underside of the head, or it may terminate short of the head to provide an unthreaded shank portion of smaller diameter than the thread crest. Alternative features to the smaller diameter shank include a full diameter shank, equal to or slightly greater than the nominal screw diameter, and a spacing collar substantially larger than the nominal screw diameter. Furthermore, there could be a combination of such features, which may or may not be circular in cross-section.
There is preferably a single start thread which is raised slowly from the entry portion of the screw to the full diameter or load bearing thread diameter. Generally, the entry portion will comprise a circular section with a diameter approximately 75% to 80% of the nominal screw diameter. The circular section blends into a truncated crest trilobular tapered section in which the truncation varies through several thread turns from a maximum to zero, although not necessarily at a constant rate. The truncated section in turn eventually blends into a fully trilobular tapered section. Finally, the fully trilobular tapered section blends into a fully trilobular load bearing thread. By way of example but not of limitation, the overall length of the entry portion may be 2.5 to 3 times the nominal screw diameter. The taper of the tapered section may vary from about 15 degrees at the small end to about 5 degrees at the large end. The truncations provide for a progressive clearing action of the hard contaminated coating with the progressive action beginning at the tip of the thread and increasing as the tapered screw is inserted into the mating thread. Further clearing takes place as the screw is inserted further into the mating thread until the full diameter body portion of the screw is in the mating thread. The truncations or cut-outs, as they may be called, provide diametral clearance between the screw and the mating thread to collect debris (such as paint chips), removed by the clearing action.
Further in accordance with the present invention there is provided a locking screw having an elongated shank section with a central axis, said shank section having a thread with opposed flanks that comprise radially inner and outer portions, said inner portion having flanks each at a first angle to a line perpendicular to said axis and said outer portion having flanks at the thread crest, and each outer portion flank being at a second angle to said line, said second angle being smaller than said first angle, and a tip section at which the screw is initially inserted into a pre-tapped hole in which the thread is contaminated by a coating thereon; characterized by a tapered entry section intermediate said shank section and said tip section, said entry section comprising a thread with a lobular cross-sectional shape having circumferentially spaced lobes separated by intermediate arcuate sides, said entry section thread also being a continuation of the thread in said shank section and having truncations, said truncations forming indentations radially inwardly from the thread crest and with radial outer crest portions of the indentations constituting elements for engaging the coating and providing progressive action means commencing at the smaller end of the tapered entry section for clearing contaminating coating from said pre-tapped hole thread as the shank is threaded into said pre-tapped hole.
A further object of this invention is to provide the combination of a locking screw and a pre-tapped nut or threaded hole having the advantages as aforesaid.
A still further object of this invention is to provide a novel screw blank which can be thereafter rolled in threading dies to form the screw of the present invention.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a fragmentary elevational view of a screw blank constructed in accordance with and embodying the present invention;
FIG. 2 is an end elevational view as seen from the right hand side of FIG. 1;
FIG. 3 is an enlarged fragmentary sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a fragmentary elevational view of a roll-threaded screw formed in accordance with the present invention;
FIGS. 5, 6 and 7 are sectional views taken along lines 5--5, 6--6, and 7--7 respectively of FIG. 4;
FIG. 8 is an enlarged sectional view of a thread showing the thread profile in the load bearing or shank section of the screw;
FIG. 9 is a fragmentary sectional view showing a partially assembled screw and mating nut or other structure having a pre-tapped hole;
FIG. 10 is a fragmentary sectional view showing the screw fully assembled with the nut or other device having the pre-tapped hole; and
FIGS. 11, 12, and 13 show screws with various underhead features which may be utilized in connection with the present invention.
DETAILED DESCRIPTION
Referring now in more detail to the drawings there is shown a metal elongated blank 2, usually of low carbon steel, which is cropped from drawn lobular wire stock and then cold headed and otherwise reshaped in a desired manner. The blank 2 has a tip section 4 and remote therefrom a lobular shank section 6 corresponding to the general diameter of the headed blank. The lobular form on the shank section 6 may be of a known configuration, for example a trilobular form of uniform width throughout 360 degrees and having circumferentially spaced lobes 5 separated by arcuate sides 7 of longer radius than the radius of the lobes 5. A shank section 6 with a greater or lesser number of lobes may also be used. At one end of the shank section 6 is a conventional head 19.
Intermediate the cylindrical dog point or tip section 4 and the shank section 6 is an intermediate lobular section 8 which is generally tapered from the shank section 6 toward the tip section 4 and includes novel cutaways or surface regions 10. These surface regions 10 may be respectively aligned with the lobes 5 and may include adjacent surfaces 12, 14 which are generally planar and intersect along a line Y to form an obtuse angle. The line Y lies in a plane which is perpendicular to the central axis 16 of the screw blank. By way of example the angle of taper at the leading end of the surface 14, namely that end of the surface 14 adjacent to the tip section 4, is at a small angle B which may be of the order of 15 degrees. Furthermore, the angle A formed by the extension of the plane of the surface 14 with the surface 16 is approximately 10 degrees. The length of the surface 14, measured in a direction longitudinally of the blank, is approximately 3 pitches whereas the corresponding length of the surface 12 is approximately 1 pitch. The radial exent of the outer surface of the shank section 6 beyond the surface 14 is approximately 1/2 pitch, all as best shown in FIG. 3. The broken line L shows the normal configuration of a tapered lobular blank which does not include the cutaway regions 10. Also, as noted in FIGS. 1 and 3, the transverse dimension, i.e., the dimension parallel to the line Y of each surface 12, 14 decreases in a direction away from the line Y whereby the surface 14 is narrowest adjacent to the tip section 4 whereas the surface 12 is narrowest adjacent to the shank section 6. These novel cutaway portions 10 are utilized to form truncations in the finished screw, as will be hereinafter described
The blank 2 is roll threaded in a known manner to provide the screw shown in FIGS. 4-10. During the rolling action the blank is shaped to form a screw 20 with a cylindrical point or tip section 22, a tapered lobular truncated section 24, and a full width non-tapered lobular section 26, the later containing the holding or load bearing thread of the screw. The rolling action induces a taper in the lobular truncated section 24, the taper being toward the cylindrical point 22, and approaching the point 22 at an angle of approximately 15 degrees. The taper merges smoothly at a near zero degree angle at the junction of the section 24 and the section 26.
The rolling action of the dies results in a series of truncations 28 which extend over the first 4 to 6 pitches (approximately) and with the truncations being slightly indented as best shown in FIG. 6. These indentations form radially outer thread crest portions 29 which, when the screw is threaded into a mating thread, serve the clear progressively contaminated material in the mating thread.
Referring to FIG. 4 the truncations 28 are relatively small in circumferential extent adjacent to the point 22. In the direction from the point 22 toward the full width shank section 26 the truncations 28 increase progressively in width and circumferential extent up to a maximum and then decrease until the full thread section 26 is reached.
The thread on the shank section 26 is fully developed and has a profile shown in enlargement in FIG. 8. This thread is of a double angle form symmetrical about an axis perpendicular to the longitudinal axis of the screw. By way of example but not of limitation, the flanks 30, 30 of the thread may be at a conventional 60 degree angle from the root of the thread radially outwardly beyond the pitch circle but with the portion 32 of the thread at the crest region being at about 30 degrees to form an interference fit with a conventional nut 34 or threaded hole formed with an internal thread with flank angles of 60 degrees. As will be apparent the thread turns in the tapered lobular section 24 have substantially no developed 30 degree crest portion at those thread turns near the point 22; however, the crest portion becomes more fully developed as the thread turn approaches and merges with the full width shank portion 26.
FIG. 9 shows the screw 20 threaded partially into a workpiece 34, which may be a nut, threaded hole, or the like. During the threading action the truncations serve to remove hardened contaminated coating from the internal thrad on the workpiece 34. At the same time the presence of the novel truncations tends to reduce installation noise level and maintains a more consistent torque-tension relationship during installation of the screw. Moreover, the interference fit between the crest portions 34 of the screw thread and the normal thread configuration of the nut 34 provides a locking action which resist vibrational loosening of the screw.
FIGS. 11, 12 and 13 show different applications of the invention. In FIG. 11 the thread on the shank section 26 extends up to the screw head 40. In FIG. 12 the screw shown has an unthreaded portion 42 between the threaded portion or shank 26 and the head 50. The diameter of the unthreaded portion 42 is less than the crest diameter of the threaded portion 26. However, the unthreaded portion 42 may be substantially equal in diameter or width to the crest diameter of the section 26 or it may be greater than the same. Moreover, the unthreaded section 42 may be of other cross-sectional shapes, for instance circular. In FIG. 13 the screw is similar to that of FIG. 12 except that an enlarged cylindrical section 60 is formed beneath the head to provide a shoulder 62. | A locking screw having a head at one end, a special entry portion at the other end, and a trilobular shank portion extending from the entry portion toward the head. The screw is further characterized in that the thread profile is of a double angle configuration symmetrical about an axis perpendicular to the longitudinal axis of the screw. The entry section is tapered and is formed with a series of truncations which serve to clear progressively a contaminating coating in an internally threaded workpiece, such as a nut, when the screw is threaded therein. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] NON-APPLICABLE
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] NON-APPLICABLE
BACKGROUND OF THE INVENTION
[0003] The 3-d panel cannot just be placed on the roof and covered with 1.5 inch of concrete. The panels are stiff, but they are too weak to be treated like this. It is easy to see why:
[0004] 56 Square feet of a 14 foot by 4 foot panel
[0005] 8064 Square inches in this panel
[0006] 12096 Cubic inches of concrete at 14 feet by 4 feet by 1.5 inches
[0007] 0.087 Weight of 1 cubic inch of concrete at 150 pounds per cubic foot.
[0008] 1050 Weight of 1.5 inches concrete on a 14 foot by 4-foot panel.
[0009] There is just no way an unsupported, un-reinforced panel can hold a half ton of concrete in a straight configuration, or, indeed, to hold it at all. The panel will buckle and collapse before the 1.5-inch pour is completed. But 3-d panels can be used as a concrete covered roof. Placing the lightweight panels, of course, is no problem. Spraying the roof with concrete can to be successfully done in two different ways:
[0010] The fast expensive way is using 2×4 roof jacks with a 46″ cross T at the top. These are placed under each roof panel, (at considerable cost and labor), and set 3 feet apart down the length of the panel.
BRIEF SUMMARY OF THE INVENTION
[0011] Spraying the roof with concrete can to be successfully done in two different ways:
[0012] The fast expensive way is using 2×4 roof jacks with a 46″ cross T at the top.
[0013] These are placed under each roof panel, (at considerable cost and labor), and set 3 feet apart down the length of the panel, Or the very slow inexpensive way is to support the panel by putting concrete beams on top.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The 3-d panel cannot just be placed on the roof and covered with 1.5 inch of concrete. The panels are stiff, but they are too weak to be treated like this. It is easy to see why:
[0015] 56 Square feet of a 14 foot by 4 foot panel
[0016] 8064 Square inches in this panel
[0017] 12096 Cubic inches of concrete at 14 feet by 4 feet by 1.5 inches
[0018] 0.087 Weight of 1 cubic inch of concrete at 150 pounds per cubic foot.
[0019] 1050 Weight of 1.5 inches concrete on a 14 foot by 4-foot panel.
[0020] There is just no way an unsupported, un-reinforced panel can hold a half ton of concrete in a straight configuration, or, indeed, to hold it at all. The panel will buckle and collapse before the 1.5-inch pour is completed. But 3-d panels can be used as a concrete covered roof. Placing the lightweight panels, of course, is no problem. Spraying the roof with concrete can to be successfully done in two different ways:
[0021] The fast expensive way is using 2×4 roof jacks with a 46″ cross T at the top. These are placed under each roof panel, (at considerable cost and labor), and set 3 feet apart down the length of the panel.
[0022] The very slow inexpensive way is to support the panel by putting concrete beams on the top. This seems insane at first glance, but it works very well. While the panel is on a flat surface on the ground, lay two 1 inch by 4 inch planks down the length of the panel, one inch apart. That is to say, leave a 1-inch gap between the planks. Position the planks so that the center of the gap is 6 inches from one side of the panel. The best way to hold the planks in position is with sealed plastic bags containing 25 pounds of sand. Now lay two more planks lengthwise with a 1-inch gap. Position the new planks so that the gap center is one foot from the gap center of the first two. Place 25 pound sand filled plastic bags the hold the new planks. Repeat this with two more planks, and then two more for a total of eight planks, producing four gaps one foot apart. The last two planks should end like the first two started, with the center of the gap 6 inches from the panel edge. When you have the eight planks held firmly on the panel, press high slump, high grade grout into the gaps. leaving no spaces or voids. When you pull the forms away the grout will stick up in the air % inch above the panel. These concrete beams give the panel great strength, but is still light enough to handle and pick up for placement on the roof. The problem with this technique is that it is so slow. You will need to wait until the beams gain strength, a week to ten days. You then must cast the roof in four stages, filling a fourth of the roof area at a time and waiting a week between each cast. The advantage is that it is very low skill and very cheap. You do not need to use floor jacks with these concrete strips. They will hold the weight of one fourth of the wet concrete. As each part is cast, the holding strength is increased. | The usefulness of this invention is based on the building roof construction options it gives:
1. Very slow (three weeks) but very cheap; unskilled hand labor
2. Very fast (one Day) but very expensive, placing timber floor jacks every square yard.
With this invention those without money can still build houses. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of digital image processing, and in particular to image registration.
BACKGROUND OF THE INVENTION
[0002] Medical imaging diagnostics has been a growing area of research in the past several decades. In many cases, image fusion, or the combination of multiple associated images to form a composite image integrating the data therefrom is often desirable in a clinical setting. The first step in combining multiple associated images involves a spatial alignment of these images, a process known as image registration. Image registration is the act of spatially mapping the coordinate system of one image to the coordinate system of another image.
[0003] WO Patent application No. 02/23477 A2, assigned to Zhu, Yang-Ming and Cochoff, Steven M., and incorporated herein by reference, teaches a method of image registration by employing a registration processor to calculate a statistical measure of likelihood for two volumetric images based on an assumption that the images are probabilistically related. The likelihood is calculated using mutation probabilities (either calculated from prior knowledge of the image relationship or estimated purely from the image data) for some or all voxel pairs in the overlapping volume. The likelihood is calculated for a plurality of transformations in iterative fashion until a transformation that maximizes the likelihood is found. The transformation that maximizes likelihood provides an optimal registration of the two images.
[0004] U.S. Pat. No. 6,343,143 B1, assigned to Regis Guillemaud and Sebastien Durbec, and incorporated herein by reference, teaches a method of image registration that consists of breaking down each of the images into space components representing the distribution of the gray levels of the image, applying a phase registration method to the components to bring about a correspondence between the components of one image with those of the other image, summating all the results of the bringing into correspondence and detecting, in the image resulting from said sum, the maximum gray level defining the transformation between the two initial images.
[0005] P. Viola and W. M. Wells III teach a method (see “Alignment by maximization of mutual information,” in the proceedings of International Conference on Computer Vision, pp. 16-23, IEEE Computer Society Press, Los Alamitos, Calif., 1995, http://citeseer.nj.nec.com/cache/papers/cs/17410/ftp:zSzzSzftp.ai.mit.eduzSzpubz SzuserszSzswzSzpaperszSziccv-95.pdf/viola95alignment.pdf) that aligns two images by adjustment of the relative pose until the mutual information between the two images is maximized.
[0006] A drawback of the above methods is that the dependence of the gray values of neighboring voxels is ignored. The assumption of independence does not hold in general. Incorporating the dependence of the gray values of neighboring voxels, i.e., the spatial information of a voxel, could improve registration.
[0007] J. P. Pluim, J. B. Maintz, and M. A. Viergever teach a method (see “Image Registration by Maximization of Combined Mutual Information and Gradient Information,” IEEE Transactions on Medical Imaging, vol. 19, no. 8, pp. 809-814, 2000, http://www.isi.uu.nl/People/Josien/Papers/Pluim_TMI_19 — 8.pdf) that incorporates gradient information of the involved images into the registration process using the mutual information technique. This method requires separate gradient images (information) in addition to intensity images. It would be desirable to include spatial information of a voxel within the mutual information technology without the need for separate gradient images.
[0008] There is a need therefore for an improved image registration method that overcomes the problems set forth above.
[0009] These and other aspects, objects, features and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings.
SUMMARY OF THE INVENTION
[0010] The need is met according to the present invention by proving a digital image processing method for image registration that includes the steps of: (a) acquiring a reference intensity image and a floating intensity image that is to be registered; (b) preprocessing the reference and the floating images; (c) converting the preprocessed reference image to a vectorized reference image; (d) converting the vectorized reference image to a reference index image; (e) spatially transforming the preprocessed floating image using a transformation matrix; (f) converting the transformed floating image to a vectorized floating image; (g) converting the vectorized floating image to a floating index image; (h) obtaining joint statistics of the index images; (i) computing a cost function due to misalignment of the two images using the joint statistics; and j) updating the transformation matrix and repeating steps (e), (f), (g), (h), and (i) if the cost function does not satisfy a predefined criterion, otherwise, applying the transformation matrix to acquired floating intensity image.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective diagram of a computer system for implementing the present invention.
[0012] FIG. 2A is a flowchart illustrating the image registration method of the present invention.
[0013] FIG. 2B is a flowchart illustrating a method of updating a transformation matrix for image registration.
[0014] FIG. 3 is an illustration of a reference image.
[0015] FIG. 4 is an illustration of a floating image.
[0016] FIG. 5 is an illustration of neighborhood regions.
[0017] FIG. 6 is an illustration of a registered floating image.
DETAILED DESCRIPTION OF THE INVENTION
[0018] FIG. 1 shows an image processing system useful in practicing the present invention. Said system includes a digital image source 100 , such as an MRI machine (not shown), a CT scanner (not shown), or a digital image storage device (such as a compact disk drive with a Picture CD). The digital image from the digital image source 100 is provided to an image processor 102 , such as a programmable personal computer, or digital image processing work station such as a Sun Sparc workstation. The image processor 102 may be connected to a CRT display 104 , an operator interface such as a keyboard 106 , and a mouse 108 . Image processor 102 is also connected to computer readable storage medium 107 . The image processor 102 transmits processed digital images to an output device 109 . Output device 109 can comprise a hard copy printer, a long-term image storage device, a connection to another processor, or an image telecommunication device connected, for example, to the Internet.
[0019] In the following description, one embodiment of the present invention will be described as a method. However, in another embodiment, the present invention comprises a computer program product for registering two images in accordance with the method described. In describing the present invention, it should be apparent that the computer program of the present invention could be utilized by any well-known computer system, such as the personal computer of the type shown in FIG. 1 . However, many other types of computer systems can be used to execute the computer program of the present invention. Consequently, the computer system will not be discussed in further detail herein.
[0020] It will be understood that the computer program product of the present invention may make use of image manipulation algorithms and processes that are well known. Accordingly, the present description will be directed in particular to those algorithms and processes forming part of, or cooperating more directly with, the method of the present invention. Thus, it will be understood that the computer program product embodiment of the present invention may embody algorithms and processes not specifically shown or described herein that are useful for implementation. Such algorithms and processes are conventional and within the ordinary skill in such arts.
[0021] Other aspects of such algorithms and systems, and hardware and/or software for producing and otherwise processing the images involved or cooperating with the computer program product of the present invention, are not specifically shown or described herein and may be selected from such algorithms, systems, hardware, components, and elements known in the art.
[0022] The computer program for performing the method of the present invention may be stored in a computer readable storage medium. This medium may comprise, for example: magnetic storage media such as a magnetic disk (such as a hard drive or a floppy disk) or magnetic tape; optical storage media such as an optical disc, optical tape, or machine readable bar code; solid state electronic storage devices such as random access memory (RAM), or read only memory (ROM); or any other physical device or medium employed to store a computer program. The computer program for performing the method of the present invention may also be stored on computer readable storage medium that is connected to the image processor by way of the Internet or other communication medium. Those skilled in the art will readily recognize that the equivalent of such a computer program product may also be constructed in hardware.
[0023] Referring to FIG. 2A , the method of the present invention will now be outlined. FIG. 2A is a flowchart illustrating an embodiment of the image registration method of the present invention. Given two images to be registered, one image is denoted as a reference image 202 and the other as a floating image 204 , as shown in FIG. 2A . An exemplary reference image 302 is shown in FIG. 3 . An exemplary floating image 402 is shown in FIG. 4 . The floating image is to be spatially transformed until it is aligned spatially with the reference image for the two images to be superimposed. Both the reference intensity image 202 and the floating intensity image 204 are first preprocessed in step 210 . In the embodiment of the image registration method of the present invention shown in FIG. 2A , a preferred preprocess is an image normalization step. The normalization step is useful for the present invention when the reference image 202 (exemplary reference image 302 in FIG. 3 ) and the floating image 204 (exemplary floating image 402 in FIG. 4 ) come from different imaging modalities, for example, MRI and CT. People skilled in the art will understand that the normalization operation in the preprocess can be skipped, and a similar operation can be carried out in subsequent steps to have equivalent effect. People skilled in the art will also recognize that other operations such as noise reduction, histogram equalization, edge preserving filtering, etc. can be included in the preprocessing 210 .
[0024] A drawback of the conventional image registration methods such as those using mutual information is that the dependence of the intensity values of neighboring pixels is ignored. This assumption of independence does not hold in general. Incorporating the dependence of the intensity values of neighboring pixels, i.e., the spatial information of a pixel, could improve registration. Therefore, in the present invention, the preprocessed reference image 206 and the preprocessed floating image 208 are converted to a reference vector image 214 and a floating vector image 216 , respectively, through a step of Converting to a Spatially Vectorized Image 212 . This conversion involves the neighborhood of pixels around each pixel. The intensities in the neighborhood are transformed into a 1-D vector. A U×V neighborhood window is centered at the pixel to be converted. The 1-D vector of intensities then replaces said pixel. Now, the new pixel contains spatial (structural) information of the local surrounding region. An exemplary method of transforming the intensities in the neighborhood into a 1-D vector could be a raster scanning row by row of the neighborhood pixels. People skilled in the art are capable of using other more sophisticated transforming methods such as a rotationally invariant transformation.
[0025] After step 212 , the original image is defined in a vector space. It is convenient to represent the vector space by a set of numbers, for example, indices. Each vector in the vector space is assigned to a single value (index). This is done in step 218 of Converting to an Index Image, resulting in a reference index image 222 and a floating index image 224 .
[0026] A preferred method for converting the vector images 214 and 216 to index images 222 and 224 is the well-known method of vector quantization (see http://www.geocities.com/mohamedgasem/vectorquantization/vq.html).
[0027] Vector quantization (VQ) is the process of reducing a family of vectors by mapping M k-dimensional vectors in the vector space R k into a set of N k-dimensional vectors where M>N. The collection of N vectors is known as the codebook, and the elements of the codebook are known as codewords. A vector in R k is associated with a vector in the codebook using a minimum Euclidean distance measure. Formally stated, given a codebook Y
∀ y i ε Y, i=1, 2, . . . , N
there exists a Voronoi region V i such that
V i ={x ε R k :∥x−y i ∥≦∥x−y j ∥, ∀ j≠i}
The set of Voronoi regions partition the entire space R k such that:
⋃ i = 1 N V i = R k and ⋂ i = 1 N V i = ∅
The entire process is essentially similar to “rounding off” to the nearest integer.
[0028] The design of the codebook that best represents a set of input vectors is a NP-hard problem. An exhaustive search is required for the best possible set of codewords in a space, and the search increases exponentially as the number of codewords and vector dimensions increases. This difficulty leads to the use of techniques that are simple to implement even though they yield sub-optimal solutions. One such technique is called the LBG algorithm, named after its authors Linde, Buzo, and Gray (see “An Algorithm for Vector Quantizer Design,” IEEE Trans. Communication, COM28 (1), pp. 84-95, January 1980). The algorithm is stated below:
1.) Determine the number of codewords, N. 2.) Select N codewords at random, and let that be the initial codebook that contains the codewords. 3.) Use the Euclidean distance measure to cluster the vectors around each codeword. 4.) Compute the new set of codewords by obtaining the average of each cluster. 5.) Repeat steps 2 and 3 until either the codewords do not change or the change in the codewords is small.
Pre-selected sample images are used to generate the codebook. An exemplary sample image is the reference image 302 shown in FIG. 3 . A vector is formed by obtaining the U×V (e.g., 9×9) neighborhood for each image pixel. Examples of 8×8 exemplary neighborhoods 502 are shown in FIG. 5 . Vectors formed from sample images are used to train the codewords by iterating the LBG algorithm until the codewords converge.
[0034] The above technique is adopted to generate vector indices 220 , which are representatives of the codewords. Exemplary representatives are integers.
[0035] The reference index image 222 and floating index image 224 are used in the subsequent steps 226 , 228 , 230 in FIG. 2A to complete the registration (alignment) process. Common steps to align two images are:
1) Choose a cost function that will determine the degree of misalignment between the reference image and the spatially transformed floating image. Also, choose a stopping point (satisfied minimum cost) that indicates the images are aligned (registered). 2) Optimize the transformation on the floating image such that the stopping point (satisfied minimum cost) is met.
[0038] Registration (alignment) methods such as cross-correlation and mutual information are some of the more commonly used techniques found in the literature. Correlation techniques perform well in mono-modal registration wherein there is a linear relationship between the measurements for the same spatial elements in the two images. However, because of the non-linear relationship that can arise between the intensities of images across different modalities, correlation has been shown generally not to be a suitable candidate for a cost function in multi-modal image registration. A much more suitable cost function is mutual information, which is a statistical measure that assesses the strength of dependence between two stochastic variables. Since its introduction in 1995 by Viola and Wells, mutual information has been one of the most widely acclaimed registration measures for multi-modal image registration. Therefore, mutual information is currently selected as a preferred cost function for the present invention.
[0039] Mutual information (MI) as a statistical measure finds its roots in information theory. Mutual information is a measure of how much information one random variable contains about another. The MI of two random variables A and B is defined as
I ( A , B ) = ∑ a , b p A , B ( a , b ) log p A , B ( a , b ) p A ( a ) · p B ( b ) ( 1 )
where p A.B (a, b) is the joint probability distribution function (pdf) of the random variables A and B, and P A (a) and p B (b) are the marginal probability distribution functions for A and B, respectively.
[0040] The mutual information can also be written in terms of the marginal and joint entropy of the random variables A and B as follows
I ( A, B )= H ( A )+ H ( B )− H ( A, B ) (2)
where H(A) and H(B) are the entropies of A and B, respectively, and H(A, B) is the joint entropy between the two random variables. They are defined as
H ( A ) = - ∑ a p A ( A ) log p A ( A ) ( 3 ) H ( A , B ) = - ∑ a , b p A , B ( a , b ) log p A , B ( a , b ) ( 4 )
One interpretation of entropy is as a measure of uncertainty of a random variable. A distribution with only a few large probabilities has a low entropy value; the maximum entropy value is reached for a uniform distribution. The entropy of an image indicates how difficult it is to predict the gray value of an arbitrary point in the image. MI is bounded by cases of either complete dependence or complete independence of A and B, yielding values of I=H and I=0, respectively, where H is the entropy of A or B.
[0041] In FIG. 2A , the reference index image 222 and floating index image 224 serve as the random variables A and B. In working with images, the functional form of the joint pdf is not readily accessible. Therefore, in a step of Computing a Joint Distribution Function using the index images 226 , a joint histogram of the values for each image ( 222 and 224 ) approximates the joint probability distribution function.
[0042] The strength of the mutual information similarity measure lies in the fact that no assumptions are made regarding the nature of the relationship between the image values in both modalities, except that such a relationship exists. This is not the case for correlation methods, which depend on a linear relationship between image intensities. For image registration, the assumption is that maximization of the MI is equivalent to correctly registering the images.
[0043] Maximizing the MI is equivalent to minimizing the joint entropy. The joint entropy is minimized when the joint pdf of A and B contains a few sharp peaks. This occurs when the images are correctly aligned. When the images are mis-registered, however, new combinations of intensity values from A and B will be aligned in the joint pdf, which cause dispersion in the distribution. This dispersion leads to a higher entropy value. Because a cost function must reach its minimum value when two images are aligned, a suitable cost function would be either joint entropy or negative mutual information. In a step of Computing a Cost Function for Misalignment of Reference and Floating Images 228 , the cost function (negative mutual information) of the two images to be aligned is computed. The alignment is an iterative process involving spatially transforming the floating image (see step 230 in FIG. 2A ) using, for example, rotation, translation or affine transformations. If the two images are not aligned, the cost function computed in step 228 does not reach its minimum or meet a predefined criterion. Then the alignment process performs spatial transformation on the floating image 208 and repeats steps 212 , 218 , 226 , and 228 . The output of step 230 is an Aligned floating intensity image 232 such as the exemplary registered (aligned) floating image 602 shown in FIG. 6 . Details of the registration alignment steps are given below.
[0044] Denote the reference image as R, and the floating image as F. The floating image F is transformed by some linear transformation until it is spatially aligned with the reference image R. Let T {right arrow over (α)} be the linear transformation with the parameter {right arrow over (α)}. The number of elements in {right arrow over (α)} determines the degrees of freedom. For this 2-D application, an affine transformation with six degrees of freedom is chosen as an exemplary transformation to perform the registration. The transformation is given as
F ′ = T α _ ( F ) or ( 5 ) [ x ′ y ′ 1 ] = [ a 11 a 12 t x a 21 a 22 t y 0 0 1 ] [ x y 1 ] ( 6 ) α _ = ⌊ a 11 a 12 a 21 a 22 t x t y ⌋ ( 7 )
where (x, y) are coordinates in the floating image F and (x′, y′) are coordinates in the transformed floating image F′. It is obvious that the selection of T {right arrow over (α)} is not restricted to the transformation matrix given in (6). Other transformation matrices can be used based on the assumptions made regarding the nature of the mis-registration.
[0045] For a given reference image R, a floating image F′, and a transformation T {right arrow over (α)} , the MI is calculated by
I ( R , F ′ , T α ) = ∑ m , f ′ p M , F ′ ( m , f ′ ) log p M , F ( m , f ′ ) p M ( m ) · p F ′ ( f ′ ) ( 8 )
where the transformation that correctly registers the images is given by
T {right arrow over (α)} reg =arg max I ( R, F′, T {right arrow over (α)} ) (9)
or
T {right arrow over (α)} reg =arg min− I ( R, F′, T {right arrow over (α)} ) (10)
[0046] The process of Equation (10) is illustrated in FIG. 2B . Equation (10) implies that the transformation matrix T {right arrow over (α)} is updated in step 205 shown in FIG. 2B in the minimization process by changing the parameter {right arrow over (α)}. The updated transformation matrix T {right arrow over (α)} is applied to floating image 208 in step 203 . New mutual information is then computed and evaluated (in steps 226 , 228 and 231 ). These steps are repeated until the cost function (−I) reaches a minimum (a query step 231 ). After a final transformation matrix T {right arrow over (α)} reg ( 233 ) is found, it is then applied to the floating image F ( 204 ) to produce F reg ′ . The reference image R and the registered floating image F reg ′ are compared to test how well the registration process performed.
[0047] The initial estimation step 201 in FIG. 2B for the transformation parameters of matrix T {right arrow over (α)} is made based on a rough alignment using principal component analysis. With this technique, the rotation is estimated by finding the difference between the principal component angles. The initial value of the translation in the x and y directions is estimated by comparing the center of gravity (COG) of the two images. The scale in the x and y directions is estimated by finding the width of the images along both principal axes. The ratios of these widths are calculated and used as scale approximations. Given the initial guess
{right arrow over (α)} o =└α 11 o α 12 o α 21 o α 22 o t x o t y o ┘ (11)
an optimization routine based on a simplex algorithm was used to find the maximum value of I (or the minimum value (minimum cost) of −I) for the transformation T {right arrow over (α)} as shown in (9) and (10). The MI given in (1) is calculated by generating a joint histogram based on the intensities of both the reference image R and the transformed floating image F′. Calculation of the MI based on this joint histogram can yield a function with spurious local minima. These local minima can be eliminated by utilizing a number of techniques, e.g., blurring the images before calculating I, blurring the joint histogram, or partial volume interpolation.
[0048] The specific algorithm (image registration using mutual information) disclosed in the preferred embodiment of the present invention may stand alone or may be a component of a larger system solution. Furthermore, the interfaces with the algorithm, e.g., the scanning or input, the digital processing, the display to a user (if needed), the input of user requests or processing instructions (if needed), the output, can each be on the same or different devices and physical locations, and communication between the devices and locations can be via public or private network connections, or media based communication. Where consistent with the foregoing disclosure of the present invention, the algorithm(s) themselves can be fully automatic, may have user input (be fully or partially manual), may have user or operator review to accept/reject the result, or may be assisted by metadata (metadata that may be user supplied, supplied by a measuring device (e.g. in an image capturing device), or determined by an algorithm). Moreover, the algorithm(s) may interface with a variety of workflow user interface schemes.
[0049] The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
PARTS LIST
[0000]
100 image source
102 image processor
104 image display
106 data and command entry device
107 computer readable storage medium
108 data and command control device
109 output device
201 a step
202 reference intensity image
203 a step
204 floating intensity image
205 a step
206 preprocessed reference image
208 preprocessed floating image
210 a step
212 a step
214 reference vector image
216 floating vector image
218 a step
220 trained vector indices
222 reference index image
224 floating index image
226 a step
228 a step
230 a step
231 a query
232 aligned floating intensity image
233 a final transformation matrix
302 an image
402 an image
502 images
602 an image | A digital image processing method for image registration, that acquires a reference intensity image and a floating intensity image that is to be registered; and preprocesses the reference and the floating images, before converting the preprocessed reference image to a vectorized reference image. Subsequently, the vectorized reference image is converted to a reference index image. Additional image processing includes spatially transforming the preprocessed floating image using a transformation matrix; converting the transformed floating image to a vectorized floating image; converting the vectorized floating image to a floating index image; and obtaining joint statistics of the index images. Other steps include, computing a cost function due to misalignment of the two images using the joint statistics; and updating the transformation matrix and repeating several aforementioned steps, if the cost function does not satisfy a predefined criterion, otherwise, applying the transformation matrix to an acquired floating intensity image. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to bushings and more specifically a bushing for railroad equipment.
Bushings for railroad equipment have generally included brass. Other parts that have acted as bushings also include stainless steel. This is because of the severe environment in which railroad equipment operates, for example, extreme temperatures, from the very hot deserts to the very cold north. Bushings are generally used with a valve element generally connected to a piston responsive to differential pressure to open and close the valve. Seals, for example, O-rings and K-rings are provided on the valve element as it moves in the bushing. Lubricant between the bushing and the valve element may be affected by severe temperatures, as well as being diluted by water or solvents inherent in the railroad air system. Also, in certain environments, contaminants, for example, coal dust, score the brass bushing and affect its ability to seal with the O-rings or K-rings. Brass is not inexpensive and adds to the weight of the overall valve.
The present invention provides a bushing for a railroad control valve composed of aluminum having an anodized surface with a teflon layer at least where a valve element moves within the bushing. The teflon is preferably impregnated into the anodized surface or may be a continuous teflon sheet bound to the anodized surface. The anodized surface is a hard coat anodize having a thickness in the range of 0.0006 to 0.001 inches. The valve element includes at least one seal riding on the teflon surface without lubrication. The control valve is a pneumatic brake control valve and the valve element may be part of a piston of a vent valve, an emergency portion or service portion of the control valve.
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a vent valve incorporating the principles of the present invention.
FIGS. 2A and 2B is an enlarged cross-sectional view of a bushing incorporating the principles of the present invention.
FIG. 3 is a cross-sectional view of an emergency portion of a brake control valve incorporating the principles of the present invention.
FIG. 4 is a cross-sectional view of a service portion of a brake control valve incorporating the principles of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A vent valve 10 is shown in FIG. 1 as including a valve disc 12 cooperating with the valve seat 14 for venting a railroad brake control valve to atmosphere in an emergency condition. The valve disc 12 was connected by valve piston stem 16 to piston 18. The piston includes K-rings 20 and 22 in the circumference thereof and rides within bushing 24. The bushing 24 is received in bore 26 of housing 28. The piston 18 is responsive to the differential pressure in chambers 17 and 19 to control the opening of the vent valve 10.
The bushing 24 has historically been made of brass. Early versions of the bushing 24 included four separate bushings wherein the portions of the bushing on which the K-rings 20 and 22 moved were of brass while the remainder was stainless steel or other materials.
An improvement of the present invention is to make bushing 24 as an aluminum bushing having an anodized surface with a teflon coating at least where the valve element moves within the bushing. Thus, with bushing 24 was a single element, the total bushing would be aluminum with at least the interior surface on which the K-rings 20 and 22 ride being anodized and include a teflon layer. If bushing 24 was a plurality of bushings, at least the portions on which the K-rings 20 and 22 ride would have an anodized aluminum surface with a teflon layer.
Details of the surface of the bushing 24 is illustrated in FIGS. 2A and 2B. The bushing generally is an aluminum bushing 30 having an anodized surface 32 with a teflon layer, either shown as particles of teflon 34 embedded in the anodized surface 32 in FIG. 2A or as a teflon sheet or film 38 in FIG. 2B. The aluminum is an aluminum alloy for example, a 6020 aluminum alloy that has a hard coat anodization. Typically, this would include a 0.004 inch build-up and a 0.004 subsurface. The dotted line 36 in FIGS. 2A and 2B indicates an approximation of the location of the separation of the build-up versus the subsurface. Total thickness of the anodized layer 32 would be in the range of 0.0006 to 0.001 inches.
The formation of the anodized surface 32 with teflon particles 34 embedded therein is produced by a process for example, AnoLube III from AnoPlate Corporation, Syracuse, N.Y. Other anodized processes producing embedded teflon particles 34 may be used. With respect to FIG. 2B, the teflon sheet 38 may be applied to the anodized surface 32 after anodization by being sprayed thereon and subsequently baked. This is a well known technique presently used on the ball of an angle cock at New York Air Brake Corporation.
The advantage of the anodized aluminum with the teflon layer over brass is the reduced cost, reduced weight and increase performance and longevity. Also, since aluminum alloy does not contain lead and brass has a relatively high percent of lead, the use of aluminum eliminates lead. The ability to provide teflon in the surface, provides a lubricant for the O-rings and K-rings which will not wash away, or be diluted by water or solvents inherent in the railroad air system. Teflon provides a non-stick, reduced coefficient friction surface which slides against plastic brass, rubber or stainless steel parts. The hard anodized surface 32 also has a scratch resistance greater than the hardest commercially available brasses. This is important due to contaminants for example, coal dust, in some railroad uses. Also, teflon has no viscosity which would be effected by the temperature extremes that railroad equipment is subject to as grease lubricants would be. The anodized aluminum in combination with the teflon provides a high corrosion resistant material.
Other bushings in a brake control valve for example, a DB-60 available from New York Air Brake Corporation, would include bushing 40 in the main stack of the emergency portion 42 as illustrated in FIG. 3. The bushing 40 is received in bore 44 of the emergency portion. A pair of wear rings 46 in the interior bore of bushing 40 receives stem 48 of piston 50. The piston 50 operates the accelerated application sensor valve 52 and the quick action chamber pressure discharge valve 54. The internal bore of bushing 44 has the anodized surface with a teflon layer according to FIGS. 2A or 2B.
FIG. 4 illustrates bushings 60 and 62 as other candidates for the anodized aluminum bushing having a teflon layer. The bushings 60 and 62 are in bores 64 and 66 of the service portion 68. A piston 70 having K-rings 72 and 74 rides within the bushings 60 and 62. This piston is the balancing piston operating on spring 76 against piston 78. Piston 78 operates a quick service chamber inlet valve 80 and brake cylinder outlet valve and auxiliary reservoir and brake cylinder outlet valve 82.
The anodized aluminum teflon coated bushing of the present invention has been illustrated with respect to the DB-60 brake control valve. These bushings may be used in other brake control valves as well as other valves or accessory equipment within the railroad air system with particular advantage to the bushing which receives the piston or actuator of the valve element.
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. | A bushing for a railroad control valve composed of aluminum having an anodized surface with a teflon layer at least where a valve element moves within the bushing. The teflon is preferably impregnated into the anodized surface or may be a continuous teflon sheet bound to the anodized surface. | 1 |
FIELD AND BACKGROUND OF INVENTION
[0001] This invention relates to computer system design and particularly to data transfers through a shared chip to chip interface.
[0002] Heretofore, allocating usage for a shared interface that sends data between two chips at two different speeds depending on the type of transfer resulted in all transfers taking place at a slower rate of speed. This solution is for scenarios where an interface is shared by several different requesters, some which transfer data at one data shot every clock cycle (full or high speed), and some which transfer data at one data shot every other cycle (half or low speed). Requests that are designed to transfer data at full speed are more critical to system performance than requests that are designed to transfer data at half speed.
[0003] A simple solution is to block a high speed transfer request when an ongoing low speed transfer is going on. However, this would result in a solution that has performance critical requests stuck behind less critical half speed transfers that last twice as long and only use half the available bus bandwidth. This is a severe performance degradation.
SUMMARY OF THE INVENTION
[0004] The shortcomings of such prior arrangements are overcome and additional advantages are provided through the utilization of the extra half of bus bandwidth for performance critical data transfers. Performance critical data transfers are transfers from the cache interleaves to the chip interface. Access to the interface is serialized via a central pipeline. As a performance critical (high or full speed request for the data bus travels down the central pipeline, the system detects whether the interface data bus is currently empty or there is an ongoing half-speed transfer. If there is an ongoing low speed transfer, the system will dynamically slow down the read rate out of the interleave buffer to half speed, and utilize the free half of the bandwidth. This dynamic zippering or time shifting of data prevents a pipe pass from being rejected because the whole data bus is unavailable.
[0005] Additionally, a new interface request that arrives during an ongoing half speed transfer can be skewed by one cycle to line up with the unused bus cycles. This prevents the request that arrives in the ‘busy’ cycle from being rejected and having to retry its pipe pass.
BRIEF DESCRIPTION OF DRAWINGS
[0006] Some of the puts of the invention having been stated, others will appear as the description proceeds, when taken in connection with the accompanying drawings, in which:
[0007] FIG. 1 illustrates a flowchart of the interface response and data bus allocation process;
[0008] FIG. 2 illustrates the relevant dataflow;
[0009] FIG. 3 illustrates an example of the timing relationship between an ongoing half-speed transfer and a new transfer that was dynamically slowed to half speed;
[0010] FIG. 4 illustrates an example of the timing relationship between an ongoing half-speed transfer and a new transfer that was dynamically slowed to half speed and skewed by one cycle to line up with the free half of the data bus bandwidth; and
[0011] FIG. 5 shows a computer readable medium bearing code which implements this invention.
DETAILED DESCRIPTION OF INVENTION
[0012] While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which a preferred embodiment of the present invention is shown, it is to be understood at the outset of the description which follows that persons of skill in the appropriate arts may modify the invention here described while still achieving the favorable results of the invention. Accordingly, the description which follows is to be understood as being a broad, teaching disclosure directed to persons of skill in the appropriate arts, and not as limiting upon the present invention.
[0013] Turning now to the drawings in greater detail, it will be seen in FIG. 1 that the dynamic data rate change takes place via a series of decisions, the results of which trigger certain signals to be sent to the dataflow buffers. Control flow 100 represents the decision tree made by the interface response and data bus arbiter and model, the embodiment of which enables the basic usage of the interface buses as well as the dynamic data return speed reduction described herein. Control flow 100 starts with the initiation of a performance critical request 101 for the usage of both the response bus and data bus portion of the chip to chip interface. A decision 111 is first made by the bus arbiter to determine if the response bus and data bus are available to send a new response over the interface. Most interface responses busy the response bus for two cycles, so the response portion of the bus is not always available. The bus arbiter reports the data bus available as long as its bandwidth is not being fully utilized. If the response bus is unavailable or the data bus is entirely busy, the request does not win access to the interface. As a result the request is rejected and the data transfer is cancelled as indicated at 180 . The request 101 will not gain access to the interface at this time. The request for the interface must then be retried as indicated at 181 . However, if the response bus is available and at least half the bandwidth on the data bus is available, the request 101 is guaranteed access to the response bus and at least half of the data bus. At this stage it is known that the request 101 will have access to the interface and will be returning its response and data. This therefore concludes the portion of the flow that handles decisions for access to the bus itself.
[0014] The remaining portion of the flowchart handles the decisions required to determine whether or not to dynamically slow down the data. A decision point 121 determines if the full data bus is available or if half the bus is currently in use. If it is determined that the full bus is available, and a hardware disable switch 122 is set to enable full speed transfers, the data is read out of the buffer and sent across the interface at full speed as indicated at 130 .
[0015] However, if the determination is that only half the bus is available the hardware will have to trigger a dynamic data slowdown and enable the new request to be “zippered” onto the available half of the bus, interleaving with the ongoing data transfer. Since this interleaving can be selectively disabled, the interface arbitration hardware first must determine the setting of a zipper enable disable switch via a decision point indicated at 140 . If the zipper or time shifting function is disabled, the request is rejected and the data transfer is cancelled as indicated at 180 . The request 101 will not gain access to the interface at this time. The request 101 for use of the interface must then be retried as indicated at 181 . If the zipper function is enabled, a special zipper signal is sent to the buffer dataflow read controls and interface muxing, as indicated at 141 , indicating that the read rate should be decreased to one data entry every other cycle. At this point, the logic knows half the bus is available, but since there is a fixed timing between the arrival of the request 101 and the cycle in which the data is read out of the buffer and onto the interface data bus, the request 101 has a fifty percent chance of arriving in a cycle that lines up with the free half of the data bus. The bus arbitration hardware must decide if the request arrival lines up with the free half of the bus as indicated at 150 . If it does, no further action is required; the zipper signal 141 will trigger the dataflow to send the data over the interface at half speed as indicated at 170 .
[0016] If it is determined at step 150 that the arrival of the request 101 does not line up with the free portion of the bus, a one cycle ‘skew’ is required. The ‘skew’ involves delaying the first cycle of the response and data bus access for request 101 by one cycle to avoid data collisions between the new request's data and the ongoing data transfer. The timing relationship between the response and the data bus must be maintained, so the response bus must be delayed as well. As long as the skew is enabled as indicated at 151 , the response and data will be sent with a one cycle delay as indicated at 161 . The bus arbitration logic delays the response bus on its own, and notifies the dataflow buffer read controls and interface multiplexers of the delay by sending a unique ‘skew’ signal 160 to the dataflow. If however, the ‘skew’ functionality is disabled for any reason, the request 101 is rejected and the data transfer is cancelled 180 . The request 101 will not gain access to the interface at this time. The request 101 for use of the interface must then be retried 181 .
[0017] FIG. 2 illustrates a structure to handle the movement of data associated with a performance critical request for data 101 . Performance critical data transfers are sourced by the cache interleave buses 201 and destined for one of many chip interfaces 212 . The dataflow has the capability to source data from additional locations 208 if necessary.
[0018] Due to narrow chip interface data bus wits, data transfers require multiple cycles to complete. In addition, due to varying transfer rates, the control flow logic described previously must decide what rate to transfer the data (full speed or half speed) and whether to skew the data return relative to the request (1 cycle delayed or no delay).
[0019] In this embodiment, the cache array is sliced into multiple interleaves and each interleave has a dedicated cache interleave data bus 201 . This allows multiple cache army reads to be active simultaneously. A data transfer request may source data from one or more of the cache interleave buses. The access delay of the cache interleaves 201 is fixed relative to the request passing through the pipe. In addition, the data is always supplied at a fixed rate equivalent to the full-speed interface rate. The data flow is able to accommodate the differences in timing and bandwidth between the data source and destination.
[0020] Data returns at full speed with no time delay 130 occur when the bus is fully available. For this data transfer type, data moves from the appropriate cache interleave buses 201 to the chip interface 212 through one of the cache interleave multiplexers 202 , 203 , the bypass multiplexer 206 , the bypass staging register 207 , and the interface multiplexer 211 . All subsequent data shots—the second through the last data shots—follow the same path through the dataflow until the data transfer completes. The data buffer register files 204 , 205 , which can store an entire data transfer, are bypassed in this case to avoid incurring the write and read access delay associated with these storage elements, thus this path is referred to as the “bypass” data path.
[0021] Data returns at half-speed with no time delay 170 occur when the transfer request aligns with an available cycle on the interface and there is already another half-speed transfer in progress. In this scenario, the data flow will return the first cycle of data using the “bypass” data path, which is the same path used by the full speed with no delay return so the first cycle of data is not delayed. All subsequent data, shots—the second through last data shots—are written Into and read out one of the cache interleave (ILV) data buffers 204 , 205 , to store the cache Interleave data read from the cache arrays at full-speed. Data read out of the ILV buffers passes through a multiplexer 209 and stage 210 before being multiplexed with the “bypass” data 211 . The stage 210 at the output of the data buffers 204 , 205 is to accommodate the read access delay incurred when reading the storage element.
[0022] Data returns at half-speed with a one cycle delay are used to align a new half-speed transfer with an existing half-speed transfer. To align the first data shot to the available interface cycle, the cache interleave data 201 is written into an available ILV buffer 204 , 205 and staged 210 before being passed to the chip interface. The ILV buffer is written with the entire data transfer at the full-speed rate, while the buffer is read at the half-speed rate.
[0023] There are two parallel data paths 202 , 203 and data buffers 204 , 205 from the cache interleaves to the chip interface in order to support two half-speed transfers simultaneously. Selection between the two data paths and data buffers is determined by availability. The control flow will prevent collisions between an existing data transfer and a new transfer.
[0024] FIGS. 3 and 4 illustrate the timing difference between the scenario where a one cycle skew is not required ( FIG. 3 ) and when it is required ( FIG. 4 .) Examining FIG. 3 in further detail reveals that the Interface request 302 is presented to the response bus arbiter in the first cycle of the serialization pipeline 301 . The response bus arbitration takes place in the following clock cycle 311 . In the next cycle 312 the dynamic data rate change decisions take place. During this cycle 312 , the response bus arbitrator determines if the request arrived in a cycle that lined up with the free half of the bus, by cross checking with the data bus model for the existing data transfer on the interface 333 . It the response lines up correctly and is not canceled for any other reason and these decisions reveal that the data needs to be dynamically slowed down, in the next clock cycle the time shift or ‘zipper’ signal is sent 313 to the dataflow buffer controller. This signal is sent in cycle C 4 of the serialization pipeline 301 . The arrival of this signal at the dataflow buffer controller triggers the buffer outgate multiplexer to assert the following cycle 322 and to continue to assert every other cycle for the length of the transfer. In addition the time shift or ‘zipper’ signal 313 triggers the read address pointer to begin incrementing 321 . Because of the slowed data rate, the read address pointer 321 is incremented, then held for one cycle before being incremented again. The first read address pointer increment 323 takes place one cycle after the buffer outgate multiplexer 324 assets for the first time. Multiplexer assert 324 is to outgate the first shot of data from the buffer and onto the interface, which corresponds to buffer address 00. The assertion of 324 is done at his time to allow the first shot of data 335 to be active on the chip to chip interface in two cycles.
[0025] The first beat of the two cycle response 331 which always accompanies the data transfer is active on the chip to chip Interface the same cycle the ‘zipper’ signal 313 is sent to the dataflow controls. The second response beat 332 follows one cycle afterwards. The interface specification requires that the first shot of data 335 follow the second response beat 332 by two cycles. The buffer outgate multiplexer select 322 activation triggers the arrival of the data on the free half of the interface 334 two cycles later.
[0026] FIG. 4 shows the timing of the dynamic data reduction scenario when a one cycle skew is required. Examining FIG. 4 in detail reveals that the interface request 402 is presented to the response bus arbiter in the first cycle of the serialization pipeline 401 . The response bus arbitration takes place in the following dock cycle 411 . In the next cycle 412 the dynamic data rate change decisions take place. During this cycle 412 , the response bus arbitrator determines if the request arrived in a cycle that lined up with the free half of the bus, by cross checking with the data bus model for the existing data transfer on the interface 433 . If the response is not canceled for any other reason and these decisions reveal that the data needs to be dynamically slowed down, in the next clock cycle the time shift ‘zipper’ signal is sent 413 to the dataflow buffer controller. If these decisions further reveal that the data needs to be skewed by one cycle to line up with the free portion of the data bus and not collide with the existing half speed transfer on the data bus 433 , skewing is necessary. If the skewing is necessary, the ‘skew’ signal 414 is also sent to the dataflow buffer controller in this cycle. This signal is sent in cycle C 4 of the serialization pipeline 401 . The arrival of these two signals at the dataflow buffer controller triggers the buffer outgate multiplexer to assert two cycles later 422 and to continue to assert every other cycle for the length of the transfer. The extra cycle delay is introduced to delay the data outgate to line up with the free portion of the bus 434 and not collide with the existing data transfer 433 . In addition, the combination of the ‘skew’ signal 414 and the time shift ‘zipper signal’ 413 trigger the read address pointer to begin incrementing 421 . Because of the slowed data rate, the read address pointer 421 is incremented, then held for one cycle before being incremented again. The first read address pointer increment 423 takes place one cycle after the buffer outgate multiplexer 424 asserts for the first time. This is to outgate the first shot of data from the buffer and onto the interface, which corresponds to buffer address 00. The assertion of the multiplexer 424 is done at this time to allow the first shot of data 435 to be active on the chip to chip interface in two cycles. However, as a result of the ‘skew’ 414 , both the read address increment 423 and the multiplexer outgate select 424 , as well as the first shot of date on the interface 435 (and all subsequent data shots 434 ) are delayed by one cycle.
[0027] The first beat of the two cycle response 431 which always accompanies the data transfer is active on the chip to chip interface the cycle after the ‘zipper’ signal 413 and the ‘skew’ signal 414 are sent to the dataflow controls. The second response beat 432 follows one cycle after the first response beat. The interface specification requires that the first shot of data 435 follow the second response beat 432 by two cycles. The buffer outgate multiplexer select 422 activation triggers the arrival of the data on the free half of the interface 434 two cycles later. The response arbitration logic remembers that the ‘skew’ signal 414 was sent to the dataflow and delays the launch of each of the response beats ( 431 , 432 ) by one cycle.
[0028] The capabilities of the present invention can be implemented. In software, firmware, hardware or some combination thereof.
[0029] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media, indicated at 500 in FIG. 5 . The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately. Machine readable storage mediums may include fixed hard drives, optical discs, magnetic tapes, semiconductor memories such as read only memories (ROMs), programmable memories (PROMs of various types), flash memory, etc. The article containing this computer readable code is utilized by executing the code directly from the storage device, or by copying the code from one storage device to another storage device, or by transmitting the code on a network for remote execution.
[0030] The flow diagrams depicted herein are just examples. There nay be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0031] In the drawings and specifications there has been set forth a preferred embodiment of the invention and, although specific terms are used, the description thus given uses terminology in a generic and descriptive sense only and not for purposes of limitation. | As a performance critical (high or full speed) request for a computer system data bus travels down a central pipeline, the system detects whether the interface data bus is currently empty or there is an ongoing half-speed transfer. If there is an ongoing low speed transfer, the system dynamically time shift or slows down the read rate out of the interleave buffer to half speed, and utilizes the free half of the bandwidth. This dynamic “zippering” or time shifting of data prevents a pipe pass from being rejected because the whole data bus is unavailable. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/576,893, filed May 31, 2007 now U.S. Pat. No. 7,320,567, which is the U.S. National Stage Application of International Application No. PCT/EP05/11052, filed Oct. 14, 2005. The International Application claimed priority to German Patent Application No. 10 2004 051 031.8, filed Oct. 20, 2004.
FIELD OF THE INVENTION
The invention relates to a clamping device for clamping a tool or tool holder in a working spindle, in particular, of a machine tool.
BACKGROUND OF THE INVENTION
A clamping device of this type is known from DE 100 43 006 C1. There, the machine tools are held by mean of a clamping set arranged in the working spindle, which clamping set is arranged at the front end of a drawbar placed under prestress by means of a spring arrangement. The clamping set commonly comprises several radially movable gripper elements by means of which the machine tool is drawn into the working spindle. In order to release the machine tool, the drawbar is displaced by means of a releasing unit against the force of the spring arrangement, such that the clamping set with gripper elements is opened and releases the machine tool. The releasing unit comprises a hydraulically operated piston-cylinder arrangement by means of which the clamping set can be moved by the drawbar into the released position against the force of the spring arrangement. However, this necessitates relatively expensive supply aggregates and hook-ups or connections in order to supply the releasing unit with hydraulic fluid. In addition, special scaling measures must be provided.
Known from DE 101 01 093 A1 is a clamping device featuring an electric motor operating device to operate the drawbar. However, no spring arrangement is provided to generate the drawing force of the clamping set for this known clamping device.
The problem of the invention is to create a clamping device of the aforementioned type that enables simplified operation.
SUMMARY OF THE INVENTION
Expedient improvements and advantageous configurations of the invention are indicated in the subordinate claims.
For the clamping device according to the invention, the releasing unit is operated by means of an electrical actuator such that no special hydraulic or pneumatic aggregates are required here. Also, expensive sealing measures can be waived.
The electrical actuator expediently comprises an electric motor and a linear gear unit that converts the rotational movement of the electric motor into a linear movement of a piston or other suitable component in order to displace the drawbar.
For the electric motor, this can be a matter of a separate motor, the stator and rotor of which is accommodated in a housing of the releasing unit. In an additional advantageous embodiment of the invention, the actuating motor provided for rotating the working spindle can be employed to actuate the linear gear unit. Here, an engageable coupling can be provided by means of which the working spindle can be connected to the linear gear unit in order to carry out a tool change.
In an expedient embodiment, the linear gear unit is executed as a threaded mechanism having a rotary driven spindle sleeve and an associated threaded spindle.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features and advantages of the invention are yielded from the following description of a preferred embodiment with the aid of the drawing. Shown are:
FIG. 1 An actuating unit of a machine tool having a clamping device in longitudinal section;
FIG. 2 An enlarged longitudinal section of a releasing unit of the clamping device shown in FIG. 1 in a clamping position;
FIG. 3 An enlarged longitudinal section of a releasing unit of the clamping device shown in FIG. 1 , in a released position;
FIG. 4 An enlarged longitudinal section of an additional releasing unit in a clamping position and
FIG. 5 An enlarged longitudinal section of the releasing unit shown in FIG. 4 in a released position.
DETAILED DESCRIPTION OF THE INVENTION
Shown in longitudinal section in FIG. 1 is an actuating unit executed as a motor spindle of a machine tool, having a spindle housing ( 1 ), a working spindle ( 4 ) rotationally mounted within the spindle housing ( 1 ) by means of bearings ( 2 , 3 ), a stator ( 5 ) arranged in the spindle housing ( 1 ) and a rotor ( 6 ) arranged concentrically about the working spindle ( 4 ) and non-rotationally linked to same. The actuating motor formed of the stator ( 5 ) and rotor ( 6 ) is designed such that the working spindle ( 4 ) can be driven both at a high rotational speed as well as at a slight rotational speed and a higher level of positioning precision. The left front end in FIG. 1 of the working spindle ( 4 ) features a female taper ( 7 ) in order to receive a tool taper ( 8 ) on a tool or tool holder. In the embodiment shown, the tool taper ( 8 ) is executed as a hollow shank taper. A clamping device is integrated in the working spindle ( 4 ) in order to clamp a tool or tool holder.
The clamping device comprises a drawbar ( 10 ) within the working spindle ( 4 ), concentric to the centerline ( 9 ) thereof, to the front end of which drawbar is mounted a clamping taper ( 11 ) of a known clamping set ( 12 ). The clamping set ( 12 ) comprises a collet chuck, arranged about the clamping taper ( 11 ), having several gripper elements ( 13 ) that can be moved radially by axially displacing the clamping taper ( 11 ) in order to clamp or release the tool taper ( 8 ). The drawbar ( 10 ) is placed tinder a backward prestress by means of a spring arrangement ( 14 ) arranged concentrically about said drawbar. The spring arrangement ( 14 ) executed here as a disk spring package is supported at one side by a contact disk ( 15 ) supported within the working spindle ( 4 ) and at the other side by a collar ( 16 ) located at the rear end of the drawbar ( 10 ). The drawbar ( 10 ) is of a hollow execution in order to supply a working fluid to the tool taper ( 8 ). Arranged at the rear end of the drawbar ( 10 ) is an electrically actuated releasing unit ( 17 )—expounded upon in the following—by means of which the drawbar ( 10 ) can be pressed forward against the force of the spring arrangement ( 14 ). If the drawbar ( 10 ) is pressed forward, the clamping set ( 12 ) arranged at the front end of the working spindle ( 4 ) releases the tool taper ( 8 ) of the tool or tool holder. If, in contrast, the drawbar ( 10 ) is again drawn backward by means of the force of the spring arrangement ( 14 ), the tool taper ( 8 ) is drawn into the working spindle ( 4 ) and clamped. The construction and mode of operation of the clamping set ( 12 ) as such are known, so that an exhaustive description can be avoided.
FIGS. 2 and 3 show an enlarged longitudinal section of the releasing unit ( 17 ) on the actuating unit represented in FIG. 1 , in a clamping position and released position. The releasing unit ( 17 ) comprises an axially displaceable piston ( 18 ) that, in order to operate the drawbar ( 10 ) by means of the powered rotating working spindle ( 4 ), is arranged by means of an engageable coupling and a linear gear unit to be able to be displaced axially within a housing non-rotationally linked with the spindle housing ( 1 ). The housing includes a front housing part ( 19 ) having supporting surfaces ( 20 ), a covering tube ( 21 ) and a rear housing part ( 22 ). The front housing part ( 19 ) is screwed together by means of a ring flange to the spindle housing ( 1 ). The axially displaceable piston ( 18 ) is able to displace the drawbar ( 10 ) against the force of the spring arrangement ( 14 ).
The engageable coupling comprises a coil body ( 23 ), non-rotationally arranged within the front housing part ( 19 ), in which coil body is arranged a coil ( 24 ). The engageable coupling moreover comprises an armature element ( 26 ), rotationally mounted within the coil body ( 23 ) by means of a bearing ( 25 ), the front face of which armature element features a friction lining ( 27 ) that engages with a friction ring ( 28 ) arranged at the rear face of the working spindle ( 4 ). The friction ring ( 28 ) is drawn by means of several spring-loaded tension bolts ( 29 ) axially to the rear face of the working spindle ( 4 ). Several screws ( 30 ) and corresponding pull-in holes ( 31 ) secure the friction ring ( 28 ) against rotation, yet connect same in an axially movable way to the working spindle ( 4 ).
For the embodiment shown, the linear gear unit is executed as a threaded mechanism having a hollow threaded spindle ( 33 ) and an associated spindle sleeve ( 34 ) that are connected to one another by means of a motional thread ( 35 ) executed, e.g., as a trapezoidal thread. The spindle sleeve ( 34 ) is connected to the rotating armature ( 26 ) in a positive and axially secured way by means of fit-in keys ( 47 ). The threaded spindle ( 33 ) includes a rear support section ( 36 ) of an enlarged diameter in which are arranged radially projecting support bodies ( 37 ). For the embodiment shown, the support bodies ( 37 ) are executed as rotationally mounted support rollers. Said support bodies ( 37 ) support the threaded spindle ( 33 ) by the support surfaces ( 20 ) of the stationary front housing part ( 19 ) such that said threaded spindle is axially movable, yet secured against rotation. The rear support section ( 36 ) of the threaded spindle ( 33 ) is arranged in a sleeve ( 38 ) and axially secured therein by means of a tension ring ( 39 ). The piston ( 18 ) includes a tube ( 40 ) progressing through the hollow threaded spindle ( 33 ) and a disk-shaped rear part ( 41 ), one face of which is supported against the rear side of the support section ( 36 ) and the other face of which is supported by means of a disk spring ( 42 ) or other spring against a collar ( 43 ) of the sleeve ( 38 ). The sleeve ( 38 ) entrains the piston ( 18 ) thus by the threaded spindle ( 33 ) during axial movement of the latter. Mounted to the front end of the piston ( 18 ) is an axial bearing ( 44 ), the rotating bearing ring of which comes into contact with the rear end of the drawbar ( 10 ) when the clamping device is released. Progressing through the hollow piston ( 18 ) is a connecting tube ( 45 ) that connects the drawbar ( 10 ) of hollow design for the supply of lubricant or compressed air to a known rotary feedthrough ( 46 ).
The mode of operation of the aforementioned clamping device is expounded upon in the following:
In order to carry out a tool change, first, in the clamping position represented according to FIG. 2 , current is applied to the coil ( 24 ) while the working spindle ( 4 ) is stationary such that the friction ring ( 28 ) is drawn toward the coil ( 24 ) against the force of the spring-loaded tension bolts ( 29 ), and pressed against the friction lining ( 27 ). A corresponding control of the actuating motor then is used to rotate the working spindle ( 4 ) at a slower rotational speed, with the armature ( 26 ) and the spindle sleeve ( 34 ) non-rotationally linked thereto being rotated along with this by means of the engaged coupling. Since the threaded spindle ( 33 ) arranged within the spindle sleeve ( 34 ) is secured against rotation by means of the support bodies ( 37 ), said threaded spindle carries out an axial movement, by means of the rotation of the likewise axially secured spindle sleeve ( 34 ). In the process, it entrains, by means of the sleeve ( 38 ), the piston ( 18 ). In order to release the clamping device, the spindle sleeve ( 34 ) is rotated such that the threaded spindle ( 33 ) and piston ( 18 ) move in the direction of the drawbar ( 10 ) and displace same to a front released position represented in FIG. 3 . The axial bearing ( 44 ) arranged at the front face of the piston ( 18 ) reduces the friction between the non-rotating threaded spindle ( 33 ) and the rotating drawbar ( 10 ) during their contact, The disk spring ( 42 ) mounted between the rear end ( 41 ) of the piston ( 18 ) and the collar ( 43 ) of the sleeve ( 38 ) provides for a spring suspension of the piston ( 18 ) if the drawbar ( 10 ) travels in the front released position against a fixed front limit stop and the working spindle continues to rotate somewhat despite the motor being switched off. This cushions and absorbs possible impacts during travel into the released position.
In order to tension the clamping device, the direction of rotation of the motor can again be reversed such that the piston ( 18 ) again travels to the rear position shown according to FIG. 2 . In the process, the spring arrangement ( 14 ) again presses the drawbar ( 10 ) in the rear clamping position. Mounted at the rear housing part ( 22 ) is a limit switch ( 48 ) that switches off the motor if the sleeve ( 38 ) reaches the rear end position thereof. Here also the spring ( 42 ) again serves as a cushioning element if the sleeve ( 38 ) in the course or traveling back comes to a stop at the rear housing part ( 22 ) and the working spindle ( 4 ), despite the motor being switched off, continues to rotate somewhat due to inertia.
FIG. 4 shows an additional embodiment of an electrically operated releasing unit ( 49 ) to displace the drawbar ( 10 ) of a clamping device integrated in the working spindle ( 4 ) of a machine tool. The releasing unit ( 49 ) comprises a stationary housing having a ring-shaped front housing part ( 50 ), a covering tube ( 51 ) in a fixed connection with the former, and a rear housing part ( 52 ) screwed together with the covering tube ( 51 ). The rear housing part ( 52 ) has a threaded spindle ( 53 ) projecting forward, upon which is rotationally arranged a spindle sleeve ( 54 ) by means of a motional thread ( 55 ) executed, e.g. as a trapezoidal thread. On a bearing shoulder ( 56 ) of the rear housing part ( 52 ), an actuating bush ( 59 ) composed of a front part ( 57 ) and a rear part ( 58 ) is rotationally arranged by means of a rear bearing ( 60 ) and a front bearing bush ( 61 ).
The actuating bush ( 59 ) can be actuated by means of a motor having a rotor ( 62 ) arranged concentrically about said actuating bush ( 59 ) and non-rotationally linked thereto and a stator ( 63 ) concentrically enclosing said rotor. The stator ( 63 ) is accommodated in a fixed manner within the housing and concentrically encloses the rotor ( 62 ) arranged on the actuating bush ( 59 ). Several forward protecting transfer pins ( 64 ) are affixed in the front part of the actuating bush ( 59 ). A transfer ring ( 65 ) having corresponding bore holes is slipped on the transfer pins ( 64 ) in a way permitting axial displacement. A spindle sleeve ( 54 ) is non-rotationally fixed in the transfer ring ( 65 ). Additionally arranged in the transfer ring ( 65 ) is a hollow piston ( 66 ) the rear face of which is rotationally supported by means of an axial bearing ( 67 ) against the front face of the spindle sleeve ( 54 ) and the front face of which comes into contact with the rear face of the drawbar ( 10 ) when the clamping device is released. Likewise progressing through the hollow-design housing part ( 52 ) and the hollow piston ( 66 ) is a connecting tube ( 68 ) that connects the drawbar ( 10 ) to a rotary feedthrough ( 69 ) in order to supply a coolant or lubricant. For this embodiment as well, the linear gear unit, in order to convert rotary movement of the motor to a linear movement is executed as a threaded mechanism having an actuated spindle sleeve ( 54 ) and a threaded spindle ( 53 ) provided for this. Here however, in contrast to the first embodiment, the threaded spindle ( 53 ) is stationary and the actuated spindle sleeve ( 54 ) is movable in the axial direction. If the spindle sleeve ( 54 ) is actuated by means of the motor via the actuating bush ( 59 ), the transfer ring ( 65 ) carries out an axial movement with the piston ( 66 ) arranged therein.
The clamping device according to the invention is not limited to the aforementioned embodiments. Thus, the clamping system according to the invention may find application not only for a hollow taper clamping system but also for a steep taper clamping system. The clamping set can he executed both in order to hold a tool having a hollow shank taper (HSK) as well as to hold a tool having a steep taper (SK) in the manner of a chuck or similar. In addition, an electric linear actuator also can be employed to actuate the releasing unit. | The invention relates to a clamping device for clamping a tool ( 8 ), or tool holder in a working spindle ( 4 ), in particular, of a machine tool, comprising a drawbar ( 10 ), arranged to be displaced within the working spindle ( 4 ), a clamping set ( 12 ), arranged in the working spindle ( 4 ) and displaceable between a clamping position and a released position by means of the drawbar ( 10 ), a spring arrangement ( 14 ) provided for the drawbar ( 10 ) to generate the drawing force for the clamping set ( 12 ) and a releasing unit ( 17; 49 ), by means of which the clamping set ( 12 ) may be moved into the released position by the drawbar ( 10 ) against the force of the spring arrangement ( 14 ). According to the invention, a simplified operation of the clamping device may be achieved, whereby the releasing unit ( 17; 49 ) may be operated by an electrical actuator ( 62, 63, 53, 54 ). | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a divisional application of U.S. application Ser. No. 10/665,188, filed Sep. 17, 2003 now abandoned and entitled USE OF A HUMAN AMNIOTIC MEMBRANE COMPOSITION FOR PROPHYLAXIS AND TREATMENT OF DISEASES AND CONDITIONS OF THE EYE AND SKIN, which claims the priority of U.S. Provisional Application No. 60/411,738 filed Sep. 18, 2002 entitled, EXTRACT OF HUMAN AMNIOTIC MEMBRANE FOR TREATMENT OF OCULAR INJURIES AND DISEASES, the whole of which are hereby incorporated by reference herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
Corneal epithelium integrity and corneal sensory innervation play a pivotal role in maintaining ocular surface health (Tseng et al., 1997). Clinical conditions leading to corneal nerve disruption associated with epithelial defects and persistent and progressive corneal ulcers include viral infections, autoimmune and endocrine diseases, thermal and chemical burns, multiple ocular surgeries and V pair ganglion or sensory routes affections (Donzis et al., 1987; Gould, 1967; Hyndiuk et al., 1977; and Liesegang, 1985). Current therapeutic strategies adopted for such conditions include medical therapy (e.g., tear substitutes, topical and systemic drugs), surgical approaches based on amniotic membrane transplantation (Chen et al., 2000), and, quite recently, a panacea of novel compounds, especially growth factors able to promote effectively corneal epithelial re-growth. These molecules, mainly neuropeptides, include epidermal growth factor (Kandarakis et al., 1984), aldose reductase inhibitors (Hosolani et al., 1995), insulin-like growth factor type I associated with Substance P, and nerve growth factor (Lambiase et al., 1998). In particular, amniotic membrane tissue has shown powerful and interesting properties in bringing about the anatomical recovery of the anterior ocular surface from a disease condition, along with observations regarding its composition that include even more growth factors than the list mentioned above (Uchida et al., 2000). Unfortunately, an improvement in the patient's visual outcome following application of amniotic membrane tissue is often unsuccessful (Solomon et al., 2002). Application of the amniotic membrane as a multilayer structure instead of as a monolayer has been somewhat more effective, which may be due to the quantity of amniotic membrane applied biological factors (Prabhasawat, 2001). Cryopreserved human amniotic membrane has been applied to the affected eye of a patient as a patch after defrosting (Kim et al., 1995). The applied patch released a restricted amount of factors to the damaged tissue, but the survival of the human amniotic membrane cells decreased to zero in a few days.
Despite the partial effectiveness of these approaches, these treatments are usually unable to completely restore the affected part, functionally and anatomically. Accordingly, a more effective and efficient approach in treating the symptoms and clinical conditions of ocular diseases and related conditions would be useful.
BRIEF SUMMARY OF THE INVENTION
These objectives are achieved using the compositions and methods according to the invention. In one aspect, the invention is directed to a method of preparing an amniotic membrane extract in which the method includes the steps of obtaining a healthy amniotic membrane from a pregnant mammal, such as a pig, cow, horse or human, homogenizing the membrane to obtain a homogenate solution, freezing the homogenate solution, and lyophilizing the frozen homogenate solution to dryness. Preferably, the lyophilized homogenate is pulverized to a powder. The lyophilized homogenate is then reconstituted before use, e.g., in a liquid, such as a balanced salt solution or fresh amniotic fluid, or in another substance, such a gel, an ointment, a cream or a soap, depending on the intended use.
In another aspect, the invention is directed to a pharmaceutical composition for prophylaxis and/or treatment of a disease or condition, the composition including a therapeutically effective amount of an amniotic membrane extract prepared according to the method of the invention and dispersed in a pharmaceutically acceptable carrier for administration to a patient. Exemplary pharmaceutically acceptable carriers include an ophthalmic solution for eye drops, a gel, an ointment, an emulsion, a cream, a powder and a spray. Furthermore, the amniotic membrane extract may be distributed on a bandage or a medicinal contact lens for local administration to a patient.
In a further aspect, the invention is directed to a method of prophylaxis and/or treatment of a disease or condition, the method including the steps of providing a patient in need of such prophylaxis and/or treatment, and administering an effective amount of the pharmaceutical composition of the invention to the patient. Exemplary diseases or conditions treatable by the method of the invention include persistent corneal ulcer, Ocular Cicatritial Pemphigoid, Stevens-Johnson syndrome, conjunctival inflammation, dry eye, Sjöngren's syndrome, chemical or thermal injuries, multi-surgery effects, contact lenses over-wear, severe microbial infections, neurotrophic keratitis, ischemic keratitis, peripheral ulcerative or inflammatory keratitis, limbitis aniridia, pterigium or pseudopterigium, and multiple endocrine deficiency. For ocular use, the pharmaceutically acceptable carrier preferably includes preservative free eye drops.
In yet another aspect, the invention is directed to a kit that includes a therapeutically effective amount of an amniotic membrane extract prepared according to the method of the invention and instructions for the use thereof. Preferably, the kit further includes a pharmaceutically acceptable carrier for administering the amniotic membrane extract to a patient. The amniotic membrane extract according to the invention has the healing properties of amniotic membrane tissue, but at an enhanced level, and can be used according to the invention without the need for costly surgical procedures.
BRIEF DESCRIPTION OF THE FIGURES
Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof and from the claims, taken in conjunction with the accompanying figures, in which:
FIGS. 1A (white light) and 1 B (UV light) are photographs showing the eye of a patient with Ocular Cicatritial Pemphigoid at day 0 (2.5× magnitude);
FIGS. 2A (white light) and 2 B (UV light) are photographs showing the eye of the patient of FIGS. 1A and 1B at day 10 after treatment with the composition of the invention (2.5× magnitude);
FIGS. 3A (white light), 3 B (UV light) and FIG. 3C (white light) are photographs showing the eye of the patient of FIGS. 1A and 1B at day 30 ( FIGS. 3A and 3B ) and day 40 ( FIG. 3C ) after further treatment with the composition of the invention (2.5× magnitude); and
FIGS. 4A and 4B depict photographs of a patient having enhanced wrinkling adjacent to the eye at day 0 ( FIG. 4A ) and day 14 ( FIG. 4B ) after treatment with the composition of the invention (1.5× magnitude).
DETAILED DESCRIPTION OF THE INVENTION
The therapeutic composition of the invention comprises a healthy amniotic membrane extract derived from the amniotic membrane of a pregnant mammal, e.g., a human, a pig, a cow, or a horse. A healthy amniotic membrane is one that has been maintained under sterile conditions and that has been determined to be virus free, e.g., free from the hepatitis-B and C viruses and human immunodeficiency virus, and free from bacterial contamination. The amniotic membrane is, preferably, freshly obtained and quickly processed for preparation of the extract according to the invention, as described herein. The membrane may be stored prior to preparation of the extract. However, storage of the amniotic membrane tissue will result in some loss in cell viability.
The amniotic membrane extract according to the invention has the healing properties of amniotic membrane tissue, but at an enhanced level, and can be used according to the invention without the need for costly surgical procedures. The application of the therapeutic composition of the invention may be performed by a physician or by a capable patient at home. The composition is straightforward to prepare and may be constituted to contain any concentration of factors desired, depending on the severity of the disease or condition to be treated. The treatment may be administered as necessary without incurring undesirable side effects.
The composition of the invention is useful for treating ocular diseases and/or skin disorders and many other diseases when used in accordance with the method of the invention, as described herein. Ocular Cicatritial Pemphigliod (OCP), for example, is known to be a rare immunological related disease that involves the anterior ocular surface leading to blindness despite any kind of therapeutic approach (Foster, 1986). Therapeutic choices like anti-inflammatory drugs, steroids and immunosuppressive agents help to control the disease but very often are unable to block its natural progression. The natural history of OCP begins with recurrent conjunctival inflammations and then fibrosis, associated with fornix foreshortening, symblepharon and entropion, progressively leading to a dry eye syndrome and culminating with keratinization of the ocular surface, along with corneal limbal stem cell deficiency associated with corneal ulcer formation, all as a result of the prolonged status of inflammation (Tsai et al., 1995 and Foster et al., 1982).
A recent clinical report describes the effects of amniotic membrane transplantation in the mid-late stage (II-IV) of OCP patients. This surgical approach is considered a strategy to restore the anterior ocular surface anatomy, to maintain the fornix depth, and to reduce conjunctival inflammation (Barabino et al., 2003). Even if OCP patients may benefit from the use of multi-layer amniotic membrane transplantation, the beneficial effect of this therapy is frequently transient, and low final visual acuity is often observed. It has not yet been explained if the increasing effectiveness of multi-layer amniotic membrane transplantation is related to an increase in the mechanical support to the affected tissue or due to the higher amount of factors released by the multi-layered amniotic membranes. It is also not understood why multiple applications of amniotic membranes still are not able to completely manage the disease. A plausible explanation may be related to the biphasic course of OCP, i.e., an immediate conjunctival immune reaction, plus the changes due to this inflammation, that, when they begin, are rendered irreversible by a cascade of effects. Early diagnosis and treatment is then crucial.
In an experiment described herein, use of the composition of the invention blocked OCP progression in a human patient. The OCP was monolateral and at a relatively early stage. Treatment according to the method of the invention did not include surgery and resulted in a stable outcome. These findings suggest that treatment with amniotic membrane extract in accordance with the invention is highly effective in OCP early stage.
In addition, based on the present findings, treatment with the composition according to the invention should be considered in many anterior ocular surface conditions (see infra), whether they have immunological involvement or not, in which amniotic membrane transplantation currently shows limited effects, including lids and conjunctival inflammation associated with deep corneal ulcers.
Accordingly, in one aspect, the invention is directed to a novel extract of amniotic membrane for treating, e.g., visual system and other organ injuries or diseases. Exemplary visual system injuries or diseases that the therapeutic composition of the invention may be used to treat are as follows: for the reconstruction of the ocular surface in patients with limbal stem cells deficiency (Tseng et al., 1998); for the treatment of visual system age-related diseases in general; for reconstruction of the ocular surface in patient with corneal persistent epithelial defect (Tseng et al., 1998); for corneal epithelial healing and to avoid corneal stromal remodeling and haze formation after photorefractive keratectomy (Woo et al., 2001); as a substance that can promote and support healing processes following ocular surface damage related to Stevens Johnson Syndrome and OCP (Tsubota et al., 1996); for healing support and a therapeutic approach in other eye anterior surface diseases including dry eye, Sjögren's syndrome, thermal and chemical burns, and acute and chronic inflammation; and as a versatile compound that can treat the causes of total and partial epithelial stem cells deficiency. Exemplary total epithelial stem cell deficiencies include, but are not limited to, chemical and thermal injuries, Stevens Johnson Syndrome, multi-surgery effects in the limbal region, contact lens over-wear and severe microbial infections. Exemplary partial epithelial stem cell deficiency include, but are not limited to, neurotrophic keratitis, ischemic keratitis, peripheral ulcerative and inflammatory keratitis, limbitis, aniridia, pterigium, pseudopterigium and multiple endocrine deficiency (Tseng et al., 1998; Uchida et al., 2000).
Other exemplary uses of the composition according to the invention are as a treatment for skin dystrophies, burn injury and skin ulcers (Trelford et al., 1979); as a therapy for chemiotheraphic stomatitis; as an immunomodulator in autoimmune disease; to increase tolerance in the treatment of auto-, allo- and xeno-transplants; as an osteoinductive property substance for guided bone regeneration (Gomes et al., 2001); as a substance that can be incorporated in the actual hardware currently used for bacterial and other simple organism culture in vitro or in vivo; as a substance that can be incorporated in currently used devices dedicated to cell culture, such as cell culture dishes, a three-dimensional matrix or a gel (Uchida et al., 2000); as a storage or culture medium for human cells; as a part of an integrated delivery system that will transport the effective compound from an accessible site to the site in need, for remote release of all the beneficial effects of the amniotic membrane; as a bone and tissue anti-inflammatory drug; as a source of factors and receptors for used in neuro-degenerative or inflammatory diseases; and as a source of receptors that mediate glucose transport.
The amniotic membrane extract according to the invention comprises all of the cytokines in a fresh amniotic membrane, e.g., growth factors, receptors and molecules necessary for, e.g., wound healing and other effects. The term “cytokines” includes, but is not limited to, growth factors, interleukins, interferons and colony stimulating factors. Growth factors include, but are not limited to, epidermal growth factor, fibroblast growth factor, nerve growth factor, mast cell-stimulating growth factor and Schwann cell growth factor. These factors are present in normal tissue at different stages of tissue development, marked by cell division, morphogenesis and differentiation. Among these factors are stimulatory molecules that provide the signals needed for in vivo tissue repair. These cytokines can stimulate repair of injured tissue.
In one aspect, the amniotic membrane extract of the invention can be in the form of a powder, where the homogenated amniotic membranes have been lyophilized to dryness. Samples of a frozen homogenate can be processed in a lyophilizer to remove all the water content from the homogenate and to form a powder. The lyophilized powder should be stored at least under refrigeration (4° C.) and preferably at −20° C. The powder can be transported where needed and reconstituted gently (e.g., preferably without shaking or stirring, at 4° C.), protected from light and under sterile conditions at neutral pH, e.g., in balanced salt solution (or other carriers such as gels, ointments, creams, soaps, suspensions, membranes, 3D matrix, delivery systems, biological carriers, etc.) before use. At least four hours should be allowed for the powder to dissolve or be dispersed in the delivery medium. The extract according to the invention also can be reconstituted, or diluted, if desired, with fresh amniotic fluid, autologous serum from a prospective patient or other liquid medium.
In yet another aspect of the invention, the therapeutic composition can be used as an ingredient in cosmetics, to improve wound healing, for example, for patients affected by facial dermabrasion and other skin dystrophies (Kucan, 1982). Other exemplary cosmetic uses may include, but are not limited to, moisturizing and treating dry and sensitive skin, providing anti-aging effects and improving the health of hair roots. The amniotic membrane composition according to the invention may also be used, e.g., as an anti-wrinkle, anti-aging moisturizer; in eczematoid skin conditions; in psoriasis vulgaris skin conditions; in acne vulgaris skin condition; in unspecified or idosyncratic inflammatory skin conditions; and as a compound to hydrate and moisturize pressure ulcers, diabetic ulcers, ischemic ulcers, and any other kind of dystrophic ulcers.
The therapeutic compositions of the invention may be administered topically or by routine methods in pharmaceutically acceptable inert carrier substances. For example, the compositions of the invention may be administered in a sustained release formulation using a biodegradable biocompatible polymer, or by on-site delivery using micelles, gels, ointments or liposomes. For example, for skin disorders or for cosmetic purposes, the amniotic membrane composition of the invention may be administered in a spreadable ointment. The human amniotic membrane extract of the invention can be administered in different dosages as described below (e.g., several times per day at an amount from 1 □g to 1 mg amniotic membrane tissue equivalents per administration), as appropriate. Optimal dosage and modes of administration can readily be determined by conventional protocols.
The therapeutic compositions of the invention can be administered independently or co-administered with another agent as desirable. For example, an extract of another vital organ such as the placenta could also be included. It is contemplated that the therapeutic compositions of the invention will be particularly useful for ocular diseases and conditions, for example, when administered in preservative-free eye drops containing an antibacterial agent.
The therapeutic compositions of the invention can also be prepared as a kit for the curative or prophylactic treatment of disease with instructions for use thereof. The kit of the invention may comprise the amniotic membrane extract in powder form or provided in a saline solution in a pharmaceutically acceptable carrier vehicle, or incorporated in different carriers, media or matrices.
The contents of all references, pending patent applications and published patent applications, cited throughout this application are hereby incorporated by reference.
The following examples are presented to illustrate the advantages of the present invention and to assist one of ordinary skill in making and using the same. These examples are not intended in any way otherwise to limit the scope of the disclosure.
Example I
Preparation of the Amniotic Membrane Extract
In an exemplary isolation procedure, the amniotic membrane was removed from a pregnant woman in the operating room, at the moment of Caesarian parturition, dissected from the other tissues of the placenta and rinsed in a sterile solution, e.g., phosphate-buffered saline (PBS) as described by Kim et al., 1995. Sections of the amniotic membrane were divided into one cm square pieces under sterile conditions and stored at 4° C. in PBS containing 1000 U/ml penicillin and 20 mg/ml streptomycin until processing.
The following procedures were all carried out at 4° C. and neutral pH (approximately 7.4) under sterile conditions and with protection from direct light: Amniotic membrane pieces were weighed and the volume was adjusted to reach a ratio of the g of amniotic membrane/ml of neutral buffer solution of approximately 0.3. The membrane pieces were then sonicated using a Branson 250 sonicator with 3 steps of 3 min each at the following conditions: 20% duty cycle, output in micro tip limit 8. After a pH check, the homogenate was centrifuged for 10 minutes at 4° C. and 4000 rpm and then the supernatant centrifuged for another 5 minutes at 14000 rpm to get rid of any undesired residues present in the extract.
After another pH check, an aliquot of the homogenate (supernatant) was analyzed by a protein assay to quantify the total protein amount present in the homogenate. The homogenated sample was then filtered through 0.8 micron filters under a sterile hood, protecting the compound from light and overheating 1 and maintaining the homogenate temperature at 4° C. or below. Aliquots of the sample suspension were quickly frozen in 100% ethanol-dry ice and stored at −80° C. until the lyophilization procedure. The aliquots were then lyophilized for 24 hours at −20° C. in a sterile lyophilizer.
According to the above protocol, the approximate amount of homogenated amniotic membrane tissue per 1 ml of solution before lyophilization was about 300-350 mg. Thus, 1 ml aliquots of homogenate, lyophilized, are equivalent to approximately 300-350 mg of amniotic membrane tissue. (This amount of protein was also confirmed by protein assay after reconstitution.) The lyophilized powder was stored (e.g., at −20° C.) for six months at least so as to allow for the growth of any viruses that might have been present but undetected in the original homogenate preparation. Any reconstituted samples testing positive for the presence of viruses will be destroyed.
Lyophilized homogenate was then reconstituted gently at 4° C. and neutral pH, under sterile conditions and protected from light, in an appropriate vehicle and at an appropriate concentration for the intended use. For the high concentrations used at the start of the treatment protocol of Example II, the lyophilized homogenate was reconstituted at approximately 8 mg amniotic tissue equivalents/ml balanced salt solution (BSS). Before use, a sample of the reconstituted stock was re-tested for the presence of any viruses.
Example II
Treatment of an Ocular Condition in a Human Patient
A patient who developed Ocular Cicatritial Pemphigoid (OCP) and who had refused many available treatments was successfully treated with the novel composition of the invention. The treatment was for a short period of time, but this treatment was able to stabilize the patient's clinical condition even after use of the amniotic membrane composition was discontinued.
In July 2001, a 57 year old female patient was identified with a history of asymmetric intense burning-like pain, foreign body sensation, photophobia, epiphora and mucous discharge with a severely low visual acuity in the right eye (able to see hand movements). She had an absence of corneal sensitivity (established looking for a change in Cochet-Bonnet esthesiometer reading), a chronic corneal ulcer extended to the limbus ( FIGS. 1A and 1B , day 0 ) and inferior fornix foreshortening with trichiasis but not entropion. She had had previous episodes of conjunctival inflammation followed by inferior lids conjunctiva progressive scars and was diagnosed clinically and histologically as having OCP (showing linear deposition of IgG in the basement membrane). According to the Foster et al. (1982) OCP classification, the patient was compatible with late stage 2 to early stage 3 . Her treatment history had included tear substitutes, soft contact lenses and anti-inflammatory drugs. She refused any topical corticosteroids or immunosuppressive agents in combination with short-term steroids or minor surgical procedures. The therapies previously mentioned, including midriatic agents, were able to provide relief for only a short period of time. The conjunctival inflammation did not resolve, and the persistent corneal epithelial defect became chronic. Low visual acuity (e.g., the ability to count a clinician's fingers) was also observed.
The patient's case was managed with the amniotic membrane composition according to the invention in association with other preservative-free eye drops. During the first week of treatment, the treatment protocol included the composition of the invention in high doses (1-2 drops in the affected eye of a composition consisting of 8 mg amniotic membrane tissue equivalents/ml BSS) 5 times a day and with a preservative-free antibiotic (e.g., netilmicina sulfate) 3 times a day, preservative-free artificial tears (e.g., Carbossilmetil-cellulose) 8 times a day and preservative-free Carbomer gel at bedtime. The preservative-free drops were used to prevent bacterial growth and to promote the growth of healing cells. The second and third week of treatment consisted of the composition of the invention at a medium dose (1-2 drops in the affected eye of a composition consisting of 4 mg amniotic membrane tissue equivalents/ml BSS) 3 times a day, preservative-free netilmicina sulfate 2 times a day, preservative-free artificial tears (Carbossilmetil-cellulose) 8 times a day and preservative-free Carbomer gel at bedtime. In the fourth and fifth weeks, treatment consisted of the composition of the invention 3 times a day at a low dose (1-2 drops in the affected eye of a composition consisting of 0.4 mg amniotic membrane tissue equivalents/ml BSS) preservative-free netilmicina sulfate 2 times a day, preservative-free artificial tears (Carbossilmetil-cellulose) 8 times a day and preservative-free Carbomer gel at bedtime. Starting in the sixth week, the use of the amniotic membrane composition was suspended, keeping preservative-free artificial tears (Carbossilmetil-cellulose) treatment every hour in association with soft contact lenses.
From the very beginning of this therapeutic regimen, the patient began to feel less pain. After a transient limbal and conjunctival inflammation, the pain disappeared totally within 2 weeks along with the burning-like pain, the photophobia and, less rapidly, the conjunctival inflammation previously described. The chronic corneal ulcer resolved completely ( FIGS. 2A and 2B , day 10 and FIGS. 3A-3C , days 30 and 40 , respectively) within 6 weeks. The patient also recovered her corneal sensitivity and visual acuity (20/200). She had no further episodes of conjunctival inflammation or other episodes of inferior fornix foreshortening and trichiasis. These clinical findings still represent the stable condition of the patient.
Example III
Treatment of a Skin Condition in a Human Patient
A patient having age-related enhanced wrinkling adjacent to the eye was successfully treated with a composition according to the invention. FIG. 4A shows the wrinkling adjacent to the right eye of the patient at day 0 . A 0.35 mg/ml amniotic membrane tissue equivalent preparation in a BSS suspension was administered to the patient's skin in the treatment area at a dosage and frequency of 1-2 drops per day, at bed time. After 14 days, the wrinkling was substantially diminished, as shown in FIG. 4B .
The composition according to the invention has also been tested in a cell culture system at a concentration range of 0.3-30 mg/ml and shown to be highly effective in ensuring the function and survival of the cultured cells. Testing of the inventive composition has also been carried out in a corneal injury (scraping) mouse model with recovery substantially to normal within 14 days in corneal transparancy, specularity and reflection.
REFERENCES
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Chen H J et al. RTF Pires, S C G Tseng. Amniotic membrane transplantation for severe neurotrophic corneal ulcers. Br. J. Ophthalmol. 2000, 84:826-833.
Chikama T et al. Treatment of neurotrophic keratopathy with substance —P— derived peptide (FGLM) and insulin growth factor-1. Lancet 1998, 351:1783-1784.
Donzis P B et al. Management of noninfectious corneal ulcers. Surv. Ophthalmol. 1987, 32:94-110.
Foster C S et al. Immuno-suppresive therapy for progressive ocular cicatricial pemphigoid. Ophthalmol. 1982, 89:340-353.
Foster, C S. Cicatricial pemphigoid. Trans. Am. Ophthalmol. Soc. 1986, 527-663.
Foster, C S et al. Immunosuppressive therapy for progressive ocular cicatricial pemphigoid. Ophthalmol. 1982, 340-353.
Gomes M F et al. Int. J. Oral Maxillofac. Implants 2001, 16(4): 563-71.
Gould H L. Treatment of neurotrophic keratitis with scleral contact lenses. Eye, Ear, Nose and Throat Monthly 1967, 46:1406-14.
Hosolani H et al. Reversal of abnormal corneal epithelial cell morphologic characteristics and reduced corneal sensitivity in diabetic patients by aldose reductase inhibitor, CT-112. Am. J. Ophthalmol. 1995, 119:288-294.
Hyndiuk R A et al. Neurotrophic corneal ulcers in diabetes mellitus. Arch. Ophthalmol. 1977, 95:2193-6.
Kandarakis A S et al. The effect of epidermal growth factor on epithelial healing after penetrating keratoplasty in human eyes. Am. J. Ophthalmol. 1984, 98:411-415.
Kim J C et al. Transplantation of preserved human amniotic membrane for surface reconstruction in severely damaged rabbit corneas. Cornea. 1995, 14:473-484.
Koizumi et al. Curr. Eye Res. 2000, 20:173-7.
Kubo et al. I.O.V.S. 2001, 42:1539-46.
Kuncan J O et al. Amniotic membranes as dressings following facial dermabrasion. Ann. Plast. Surg. 1982, 8:523-7.
Lambiase A et al. Topical treatment with nerve growth factor for corneal neurotrophic ulcers. N. Engl. J. Med. 1998, 338:1174-80.
Sao-Bing Lee et al. Curr. Eye Res. 2000, 20:325-34.
Liesegang T J. Corneal complications from herpes zoster ophthalmicus. Ophthalmol. 1985, 92:316-24.
Prabhasawat P. Single and multilayer amniotic membrane transplantation for persistent corneal epithelial defect with and without stromal thinning and perforation. Br. J. Ophthalmol. 2001, 85:1455-1463.
Saiko U et al. Neurotrophic Function of Conditioned Medium From Human Amniotic Epithelial Cells. J. Neurosci. Res. 2000, 62:585-592.
Solomon A et al. Amniotic Membrane Grafts for non traumatic Corneal Perforations, Descemetoceles, and Deep Ulcers. Ophthalmol. 2002, 109:694-703.
Trelford J D et al. Am. J. Obstet. Gynecol. 1979, 134:833-845.
Tsai R J F et al. Effect of stromal inflammation on the outcome of limbal transplantation for corneal surface reconstruction. Cornea. 1995, 439-449.
Tseng S C G et al. Important concepts for treating ocular surface and tear disorders. Am. J. Ophthalmol. 1997, 124:825-35.
Tseng et al. Arch. Ophthalmol. 1998, 116:431-441.
Tsubota et al. Am. J. Ophthalmol. 1996, 122:38-52.
Uchida et al. J. of Neurosci. Res. 2000, 62:585-590.
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While the present invention has been described in conjunction with a preferred embodiment, one of ordinary skill, after reading the foregoing specification, will be able to effect various changes, substitutions of equivalents, and other alterations to the compositions and methods set forth herein. It is therefore intended that the protection granted by Letters Patent hereon be limited only by the definitions contained in the appended claims and equivalents thereof. | A method of preparing an amniotic membrane extract including the steps of obtaining a healthy amniotic membrane from a pregnant mammal, such as a pig, cow, horse or human, homogenizing the membrane to obtain a homogenate solution, freezing the homogenate solution, and lyophilizing the frozen homogenate solution to dryness is disclosed. Preferably, the lyophilized homogenate is pulverized to a powder. The lyophilized homogenate is then reconstituted before use, e.g., in a liquid, such as a balanced salt solution or fresh amniotic fluid, or in another substance, such a gel, an ointment, a cream or a soap, depending on the intended use. Also disclosed is a pharmaceutical composition prepared according to the method of the invention, for prophylaxis and/or treatment of a disease or condition, especially of the eye or the skin. Exemplary pharmaceutically acceptable carriers for the composition of the invention include an ophthalmic solution for eye drops, a gel, an ointment, an emulsion, a cream, a powder and a spray. | 0 |
RELATED APPLICATION
[0001] The present invention claims priority from and is a continuation-in-part of U.S. Provisional Patent Application 61/027,116 filed Feb. 8, 2008.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the distribution of ink cartridges for use in printers, copiers, facsimile machines and multifunctional variations thereof.
[0003] Printers, copiers, facsimile machines, and/or multifunctional variations thereof have become indispensable components of the modern office (hereinafter they may be collectively referenced as “printer” or “printers”). One common feature of many modern printers is that they consume ink and toner that are supplied by ink cartridges, such as all-in-one ink and toner cartridges that are single, self-contained, replaceable vessels for delivering ink and toner to printers. However, there are a number of different types of cartridges that contain combinations of ink and/or toner. Whether a cartridge delivers ink, toner or a combination thereof and whether the cartridge is to be used in a printer, copier, facsimile machine or a multifunctional variation thereof, for purposes of this disclosure it will be referenced as a cartridge or an ink cartridge.
[0004] The convenience of printers can be off-set when they fail to operate or “go down.” When even one printer goes down, the productivity of the office may slow down and in smaller offices may even grind to a halt. Although there are numerous reasons for printers to fail, a common reason for a printer to fail is simply that the printer has run out of ink or toner. Most offices recognize this eventuality and stock backup cartridges. However, it is not uncommon for a backup cartridge to be stored too long, for an office to not have stocked enough cartridges, or for an office to fail to stock all of the different cartridges needed to service all of the different printers used in the office.
[0005] In addition, although ink cartridges provide a convenient method of delivering the ink and toner to printers, unrecycled cartridges have become a landfill problem. In response, many businesses have begun to recycle cartridges by refilling the cartridges after the ink and toner have been expended (“remanufacturing”). Remanufacturing is most often done by third-party remanufacturers, and not by the businesses themselves. However, many businesses recycle ink cartridges on an as-needed basis. This further complicates the cartridge stockpiling problems described above. Unless the business has stocked spare cartridges for a particular printer, the business may not be able to use that printer until its cartridge is remanufactured. However, the stockpiling of extra cartridges may detract from the business's effort to recycle the cartridges.
[0006] The present invention provides a systematic method of tracking, aging, remanufacturing and delivering cartridges. Some benefits of the inventive distribution method and system include limiting the occasions when a printer goes down, limiting the occasions when a cartridge is stored too long, and providing for the recycling of cartridges without an adverse effect on the productivity of the printers.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention is directed to a method and system of scheduling the delivery of printer cartridges to businesses that minimizes the number of cartridges that a business needs to stock and the likelihood that a printer will not have a compatible cartridge when it runs out of ink or toner. The method comprises conducting a survey of the printers in a business and the consumption of ink cartridges by the printers. Such a survey may be initiated by keeping track of the use of cartridges by each printer or by reviewing records of historical cartridge purchases. The data is used to calculate a schedule for the manufacture or remanufacture, distribution and storage of cartridges for the business. At a scheduled time, a remanufacturer is contacted to remanufacture cartridges that are needed by the business. Optionally, if recyclable cartridges are not available, an original equipment manufacturer (OEM) is contacted to provide a replacement cartridge. The cartridges may be delivered to a distribution center, which then delivers the cartridges to the business, or may be delivered directly to the client. At the time of delivery, consumed cartridges are collected from the business and the survey of equipment and cartridge consumption is updated. Where there is a change in the survey, the new data is used to calculate an updated schedule.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of an embodiment illustrating the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0009] In FIG. 1 , an embodiment of the system according to the invention is shown with a scheduling computer 10 linked by connection 12 to distribution center 14 which services a number of clients 20 , 22 and 24 through channels 30 , 32 and 34 , where client 24 is optionally a self-service kiosk, which is optionally a vending machine capable of delivering cartridges 24 hours a day and seven days a week. For purposes of the present disclosure, the term connection is selected from the group consisting of a hardwire electronic connection, a wireless electronic connection, physical presence of computer 10 in or proximate to distribution center 14 such that the output of computer 10 can be transmitted to and used by the distribution center, and combinations thereof. A hardwire electronic connection can include the transmission of data through optical fibers and other means known in the art.
[0010] Herein, the term channel encompasses a communication system and/or a distribution system. Channels 30 , 32 and 34 connects the clients and the distribution center so that they may communicate and provide for the delivery of charged cartridges from the distribution system to the clients and the collection of consumed cartridges from the clients to the distribution system. In an embodiment, channels 30 , 32 and 34 are represented by a technician who according to a schedule calculated by the computer delivers the cartridges, surveys the printers and the cartridges used by the client, and collects and returns the consumed cartridges to the distribution center. In another embodiment, cartridges are delivered and collected by a delivery service such as the post office or a private parcel service according to a schedule calculated by the computer. In this embodiment, the client accepts delivery of the charged cartridges and collects and returns the consumed cartridges along with a survey of printers and consumed cartridges.
[0011] Distribution center 14 is further connected to remanufacturer 40 by channel 42 and to OEM 50 by channel 52 . Similar to the previously described channels, channels 42 and 52 , the channels encompass a communication system and a delivery system which provides the means by which the distribution center can order and take delivery of either recharged cartridges or new cartridges from the remanufacturer or the OEM, respectively. For purposes of this disclosure both the remanufacturer and the OEM may be called cartridge makers, and although the remanufacturer actually recycles the cartridges, the cartridges may be referenced as new as if originally made by the OEM.
[0012] Optionally, remanufacturer 40 and OEM 50 are connected directly with computer 10 by connections 44 and 54 , respectively. In this embodiment, remanufacturer 40 can receive orders directly from computer 10 to recharge a number of cartridges in accordance to the requirements calculated by the computer. Once an order is fulfilled, remanufacturer 40 can deliver the order to distribution center 14 via channel 42 for distribution center 14 to deliver the charged cartridges to the clients via channels 30 , 32 and 34 . Alternatively, once an order is fulfilled, remanufacturer 40 can deliver the order directly to the clients via channels 60 , 62 and 64 .
[0013] If remanufacturer 40 determines that one or more of the cartridges collected from the clients cannot be remanufactured, it may request replacement cartridges from alternative sources. In one case, it may notify computer 10 via connection 44 which then orders a replacement cartridge from OEM 50 via connection 54 . OEM 50 then delivers the replacement cartridge via channel 58 for remanufacturer 40 to work into the rotation of cartridges that are recycled among the clients. In another case, remanufacturer 40 notifies distribution center 14 via channel 42 , which orders a replacement cartridge from OEM 50 via channel 52 , which fulfills the order by delivering the replacement cartridge to remanufacturer 40 via channel 58 . In yet another embodiment, remanufacturer 40 orders and takes delivery of the replacement cartridge directly from OEM 50 via channel 58 .
[0014] In a yet another embodiment, computer 10 is electronically linked to clients 20 , 22 and 24 via connections 70 , 72 and 74 . The number and types of printers and cartridges used are automatically communicated to computer 10 which runs a constant calculation of an optimal schedule of the delivery and collection of cartridges from the clients. The computer can order cartridges in accordance to its calculations from remanufacturer 40 via connection 44 . Remanufacturer 40 can fulfill the orders by directly delivering the orders to the clients or indirectly by delivering the orders to the distribution center.
[0015] In the case, where client 24 is a kiosk, it is apparent that the kiosk must be physically restocked. In this case, the kiosk can be restocked by a technician or an automaton from distribution center 14 or remanufacturer 40 . Nevertheless, distribution of cartridge can be ascertained electronically, so that cartridges that do not move well can be replaced by more popular cartridges. The kiosk can also have an input device which allows consumers to order specific types of cartridges. The frequency of consumer requests can also be used to calculate what types of cartridges are more likely to be sold from the self-service kiosks.
[0016] The method according to the invention relies primarily on the survey of the client's printers and cartridge consumption, and the input of that data into the computer so that an optimal schedule of cartridge replacement can be calculated to minimize both printer down time and the need to stock too many cartridges. If done for a single client, it would be simple but inefficient. However, as the number of clients increase the complexity of the scheduling lo increases, but the overlap of the types of printers used by the clients can provide for efficiencies in rotating the cartridges for recycling. In addition, the economies of scale provides for greater efficiencies in the pricing, remanufacture and delivery of the cartridges.
[0017] The method is best illustrated by an example. It should be apparent that the example is only illustrative and not limiting. A survey is conducted of clients 20 , 22 and 24 . In this example, client 24 is a self-service kiosk. Client 20 has two different printers 100 and 102 requiring cartridges 200 and 202 , respectively. It is estimated that both printers consume a cartridge every three weeks. Client 22 uses printer 100 ′ which is identical to printer 100 used by client 20 , and identical printers 103 and 103 ′ which require cartridge 203 . It is estimated that printer 100 ′ uses a cartridge about every five weeks, printer 103 uses a cartridge every 8 weeks, and printer 103 ′ uses a cartridge every 9 weeks. Based upon industry data, kiosk 24 is stocked with 8 units of cartridge 200 , 4 units of cartridge 202 , 4 units of cartridge 203 and 16 units of cartridge 204 (although not shown, in this example cartridge 204 is used in popular home printer 104 ). It is estimated that the Kiosk runs out of cartridge 204 in about 2 weeks, cartridge 200 in about two weeks, cartridge 202 in about 4 weeks, and cartridge 203 in about 8 weeks.
[0018] A software program is used to calculated how often each client is visited, which cartridges are to be delivered at each visit, how many cartridges need to be stocked for each client, and how many of each type of cartridges need to be delivered. The program assigns a frequency of visit to each client, a frequency of replacement for each cartridge, and the number of backup cartridges needed to make sure that a printer does not goes down from running out of ink or toner. In addition, based upon the frequency of visit to a client, the client is also assigned a rotation number to determine when a delivery should be made to the client.
[0019] Numerous scheduling options are available, including daily, weekly, monthly delivery frequencies. The frequencies can also be varied to optimize efficiency of delivery. For example, one can use a 60 day rotation, where deliveries and cartridge replacements can take place daily or every 2, 3, 4, 5, 6, 10, 12, 15, 20, 30 or 60 days. For purposes of this example, a 24 week frequency rotation having a rotation frequency of 1, 2, 3, 4, 6, 8, 12 or 24 weeks is illustrated. In the case of a 1 week frequency for replacement of, for example, cartridge 200 for client 20 , cartridge 200 should be replaced every week. However, because of other factors, delivery to client 20 may not necessarily occur every week. If, for example, delivery to client 20 occurs every two weeks, the scheduling program would assign the delivery of two units of cartridge 200 every two weeks for client 20 , and would assign the stockpiling of one cartridge 200 for client 20 , where the backup cartridge 200 would be part of the turnover of cartridge 200 for the client 20 .
[0020] From the examples above, and illustrated rotational frequency, client 20 is assigned a three week rotation for delivery of cartridges 200 and 202 and the stockpiling of one of each of cartridges 200 and 202 that is rotated into the turnover of the cartridges. Thus, for the initial delivery a cartridge will be installed in each of printers 100 and 102 , and one of each cartridge 200 and 202 will be stocked in case the installed cartridges run out. Thus four cartridges are initially delivered. For a three week rotation there are three possible flights: 3A (weeks 1, 4, 7, 10, 13, 16, 19 and 22); 3B (weeks 2, 5, 8, 11, 14, 17, 20 and 23); and 3C (weeks 3, 6, 9, 12, 15, 18, 21 and 24). For this example, client 20 is assigned flight 3A on Mondays. Assuming that the initial delivery occurred on week 1, client 20 will receive a delivery of one cartridge 200 and one cartridge 202 on the Monday of week 4. The new cartridges replace the backup cartridges, the backup cartridges replace the installed cartridges, and the install cartridges (which we presume will be substantially exhausted) are collected for remanufacturing. The process is repeated on Monday of week 7, week 10 and so on. After week 24, the following weeks are labeled sequentially from 1-24, and the assigned flights are repeated. At any time, the schedule can be adjusted as printers are added, replaced or retired, or as cartridge consumption increase or decrease.
[0021] Client 22 would be assigned a four week frequency. For a four week rotation there are four possible flights: 4A (weeks 1, 5, 9, 13, 17 and 21); 4B (weeks 2, 6, 10, 14, 18 and 22); 4C (weeks 3, 7, 11, 15, 19 and 23); and 4D (weeks 4, 8, 12, 16, 20 and 24). Client 22 is assigned flight 4B on Mondays. The initial delivery on Monday of week 2 would be 2 units of cartridge 200 (one installed in printer 100 ′ and one stocked for printer 100 ′) and three units of cartridge 203 (one installed in each of printers 103 and 103 ′, and one as backup for both) for five initial cartridges. On Monday of week 6, only one unit of cartridge 200 should be delivered. At that time, the installed cartridge 200 should have about a week of use left. One could keep the installed cartridge for the extra week before rotating in the backup cartridge, designating the newly delivered cartridge as the backup. Alternatively, one could replace the installed cartridge with the backup cartridge, designate the newly delivered cartridge as the backup, and send the consumed cartridge to be remanufactured at the time of delivery. For the sake of simplicity, this example will immediately replace the installed cartridge. For week 6, there should be no need to deliver cartridge 203 since the one installed in printer 103 should have four weeks of use left, while the one installed in printer 103 ′ should have five weeks of use left. Thus, back up cartridge 203 should be sufficient to contend with unexpected consumption for at least one more cycle.
[0022] For client 22 , on Monday of week 10, a cartridge 200 and two cartridges 203 are delivered. The new cartridge 200 replaces the backup cartridge 200 which replaces the installed cartridge 200 which is collected for remanufacturing. The backup cartridge 203 replaces the cartridge installed in printer 103 which should be substantially exhausted. Once again there are alternative scenarios for the cartridge in printer 103 ′ which should have about a week of use left. That cartridge can be immediately replaced with one of the new cartridges or can remain in the printer for anther week. For the sake of simplicity, it is immediately replaced and the remaining new cartridge becomes the backup. For client 22 , the delivery times alternate between deliveries of only one cartridge 200 and deliveries of one cartridge 200 and two cartridges 203 .
[0023] In another embodiment, the cartridges are replaced regardless of whether they are exhausted or not. The rate of consumption is measured by weighing the cartridges before and after use, and the business is charged only based upon the pro rata use of the ink or toner.
[0024] For the self-service kiosk, client 24 , one would assign a weekly delivery schedule, which, for purposes of this example, is also assigned to Monday. However, based upon the historical turnover of cartridges, each week should only require the delivery of 4 units of cartridge 200 ; 1 unit of cartridge 202 ; 1 unit of cartridge 203 ; and 8 units of cartridge 204 . It should be noted that the units of cartridge 202 and 203 though made available are not necessarily stocked since consumption of these cartridges are relatively low. In an alternative embodiment, the kiosk would transmit the sale of each cartridge to the scheduling computer, so that the technician would know exactly how many of each type of cartridges are needed. In yet another embodiment, the kiosk would have a receptacle for consumed cartridges. As a further alternative, depositing a cartridge for recycling could provide a discount on the purchase of the next cartridge.
[0025] Because of the overlaps in the needs of each client, scheduling computer 10 can provide for an efficient schedule for the remanufacture and delivery of cartridges to, in this example, all three clients. Ignoring the initial deliveries (weeks 1-2), on weeks 3, 5, 8, 9, 11, 12 15, 17, 20 and 21, only client 24 needs to be restocked with 4 units of cartridge 200 ; 1 unit of cartridge 202 ; 1 unit of cartridge 203 ; and 8 units of cartridge 204 . However, on weeks 4, 7, 13, 16 and 19, client 24 needs to be restocked with 4 units of cartridge 200 ; 1 unit of cartridge 202 ; 1 unit of cartridge 203 ; and 8 units of cartridge 204 , while client 20 needs to be restocked with 1 unit of cartridge 200 and 1 unit of cartridge 202 . Thus, prior to Monday of those weeks, the scheduling computer orders 5 units of cartridge 200 ; 2 unit of cartridge 202 ; 1 unit of cartridge 203 ; and 8 units of cartridge 204 and the technician visits both clients 20 and 24 to deliver the cartridges in one trip.
[0026] Further, on weeks 6, 14 and 18, the needs of client 22 and 24 also overlap. However as indicated above, the rotation for client 22 does not produce the same delivery each time. On weeks 6 and 14, only one unit of cartridge 200 for client 22 is added to the requirements of client 24 . On week 18, one cartridge 200 and two cartridges 203 for client 22 are added to the cartridges needed for client 24 . As shown above, the combined requirements can be ordered and delivered efficiently.
[0027] Moreover, on weeks 10 and 22, the needs of all three clients overlap. However, client 22 only requires one unit of cartridge 200 on week 22 while it needs one cartridge 200 and two cartridges 203 on week 10. Thus, prior to week 10, the scheduling computer orders 6 units of cartridge 200 (1 for each of clients 20 and 22 and 4 for client 24 ); 2 unit of cartridge 202 (1 for client 20 and 1 for client 24 ); 3 unit of cartridge 203 (2 for client 22 and 1 for client 24 ); and 8 units of cartridge 204 (all for client 24 ). Prior to week 22, the scheduling computer orders 6 units of cartridge 200 (1 for each of clients 20 and 22 and 4 for client 24 ); 2 unit of cartridge 202 (1 for client 20 and 1 for client 24 ); 1 unit of cartridge 203 (for client 24 ); and 8 units of cartridge 204 (all for client 24 ). In each case, the technician visits each client to deliver their cartridges on the following Monday.
[0028] Although shown in the context of only three clients, as clients are added, they are slotted to particular frequencies, particular flights and particular days of the week, depending upon their particular cartridge requirements. Through the scheduling program, the ordering and delivery of cartridges benefit from synergistic needs and economies of scale, such that the cost of production and delivery decreases on a per client basis as the client base grows.
[0029] Finally, all references, including any recited priority document, cited herein are hereby incorporated by reference. While the present invention has been described in considerable detail by the illustrated examples, it will be obvious to those having ordinary skilled in the art that alterations may be made without departing from the concept and scope of the present invention as described in the following claims. | The present invention is directed to a method and system of scheduling the delivery of printer cartridges to businesses that minimizes the number of cartridges that a business needs to stock and the likelihood that a printer will not have a compatible cartridge when it runs out of ink or toner. The method comprises conducting a survey of the printers in a business and the consumption of ink cartridges by the printers. The data is used to calculate a schedule for the manufacture or remanufacture, distribution and storage of cartridges for the business. At a scheduled time, a remanufacturer is contacted to remanufacture cartridges that are needed by the business. Optionally, if recyclable cartridges are not available, an original equipment manufacturer (OEM) is contacted to provide a replacement cartridge. The cartridges may be delivered a distribution center, which then delivers the cartridges to the business, or may be delivered directly to the client. At the time of delivery, consumed cartridges are collected from the business and the survey of equipment and cartridge consumption is updated. Where there is a change in the survey, the new data is used to calculate an updated schedule. | 6 |
FIELD OF THE INVENTION
[0001] The subject matter of the present disclosure relates generally to a light fixture, and more particularly, to a light fixture having multiple light sources arranged in a linear or substantially linear manner.
BACKGROUND OF THE INVENTION
[0002] The illumination of items placed on a shelf or series of shelves presents certain challenges. Depending on the location of the light source, one shelf may block light from illuminating another shelf. Similarly, if a light is placed to one side, large items closest to the light may block light from illuminating other items on the same shelf.
[0003] Aesthetics can also be a concern particularly when attempting to optimize the positioning of the light source to address the above-mentioned illumination issues. For example, in a commercial setting where the items being displayed are e.g., consumer products, it is desirable to properly illuminate the consumer products without blocking the consumer's view or detracting from the presentation of the products. Additionally, variables such as the color and intensity of the lighting can be particularly important.
[0004] The use of light sources such as light emitting diodes, halogen bulbs, and others can present additional issues. For example, certain types of light sources can generate significant amounts of heat. This heat must be properly dissipated to e.g., avoid damaging the light fixture or improperly heating surfaces near the light fixture. If the application involves an environment where moisture may be present, such as e.g., a refrigerated display case, it may also be necessary to protect the light sources and/or associated electronics from exposure to such moisture.
[0005] Accordingly, a light fixture that can provide light from a linear source—i.e. a source where one or more light sources are aligned substantially along a longitudinal direction—would be particularly useful for certain applications. For example, such an arrangement could be used to provide lighting for items placed along a shelf or series of shelves. Such a light fixture that can also be used to provide e.g., the desired color and intensity of light would also be beneficial. Additionally, such a light fixture that can also be provided with features for varying the direction of the light would also be useful.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The present invention provides a light fixture that includes a plurality of light emitting sources, such as e.g., LEDs, which may be arranged along a longitudinal direction. At least one heat sink provides a support structure for the light emitting sources while also assisting with the dissipation of heat. A diffuser covers the light emitting sources and is also supported by the heat sink. One or more optical elements such as e.g., a reflector or internally reflecting lens, may be used to help direct light rays from the light emitting sources. Certain features may be added at the ends of the light fixture for mounting upon a surface and/or for further controlling the direction of light rays projecting from the light fixture. The light fixture may be suitable for a variety of applications including e.g., the illumination of products displayed on shelving for consumer viewing. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.
[0007] In one exemplary embodiment, the present invention provides a light fixture that includes at least one heat sink defining a longitudinal direction. At least one circuit board is attached to the heat sink. A plurality of light emitting sources are mounted to the at least one circuit board. The light emitting sources are spaced apart from each other and may be arranged along the longitudinal direction. A diffuser extends along the longitudinal direction and is attached to the heat sink. The diffuser covers the light emitting sources.
[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0010] FIG. 1 provides a perspective view of an exemplary embodiment of a light fixture of the present invention with an exemplary diffuser shown in position.
[0011] FIG. 2 provides another perspective view of the exemplary embodiment of FIG. 1 without the exemplary diffuser.
[0012] FIG. 3 illustrates a perspective view of one end of the exemplary light fixture of FIG. 1 with certain mounting features shown in place.
[0013] FIG. 4 is a cross-sectional view of the exemplary embodiment of FIG. 1 as taken along line 4 - 4 in FIG. 1 .
[0014] FIG. 5 is another perspective view of one end of the exemplary light figure of FIG. 1 with an exemplary mounting feature—i.e. an end cap—shown in place.
[0015] FIG. 6 illustrates a perspective view of the exemplary end cap of FIG. 5 .
[0016] FIG. 7 illustrates a perspective view of one end of another exemplary light fixture where certain mounting features have been removed to reveal interior components of the fixture.
[0017] FIG. 8 is a close up of a portion of the exemplary light fixture of FIGS. 1 and 2 .
[0018] FIG. 9 is a cross-sectional view of a portion of the exemplary light fixture of FIG. 1 .
[0019] FIG. 10 illustrates a perspective view of the one end of another exemplary light fixture of the present invention.
[0020] FIG. 11 is a cross-sectional, end view of another exemplary light fixture of the present invention.
[0021] FIG. 12 is an end view of an exemplary lens of the present invention while FIG. 13 is a perspective view of the same.
[0022] The use of the same or similar reference numerals in the figures indicates the same or similar features.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0024] FIGS. 1 and 2 provide a perspective view of an exemplary embodiment of a light fixture 100 of the present invention. A diffuser 102 is shown in position in FIG. 1 while in FIG. 2 diffuser 102 has been removed to reveal other components. FIG. 3 provides close-up view of a first end 104 of fixture 100 .
[0025] Light fixture 100 includes a heat sink 112 that extends along longitudinal direction L between first end 104 and a second end 106 . Each end 104 and 106 includes a bracket 108 and 110 , respectively. Brackets 108 and 110 may be used to mount fixture 100 to a surface. Apertures 114 in each bracket 108 and 110 may be used along with fasteners for such mounting. Other features may be used for mounting light fixture 100 as well. By way of example, light fixture 100 could be mounted at the top and/or bottom of a refrigerated display case and used to illuminate products on shelves in the case. Light fixture 100 may be used in other applications as well.
[0026] Fixture 100 includes a plurality of light emitting sources 116 spaced apart from each other and arranged along longitudinal direction L as shown. Each light emitting sources 116 may be e.g., one or more light emitting diodes (LEDs). The density and number of LEDs along longitudinal direction L can be determined based on e.g., the application intended for fixture 100 . As shown in FIG. 2 , light emitting sources 116 are positioned in a straight-line manner along the longitudinal direction. However, it should be understood that it is within the scope of the present invention for light sources 116 to be arranged in other manners, e.g., arranged longitudinally but not necessarily along a straight-line as shown in FIG. 2 , or arranged laterally.
[0027] For this exemplary embodiment, a reflector 118 is provided that also extends along longitudinal direction L. Reflector 118 defines a plurality of cavities (or recesses) 120 that are also spaced apart and positioned along longitudinal direction L. More particularly, each cavity 120 is positioned around or otherwise contains at least one of the light emitting sources 116 and includes one or more light reflecting surfaces 122 and 124 for reflecting light away from light fixture 100 . By way of example, reflector 118 could be constructed from a metallized plastic so as to provide light reflective surfaces 122 and 124 . Light reflected from surfaces 122 and 124 passes through diffuser 102 . For this exemplary embodiment, diffuser 102 is constructed from a material of uniform thickness that helps control e.g., the color and/or distribution of the light.
[0028] FIG. 4 provides cross-sectional view of first end 104 while FIG. 5 provides a perspective view of first end 104 with a cap 134 in place. Reflector 118 is mounted to a circuit board such as e.g., a fiberglass reinforced printed circuit board 126 . Reflector 118 can be attached using e.g., fasteners 132 . Other fastening mechanisms may also be used. For example, reflector 118 could be manufactured with pegs that provide an interference fit with holes or openings in circuit board 126 .
[0029] Circuit board 126 also extends along longitudinal direction L and is attached to heat sink 112 . By way of example, circuit board 126 could be provided with fasteners or pegs that extend into a slot 128 provided by heat sink 112 and positioned at the bottom of circuit board 126 . Heat sink 112 is constructed from one or materials that help dissipate heat created by light emitting sources 116 . Heat sink 112 also provides the structure or frame for light fixture 100 . By way of example, heat sink 112 could be constructed from anodized aluminum. For this exemplary embodiment, heat sink 112 is configured to resist collecting dirt and debris, to be readily cleanable by e.g., wiping, and still have substantial surface area for convective cooling.
[0030] Ends 104 and 106 each include apertures 130 that are oriented along longitudinal direction L. Apertures 130 are configured for the receipt of fasteners 132 that extend through apertures 142 ( FIG. 6 ) in cap 134 to secure cap 134 onto end 104 . As shown in FIG. 5 , cap 134 includes a peg 136 that extends along longitudinal direction L. Peg 136 is rotatably received into an aperture 140 defined by bracket 108 as shown in FIG. 6 . A similar construction is used for a cap (not shown) positioned on second end 106 with bracket 110 . As such, after mounting brackets 108 and 110 , light fixture 100 can be rotated in the direction desired as the pegs at first end 104 and 106 rotate within brackets 108 and 110 . A fastener such as a set screw can be inserted into aperture 138 ( FIG. 3 ) to apply force against peg 136 and fix the rotational position of light fixture 100 . A metal insert can be provided that is either heat-staked, ultra-sonically welded, or molded-in to allow such set screw or thumb screw.
[0031] Returning to FIG. 4 , an exemplary technique for mounting diffuser 102 to heat sink 112 is shown. Heat sink 112 includes a pair of grooves 150 and 152 positioned on opposite sides of reflector 118 and the plurality of light emitting sources 116 . Grooves 150 and 152 extend along longitudinal direction L. Diffuser 102 may include a pair of opposing longitudinal edges 154 and 156 that are received in a complementary manner into grooves 150 and 152 . Diffuser 102 provides a spring-like force that urges edges 154 and 156 into grooves 150 and 152 to secure the attachment of diffuser 102 .
[0032] FIG. 7 illustrates another exemplary technique for mounting diffuser 102 to heat sink 112 . More specifically, for the exemplary embodiment of FIG. 7 , heat sink 112 includes a pair of ribs 142 and 144 positioned on opposite sides and extending along longitudinal direction L. Ribs 142 and 144 project outwardly or face away from each other as well as light emitting sources 116 . Diffuser 102 includes a pair of grooves 146 and 148 positioned on opposite sides of diffuser 102 and also extending along longitudinal direction L. As shown, ribs 142 and 144 are received in a complementary manner into grooves 146 and 148 , respectively, to secure diffuser 102 into position.
[0033] FIGS. 8 provides a close up of a cavity 120 at first end 104 of light fixture 100 . Cavity 120 includes a first pair of light reflective surfaces 122 positioned in an opposing manner about light emitting source 116 . Cavity 120 also includes a second pair of light reflective surfaces 124 positioned in an opposing manner along with the first pair of light reflective surfaces 122 about light emitting source 116 . FIG. 9 provides a cross-sectional view of light fixture 100 taken along a plane parallel to circuit board 126 and at a position above light emitting source 116 . As shown, the first pair of light reflective surfaces 122 having a first parabolic shape, while the second pair of light reflective surfaces 124 have a second parabolic shape different than the first parabolic shape. The shapes of surfaces 122 and 124 are configured as such to help direct light rays emitted from source 116 . In other exemplary embodiments of light fixture 100 , other shapes may be used for surfaces 122 and 124 in addition to that which is shown including e.g., non-parabolic shapes.
[0034] FIG. 10 illustrates an end view of another exemplary embodiment of a light fixture 100 of the present invention (mounting features have been removed for purposes of illustrating interior components). Unlike the previously described embodiments, the light fixture 100 shown in FIG. 10 does not include a reflector. In addition, FIG. 10 illustrates another exemplary technique for mounting diffuser 102 to heat sink 112 . More specifically, for the exemplary embodiment of FIG. 7 , heat sink 112 includes a pair of ribs 158 and 160 positioned on opposite sides and extending along longitudinal direction L. Ribs 158 and 160 project inwardly or face towards each other as well as light emitting sources 116 . Diffuser 102 includes a pair of grooves 162 and 164 positioned on opposite sides of diffuser 102 and also extending along longitudinal direction L. As shown, ribs 158 and 160 are received in a complementary manner into grooves 162 and 164 , respectively, to secure diffuser 102 into position.
[0035] FIG. 11 is a cross-sectional, end view of another exemplary light fixture 100 of the present invention. Unlike previous embodiments, the embodiment of FIG. 11 includes an optical element or lens 166 . Referring now to FIGS. 11 , 12 , and 13 , lens 166 extends along longitudinal direction L and is positioned directly over the plurality of light emitting sources 116 , which are received into a channel 176 defined by the inside surface 178 of lens 166 . By way of example, lens 166 is provided with a pair of projecting inserts 168 and 170 that are received into circuit board 126 to secure lens 166 using an interference fit. Other features may be used to secure lens 166 as well.
[0036] Lens 166 includes a pair of internally reflecting surfaces 172 and 174 . For this exemplary embodiment, surfaces 172 and 174 may be arcuate in shape (and each may provide an external surface that is convex) within a plane that is orthogonal to longitudinal direction L as shown in FIG. 12 . As such, some of the light rays from light sources 116 will enter lens 166 through inside surface 178 , reflect off of surfaces 172 and 174 , and exit lens 166 through outer surface 180 . Other shapes for surfaces 172 , 174 , 178 , and 180 may also be used in an effort to direct light rays from light emitting sources 116 away from light fixture 100 . By way of example, lens 166 can be manufactured from a polycarbonate or an acrylic material. Lens 166 may be constructed in a variety of lengths to cover one or several light emitting sources 116 .
[0037] Light fixture 100 can be constructed in a modular manner to help simplify manufacture. For example, referring to FIG. 2 , a series of modules 182 can be installed on a heat sink 112 that is cut to the desired length. For example, heat sink 112 may be cut to a length of four feet to accept four modules 182 , each constructed at a one foot length. In turn, each module 182 could individually include e.g., a reflector 118 or lens 166 , circuit board 126 , and one or more light emitting sources 116 . Modules 182 can be connected electrically using e.g., connector 184 with wire slots 188 ( FIG. 7 ), mating pin connections 186 ( FIG. 9 ), or other connection mechanisms positioned at the ends of modules 182 .
[0038] It should be understood that for each exemplary embodiment, diffuser 102 may be constructed with a non-uniform shape and thickness so as to assist in directing light where desired. Additionally, the shape of e.g., diffuser 102 and either reflector 118 or lens 166 can be used together to minimize color separation. For example, lens 166 can be used to focus the light to increase flux density on the target plane while the diffuser 102 can un-focus the light slightly to remove color separation issues.
[0039] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | A light fixture is provided that includes a plurality of light emitting sources, such as e.g., LEDs, that are arranged along a longitudinal direction. A heat sink provides a support structure for the lights while also assisting with the dissipation of heat. A diffuser covers the light emitting sources and is also supported by the heat sink. One or more optical elements such as e.g., a reflector or internally reflecting lens may be used to help direct light rays from the light emitting sources. Certain features may be added at the ends of the light fixture for mounting upon a surface and/or for further controlling the direction of light rays projecting from the light fixture. The light fixture is suitable for a variety of applications including e.g., the illumination of products displayed on shelving for consumer viewing. | 5 |
This application is a continuation-in-part of U.S. Ser. No. 414,369 filed Nov. 9, 1973, now abandoned.
This invention relates to a Method and Apparatus for Nuclear Thermochemical Water Cracking and in particular utilizes the charged products from a nuclear fusion reaction for obtaining the dissociation of water into hydrogen and oxygen.
BACKGROUND
Much work is presently being done on the achievement of ignition and burn of fusion fuel such as, for example, deuterium-tritium in pellet form. While there are a number of different approaches to this problem, one of them includes the utilization of a source of energy from a laser and particular pellet configurations which will make it possible to achieve ignition and burn in a reaction chamber. Patents which illustrate generally the apparatus which can be used in this type of system are:
Hedstrom: U.S. Pat. No. 3,762,993--Oct. 2, 1973;
Whittlesey: U.S. Pat. No. 3,378,446--Apr. 16, 1968;
Daiber: U.S. Pat. No. 3,489,645--Jan. 13, 1970.
Many other U.S. patents issued in this field recently, e.g. U.S. Pat. Nos. 3,802,993; 3,748,226; 3,624,239; 3,152,958; 3,037,922; 3,748,226 and 3,152,958, exemplify the state of the art for production of chemicals by exposure to nuclear radiation in both fusion and fission reactor environment.
Publications which show the details of construction of the reactors, laser systems and report the status of the art include:
(a) Research/Development, May 1975, Vol. 26, No. 5, pp 55ff., "Thermonuclear fusion research with high-power lasers", an article showing fusion optics structure and requirements.
(b) "Plasma Physics and Controlled Nuclear Fusion Research", 1974, Vol. II, International Atomic Energy Agency Vienna, which defines detailed conditions of target physics in laser fusion reactions.
(c) Laser Focus, September 1975, pp 39ff., "More Evidence that Fusion Works", an article showing the production of neutrons by the laser-fusion process.
(d) Advances in Nuclear Science and Technology, 1962, Academic Press, a general report of chemonuclear reactors and chemical processing.
(e) KMS Optical Systems brochure pricing laser fusion systems and fuel pellets in the commercial market.
(f) A joint KMS Industries and General Electric catalog of commercially available Laser Systems for Plasma Research (E H M 12,214).
(g) Lawrence Livermore Laboratory reports including UCID 16850 reporting DT Fusion neutron radiation of various chemicals.
(h) "Advances in Activation Analysis", Vol. 2, Academic Press, 1972, activation analysis with 14 MeV neutron generators, and
(i) "The relevance of various neutron sources to Fusion-Reactor Radiation Effects", Nuclear Technology, Vol. 22, April 1974.
All of the aforesaid art is incorporated into and made part of this specification and disclosure.
Therefore, it is clear that the status of the art is well known, and it is unnecessary in this disclosure to obscure the nature of the invention in a myriad of details within the skill of those currently working in the nuclear arts.
OBJECTIVES
Current calculations of a first generation laser-driven nuclear fusion reaction utilizing deuterium-tritium pellets show that about 20 percent of the energy is available in the form of charged particles (particularly alpha-particles) which must be absorbed inside the reaction chamber, or on collision with the chamber wall.
If this available energy can be absorbed and utilized within the cavity, there are a number of advantages which will accrue as follows:
1. The energy will be available directly without the losses occasioned by passage through the chamber wall and possible exterior heat transfer loops;
2. Thermal and mechanical stresses in the chamber wall will be alleviated; and
3. The radiation damage to the chamber wall will be reduced.
It is, therefore, one of the primary objectives of the present invention to disclose a method and apparatus whereby an appreciable fraction of the fusion energy may be applied directly to the cracking of steam.
Another object of the invention is to improve the integrity of the fusion reaction chamber by reduction of the direct charged particle impact on the wall.
It is a further object of the invention to provide a source of hydrogen gas and oxygen from the dissociation of steam, each of which are valuable materials which may be utilized for additional sources of heat and fuel.
BRIEF DESCRIPTION OF THE INVENTION
The above, as well as other objects, features and advantages of the invention, will become apparent by reference to the following detailed description and claims wherein there is set forth the principles of the invention together with a description of the utility thereof in connection with the best mode presently contemplated for the practice of the invention.
THE DRAWING
Drawings accompany the application wherein there is illustrated:
In FIG. 1, a schematic view of a reaction chamber and the necessary connections thereto for the present apparatus.
In FIG. 2, a view of a particular separation nozzle.
DETAILED DESCRIPTION
A central fusion reaction chamber 10 is formed by a surrounding neutron-moderating heat transfer and/or breeding blanket 12 which performs the usual functions of containment and heat recovery in common use in nuclear devices. The apparatus is operated by utilizing a source of energy from a laser 14 discharging through a channel 16 to the center of the reaction chamber where a pellet 18 will be provided in timely fashion for the laser pulse. A pellet injector housing 20 having an injector tube 22, leading to the center of the reaction chamber, is provided to place pellets sequentially into ignition position in a conventional manner. A chamber 24 is provided as a source of steam which will be transferred to the reaction chamber through a channel 26 and a port 28 at a suitable pressure. An effusion escape port 30 is provided from central chamber 10 leading to a nozzle outlet 32.
In the operation of the apparatus, the source of steam 24 is at appropriate pressure to inject a quantity of steam M (in Kilograms Kg) into the chamber having a radius R (meters, m) through the steam entry port 28 for each pellet. The laser fusion fuel pellet is, with suitable timing, injected through the pellet injector tube 22 from the storage chamber 20; and when it reaches the center of the chamber 10, the laser beam is fired through the external laser tube 16 and the interior protective tube 17, the latter being desirable to prevent the laser beam from being refracted and attenuated by the steam or possibly absorbed by breakdown of the steam. In some cases the pellet 18 may be mechanically positioned at the center of the chamber in the focus of the laser beam or brought to this position in any desirable way available in the art. With the energy of the laser focused on the pellet, there will be a release of a quantity of energy E (megajoules MJ) of which about one-fifth is in the form of alpha-particles of energy 3.52×10 6 electron volts (3.52 MeV).
The range r (centimeters, cm) of such particles in steam is given by the formula r=10.85 (R 3 /M) having reference to the units above defined. This relationship follows from the data given in the following:
Nuclear Engineering Handbook, edited by H. Etherington, McGraw Hill, New York, 1958; and
Nuclear Physics, I. Kaplan, Edison Wesley, Cambridge, 1956.
The corresponding mass of the steam, m (grams, gm) in which the alpha-particle energy is initially deposited is thus m=1.28 (R 6 /M 2 ): These quantities are preferably chosen so that r<100 R, so that all of the alpha-particles are absorbed in the steam within the chamber. This requires that M>0.109R 2 for a typical configuration, M˜1, R˜1, so that m≃1.
The alpha-particle energy is thus initially absorbed in about one-tenth (0.1) of the volume of the chamber, surrounding the center which is heated to a very high temperature represented by the following: ##EQU1##
Using the information in the 3rd Edition of the American Institute of Physics Handbook, edited by E. Gray, McGraw Hill, New York, 1972, it can be determined that the time for the heat to diffuse through the entire chamber is: ##EQU2##
Taking the above values, and E=20, t≃4.6×10 -6 s. This is a very small value compared to the pulse rate of one-fifth of a second (0.2 sec) for injecting pellets in this general configuration and thus allows the steam to attain a uniform temperature T (°K) throughout the cavity, the relationship being T=(131 E/M).
The equilibrium constant for thermal dissociation of the steam is then: ##EQU3## This is in accordance with the information available in Heat and Thermodynamics, 5th Edition, M. W. Zemansky, McGraw Hill, New York, 1968.
The equilibrium pressure in the chamber can be defined as p=(0.14E/R 3 ) (atmospheres). The equilibrium degree of dissociation ε is given by the equation: ##EQU4## When R=1 and M=1, (p/K 2 ) is much less than 1 for E is > than 20, so that the steam is almost completely dissociated under these conditions.
The mean temperature T is 2620° K., and the pressure 2.8 atmospheres. The mean molecular velocities under these conditions are 1.6×10 5 cm/s. With reference to Modern Chemical Kinetics, H. Eyring and E. M. Eyring, Reinhold Publishing Company, New York, 1963, the recombination coefficient of the hydrogen and oxygen of the dissociated steam under these conditions is estimated to lie in the range 0.3×10 5 cm 3 /mole/s to 10 6 cm 3 /mole/s.
Accordingly, the amount of dissociated material effusing through an aperture is thus determined approximately by an equation of the form: ##EQU5## Accordingly, the ultimate amount of emitted dissociated material is: ##EQU6## where M is the initial amount in the cavity and a=(c/K) is the ratio of the escape velocity and the recombination constant in appropriate units.
Thus, for 0.17<a<0.5 one has .28 M<m∞<0.5 M. This indicates an external yield of dissociated material corresponding to the range 28 percent to 50 percent. The use of a nozzle such as shown schematically at 32 in the drawing and the diffusing material results in cooling and substantially reduces the chances of recombination. Because of the fact that the velocity of the hydrogen and the oxygen will be different, it is possible to maintain the separation of the gases and to capture them in isolated quantities.
In order to remove the separated products rapidly enough to ensure a reasonable yield and reduce recombination it is necessary to have the dissociated material move out as rapidly as possible and maintain (and indeed increase) its degree of separation. This may be accomplished by the use of a nozzle designed for supersonic flow (sonic velocity at the throat) [cf "Introduction to Aeronautical Dynamics" by M. Rauscher, (Wiley, NY 1953) p. 143f]; with such a nozzle one may estimate a fractional yield (3f w t f 10 3 /R) grams per pulse, where f w is the fraction of the wall used for nozzle apertures, t f the flow time and R the chamber radius in meters as before. Taking R=1, t f =10 -2 and f w =10 -2 , one obtains a yield of 30%.
As shown in FIG. 2, in order to maintain (and accentuate) the separation of hydrogen and oxygen, a portion of the nozzle 32 may be constructed of a honeycomb or grid of zirconium dioxide (Zr O 2 ) a high temperature ceramic, through which oxygen diffuses much more rapidly than hydrogen. If a section of the nozzle is as shown in FIG. 2, there will be an additional separation as the dissociated gas passes through the nozzle. While the separation may not be complete, the various outlets shown will produce mainly O 2 or H 2 as shown.
It will thus be seen that there is described a method and apparatus for utilizing a nuclear fusion reaction source to heat steam by charged particle deposition and decompose it to hydrogen and oxygen and then allow these products to diffuse out of the reaction chamber before recombination can occur. It will be appreciated that the fusion source may be modified to produce most of its energy in charged particles and less in the form of externally deposited neutrons if the primary purpose is to crack steam. It has been found possible to reduce the recombination of the decomposed materials by cooling them as to effuse from the reaction chamber by the expansion nozzle provided or some other common means.
It will be appreciated that the above-described process may be either used as a part of a fusion reactor, primarily for the purpose of protecting the reaction chamber when steam cracking is not the primary or supplemental purpose of the system or it can be used as a primary source of hydrogen and oxygen devoted entirely to the production of those elements. | A method and apparatus for dissociating steam in a fusion reaction central chamber. The charged particle energy from an ignited fusion fuel pellet is directed to and distributed in a suitable volume of steam, bringing the steam to temperature and pressure conditions leading to dissociation into hydrogen and oxygen. The resulting atomic and molecular velocities are sufficiently high to allow egress of the separated products through a suitable shaped nozzle prior to recombination, making it practical to separate and capture the dissociated products. | 8 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/721,000, “Folding Knife with Replaceable Blade,” filed Oct. 31, 2012, and Chinese Patent CN201210418907.0, entitled Cutting Tool with Replaceable Blade,” filed Oct. 26, 2012, the entire disclosures of which are incorporated by reference herein.
[0002] This application is also related to U.S. Pat. No. D592,033, which discloses a locking version of the knife described in U.S. Patent Application Publication No. 2005/0229404 and European Patent No. EP1570959, the entirety of each of these references being incorporated by reference herein.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention generally relate to knives. More specifically, one embodiment of the present invention is a folding knife that has a replaceable blade element. Another embodiment is a non-folding knife with a replaceable blade element.
BACKGROUND OF THE INVENTION
[0004] Knives are usually comprised of a handle with a blade that is interconnected thereto. Some knives employ blades that are rotatably interconnected, and selectively lockable, to the handle. When the knife is not in use, it is sheathed or, in the case of folding knives, the blade is folded into the handle. When in use, the rotatable blade is extended from the handle and locked in place. Such locking mechanisms are known and engage a portion of the blade to hold it in place until the user disengages the lock mechanism, which allows the blade to be folded into an opening in the handle to conceal all or a portion of the blade.
[0005] Regardless of knife type, it is desirable to provide a cutting edge that is very sharp, similar to the sharpness provided by a razor blade. However, razor blade sharpness comes at a price. More specifically, razor blades often possess very thin edges that are brittle and wear, i.e., lose their edge, relatively quickly. Blade performance can be repaired by sharpening, but doing so will reduce blade size and durability. In addition, thin razor blades lack lateral strength and are thus flimsy and can fracture easily when put to hard use to cut forcibly or when cutting at an angle that applies lateral side-force to the blade. Thus, some knives employ a razor-sharp replaceable blade element that fits within a blade carrier, which may be foldable within a handle. Once the replaceable blade element becomes dull, or after repeated sharpening, it is removed from the blade carrier and discarded. Another razor blade is then inserted into the carrier.
[0006] Some knives of this type employ a complicated blade interconnection mechanism. For example, U.S. Pat. Nos. 5,689,889 and 6,574,868 to Overholt disclose razor blades for interconnecting to a blade carrier of folding knife. These knives receive the replacement blade member in a complicated fashion wherein the replaceable blade element must be first introduced into the blade carrier at and angle and then rotated into place. Finally, the replaceable blade element is locked within the blade carrier. As one of skill in the art will appreciate, replacing a blade in this fashion is difficult and, because the replaceable blade members are extremely sharp, manipulating the blade into place can cause injury. To lock and secure the blade, Overholt discloses the use of a separate threaded fastener that attaches to the blade carrier. To replace the blade, the fastener must first be loosened and completely detached from the blade carrier before the sharpened razor blade portion can be removed. This is time consuming and dangerous because the user must remove the fastener by hand from the blade carrier, which is located in close proximity to the sharp cutting edge of the razor blade. Further, loosening or removing the fastener requires the use of both hands, which makes it not possible to safely hold the knife or secure the knife by the handle while removing the fastener. Further, the fastener is commonly made up of two or more small parts that must be detached from the blade carrier to replace the blade. The fastener parts can easily be dropped and lost, especially when used in the outdoors. If one or more small parts of the fastener are lost when changing the blade, the new blade cannot be attached to the blade carrier and the knife is no longer functional.
[0007] The following disclosure describes a knife with the replaceable blade that is selectively inserted into blade carrier in a way that facilitates easy interconnection, reduces the chance of injury, and eliminates the need for separate parts that must be detached from the knife to remove and insert a new blade.
SUMMARY OF THE INVENTION
[0008] It is one aspect of embodiments of the present invention to provide a folding knife with a replaceable blade. More specifically, one embodiment of the present invention includes a handle having a first portion and a second portion spaced from the first portion. The space between the first handle portion and the second handle portion receives the replaceable blade when the knife is not in use. A blade carrier is rotatably interconnected to the handle and operates as in a traditional folding knife: 1) in a first position of use wherein at least a portion of the blade carrier is positioned within the housing; and 2) in a second position of use wherein the blade carrier is locked in an open position and extended from the housing. The blade carrier selectively receives a replaceable blade element.
[0009] It is another aspect of embodiments of the present invention to provide a non-folding knife with the replaceable blade portion. More specifically, one embodiment of the present invention includes a handle with a fixed blade carrier.
[0010] The blade carrier of embodiments of the present invention have a first carrier portion and a second carrier portion, which is spaced from the first carrier portion, which receives the replaceable blade. The first carrier also includes a channel that selectively receives a pin. The second blade carrier includes a flexible member with a pin that selectively engages an aperture in the replaceable blade member to secure it to the blade carrier.
[0011] To replace the blade, a release button, which is spring-biased relative to the handle, is depressed which deflects portion of the second blade carrier. Deflection of the blade carrier removes the pin from the aperture, which allows the blade to be removed. The blade is inserted in a direction generally parallel to the longitudinal axis of the handle, i.e., in a direction parallel to the length of the handle. Thus complicated blade rotation is not necessary to secure the blade to the blade carrier.
[0012] It is another aspect of embodiments of the present invention to provide a knife that includes a replaceable blade that is safe and easy to remove. More specifically, as mentioned above, replaceable blades of the prior art are in many respects difficult to engage into the blade carrier and require a complicated interconnection sequence requiring the use of both hands to remove the locking/retaining portion of the blade from the blade carrier. The contemplated replaceable blade portion is inserted longitudinally relative to the handle. Also, the blade is designed to extend from the carrier so that is easy to grasp with the thumb and forefinger of one hand while the other hand securely grasps the handle portion and depresses the lock release button with one finger. This makes it much easier, faster, and safer to attach and remove the replaceable blade.
[0013] It is another aspect of embodiments of the present invention to provide a knife that eliminates the need for small separate parts (other than the replacement blades) that must be detached from the knife to change the blade. The prior art teaches a blade fastener that requires small parts that must be detached and can easily be lost when replacing the blade. With embodiments of the present invention, there are no separate parts required to fasten and detach the replaceable blade from the knife.
[0014] It is another aspect of embodiments of the invention to provide a knife, comprising: a blade carrier having a first portion that is spaced from a second portion, the blade carrier being connected to a handle; a first blade liner portion associated with the first blade carrier; a second blade liner portion associated with the second portion of the blade carrier; a replaceable blade positioned between the first blade carrier and the second portion of the blade carrier; a replaceable blade release button associated with a deflectable portion of the first blade liner portion; and a pin interconnected to the second portion of the blade carrier that is deflected to release the replaceable blade when the release button is depressed.
[0015] It is yet another aspect of embodiments of the present invention to provide a cutting tool having a blade carrier that is connected to a handle and selectively lockable relative thereto, a blade liner associated with the carrier, and a replaceable blade selectively interconnected to the blade carrier, the improvement comprising: a release button associated with a deflectable portion of the blade liner portion; a pin interconnected to the blade carrier and adapted to be received within an aperture of the replaceable blade that is deflected by the release button to release the replaceable blade; and wherein the replaceable blade includes a hook on an upper edge thereof that selectively engages a member integrated within the blade carrier, and wherein the replaceable blade is positioned within the blade carrier along a longitudinal axis of the blade carrier.
[0016] It is still yet another aspect of embodiments of the present invention to provide a method of replacing a replaceable blade into a knife comprising a blade carrier having a first portion that is spaced from a second portion, the blade carrier being connected to a handle; a first blade liner portion associated with the first blade carrier; a second blade liner portion associated with the second portion of the blade carrier; a replaceable blade positioned between the first blade carrier and the second portion of the blade carrier; a replaceable blade release button associated with a biasing member of the first blade liner portion; and a pin interconnected to the second portion of the blade carrier, comprising: depressing the release button; engaging an end of the release button onto the second portion of the blade carrier; deflecting a portion of the second portion of the blade carrier; removing the pin away from an aperture of the replaceable blade; and moving the replaceable blade from the blade carrier.
[0017] The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
[0019] FIG. 1 is a front elevation view of a folding knife with a replaceable blade of one embodiment of the present invention;
[0020] FIG. 2 is a front elevation view of FIG. 1 ;
[0021] FIG. 3 is a front elevation view of FIG. 1 wherein the replaceable blade has been removed;
[0022] FIG. 4 is a perspective view of FIG. 1 ;
[0023] FIG. 5 is a perspective view of FIG. 1 , wherein the blade is partially inserted in the carrier portion of the knife but not locked in a position of use;
[0024] FIG. 6 is a partial cross-section of FIG. 1 ;
[0025] FIG. 7 is a detailed front perspective view wherein a first handle portion has been removed for clarity;
[0026] FIG. 8 is another detailed front perspective view wherein a first handle portion has been removed for clarity;
[0027] FIG. 9 is yet another detailed from perspective view wherein a first handle portion has been removed for clarity; and
[0028] FIG. 10 is a perspective view of another embodiment of the present invention wherein the removable blade element is used in conjunction with a fixed blade;
[0029] FIG. 11 is a front elevation view of FIG. 10 ;
[0030] FIG. 12 is a top plan view of FIG. 10 ;
[0031] FIG. 13 is a front elevation view of FIG. 10 showing the removable blade element partially inserted in the carrier portion of the knife but not locked in a position of use;
[0032] FIG. 14 is a cross-sectional view of FIG. 11 ;
[0033] FIG. 15 is a detailed view of FIG. 14 ;
[0034] FIG. 16 is a detailed view of FIG. 14 , showing an alternate embodiment;
[0035] FIG. 17 is a perspective view showing a fixed blade version of the knife without the handle;
[0036] FIG. 18 is a detailed view of FIG. 17 ;
[0037] FIG. 19 is a perspective view is a rear perspective view of a fixed blade version if the knife wherein half the handle is omitted for clarity; and
[0038] FIG. 20 is a perspective view of the fixed blade version of the knife.
[0039] To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein:
# Component
[0000]
2 Knife
6 Handle
10 Blade
14 Blade carrier
15 Member
16 Blade carrier lock release
17 Guide surface
18 Replaceable blade
22 Blade carrier lock
26 Upper portion
30 Replaceable blade lock release button
34 Front blade portion
38 Front edge
46 Replaceable blade lock protrusion
50 Hook
54 Blade carrier liner
58 Lock release button pin end
62 Channel
66 Biasing member
68 Recess
70 Tab
72 Recess
74 Aperture
78 Sloped surface
82 Blade end
102 Knife
106 Handle
110 Blade
114 Blade carrier
115 Member
118 Replaceable blade
130 Replaceable blade lock release button
134 Front blade portion
138 Front edge
146 Replaceable blade lock protrusion
150 Hook
154 Blade carrier support
158 Lock release button pin end
162 Opening
166 Biasing member
168 Recess
169 Spring plate
170 Tab
172 Recess
174 Aperture
178 Sloped surface
182 Blade end
184 Sloped surface
[0088] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0089] FIGS. 1-9 show a knife 2 of one embodiment of the present invention that includes a handle 6 that is operably interconnected to a blade 10 . The blade 10 is comprised of a blade carrier 14 that selectively receives a replaceable blade 18 . The blade carrier 14 is locked in place by a common locking mechanism 22 (see, FIGS. 8 and 9 ). In one embodiment of the present invention a lock 22 selectively engages an upper portion 26 of the blade carrier 14 wherein a release button 16 is used to move the lock 22 and a lateral direction which unseats the lock 22 from the blade carrier 14 .
[0090] FIGS. 2 and 3 show the replaceable blade 18 captured by the blade carrier 14 and removed therefrom, respectively. A front blade portion 34 of the replaceable blade 18 extends from a front edge 38 of the blade carrier 14 , which facilitates grasping of the replaceable blade 18 . That is, the replaceable blade 18 also extends from the front edge 38 of the blade carrier 14 , which provides ample room for the user to grasp the replaceable blade 18 with their thumb and forefinger. In addition, the majority of the length of the replaceable blade 18 is supported by the carrier 14 , which provides enhanced stiffness and support. More specifically, the blade carrier in some instances will support the replaceable blade 18 such that it can be sharpened. To release the replaceable blade 18 , which will be discussed in further detail below, the user engages a replaceable blade lock release button 30 . The replaceable blade 18 is secured to the carrier 14 on one end by a lock pin 46 and on the other end by a member 15 positioned between the first blade carrier 14 ′ and the second blade carrier 14 ″ that receives a hook 50 on the replaceable blade 18 . The member 15 also includes a guide surface 17 that facilitates interconnection of the replaceable blade 18 and the carrier 14 .
[0091] FIG. 3 shows that in one embodiment of the present invention the first blade carrier portion 14 ′ and the second blade carrier portion 14 ″ have different widths and/or lengths. More specifically, the first blade carrier portion 14 ′ may have a width/length that is less than the width/length of the second blade carrier portion 14 ″. In operation, the replaceable blade 18 is abutted against a portion of the second blade carrier portion 14 ″ that extends beyond the width or length of the first blade carrier portion 14 ′. The offset surface between the blade carrier portion forms a ledge that acts as a guide that facilitates interconnection of the replaceable blade 18 into the carrier 14 . Without this offset surface, the replaceable blade 18 must be aligned and inserted directly into the small gap between the first blade carrier 14 ′ and the second blade carrier 14 ″, thus requiring greater skill and dexterity to facilitate the interconnection of the replaceable blade 18 into the carrier 14 . In addition, to facilitate interconnection, an end of the replaceable blade 82 is abutted against the guide surface 17 and slid rewardly until the hook 50 is engaged onto a corresponding portion of the member 15 . In this fashion, a user must only grasp the front blade portion 34 of the replaceable blade 18 and safety is enhanced.
[0092] FIG. 6 is a cross-sectional view of one embodiment of the present invention. The handle is composed of a first handle portion 6 ′ and a second handle portion 6 ″ that are spaced to provide a gap for receipt of a first blade carrier portion 14 ′ and the second blade carrier portion 14 ″. A first blade carrier liner 54 ′ is associated with the first handle portion 6 ′ and a second blade carrier liner 54 ″ is associated with the second handle portion 6 ″. The first blade carrier liner 54 ′ and the second blade carrier liner 54 ″ are associated with corresponding blade carrier portions and provide support thereto. The blade lock release button 30 is associated with the first blade carrier liner 54 ′ and has an end 58 that selectively engages a flexible portion of the second blade carrier 14 ″. The first blade carrier 14 ′ also has an arcuate channel 62 ( FIG. 8 ) that receives a portion of the blade lock release button 30 .
[0093] FIG. 7 shows the first blade carrier liner 54 ′ in greater detail. The first blade carrier liner 54 ′ has a biasing member 66 , i.e., an outwardly extending portion thereof that biases the blade release button 30 in a locked position. Depression of the blade release button 30 flexes the biasing member 66 inwardly which forces a portion of the second carrier 14 ″ into a recess 68 ( FIG. 6 ) of the second blade carrier liner 54 ″ which removes the lock pin 46 from the replaceable blade 18 . One of skill in the art will appreciate that the biasing member may be a deflectable portion of the carrier liner 54 ′, a leaf spring, a coil spring associated with the blade lock release button 30 , or any other spring device known in the art.
[0094] More specifically, the blade lock release button 30 , when depressed, selectively engages a flexible tab 70 of the second blade carrier. The tab also includes the lock pin 46 . Depression of the release button 30 deflects the tab 70 and moves the lock pin 46 in a lateral direction which moves the lock pin 46 out of an aperture 74 of the blade 18 . The flexible tab 70 may further include a recess 72 , indent, or scalloped portion that facilitates deflection. When the obstruction created by the lock pin 46 is removed, the blade 18 can be removed from the blade carriers 14 . The lock pin 46 may have a sloped surface 78 that when contacted by an inserting blade deflects the tab 70 so that the blade can be fully inserted. More specifically, sliding the blade 18 in a direction parallel to the longitudinal axis of the knife 2 will engage the rear surface 82 of the blade 18 against the sloped surface 78 of the pin, which will deflect the tab 70 . The blade end 82 may employ a corresponding sloped surface (see, FIG. 15 , reference no. 184 ) that interacts with the sloped surface 78 of the pin, which facilitates insertion of the replaceable blade. Once the end portion 82 of the blade 18 is positioned past the lock pin 46 , the aperture 74 will eventually be positioned over the lock pin 46 and the pin will recoil to secure the blade.
[0095] FIGS. 10-20 show a knife 102 of one embodiment of the present invention that includes a handle 106 that is fixedly interconnected to a blade 110 . The blade 110 is comprised of a blade carrier 114 that selectively receives a replaceable blade 118 .
[0096] FIGS. 11-13 show the replaceable blade 118 captured by the blade carrier 114 and removed therefrom, respectively. A front blade portion 134 of the replaceable blade 118 extends from a front edge 138 of the blade carrier 14 , which facilitates grasping of the replaceable blade 118 . That is, the replaceable blade 118 also extends from the front edge 138 of the blade carrier 114 , which provides ample room for the user to grasp the replaceable blade 118 with their thumb and forefinger. In addition, the majority of the length of the replaceable blade 118 is supported by the blade carrier 114 , which provides enhanced support. To release the replaceable blade 118 , which will be discussed in further detail below, the user engages a replaceable blade lock release button 130 . As described above with respect to FIGS. 2 and 3 , the replaceable blade 118 is secured to the carrier 114 on one end by a lock pin 146 ( FIG. 15 ) and on the other end by a member 115 positioned between the first blade carrier 114 ′ and the second blade carrier 114 ″ that receives a hook 150 on the replaceable blade 118 . The member 115 also includes a guide surface similar to that described above that facilitates interconnection of the replaceable blade 118 and the carrier 114 .
[0097] Similar to the embodiment shown in FIG. 3 , this embodiment of the present invention may also have a first blade carrier portion 114 ′ and the second blade carrier portion 114 ″ have different widths and/or lengths. More specifically, the first blade carrier portion 114 ′ may have a width/length that is less than the width/length of the second blade carrier portion 114 ″. In operation, the replaceable blade 118 is abutted against a portion of the second blade carrier portion 114 ″ that extends beyond the width and/or length of the first blade carrier portion 114 ′. The offset surface between the blade carrier portion forms a ledge that acts as a guide that facilitates interconnection of the replaceable blade 118 into the carrier 114 . Without this offset surface, the replaceable blade 118 must be aligned and inserted directly into the small gap between the first blade carrier 114 ′ and the second blade carrier 114 ″, thus requiring greater skill and dexterity to facilitate the interconnection of the replaceable blade 118 into the carrier 114 . In addition, to facilitate interconnection, an end of the replaceable blade 182 ( FIG. 15 ) is abutted against the guide surface (not show, but similar to the guide surface 17 described above) and slid rewardly until the hook 150 is engaged onto a corresponding portion of the member 115 ( FIG. 12 ). In this fashion, a user must only grasp the front blade portion 134 of the replaceable blade 18 and safety is enhanced.
[0098] FIGS. 14 and 15 are cross-sectional views of a fixed blade embodiment of the present invention. The handle 106 is composed of a first handle portion 106 ′ and a second handle portion 106 ″. A first blade carrier support 154 ′ is associated with the first handle portion 106 ′ and a second blade carrier support 154 ″ is associated with the second handle portion 106 ″. The blade lock release button 130 is associated with the first blade carrier support 154 ′ and has an end 158 that selectively engages a flexible portion of the second blade carrier 114 ″.
[0099] FIG. 15 shows the first blade carrier support 154 ′ in greater detail. The first blade carrier support 154 ′ has a biasing member 166 , i.e., an outwardly extending portion thereof that biases the blade release button 130 , which is secured thereto. Depression of the blade release button 130 flexes the biasing member 166 inwardly which forces a portion of the second carrier 114 ″ into a recess 168 which removes the lock pin 146 from the blade 118 . One of skill in the art will appreciate that the biasing member may be a deflectable portion of the carrier support 54 ′, a leaf spring, a coil spring associated with the blade lock release button 30 , or any other spring device known in the art.
[0100] FIG. 16 shows the first blade carrier 114 ′ in greater detail. In this embodiment the first blade carrier 114 ′ and the second blade carrier 114 ″ extend towards the midpoint of the handle 106 . Further, the biasing member 166 is integral with the first blade carrier 114 ′. In addition, liners described above are not needed. Depression of the blade release button 130 flexes the biasing member 166 inwardly which forces a portion of the second carrier 114 ″ into a recess 168 which removes the lock pin 146 from the blade 118 . One of skill in the art will appreciate that the biasing member may be a leaf spring, a coil spring associated with the blade lock release button 30 , or any other spring device known in the art.
[0101] More specifically, the blade lock release button 130 , when depressed, selectively engages a flexible tab 170 of the second blade carrier 114 ″. The tab 170 also includes the lock pin 146 . The flexible tab 170 may further include a recess 172 , indent, or scalloped portion that facilitates deflection. Depression of the release button 130 deflects the tab 170 and moves the lock pin 146 in a lateral direction which moves the lock pin 146 out of an aperture 174 of the blade 118 . When the obstruction created by the lock pin 146 is removed, the blade 118 can be removed from the blade carriers 114 . The lock pin 146 may have a sloped surface 178 that when contacted by an inserting blade deflects the tab 170 so that the blade can be fully inserted. The blade end 182 may employ a corresponding sloped surface 184 that interacts with the sloped surface 178 of the pin, which facilitates insertion of the replaceable blade. More specifically, sliding the blade 118 in a direction parallel to the longitudinal axis of the knife 102 will engage the rear surface of the blade 118 against the sloped surface 78 of the pin, which will deflect the tab 170 . Once the end portion 182 of the blade 118 is positioned past the lock pin 146 , the aperture 174 will eventually be positioned over the lock pin 146 and the pin will recoil to secure the blade.
[0102] The blade of embodiments of the present invention is made out of high carbon or high carbon stainless steel and is approximately 2.5-4.0 inches (about 63.5-102 mm) long. The blade carriers are made of stainless steel and are spaced about 0.02-0.15 inches (about 0.55-3.8 mm) from each other. The blade carrier supports are made out of stainless steel or plastic however, one of skill in the art will appreciate that the replaceable blade, blade carriers, and blade supports may be made of any suitable material.
[0103] While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. In addition, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. | A knife is provided that includes a replaceable blade element. The knife employs a blade carrier that is fixedly interconnected to or foldable with respect to a handle. The blade carrier selectively receives the replaceable blade element that is locked into the blade carrier by way of a hook and movable pin combination. The replaceable blade element is designed to be inserted within the blade carrier quickly, easily, and safely. | 8 |
FIELD OF THE INVENTION
The present invention relates to hairstyling, and, in particular to an improved tease comb and hair pick for increasing the volume and speed of backcombing and facilitating its placement.
BACKGROUND OF THE INVENTION
Various techniques are employed by individuals and hair stylists in smoothing hair and giving the hair illness and height. Normal brushing and combing for smoothing hair is readily accomplished without undue skills and a multitude of satisfactory products are conventionally employed. Backcombing and teasing, however, require substantially greater skills to achieve the desired effect.
Teasing or backcombing generally involves combing small portions of the hair ends toward the scalp and establishing a mat adjacent the scalp that forms a cushion or base. Such techniques are also known as ratting, lacing, roughing or fluffing. The purpose of such techniques is to increase the apparent volume of hair preparatory to final combing. These effects are accomplished by lifting portions of hair strands and combing them from the outer ends toward the scalp, as opposed to general smoothing wherein the motion is from the scalp toward the outer ends. By rapid back and forth movement, a portion of the strands are compacted against the scalp to create the volume. After creation of the volume, hair picks are used to raise the hair mass from the scalp to achieve the desired styling effect.
The skills and dexterity required for achieving these effects are difficult for individuals to master, and even professionals require considerable experience in order to create backcombed volume in an effective and efficient manner, and to reposition the volume for optimum effect. Recognizing these limitations, many specialized combs, brushes and pick constructions have been proposed to increase the formation of the backcombed volume and to reduce the skills necessary for its creation.
In one approach widely commercially used, a combined comb and hair pick employs a longitudinal series of regular length teeth that are periodically interrupted by an intermittent series of shorter length teeth. It is thoughts by many hair stylists that the shorter teeth have the effect of forcing greater numbers of hair strands toward the scalp without reextending these strands during the backstroke. The integral hair pick allows the user to probe and reposition the volume without using a separate tool. Nonetheless, considerable skill is required to master the required manipulative skills for creating and positioning the styling effect.
Other comb and brush modifications have been proposed to increase the volume and to reduce the skills attendant to teasing for volume and picking for placement. For example, U.S. Pat. No. 4,917,129 to Olson provides a tease comb/hair pick having teeth of three different lengths and of varying cross section, i.e. circular and oval. Such arrangement is proposed as a basis for increasing volume and reducing tangling and knotting.
U.S. Pat. No. 5,694,953 to Stephan et. al. provides a hairdressing comb having a series of spaced pairs of hair lifting teeth with opposed, staggered barbs that selectively engages portions of the strands to lift them during the upward brushing for selective streaking and like purposes.
U.S. Pat. No. 3,628,545 to Moody proposes using a high friction material at the base of conventional low friction comb teeth. Such a format is suggested as a technique for increasing formation of compacted hair strands during forward brushing movement. U.S. Pat. No. D389,271 to Celik provides enlarged roots for the teeth that are inclined relative to the tips, apparently also providing differential gripping effects for the hair strands during the teasing thereof.
In U.S. Pat. No. 3,603,323 to Avella, opposed combs that may be actuated toward one another into juxtaposed overlapping engagement to increase engagement on hair strands during forward movement. The combs are biased away from each other during the return-combing stroke.
The foregoing approaches while increasing movement of hair strands toward said scalp require considerable dexterity to avoid overly compacting hair mass during the forward stroke, and to release sufficient hair strands during the return stroke to establish an orderly buildup of the teased volume in the desired areas and achieve the intended styling effect. Moreover, to the extent a pick capability is provided on the comb, the hair engagement surface is essentially linear resulting in only localized lifting that can distort the teased volume and require substantial time consuming repetition to achieve the desired result.
SUMMARY OF THE INVENTION
The present invention provides a dual blade tease comb and hair pick that can be readily used by individuals and professionals, employs conventional backcombing techniques, creates quickly and efficiently desired teased volumes at easily controlled locations, and conveniently repositions the teased volume at desired locations without distortion. More particularly, the tease comb and hair pick of the present invention provides a pair of comb and pick units that are positioned in parallel, laterally spaced relationship and pivotally and longitudinally slidably interconnected to establish a multiplicity of closely spaced teeth, the juxtaposition and angularity of which can be easily controlled to effect discrete localized preferential gripping and matting of controlled amounts of hair. Tandem movement of the comb and pick using conventional backcombing techniques quickly compresses the hair into a teased volume that can be repositioned by controlled divergence and lifting of the picks.
Accordingly, it is an object of the present invention to provide a hairstyling device for quickly establishing and positioning teased hair volumes using conventional backcombing techniques.
Another object of the invention is to provide a dual bladed tease comb having tandem spaced sets of teeth effective for increasing the teasing effect during hairstyling.
A further object of the invention is to provide a method of hairstyling using successive comb teeth sets to increase teased hair mass during repeated backcombing strokes.
DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will become apparent upon reading the following detailed description, taken in conjunction with the accompanying drawings in which:
FIG. 1A is a side elevational view of the dual blade tease and pick comb in accordance with one embodiment of the present invention using pivotal comb blades;
FIG. 1B is a side elevational view of another embodiment of the invention using fixed comb blades;
FIG. 2 is a mirror image side elevational view of the tease comb and hair pick of FIG. 1A in a rotated condition;
FIG. 3 is a disassembled side elevational view of the tease comb and hair pick shown in FIG. 1A;
FIG. 4 is a cross sectional view taken along line 4--4 in FIG. IA;
FIG. 5 is an enlarged fragmentary view of another embodiment of the present invention; and
FIG. 6 is a cross sectional view taken along line 6--6 in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to drawing for the purpose of describing the preferred embodiments of the present invention, FIGS. 1 through 3 show a dual blade tease comb and hair pick 10 for use in styling hair using backcombing and teasing techniques. The comb and pick 10 comprises a first or front blade 12 and a second or rear blade 13. The blades 12 and 13 are pivotally connected in parallel juxtaposed relation for relative rotation about an axis 14 and relative translation along a horizontal longitudinal plane 16 (FIG. 5). Each blade 12 and 13 comprises a comb body 20 having an elongated cylindrical pick 22 extending rearwardly thereof. The comb body 20 has a longitudinal spine 24 and a uniform longitudinal series of laterally extending teeth 26 extending between a rear heel tooth 28 and a frontal tooth 30.
In the preferred form the teeth 26 comprise a pair of long teeth 32 spaced by a shorter tooth 34. A particularly effective comb and pick is commercially available from Champion as Model 43T. However, as shown in FIG. 1B the teeth may also comprise a uniform longitudinal series of equal length teeth with the respective blades fixedly connected. Preferably, the comb body 20 is formed of a low friction molded material such as urethane. The pick 22 is a metallic, polished rod integrally molded therewith and outwardly terminating with a tapered point 38.
The dual blade tease comb and hair pick utilizing the above described tandemly spaced tooth sets have been determined to produce sufficiently greater teased volume with less operator dexterity and in less time than a single unit employing similar teasing techniques. Such results are attained when the comb and picks are attached in permanent aligned juxtaposed parallel relation. Further improvements are realized when the comb and picks are pivotally connected and further when they are additionally relatively translatable.
In typical usage, a stylist will extend a grouping of hair strands, insert the comb teeth therein and repeatedly forwardly and backwardly manipulate the combs to establish a hair mat or teased volume adjacent the scalp. When using a single comb, it has been found that while portion of hairs are buckled or compressed during the downward stroke, many will partially return to extended positions during the upward stroke, thus undoing the desired effect. Further, the matted hair is typified by relatively long buckled overlapping hair sections of light density and compaction.
On the other hand, the laterally spaced sets of teeth of the present invention consistently produce more discrete overlapping of shorter compressed lengths, resulting in a greater density and increased volume for comparable teasing strokes. In usage it is not totally apparent what the exact reasons are for such results. However, it appears that the first teeth create an initial bucking of individual strands as they are released from the stylist's grasp. The partially buckled strands, particularly the strands no longer engaged by the first tooth set, are then engaged by the second tooth set, accentuating the compression toward the scalp. This results in additional matting for each strand. Moreover, it appears to leave lesser length free ends for the compressed strands decreasing the possibility of re-extending such strands during upward, reverse motion. Accordingly, fewer strokes are required to effect the teasing of the manipulated hair bundle.
The aforementioned results are further enhanced by providing relative pivotal and translational movement between the hair sets. Referring to FIGS. 1A, 2 and 4, a pivot pin 40 interconnects the heel portions of the comb and picks and accommodates relatively rotation about a transverse axis 14. The pin 40 includes a head section 44 received in a counterbore in the front side wall of the front blade 12 and a shank 48 slidably received in a through hole in the front blade 12 and fixedly received within a blind hole in the rear blade 13. In use, the stylist may manipulate the combs to rotated positions such as shown in exaggerated form in FIG. 3. During actual usage, such movement, while significant in producing surprising results, may only involve rotation of 10° or less.
Such relative rotation, by changing the angle of attack of the second comb appears to more affirmatively engage the initially buckling strands to drive the latter toward the scalp and to limit unwinding during upward movement. The location of the axis is conveniently located adjacent the heel end of the comb and pick for normal gripping by the stylist. This location has been found to provide for sensitive minute movements. However, the pivot connection may be positioned at other locations so as to achieve similar benefits.
Referring to FIG. 5, further benefits over the fixed tooth pairs may be provided by employing a sliding connection between the sets of comb teeth. Such a connection may be provided singularly or in combination with the pivotal connection. Such sliding connection may be accomplished in many ways. For instance, rather than a clearance hole in the front blade 12, the front blade may be provided with an elongated slot 50 for accommodating movement of the shank within the confines thereof. The slot 50 further accommodates rotation relative to the second blade. The resulting offsets between the tooth sets also provides for secondary engagement of the compressing hair strands.
After establishing the teased volume, the picks may be employed to lifts sections thereof into a proper orientation on the scalp to enhance further the desired styling effect. Whereas a single pick will lift only along the engaged line causing a creased effect requiring multiple insertions and movements to realign properly the teased volume, the relatively angularly spaced picks provided by the rotated comb picks allows discrete areas of the hair mat to be accurately and easily repositioned.
In achieving the foregoing advantages, it is important to laterally space the tooth sets in close proximity, generally 3/4 inch or less, preferably 1/8 inch to 3/8 inch apart. Further, while various tooth configurations proposed in the art and those available commercially to the art may be used, good results have been achieved using teeth of uniformly varying lengths. Moreover, while many metallic or synthetic moldable compounds may be used for the comb body. Suitable synthetic compositions include urethanes, rubbers, nylons, acrylics, polycarbonates and the like.
While the present invention has been described with reference to the foregoing preferred embodiment, other modifications and variations thereof will become apparent to those skilled in the art. Therefore, it will be appreciated that modifications and variations are within the scope of the invention is defined by the following claims. | A dual blade teasing comb and hair pick includes a laterally space pair of comb blades, each including an elongated spine having a longitudinal series of teeth depending therefrom and an elongated rearwardly extending cylindrical hair. The combs may be pivotally and slidably interconnect whereby the comb teeth are effective for increasing teased volume during backcombing and the picks may be pivoted to permit repositioning of the teased volume. | 0 |
RELATED APPLICATIONS
This application is a divisional of co-pending application Ser. No. 666,664, filed Mar. 15, 1976, which in turn is a continuation of application Ser. No. 505,149, filed Sept. 11, 1974 (now abandoned), which in turn is a division of application Ser. No. 447,376, filed Mar. 1, 1974, which was abandoned in favor of application Ser. No. 643,295, filed Dec. 22, 1975 (now abandoned) of Wayne R. Matson.
BACKGROUND OF THE INVENTION
It has long been possible to test both qualitatively and quantitatively for ionic materials in an aqueous sample by electrolytic means, and to record the electric potential of deposition of the ions on an electrode. In one form of such testing known as stripping voltammetry, the ions are first deposited on an electrode and thereafter the potential is continuously or continually varied to strip the deposited material from the electrode and redissolve it in the sample liquid. This operation is known as stripping voltammetry and since it is ordinarily used by plating cathodically and stripping anodically to detect and measure metallic ions, it is often known as anodic stripping voltammetry. By means of anodic stripping voltammetry, it has been found possible to perform relatively quick simple and accurate tests to measure minute traces of appropriate materials. Recently, in connection with environmental studies, it has become important to collect small quantities of polluting impurities from the atmosphere or from other portions of the environment to test for the presence of dangerous pollutants. A very immediate concern has been the need to test for the presence of informative or dangerous impurities in the human bloodstream, and anodic stripping voltammetry has proven itself capable of performing such tests. The present inventor and his associates have been interested in problems relating to this general field of activity for a number of years. Among other things, they have devised and developed certain useful apparatus for anodic stripping voltammetry as disclosed in application Ser. No. 167,330 and certain improved electrodes disclosed in Ser. No. 168,161 and Ser. No. 327,788. The present invention is a unified system for anodic stripping voltammetry or cathodic stripping voltammetry capable of performing analysis of trace materials on an extremely rapid and an extremely accurate basis. In particular, the system according to the present invention can analyze human blood samples in the field or in the normal environment of such human beings at the rate of many hundreds of samples per day and can obtain critical output data regarding the presence of impurities such as lead, cadmium, zinc or the like in the human bloodstream within about a minute after a blood sample is actually taken from the human being, thus permitting such sampling in the environment of the real world. The quickness of completion of testing is of unusual importance, in light of experience which shows that the 7% of people tested in urban slum areas cannot later be located if they are once allowed to leave the test area.
GENERAL NATURE OF THE INVENTION
The present invention is a unified system, preferably automated, for electrochemical testing. In its usual embodiment it is an automated system for anodic stripping voltammetry. According to a preferred form of the invention, a sample holder is removably positioned to receive a special electrode having a very large, smooth active electrode surface. On the turn of a switch, electrical means are actuated to apply a cathodic potential to the electrode, plating out cations on the electrode, after which the electrical means apply the operating anodic voltage to strip out the deposited cations and monitor the potential and current.
The anodic stripping potential desirably is pulsed and the pulsed changed in voltage in a stepwise mode. Each step desirably is raised 0.01 volts. The initial few pules on each step are ignored and the remainder are counted and measured. The readout is either charted or digitalized. The potential at which electrolytic current flows is an identification of the specific cations being stripped, and the quantity of current is a quantitative measure of the cation.
A presently preferred use and application of the invention is measurement of heavy metals such as lead in the human blood stream. A blood sample is taken, and an aqueous solution containing a metallic ion such as Cr 3+ or Ca 2+ is added to exchange with the lead complexed with the blood. The sample is then placed in operating position on the apparatus and the switch turned on. A lead content of 40 micrograms of lead per 100 ml of blood is a recognized standard of a dangerous level of lead in the human blood stream. In broader usage and application, identification and measurement of different metals in blood is now thought to have medical diagnostic value: for example, the profile of zinc and copper appear to be one diagnostic test for leukemia.
The apparatus according to the present invention can employ various kinds of waveforms to accomplish various different tests and to accommodate numerous electrical or chemical problems. The output may be in chart form, but one of the advantageous results is that there can be direct digital readout obtained essentially automatic and directly calibrated in end units; in practice, for example, the digital readout of lead in blood samples is directly in terms of micrograms of lead per 100 ml of blood. With calibrated digital readout, all the operator need do is record a single number.
The cell and electrode structure employs a hollow electrode with inner and/or outer surfaces active. Coaxial stirring produces reliable, reproducible results with an unusually fast time constant, and the preferred chemical ion exchange procedure joins with structure and method to give results on the spot. As presently in practical use, the system gives test results on biological samples within a minute or two, and it is well adapted to give equally fast results on other types of samples.
The system also has a high degree of flexibility to use conventionally prepared (digested) samples or non-digested samples, to use biological material such as blood or tissue or non biological samples such as paint, gasoline or other "environmental" materials for tests of lead or other metals, to use industrial materials for sampling and testing, and to test for a wide variety of metals including lead, cadmium, copper, zinc, thallium, silver, gold, bismuth and the like.
The nature of the invention is further illustrated in the drawing in which:
FIG. 1 is a perspective view of testing apparatus according to one embodiment of the invention.
FIG. 2 is a front view, partially in section, of sample support apparatus according to the embodiment of FIG. 1.
FIG. 3 is a front view, partially in section of electrode assembly components according to another embodiment of the invention.
FIG. 4 is a block diagram of an electrical system in conjunction with apparatus according to one embodiment of the invention.
FIG. 5 is a front view of a front control panel of apparatus according to a modified embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 is illustrated a cabinet generally designated 10 on which is mounted a support assembly 11 serving as a cell and motor support. Mounted on the support assembly 11 is a motor 12. Mounted beneath the support assembly 11 is an electrode 13 held in an electrode head 14. The electrode 13 is adapted to fit within a sample holder (not shown). The sample holder in practice is a plastic or glass member shape essentially like a test tube and characterized by being made of a material which is free from detectable quantities of any metal for which testing is to be performed. One principal intended use of the apparatus, according to this invention, is testing for trace quantities of lead and accordingly, the sample holder is made of lead-free glass or plastic which has been additionally treated to eliminate detectable trace quantities of lead. Desirably the support assembly 11 is pivotally mounted in the cabinet by means of mounting pins 16 whereby the entire assembly may be rotated in our out of position for easy insertion or removal of a sample holder from the head 14 on which it is held by a snug fit between the head and the sample holder.
On the cabinet is positioned in a convenient location, an off/on switch 17, an off/on motor switch 18, and desirably, a reset switch 19. Also, on the front of the cabinet is a meter 20 for visual read out of voltage or current a recorder off/on switch 21, a sweep offset 22, and a recorder offset button 23. Desirably, there is also on the cabinet face a current range indicator 24.
In FIG. 2 is illustrated further detail of the cell and motor assembly. Mounted on support assembly 11 is motor 12 having a shaft 26 extending therefrom. By means of a coupling 27 the shaft 26 is connected to a propeller shaft 28 which terminates in a propeller blade 29 positioned within and near the bottom of electrode shield 14. Mounted at the bottom of support assembly 11 is an electrode holder 31 which is adapted and positioned to hold the electrode shield 14. Mounted within the electrode shield 14 is a stop 32 receiving and bearing against the electrode shield 14. The electrode 33 is in turn positioned within the stop 32 and is held in its proper position thereby. Mounted within the electrode are dividers 35 forming internal electrode compartments through which extends propeller shaft 28 and which, among other thing, serves as a guide for the propeller shaft. In practice three dividers are employed to form compartments. A bearing 36 at the bottom of the electrode compartment rotatably holds and guides the propeller. Optionally, a fine tube 37 or nitrogen line is positioned extending through the electrode shield and electrode with its nozzle positioned within the electrode compartment to assure a neutral atmosphere.
The electrode 33 is constructed and adapted for anodic stripping voltammetry or other electrode chemical operation. The electrode 33 consists of a hollow cyllindrical electrode 40 desirably having one or more openings 41 in its side. The electrode body 40 according to one form of this invention is a hollow cylinder of graphite impregnated with a film forming material such as paraffin wax or the like and having on its surface a deposit of an electrode surface layer such as, for example, a layer of mercury. The electrode surface layer is present in the form of a multiplicity of dots or islands of mercury, each depositied on a graphite point and surrounded by a portion of impregnated wax surface. The electrode can be produced by impregnating a graphite rod with wax, scraping the wax from the graphite surface to lay bare a multiplicity of graphite points and coating mercury thereon by electrode chemical disposition using the graphite body as an electrode chemical cathode. The preparation of mercury coated graphite electrode described in co-pending application Ser. No. 168,161 referred to herein before.
In at least exposed active areas of the electrode area 33 according to one embodiment of the invention, both the outer surface 42 and the inner surface 43 of the electrode body 40 are coated with the electrode metal as described. When the apparatus of the present invention is employed for testing for trace elements of lead, the electrode metal preferably is mercury. In this manner a mercury electrode surface is positioned vertically within the saample holder and has an extremely high ratio of surface area in relation to sample volume. The area/volume relationship should be at least 3 cm 2 electrode area per milliliter sample volume, and preferably 4:1 or greater. At present, an electrode to sample ratio is 20 cm 2 per 3.6 milliliter sample. The propeller shaft 28 passes through the center of the electrode 33 and propeller blade 29 is positioned near the base of the electrode and is adapted to cause circulation of the sample liquid both inside and outside the electrode body 40.
Apparatus of the type herein disclosed can be employed by means of manual switching and manual controls in anodic stripping voltammetry. In such manual operation a sample holder containing a liquid for test is placed in position with the electrode assembly immersed therein. The electrode is connected in cathode mode to a suitable power source and ionic components are deposited on the electrode surface. In particular, if the apparatus is employed to test for the presence of lead, then lead is electrolytically deposited on the mercury electrode surface and is alloyed therein. After cathodic deposition on the electrode surface, the electrode is placed in anodic mode and the voltage applied thereto is gradually raised, and the electrolytic current is monitored. Metallic elements are identified by the potential or voltage of which the flow of current indicates that a trace of metal is being anodically stripped from the electrode and the quantity of the trace element is measured by the quantity of anodic current.
In FIG. 3 is illustrated a modified electrode assembly in which the electrode 13 is mounted on a support or holder 31 and adapted to fit within a suitable sample holder (not shown) in much same manner as with the assembly in FIG. 2. A coupling 27 connects the motor 12 (see FIG. 1) with a propeller shaft 28 extending axially through holder 31 and to a point approximately level with the electrode 13. The electrode 13 is hollow, as with the electrode shown in FIG. 2, and within the hollow electrode the propeller shaft 28 is of significantly bigger radius leaving only a relatively small space between shaft 28 and inner surface of electrode 13. At the bottom of this shaft, once again, is a propeller blade 29. A counter electrode 30 extends through the electrode holder 31 and is positioned to be immersed in the sample within the sample holder. A reference electrode 34 also extends through the holder 31 to a position within the sample. Desirably, the counter electrode 30 is a platinum wire which may directly contact the solution or, as presently preferred, is a platinum electrode contained in a porus glass compartment or shell. The reference electrode desirably is a silver or silver cloride wire immersed in a saturated sodium chloride solution. Desirably the propeller shaft 28 may extend through one or several bearings 21. In the preferred form of the structure, the electrode holder 31 is adapted to fit snuggly with in a sample holder so that during operation a sample holder is retained firmly but releasably in a position into which it can be manually fitted.
In one form of the invention, as illustrated in FIG. 3, the electrode 13 has a coating 15 on its outer or exposed surface. This coating is a plastic tubing shrunk around the outside of the active electrode. When the coating is employed, the electrode is generally protected from accidential damage and can, in fact, be handled carefully when the electrode is removed from a sample. There is relatively small clearance between the electrode and the sample holder when in position, and again is there relatively small clearance between the electrode and the lower end of stirrer 28. Moreover, the stirrer 28 is slightly tapered, being slighty larger at its lower end than it is at the upper end, so that the space between this stirrer 28 and the inner electrode surface also is tapered, being narrower at the bottom than at the top. As the stirrer rotates within the electrode, this tapering causes not only localized currents of the test liquid, but also causes a general flow of the liquid downwards in the space between stirrer and electrode.
In high speed sample testing it is important that the sample liquid should circulate well, but it is also desired that the relatively still layer adjacent to the electrode be as thin as practical. This layer, known as the Nernst layer, appears to be about 1-2 micron in the apparatus of FIG. 3.
In FIG. 4 is illustrated, in the form a block diagram, the electrical controls for automation of the equipment according to one embodiment of the invention. A clock generator and timer controlled sequence serves as a control mechanism for all functions. A plate and strip control 51 serves to apply a plating potential to the electrode and under the control of the timer 50 applies such control for a perios of one minute or selectively for some other period of time such as 3 minutes or 5 minutes. A motor 52 energizes the stirring mechanism (propeller shaft 28 and 29) and under the control of timer 50, causes stirring of the sample while the plating potential is applied.
A sweep generator 53 is adapted to supply a stripping voltage to electrode 32 and under the control of timer 50, supplies this voltage 10 seconds after the plate and strip control 51 and motor 52 and turned off by the timer 50. The sweep generator 53 is essentially a staircase generator and steps down in 10 millivolt steps at 100 milliseconds per step. When the apparatus is used for detection and measurement of lead, the plating voltage is -1.0 volts and the sweep generator steps down from -1.0 volts to 0.1 volts in 90 steps in an elapsed time of about nine seconds. The sweep generator operates through an electrode supply 54.
Adapted to read out from the electrode during stripping, and optionally during plating, is an I/E converter which serves to convert current to voltage to supply a signal more suitable for being amplified. The I/E converter 55 feeds to an optional strip chart recorder 56. As will be seen hereinafter, the apparatus under the control of the elements in FIG. 4 produces a direct digital readout but a chart readout may be desired and is illustrated in FIG. 4. This readout, when employed, is a conventional charting device to chart current flow vs. time; the current flow being expressed in terms of voltage output from the I/E converter 55. The time vector, is relation to the output of sweep generator 53, identified and stripping voltage. The chart represents, therefore, the readout from the electrode and is shown in the figure as an analog selector 57.
As S & H I/E zeroing unit 59 (sample and hold) delays for a selected time which, in operation, may be 20 milliseconds, before counting the electrode output. In order to eliminate initial noise upon each change in step as the stripping potential is stepped down, an I/E zero selector 60 is set for a zero point at 100±50 millivots before the integration zone.
A connection to a power supply or voltage source 61 operates through switch 62 energize the various electrical components, energizes the timer 50 and the other power units previously and hereinafter described. For digital readout, which is a presently preferred embodiment of the invention, a dual slope integrator 64 integrates the output signal and converts the analog signal to a digital representation. An S & H integrator 65 operates from the dual slope integrator 64 to identify and isolate the zone of the stripping potential in which the current signal occurs. An S & H delayed analog 66 optionally permits a variation in sample and hold time. This adjustability is not required if the apparatus is employed for a single use and the application, as is now the case where the apparatus is employed for the detection of lead which has a single deplating or stripping potential.
An integration set point and logic circuit 68 is adapted to receive the readout signal and to discard as noise an initial signal less than a pre-determined value. This integration setpoint and logic 68 then, together with an output from the dual slope integrator 64, feeds to an up/down count control logic 69. This up/down count control logic 69, for its first count, counts down six times and next, for twelve counts, counts up followed by a fourteenth count which, once again, counts down six times thus making a count equivalent to a digital output from the output signal. The up/down count control logic 69 in turn feeds to an up/down counter 70 and to a data latch 71 which finally feeds to a digital readout 72. The up/down counter 70 merely counts the signal received from the up/down counter control logic 69 in the number and direction designated by such logic. The data latch 71 brings the process to a halt after the signal in the desired zone has been completed. The digital signal received from the total count from up/down counter 70 and is converted into a digital reading thus corresponding to a digital representation of quantity of metal or other ion detection and measurement. In practice, this readout is set to present digitally a direct reading of micrograms of lead per 100 cc of blood sample. The digital readout 72 can, accordingly, be set to translate a signal to correspond to any desired digital measure.
In FIG. 5 is shown the panel of apparatus which may operate in accordance with the diagram of FIG. 4. The upper part of the panel is normally visible; the lower portion may be covered after the appropriate settings and calibration are made.
A digital display 80 reads out and displays the digital record of a test while a meter 81 may indicate the current flow or voltage during a run. An indicator lamp panel has lights for "ready" 83, "plate" 84 and "strip" 85 indicating the phase of the operation. A push button 86 labelled "cancel analysis" operates to interupt and return the analysis to zero. At the upper right hand corner a push button 87 labelled "start analysis" is adopted to start timer 50, and pushing this button is the only act required of the operator once the sample is in place. A motor light 88 indicates when motor 52 is operating.
Adapted for preliminary set up and calibration is a lower panel. A potentometer 90 is adjustable, being adapted to control the digital readout 72 of FIG. 4, desirably so that the readout is directly in the correct digital units. When blood is tested for lead, this readout is set against a known standard sample so that the readout is the number of micrograms of lead per 100 milliliters of blood. A rotary switch 91 selects a desired scale expansion if needed, and a blank correction potentiometer 92 is adjustable to set a desired zero point.
In the lower left corner of the panel is a run indicator 93, with screw potentometers 94, 95, 96, 97 and 98 for indicated settings for initial potential, sweep rate, recorder set point and recorder integration. Finally, in the lower right is a slope correction setting 99, a rotary switch 100 selecting one of several automatic time controls for timer 50 (or selecting a manual control) and a "function test" switch 101 for selecting a dummy cell or analysis cell for calibration or other purposes.
The panel of FIG. 5 serves the purpose that in part illustrates the instrument and in part illustrates the ease of operation. A skilled operator can first set and calibrate the instrument for a specific test condition, after which an operator who may be unskilled measures a predetermined quantity of sample into a prepackaged sample holder, places the sample holder on the machine, pushes the "start analysis" button 87 and a minute later reads the result in digital display 80.
The apparatus discussed, herein in accordance with the present invention is intended to be employed for detection and measurement of trace quantities of certain heavy metals including zinc, cadmium, lead, copper, bismuth, silver, gold and thallium. Analysis can be made of nanogram quantities of these trace metals in periods of time of a few seconds up to one or occasionally several minutes. In particular, it is possible to detect and measure quantities of certain of these trace elements in the human blood stream. One of the very important social purpose of this invention is the detection and measurement of small quantities of lead in the human blood stream and in particular, in the blood stream of children residing in city slum areas.
For such lead detection and measurement, the desired sample holder is a test tube shaped plastic or glass vessel made of lead-free glass or lead-free plastic or other convenient container. Desirably, the sample holder is preconditioned by electro-chemical treatment to electrolyze out of the glass any trace quantities of lead which may originally have been present. A reagent solution is prepared in advance containing a dissolved chromium or calcium ionic material Cr +3 or Ca +2 . A measured sample of blood is taken from a human blood stream. A small quantity of the chromium or calcium reagent is added, and as presently preferred, a mixed calcium-chromium reagent is employed. The precise amounts and concentrations can be adjusted for convenience, provided a standard procedure is adopted and suitable calibration made. It has been found satisfactory to employ CrCl 3 prepared with 0.03 to 0.04 molar Cr +3 in 0.001 to 0.02 molar HCl; this chromium ion solution may be employed in the amount of 3.6 cc to exchange the lead in 100 microliters of blood sample. In one embodiment there is used a dilute solution of calcium chloride, chromium trichloride, hydrogen ion, perchlorate ion and a dispersing agent (Surfynol 104 is the agent currently employed, and is believed to be a non-ionic higher alcohol wetting agent). One formula which has been used with biological samples such as blood, foods, is:
______________________________________CaCl.sub.2 0.08FCrCl.sub.3 0.04FHgCl.sub.2 0.000225FH.sub.2 NNH.sub.2 --(HCl).sub.2 (hydrazine) 0.019FSurfynol 104 0.001 weight percentClO.sub.4 - 0.458FH+ 0.0398 (to bring to pH 1.4)______________________________________
Another formula which is now presently preferred is different in some details of composition and is now thought to be more reliable for use with fresh human blood samples, and comprises:
______________________________________Calcium Acetate 0.08FCrCl.sub.3 0.04FHgCl.sub.2 0.000225FH.sub.2 NNH.sub.2 --(HCl).sub.2 (hydrazine) 0.019FSurfynol 104 0.001 weight percentH.sub.3 PO.sub.4 0.01FH+ to bring to pH 1.0______________________________________
The mixture of calcium ion and/or chromium ion cause release of complexed lead in the blood so that the total concentration of lead in blood can be effectively measured when one of the reagents just described is employed in the equipment and method of the invention.
Heavy metals which are complexed or bound in other sample materials can also be released. For example, a mix of 0.01 molar bromide ion; 0.1 molar NaCl; 0.01 molar HNO 3 ; and 0.01% Triton X-100 (a polyalcohol) is suitable for releasing lead in gasoline. The same and other releasing components can be used to release the various neavy metals from a wide variety of organic samples. What is used is a metal ion or mixture of metal ions which will displace the test metal and which will not plate out or strip out at the plating or stripping potentials used in detection and measurement of the metal being tested.
After the test material is treated with a release agent, or after other sample preparation as may be necessary such as digestion, or other treatment and dilution or concentration as needed, the sample in the sample holder is placed in position on the apparatus and the apparatus is turned on. The chromic ion in the solution acts to displace lead from any complexes which it may have formed with components off the blood sample, and the chromium does not plate out at the operating potentials used for lead analysis. Within a sixty second operating time, the apparatus will cause any lead to be largely deposited on or in the mercury electrode coating and thereafter anodically stripped from the electrode with both identification and quantitative measurement. An important value of the invention is that the detection and measurement can be carried out in a time of no more than a minute or two after extraction of the blood sample from the blood stream so that the person himself can be advised as to the test results without being required to return on a subsequent occasion or even being required to wait for a significant period of time for such test results.
A presently preferred sample holder is a self-contained unit which is factory preconditioned. It comprises a plastic sample holder cylindrical in shape having a volume of 5 cc. and containing 3.6 millimeters of a liquid sample which contains chromic ion, mercury, hydrogen and hydrochloric acid. It is sterilized, purified to remove lead, or to remove other metallic ion being tested and measured and sealed. | A reagent composition particularly adapted for use in treating organic samples suspected of containing chemically-bound heavy metals preparatory to electrically detecting and measuring the heavy metal content of the samples. The composition includes an electrolyte vehicle which is essentially free of the heavy metal being detected and measured, a measured quantity of at least one metal ion-containing reagent dissolved therein, said metal ion (1) being adapted to displace the heavy metal from its organic chemical bonding and (2) remaining in electrolytic solution at the electrolytic deposition potentials of the heavy metals being detected and measured, a dispersing agent, and a hydrogen ion source for adjusting the pH of said composition to pH about 1. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of treating waste liquors containing phenolics and formaldehyde, particularly to a method of treating such waste liquors by a microorganism.
The term "phenolics" used herein means a compound or compounds selected from the group consisting of phenol, o-, m- and p-cresol, saligenine, o-, m- and p-hydroxybenzaldehyde, salicylic acid, catechol, 3-methylcatechol and 4-methylcatechol, etc.
2. Description of the Prior Art
Heretofore, waste liquors containing phenolics have been known which contain high concentration of formaldehyde in addition to high concentration of phenolics, such as waste liquors discharged from phenolic resin production plants and the like. Phenolics and formaldehyde have large adverse influences on biological treatment of such waste liquor due to their toxicities. A conventional process of treating such waste liquor is to dilute the waste liquor by using a large amount of dilution water or treat the waste liquor by a complicated physicochemical and/or chemical treatment to reduce their toxicities in the waste liquor, and thereafter treat the waste liquor of reduced toxicities by means of activated sludge method, as described in Japanese Patent Application laid-open No. 62,659/79. However, the method has drawbacks in that the use of a large amount of dilution water necessarily increases the amount of the waste liquor to be treated to an extremely large extent, that a cost of the dilution water is not always cheap but rather expensive, that the physicochemical and/or chemical treatment necessitates a large amount of chemicals, labours, work time and a large scale of apparatus, and that the activity of acclimated bacterium in the sludge is hardly maintained because they are weak to fluctuation in phenolics concentration of an influent waste liquor to be treated. From this reason, the inventors have formly proposed a method of treating waste liquors containing phenolics by removing phenolics by means of a microorganism of genus Aureobasidium and obtained Japanese Pat. No. 1,087,941, which was however not perfectly satisfactory.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a method of treating waste liquors containing phenolics and formaldehyde, which achieves the following advantages of (1) considerably decreasing the amount of dilution water to be used, (2) minimizing the initial and running costs, (3) withstanding or durable to fluctuation in phenolics and formaldehyde concentrations of influent waste liquors, and (4) treating the waste liquors rapidly and economically in a considerably small apparatus.
Another object of the present invention is to provide a method of treating the waste liquors containing phenolics and formaldehyde, wherein a fungus is used which is excellently capable of decomposing and assimilating phenolics and formaldehyde and is able to propagate against the multiplicative adverse influences of the toxicities of high concentrations of phenolics and formaldehyde to sufficiently remove the same from the waste liquor.
The present invention is a method of treating a waste liquor containing phenolics and formaldehyde, comprising, culturing a fungus of genus Trichsporon which is capable of decomposing and assimilating high concentrations of phenolics and formaldehyde in the waste liquor to remove the same from the waste liquor.
Another objects and advantages of the present invention will become apparent from the ensueing descriptions of the specification and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a characteristic graph showing relations between operation time and removals of phenolics and formaldehyde, and
FIG. 2 is a graph showing relations between initial phenolics concentration and formaldehyde concentration in influent waste liquors which can be completely treated according to the present invention.
DETAILED EXPLANATION OF THE INVENTION
The present invention is different from the activated sludge method in that it does not use a bacterium and uses a fungus which has larger cell sizes than those of bacteria and still has a comparatively large surface area. Because bacteria have generally an intolerance to phenolics and formaldehyde while the fungus has strong ability of decomposing phenolics and formaldehyde, the present invention is far superior to the activated sludge method.
The fungus used in the present invention belongs to Eumycetes of genus Trichosporon and can decompose and assimilate high concentrations of phenolics and formaldehyde. The inventors have found out that the strain Trichosporon sp. No. 36 (hereinafter abbreviated as "present fungus") isolated from a soil sample has a particularly splendid ability of decomposing and assimilating phenolics as well as formaldehyde in the waste liquors. The present fungus was deposited to Fermentation Research Institute Agency of Industrial Science and Technology, Ministry of International Trade and Industry (abbreviated as "FRI") on Mar. 9, 1983 with international deposition No. FERM P-6977 under Budapest Convention. The present fungus has the following cultural characteristics.
Cultural Characteristics
Malt extract-peptone-yeast extract liquid culture: Fungal cells obtained after three days of culture at 30° C. were oval or cylindrical. Cell sizes were (2.0-5.0)×(4.0-12.0)μ, (3.0-6.0)×(7.0-19.0)μ. A few rings were formed on the surface of the culture liquid, and precipitates were formed at the bottom of the culture liquid.
Malt extract-peptone-yeast extract-agar culture: The growth was white or cream in colour. Raised and conical. Partially floccose moist colonies without luster were formed.
Corn meal-agar slide culture: Hyphae grew well. The hyphae were split into arthrospores of various lengths.
Improved Gorodokowa agar culture: Sporangium spores were not formed.
Gelatin culture medium culture: After 30 days of culture at 15° C., giant colonies of white or cream colour were observed. The central portion was partially floccose.
______________________________________Physiological properties______________________________________Optimum temperature for growth 25-30° C.Temperature capable of growth 12-35° C.Optimum pH for growth 5.5-7.0pH capable of growth 3.0-9.5Assimilation and reduction of nitrate NoneLitmus milk test No changeOsmophilic property Yes(in 8% NaCl culture medium)Liquefaction of gelatin NoneRequire for vitamin NoneDecomposability of albutin NoneProduction of starchy substance NoneDecomposability of fat YesAssimilation of urea Yes______________________________________
Fermentability: Ferments in glucose and galactose. pH value is decreased in glucose, galactose and L-sorbose.
Utilizability of carbonaceous sources: Glucose, galactose, L-sorbose, cellobiose, D-xylose, L-arabinose, D-arabinose, D-ribose, ethanol, glycerol, ribitol, D-mannitol, D-glucitol, succinic acid, citric acid, D-sorbitol, lactic acid, D-mannose, D-fructose, phenol, protocatechuic acid, pyrocatechol, galactitol, p-hydroxybenzoic acid are assimilated.
While, saccharose, maltose, trehalose, lactose, melibiose, raffinose, melezitose, inulin, soluble starch, L-rhamnose, erythritol, and α-methyl-D-glucoside and inositol are not assimilated.
The present fungus decomposes and oxidizes or assimilates vast varieties of many kinds of compounds. The present fungus can decompose and oxidize or assimilate phenolics of a concentration of about 3,000 ppm at the maximum in the waste liquor. Usually, waste liquors containing not more than about 1,800 ppm of phenolics, preferably of not more than about 1,300 ppm of phenolics, are treated. The present fungus can decompose and assimilate formaldehyde of a concentration of not more than about 1,300 ppm, preferably of not more than about 1,000 ppm. The present fungus can, of course, sufficiently assimilate phenolics of a concentration of about 300 ppm and formaldehyde of a concentration of about 100 ppm in the waste liquor.
The present fungus is classified to yeast which has a larger fungal cell size than usual bacterium, thus the fungal cell of the present fungus has better setting property than bacterium so that it can be easily separated in a sedimentation tank.
The present fungus can be grown even in an aerobic condition, so that it can be easily operated for treatment.
The present fungus propagates relatively quickly and easily assures necessary amount of fungal cells.
The present fungus provides sufficient treatment even at a concentration of 1/20 of concentration of usual culture medium (I culture medium).
The present fungus affords stable treatment by returning the fungal cells contained in the treated waste liquor into the treatment and utilizing them in the treatment.
The present fungus can withstand fluctuation of concentration of phenolics and formaldehyde in waste liquors. An illustrative example of treatment for such purpose is to use an air-permeable material such as non-woven web or needle punched felt as a fixing bed for fungal cells. This treatment gives a stable treatment.
In treating waste liquors containing phenolics and formaldehyde, the present fungus is cultured at first to a large amount and the cultured large amount of fungus is acquired. For that purpose, there are two ways.
The first way is to culture the present fungus in a culture medium suitable for propagation thereof. Thus, in a culture medium containing a usual carbonaceous source such as glucose, saccharose, waste molasses or the like, the present fungus is cultured to a large amount and the large amount of fungus is acquired. In this case, the culture medium is additionally added with a nitrogen source, an inorganic substance and a minor nutrient which are optionally and properly selected from publicly known ones, upon request. Thus, as a nitrogen source, use is made of ammonium sulfate, ammonium nitrate, ammonium chloride or a mixture thereof. As an inorganic substance, use is made of magnesium salt, calcium salt, phosphate, sodium salt, iron salt, manganese salt or a mixture thereof. As a minor nutrient, use is made of yeast extract or the like. Alternatively, the present fungus is cultured at first in a natural culture medium which grow the present fungus well, such as malt extract-peptone-yeast extract culture medium (to be referred to as "MPY culture medium" hereinafter), malt extract-glucose-peptone culture medium, potato-glucose culture medium or the like, to acquire a large amount of fungal cells, and thereafter the fungal cells are imparted with a capability of decomposing and assimilating phenolics and formaldehyde for use in the aimed purpose.
The second way is to culture the present fungus in the culture medium of the first way wherein the carbonaceous source is substituted by phenolics and formaldehyde to a large amount, and acquire the large amount of fungal cells. According to this way, the fungus is originally imparted with a capability of decomposing and assimilating phenolics and formaldehyde, so that a time required to the fungus to acclimate with phenolics and formaldehyde is not necessary. However, according to this way, propagation of the fungus is delayed owing to toxicities of phenolics and formaldehyde, so that a prolonged period of culture of a large amount of fungus is sometimes required for obtaining a large amount of fungal cells.
The acquired large amount of fungal cells imparted with the capability of decomposing and assimilating phenolics and formaldehyde is used for treating waste liquors containing phenolics and formaldehyde. There are three methods for treating the waste liquors.
The first method is to suspend a large amount of fungal cells in the waste liquor preliminarily added with a suitable concentration of the above-mentioned culture medium in a tank equipped with an agitator and an air-dispersing device as in the treating tank of the activated sludge treating method, and agitate or air-ventilate the waste liquor for a short period of time so as to contact the fungal cells with phenolics and formaldehyde, thereby to decompose and assimilate phenolics and formaldehyde to remove the same from the waste liquor. After the decomposition and removal of phenolics and formaldehyde, the fungal cells are sedimentated, and the supernatant liquor is discharged to the exterior as a treated waste liquor. If desired, a precipitation tank for removing solid substances from the discharged liquor is provided to separate and remove fungal cells in the treated waste liquor from the waste liquor. Subsequently, the waste liquor containing phenolics and formaldehyde preliminarily added with the above-mentioned culture medium of a suitable concentration is passed into the tank so as to suspend the sedimentated fungal cells, and is air-ventilated or agitated for a short period of time so as to contact the fungal cells with phenolics and formaldehyde, thereby to decompose and assimilate phenolics and formaldehyde to remove the same from the waste liquor. Thus, the first method is a batch process wherein the above steps are sequential effected, which may be repeated a plurality of times for treating the waste liquor, if necessary.
The second method is a process wherein the batch process of the first method is continuously effected. Thus, the treatment is started by suspending a large amount of fungal cells in the waste liquor preliminarily added with a suitable concentration of the above-mentioned culture medium in a treating tank equipped with an agitator and an air-dispersing device as in the treating tank of the activated sludge treating method, and agitating or ventilating the suspension. After removal of phenolics and formaldehyde through decomposition and assimilation thereof has been accomplished to a certain extent in the tank, the waste liquor containing phenolics and formaldehyde is continuously fed into the tank at a constant rate to remove phenolics and formaldehyde through decomposition and assimilation thereof. In this case, a constant rate of the above-mentioned culture medium of a suitable concentration is continuously fed to the tank. Treated waste liquor is passed to a precipitation tank wherein it is separated from the fungal cells and discharged to the exterior. If desired, the separated fungal cells may be returned to the tank for treating the waste liquor so as to maintain the amount of the fungal cells in the tank at a constant ratio relative to the waste liquor.
The third method is a process wherein a large amount of fungal cells is adhered on a fixed bed for use in a continuous treatment. The present fungus can be propagated relatively well, so that there is no need of growing it in advance on a fibrous or porous support or substance. For effecting the method, a fixed bed made of an air-permeable material such as air-permeable non-woven web or needle punched felt is preliminarily arranged in the same tank as used in the first and the second methods equipped with a ventilator and an agitator. As the first step, the present fungus is cultured in a culture medium which grows the present fungus well for about 1-2 days under ventilation and agitation in the tank having the fixed bed so as to fix the fungal cells on the fixed bed. As the second step, a waste liquor containing phenolics and formaldehyde is continuously fed to the tank at a constant feed rate to remove phenolics and formaldehyde therefrom continuously through decomposition and assimilation of phenolics and formaldehyde. In this case, an artificial synthetic culture medium of a suitable concentration is continuously fed into the waste liquor at a constant rate. Treated waste liquor is passed to a precipitation tank wherein it is removed from the fungal cells and discharged to the exterior.
For growing the present fungus to a large amount for treating a waste liquor, a temperature of 12°-35° C., preferably 25°-30° C., and a pH of 3-9.5, preferably 5.5-7.0 are maintained in the tank. Illustrative culture media suitable to the present fungus are malt extract-peptone-yeast extract culture medium (MPY culture medium) as a natural culture medium, and I culture medium as an artificial synthetic culture medium, which have the following compositions.
______________________________________Composition of MPY culture mediumMalt extract 30 gPeptone 5 gYeast extract 0.1 gDistilled water 1,000 mlComposition of I culture mediumNH.sub.4 NO.sub.3 5.0 gKH.sub.2 PO.sub.4 2.5 gMgSO.sub.4.7H.sub.2 O 1.0 gNaCl 0.1 gYeast extract 0.1 gFeCl.sub.3.6H.sub.2 O 0.01 gCaCl.sub.2.2H.sub.2 O 0.01 gH.sub.3 BO.sub.3 0.5 mgCuSO.sub.4.5H.sub.2 O 0.01 mgKI 0.1 mgMnSO.sub.4 0.4 mgNa.sub.2 MoO.sub.4.2H.sub.2 O 0.2 mgZnSO.sub.4.7H.sub.2 O 0.4 mgDistilled water 1,000 ml______________________________________
DESCRIPTION OF PREFERRED EMBODIMENTS
Hereinafter, the present invention will be explained in more detail which, however, should not be construed by any means as limitations of the present invention.
EXAMPLE 1
A slant of the present fungus is innoculated on 100 ml of MPY culture medium, cultured for 2 days at 30° C., subjected to centrifugal separation, and washed three times to obtain the present fungus. Thus obtained fungus is innoculated to 100 ml of I culture medium containing about 0.05% of phenol and about 0.05% of formaldehyde in a 500 ml flask, and cultured for 2 days at 30° C. After centrifugal precipitation, the present fungus is separated from the I culture medium for use as a seed fungus.
The seed fungus obtained from the above mass culture is innoculated to 100 ml of an artificial culture medium wherein phenol and formaldehyde are added to the I culture medium in a 500 ml of flask, and cultured at 30° C. to remove phenol and formaldehyde.
Initial concentrations of phenol and formaldehyde and concentrations thereof during the culturing step with elapse of time are measured by gas chromatography using a column of PEG20M type of Shimazu Seisakusho with respect to phenol, and according to a quantitative analysis method defined by JIS K 0102 "Method for Testing Plant Waste Liquors" as for formaldehyde. The results of treatment are as follows, which are also shown in the attached FIGS. 1 and 2.
Results of Treatment
(1) Phenol was completely removed in about 8.5 hrs. Average treating rate was 96.2 mg/l·hour, and the maximum treating rate was 207.5 mg/l·hour.
Formaldehyde was completely removed in about 12 hrs. Average treating rate was 45.4 mg/l·hr, and the maximum treating rate was 122.5 mg/l·hour.
(2) Treatment results are shown in FIG. 1. As shown in FIG. 1, phenol and formaldehyde have shown simultaneous start of treatment. Phenol treating rate was gradually increased, while formaldehyde treating rate was large at the initial period of treatment wherein the concentration was high, and gradually reduced to small rate.
EXAMPLE 2
The process of Example 1 was repeated except that the phenol concentration and formaldehyde concentration were modified to various values. Results of treatment same as that of Example 1 in terms of phenol concentration and formaldehyde concentration after complete removal thereof are shown in FIG. 2. Waste liquors with the combinations of phenol concentration and formaldehyde concentration as shown in the following Table 1 were able to be treated for removal of phenol and formaldehyde therefrom.
TABLE 1______________________________________Phenol Formaldehydeconcentration concentration______________________________________1,190 ppm 400 ppm1,100 4701,095 4951,065 4251,050 5001,050 645890 785855 1,190825 775785 1,190750 1,110675 1,060540 9251,520 200300 1,100400 1,000500 950600 8701,650 100200 1,2001,700 50______________________________________
Thus, according to the present invention, waste liquors containing phenolics and formaldehyde can be rapidly and economically treated in a stable manner.
Although the present invention has been explained with a certain degree of particularity, it is understood that the present disclosure has been made only by way of example and many variations and modifications are possible to those skilled in the art without departing from the broad aspect and scope of the present invention as defined in the appended claims. | Waste liquors containing phenolics and formaldehyde can quickly and economically be treated by a microorganism of genus Trichosporon to prevent water pollution. | 8 |
PRIORITY CLAIM
This application is a continuation-in-part of and claims the benefit of U.S. patent application Ser. No. 10/186,368, filed Jun. 27, 2002 now U.S. Pat. No. 6,884,459, the entire contents of which are incorporated herein.
BACKGROUND OF THE INVENTION
The present invention relates in general to coated glass, and specifically to perfluoroalkoxy copolymer coated glass, tetrafluoroethylene perfluoromethyl vinyl ether copolymer coated glass, a method of manufacturing perfluoroalkoxy copolymer coated glass and a method of manufacturing tetrafluoroethylene perfluoromethyl vinyl ether copolymer coated glass.
Coatings have been applied to glass to change one or more characteristics of the glass. One such coating is perfluoroalkoxy copolymer (“PFA”) which is one of the compounds sold by E.I. Du Pont de Nemours and Company under the trademark Teflon®. PFA is most commonly used as a non-stick coating on cookware such as pots and pans. PFA has also been used to coat glass such as automobile windshields and light bulbs.
The structure of PFA makes it highly resistive to sticking or adhering to other substances. In particular, the structure of perfluoroalkoxy copolymer is a copolymer of tetrafluoroethylene (CF2=CF2) with a perfluoroalkoxy vinyl ether [F(CF2)mCF20CF—CF2]. The resultant polymer contains the carbon-fluorine backbone chain typical of polytetrafluoroethylene with perfluoroalkoxy side chains. The side chains are connected to the carbon-fluorine backbone of the polymer through flexible oxygen linkages. The fluorine atoms in the chain resist almost any other atom or molecule, even other fluorine atoms. As a result, the fluorine atoms in PFA resist adhering to or even being near other molecules. Thus, molecules at the surface of PFA repel the other molecules and almost anything else that attempts to adhere or come close to the PFA molecule. Additionally, the bond between the carbon and fluorine atoms is extremely strong. The bond is so stable that little to almost nothing will react with it. Thus, PFA is a desirable coating to coat glass products because it is a material, which minimally reacts with other compounds. PFA also includes very strong bonds between its atoms which enables the coating to withstand extreme temperature and pressure conditions.
Another such coating is tetrafluoroethylene perfluoromethyl vinyl ether copolymer (MFA). MFA, sold by Solvay Solexis under the trademark Hyflon® is a copolymer of tetrafluoroethylene (CF2=CF2) with a perfluoromethyl vinyl ether [CF2=CF—OCF3]. The chemical composition of MFA provides increased resistance to chemicals, good permeation characteristics and very high stress cracking resistance. Similar to PFA, MFA is highly resistive to sticking or adhering to other substances. Additionally, MFA's increased optical translucency or transparency and reduced haze make it particularly suitable for coating of light bulbs. Thus, MFA is a desirable coating to coat glass products because it is a material, which minimally reacts with other compounds. MFA also includes very strong bonds between its atoms which enables the coating to withstand extreme temperature and pressure conditions.
Another such coating is polyethylene polymer (PE). The chemical composition of PE is a chain of carbon atoms with two hydrogen attached to each carbon atom ([CH 2 ═CH 2 ] n ). Additionally, in branched or low-density polyethylene, one or more of the carbon atoms, instead of having hydrogens attached to them, will have another chain of PE attached to them. The chemical composition of PE provides for increased resistance to chemicals, good permeation and very high stress cracking resistance characteristics. PE is a low cost coating that is impact, abrasion and chemical resistant. PE is translucent to opaque, very flexible and non-reactive at temperatures from −50° C. to 80° C. Thus, PE is a desirable coating to coat glass products because it is a material, which minimally reacts with other compounds.
However, there are certain problems with known PFA, MFA or PE coated glass. One known problem is that although the PFA, MFA or PE coats the glass, it does not form a strong bond with or strongly adhere to the glass because of its highly resistive nature with respect to other molecules. Thus, when a glass substrate or glass product coated with PFA, MFA or PE shatters or breaks, certain of the glass shards or pieces break away from the PFA, MFA or PE coating. In some coated glass products such as coated light bulbs, the PFA, MFA or PE coating is applied to the outside of the light bulb. When the light bulb coated with PFA, MFA or PE breaks, the glass pieces remain inside the light bulb because the PFA, MFA or PE layer creates a closed container such that the glass pieces are contained inside the light bulb. However, other glass products such as laboratory beakers are open glass containers. Therefore, the glass shards in these products can become loose and break away from the surfaces of these products. The glass shards are unsafe and may cause injury or severe injuries to users of these glass products.
Accordingly, there is a need for glass-coated materials and glass products that are coated with a material that has a very high bond strength and which strongly adheres to glass. Additionally, there is a need for a glass-coated materials and products that maintain the structural integrity of the surfaces of the glass materials and products.
SUMMARY OF THE INVENTION
The present invention relates in general to coated glass, and specifically to perfluoroalkoxy copolymer coated glass and a method of manufacturing perfluoroalkoxy copolymer coated glass.
One embodiment of the perfluoroalkoxy copolymer or PFA coated glass of the present invention includes a glass substrate, which may be any suitable glass substrate, a layer of primer applied to the surface of the glass substrate being coated, an electro-conductive enhancer applied to the primer and a layer of PFA applied to the electro-conductive enhancer to form the coated glass substrate, wherein the electro-conductive enhancer is evaporated to secure the PFA to the surface of the glass substrate.
In another embodiment of the present invention, the tetrafluoroethylene perfluoromethyl vinyl ether copolymer or MFA coated glass includes a glass substrate, which may be any suitable glass substrate, a layer of primer applied to the surface of the glass substrate being coated, an electro-conductive enhancer applied to the primer and a layer of MFA applied to the electro-conductive enhancer to form the coated glass substrate, wherein the electro-conductive enhancer is evaporated or removed by evaporation to secure the MFA to the surface of the glass substrate.
In another embodiment of the present invention, the polyethylene copolymer or PE coated glass includes a glass substrate, which may be any suitable glass substrate, a layer of primer applied to the surface of the glass substrate being coated, an electro-conductive enhancer applied to the primer and a layer of PE applied to the electro-conductive enhancer to form the coated glass substrate, wherein the electro-conductive enhancer is evaporated or removed by evaporation to secure the PE to the surface of the glass substrate.
In one presently preferred embodiment of the method of the present invention, a glass substrate is positioned on an electrically conductive support. The surface of the glass substrate being coated is cleaned with a cleaner such as a solvent. In one embodiment, the solvent is methyl ethyl ketone (“MEK”). This solvent cleans and removes impurities which may be present on the surface of the glass substrate. In this step, the solvent may be manually applied or mechanically applied to the glass substrate as desired by the manufacturer. Alternatively, the substrate may be pre-cleaned and the coating method may be performed in a suitable “clean room” where the cleaning step is not necessary.
In the next step, a layer of primer is applied to the surface of the substrate. The primer is applied as a mist or atomized spray so that a cloudy or opaque appearance does not form on the surface of the glass substrate. After the primer is applied, the primer is cured using a suitable curing process. The curing process dries the primer and strengthens the bonds between the primer and the surface of the glass substrate. In a presently preferred embodiment, the primer is cured at a temperature of approximately 500° F. (260° C.) for approximately five minutes. It should be appreciated that other suitable curing processes may be employed in accordance with the present invention.
When the primer has been properly cured, an electro-conductive enhancer is applied on the primer on the surface of the glass substrate. In the presently preferred embodiment, the enhancer is a highly polar solvent which is electrically conductive. When the solvent is applied, the glass substrate becomes electrically grounded. By grounding the glass substrate, the solvent becomes charged and thereby attracts oppositely charged particles. In one presently preferred embodiment, the solvent is a water soluble solvent such as N-methyl-2-pyrrolidone (NMP). In a presently preferred embodiment, the NMP layer is sprayed or applied to the surface as a fog or mist so as to completely wet the surface of the glass substrate. However, the NMP layer is preferably applied so as to avoid forming a thick layer and avoid drippings which might detract from the bonding ability of the coatings.
While the solvent or NMP layer is still wet, a layer of PFA, MFA or PE in powder form is sprayed over the wet NMP. The PFA, MFA or PE particles have a charge which is opposite to the charge of the NMP. Thus, the PFA, MFA or PE particles are attracted to the NMP on the surface of the glass substrate. As a result, the PFA, MFA or PE particles uniformly coat the surface of the NMP on the glass substrate. The PFA, MFA or PE is applied to the NMP until the coatings on the surface of the glass substrate achieve a desired thickness. In one presently preferred embodiment, the desired thickness is approximately 0.002 and 0.003 inches. Other suitable thickness ranges may be used as desired by the manufacturer for other types of glass substrates or glass products.
Once the PFA, MFA or PE layer is applied to the surface of the glass substrate, the NMP and PFA, MFA or PE layers are heated, to evaporate the solvent or NMP from the surface of the glass substrate and cure the PFA, MFA or PE. In one embodiment, the NMP and PFA or MFA layers are heated to a temperature of approximately 800° F. (427° C.) for approximately twenty minutes. In another embodiment, the NMP and PE layers are heated to a temperature of approximately 400° F. (204° C.) for approximately five to ten minutes depending on the mass of the glass. The heating process evaporates the NMP and cures the PFA, MFA or PE layer which directly adheres to the primer on the surface of the glass substrate. Because the PFA, MFA or PE was applied to the wet solvent, the PFA, MFA or PE is tightly packed and forms a uniform coating on the surface of the glass substrate. As a result, the coated glass substrate is clearer or more transparent and translucent. It should be appreciated that any suitable fluoropolymer, such as other polytetrafluoroethylene copolymers may be employed in accordance with the present invention. It should be further appreciated that any suitable non-fluoropolymer, such as any vinyl or transparent powders may be employed in accordance with the present invention.
It should be appreciated that the method of manufacturing or forming the PFA, MFA or PE coated glass may be performed as described above by applying or spraying the coatings on to the surface of a glass substrate or glass product. Alternatively, the coatings may be applied using other suitable coating methods. In one embodiment, the NMP layer is applied by dipping the glass substrate in the NMP solvent. This coating process ensures that the surface of the glass substrate is completely coated with the solvent.
It is therefore an advantage of the present invention to provide PFA, MFA or PE coated glass and a method for manufacturing the PFA, MFA or PE coated glass that maintains the structural integrity of the glass.
Another advantage of the present invention is to provide a method for manufacturing coated glass which enables a perfluoroalkoxy copolymer coating or a non-fluoropolymer coating to adhere to a glass substrate.
Another advantage of the present invention is to provide a method for manufacturing coated glass which enables a tetrafluoroethylene perfluoromethyl vinyl ether copolymer coating to adhere to a glass substrate.
A further advantage of the present invention is to provide a method of manufacturing coated glass that forms a strong bond between a perfluoroalkoxy copolymer and a glass substrate.
Another advantage of the present invention is to provide a coated glass substrate and a method of manufacturing same that can be used on a wide variety of glass substrates and products.
Additional features and advantages of the present invention are described in and will be apparent from, the following Detailed Description of the Invention and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is an enlarged fragmentary side view of a coated glass substrate of one embodiment of the present invention.
FIG. 1B is an enlarged fragmentary cross-sectional view of the coated glass substrate of FIG. 1A .
FIG. 2 is a flowchart illustrating one embodiment of the coating method of the present invention.
FIG. 3A is an enlarged fragmentary side view of a coated glass substrate of one embodiment of the present invention illustrating the coated glass substrate before the solvent layer is evaporated.
FIG. 3B is an enlarged fragmentary cross-sectional view of the coated glass substrate of FIG. 3A .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1A , 1 B, 2 , 3 A and 3 B, one embodiment of the coated glass product or substrate of the present invention is illustrated. The coated glass substrate or glass product 100 includes a glass substrate 102 , a layer of primer 104 applied to at least one portion, area or surface of the glass substrate and a layer of PFA, MFA or PE 108 applied to the primer layer on the surface of the glass substrate 102 . This combination creates a very strong bond between the PFA, MFA or PE and the primer on the surface of the glass substrate and thereby enables the PFA, MFA or PE layer to adhere to and stretch with the glass substrate, which substantially holds the glass substrate in tact. Additionally, the strong bond formed between the PFA or MFA and the glass substrate enables the coated glass substrate to withstand extreme conditions such as extreme temperatures and pressures. It should be appreciated that the glass substrate 102 may be any suitable type of glass substrate. Additionally, the glass substrate 102 may also be any suitable shape or configuration.
Referring now to FIGS. 2 , 3 A and 3 B, in one presently preferred embodiment of the method of the present invention, the glass substrate is positioned on an electrically grounded support or holder as indicated by block 200 . In one embodiment, the grounded support is made of an electrically conductive material such as metal and contacts and supports the glass substrate. In another embodiment, the grounded support includes a grounding plate or surface which supports and contacts a surface of the glass substrate. It should be appreciated that any suitable grounding support may be used to support and ground the glass substrate.
Before any coatings are applied to the glass substrate, one or more surfaces of the glass substrate 102 such as the outer surface of a glass beaker, are cleaned using a suitable cleaner to remove all or a substantial portion of the impurities from the surface of the glass substrate as indicated in block 201 . In the presently preferred embodiment, the cleaner is a solvent such as methyl ethyl ketone (“MEK”). The cleaning of the surface of the glass substrate may be performed manually or mechanically such as by a machine. It should be appreciated that other suitable cleaning methods and cleaners may be used to clean the surface of the glass substrate. It should also be appreciated that the surface of the glass substrate does not have to be cleaned prior to applying the primer. For example, the glass substrate itself may be clean or substantially free of impurities prior to applying the layers to the glass substrate. The layers are then applied to the substrate in a clean room or a room virtually free from impurities. It should be appreciated that the glass substrate could also be manufactured in a clean room. It should further be appreciated that the glass substrate may be cleaned by a separate cleaning process or in a separate cleaning area prior to positioning the glass substrate on the grounded support.
A layer of primer 104 is applied to the cleaned surface of the glass substrate as indicated by block 202 . The primer may be any suitable primer such as the 1200 clear primer manufactured by the Dow Corning Corporation. In a presently preferred embodiment, the primer is a clear primer and is applied or sprayed onto the surface of the glass substrate as a mist or atomized spray. It should be appreciated that the primer may be applied using other suitable coating processes such as dipping the substrate into a container of the primer. In this embodiment, the purpose of applying the primer as a mist is to avoid or reduce the chances of the surface of becoming wet or saturated with the primer. If the surface is wet or saturated with the primer, the appearance of the final coated glass substrate might appear cloudy or obscured due to the pooling of the primer on the surface of the glass substrate. Therefore, the pooling of the primer may also cause the surface to be uneven and inhibit light from passing through or cause refraction of the light through the coated glass substrate. The obscure nature of the glass substrate may also inhibit a user from being able to see through the substrate. Therefore, a fine mist or atomized spray is preferably applied to the substrate in relatively small quantities over the surface of the substrate. The primer adheres to the surface of the glass substrate being coated and acts as a bonding agent for subsequent coating layers. Once the primer is applied to the surface of the glass substrate, the primer is cured using a suitable curing process as indicated by block 204 . In one embodiment, the primer is cured in an oven or other suitable heater. In another embodiment, the primer is air-dried to cure the primer. It should be appreciated that any suitable curing process or method may be used to cure the primer in accordance with the present invention. In the presently preferred embodiment, the primer is cured by heating the primer with an oven or kiln to a temperature of approximately 500° F. (260° C.) for approximately five minutes.
After the primer has properly cured, an electro-conductive enhancer is applied to the primer as indicated by block 206 . In the presently preferred embodiment, the enhancer is a highly polarized solvent which is electrically conductive. When the solvent is applied to the primer the glass substrate becomes grounded. As a result, the solvent and the glass substrate develop a charge which attract materials or particles having an opposite charge. In one embodiment, the solvent is a water soluble solvent. In another embodiment, the solvent is N-methyl-2-pyrrolidone (NMP), which is water soluble. In the presently preferred embodiment, the NMP solvent is applied as a fog spray onto the primer layer 104 of the surface of the glass substrate 102 . This process continues until the surface of the glass substrate is wet or completely coated with the NMP. It should be appreciated that in one embodiment, for example wherein PE is applied to the surface of the glass substrate, rather than utilizing a separate primer as described above, the NMP solvent functions as both a primer and as a wetting agent or electro-conductive enhancer.
While the layer of NMP is still wet, a layer of PFA, MFA or PE is applied to the wet NMP layer. In the presently preferred embodiment, the PFA, MFA or PE is applied as particles which have an opposite charge from the NMP layer. As described above, the glass substrate is grounded, which promotes the flow of electric charge from the PFA, MFA or PE layer to the solvent layer. The voltage differential causes the NMP layer to attract the oppositely charged PFA or MFA particles to the NMP as indicated by block 208 . It should be appreciated that although not shown in FIG. 2 , the oppositely charged PE particles are attracted to the NMP layer. This process causes the PFA, MFA or PE layer to uniformly coat the NMP layer without pooling or forming drips. Once the particles coat the solvent or NMP layer, the particles act as an insulator against further particles accumulating on the NMP layer. In a presently preferred embodiment, the PFA, MFA or PE layer 108 is powder sprayed and electrically attracted to the wet NMP layer until the thickness of the coatings on the glass substrate achieves a desired thickness. Specifically, the desired thickness of the coatings is approximately 0.002 to 0.003 inches. Once the PFA, MFA or PE layer 108 is applied, the coated glass substrate includes three coating layers 104 , 106 and 108 as illustrated in FIGS. 3A and 3B . It should be appreciated that any suitable thickness may be implemented with the present method based on the desire of the manufacturer. Additionally, the PFA layer 108 may include any suitable PFA coating such as 532-5010 or 5011 PFA manufactured by E.I. Du Pont de Nemours and Company. The MFA layer 108 may include any suitable MFA coating such as MFA 620, MFA 640, MFA 6010, MFA 660, MFA 6012 or MFA 1041 manufactured by Solvay Solexis Inc. The PE coating may include any suitable PE coating such as Glas-Lok GLS® powder manufactured by Innotek Powder Coatings.
After the PFA, MFA or PE layer 108 has been applied to the NMP layer 106 on the surface of the glass substrate, the coated substrate is heated to evaporate the solvent layer and secure or adhere the PFA, MFA or PE layer 108 to the primer 104 on the surface of the glass substrate as indicated by block 210 . It should be appreciated that any suitable evaporation method may be employed to evaporate the solvent. It should also be noted that the solvent evaporates at a temperature of 400° F. (204° C.) and the PFA or MFA particles or layer begins to melt and cure at 500° F. (260° C.) and the PE particles or layer begins to melt or cure at 203° F. (95° C.). In a presently preferred embodiment, the PFA or MFA layer is heated at a temperature of approximately 800° F. (427° C.) for approximately twenty minutes and the PE layer is heated at a temperature of approximately 400° F. (204° C.) for approximately five to ten minutes. Because the solvent evaporates at 400° F., the solvent evaporates first as the coated substrate is heated. Once the solvent evaporates from the surface of the coated glass substrate, the PFA, MFA or PE remains and begins to melt and cure on the surface of the glass substrate.
The PFA, MFA or PE layer is tightly packed due to application of the PFA, MFA or PE to the wet layer of solvent. As a result, the PFA, MFA or PE layer adheres directly to the primer on the surface of the glass substrate when the solvent (NMP) evaporates from the surface of the glass substrate. This enables the final PFA, MFA or PE coated glass substrate to have a much clearer appearance. Therefore, a user can see through the coated glass substrate and light is able to pass through the coated glass substrate. These transparent and translucent characteristics of the coated glass substrate of the present invention enable the coated glass substrate and method of the present invention to be used for several commercial and industrial applications such as light bulbs, home glassware, laboratory glassware, windows and windshields. Once the curing process is complete, the coated glass substrate is transferred to another manufacturing area for further processing. It should be appreciated that as fluorescent tubes/bulbs function at lower temperatures than incandescent tubes/bulbs, the use of PE provides an economically attractive alternative to the costs associated with the high temperature capabilities of PFA or MFA.
In one embodiment, one or more pigmented primers may be implemented in accordance with the present invention. These pigmented primers may be opaque or translucent. In another embodiment, the coatings of PFA, MFA or PE are pigmented to provide different colored hues to the coated glass substrate. For example, the coatings may be pigmented to a pink, green or blue hue to enhance the appearance of food displayed in deli display cases which include the coated glass substrate.
The method of the present invention creates very strong bonds between the PFA, MFA or PE and the primer on the surface of the glass substrate 102 . As a result, the PFA, MFA or PE layer conforms to the glass and stretches to hold the glass surface together even when the glass shatters into several pieces. This prevents the glass from breaking up and falling away from the glass surface. Therefore, the coated glass substrates and products produced according to the present invention are very durable and resistant breaking apart, which makes the coated glass substrate of the present invention suitable for several different applications. For example, the PFA, MFA or PE coated glass substrate may be used for laboratory glassware such as a test tube or beaker. The strength of the bonds created between the PFA, MFA or PE layer 108 and the surface of the glass substrate 102 enables the glass surface of the laboratory glassware to substantially maintain its structural integrity upon shattering or breaking. This is very important for safety purposes because injuries or potentially serious injuries can be minimized or prevented. Also, the strength of the PFA or MFA bonds enables the coated glass to withstand high pressure and temperature cleaning systems found in laboratories and hospitals. It should be appreciated that any suitable fluoropolymer, such as other polytetrafluoroethylene copolymers, or non-fluoropolymer, such as vinyl powders, may be implemented in accordance with the present invention. For example, vinyl powder sold by Duravin under the name Seb-Evh Clear may be electrostically sprayed over the primed glass surface while it is still wet and then cured at 390° F. (199° C.) to 400° F. (204° C.) for five to ten minutes, depending on the mass of the glass substrate. In this example, the primer is a dispersion of the vinyl powder dissolved in NMP, wherein the dispersion includes twenty-five percent vinyl powder.
In another embodiment of the present invention, the surface of the substrate to be coated is first grit blasted to roughen it and promote the adherence of subsequent layers of the PFA, MFA or PE coating. For example, the bottom surfaces of the substrate are concave and need to be grit blasted to prevent delamination while a Bunsen burner is used to heat the bottom of the substrate. In this example, a black colored primer is used to even out the heat provided by the Bunsen burner and also to provide an enhanced bond with the PFA, MFA or PE. In another embodiment, sand of aluminum oxide is added to the black primer to create a rough surface that remains rough after the application of the PFA, MFA or PE topcoat. In this embodiment, the rough surface prevents the sliding of objects on the surface of the substrate
It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims. | A method for coating glass, and specifically for manufacturing perfluoroalkoxy copolymer coated glass and tetrafluoroethylene perfluoromethyl vinyl ether copolymer coated glass. The method includes placing a glass substrate on an electrically grounded support and cleaning it with a solvent to remove impurities and prepare the surface of the substrate to be coated. The method also includes coating the surface with a primer and uniformly applying an electro-conductive enhance to the primer so that the surface of the glass substrate is wet, but not uneven. The method includes powder spraying periluoroalkoxy copolymer or tetrafluoroethylene perfluoromethyl vinyl ether copolymer on the electro-conductive enhancer while the enhancer is still wet. The method also includes securing the perfluoromethyl vinyl ether copolymer to the glass substrate by evaporating the electro-conductive enhance. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to containers and methods for delivering liquid chemicals to a point of use. Mores specifically, to containers and methods wherein a gaseous media is used to push the liquid chemical out of the container.
2. Related Art
In certain chemical processes, such as chemical vapor deposition with organometallic precursors (MOCVD), there is often the need to pressurize supply reagent containers with inert gas in order to provide sufficient pressure in the container to deliver the chemical to the chemical vapor deposition tool. The vapor pressure of the liquid chemical at use temperature alone is frequently not sufficient to deliver the chemical to the chemical vapor deposition tool. Heating the chemical to raise its vapor pressure in these cases is not practical and often leads to premature degradation of the precursor chemical. Mechanical pumps may also lead to contamination.
It is known practice to introduce inert gas under pressure into a container in order to force chemical out of the container and down a process line. Indeed, certain suppliers advertise integral internal filters for gas delivery cylinders. However, unlike other applications, in MOCVD, the precursor such as pentaethoxy tantalum, zirconium t-butoxide, titanium tetrachloride, and the like, are extremely reactive to air contaminants, particularly moisture, to form metal oxide solids and various other hazardous materials (depending on the compound) often along with large releases of energy. For this reason, even minute traces of air contaminants cannot be tolerated in delivery equipment for such precursor chemicals. Furthermore, there is need to periodically change out supply containers as chemicals are consumed during processing of semiconductors. It is mainly in the change-out of containers where there is greatest potential to contaminate the delivery system and therefore the precursor chemical. For this reason good purge out sequences for delivery systems are required to be carried out as stipulated by semiconductor equipment manufacturers.
The need for good purging techniques are required for all air-sensitive compounds, even those with high vapor pressure precursors. However, in the case of low vapor pressure chemicals, the air contaminant issue is much more severe because such contaminants are introduced into the container and hence contaminate the entire container of product after which these contaminants cannot be simply flushed out using a purging manifold. Such contamination can be quite costly to the user since the cost of chemicals involved can reach several thousands of dollars per kilogram. Further, contamination by-products that form are much harder to remove and can leave solid residue on the seals of valves and other components downstream of the container leading to component failure, and possibly to serious health and costly down time risks.
To improve the purging operation during container change-outs, better manifolds have been designed over the years (for example, see U.S. Pat. Nos. 5,590,695 and 5,964,254). However, even though better manifold design indeed leads to improved purging efficiency, operationally mishaps can occur from human error, computer controller errors, and component failures. Many compounds can lead to solid residues on valve seals, for example, which in turn leads to valve malfunctions. When such problems occur at chemical container filling locations, the degraded product will be detected in the routine product quality control procedures; however, when it occurs at a user's site location the problem exhibits itself only after it causes down time and hazardous shut-down scenario.
An alternate means of preventing air contamination from entering the container is the use of breakseals (for example, see U.S. Pat. Nos. 4,134,514; 4,140,735; 4,298,037; 4,851,821; 4,966,207; and 4,979,643). As indicated in many previous patents, use of breakseals is indeed quite common in the handling of air-sensitive compounds and does effectively prevent direct contact of air into the container. However, in the case of inefficient purge sequences, component failure, computer control problem or human error, such breakseals will not prevent air contaminants from entering the container.
SUMMARY OF THE INVENTION
In accordance with the present invention, containers for delivery of high purity reactive liquids using gaseous assist are presented, as well as methods of use of same. In one embodiment, the container comprises a container body, the container body having fluidly connected thereto a gas inlet and a reactive liquid outlet, the gas inlet fitted with a means adapted to hold a gas filter media, preferably internally in the container, and a gas filter media positioned within the means adapted to hold a gas filter media, the gas inlet having a gas inlet valve, the liquid outlet having a liquid outlet valve. Preferred containers are those wherein the gas filter media is selected from a group consisting of silica, alumina, aluminosilicates; and containers wherein the liquid outlet is fitted with a means adapted to hold a liquid filter media, and a liquid filter media is positioned within the means adapted to hold a liquid filter media. Preferably, the liquid filter media is selected from a group consisting of silica, alumina, aluminosilicates. Other preferred containers are those wherein the means adapted to hold a gas filter media, and the gas filtered media, are integral to the container, and containers wherein the means adapted to hold a gas filter media comprises a conduit having a conduit inlet end positioned in said gas inlet of the container, the conduit having a conduit outlet end. Preferably, the conduit outlet end is internal to the container body. Preferably, the gas filter media is positioned between first and second gas filter media holders, both of the gas filter media holders being porous to gas used in gaseous assist delivery of liquid chemical adapted to be delivered from the container. Yet other preferred containers of the invention include those wherein the body has fluidly connected therewith a degas unit, the degas unit preferably integral with the liquid outlet and internal to the container body. Particularly preferred are containers of the invention wherein the reactive liquid does not make physical contact with the liquid filter media. This may be accomplished by use of means such as check valves, fine porous filter media, or even an elongated or coiled tube, as discussed herein. Also, the gaseous and liquid filter media may be external to the container in certain embodiments, positioned in close proximity to the container top.
Another aspect of the invention is a method of delivery of a high purity reactive liquid chemical to a point of use using gaseous assist, the method comprising the steps of:
(a) connecting the gas inlet of the inventive container to a source of gas, the container having liquid chemical therein;
(b) connecting the liquid outlet of the container to means able to accept the liquid chemical;
(c) initiating flow of gas by opening the gas inlet valve; and
(d) preventing impurities from entering the container through the gas inlet means. Preferred methods of the invention are those including preventing impurities from leaving the container through the liquid outlet, preferably methods wherein step (d) comprises passing the gas through the gas filter media, the gas filter media selected from a group consisting of silica, alumina, aluminosilicates, and the like. Still other preferred methods are those wherein the step of preventing impurities from leaving the container comprises passing the liquid chemical through a liquid filter media, the liquid filter media preferably selected from the same group of filter media that the gas filter media is selected from.
A second method embodiment of delivery of a high purity reactive liquid chemical to a point of use using gaseous assist comprises the steps of:
(a) connecting the gas inlet of the inventive container to a source of gas, the container having liquid chemical therein;
(b) connecting the liquid outlet of the container to means able to accept the liquid chemical;
(c) initiating flow of gas by opening the gas inlet valve;
(d) preventing impurities from entering the container through the gas inlet means; and
(e) degassing the liquid chemical before the liquid chemical exits the container. Preferred methods within this aspect of the invention are those wherein the method includes preventing impurities from leaving the container through the liquid outlet; methods wherein step (d) comprises passing the gas through the gas filter media, the gas filter media selected from the group consisting of alumina, silica, and aluminosilicates; and methods wherein the step of preventing impurities from leaving the container comprises passing liquid chemical through a liquid filter media. Other preferred methods include those wherein the liquid filter media is selected from the group consisting of silica, alumina, and aluminosilicates.
As used herein, the term “integral” means that a component is unable to be removed from the container body without great difficulty by an enduser. In this sense, “integral” does not mean that the component cannot be moved at all, but merely that the component cannot be removed during the normal course of use of the container.
As used herein the term “high purity” means that the liquid chemical is susceptible to contamination by contact with atmospheric air and its contaminants. Similarly, the term “reactive” means that the liquid chemical may decompose upon contact with air and its contaminants.
Chemicals such as organometallic precursors used in chemical vapor deposition need to be delivered at higher pressure than that of their own vapor pressure. A non-comprehensive list of chemicals which may benefit from the invention are listed in Table 1. This is easily done by pressurizing the container with inert gas to force the liquid out of the container. However, in such operations, such liquid chemicals run the risk of being contaminated with air impurities. These impurities, particularly moisture, react with many organometallic compounds to form other hazardous materials from the container. To prevent this from occurring, the container of the present invention has a design with an appropriate purifier to remove atmospheric contaminants before entering the container in the event of residual air being present in connecting lines which was not removed due to improper purge from operator handling, computer controller errors, or equipment component failures. Thus, better safety of chemical storage and improved assurance of chemical purity is attained which is often needed for critical processes such as that in the semiconductor industry. A particularly preferred method in accordance with the invention of preventing air contaminants from entering the container of the invention is to incorporate a purifying medium integral to the container itself and downstream of any line fittings that are disconnected for container change-outs. In accordance with the present invention, such purifier is preferably placed inside the container on the gas inlet port. Alternatively, such purifiers can be installed on both gas inlet and liquid outlet ports of the container. By making them an integral part of the container, no operator maintenance or intervention is required and the user is guaranteed the appropriate size and media to use for a particular chemical.
Thus, by incorporating a purifier on the gas inlet port of the container the inert gas used to pressurize the container will not contribute contaminants to the chemical. By making such purifier an integral part of the container, rather than fastening the purifier to the gas inlet line exterior to the container, there is far more certainty that all gas entering the container goes through the purifying media, thereby more effectively preventing error of contamination. Furthermore, preferably changing the filter media with every container change prevents over use of the filter media, and a human operator does not have to closely track usage of the filter media. The filter media is preferably economically sized for just one container volume of chemical, and preferably the filter media can be regenerated for use with another container.
As far as known to the inventor, no such container is available which incorporates purifiers directly into the container itself. Further, while it may be obvious that using gas purifies upstream of the gas flow can help assure purity of the gas itself, today, gas purity is rarely the problem since very high purities are usually attainable and commercially available. More frequently, the difficulty is in providing the user of liquid chemicals the assurance of reliable operations in purging out air contaminants sufficiently that result from installing new or replacement container by chemical delivery system.
The invention will be better understood with reference to the drawing figures and description of preferred embodiments which follows.
TABLE 1
Chemicals That May Benefit From the Invention
Chemical
Name
Structure
Chemical Name
Application
Film
PET
Ta(Oet)5
Pentaethoxytantalum
High-k Capacitor,
Ta2O5
High-k Gate Oxide
Zr(t-OBu)4
Zr(O(CH3)3)4
Zirconium tertiary butoxide
High-k Gate Oxide
ZrO/ZrSiO
MS
(CH3)SiH3
Monomethylsilane
Low-k
SiOC
4MS
Si(CH3)4
Tetramethylsilane
Barrier Low-k
SiC
TiCl4
TiCl4
Tetrachlorotitanium
Barrier Metal
TiN
TDMAT
Ti(Nme2)4
Tetrakisdimethylaminotitanium
Barrier Metal
TiN, TiSiN
TDEAT
Ti(NEt2)4
Tetrakisdiethylaminotitanium
Barrier Metal
TiN, TiSiN
EtCp2Ru
BisEthyl Cyclo PentaDienyl
Electrode
Ru/RuO
Ruthenium
DMDMOS
(CH3)2Si(OCH3)2
Dimethyldimethoxysilane
Low-k
SiOC
HCDS
Si2Cl6
Hexachlorodisilane
Etch Stopper, Cap
SiN
Layer, Spacer
Zr(NEt2)4
Tetrakisdiethylaminozirconium
High-k Gate Oxide
ZrO/ZrSiO
Hf(NEt2)4
Tetrakisdiethylaminohafnium
High-k Gate Oxide
HfO/HfSiO
Si(Nme2)4
Si(N(CH3)2)4
Tetrakisdimethylaminosilane
High-k Gate Oxide
HfSiO/ZrSiO
Zr(Nme2)4
Zr(N(CH3)2)4
Tetrakisdimethylaminozirconium
High-k Gate Oxide
ZrO/ZrSiO
HSi(Net2)3
HSi(N(C2H5)2)3
Trisdiethylaminosilane
High-k Gate Oxide
HfSiO/ZrSiO
Hf(t-OBu)4
Hf(O(CH3)3)4
Hafniumtertiarybutoxide
High-k Gate Oxide
HfO/HfSiO
Si(i-Opr)4
Si(O(CH(CH3)2)4
Silicon iso propoxide
High-k Gate Oxide
HfSiO/ZrSiO
Si(NEt2)4
Si(N(C2H5)2)4
Tetrakisdiethylaminosilane
High-k Gate Oxide
HfSiO/ZrSiO
3MS
(CH3)3SiH
Trimethylsilane
Low-k, Barrier Low-k
SiOC, SiC
TMCTS
C4H16O4Si4 ??
Tetramethylcyclotetrasiloxane
Low-k
SiOC
HSi(NMe2)3
HSi(N(CH3)2)3
Trisdimethylaminosilane
High-k Gate Oxide
HfSiO/ZrSiO
TATDMAE
Ta(OC2H5)4(C4H10NO
Tantalumtetraehoxydimethyl-
High-k Capacitor,
Ta2O5
aminoethoxide
High-k Gate Oxide
ZrCl4
ZrCl4
TetraChlorozirconium
High-k Gate Oxide
ZrO/ZrSiO
Pt(hfa)2
Bis Hexa Fluoro Acetyl
Electrode
Pt/PtO
Acetonato Platinum
Ir(acac)3
Tris Acetyl Acetonato
Electrode
Ir/IrO
Iridium
PbDPM2
Bis Di Pivaloyl Methanato
Ferro Electric (PZT)
PZT
Lead
ZrDPM
Tetra Di Pivaloyl Methanato
Ferro Electric (PZT)
PZT
Zirconium
Ti(DPM)2(i-OPr)2
Ferro Electric (PZT)
PZT
Sr(DPM)2
Bis Di Pivaloyl Methanato
Ferro Electric (SBT)
SBT
strontium
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates schematically, in side-sectional view, a first container embodiment of the invention;
FIG. 2 illustrates schematically, in side-sectional view, a second container embodiment of the invention; and
FIG. 3 illustrates schematically, in side-sectional view, a third container embodiment of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the Figures, FIG. 1 illustrates a first embodiment 100 of a container of the invention. Container 100 includes a container body 2 having a top 4 and a gas inlet line 6 , through which gas is controlled using the gas inlet valve 8 . Gas inlet tube 6 traverses through top 4 of container 2 and preferably enters first porous media disc 10 . Disc 10 is held in place by a tube 12 , and tube 12 in turn holds in place a gas filter media cartridge 14 along with a second force disc 16 . Completing the gas inlet is a gas exit tube 18 which may or may not be present in all embodiments. Tube 18 prevents backsplash of liquid chemical into porous media 16 . Again, porous media 10 , 16 and gas outlet tube 18 are only preferred and not necessary to the practice of the invention. The dotted portion 19 illustrates that tube 18 May be extended in an “S” shape, to help preclude liquid from entering the gas filter media 14 . Completing the first embodiment is a liquid exit tube 20 and a liquid control valve 22 . Liquid exit tube 20 extends through top 4 of container body 2 and into the liquid chemical, and preferentially extends near the bottom of container body 2 so that the chemical may be withdrawn even when the liquid level is low. It may be seen by this embodiment that any air impurities that may seek to enter container body 2 through the gas inlet will be caught by the filter media 14 and hence not enter into the container.
FIG. 2 illustrates a second embodiment 200 of the container of the invention, which is similar to the embodiment 100 of FIG. 1, however, container 200 of FIG. 2 includes a liquid filter media 26 held within a liquid filter media cartridge 24 both of which are attached to the end of liquid exit tube 20 . Although impurities are prevented from entering container body 2 through the inert gas inlet tube 6 , there could be occasion for impurities to generate within container 2 itself, for example, if the liquid chemical is exposed to higher than normal temperatures for prolonged time. Liquid filter 26 will filter out any developed impurities which happen to be generated within the container 2 and will not exit with liquid chemical out liquid exit tube 20 .
Another embodiment of the liquid delivery container of the invention is illustrated in FIG. 3 as embodiment 300. Embodiment 300 of FIG. 3 has all of the features of embodiment 200 of FIG. 2 on the gas inlet, but includes a pipe-in-pipe dip tube 28 . Dip tube 28 also includes a gas exit tube 30 which allows extraneous gas developed from impurities which may be generated within container body 2 to exit the system. These units are sometimes referred to as permeable degas units. Typically, gas exit 30 is attached to a suitable negative pressure device, such as a hood, exhaust manifold, or to a source of vacuum. In this embodiment, tube 20 preferably comprises a gas permeable material, having the function allowing gas to escape from liquid flowing therein. Also included in this embodiment is a liquid filter media 27 .
As illustrated in FIG. 1, in one of the simplest embodiments, the purifying media is enclosed in a small tube extending from the gas inlet port of the container. Preferably, the both ends of the purifying media have fitted therewith a fitted metal disc or other fine filtering substrate that can be welded in place in order to contain the gas filtering media. In this particular application, a proper choice of gas filtration media is important since it not only must remove trace air contaminants but also must be compatible with the liquid chemical itself. In this application, silica, alumina, and aluminosilicate materials are preferred since they are chemically inert and yet have the capability to remove moisture to very low levels. Furthermore, prewashing the purifying material itself with the liquid chemical to be delivered from container 2 will help assure compatibility. The volume of gas required to pass through the gas filter media is not very large, typically only two to three times that of the container volume itself, more preferably 3 or 4 times, so that there is no large capacity requirement for the gas purifying media. This allows a large range of materials to be used. The only critical requirement is that the gas filtering media be chemically compatible with the liquid chemical itself. The liquid contact with the gas purifying media can easily be eliminated by means of use of very fine porous filter substrates, a check valve, or by extending tube 18 , as illustrated in FIG. 1, below the downstream gas purifying media so as to maintain an inert gas pocket between gas filter media and the liquid itself. An alternative “S”-shaped tubing embodiment 19 is illustrated in FIG. 1 .
Alternatively, and as illustrated in FIGS. 2 and 3, purification media can be placed on both gas inlet and liquid outlet, provided the purifying media is fully compatible with the liquid chemical being delivered and the design can accommodate liquid flow rates required by the user. Since some liquid chemicals can degrade over time during storage to form solid particulates, the use of an appropriate filter on the outlet port can be very desirable. Again, as with the integral gas inlet filter media having a liquid particulate filter on the outlet port integral to the container itself is advantageous to the user in that the liquid filtration media has been properly pre-selected by the supplier and it “automatically” undergoes replacement with every container change-out. In an alternative embodiment, purifying media, whether for gas or liquid, are preferably contained in the gas and liquid valve ports. This may have advantages for assembly and disassembly.
As with the gaseous and liquid filtration media, if a permeable degas cartridge is used it is preferably integral to the container. This assures proper selection of the components compatible with the liquid chemical being delivered and the user does not have to worry that the appropriate permeable degas cartridge is installed in containers delivering appropriate chemical to the end use. It becomes an automatic replacement as the containers are changed out.
Methods of use of the containers of the invention are now described. As in most chemical usage situations, the procedures are cyclical. Assuming an empty container situation, the end user may prefer to simply purge container body 2 by keeping valves 8 and 22 open for a time, either controlled by human or computer control. After a sufficient purge time, valves 8 and 22 are closed and the container is disconnected from the user system through connections upstream of valve 8 and downstream of valve 22 (not shown). A new container 100 is then attached to the system. If the user desires flow of liquid, valve 22 is opened and valve 8 is opened, allowing gas to flow into container body 2 , thereby pushing liquid chemical out through liquid exit tube 20 and liquid exit valve 22 . As with the purge out sequence, this may be human controlled or computer controlled.
As gas enters the system through valve 8 and tube 6 the gas will be purified, or at least air contaminants will be removed, through filter media 14 . If the container embodiment 200 of FIG. 2 is used, furthermore, any impurities which are generated inside the container after the container itself has been installed, will be removed by liquid filter media 26 as liquid chemical is being delivered out of container 200 . Finally, as a further assurance of purity, a gas permeable pipe-in-pipe dip tube 28 with filter media 27 may be installed integrally as in the embodiment 300 of FIG. 3, thereby comprising the greatest assurance of purity for the end user. In embodiment 300, as inert gas enters through valve 8 and tube 6 , and is maintained clean by gas filter media 14 , liquid filter media 27 maintains liquid of high purity, while any gas that is developed from the liquid chemical is removed by the permeable unit 28 , through tube 30 which is connected to a negative pressure source.
Although not a feature of the present invention, it is preferable for containers of the invention to be equipped with liquid level sensing. This may either be accomplished through known means, such as float sensors, or through novel methods such as liquid level sensing via gas volume expansion monitoring. The containers of the invention my also be equipped with quick-purge canister change-out connections, thermally heated degas units, and delivery manifolds with liquid recovery (solvent or process chemical flushing) recovery canisters. Containers of the invention may also be supplied with mechanical pressurization (piston type) or bag (canisters). Solvent purge cleaning may also be equipped with the containers of the invention. All of these components are preferably “modular” add-on design, which can be installed and uninstalled in quick fashion by the user. For example, a modular design might include in one module all utilities such as gas pressurization flow, vacuum and solvent flow, while another module may consist of liquid output functions such as flow accumulation, flow meters, pressure sensors, filters, and degas units. Another module may contain purging and pressurizing sequences of valves.
Another module may include a scale to weigh the containers of the invention as they are being emptied, the scale may have variable height supports. Containers of the invention may include wheels, a weight scale, a bypass line, sight glasses for level sensing, UV/VIS level sensing and chemical purity monitoring, gas inlet purifies and degassing dip tubes. Specially preferred are UV/VIS probe sensors for level and purity monitoring as more fully explained in Applicant's copending application Ser. No. 09/905,598, filed on even date herewith, and incorporated by reference herein.
Preferred methods and apparatus for practicing the present invention have been described. It will be understood and readily apparent to the skilled artisan that many changes and modifications may be made to the above-described embodiments without departing from the scope of the present invention. The foregoing is illustrative only and other embodiments of the methods and apparatus may be employed without departing from the scope of the invention defined by the following claims. | Methods and apparatus for delivery of high purity reactive liquids using gaseous assist are described, the apparatus comprising a container body, the container body having fluidly connected thereto a gas inlet and a reactive liquid outlet, the gas inlet fitted with a means adapted to hold a gas filter media, and a gas filter media positioned within said means adapted to hold a gas filter media, the gas inlet having a gas inlet valve, the liquid outlet having a liquid outlet valve. | 1 |
This work was funded by the National Institutes of Health (GM-35572) and was supported in part by National Research Service Award T32 GM07767. Thus, the United States Government may have some rights in this application.
This application claims priority to and incorporates U.S. Provisional Application Ser. No. 60/027,807 filed Oct. 4, 1996.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for preparing swainsonine. The present invention also relates to novel intermediates useful for the production of swainsonine.
2. Discussion of the Background
The indolizidine alkaloid (-)-swainsonine (1) is of long standing interest due to its diverse biological activity. For the isolation from the fungus Rhizoctonia leguminicola, see:
(a) Guengerich, F. P.; DiMari, S. J.; Broquist, H. P. J. Am. Chem. Soc. 1973, 95, 2055.
(b) Schneider, M. J.; Ungemach, F. S.; Broquist, H. P.; Harris, T. M. Tetrahedron 1983, 39, 29-32.
For the isolation from the fungus Metarhizium anisopliae, see:
(c) Hino, M.; Nakayama, O.; Tsurumi, Y.; Adachi, K.; Shibata, T.; Terano, H.; Kohsaka, M.; Aoki, H.; Imanaka, H. J. Antibiot. 1985, 35, 926-935.
(d) Patrick, M. S.; Adlard, M. W.; Keshavarz, T. Biotechnol. Lett. 1995, 17, 433-438.
For the isolation from the legume Swainsona canescens, see:
(e) Colegate, S. M.; Dorling, P. R.; Huxtable, C. R. Aust. J. Chem. 1979, 32, 2257-64.
For the isolation from the locoweed Astragalus lentiginosus, see:
(f) Molyneux, R. J.; James, L. F. Science, 1982, 216, 190-191.
For the isolation from Weir vine, see:
(g) Molyneux, R. J.; McKenzie, R. A.; O'Sullivan, B. M.; Elbein, A. D. J. Nat. Prod. 1995, 58, 878-886.
For a review of the synthesis and biological activity of swainsonine and other glycosidase inhibitors, see: Nishimura, Y. In Studies in Natural Products Chemistry; Atta-ur-Rahman, Ed.; Elsevier: Amsterdam, 1992; Vol. 10; pp 495-583.
(-)-Swainsonine may be considered an azasugar analog of mannose, and is indeed a potent inhibitor of many mannosidases including the glycoprotein processing enzyme mannosidase II (see: Elbein, A. D. Ann. Rev. Biochem 1987, 56, 497-534; Cenci Di Bello, I.; et al Biochem. J. 1989, 259, 855-861; Winchester, B., et al; Glycobiology, 1992, 2, 199-210; and Kaushal, G. P.; Elbein, A. D. Methods in Enzymology 1994, 230, 316-329). Swainsonine is the first glycoprotein-processing inhibitor to be selected for clinical testing as an anticancer drug (see: Goss, P. E.; Baker, M. A.; Carver, J. P.; Dennis, J. W. Clin. Cancer Res. 1995, 1, 935-944; and Das, P. C.; Roberts, J. D.; White, S. L.; Olden, K. Oncol. Res. 1995, 7, 425-433), but its high cost has hindered clinical trials. For example, Sigma Chemical Co. currently sells 1 mg of (-)-swainsonine isolated from Rhizoctonia leguminicola for ca. $100 USD (1995 catalog). Toronto Research Chemicals currently sells 1 mg of synthetic (-)-swainsonine for ca. $40. Apparently, there is still no cost-effective way to either isolate swainsonine from natural sources or to prepare it synthetically.
A great deal of effort has been expended on developing synthetic routes to swainsonine. See e.g.,
(a) Suami, T.; Tadano, K.; Iimura, Y. Chem. Lett. 1984, 513-516.
(b) Ali, M. H.; Hough, L.; Richardson, A. C. J. Chem. Soc., Chem. Commun. 1984, 447-448.
(c) Fleet, G. W. J.; Gough, M. J.; Smith, P. W. Tetrahedron Lett. 1984, 25, 1853-1856.
(d) Yasuda, N.; Tsutsumi, H.; Takaya, T. Chem. Lett. 1984, 1201-1204.
(e) Adams, C. E.; Walker, F. J.; Sharpless, K. B. J. Org. Chem. 1985, 50, 420-422.
(f) Suami, T.; Tadano, K. Iimura, Y. Carbohydr. Res. 1985, 136, 67-75.
(g) Ali, M. H.; Hough, L. Richardson, A. C. Carbohydr. Res. 1985, 136, 225-240.
(h) Setoi, H.; Takeno, H.; Hashimoto, M. J. Org. Chem. 1985, 50, 3948-3950.
(i) Ikota, N.; Hanaki, A. Chem. Pharm. Bull. 1987, 35, 2140-21433.
(j) Ikota, N.; Hanaki, A. Heterocycles 1987, 26, 2368.
(k) Bashyal, B. P.; Fleet, G. W. J.; Gough, M. J.; Smith, P. W. Tetrahedron 1987, 43, 3083.
(l) Dener, J. M.; Hart, D. J. Ramesh, S. J. Org. Chem. 1988, 53, 6022-6030.
(m) Carpenter, N. M.; Fleet, G. W. J.; diBello, I. C.; Winchester, B.; Fellows, L. E.; Nash, R. J. Tetrahedron Lett. 1989, 30, 7261-7264.
(n) Bennett, R. B., III; Choi, J.-R.; Montgomery, W. D.; Cha, J. K. J. Am. Chem. Soc., 1989, 111, 2580-2582.
(o) Pearson, W. H.; Lin, K.-C. Tetrahedron Lett., 1990, 31, 7571.
(p) Miller, S. A.; Chamberlin, A. R. J. Am. Chem. Soc., 1990, 112, 8100-8112.
(q) Ikota, N.; Hanaki, A. Chem. Pharm. Bull. 1990, 38, 2712.
(r) Fleet, G. W. J. U.S. Pat. No. 5,023,340, 1991.
(s) Naruse, M.; Aoyagi, S.; Kibayashi, C. J. Org. Chem., 1994, 59, 1358-1364.
(t) Hunt, J. A.; Roush, W. R. Tetrahedron Lett. 1995, 36, 501-504.
(u) Kang, S. H.; Kim, G. T. Tetrahedron Lett. 1995, 36, 5049-5052.
For a synthesis of the non-natural (+)-enantiomer of swainsonine, see:
(v) Oishi, T.; Iwakuma, T.; Hirama, M.; Ito, S. Synlett 1995, 404-406.
For formal syntheses, see:
(w) Gonzalez, F. B.; Barba, A. L.; Espina, M. R. Bull. Chem. Soc. Jpn. 1992, 65, 567-574.
(x) Honda, T.; Hoshi, M.; Kanai, K.; Tsubuki, M. J. Chem. Soc., Perkin Trans. 1 1994, 2091-2101.
(y) Angermann, J.; Homann, K.; Reissig, H.-U.; Zimmer, R. Synlett 1995, 1014-1016.
(z) Zhou, W.-S.; Xie, W.-G.; Lu, Z.-H.; Pan, X.-F. Tetrahedron Lett., 1995, 36, 1291-1294.
(aa) Zhou, W.-S.; Xie, W.-G.; Lu, Z.-H.; Pan, X.-F. J. Chem. Soc., Perkin Trans. 1 1995, 2599-2604.
However, there is still a need for a practical synthesis of this important alkaloid. Perhaps the most practical routes developed to date are those reported by the research groups of Fleet (see: Carpenter, N. M.; Fleet, G. W. J.; diBello, I. C.; Winchester, B.; Fellows, L. E.; Nash, R. J. Tetrahedron Lett. 1989, 30, 7261-7264; and Fleet, G. W. J. U.S. Pat. No. 5,023,340, 1991) and Cha (see: Bennett, R. B., III; Choi, J.-R.; Montgomery, W. D.; Cha, J. K. J. Am. Chem. Soc., 1989, 111, 2580-2582). In addition, a short synthetic route recently developed has not proven amenable to scale-up (Pearson, W. H.; Lin, K.-C. Tetrahedron Lett., 1990, 31, 7571).
Thus, there remains a need for a synthesis of (-)-swainsonine that is relatively short and efficient and uses simple reactions that allow good reproducibility and material throughput. There also remains a need for intermediates useful for the production of swainsonine.
SUMMARY OF THE INVENTION
Accordingly, it is one object of the present invention to provide a novel method for producing swainsonine.
It is another object of the present invention to provide a novel method for producing (-)-swainsonine.
It is another object of the present invention to provide a novel method for producing (-)-swainsonine which is convenient and economical and affords (-)-swainsonine in high yields.
It is another object of the present invention to provide novel intermediates useful for producing swainsonine.
It is another object of the present invention to provide novel intermediates useful for producing (-)-swainsonine.
These and other objects, which will become apparent during the following detailed description, have been achieved by the inventors' discovery that:
(i) reacting a compound of formula (8): ##STR4## in which R' is methanesulfonyl, trifluoromethanesulfonyl, or toluenesulfonyl, preferably methanesulfonyl with H 2 in the presence of Pd(OH) 2 followed by NaOMe, to obtain a compound of the formula (9): ##STR5## and
(ii) reducing the carbonyl group and hydrolyzing the ketal group in the compound of formula (9) affords (-)-swainsonine of formula (1): ##STR6##
The present invention has also been achieved by the inventors'discovery of the following novel intermediates useful for producing (-)-swainsonine: ##STR7## in which R is selected from the group consisting of trimethylsilyl, triethylsilyl, tri-isopropylsilyl, diphenyl-tert-butylsilyl and tert-butyldimethysilyl, preferably tert-butyldimethylsilyl, and X is C 1-4 -alkyl; ##STR8## in which R is selected from the group consisting of trimethylsilyl, triethylsilyl, tri-isopropylsilyl, diphenyl-tert-butylsilyl and tert-butyldimethysilyl, preferably tert-butyldimethylsilyl; ##STR9## in which R is selected from the group consisting of trimethylsilyl, triethylsilyl, tri-isopropylsilyl, diphenyl-tert-butylsilyl and tert-butyldimethysilyl, preferably tert-butyldimethylsilyl; and ##STR10## in which R' is selected from the group consisting of hydrogen, methanesulfonyl, trifluoromethanesulfonyl, and toluenesulfonyl, preferably hydrogen or methanesulfonyl.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Thus in a first embodiment, the present invention provides a novel, convenient, and economical synthesis of (-)-swainsonine, using the strategy shown in scheme 1. ##STR11## The reductive double-cyclization of an azide bearing two remote electrophilic centers for the synthesis of other bioactive alkaloids and their analogs has previously been used for the synthesis of:
A. Slaframine:
Pearson, W. H.; Bergmeier, S. C. J. Org. Chem. 1991, 56, 1976-1978.
Pearson, W. H.; Bergmeier, S. C.; Williams, J. P. J. Org. Chem. 1992, 57, 3977-3987.
B. Australine and alexine stereoisomers:
Pearson, W. H.; Hines, J. V. Tetrahedron Lett. 1991, 32, 5513-5516.
C. Ring-expanded analogs of swainsonine:
Pearson, W. H.; Hembre, E. J. Tetrahedron Lett. 1993, 34, 8221-8224.
Pearson, W. H.; Hembre, E. J. J. Org. Chem., 1996, 61, 5537-5545.
D. Ring-expanded analogs of australine and alexine:
Pearson, W. H.; Hembre, E. J. J. Org. Chem., 1996, 61, 5546-5556.
For related one-pot double cyclizations using azido epoxides or amino epoxides, see: Setoi, H., et al J. Org. Chem. 1985, 50, 3948-3950; Carpenter, N. M., et al Tetrahedron Lett. 1989, 30, 7261-7264; Kim, Y. G.; Cha, J. K. Tetrahedron Lett. 1989, 30, 5721-5724; Ina, H.; Kibayashi, C. J. Org. Chem., 1993, 58, 52-61; Jirousek, M. R.; Cheung, A. W.-H.; Babine, R. E.; Sass, P. M.; Schow, S. R.; Wick, M. M. Tetrahedron Lett., 1993, 34, 3671-3674; Kim, N.-S.; Choi, J.-R.; Cha, J. K. J. Org. Chem 1993, 58, 7096-7099; Poitout, L.; Le Merrer, Y.; Depezay, J.-C. Tetrahedron Lett., 1994, 35, 3293-3296; and Lohray, B. B.; Jayamma, Y. and Chatterjee, M. J. Org. Chem 1995, 60, 5958-5960.
The synthesis of swainsonine (Scheme 1) may begin with 2,3-O-isopropylidene-D-erythronolactone (2), which is commercially available (Aldrich) or may be prepared in large quantities from inexpensive D-isoascorbic acid (see: Cohen, N.; Banner, B. L.; Laurenzano, A. J.; Carozza, L. In Organic Syntheses, Collective Vol. IV; J. P. Freeman, Ed.; Wiley: N.Y., 1990; pp 297-301; and Dunigan, J.; Weigel, L. O. J. Org. Chem. 1991, 56, 6225-6227). Reduction of (2) with diisobutylaluminum hydride (see: Cohen, N., et al J. Am. Chem. Soc. 1983, 105, 3661-3672) provided 2,3,-O-isopropylidene-D-erythrose. Addition of vinylmagnesium bromide (see: Mekki, B.; et al Tetrahedron Lett. 1991, 32, 5143-5146) followed by selective monoprotection of the resulting diol afforded the allylic alcohol (3) (97:3 anti/syn) in 73% yield from (2).
Separation of the diastereomeric mixture was possible, however it was unnecessary, since both allylic alcohols (3) produce the same g,d-unsaturated ester (4) when subjected to Johnson orthoester Claisen rearrangement conditions (see: Johnson, W. S.; et al J. Am. Chem. Soc. 1970, 92, 741-743). The rearrangement produced only the E-isomer within the limits of detection by high-field 1 H-NMR.
Without purification, (4) was submitted to the Sharpless dihydroxylation procedure (see: Sharpless, K. B.; et al J. Org. Chem. 1992, 57, 2768-2771; Wang, Z.-M.; et al Tetrahedron Lett. 1992, 33, 6407-6410; and Keinan, E.; et al Tetrahedron Lett. 1992, 33, 6411-6414) affording the lactones (5a) and (5b) in 70% and 9% yields, respectively, after separation. Alternatively, Cha's method may be used to transform (4) into swainsonine. Cha and coworkers made a compound similar to (4) (ethyl ester, Z-alkene, free hydroxy instead of t-butyldimethylsilyloxy) by a Wittig route.
Removal of the silyl protecting group from (5a) gave the diol (6), which was smoothly converted to the crystalline dimesylate (7). Selective displacement of the less hindered mesylate of (7) with sodium azide afforded (8). Palladium-catalyzed hydrogenolysis of (8) to the amine followed by filtration of the catalyst and treatment of the filtrate with sodium methoxide caused cyclization to the known crystalline bicyclic lactam (9) in 75% yield. Reduction of (9) with borane-methyl sulfide complex gave a 94% yield of crystalline (10), also a known compound (see Setoi, H.; et al J. Org. Chem. 1985, 50, 3948-3950; Bashyal, B. P.; et al Tetrahedron 1987, 43, 3083; Bennett, R. B.; et al J. Am. Chem. Soc. 1989, 111, 2580-2582; and Naruse, M.; et al J. Org. Chem. 1994, 59, 1358-1364) which was hydrolyzed to swainsonine (1) in 96% yield. While the reduction of (9) to (10) has been reported by Fleet using BH 3 .Me 2 S (see: Carpenter, N. M.; et al Tetrahedron Lett. 1989, 30, 7261-7264) their procedure involves isolation of the borane complex of (10). The present procedure is adapted from a similar one by Keck which was used to make an epimer of swainsonine, see: Keck, G. E.; Romer, D. R. J. Org. Chem. 1993, 58, 6083-6089. While not the shortest synthesis, this route involves simple, reproducible steps that work well on a substantial scale. Using this method, 4.5 g of swainsonine was be prepared in 20% overall yield from the lactone (2), requiring 11 steps involving three chromatographic separations and five crystallizations.
To summarize, a simple route to the clinically useful anticancer agent (-)-swainsonine (1) has been developed. Given the current scarcity and high cost of this material, this preparation will be useful to researchers in this area.
Other features of the invention will become apparent in the course of the following descriptions of exemplary embodiments which are given for illustration of the invention and are not intended to be limiting thereof.
EXAMPLES
General methods
All commercial reagents (if liquid) were distilled prior to use. All other solid reagents were used as obtained. Tetrahydrofuran was distilled from sodium/benzophenone ketyl. Toluene, dichloromethane, dimethyl sulfoxide, and triethylamine were distilled from calcium hydride. Dimethylformamide was distilled from barium oxide at reduced pressure. Methanol and ethanol were distilled from calcium oxide. All reactions were conducted under an atmosphere of dry nitrogen. Analytical thin layer chromatography (tlc) was conducted on precoated silica gel plates (Kieselgel 60 F254, 0.25 mm thickness, manufactured by E. Merck & Co., Germany). For visualization, tlc plates were either stained with iodine vapor or phosphomolybdic acid solution. Flash column chromatography was performed according to the general procedure described by Still (see: Still, W. C.; et al J. Org. Chem. 1978, 43, 2923-2925) using flash grade Merck Silica Gel 60 (230-400 mesh). Gas chromatographic (GC) analyses were performed using a 530 m methylpolysiloxane column (3 m film thickness, 5 m length) using flame ionization detection. A standard temperature program of 100° C. for 2 min followed by a 40° C./min ramp to 200° C. was used. Elemental analyses were performed by the University of Michigan Department of Chemistry CHN / AA Services Branch. High resolution mass spectrometric (HRMS) measurements are accurate to within 2.2 ppm (electron impact, EI), 3.9 ppm (chemical ionization, CI), or 3.3 ppm (fast-atom bombardment, FAB), based on measurement of the performance of the mass spectrometer on a standard organic sample.
EXAMPLE 1
(3S,4S,5R)-6-tert-Butyldimethylsilyloxy-4,5-O-isopropylidenedioxy-1-hexen-3-ol (3).
The reduction of 2,3-O-isopropylidene-D-erythronolactone (2) was performed using a modified version of Cohen's procedure (see: Cohen, N.; et al J. Am. Chem. Soc. 1983, 105, 3661-3672). Diisobutylaluminum hydride (101 mL of a 1.5 M soln. in toluene, 152 mmol) was added in a dropwise fashion via an addition funnel to a cold (-78° C.) solution of 2,3-O-isopropylidene-D-erythronolactone (2) (see: Cohen, N.; et al in Organic Synthesis, Collective Vol, IV; J. P. Freeman, Ed.; Wiley, N.Y., 1990; pp 297-301) (20.0 g, 126 mmol) in CH 2 Cl 2 (360 mL). After 2 h, methanol (20 mL) was added, followed by brine (10 mL). After warming to room temperature, the mixture was diluted with ether (500 mL) and MgSO 4 (150 g) was added. After stirring vigorously for 4 h, the mixture was filtered with suction through a sintered glass funnel, and the filter cake was washed with ether (100 mL). The filtrate was concentrated to give 17.0 g (84%) of crude 2,3 -O-isopropylidene-D-erythrose as a pale yellow oil that was used without further purification.
The addition of vinylmagnesium bromide to 2,3-O-isopropylidene-D-erythrose was carried out according to Mekki et al (see: Mekki, B.; Singh, G.; Wightman, R. H. Tetrahedron Lett. 1991, 32, 5143-5146). Since the communication by Mekki, et. al does not provide experimental procedures or spectroscopic data, we have chosen to include these details herein. The crude lactol was dissolved in THF (380 ml), cooled to -78° C., and vinylmagnesium bromide (315 ml of a 1 M soln in THF, 315 mmol) was added in a dropwise fashion via an addition funnel. The mixture was then warmed to 0° C. After 6 h, the reaction was quenched by the addition of saturated aqueous NH 4 Cl (100 mL). The resulting mixture was diluted with water (200 mL) and extracted with EtOAc (3×200 mL). The combined organic layers were washed with brine, dried (MgSO 4 ), filtered, and concentrated to give 19.5 g of a yellow oil that was used without further purification. Purification of a small sample by chromatography (3:1 to 2:1 hexane/EtOAc gradient) provided an analytically pure sample of the pure anti-diol, (2R,3S,4S)-2,3-O-isopropylidene-1,2,3,4-tetrahydroxy-5-hexene: Rf=0.14 (3:1 hexane/EtOAc); bp 94-100° C. at 0.25 mmHg; α!23D -42.5°(c 1.53, CHCl 3 ); 1 H NMR (300 MHz, CDCl 3 ) d 5.99 (ddd, J=5.6, 10.6, 17.3 Hz, 1H), 5.38 (dt, J=1.4, 17.3 Hz, 1H), 5.27 (dt, J=1.4, 10.5 Hz, 1H), 4.3 (m, 2H), 4.05 (dd, J=5.8, 8.4 Hz, 1H), 4.02 (m, 1H), 3.8 (m, 3H), 1.43 (s, 3H), 1.35 (s, 3H); 13 C NMR (75 MHz, CDCl 3 ) d 137.5, 116.5, 108.4, 79.6, 77.3, 70.6, 60.7, 27.7, 25.3:IR (neat) 3383 (s), 2987 (s), 2937 (m), 1456 (w), 1382 (m), 1220 (s), 1048 (s); MS (CI, CH 4 ) m/z (rel intensity) 189 (M+H)+, 40!, 173 (22), 131 (80), 113 (100); HRMS (CI, CH 4 ) calcd for C 9 H 16 O 4 H (M+H)+! 189.1127, found 189.1122; Anal calcd for C 9 H 16 O 4 : C, 57.43; H, 8.57; found C, 57.44; H, 8.60.
The crude diol mixture was dissolved in THF/DMF (3:1, 400 mL). The solution was cooled to 0° C. and tert-butyldimethylsilyl chloride (18.8 g, 125 mmol) and imidazole (17.6 g, 259 mmol) were added. After 45 min, the mixture was poured into ether (400 mL) and the organic layer was washed with 1M HCl (2×200 mL). The combined aqueous layers were back-extracted with ether (2×100 mL). The combined organic layers were washed with water, 5% NaHCO 3 , and brine, then dried (MgSO 4 ), filtered, and concentrated. Chromatography (100:1to 20:1 hex/EtOAc gradient) provided 27.1 g (71% from (2) of the anti-allylic alcohol (3) followed by 0.88 g (2% from (2) of the syn-allylic alcohol diastereomer. Data for 3-anti Rf=0.48 (6:1 hexane/EtOAc); α!23D -36.3°(c 0.58, CHCl 3 ); 1 H NMR (CDCl 3 , 300 MHz) d 6.02 (ddd, J=5.2, 10.6, 17.2 Hz, 1H), 5.44 (dt, J=1.6, 17.2 Hz, 1H), 5.25 (dt, J=1.6, 10.6 Hz, 1H), 4.3-4.2 (m, 2H), 4.19 (d, J=3.2 Hz, 1H), 4.06 (dd, J=5.5, 9.2 Hz, 1H), 3.86 (dd, J=9.9, 10.5 Hz, 1H), 3.65 (dd, J=3.5, 10.5 Hz, 1H), 1.39 (s, 3H), 1.34 (s, 3H), 0.92 (s, 9H), 0.14 (s, 6H); 13 C NMR (CDCl 3 , 75 MHz) d 137.4, 115.7, 108.5, 80.6, 77.2, 69.8, 62.0, 28.0, 25.8, 25.3, 18.3, -5.47, -5.52; IR (neat) 3470 (br m), 2933 (s), 2885 (s), 2859 (s), 1472 (m), 1380 (m), 1077 (s) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 303 (M+H)+, 18!, 285 (9), 262 (19), 245 (100), 227 (42), 173 (46); HRMS (CI, NH 3 ) calcd for C 15 H 30 O 4 SiH (M+H)+! 303.1992, found 303.1984; Anal. calcd for C 15 H 30 O 4 Si: C, 59.56; H, 10.00; found C, 59.29; H, 10.00.
Data for minor isomer (3-syn): Rf=0.41 (6:1 hex/EtOAc); α!23D -3.9°(c 1.05, CHCl 3 ); 1H NMR (CDCl 3 , 360 MHz) d 6.01 (ddd, J=5.2, 10.6, 17.2 Hz, 1H), 5.40 (dt, J=1.7, 17.2 Hz, 1H), 5.22 (dt, J=1.6, 10.6 Hz, 1H), 4.37 (m, 1H), 4.21 (td, J=4.4, 6.7 Hz, 1H), 4.13 (dd, J=4.0, 6.5 Hz, 1H), 3.96 (dd, J=7.0, 10.7 Hz, 1H), 3.76 (dd, J=4.4, 10.7 Hz, 1H), 3.01 (d, J=5.8 Hz, 1H), 1.49 (s, 3H), 1.37 (s, 3H), 0.91 (s, 9H), 0.10 (s, 6H); 13 C NMR (CDCl 3 , 90 MHz) d 137.7, 115.8, 108.2, 79.6, 77.3, 67.0, 61.7, 27.2, 25.8, 24.9, 18.3, -5.6; IR (neat) 3475 (br, m) 2931 (s), 1858 (s), 1472 (m), 1381 (m) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 303 (M+H)+, 1.5!, 287 (6), 245 (100), 227 (26), 117 (41); HRMS (CI, NH 3 ) calcd for C 15 H 30 O 4 SiH (M+H)+! 303.1992, found 303.1983; Anal. calcd for C 15 H 30 O 4 Si: C, 59.56; H, 10.00; found C, 59.61; H, 10.01.
EXAMPLE 2
Methyl (E)-(6S,7R)-8-tert-butyldimethylsilyloxy-6,7-O-isopropylidenedioxy-4-octenoate (4).
Trimethyl orthoacetate (77 mL, 640 mmol) and propionic acid (1.9 mL, 26 mmol) were added to a solution of the allylic alcohol (3) (27.9 g, 92.3 mmol) in toluene (500 mL). The flask was fitted with a distillation head and the mixture was heated at reflux, distilling off methanol as it formed. GC was used to monitor the disappearance of starting material (tR=4.0 min) and the appearance of product (tR=5.2 min, see General methods above for GC conditions). After 24 h, the mixture was cooled to room temperature and concentrated to give 32.7 g (99%) of the title compound (4) as a pale yellow oil that was used without further purification. Purification of a small sample by chromatography (10:1 hex/EtOAc) provided an analytically pure sample. Rf=0.40 (6:1 hex/EtOAc); α!23D -0.9°(c 1.08, CHCl 3 ); 1 H NMR (CDCl 3 , 360 MHz) d 5.77 (m, 1H), 5.57 (dd, J=7.7, 15.4 Hz, 1H), 4.58 (t, J=7.1 Hz, 1H), 4.15 (dd, J=6.1, 12.2 Hz, 1H), 3.68 (s, 3H), 3.59 (m, 2H), 2.41 (m, 4H), 1.46 (s, 3H), 1.36 (s, 3H), 0.89 (s, 9H), 0.06 (s, 6H); 13 C NMR (CDCl 3 , 90 MHz) d 173.3, 132.8, 126.5, 108.3, 78.6, 78.3, 62.3, 51.6, 33.4, 27.9, 27.6, 25.8, 25.4, 18.2, -5.4; IR (neat) 2930 (s), 2857 (m), 1743 (s), 1438 (m), 1375 (m) cm -1 ; MS (CI, NH 3 ) m/Z (rel intensity) 376 (M+NH 4 )+, 12!, 318 (87), 301 (100), 271 (29), 186 (32), 169 (29), 151 (28); HRMS (CI, NH 3 ) calcd for C 18 H 34 O 5 SiNH 4 (M+NH 4 )+! 376.2519, found 376.2519; Anal. calcd for C 18 H 34 O 5 Si: C, 60.30; H, 9.56; found: C, 60.12; H 9.61.
EXAMPLE 3
(5R)-5- (1'S,2'R,3'R)-(4'-tert-Butyldimethylsilyloxy)-1'-hydroxy-2',3'-O-isopropylidenedioxybutyl!tetrahydrofuran-2-one (5a) and (5S)-5- (1'R,2'R,3'R)-(4'-tert-Butyldimethyl-silyloxy)-1'-hydroxy-2',3'-O-isopropylidenedioxybutyl!tetra-hydrofuran-2-one (5b).
The dihydroxylation was performed using the general procedure reported by Sharpless (see: Sharpless, K. B.; Amberg, W.; Bennani, Y. L.; Crispino, G. A.; Hartung, J.; Jeong, K.-S.; Kwong, H.-L.; Morikawa, K.; Wang, Z.-M.; Xu, D.; Zhang, X.-L. J. Org. Chem. 1992, 57, 2768-2771). A solution of the crude alkene (4) (32.0 g, 89.2 mmol) in t-BuOH (150 mL) was added to a cold (0° C.), mechanically stirred, biphasic mixture of water (475 mL) and t-butanol (300 mL) containing potassium ferricyanide (93 g, 280 mmol), potassium carbonate (39 g, 280 mmol), potassium osmate dihydrate (0.35 g, 0.95 mmol), (DHQD)2-PHAL (0.75 g, 0.96 mmol), (see Sharpless, K. B.; et al J. Org. Chem. 1992, 57, 2768-2771), and methanesulfonamide (9.0 g, 94.5 mmol). The solution was allowed to warm slowly to room temperature. GC was used to monitor the disappearance of the alkene (4) (tR=5.2 min) and the appearance of the product (tR=6.8 min, see General methods above for GC conditions). After 18 h, sodium sulfite (150 g) was added, and the mixture was stirred an additional 1 h. EtOAc (400 mL) was then added, the layers were separated, and the aqueous layer was extracted with EtOAc (3×400 mL). The combined organic layers were washed with 2N KOH (400 mL), then dried (MgSO 4 ) and concentrated. Chromatography (10:1 to 3:1 hex/EtOAc gradient) provided 22.6 g (70% from (3) of (5a) as a colorless oil followed by 2.98 g (9% from (3) of (5b) as a colorless oil. Data for (5a): Rf=0.28 (3:1 hex/EtoAc); α!23D -36.3° (c 0.58, CHCl 3 ); 1 H NMR (CDCl 3 , 360 MHz) d 4.84 (ddt, J=1.4, 5.7, 7.2 Hz, 1H), 4.42 (dd, J=5.6, 9.7 Hz, 1H), 4.26 (ddd, J=3.6, 5.6, 9.9 Hz, 1H), 4.14 (br d, J=3.3 Hz, 1H), 3.77 (m, 2H), 3.65 (dd, J=3.5, 10.5 Hz, 1H), 2.72 (m, 1H), 2.44 (m, 1H), 2.32 (m, 2H), 1.37 (s, 3H), 1.35 (s, 3H), 0.91 (s, 9H), 0.13 (s, 6H); 13 C NMR (CDCl 3 , 90 MHz) d 178.0, 108.7, 79.1, 76.6, 76.4, 71.0, 61.8, 28.4, 27.9, 25.7, 25.3, 23.8, 18.2, -5.6, -5.7; IR (neat) 3430 (br w), 2934 (m) , 2858 (m) , 1778 (s), 1472 (w), 1370 (m) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 378 (M+NH 4 )+, 52!, 361 (M+H)+, 100!, 170 (27), 153 (27); HRMS (CI, CH 4 ) calcd for C 17 H 32 O 6 SiH (M+H)+! 361.2046, found 361.2035; Anal. calcd. for C 17 H 32 O 6 Si: C, 56.64; H, 8.95; found C, 56.58; H, 9.04.
Data for (5b): Rf=0.18 (3:1 hex/EtOAc); α!23D +4.5° (c 0.95, CHC 13 ); 1 H NMR (CDCl 3 , 300 MHz) d 4.77 (td, J=2.9, 6.6 Hz, 1H), 4.31 (t, J=6.0 Hz, 1H), 4.18 (ddd, J=3.6, 5.8, 8.5 Hz, 1H), 3.94 (ddd, J=3.0, 4.1, 6.0 Hz, 1H), 3.83 (dd, J=8.5, 10.7 Hz, 1H), 3.66 (dd, J=3.6, 10.7 Hz, 1H), 2.85 (d, J=4.2 Hz, 1H), 2.69 (m, 1H), 2.46 (m, 1H), 2.28 (m, 2H), 1.45 (s, 3H), 1.36 (s, 3H), 0.89 (s, 9H), 0.08 (s, 6H); 13 C NMR (CDCl 3 , 75 MHz) 177.3, 108.4, 79.8, 77.2, 76.8, 70.6, 61.6, 28.2, 27.6, 25.8, 25.3, 24.1, 18.3, -5.4; IR (neat) 3470 (br, m), 2954 (m), 2858 (m), 1778 (s), 1463 (m), 1381 (m) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 378 (M+NH 4 )+, 100!, 361 (M+H)+, 31!, 320 (20), 303, (20), 170 (18), 153 (23); HRMS (CI, NH 3 and CH 4 ) calcd for C 17 H 32 O 6 SiH (M+H)+! 361.2046, found 361.2033; Anal. calcd. for C 17 H 32 O 6 Si: C, 56.64; H, 8.95; found C, 56.27; H, 8.91.
EXAMPLE 4
(5R)-5- (l'S,2'R,3'R)-1',4'-Dihydroxy-2',3'-O-isopropylidenedioxybutyl!tetrahydrofuran-2-one (6).
A solution of tetra-n-butylammonium fluoride (19.8 g of a 75% w/w solution in water, 56.7 mmol) in THF (50 mL) was added to a cold (0° C.) solution of (5a) (18.6 g, 51.6 mmol) in THF (250 mL). After 1.5 h, silica gel (25 g) and water (10 mL) were added, and the mixture was stirred another 10 min. The mixture was then filtered through Celite, rinsing with ether (300 mL). The filtrate was dried (MgSO 4 ) and concentrated. Chromatography (30:60:1 to 30:60:10 hex/EtOAc/EtOH gradient) provided 11.7 g (84%) of the diol (6) as a pale yellow oil. Rf=0.25 (20:1 CHCl 3 /MeOH); α!23D -66.9° (c 0.90, CHCl 3 ); 1 H NMR (CDCl 3 , 360 MHz) d 4.87 (m, 1H), 4.33 (m, 2H), 4.22 (d, J=6.3 Hz, 1H), 3.8 (m, 3 H), 3.38 (t, J=5.7 Hz, 1H), 2.68 (ddd, J=7.2, 9.3, 17.5 Hz, 1H), 2.50 (ddd, J=7.3, 10.0, 17.5 Hz, 1H), 2.33 (m, 2H), 1.41 (s, 3H), 1.36 (s, 3H); 13 C NMR (CDCl 3 , 90 MHz) d 178.5, 108.6, 80.0, 76.8, 76.2, 70.8, 60.7, 28.6, 27.8, 25.2, 23.6; IR (neat) 3390 (br, s), 2987 (s), 2939 (s), 1770 (s), 1372 (s) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 264 (M+NH 4 )+, 100!, 247 (M+H)+, 55!, 229 (15), 206 (15), 160 (11); HRMS (CI, NH 3 ) calcd for C 11 H 18 O 6 H (M+H)+! 247.1182, found 247.1187; Anal. calcd. for C 11 H 18 O 6 : C, 53.65; H, 7.37; found C, 53.44; H, 7.33.
EXAMPLE 5
(5R)-5- (1'S,2'R,3'R)-1',4'-Bis(methanesulfonyloxy)-2',3'-O -isopropylidenedioxybutyl!tetrahydrofuran-2-one (7).
Methanesulfonyl chloride (10.1 mL, 130 mmol) was added to a cold (0° C.) solution of the diol (6) (10.7 g, 43.3 mmol) and DMAP (0.265 g, 2.16 mmol) in pyridine (130 mL). The mixture was stirred for 30 min and then placed in a refrigerator (2 ° C.). After 16 h, ethyl acetate (400 mL) was added, and the solution was washed with 10% HCl (3×100 mL). The aqueous layers were back extracted with ethyl acetate (100 mL). The combined organic layers were washed with sat. NaHCO 3 and brine, then dried (MgSO 4 ), and concentrated to give a foamy yellow solid. Recrystallization from EtOAc/hex (˜1:1) provided 15.7 g (90%) of the dimesylate (7) as a pale yellow crystalline solid in three crops. Rf=0.11 (1:1 hex/EtOAc); mp 120-123° C.; α!23D +39.8° (c 1.31, CHCl 3 ); 1 H NMR (CDCl 3 , 300 MHz) d 4.81 (ddd, J=2.9, 5.9, 7.7 Hz, 1H), 4.52 (td, J=3.1, 6.4 Hz, 1H), 4.46 (dd, J=3.1, 10.8 Hz, 1H), 4.40 (dd, J=4.8, 5.8, 1H), 4.32 (dd, J=6.6, 10.8 Hz, 1H), 3.25 (s, 3H), 3.08 (s, 3H), 2.74 (m, 1H), 2.58 (m, 1H), 2.44 (m, 2H), 1.54 (s, 3H), 1.40 (s, 3H); 13 C NMR (CDCl 3 ,90 MHz) d 175.9, 109.4, 78.8, 77.9, 76.1, 75.1, 69.3, 39.2, 37.3, 27.4, 27.3, 25.6, 23.9; IR (neat) 3027 (w), 2989 (m), 2942 (m), 1784 (s), 1462 (w), 1359 (s) cm- -1 ; MS (CI, NH 3 ) m/z (rel intensity) 420 (M+NH 4 )+, 100!, 403 (M+H)+, 2!, 246 (56); HRMS (CI, NH 3 ) calcd for C 13 H 22 O 10 S 2 NH 4 (M+NH 4 )+! 420.0998, found 420.0998; Anal calcd for C 13 H 22 O 10 S 2 : C, 38.80, H, 5.51; found C, 38.93; H, 5.63.
EXAMPLE 6
(5R)-5- (1'S,2'R,3'R)-4'-Azido-2',3'-O-isopropylidenedioxy-1'-methanesulfonyloxybutyl!tetra-hydrofuran-2-one (8).
Sodium azide (12.1 g, 187 mmol) was added to a solution of the dimesylate (7) (15.0 g, 37.4 mmol) in DMSO (110 mL), and the flask was heated at 80° C. (oil bath). After 36 h, the solution was cooled and poured into water (300 mL) and extracted with EtOAc (3×200 mL). The combined organic extracts were washed with brine, then dried (MgSO 4 ), and concentrated. Crystallization from CHCl 3 /Et 2 O provided 8.50 g (65%) of the azido-mesylate (8) as a white crystalline solid in two crops. The mother liquor was concentrated, and chromatography (2:1 hex/EtOAc to 50:50:1 hex/EtOAc/EtOH gradient) provided 0.99 g (9%) of the diazide Rf=0.62 (1:1 hex/EtOAc)!, followed by an additional 1.33 g of (8) total yield 9.83 g (75%)!, and 0.75 g (5%) of recovered starting dimesylate (7). Data for (8): Rf=0.33 (1:1 hex/EtOAc); α!23D +75.0° (c 0.52, CHCl 3 ); mp 136° C.; 1 H NMR (CDCl 3 , 300 MHz) d 5.01 (dd, J=3.8, 6.0 Hz, 1H), 4.81 (ddd, J=3.7, 6.1, 7.8 Hz, 1H), 4.43 (ddd, J=3.5, 5.9, 7.2 Hz, 1H), 4.35 (t, J=5.7 Hz, 1H), 3.53 (dd, J=3.5, 13.1 Hz, 1H), 3.47 (dd, J=7.2, 13.1 Hz, 1H), 3.22 (s, 3H), 2.69 (m, 1H), 2.56 (dd, J=7.1, 9.8 Hz, 1H), 2.3-2.5 (m, 2H), 1.54 (s, 3H), 1.40 (s, 3H); 13 C NMR (CDCl 3 , 90 MHz) d 175.8, 109.2, 78.8, 78.1, 76.6, 75.8, 51.6, 39.2, 27.6, 27.5, 25.4, 24.2; IR (neat) 2990 (m), 2940 (m), 2105 (s), 1784 (s), 1360 (s) cm -1 ; MS (CI, NH 3 ) m/z (rel intensity) 367 (M+NH 4 )+, 100!, 322 (16), 228 (24); HRMS (CI, NH 3 ) calcd. for C 12 H 19 N 3 O 7 SNH 4 (M+NH 4 )+! 367.1287, found 367.1288; Anal. calcd. for C 12 H 19 N 3 O 7 S: C, 41.26; H, 5.48; N, 12.03; found C, 40.97; H, 5.36; N, 11.98.
EXAMPLE 7
(1S,2R,8R,8aR)-8-Hydroxy-1,2-O-isopropylidenedioxy-indolizidin-5-one (9).
Palladium hydroxide on carbon (1.50 g) was added to a solution of the azido mesylate (8) (9.75 g, 27.9 mmol) in MeOH (500 mL). The flask was evacuated by aspirator and purged with hydrogen three times, and the resulting heterogeneous mixture was stirred under a balloon of hydrogen. After 6 h, the hydrogen was evacuated and the mixture was filtered through Celite, rinsing with MeOH (100 mL). Sodium methoxide (3.20 g, 59.3 mmol) was added, and the solution was warmed to reflux. The reaction was monitored by IR for the disappearance of the lactone carbonyl stretch at 1784 cm -1 and appearance of the lactam carbonyl stretch at 1625 cm -1 . After 60 h, the solution was cooled to room temperature and concentrated to a volume of ca. 50 mL, causing precipitation of a white solid. The mixture was diluted with CH 2 Cl 2 (500 mL), florisil (50 g) was added, and the mixture was stirred at room temperature for 30 min. The suspension was then filtered through Celite, and the filtrate was concentrated to give a yellow oil that crystallized upon standing. Recrystallization from EtOAc/ether (1:2) provided 3.85 g (61%) of lactam (9) as a white crystalline solid. The mother liquor was concentrated to give a yellow oil that was purified by chromatography (10% EtOH/EtOAc) to give another 0.91 g of crystalline (9) total yield: 4.76 g (75%)!. Rf=0.38 (10:1 CHCl 3 /MeOH); mp 129° C. (lit 126-128° C., 125-127° C.); α!23D +12.6° (c 1.06, MeOH), lit. α!25D +4.30 (c 0.16, MEOH); 1H NMR (300 MHz, CDCl 3 ) d 4.81 (dd, J=4.5, 6.0 Hz, 1H), 4.75 (t, J=5.5 Hz, 1H), 4.19 (d, J=13.5 Hz, 1H), 4.15 (ddd, J=4.2, 8.4, 15.5 Hz, 1H), 3.33 (dd, J=4.5, 13.6 Hz, 1H), 2.69 (d, J=4.5 Hz, 1H), 2.53 (ddd, J=2.9, 6.6, 18.0 Hz, 1H), 2.41 (ddd, J=6.4, 11.7, 18.0 Hz, 1H), 2.13 (m, 1H), 1.87 (m, 1H), 1.43 (s, 3H), 1.34 (s, 3H); 13 C NMR (CDCl 3 , 75 MHz) d 168.2, 112.1, 79.8, 77.6, 77.2, 66.3, 65.4, 50.6, 29.8, 26.4, 24.7; IR (neat) 3361 (br m), 2987 (m), 2938 (m), 2870 (m), 1625 (s), 1471 (m), 1454 (m) cm -1 ; MS (EI, 70 eV) m/z (rel intensity) 227 (M+, 58), 212 (53), 152 (51), 85 (100), 68 (53), 43 (76); HRMS calcd for C 11 H 17 NO 4 (M+) 227.1157, found 227.1159. These data are consistent with literature values (see: Setoi, H.; Takeno, H.; Hashimoto, M. J. Org. Chem. 1985, 50, 3948-3950).
EXAMPLE 8
(1S,2R,8R,8aR)-8-Hydroxy-1,2-O-isopropylidenedioxy-indolizidine (10).
Borane-methyl sulfide complex (59 mL of a 2 M solution in THF, 118 mmol) was added over a period of 30 min via an addition funnel to a cooled (0° C.) solution of the lactam (9) (6.65 g, 29.3 mmol) in THF (725 mL). After 30 min, the solution was warmed to room temperature. After another 2 h, the reaction was quenched by the slow addition of ethanol (440 mL, caution: hydrogen evolution) and concentrated to give a viscous oil which was redissolved in EtOH (700 mL) and heated at reflux for 2 h. After cooling to room temperature, the solution was concentrated to give 6.6 g of a colorless, crystalline solid which was recrystallized from 200 mL of hot hexanes to provide 5.87 g (94%) of the title compound, Rf=0.41 (10:1 CHCl 3 /MeOH); mp 101-103° C. (lit mp 104-106° C., 106-108° C., 100-103° C., 101-104° C.); α!23D -81.7° (c 1.10, MeOH), lit α!25D -73.3° (c 0.35, MeOH), α!20D -65.8° (c 0.5, MeOH), α!25D -67.3° (c 0.46, MeOH), α!25D -72.76 (c 0.43, MeOH)! 1 H NMR (300 MHz, CDCl 3 ) d 4.70 (dd, J=4.6, 6.2 Hz, 1H), 4.61 (dd, J=4.2, 6.3 Hz, 1H), 3.83 (m, 1H), 3.15 (d, J=10.7 Hz, 1H), 2.99 (dt, J=3.0, 10.4 Hz, 1H), 2.33 (br s, 1H), 2.12 (dd, J=4.2, 10.7 Hz, 1H), 2.05 (m, 1H), 1.85 (m, 1H), 1.6-1.7 (m, 3H), 1.51 (s, 3H), 1.34 (s, 3H), 1.2-1.3 (m, 1H); 13 C NMR (90 MHz, CDCl 3 ) d 111.3, 79.1, 78.2, 73.6, 67.3, 59.8, 51.6, 32.9, 25.9, 24.7, 24.0; IR (neat) 3198 (br m), 2980 (m), 2941 (s), 2857 (w), 2792 (m), 1466 (w), 1446 (w), 1371 (m) cm -1 ; MS (EI, 70eV) m/z (rel intensity) 213 (M+, 53), 198 (24), 138 (100), 113 (82), 96 (712), 43 (41); HRMS calcd for C 11 H 19 NO 3 (M+) 213.1365, found 213.1367. These data are consistent with those reported in the literature (see: Bennett, R. B., III; Choi, J.-R.; Montgomery, W. D.; Cha, J. K. J. Am. Chem. Soc., 1989, 111, 2580-2582).
EXAMPLE 9
(1S, 2R, 8R, 8aR)-1,2,8-Trihydroxyindolizidine (-)-Swainsonine! (1).
Prepared according to the published procedure. A solution of 10 (5.75 g, 27 mmol) in THF (27 mL) was treated with 6N HCl (27 mL) at room temperature for 12 h. The solution was then concentrated, the residue was applied to an ion exchange column (Dowex 1×8 200 OH--, 30 g), which was eluted with water. The fractions containing (1) were identified by TLC (iodine stain). These fractions were concentrated to give a white crystalline solid which was recrystallized from CHCl 3 /MeOH/ether to give 4.50 g (96%) of swainsonine (1) in three crops. Rf=0.35 (3:1 CHCl 3 /MeOH w/1% NH 4 OH); mp 139-142° C. (lit mp 141-143° C., 144-145° C., 140-142° C.); α!23D -74.0° (c 0.98, MeOH) lit α!25D -82.6° (c 1.03, MeOH), α!25D -73.8° (c 0.21, EtOH), α!25D -75.7° (c 2.33, MeOH)!; 1 H NMR (300 MHz, D 2 O) d 4.39 (ddd, J=2.8, 5.9, 8.0 Hz, 1H), 4.29 (dd, J=3.5, 5.8 Hz, 1H), 3.84 (app td, J=4.6, 10.3 Hz, 1H), 3.0 (m, 1H), 2.97 (dd, J=2.8, 11.3 Hz, 1H), 2.70 (dd, J=8.1, 11.3 Hz, 1H), 2.04-2.15 (m, 3H), 1.76 (m, 1H), 1.55 (qt, J=4.1, 13.2 Hz, 1H), 1.28 (qd, J=4.5, 12.3 Hz, 1H); 13 C NMR (90 MHz, D 2 O, MeOH internal standard) d 72.6, 69.4, 68.9, 66.0, 60.3, 51.6, 32.2, 22.9; IR (neat) 3366 (br s), 2944 (s), 2884 (m), 2804 (m), 2727 (m), 1660 (w), 1378 (m) cm-1; MS (EI, 70 eV) m/z (rel intensity) 173 (M+, 16), 155 (30), 113 (73), 96 (73), 83 (100); HRMS calcd for C 8 H 15 NO 3 (M+) 173.1052, found 173.1052. These data are consistent with those reported in the literature (see: Bennett, R. B., III; Choi, J.-R.; Montgomery, W. D.; Cha, J. K. J. Am. Chem. Soc., 1989, 111, 2580-2582).
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | (-)-Swainsonine may be prepared by (i) reacting a compound of formula (8): ##STR1## wherein OMs is methanesulfonyl with H 2 in the presence of Pd(OH) 2 followed by NaOMe, to obtain a compound of formula (9): ##STR2## and (ii) reducing the carbonyl group and hydrolyzing the ketal group in the compound of formula (9) to obtain (-)-swainsonine of formula (1): ##STR3## | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of the patent application of Kahan et al for "Knitting Machine for Producing Programmed Designs," Ser. No. 612,815, filed Sept. 12, 1975 now U.S. Pat. No. 3,983,718.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to flat bed knitting machines which can be programmed to produce prescribed designs in a fabric and has particular application to home knitting machines.
2. Description of the Prior Art
Programmable home knitting machines which pick up patterning instructions photoelectrically from a program card and utilize such instructions during the knitting of fabric as the carriage is moved back and forth across the needle bed of the machine are known and are exemplified by the machines of U.S. Pat. No. 3,885,405 and Japanese laid-open Patent 85853/73. It is a disadvantage of such machines that they do not include control means enabling an operator to readily select a needle at a chosen location in the bed of the machine to knit a particular column of a design unit and to thereby fix the horizontal position of the entire design within a width of fabric to be knit and it is a prime object of the invention to remedy such deficiency.
SUMMARY OF THE INVENTION
A home knitting machine according to the invention includes means for reading and memorizing patterning instructions on a program card. Fabric is knitted pursuant to the patterning instructions as signals representing such instructions are recalled from memory and used to control the operations of electromagnetic needle selectors on the carriage while the carriage is moved back and forth across the bed of the machine. Switch means connected with the memory and operable with the carriage over a selected needle enable an operator to precondition recall means and cause signals to be recalled from memory during knitting such that a particular column of a design unit is knitted by the selected needle and the overall design is thereby positioned accordingly in the fabric.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a home knitting machine according to the invention;
Fig. 2 is a plan view of a program card for use with the knitting machine;
Fig. 3 is a block diagram showing components of the control system of the knitting machine of the invention and their interrelation;
FIG. 4 is a schematic view in perspective of the pulse generator of said control system;
Fig. 5 (a and b) are diagrams showing the signal outputs of components of the pulse generator;
FIG. 6 is a somewhat schematic fragmentary bottom plan view of the carriage illustrating the operation of one of the needle selectors of the machine of the invention and;
FIG. 7 is a view taken on the plane of the line 7--7 of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, reference characters 10 and 12 designate the bed and carriage respectively of the home knitting machine of the invention. The carriage is slidably mounted on guide rails 14 and 16 affixed to the bed, and includes handles 18 and 20 which an operator may grasp and utilize to move the carriage back and forth on the bed. Knitting needles 22 are supported in side by side relation in the bed 10 and are caused to follow a selected path through conventional camming in the carriage as determined by the operation of electromagnetic needle selectors 24 and 26. Such needles selectors are operated according to a prescribed design and the needles 22 being thereby caused to move along one path or another through the carriage camming selector either a base or a secondary yarn.
The needle selectors 24 and 26 are responsive to the operation of a control system which is wholly carried by the carriage 12 and includes a control switch 27 (OPK switch); a photoelectric reader 28 capable of detecting an entire design indicated on a program card 30 during one pass of the card through it; a silicon memory 32 capable of storing all of the patterning instructions read by the card; and sequencing control means including an up-down column counter 34 which regulates the admission and recall of signals to and from the memory, a row counter 36 and multiplexer 38 which regulate the recall of signals from the memory, and a pulse generator 39. The memory associated control components 34, 36 and 38 may be on separate silicon chips as shown or incorporated into a single chip with the memory. Batteries 40 and 42 may be utilized as the power supply for the control system and mounted on the carriage as shown to eliminate the necessity of providing power lines between a remote stationary power source and the movable carriage. The OPK switch 27 is a three position switch which an operator may move from a first position (O) in which the control system is turned off, to a second position (P) in which the system is conditioned for reading the program card 30 into the memory 32, from the second to a third position (K) in which the system is conditioned for knitting a programmed design, and from the third position back to the off position.
The card which may be best seen in FIG. 2 is used to instruct the needle selector control system concerning a design which is to be produced on the knitting machine. As shown the card includes mutually perpendicular lines which define rectangles 44 that extend in numbered columns (1 through 32) and numbered rows (1 through 16). The card also includes a row of strobe markings 46 which are provided for a purpose hereinafter explained. An operator indicates the design unit he wishes produced, such as that shown in FIG. 2, by darkening selected ones of the rectangles 44 on the card with a pencil or other marker (preferably one leaving an erasable mark), and then feeds the card (left end first) through the reader.
The reader includes a paired light emitting diode (LED) and phototransistor for each of the numbered rows on the card and for the row of strobe markings 46. In FIG. 3 which shows the control system for the needle selectors 24 and 26, the LED -- phototransistor pairs 48R 1 - 50R 1 , 52R 16 - 54R 16 , and 56R s - 58R s have been illustrated for row 1, row 16 and the strobe markings respectively, and it is to be understood that like LED phototransistor pairs are included in the reader for each of rows 2 through 15. The LED -- phototransistor pairs for the rows each connect with the memory 32 through amplifying means, as shown for the LED -- phototransistors pairs 48R 1 - 50R 1 and 52R 16 - 54R 16 at 58 and 60 respectively. The LED -- phototransistor pair 56R s - 58R s connects through amplifying means 64 with the memory 32 and up-down counter 34 when the OPK switch 27, which controls the opening and closing of contacts 68 and 70 and of contacts 72 and 74 is in the program position. In any other position of the OPK switch, the LED -- phototransistor pair 56R s - 58R s is disconnected from the memory 32 and from the up-down counter 34. Contacts 73 and 75 are closed by the OPK switch when the OPK switch is in the program position and contacts 76 and 78, the opening and closing of which is also controlled by OPK switch 27 are closed when the OPK switch is in either the program or knit position. Each of the LED-phototransistor pairs in the reader is therefore enabled when the OPK switch is in the program position, but not otherwise, by the output voltage V 1 of a voltage converter 80 which has as its potential source, the power supply of the control system, shown as the batteries 40 and 42. The memory 32 is also enabled by the voltage V 1 whenever contacts 76 and 78 are closed by reason of the OPK switch being in either the program or knit positions, but is not otherwise operable. The voltage converter in addition to providing the voltage V 1 also provides a voltage V 2 at a higher potential for operating the needle selectors 24 and 26. The OPK switch, when moved from the off to the program position closes contacts 86 and 88 to condition the memory for writing and when moved from the program to knit position closes contacts 86 and 90 to condition the memory for reading. Contacts 92 and 94 are also closed by the OPK switch when it is moved from the off to program position and as a consequence mono-stable multivibrator 95 (one shot) is caused to produce a voltage pulse which is then applied to up-down counter 34 and row counter 36 presetting them to column address 0 and row address 0 respectively. The OPK switch also closes contacts 96 and 98 when it is moved from the off to program position causing a directional signal to be applied to the counter, the signal being such as to cause the counter to count up.
With the OPK switch in the program position, the machine may be programmed to knit the particular design on the program card by feeding the card through the reader. The LED-phototransistor pairs in the reader are all arranged in a line and as a card moves through the reader the columns in the design area of the card, and the strobe markings, each of which is in alignment with the trailing half of a column, appear successively under the LED-phototransistor pairs. Phototransistor 58R s detects the strobe marks and the other phototransistors detect the presence or absence of markings within the design area of the card. As previously noted the up-down counter 34 was set to address O when the OPK switch was moved from the off to the program position and readings from the first numbered column on the card are therefore recorded in the memory at this address when phototransistor 58R s detects the first strobe mark, a write pulse being then applied to the memory over contacts 68 and 70. As the card moves through the reader, the counter is incremented by one each time the phototransistor moves beyond the trailing edge of a dark strobe mark to a light area and signals from the various columns are successively recorded as the dark strobe markings are detected causing a write pulse to be applied to the memory. The memory 32 is in the form of a semiconductor chip and is of a well known type of which Intel's P/N 2101, Signetics 2606 and the industry wide P/N 1103 are examples. The up-down counter 34 is also a semiconductor chip of a known type of which Texas Instruments Counter P/N 74191 is an example.
After the program card has been read, the OPK switch may be moved from the program to knit position to ready the machine for knitting. When the OPK switch is so moved it opens contacts 68 and 70 to disconnect the phototransistor 58R s from the memory and opens contacts 72 and 74 disconnecting phototransistor 58R s from the column counter 34. Contacts 100 and 102 which are open in the off and program positions of the OPK switch are closed thereby causing voltage V 1 to be applied as an enabling voltage to the row counter 36. Contacts 104 and 106 which are closed in the program position of the OPK switch and then cause a disabling voltage signal (ground potential) to be applied to AND gates 108 and 110 are opened when the OPK switch is moved to the knit position whereupon the disabling voltage signal is removed from the gates rendering the needle selectors operable. Contacts 72 and 112 are closed to connect the up-down counter to AND gate 114 which responds to signals from a photo-interrupter module 116 of the pulse generator 39 and a flip-flop 118, and contacts 120 and 122 are closed to connect the up-down counter and row counter to a flip-flop 124 which responds to signals from the aforesaid photo-interrupter module 116 and to a second photo-interrupter module 126 of the pulse generator.
The photo-interrupter modules of the pulse generator (See FIG. 4) each include a light emitting diode (LED) and phototransistor as shown for module 116 at 128 and 130 respectively, and for module 126 at 132 and 134 respectively, such LED's and phototransistors as shown being located on opposite sides of a toothed wheel 136 in the pulse generator. The toothed wheel 136 is affixed to a shaft 138 which is mechanically linked through a toothed pulley 140, also affixed to the shaft, and a timing belt 142 to gearing (not shown) as, for example, a pinion on the carriage and rack on the bed of the machine for driving the wheel as the carriage is moved across the bed. The wheel 136 moves in synchronism with the carriage and equally spaced teeth 144 on the wheel intermittently interrupt light between the LED and phototransistor in each of the photo-interrupter modules causing the modules to produce output pulses. Modules 116 and 126 are so located and the number of teeth 144 on wheel 136 is such as to cause module 116 to produce a counting pulse (FIG. 5a) each time the carriage passes from one needle area of the bed to the next, and module 126 to produce pulses (FIG. 5b) which lead the pulses from module 116 by 90° when the carriage is moved in one direction (to the right) and which lag the pulses from module 126 by 90° when the carriage is moved in the other direction (to the left). The output signal from module 116 controls the up-down counter 34 of FIG. 3, and the output signals from module 116 and 126 jointly control the operation of flip-flop 124 and so cause the flip-flop to provide an output signal indicative of the direction of movement of the carriage.
With the machine readied for knitting an operator chooses one of the needles in the bed to initially knit the design fragment indicated by the presence or absence of a mark in column 1, row 1, on the program card and subsequentially also the rest of the design in column 1. This is accomplished by the operator positioning the carriage so that the right needle selector may act first upon the chosen needle during knitting (the appropriate position being defined by the alignment of a mark 148 on the carriage with the said needle), and by the operator then depressing button 150 on the carriage to momentarily close contacts 152 and 154 (See FIGS. 1 and 3). The closing of contacts 152 and 154 sets flip-flop 118 which then provides an input to gate 114 permitting the up-down counter to be incremented or decremented in response to the operation of photo-interpreter module 116.
The machine is threaded with a secondary yarn as required for knitting the design pattern in a base yarn previously cast on the machine and the carriage is moved first to the right and then back and forth across the bed to repetitively knit the design unit on the card into a larger overall design located with respect to the needles of the machine according to the needle selected by the operation of button 150 to knit column 1 of the design unit. Initially column 1 information is read out of the memory since the up-down counter is at address O when button 150 is depressed (the counter having been so set when the OPK switch was moved from the off to program position closing contacts 92 and 94), and row 1 is selected by the row counter 36 and multiplexer 38 since the row counter is then also at 0. As the carriage is moved to the right on the bed beyond the chosen needle, up-down counter 34 responding to the operation of module 116 is incremented once each time the carriage moves over a new needle location. The counter is thereby caused to sequentially address the 32 columns of information in the memory and after each 32 counts repeat the process. Such column information is read into the multiplexer and the multiplexer which is at address 0 selects from each column the information in row one. During the said first knitting stroke of the carriage to the right a directional signal from flip-flop 124 directly transmitted to the gate 108 and through an inverter 109 to gate 110 causes the right needle selector 24 to be operated in response to signals from the multiplexer to the gates but prevents the operation of the left needle selector.
After the carriage has been moved beyond the fabric being knitted the operator reverses its direction causing it to be moved to the left whereupon the row counter is incremented by one and the up-down counter is caused to count down rather than up, both changes being effected in response to a changed directional signal from flip-flop 124. The up-down counter is decremented by one count as each needle location is traversed by the carriage, the column information is extracted from the memory in reverse order sequentially and repetitively, and the multiplexer because of the changed row selects the information in row 2 of each of the columns. By reason of the changed directional signal at flip-flop 124 which is reflected at gates 108 and 110, the left needle selector is caused to operate in response to output signals of the multiplexer transmitted to the gates and the right needle selector is prevented from operating. As the carriage moves to the left such left needle selector is operated to cause that portion of the design unit appearing in the second row on the program card to be knitted repetitively across the fabric. Successive rows of the design are formed in successive courses of the fabric knitted on the machine as the carriage is moved back and forth across the machine bed. Sixteen rows of design are produced in as many courses of fabric and the entire design is reknitted each time 16 courses have been completed, such repetition being controlled by the row counter which counts up to 16 and then repeats such counting process. The row counter 36 is a semi-conductor chip and is similar to the column counter 34 but lacks the up-down feature. An example of a suitable row counter is Texas Instruments counter P/N 74161.
The needle selectors 24 and 26 are without moving parts and rely solely on magnetic force to influence the positions of needles. Other types of needle selectors having moving parts that actuate needles and so influence their position might be used instead. The needle selectors 24 and 26, both of which are alike, function during movement to the right and left, respectively, of the carriage in a manner made apparent in FIGS. 6 and 7. The selector 24 includes a permanent magnet 156 fastened against the upper limb 157 of a C-shaped channel 158 of magnetic material having a lower limb 159. The upper and lower limb 157 and 159 of the channel 158 define a gap 160 which diverges toward the left as shown in FIG. 7 and presents opposing north and south magnetic poles as indicated. Needle butts 162 move through the selector as the carriage is moved on the bed of the machine and are caused by guides 164 and 166 to pass into the narrowest portions of the gap 160. A hole 172 is formed in the limb 157 adjacent to the narrowest portion of the gap 160 which so reduces the strength of the upper or north pole of the opposed magnetic poles developed solely by the permanent magnet 156 that needle butts guided into the gap 160 will be attracted to the lower or south pole against limb 159 and thereafter continue along limb 159 (needles 22a) because of the separation caused by the divergence of the pole faces.
A magnetizable core 174 is attached to the upper limb 157 of the channel 158 adjacent to the hole 172 and a coil 176 is so arranged on the core 174 that when the coil is energized a strong electro-magnetic pole is produced on the core 174 of the same polarity as that produced by the permanent magnet 156 in the gap 160. When a needle butt is in the gap while the coil 176 is energized, the upper or North magnetic pole of the opposed magnetic poles in the gap will be the strongest pole and will attract that needle butt against the upper limb 157 and it will continue along the upper limb (needles 22b) because of the separation caused by the divergence of the pole faces.
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art and it is to be understood that the present disclosure relates to an embodiment of the invention which is for purposes of illustration only. It is not to be construed as a limitation of the invention. All modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | A home knitting machine is provided with a reader for reading out patterning instructions on a programmed card, an electronic memory for storing signals read from the card, means enabling an operator to select a needle to knit a particular column of a design unit and to thereby fix the overall position of a design in a width of fabric to be knit, and means for recalling the stored signals from the memory in synchronization with movement of the carriage during knitting and for causing the operations of needle selectors on the carriage in accordance with the recalled signals. | 3 |
TECHNICAL FIELD
[0001] The present invention relates to a direct double-action extrusion press for extruding a tubular product.
BACKGROUND ART
[0002] Known in the past, for example, has been an extrusion press using copper, aluminum, an alloy thereof, etc. to extrude a tubular product by a direct double-action extrusion process. The extrusion press comprises a cylinder platen and an end platen arranged facing each other. The cylinder platen is provided with a main cylinder, main ram, extrusion stem, and mandrel, while the end platen is provided with a die. Between the extrusion stem and die, there is a container which can be made to freely advance and retract by container cylinders.
[0003] The extrusion stem has a dummy block arranged at its front end. The extrusion stem is attached to the main ram assembled in the main cylinder provided at the cylinder platen through the main cross-head. At the center position of the extrusion stem, the mandrel is arranged together with a piercer cylinder rod to be able to accompany and advance and retract with the extrusion stem. Further, the die is attached to the end platen facing the extrusion stem.
[0004] Between the extrusion stem and the die, the container is arranged to be able to advance and retract, in which a billet is held. The extrusion stem moves the billet stored in the container to the die side to thereby push the billet and complete the upset operation. After the upset operation, the mandrel advances to pierce the billet. The mandrel stops at a predetermined advancing position of the die. The extrusion stem is then again advanced to extrude the billet as a tubular product.
[0005] In this double-action extrusion press, when making the front end part of the mandrel stop at a predetermined position of a bearing part of the die and then extruding the product, the position of the mandrel is held so that its stopping position does not shift even if the relative positions of the mandrel and the bearing part of the die changes by a pulling action by the product.
[0006] PLT 1 discloses a double-action extrusion press which is provided with a piercer cylinder provided inside a main cylinder and a trigger forcibly connected with the mandrel away from the axial center of the extrusion press. This trigger acts on a hydraulic pilot valve to hold a bearing part of a die at a predetermined axial direction position (stopping position). For this, a certain amount of the pressurized fluid medium starts to be supplied to a rod side chamber of the piercer cylinder. Further, the position holding operation is controlled so that the amount of the pressurized fluid medium supplied matches the amount of increase of volume of the piercer cylinder rod side chamber when the mandrel is stationary and the main ram advances.
[0007] In this regard, in this conventional double-action extrusion press, the hydraulic pilot valve is switched mechanically through the trigger and a connecting rod to supply a certain amount of pressurized fluid medium to thereby hold the mandrel at a predetermined position of the bearing part of the die, so a delay occurs in control by exactly the amount of the stroke of movement corresponding to a land of a spool of the hydraulic pilot valve and a front end part of the mandrel moves back and forth by several millimeters with respect to the predetermined stopping position during an extrusion operation.
[0008] Furthermore, when changing the front end position of the mandrel or changing the extrusion speed, it is necessary to adjust the position of the trigger and the amount of fluid and pressure supplied to the rod side chamber of the piercer cylinder so as to adjust the pressure each time.
[0009] For this reason, the wall thickness of the extruded tubular products fluctuates and a stable quality of tubular products cannot be obtained.
[0010] Furthermore, in a conventional double-action extrusion press, there is the following problem: After pushing the billet in the container by the extrusion stem, then upsetting the billet and piercing the inside of the billet by a mandrel, then extruding it by a fixed mandrel, a frictional force occurs between the surfaces of the billet and mandrel and a pull force acts on the mandrel during extrusion. Due to this, the extrusion force acting on the die decreases by that amount, so it is not possible for the extrusion force to be effectively utilized at the start when the extrusion force is most required.
CITATION LIST
Patent Literature
[0011] PLT 1: Japanese Patent Publication No. 49-26188B
SUMMARY OF INVENTION
Technical Problem
[0012] The present invention is made so as to solve the above problem and has as its object the provision of a direct double-action extrusion press for obtaining a tubular product provided with a mandrel holding means for holding a mandrel at a predetermined stopping position at a bearing part of a die without moving forward or back so as to keep the front end position of the mandrel from fluctuating during extrusion.
Solution to Problem
[0013] The present invention provides a direct double-action extrusion press comprising an extrusion stem, a main cross-head to which the extrusion stem is fastened, a main cylinder having a main ram which makes the main cross-head and therefore the extrusion stem advance in an extrusion direction for extruding a billet, a piercer cylinder arranged in the main ram, which piercer cylinder making a piercing use mandrel advance and retract passing through the extrusion stem and the main cross-head and holding the mandrel at a predetermined position, a plurality of side cylinders making the main ram retract through the main cross-head, and a hydraulic circuit supplying a hydraulic fluid to the main cylinder, the piercer cylinder, and the plurality of side cylinders, wherein a plurality of cylinder chambers of the plurality of side cylinders at the sides discharging the hydraulic fluid when the main cross-head advances have in total a pressure receiving area equal to a rod side chamber of the piercer cylinder, and the hydraulic circuit fluidly communicates the plurality of cylinder chambers at the sides discharging the hydraulic fluid of the plurality of side cylinders and the rod side chamber of the piercer cylinder during extrusion of the billet.
[0014] In the present invention, the hydraulic circuit may comprise a variable discharge hydraulic pump adjusting an amount of fluid of the piercer cylinder.
[0015] In the present invention, not only the main ram, but also the plurality of side cylinders can make the main cross-head and therefore the extrusion stem advance in the extrusion direction.
[0016] In the present invention, the hydraulic circuit may comprise a pressure sensor for sensing an fluid pressure acting on a rod side of the piercer cylinder during extrusion of the billet and may control the fluid pressure acting in the extrusion direction of the plurality of side cylinders in accordance with the detected fluid pressure acting on the rod side of the piercer cylinder.
ADVANTAGEOUS EFFECTS OF INVENTION
[0017] The cylinder chamber pressure receiving area at the sides where the side cylinders discharge hydraulic fluid when the main cross-head moves in the extrusion direction and the rod side chamber pressure receiving area of the piercer cylinder are made substantially the same, and the hydraulic fluid discharged from the side cylinders synchronized with the extrusion stem during extrusion is supplied through a hydraulic pipeline to the rod side chamber of the piercer cylinder, so it is possible to hold the front end position of the mandrel at a predetermined certain position during extrusion, the operation of holding the position of the mandrel can be easily controlled, the position precision can be improved, and the extruded product becomes stable in quality.
[0018] Even if changing the extrusion speed during an extrusion operation, there is no need to adjust the pressure or amount of the hydraulic fluid supplied to the rod side chamber of the piercer cylinder and the operability is improved.
[0019] When the main cross-head moves in the extrusion direction, the cylinder chambers at the sides discharging the hydraulic fluid and the rod side chamber of the piercer cylinder are supplied with pressurized fluid by a pressurized fluid feeding means, so the amounts of leakage and pressure drops of the two cylinders are compensated for and control of the holding position of the mandrel is improved.
[0020] The direct double-action extrusion press of the present invention supplements the extrusion force decreased by the frictional force acting during extrusion between the surfaces of the billet and the mandrel by supplying pressurized fluid set to a specific pressure to the main ram and side cylinders to thereby make the fluid pressure act on side cylinders having a hydraulic type mandrel stopper function in the extrusion direction and increase the force. Due to this, it becomes possible to extrude thin-wall tubular products which could not be extruded in the past and long size billets, the double-action extrusion press can be made smaller in size, and improved productivity, energy saving, and labor saving can be achieved. Further, even if the extrusion force changes during the extrusion operation, there is no need to adjust the pressure or amount of the hydraulic fluid supplied to the container cylinders and the operability is improved.
BRIEF DESCRIPTION OF DRAWINGS
[0021] FIG. 1 is a cross-sectional view showing a direct double-action extrusion press of a first embodiment of the present invention in brief.
[0022] FIG. 2 is an explanatory view showing the state of extrusion where the front end of the mandrel is positioned at the bearing part of the die.
[0023] FIG. 3 is a cross-sectional view showing a direct double-action extrusion press of a second embodiment of the present invention in brief.
DESCRIPTION OF EMBODIMENTS
[0024] Below, a direct double-action extrusion press 10 according to a first embodiment of the present invention will be explained with reference to FIG. 1 .
[0025] As shown in FIG. 1 , the extrusion press 10 comprises an end platen 11 and a cylinder platen 25 arranged facing each other. The end platen 11 is provided with a die 12 , while the cylinder platen 25 is provided with a main cylinder 26 , main ram 24 , main cross-head 23 , and extrusion stem 22 . Between the end platen 11 and the cylinder platen 25 , there is a container 13 able to be advanced and retract by not shown container cylinders arranged at the end platen 11 .
[0026] The extrusion stem 22 is attached through the main cross-head 23 to the main ram 24 assembled in the main cylinder 26 provided at the cylinder platen 25 . At the center position of the extrusion stem 22 , a mandrel 31 is attached through a sub mandrel 32 and piercer cylinder rod 33 to a piercer cylinder piston 35 and is arranged to be able to accompany the extrusion stem 22 and advance and retract. The die 12 is provided at the end platen 11 facing the extrusion stem 22 .
[0027] A billet 14 is supplied between the die 12 and the container 13 moved to the cylinder platen 25 side together with a dummy block 21 by a not shown billet loader. For smoothing the supply of the billet 14 , it is also possible to insert only the billet 14 in the container 13 , then retract the extrusion stem and use a not shown dummy block supply device to move the dummy block 21 to the center of the extrusion press and insert it into the container 13 .
[0028] The cylinder platen 25 has two side cylinders 37 attached to it. Side cylinder rods 36 are fastened to the main cross-head 23 . The side cylinders 37 in the present embodiment, as will be understood from the hydraulic circuit of FIG. 1 , not only make the advanced main cross-head 23 and main ram 24 retract, but also act to push the main cross-head 23 and make it advance. In this figure, there are two side cylinders 37 , but there may also be four.
[0029] Further, inside the main ram 24 , there is a piercer cylinder 34 . The sub mandrel 32 coupled with the piercer cylinder rod 33 is arranged to be able to advance and retract inside of the extrusion stem 22 and main cross-head 23 .
[0030] Next, the direct double-action extrusion press 10 according to the first embodiment according to the present invention will be explained in more detail using FIG. 1 . In FIG. 1 , reference numeral 11 indicates the end platen, reference numeral 25 indicates the cylinder platen provided facing the end platen, reference numeral 24 indicates the main ram attached to the main cylinder 26 to be able to slide and pushing the extrusion stem 22 through the main cross-head 23 , and reference numeral 23 denotes the main cross-head coupled with the main ram 24 . The main cross-head 23 is arranged so as to slide on a not shown machine base. Note that, the end platen 11 and the cylinder platen 25 are configured to be able to be held by the same not shown tie-bars at a predetermined interval.
[0031] Further, inside the main ram 24 , the piercer cylinder 34 is provided. At the front end of the piercer cylinder rod 33 , the mandrel 31 is screwed through the sub mandrel 32 . Further, the mandrel 31 is inserted to be able to slide inside the extrusion stem 22 attached to the front end of the main cross-head 23 .
[0032] On the other hand, the end platen 11 is provided with the die 12 . The container 13 is arranged to be able to advance and retract by a plurality of container cylinders provided at the end platen 11 . Reference numeral 21 denotes the dummy block arranged at the front end of the extrusion stem 22 .
[0033] In FIG. 1 , reference numeral 40 shows a rod side chamber of the piercer cylinder 34 . The pressure receiving area is set to “A” cubic centimeters. Reference numeral 42 shows the cylinder chambers of the side cylinders 37 at the sides where the hydraulic fluid is discharged when the main cross-head 23 moves in the extrusion direction. In FIG. 1 , two side cylinders 37 are provided, so the pressure receiving areas of the side cylinders, which become substantially the same, are set to one half of the pressure receiving area “A” cubic centimeter (½ A cubic centimeter) of the rod side chamber of the piercer cylinder 34 . In FIG. 1 , the side cylinders 37 are provided at the cylinder platen 25 , so the discharge sides of the hydraulic fluid when the main cross-head 23 moves forward in the extrusion direction become the rod side of the cylinders. When configured using four side cylinders 37 , the pressure receiving area is set to one-quarter of “A” cubic centimeters (¼ A cubic centimeter).
[0034] The mandrel holding means is configured to be communicated with the sides where the hydraulic fluid is discharged when the rod side chamber 40 of the piercer cylinder 34 and the side cylinders 37 advance when extruding the billet 14 , that is, the rod side chambers 42 of the side cylinders in FIG. 1 . In the direct double acting extrusion type of extrusion press, the mandrel 31 and the main cross-head 23 synchronously move forward (accompany each other), so the hydraulic fluid discharged from the side cylinders 37 due to the communication is supplied to the rod side chamber of the piercer cylinder 34 . For this reason, even if the extrusion stem 22 moves forward, the front end of the mandrel 31 moves relatively without actually moving. As shown in FIG. 2 , the front end of the mandrel 31 holds a predetermined stopping position S from the end face of the die 12 . The front end position of the mandrel 31 is restricted.
[0035] In FIG. 2 , reference numeral 15 shows a tubular extruded product extruded from the die 12 , while 16 shows a bearing part of the die.
[0036] Referring to FIG. 1 , the configuration of the hydraulic circuit 50 of the mandrel holding means of the direct double-action extrusion press 10 according to the first embodiment will be explained. Reference numerals 51 and 52 denote variable discharge hydraulic pumps driven by not shown motors. The variable discharge hydraulic pumps 51 and 52 are provided with not shown known pressure regulators etc., are adjusted in pressure, and supply pressurized fluid to the cylinders. Reference numeral 55 denotes a solenoid valve operating the piercer cylinder 34 , while 56 is a solenoid valve operating the side cylinders 37 . Reference numerals 53 and 54 and numeral 57 denote solenoid valves and a check valve which operate when communicated with the rod side chambers 42 of the side cylinders at the sides where hydraulic fluid is discharged when the rod side chamber 40 of the piercer cylinder 34 and the side cylinders 37 advance.
[0037] The operation of the direct double-action extrusion press 10 according to the first embodiment configured as explained above will be explained. The billet 14 is placed together with a dummy block 21 on a billet loader and supplied to a center position of extrusion. Next, the main ram 24 is made to advance to make the front end of the extrusion stem 22 contact the end face of the dummy block 21 , load the billet 14 in the billet insertion hole, and then perform an upset operation. After the upset operation, an SOLb of the solenoid valve 55 is magnetized to introduce pressurized fluid to the piston head side chamber of the piercer cylinder 34 , the mandrel 31 is made to advance while piercing the billet 14 , and the front end of the mandrel 31 is made to stop at a predetermined position (S) of the bearing part 16 of the die 12 shown in FIG. 2 . The SOLb of the solenoid valve 55 is demagnetized by holding that position.
[0038] The predetermined stopping position holding operation of the mandrel 31 shown in FIG. 2 may comprise (measuring and determining the relative positions of mandrel 31 and die 12 in advance) attaching a scale sensor (not shown) in advance to the piercer cylinder rod 33 of the piercer cylinder 34 or main cross-head 23 and determining the relative positions of the piercer cylinder rod 33 and the piercer cylinder 34 , but the invention is not limited to this so long as the front end of the mandrel 31 is set to the predetermined stopping position of the bearing part 16 of the die 12 . Another method may also be used to determine the relative positions.
[0039] Next, the main ram 24 is made to again advance to make the extrusion stem 22 move and obtain the desired tubular extruded product 15 having a uniform wall thickness from the die 12 . During extrusion, the SOLb of the solenoid valve 56 is magnetized to synchronize the side cylinders 37 with the speed of advance of the mandrel 31 . Further, the SOLb's of the solenoid valves 53 and 54 are magnetized to communicate the rod side chambers 42 of the side cylinders 37 and the rod side chamber 40 of the piercer cylinder 34 . As explained above, the rod side chamber pressure receiving area of the side cylinders 37 and the rod side chamber pressure receiving area of the piercer cylinder 34 are made substantially the same areas, so the hydraulic fluid discharged from the side cylinders 37 causes the piercer cylinder rod 33 to move relatively synchronously with the advancing speed of the main cross-head 23 . For this reason, the front end face of the mandrel 31 at a predetermined stopping position of the bearing part 16 of the die 12 is constantly held at that predetermined stopping position. In the positional control for synchronization with the movement of positions of the mandrel 31 and extrusion stem 22 , the leakage from the piercer cylinder 34 and two side cylinders 37 and deviation due to pressure, volumetric efficiency, etc. are corrected by using the variable discharge hydraulic pump 51 to supply pressurized fluid to the two cylinder chambers.
[0040] At the time of the end of the extrusion, the magnetized SOLb's of the solenoid valves are demagnetized.
[0041] After the end of the extrusion, if the pressurized fluid pushing the main ram 24 to the advancing side is lowered in pressure and discharged and pressurized fluid is introduced to the rod sides of the side cylinders 37 to make the main ram 24 pull back and make the main cross-head 23 retract, the extrusion stem 22 retracts. Next, pressurized fluid is supplied to the rod side chamber 40 of the piercer cylinder 34 to make the mandrel 31 retract and pull out of the nonextruded part of the billet 14 . After this, the discard part is cut off from the die 12 .
[0042] The cylinder chamber pressure receiving area at the side where the side cylinders discharge hydraulic fluid when the main cross-head moves in the extrusion direction and the rod side chamber pressure receiving area of the piercer cylinder are made substantially the same and the hydraulic fluid discharged from the side cylinders synchronously with the extrusion stem during extrusion is supplied through the hydraulic pipeline to the rod side chamber of the piercer cylinder, so it is possible to hold the front end position of the mandrel during extrusion at a predetermined certain position, the operation of holding the position of the mandrel can be easily controlled, the position precision can be improved, and the extruded product becomes stable in quality.
[0043] Even if changing the extrusion speed during the extrusion operation, there is no need to adjust the pressure or supply of the hydraulic fluid supplied to the rod side chamber of the piercer cylinder each time and the operability is improved.
[0044] When the main cross-head moves in the extrusion direction, the cylinder chambers at the sides discharging the hydraulic fluid and the rod side chamber of the piercer cylinder are supplied with pressurized fluid from the pressurized fluid feeding means, so the leakage of the two cylinders and the drop in pressure are compensated for and the control of the holding position of the mandrel is improved.
[0045] Next, the direct double-action extrusion press according to the second embodiment of the present invention will be explained below with reference to FIG. 3 . The direct double-action extrusion press according to the second embodiment is similar in configuration of the extrusion press body with the press according to the first embodiment. The configuration of the part related to the hydraulic circuit differs. Therefore, here, the explanation of the configuration of the extrusion press body will be omitted. Further, the reference numerals of the components are the same as those according to the first embodiment other than for the newly added components.
[0046] The configuration of a hydraulic circuit 50 of a mandrel holding means of the direct double-action extrusion press 10 according to the second embodiment will be explained. Reference numerals 51 and 52 denote variable discharge hydraulic pumps which are driven by not shown motors. The variable discharge hydraulic pumps 51 and 52 are provided with proportional electromagnetic relief valves of reference numerals 63 , the pressure is adjusted, and the cylinders are supplied with pressurized fluid. Reference numeral 55 denotes a solenoid valve for operating the piercer cylinder 34 , reference numeral 56 denotes a solenoid valve for operating the side cylinders 37 , while reference numerals 53 and 54 and numeral 57 denote solenoid valves and a check valve which operate when communicated with the rod side chambers 42 of the side cylinders at the side where hydraulic fluid is discharged when the rod side chamber 40 of the piercer cylinder 34 and the side cylinders 37 advance.
[0047] In the double-action extrusion press 10 according to the second embodiment, at the same time as starting the extrusion, the SOLb's of the solenoid valve 56 and solenoid valve 58 are magnetized and pressurized fluid is sent from the variable discharge pump 52 to the main ram 24 and the side cylinders 24 at the head sides. Due to this pressurized fluid, the side cylinder rods 36 push the main cross-head 23 and the extrusion force of the extrusion stem 22 is increased.
[0048] Note that this pressurized fluid increases the extrusion force by changing the pressure setting enough to make up for the amount of loss of the extrusion force of the mandrel pull force by the proportional electromagnetic relief valves 63 .
[0049] The operation of the direct double-action extrusion press 10 according to the second embodiment configured as explained above will be explained. First, the container 13 is made to move to the die 12 and the billet 14 is placed together with the dummy block 21 on the billet loader and supplied to the extrusion center position. Next, the main ram 24 is made to advance to bring the front end of the extrusion stem 22 into contact with the end face of the dummy block 21 , load the billet 14 in the billet insertion hole, and then perform an upset operation. After the upset operation, the SOLb of the solenoid valve 55 is excited to introduce pressurized fluid into the piston head side chamber of the piercer cylinder 34 , make the mandrel 31 advance while piercing the billet 14 , and make the front end of the mandrel 31 stop (S) at a predetermined position of the bearing part 16 of the die 12 shown in FIG. 2 . The SOLb of the solenoid valve 55 is demagnetized by holding that position.
[0050] Here, the frictional force acting on the mandrel 31 of the extrusion press 10 according to the second embodiment will be explained. The frictional force acting between the billet 14 and the mandrel 31 during extrusion acts on the billet 14 in a direction opposite to the extrusion direction. The frictional force corresponds to the value obtained by multiplying the pressure acting on the piercer cylinder rod chamber 40 by the rod side area A. The control means for enabling the extrusion force to make up for the amount of loss due to the frictional force explained above will be shown next.
[0051] The method of control of the side cylinders 37 for increasing the extrusion force by the fluid pressure of the side cylinders 37 in addition to the fluid pressure of the main ram 24 explained above will be explained with reference to FIG. 3 .
[0052] The frictional force acting on the mandrel 31 is propagated as load and acts on the rod side cylinder chamber 40 of the piercer cylinder 34 . Therefore, the fluid pressure of the rod side cylinder chamber 40 of the piercer cylinder 34 (side cylinder rod chambers 42 also ok) is detected by the pressure sensor 60 , the obtained signal is amplified by the amplifier 61 and converted to pressure by the controller 62 , then the pressure of the proportional electromagnetic relief valves 63 is controlled. The pressurized fluid sent from the variable discharge hydraulic pump 52 is sent to the head sides 43 of the side cylinders 37 by a pressure value of the pressure setting of the proportional electromagnetic relief valves 63 . Due to this pressurized fluid, it is possible to increase the extrusion force.
[0053] Here, the pressure setting is set by multiplying the ratio of the piercer cylinder rod side area and total area of the main ram 24 and side cylinder head sides by the detection pressure of the piercer cylinder rod chamber 40 .
[0054] As explained above, the direct double-action extrusion press according to the second embodiment supplements the extrusion force decreased by the frictional force acting during extrusion between the billet and mandrel surface by supplying pressurized fluid set in pressure to the main ram and side cylinders to thereby make the fluid pressure act on side cylinders having a hydraulic type mandrel stopper function in the extrusion direction and increase the force. Due to this, it becomes possible to extrude thin-wall tubular products which could not be extruded in the past and long size billets, the double-action extrusion press can be made smaller in size, and improved productivity, energy saving, and labor saving can be achieved. Further, even if the extrusion force fluctuates during the extrusion operation, there is no longer a need to adjust the pressure or supply of hydraulic fluid supplied to the side cylinders each time and the operability can be improved.
[0055] Note that, the extrusion press of the present invention can be applied to not only a conventional (not short stroke type) direct double-action extrusion press, but also a front loading type short stroke direct double- action extrusion press which inserts a billet between the die and extrusion stem.
[0056] Note that, the present invention is explained in detail based on specific embodiments, but a person skilled in the art could make various changes, corrections, etc. without departing from the claims and concepts of the present invention.
REFERENCE SIGNS LIST
[0000]
11 . end platen
12 . die
13 . container
14 . billet
15 . extruded product
16 . bearing part
21 . dummy block
22 . extrusion stem
23 . main cross-head
24 . main ram
25 . cylinder platen
26 . main cylinder
31 . mandrel
32 . sub mandrel
33 . piercer cylinder rod
34 . piercer cylinder
36 . side cylinder rod
37 . side cylinder
40 . piercer cylinder rod chamber
41 . piercer cylinder head chamber
42 . side cylinder rod chamber
43 . side cylinder head chamber
51 , 52 . variable discharge hydraulic pump
53 to 56 . solenoid valves
57 . check valve
58 . solenoid valve
60 . pressure sensor
61 . amplifier
62 . controller
63 . proportional electromagnetic relief valve | A direct double-action extrusion press includes a main crosshead to which an extrusion stem is fixed; a main cylinder having a main ram that advances the main crosshead and pressing on a billet; a piercer cylinder disposed inside the main ram and drives a mandrel; a plurality of side cylinders that retracts the main ram via the main crosshead; and a hydraulic circuit for supplying hydraulic oil to the main cylinder, the piercer cylinder, and the side cylinders. Cylinder chambers of the plurality of side cylinders on a side where the hydraulic oil is discharged when the main crosshead is advancing have a pressure-receiving area equal in total to that of a rod side chamber of the piercer cylinder. During billet extrusion, the hydraulic circuit causes fluid communication through the rod side chamber of the piercer cylinder and each cylinder chamber of the plurality of side cylinders on the side where the hydraulic oil is discharged. | 1 |
[0001] This is a continuation application of co-pending U.S. patent application Ser. No. 10/673,952, filed Sep. 29, 2003.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to well drilling technology. More particularly, the present invention relates to a method and apparatus for controlling the ascent and descent of vertical pipe or other tubular members passing through a pipe or casing slip into a well borehole.
[0003] It is well known in the oil well drilling art that pipe or casing slip assemblies are utilized in oil field operations for drilling, setting casing, or placing or removing any tubular member from a well bore. An excellent explanation of the function and operation of drill pipe slip assemblies is provided in U.S. Pat. No. 6,471,439, which is incorporated herein by reference for all purposes.
[0004] One of the most significant problems encountered in setting slips is maintaining control of the descent of the pipe into the slip and the slip into the slip bowl. The extensive lengths of piping in a drill string may result in considerable weight having to be controlled by the rig operator's braking procedures. Dropping the weight too quickly may result in damage to the pipe wall leading to fatigue of the pipe or breaking of the slip dies. If a pipe section fails the entire length of the drill string below the failure may be lost. Attempts to pull stuck drill strings from the well bore often puts site personnel at considerable safety risk. The draw works (block and tackle arrangement) may snap or the derrick rigging itself may collapse. These problems are associated with the pulling or supporting of the drill string from above the rig platform and, more particularly, having the pulling or supporting force coming from above the top surface of the slip. Casing jacks have been used in the past to pull old casing from the well bore. However, these are set up after the well is drilled. With the present invention the float system may be in place before the drilling starts.
[0005] The present invention provides a number of embodiments which push or support the drill string from beneath rather than pulling from above. The same method and apparatus allows for the string to be cushioned, controlled, or dampened in its descent thereby reducing pipe or casing wall failures. Thus, the present invention further reduces the likelihood of broken slip teeth (dies) and crimping and fatiguing of the pipe wall which results in pipe failure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A is a side elevation, cross-sectional view of the pipe floating system of the present invention in a first unloaded position. The lifting member is disposed within the slip bowl.
[0007] FIG. 1B is the system of FIG. 1A in a second loaded position.
[0008] FIG. 2A is a side elevation, cross-sectional view of an alternative embodiment of the pipe floating system of the present invention in a first unloaded position. The lifting member is disposed within the slip itself.
[0009] FIG. 2B is the embodiment of FIG. 2A in a second loaded position.
[0010] FIG. 3 is a top view of the piston member of the embodiment of FIG. 2 .
[0011] FIG. 4 shows a perspective view of the slip wedge of the embodiment of FIG. 2 with the associated hydraulics.
[0012] FIG. 5 illustrates a perspective view of the piston of the floating pipe system with replaceable slip teeth inserted.
[0013] FIG. 6 shows a slip spider mechanism on a lifting platform of the present invention.
[0014] FIG. 6A is a side elevation, cross-sectional view of the embodiment of FIG. 6 .
[0015] FIG. 7 illustrates the floating platform of the FIG. 6 embodiment showing the hydraulic cylinders.
[0016] FIG. 8 is a perspective view of yet another embodiment of the present invention in a rotary table floating frame.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] FIGS. 1A and 1B illustrate a side elevation, cross-sectional view of a pipe floating system 10 of the present invention. FIG. 1A shows the system in a first unloaded position.
[0018] FIG. 1B illustrates a second loaded position. A section of drill string pipe 11 passes through a pipe or casing slip 12 into a well borehole. The construction of the conventional slip 12 is well known in the art. The slip teeth 13 engage the outer surface of the pipe or casing and are rotatably held within slip bowl bushings 14 . The ascent and descent of the pipe 11 may be controlled by the raising and lowering of the primary piston bowl assembly 16 into which the slips 12 and bushing 14 fit. It should be understood that the intent of the present invention system is to control the ascent and descent from beneath the top surface 18 of the slips.
[0019] The piston bowl assembly 16 is provided with a circumferential piston head 20 , seals 22 , and a retainer ring 24 . An upper rotary table insert 26 supports the piston bowl assembly and may optimally be driven by a gear 28 and pinion 30 drive mechanisrm Pinion 30 engages gear 28 in upper table insert 26 . Rotation of the pinion is translated into rotary motion of the insert and the piston bowl assembly 16 via meshing of splines 27 in the insert with complementary splines 17 in the bowl assembly.
[0020] The upper insert 26 is attached at joint 32 to the lower table insert 34 . Seals 36 along the inner face of upper table insert 26 seal against the sliding face 35 of piston bowl assembly 16 as will be further understood below. Lower table insert 34 is provided with a cooperating circumferential piston shoulder 29 having seals 39 . Thus, a fluid chamber 42 is formed between the underside of the piston head 20 and the upper side of piston shoulder 29 . The chamber 42 is sealed by seal sets 22 and 39 . Oil is provided to chamber 42 by an oil pressure control system 40 . A pressure control valve V allows oil to flow between chamber 42 and reservoir R.
[0021] FIG. 1A illustrates the pipe float system 10 in a first unloaded position. Pipe 11 is suspended by overhead rigging not shown but well known in the art. The slips have been inserted into the slip bushings within the piston bowl. The chamber 42 is at its full volume and filled with oil (and an inert gas to provide cushioning as desired). As the weight of the drill string is allowed to bear upon the slips, the pipe's descent is controlled by the “cushion effect” or the “dampening effect” of the oil in the chamber. The pressure control system 40 allows oil to bleed past the control valve V and into the oil reservoir R.
[0022] When the full weight of the drill string is loaded onto the pipe float system 10 , the piston bowl assembly 16 has moved to a second loaded position as shown in FIG. 1B . It should be understood that an oil reservoir 41 may be incorporated into the lower table insert 34 as shown in broken lines in FIG. 1B . Further, it is envisioned within the scope of the present inventive system that the oil pressure control system may be provided with pumps, valves, automated weight control system and piping capable of injecting oil into the chamber 42 as necessary to assist in the lifting of the slips, slip bushings, and the piston bowl assembly. Thus, with the present system both the descent and ascent of the drill string may be controlled from beneath the top surface of the slips.
[0023] To ensure that the bowl assembly is not overly extended either in the load or unload position, retainer ring 24 is threadingly secured to the bottom of piston assembly bowl 16 .
[0024] Turning to FIGS. 2A and 2B , an alternative embodiment of the present invention is illustrated. In this embodiment the system 100 employs an ascent and descent control mechanism within the slip wedge itself. An L-shaped piston member 60 slides within a cylinder housing 72 within each wedge segment 70 . The piston 60 has a cylindrical head section 62 , a horizontal extension 64 and a vertical leg 66 ( FIG. 5 ). The leg has a notch 68 which accepts replaceable slip teeth segments 80 . Each piston 60 has various sets of ring seals. O-rings 77 are attached to the outer surface of the piston to seal against the cylinder wall 73 . A bypass ring 74 may be attached to the piston to further control the oil flow within the pressure chamber 76 as will be described below. A sealing ring 78 is affixed to the piston to seal oil within and to retain a compression spring 82 in the chamber 76 .
[0025] FIG. 3 illustrates a top plan view of the piston 6 showing the head section 62 , the extension 64 , the leg 66 , and the slip teeth receiving notch 68 .
[0026] The wedge segment 70 has a piston cylinder housing 72 for retaining the piston head section 62 , a hydraulic pressure vein 84 extending from the top surface 83 of the segment and exiting at a location 85 near the bottom of the cylinder housing below the piston head. As will be described further, oil in the chamber 76 may flow through vein 84 when the piston head 60 moves within the housing 72 to raise and lower the slip segments 80 . A piston leg guide 89 ( FIG. 4 ) extends along one edge of the segment 70 to guide and retain the piston leg with the slip teeth sections. A slip seat 87 is disposed at the bottom of guide 89 to prevent the leg 66 and slip segments 80 from excessive downward travel. FIG. 4 shows a wedge segment and an associated pressure control system 90 . System 90 has an oil reservoir R, a pressure control valve V, piping 91 , and pump P as needed.
[0027] FIG. 2A depicts the piston 60 in a first unloaded position. Only one slip segment is illustrated for clarity. The slip segments 80 and the leg 66 are holding pipe 11 as it is being lowered. The weight of the pipe string is transferred to the piston head 62 as the slip teeth engage the pipe. The head 62 compresses the oil in chamber 76 and this increased fluid pressure is translated to the pressure control system 90 . Thus, the downward movement of the drill string is cushioned or dampened by the system 100 .
[0028] To provide further controls of the movement (upward and downward) of the pipe, a flow pressure ring 74 having a beveled edge or drilled through holes may be affixed to the piston head 62 . Further control may be provided by a compression spring 82 retained in the chamber 76 within the housing 72 beneath a piston ring 78 . Any number of further controls may be provided.
[0029] FIG. 2B shows the piston 60 in a second loaded position having taken the weight of the drill string and stopping at seat 87 . Again, it is within the scope of the present invention that the oil pressure control system may inject oil into the chamber 76 as necessary to assist in the ascent or lifting of the slips and the drill string. While the present discussion has disclosed the use of an oil pressure system, it is within the scope of the invention that any pressure regulation system such as springs, inert gas, or other hydraulic fluids may be used.
[0030] FIGS. 6, 6A , and 7 illustrate yet another embodiment 150 of the present invention. A spider system 91 for setting slips on production tubing and casing is well known in oil field art. A hydraulic or electric motor 95 activates an extension and retraction unit 97 which controls the clamping action of the slip wedges 96 about the pipe 11 . In the present inventive embodiment, an ascent/descent control platform 90 supports the spider system 91 on the well head.
[0031] FIG. 7 shows a simple U-shaped platform base 97 adapted to accommodate a plurality of lifting jacks 102 within housings 92 . The jacks 102 are connected by common control conduit 93 linking the jacks so that they may be raised and lowered at the same time. From the foregoing description of the other embodiments it should be understood that the final descent of the tubing or casing string may be controlled by controlling the upward and downward movement of the jack 102 . A suitable pressure control system is connected to the control conduit through piping 98 extending from the control conduit to the pressure regulation system.
[0032] Another embodiment of the present invention is illustrated in FIG. 8 . In system 200 , a rotary table (not shown), well known in the art, is supported by a frame 106 . Beneath frame 106 a plurality of hydraulic jacks 110 are disposed to support the ascent and descent of the frame (and the rotary table) as the drill and/or casing string is held, raised or lowered into the associated slips as discussed above.
[0033] In the inventive method, the slips are set and the elevators are unlatched. A joint of pipe is picked up by the operators and attached to the existing drill string. Then the entire drill or casing string is lifted with the draw works. The slips are pulled. While the entire string is being lowered and no drill string weight is on the table, electric (or air, or hydraulic) pump 112 moves the jack pistons 114 to their maximum height or extension, thereby raising the frame 110 and the rotary table (not shown).
[0034] When the drill string is lowered by the operator via the draw works to the desired position to set the slips, the slips are set. The electric control throttle valve 118 is set to take a certain minimum weight (for example 50 K lbs). A million pound drill string, for example, may activate the throttle valve 118 to open as the frame is urged downwardly by the weight of the drill string (shown by arrows with broken lines) pushing oil from the jack reservoirs JR through the connective piping past the throttle valve 118 through the oil return line 119 and into the main oil reservoir R. Thus, the drill string is “floated” downwardly in its descent. The procedure is repeated with each new pipe joint.
[0035] An automatic increase in the throttle valve 118 threshold may be provided as the drill string weight increases as more pipe is connected to the string. Oil flow may be metered by observing and monitoring oil pressure through sensor/recorder 120 and manually or automatically adjusting the throttle valve 118 to compensate for the increased or decreased weight of the string. The closer the pistons 114 get to the bottom of the stroke, the slower the float. This may be set by the throttle valve settings. A high pressure check valve 122 is provided for system safety to allow oil bleed back into the main reservoir as necessary.
[0036] As with all embodiments of the present invention, system 200 is provided with a pump 112 and piping that may be used to lift the frame 106 to jack the string out of the borehole by lifting the slips attached to the outer surface of the pipe casing. This is a safe way to push a stuck string upwardly without using forces above the rig floor to pull the string upwardly.
[0037] Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. On the contrary, various modifications of the disclosed embodiments will become apparent to those skilled in the art upon reference to the description of the invention. It is therefore contemplated that the appended claims will cover such modifications, alternatives, and equivalents that fall within the true spirit and scope of the invention. | A method for controlling the ascent and descent of a tubular member passing through a pipe or casing slip into a well bore. A float control member is affixed beneath the top surface of the pipe or casing slip. The control member is activated to control the raising or lowering of the tubular member. A piston within a cylinder housing is positioned below the top surface of the slip. As the tubular member is lowered, but before there is significant weight on the supporting structure, the piston is moved to its maximum height extension. Once the slips are set and the weight of the tubular member is applied to the slips, the piston begins to descend in the cylinder housing floating the final descent of the string. The string may be raised by activating a pump to force fluid within the housing chamber, raising the piston and thereby raising or lifting the string. | 4 |
BACKROUND
[0001] This invention relates to cooking grills, specifically to campfire grills, having means that allows users to adjust the height to fit a wider range of cooking temperatures for favorite family campfire meals, and to swivel safely the actual grill assembly hoop on and off the campfire creating a much easier and safer way for outdoor food preparation. Home grills can be very heavy, dirty and extremely hard to pack when traveling to your Family's cabin or your favorite campsite you enjoy year after year. The Campfire Cook is lightweight, with a handle for easy horizontal carrying. The Campfire Cook would look great over the fire pit in your back yard. By storing the Campfire Cook at your cabin or in your motor home, no one will have to ask, “Did we pack the GRILL”. With the Campfire Cook's easy assembly the user will be preparing the families favorite campfire meals before they ask “What's for dinner”. Clean up is a breeze with the removable 21 ½″ round porcelain enameled finished grill grate with 2 top handles.
[0002] In conclusion, insofar as I am aware, no campfire grill formerly developed provides a more lightweight, yet stronger vertical and horizontal stability with the special features offered from The Campfire Cook's support pipe and grill assembly unit.
SUMMARY
[0003] The invention, an improved campfire grill made of steel, has a support pipe with a 1″ cold rolled solid striking end cap plug at the top for easier hammering into the ground, and a 45 degree beveled base with (2) 4″ solid steel wings for maximum vertical support when inserted into the ground. The (7) through holes located on support pipe along with the height adjustment pin allow the user to adjust the grill assembly unit to the desired cooking temperature. The grill assembly unit's unique support collar features a 3″×½″ washer located at the base allows for a flatter service for the grill assembly unit to swivel on and off the campfire. Flat stock steel side panels welded onto the support collar then onto a 1 ½″ flat stock rolled into a hoop, welded inside the grill hoop are (4) 1″ precisely spaced steel tabs which allows the round grill grate to fit snug into the hoop and provides an even cooking surface. For ultimate support, a square tube grill body support stock is welded onto the support collar then to the grill hoop. The grill assembly unit has (2) cold rolled solid stock handles, one is welded to the grill support collar, this allows the user to safely swivel the grill hoop on and off the campfire. The second handle is welded onto the square tube support stock and used when adjusting the grill assembly to desired cooking temperature. Both solid steel handles designed and positioned for sturdy lightweight carrying of the grill assembly unit.
[0004] Accordingly several objects and advantages of the invention are to provide an improved campfire grill, to provide means of increasing the safety, durability and sturdiness of a campfire grill while preparing your favorite outdoor meals, to provide increased freedom of the grill's movement while cooking, and to provide a more user-friendly yet economical campfire grill. Still further objects and advantages will become apparent from a study of the following descriptions and accompanying drawings.
DRAWNINGS
[0005] Pg. 1 is an AutoCAD perspective view of a grill assembly unit, height adjustment pin and support pipe constructed in accordance with the invention.
[0006] Pg. 2 is an AutoCAD based blueprint of the support pipe, displaying features and measurements.
[0007] Pg. 3 is and AutoCAD perspective right-side view of the grill assembly unit and a top-view of the grill assembly displaying the hoop, (4) internal steel tabs, and the top opening of the support collar, side support panels and the square tube support stock.
[0008] Pg. 4 is an AutoCAD based blueprint side-view of the grill assembly displaying dimensions and measurements of the individual parts.
[0009] Pg. 5 is an AutoCAD based blueprint top-view of the grill assembly unit displaying dimensions and measurements of the individual parts.
[0010] Pg. 6 is an AutoCAD based blueprint of the right-side view of the grill assembly unit describing material used for each individual part that makes up the total unit.
[0011] Pg. 7 I a perspective AutoCAD based blueprint of height adjustment pin with measurements and stock used in accordance with the invention. Part E side and top-view of square tube support stock with measurements. Part F shows flat stock with measurements used to roll into the grill hoop.
DETAILED DESCRIPTION
[0012] Pg. 1 is a perspective view of the complete Campfire Cook's (3) part unit, right-side view of the grill assembly, left-side view of the height adjustment pin and front-view of the support pipe with (7) through holes all constructed in accordance with the invention.
[0013] Pg 2 is a front perspective view of an AutoCAD blueprint of the support pipe describing the individual units, cold rolled end cap striking plug inserted into support pipe then welded to pipe which allows the user to hammer and guide the support pipe into the ground, the (7) through holes located on the support pipe each spaced 4″ apart allowing the user to adjust the height of the grill to desired heat temperature. Front-view of solid round stock spike w/45 degree beveled cut and (2) 4″ wings welded to spike for the ultimate penetration into the ground and for maximum vertical ground support. Total weight of the support pipe unit is 9 ½ lbs. All dimensions, measurements and materials are listed in accordance with the invention.
[0014] Pg. 3 is a side and top perspective view of grill assembly. Side-view allows a true look at the support grill collar and cold rolled solid stock handle welded at back of the support collar, this handle allows the user to swivel the grill on and off the campfire. Side-view also shows the flat stock steel side panels welded to the support collar and to the grill hoop. Top-view allows a perspective view of the grill's hoop with (4) internal steel tabs for placing the round grill grate on for an even cooking surface. Top-view also shows the square tube grill body support stock welded to the support collar and then to the grill hoop, you can also view the (2) cold rolled solid stock handles welded onto the square tube support stock which allows users to safely adjust the height of the grill to desired cooking temperature, this handle is also used for lightweight horizontal carrying of the grill assembly unit. Total weight of the grill assembly unit is 12 ½ lbs. All dimensions, measurements, and materials are listed in accordance with the invention.
[0015] Pg. 4 is a perspective right-side view of each individual part with dimensions and measurements that make up the grill assembly unit, all constructed in accordance with the invention.
[0016] Pg. 5 is a perspective top-view of grill assembly of page 3 showing dimension and measurements of each individual part that makes up the grill assembly unit, solid steel handle, flat stock steel panels welded onto support collar the to grill hoop, square tube support grill body support stock welded onto the support collar then to the grill hoop, on the said square tube support stock is the second solid steel handle, and the grill hoop with the (4) 1″ solid steel tabs. All constructed in accordance with invention.
[0017] Pg. 6 is a perspective view of grill assembly unit's part detail list and measurements for A-grill handles, B-grill support collar which slides over the support pipe then by inserting the height adjustment pin at desired through hole on support pipe, C-washer on bottom of support collar for a flatter surface which allows easier swivel action for The Campfire Cook. D-flat stock side support panels welded onto top-side of the support collar then welded onto each side of the grill hoop, E-square tube grill body support stock see page 7 of AutoCAD based blueprint for part details, F-flat stock used to create the rolled grill hoop see page 7 of AutoCAD based blueprint for part details, and G-(4) 1″ flat stock solid steel pieces welded inside of grill hoop which allows the 21 ½″ porcelain enameled finished grill grate with (2) top handles fit snug into the hoop for an even cooking surface.
[0018] Pg. 7 is a perspective view of parts detail list with dimensions and measurements for height adjustment pin, E-side and top view of square tube grill body support stock, and F-1 ½ flat stock that is rolled into a 1″-9 ¾″ outer circle then welded to square tube grill body support stock. This welded circle becomes the grill's hoop that holds a 21 ½″ grill grate.
[0019] While my above description contains many specificities, these should not be constructed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations are possible.
[0020] For example: solid steel hooks for holding hot pads or cooking utensils, varied sized attachable grill hoops for the coffee or vegetables. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
[0021] The Campfire Cook's building materials consist of cold rolled, solid, square tube steel, solid and flat stock steel. Assembled by welding each individual piece that make up the support pipe and the grill assembly, then sanded, polished and painted with black high heat up to 1200 degrees to assure the user many years of outdoor enjoyment.
REFERENCE LETTERS
[0000]
A (2) The Campfire Cook's versatile handles.
B grill support collar
C 3″×⅛ washer w/1 ¼″ hole
D (2) flat stock steel side support panels
E square tube grill body support stock
F 1½″ flat stock (rolled into 1″-9 ¾″ outside circle) for grill hoop
G ( 4 ) ¾″×⅛″×1″ flat stock tabs
Operation
[0029] In operation one uses the campfire grill in a normal manner with an outdoor cooks hot pad mitt when swiveling on & off the flames or when adjusting the height of grill assembly for exact cooking temperature. The user can, when desired increase or decrease cooking temperature by adjusting the grill assembly unit into on the (7) through holes located on support pipe.
[0030] The user can swivel the grill assembly safely by using the handle located on the support collar while building the fire or during cooking to add or remove food.
[0031] When the user wishes to install The Campfire Cook over a fire pit they can be assured of a 3-step process.
[0032] 1) Hammering the support pipe into ground by striking the solid steel cold rolled end cap plug at top, the 45 degree beveled base was designed for straight, smooth ground penetration. The (2) 4″ solid steel wings on base of pipe were designed to enhance ground penetration and vertical support once in the ground.
[0033] 2) Add your grill assembly unit to support pipe by sliding the support collar with washer on bottom over the support pipe to the desired through hole then inserting the height adjustment pin into the support collar and pipe which then locks the unit together.
[0034] 3) Setting the 21 ½″ round porcelain enameled finished grill grate with (2) top handles into the grill's hoop fitting snug and even onto the (4) 1″ solid steel tabs.
[0035] When the user wishes to build a fire use the solid steel handle located on the support collar to swivel the grill away from the fire pit. The swivel feature also allows the user to safely adjust the height during cooking for the exact desired temperature.
[0036] When the user wishes to adjust the height of the grill for accurate cooling temperature use the solid steel handle located on the square tube body support stock, remove the height adjustment pin, guide your Campfire Cooks assembly unit to desired through hole and insert the height adjustment pin locking the unit together. | A campfire grill designed for providing durability for all weather conditions, strength with added features of said support pipe and said grill assembly unit, adjustability of the said grill hoop with said through holes and said height adjustment pin, and ability to swivel said grill assembly unit on and off said campfire. Thus a user can safely prepare the families favorite campfire recipes on said grill with said features of The Campfire Cook. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is the National Stage of International Application No. PCT/NL2009/000224, filed Nov. 18, 2009, which claims the benefit of Netherlands Application No. NL 2002291, filed Dec. 5, 2008, and U.S. Provisional Application No. 61/116,956, filed Nov. 21, 2008, the contents of which are incorporated by reference herein.
FIELD OF THE INVENTION
The present invention relates to a pipeline support, to a pipeline or pipe section, to a combination of a pipeline or pipe section and a pipeline support, and to a method for supporting a pipeline. The present invention also relates to a pipeline laying vessel having such a pipeline support.
BACKGROUND OF THE INVENTION
Methods and devices for laying pipelines are widely known. One method of laying a pipeline is the so-called J-lay method. Other methods are also known, such as S-lay.
Generally, the pipeline which is laid is suspended at a free end from a pipeline laying vessel during the laying thereof. New pipe sections are joined to the free end during the laying of the pipeline.
Generally, at a point at which the free end of the pipeline is suspended from the vessel, hereinafter referred to as the suspension point, large forces are transferred from the pipeline to the vessel. In the field of marine pipelaying, there is a gradual development that pipelines are laid in ever increasing water depths. This implies that longer and heavier pipelines are suspended from the vessel and thus, the force which is exerted on the pipeline support by the pipeline shows a gradual increase over time.
In one method of pipelaying, the forces are transferred from the pipeline to the vessel via a collar on the pipeline which engages a pipeline support on the vessel.
A problem which is encountered is that the forces may become too great for a collar of a known size. In some cases, it may be an option to increase the size of the bearing area of the collar. However, this is not always possible or preferable. A bigger diameter generally means an increase in cost. In the case collars are made from thick walled pipe, there may be fabrication limits to the outer diameter of the collar.
Also, for pipe-in-pipe systems of the sliding type, on certain locations collars may be required on the inner pipe. The outer diameter of a collar on an inner pipe may become too large to fit within the inner diameter of the outer pipe. In such a situation, an increase in the size of the collar would necessitate a larger outer diameter of the outer pipeline. This in turn substantially increases the cost of the total pipeline system.
Another problem encountered in the prior art is that the forces which are transferred from the pipeline to the pipeline support induce stress concentrations in the pipeline or in the pipeline support. Generally, the contact between the pipeline and the pipeline support occurs in a support surface. Depending on the situation, these local stress peaks may become too high and damage may occur in the pipeline or in the pipeline support.
U.S. Pat. No. 5,458,441 discloses an example of a traditional J-lay system. One of the embodiments shows each pipeline section containing two collars. A movable clamp 32 engages a bearing area on a first collar 12 , a fixed clamp 34 engages a bearing area on a second collar 18 . No load sharing between the two collars occurs during lowering of the pipeline or during adding a new pipe section. When loads in the pipeline increase, the bearing areas of the respective collars have to increase in order to carry the load. This will lead to an increased overall wall thickness and thus a larger protrusion of the collars from the pipeline wall. An increase of wall thickness generally leads to an increase of production cost and makes it more difficult to manufacture collars with the desired mechanical properties.
U.S. Pat. No. 6,273,643 discloses a similar system as U.S. Pat. No. 5,458,441 and has a similar disadvantages.
U.S. Pat. No. 6,729,803B1 discloses a system which is based on friction. Shoes 17 are provided having bearing surfaces 21 , A number of different shoes 17 are provided in different planes 11 , which are vertically spaced from one another, see FIG. 3 . Some load sharing occurs between the planes 11 , see column 8, lines 51-67. However, a disadvantage of U.S. Pat. No. 6,729,803 is that it is difficult to ensure a proper distribution of the forces between the levels 11 . In practice, the actual distribution of the forces will be relatively unpredictable.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved J-lay system.
It is another object of the invention to provide a J-lay system which allows higher loads from the pipeline to be transferred to the pipeline laying vessel.
It is another object of the invention to provide a J-lay system which creates lower stress peaks in the pipeline and/or the pipeline support for a given load.
It is another object of the invention to provide a J-lay system which allows smaller collars to be used.
It is another object of the invention to provide a J-lay system which allows more cost-effective pipe-in-pipe systems.
It is another object of the invention to provide a J-lay system which allows a predictable way to transfer the forces from the pipeline to the J-lay system.
At least one object is achieved by a J-lay system constructed to be positioned on board a pipeline-laying vessel, the J-lay system comprising a fixed pipeline support and a movable pipeline support configured for supporting a pipeline which is suspended from the pipeline-laying vessel,
the movable pipeline support comprising:
at least a first movable support member configured for engaging a first collar on the pipeline, at least a second movable support member configured for engaging a second collar on the pipeline,
wherein the first and second movable support members are spaced apart at a movable support member distance along an intended firing line, wherein the first movable support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second movable support member,
the fixed pipeline support comprising:
at least a first fixed support member configured for engaging a third collar on the pipeline, at least a second fixed support member configured for engaging a fourth collar on the pipeline,
wherein the first and second fixed support member are spaced apart at a fixed support member distance along an intended firing line, wherein the first fixed support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second fixed support member.
The J-lay system of the invention allows a distribution of the total axial load over at least two support members of the movable pipeline support or over at least two support members of a fixed pipeline support which are placed along the firing line of a J-lay system on board a pipeline laying vessel. Thus, each support member and each corresponding collar on the pipeline may carry a smaller load than the total axial load. In the invention, the distribution of the forces is no longer dependent on the amount of slip, as it is in U.S. Pat. No. 6,729,803. This is an advantage and increases the predictability of the distribution of the forces. Further the overall wall thickness of the collar can be reduced, allowing more cost effective fabrication as well as more control over the mechanical properties.
The movable pipeline support (sometimes indicated as a travelling block) is generally movably arranged on a tower-like construction and can make a stroke from an upper position to a lower position in order to lower a pipeline in a pipeline laying process.
The fixed pipeline support (sometimes indicated as a hang-off table) is generally provided in or below a welding station in which a new pipe section is joined to a free end of the pipeline which is suspended via the fixed pipeline support.
The total load may be distributed substantially evenly, but may also be distributed non-evenly in certain cases.
Multiple collars may be provided on the pipeline, spaced apart from one another such that in use, the combined collars transfer the total load of the pipeline to the vessel.
In a suitable embodiment,
the movable pipeline support is configured such that when a load is exerted on the first movable support member, the first movable support member moves in the direction of the second movable support member over a substantially predetermined distance, thereby decreasing the movable support member distance,
and
the fixed pipeline support is configured such that when a load is exerted on the first fixed support member, the first fixed support member moves in the direction of the second fixed support member over a substantially predetermined distance, thereby decreasing the fixed support member distance.
In this way, a relatively accurate load distribution is possible. A third and potentially even more support members can be provided, further reducing the load which each support member carries, and thereby giving the opportunity to further reduce the overall wall thickness of the collar.
In a suitable embodiment, the first and second movable support member are connected to one another via a movable frame, and the first and second fixed support member are connected to one another via a fixed frame, wherein at least part of the movable frame and at least a part of the fixed frame is configured to deform substantially elastically, such that the movable frame and the fixed frame act as a spring having the substantially predetermined load-movement relationship. A frame which deforms elastically is a simple and reliable way of creating a predetermined load-movement relationship.
In an embodiment, the at least first and second movable support members are integral with a movable frame connecting the at least first and second support members, and the at least first and second fixed support members are integral with a fixed frame connecting the at least first and second support members. An integral pipeline support, both for the movable and fixed pipeline support, is strong, easy to manufacture and reliable.
In another suitable embodiment, the substantially predetermined load-movement relationship is configured such that when in use the first collar of the pipeline exerts a typical load on the first movable support member, the first movable support member moves such a distance that the second collar of the pipeline engages the second movable support member, and that when in use the third collar of the pipeline exerts a typical load on the first fixed support member, the first fixed support member moves such a distance that the fourth collar of the pipeline engages the second fixed support member.
In a non-loaded state, the second collar does not engage the second movable support member and a gap exists between the second collar and the second movable support member. When the weight of the pipeline is added, the second collar approaches the second movable support member and at a substantially predetermined load engagement occurs. The same mechanism applies for the fourth collar and the second fixed support member when the pipeline is suspended from the fixed pipeline support.
In another embodiment, the support members are angled obliquely relative to the projected firing line. In other words, the support members taper with respect to the intended firing line. This provides a possibility of reducing the distance over which the collars protrude from the wall of the pipeline. The angled support members are constructed to engage tapering collars on the pipe section or pipeline.
In a suitable embodiment, the support member distance is adjustable. This allows the force distribution to be more accurately controlled. For this end an active system may be used, where the support member(s) which is (are) loaded above average is (are) lowered and the support member(s) which is (are) loaded below average is (are) raised. These options of variation can be achieved by this embodiment.
The invention also relates to a pipeline or pipe section constructed to be supported by a J-lay system comprising a fixed pipeline support and a movable pipeline support, the pipeline or pipe section comprising:
a first set of collars comprising at least a first collar and a second collar constructed to engage the movable pipeline support of a J-lay system, wherein the second collar is positioned at a collar distance from the first collar in the longitudinal direction of the pipeline or pipe section, a second set of collars comprising at least a third collar and a fourth collar constructed to engage the fixed pipeline support of a J-lay system, wherein the fourth collar is positioned at a collar distance from the third collar in the longitudinal direction of the pipeline or pipe section, the first collar being configured to engage a first movable support member of the movable pipeline support, the second collar being configured to engage a second movable support member of the movable pipeline support, the third collar being configured to engage a first fixed support member of the fixed pipeline support, the fourth collar being configured to engage a second fixed support member of the fixed pipeline support,
wherein the pipe section between the first and second collar and between the third and fourth collar is resilient according to a predetermined load-elongation relationship, such that when in use a certain axial load is applied on the first collar or on the third collar, the collar distance increases a substantially predetermined value such that the second collar engages the second movable support member or the fourth collar engages the second fixed support member.
This embodiment uses the pipeline itself as a spring with a known spring constant, thereby effectively distributing the total load over the collars.
Generally, the collars protrude from a wall of the pipeline. This is a simple way of applying the present invention. As explained before, it can be advantageous from cost and quality point of view to limit the protrusion.
In a suitable embodiment, the collars extend around the outer wall of the pipeline or pipe section. Collars are a simple and reliable way of creating support surfaces on the pipeline.
The invention further relates to a combination of a J-lay system and a pipeline or a pipe section,
the J-lay system comprising a fixed pipeline support and a movable pipeline support configured for supporting a pipeline which is suspended from the pipeline-laying vessel,
the movable pipeline support comprising:
at least a first movable support member configured for engaging a first collar on the pipeline, at least a second movable support member configured for engaging a second collar on the pipeline,
wherein the first and second movable support members are spaced apart at a movable support member distance along an intended firing line, the fixed pipeline support comprising:
at least a first fixed support member configured for engaging a third collar on the pipeline, at least a second fixed support member configured for engaging a fourth collar on the pipeline,
wherein the first and second fixed support member are spaced apart at a fixed support member distance along an intended firing line,
the pipeline or pipe section comprising:
a first set of collars comprising at least a first collar and a second collar constructed to engage a movable pipeline support of a J-lay system, wherein the second collar is positioned at a collar distance from the first collar, a second set of collars comprising at least a third collar and a fourth collar constructed to engage a fixed pipeline support of a J-lay system, and wherein the fourth collar is positioned at a collar distance from the third collar,
wherein:
the first collar is configured to engage the first movable support member,
the second collar is configured to engage the second movable support member,
the third collar is configured to engage the first fixed support member,
the fourth collar is configured to engage the second fixed support member,
wherein:
a) the first movable support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second movable support member, and the first fixed support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second fixed support member, such that the second collar engages the second movable support member or the fourth collar engages the second fixed support member
and/or
wherein the pipe section between the first and second collar and between the third and fourth collar is resilient according to a predetermined load-elongation relationship, such that when in use a certain axial load is applied on the first collar or on the third collar, the collar distance increases a substantially predetermined value such that the second collar engages the second movable support member or the fourth collar engages the second fixed support member.
In a suitable embodiment, the collar distance is smaller than the support member distance.
In a suitable embodiment, the difference between the collar distance and the movable and fixed support member distance is tuned to the substantially predetermined load-movement relationship of the support members of the movable and fixed pipeline support and/or to the substantially predetermined load-elongation relationship of the pipeline or pipe section between the collars, such that:
the second collar engages the second movable support member when the load on the first support member is a predetermined portion of the projected total load of the pipeline on the vessel and the fourth collar engages the second fixed support member when the load on the first fixed support member is a predetermined portion of the projected total load of the pipeline on the vessel.
In a suitable embodiment, the predetermined portion is between 30% and 70% of the projected total load of the pipeline on the vessel, in particular between 40% and 60% of the total load. The present invention allows a more or less equal load distribution.
In a suitable embodiment, the pipeline comprises six or more collars spaced apart in the direction of a main longitudinal axis of the pipeline, three or more collars for the movable pipeline support and three or more collars for the fixed pipeline support and wherein the movable pipeline support comprises three or more movable support members which are spaced apart, and wherein the fixed pipeline support comprises three or more fixed support members which are spaced apart and wherein the distances between the collars are smaller than the distances between the movable support members and between the fixed support members and wherein the load-movement relationships and the load elongation relationships are chosen such that in use, the total load which the pipeline exerts on the pipeline laying vessel is spread over the respective collars which engage the movable pipeline support or over the collars which engage the fixed pipeline support.
When multiple collars are applied, each collar can be relatively small, which allows a reduction of the width of the collars when compared to a single collar.
In a preferred embodiment, the fixed and movable pipeline support compress in the same order in response to a certain load as the pipeline extends in response to the same load, such that the difference between the collar distance and the support member distance is closed by both an increase in the distance between the respective collars of the pipeline or pipe section as a decrease in the distance between the support members. In this embodiment, the deformation capability of all material is used effectively and the elastic properties of both pipeline and support structure are used.
In another embodiment, the movable and fixed pipeline support between the respective first and second support members compress much more in response to a certain load than the extension of the pipeline between the first and second collars and between the third and fourth collars in response to the same load, such that the greater part of the difference between the collar distance and the support member distance is closed by a decrease in the distance between the respective support members.
In this embodiment, the strain in the pipeline is small in comparison to the strain in the pipeline support.
The words “much more” indicate that the decrease in the support member distance is at least three times, preferably at least five times greater than the increase in the collar distance.
In another embodiment, the movable and fixed pipeline support between the respective first and second support members compress much less in response to a certain load than the extension of the pipeline between the first and second collars and between the third and fourth collars in response to the same load, such that the greater part of the difference between the collar distance and the support member distance is closed by an increase in the distance between the respective collars of the pipeline or pipe section.
In this embodiment, the deformation capability of the pipeline is used effectively and the pipeline support can be regarded as a more or less non-deformable object.
The words “much less” indicate that the decrease in the support member distance is at least three times, preferably at least five times smaller than the increase in the collar distance.
In another embodiment, deformable rings are positioned between the collars and the support members. The deformable rings further distribute the forces more evenly over the respective support members.
The present invention also relates to a method of laying a marine pipeline, comprising providing a pipeline laying vessel having a J-lay system and a pipeline or pipe section,
the J-lay system comprising a fixed pipeline support and a movable pipeline support configured for supporting a pipeline which is suspended from the pipeline-laying vessel,
the movable pipeline support comprising:
at least a first movable support member configured for engaging a first collar on the pipeline, at least a second movable support member configured for engaging a second collar on the pipeline,
wherein the first and second movable support members are spaced apart at a movable support member distance along an intended firing line, the fixed pipeline support comprising:
at least a first fixed support member configured for engaging a third collar on the pipeline, at least a second fixed support member configured for engaging a fourth collar on the pipeline, wherein the first and second fixed support member are spaced apart at a fixed support member distance along an intended firing line
the pipeline or pipe section comprising:
a first set of collars comprising at least a first collar and a second collar constructed to engage a movable pipeline support of a J-lay system, a second set of collars comprising at least a third collar and a fourth collar constructed to engage a fixed pipeline support of a J-lay system,
wherein the second collar is positioned at a collar distance from the first collar, and wherein the fourth collar is positioned at a collar distance from the third collar,
the first collar being configured to engage the first movable support member,
the second collar being configured to engage the second movable support member,
the third collar being configured to engage the first fixed support member,
the fourth collar being configured to engage the second fixed support member,
wherein:
a) the first movable support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second movable support member, and the first fixed support member is resiliently mounted according to a substantially predetermined load-movement relationship relative to the second fixed support member,
and/or
b) wherein the pipe section between the first and second collar and between the third and fourth collar is resilient according to a predetermined load-elongation relationship, the method comprising exerting a force from the first or third collar of the pipeline or pipe section on the first movable support member or the first fixed support member, thereby increasing one of the collar distances and/or decreasing one of the support distances such that the second collar engages the second movable support member or the fourth collar engages the second fixed support member.
It is possible to distribute the total load of the pipeline substantially equally over the available collars.
The invention also relates to a vessel comprising a pipeline support according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows a cross-sectional view of a step in the suspension of a pipeline from the pipeline support according to the invention,
FIG. 1B shows a cross-sectional view of a subsequent step in the suspension of a pipeline from the pipeline support according to the invention,
FIG. 1C shows a cross-sectional view of a next step in the suspension of a pipeline from the pipeline support according to the invention,
FIG. 2 shows an partial cross-sectional view of another embodiment of the invention,
FIG. 3A shows a schematic cross-sectional view of the embodiment of FIG. 2 ,
FIG. 3B shows a more detailed cross-sectional view of the embodiment of FIGS. 2 and 3A , and
FIG. 4 shows a detailed cross-sectional view showing allowable margins in the combination of the pipeline support and the pipe section of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A , 1 B and 1 C show a section 10 of a pipeline and a pipeline support 12 of a J-lay system. The pipeline support 12 can be a fixed pipeline support or a movable pipeline support. A fixed pipeline support is generally also referred to as a hang-off table (HOT). A movable pipeline support is often referred to as a movable clamp. The pipe section 10 may form the free end of a pipeline which is suspended from the vessel. The pipeline may extend all the way down to a seabed, which in practice may be a distance of several thousands of meters.
Because a substantial length of pipeline is suspended from the vessel, a substantial axial force 14 is present. This axial force 14 is to be transferred to the pipeline support 12 . To this end, the pipe section 10 is provided with at least a first collar 16 A and a second collar 16 B. It will be appreciated by the skilled person that such collars may have many different sizes and shapes. For instance, the collars may not extend completely around the pipeline but may protrude from the pipe wall over a limited circumferential length. The collars may have a rounded form when viewed in cross-section, such as a semi-circular form or a rectangular form having rounded corners.
The collars 16 A, 16 B are provided with a first support surface 18 a and a second support surface 18 b respectively. The first and second support surfaces 18 A, 18 b are provided at a collar distance 19 from one another
In a suitable embodiment, the support surfaces are angled relative to the firing line (not shown in FIGS. 1A-1C ).
The pipeline support 12 is provided with support members 20 A and 20 B. The support members protrude from a frame 22 of the pipeline support. The support members 20 A, 20 B have support surfaces 24 A, 24 B. The first and second support surface 24 a , 24 B are provided at a support member distance 15 from one another.
The pipeline 10 has an outer wall 25 having a wall thickness 26 and the collars 16 A, 16 B protrude over a distance 28 from the outer wall 25 .
The collar distance 19 is smaller than the support member distance 15 .
FIG. 1B shows how in use the pipeline 10 (or pipe section 10 ) contacts the pipeline support 12 . The first support surface 18 A of the pipeline 10 contacts the first support surface 24 A of the first support member 20 A. A gap 30 (also indicated with δ) occurs between the second support surface 18 B of the pipeline 10 and the second support surface 24 B of the pipeline support. Due to the force 14 , the section 11 of pipeline 10 between the first support surface 18 A and the second support surface 18 B will extend and the section 13 of the pipeline support 12 between the first support member 20 A and the second support member 20 B will be compressed, as is indicated with arrows 32 and 34 . The pipeline 10 and the pipeline support 12 deform elastically and act as springs.
It is preferred that the pipeline support 12 is much stiffer than the pipeline 10 , such that the pipeline 10 will extend much more than the pipeline support 12 will compress.
It is also possible that the pipeline 10 is much stiffer than the pipeline support 12 , so that the compression of the pipeline support 12 is much greater than the extension of the pipeline 10 .
Due to the extension of the pipeline section 11 and the compression of the pipeline support 12 , the gap 30 will close, so that the second support surface 18 B of the pipeline and the second support surface 24 B of the pipeline support 12 engage. This is shown in FIG. 1C .
When the stiffness of the pipeline 10 and the pipeline support 12 are known, it is possible to determine a difference between distance 19 and distance 15 , i.e. a gap 30 , which is required for the second support surface 18 B to engage the second support surface 24 B of the pipeline support 12 for a certain force F. This force F occurs at the first support surface 18 A.
Thus, it is possible to determine a relationship between δ and F. For instance, the pipeline 10 and the pipeline support 12 may be designed such that the second support surface 18 B will meet the second support member 20 B when the load which is transferred via the first support surface is 1000 kN.
In such a way, it can be determined that the total load is distributed over the first and second support surfaces 18 A, 18 B according to a more or less predetermined distribution. A substantial equal distribution may be obtained.
The parameters which determine the value of the force at which the second support surface 18 b meets the second support member 20 B include:
1. The difference δ between the collar distance 19 and the support member distance 15 , 2. The tensile stresses which occur in the section 13 of the pipe 10 and the compressive stresses which occur in the section 13 of the pipeline support 12 , which tensile stresses are determined by the size and shape of the pipeline 10 and which compressive stresses are determined by the size and shape of the pipeline support 12 , 3. The elasticity of the respective materials from which both the pipeline and the pipeline support are made, i.e. the modulus of elasticity E.
When the Force F is known which acts on the first support surface 18 A, the tensile stresses in the pipeline 10 and the compressive stresses in the pipeline support 12 may be calculated based on the size and shape of these parts. Via Hooke's law, the known stresses and the known modulus of elasticity determine the strain in the pipeline 10 and the strain in the pipeline support 12 , i.e. the strain can be calculated based on the stresses and the elasticity modulus.
When the strain is known, the extension of the pipeline 10 and the compression of the pipeline support 12 can be calculated based on the collar distance 19 and the support member distance 15 . The combined extension and compression result in the gap 30 which is to be created in order to ensure that the second support surface 18 B and the second support member 20 B meet at the required Force F. Of course it is also possible to reverse this computation, i.e. to calculate the force F when the gap 30 is known.
Thus, it is possible to tune the gap 30 in such a way that the total load 14 on the pipeline is distributed substantially equally over the two collars 16 A, 16 B. This provides the possibility of replacing one large collar (not shown) of the prior art by two smaller collars 16 , such that the distance 28 by which the collars 16 protrude from the side wall of the pipeline 10 is decreased. Or, if the size of the collars is maintained substantially the same, it is possible to increase the total load which can be transferred from the pipeline 10 to the pipeline support 12 .
FIG. 2 shows another embodiment of the invention, in which the pipeline 10 comprises three collars 16 A, 16 B, 16 C and three support surfaces 18 A, 18 B, 18 C for a movable pipeline support. The pipeline comprises three similar collars comprising support surfaces for a fixed pipeline support which are not shown in FIG. 2 and discussed further in relation to FIGS. 3A and 3B . The support surfaces are oriented at an angle 21 relative to the main longitudinal axis of the pipeline 10 . In this example the angle 21 is <90 degrees, which allows a further reduction in the distance 28 over which the collars protrude from the wall of the pipeline 10 . However, an angle of 90 degrees is possible as well. The first and second support surface 18 A, 18 B are located at a collar distance 191 from one another, and the second and third support surfaces 18 b , 18 c are located at a collar distance 192 from one another.
The pipeline support 12 is provided with three pipeline support members 20 A, 20 B and 20 C which are provided at support member distances 251 , 252 from one another, respectively. The support member distance 251 is greater than the collar distance 191 and the support member distance 252 is greater than the collar distance 192 , creating gaps δ 1 and δ 2 . Since the gaps are small relative to the size of the pipe and the support, they are not distinctly visible in FIG. 2 . The fixed pipeline support and the movable pipeline support each comprise three support members.
By deliberately introducing the gaps δ 1 and δ 2 , it is possible to make use of the elasticity of the materials of the pipeline and the pipeline support.
By manipulating δ 1 , 191 and t 1 it is possible to control at what percentage of the total load the second support surfaces 18 b , 24 B will engage one another. The formula that applies is:
δ
1
=
(
σ
A
-
σ
B
)
L
1
E
The same applies for the second gap δ 2 .
δ
2
=
(
σ
A
-
σ
B
)
L
2
E
+
δ
1
In the equation, σ A is the tensile stress (positive value for tension) in the pipeline 10 , σ B is the compressive stress (positive value for compression) in the pipeline support 12 , L 1 is collar distance 191 , and L 2 is the collar distance 192 .
It is also possible to use four, five or six support surfaces for each of the fixed and movable pipeline supports which are spaced apart in the direction of the intended firing line.
A skilled person will understand that the axial force in the pipeline increases stepwise when travelling in a downstream direction 80 . Below each support surface, the axial force increases when compared to the axial force above the support surface.
Likewise, in the pipeline support 12 , the axial force increases when travelling in a downstream direction. It can be seen in FIG. 2 that the thickness t 2 of the pipeline support 12 between the second and third pipeline support 20 B and 20 C is greater than the thickness t 1 of the pipeline support 12 between the first and second support member 20 A and 20 B. In this way, the increased force does not lead to an increased compressive stress and/or strain in the pipeline support 12 between the second support member 20 B and third support member 20 C.
FIGS. 3A and 3B further show the embodiment of FIG. 2 , wherein three support members are provided. It can be seen in FIG. 3A that three support surfaces 18 A 1 , 18 A 2 , 18 A 3 on the pipeline 10 are provided for a fixed pipeline support 12 and three support surfaces 18 A 4 , 18 A 5 , 18 A 6 are provided for a movable pipeline support 120 . The angle 21 of the support surfaces relative to the main longitudinal axis of the pipeline is about 60 degrees. The respective support surfaces distance 191 , 192 are in the order of 50 mm. The gaps δ 1 and δ 2 are in the order of 0.10 to 0.50 mm. Generally the gaps are kept as small as possible in order to keep the total length of the upper pipe section as small as possible, which is preferred from an economical point of view. A typical total length 70 of the upper end of a pipe section will be approximately 800 to 1000 mm for the given gap values.
The form of the pipeline support members 20 A, 20 B, 20 C downstream of (or under) the actual support members is rounded, see radius 42 . Or in other words, the transition of the support members 20 A, 20 B, 20 C into the frame 22 is rounded in order to reduce peak stresses.
The transition of the collars to the pipe 10 is also rounded for the same reason which is indicated with radius 40 . Different radii of curvature may be used for both roundings.
The form of the collars 16 A, 16 B 16 C is thus defined by a curved section 40 which goes over in the actual support surface 18 A 1 , 2 , 3 resp. 18 A 4 , 5 , 6 . The support surfaces end at an outer end of the collar 16 A, 16 B, 16 c . The collars each have a part 46 which extends parallel to the pipe wall 25 . Next, an inclined section 44 tapers inward back to the pipe wall 25 . Other forms are also possible.
The form of the support members 20 A, 20 B, and 20 C is defined by a rounded section 42 , followed by a section 43 which extends parallel to the pipe wall 25 . This section ends at a corner 47 where the support surfaces 24 A, 24 B, 24 C of the support member 20 A, 20 B, 20 C starts. The support surfaces 24 A, 24 B, 24 C are oriented at an inclination and taper outwardly, back to a wall 50 of the frame 22 .
In the embodiment shown in FIG. 3 , the thicknesses of the pipeline support 12 are calculated as 16 mm for t 1 and 21 mm for t 2 .
Generally, the initial gaps 30 are calculated analytically. For a known or chosen value of thickness of the pipeline support 12 , an optimal gap that would be required to obtain equal load distribution can be calculated. Also upper and lower gap limits can be calculated.
This is illustrated in FIG. 4 . A detail of the gap between collar 16 B and support surface 24 B of FIG. 1B is schematically indicated. A nominal gap 400 is the gap where an optimal load distribution is obtained, for instance 50%-50% for a system with two support members. The distance between the minimum gap 401 and maximum gap 402 is the margin 410 which is available for fabrication tolerances. A deviation from the nominal gap 400 will result in a different load distribution between the support members. A smaller than nominal gap will lead to a lower than predicted load on an upper support member, and a larger than nominal gap will result in a higher than predicted load on an upper support member. Depending on the allowed deviation, for instance 60%-40% to 40%-60% between an upper and a lower support member, the allowable fabrication tolerances can be determined. The smaller the allowed deviation from a nominal gap 400 is, the tighter the fabrication tolerances will become.
It will be obvious to a person skilled in the art that numerous changes in the details and the arrangement of the parts may be varied over considerable range without departing from the spirit of the invention and the scope of the claims. | A J-lay system constructed to be positioned on board a pipeline-laying vessel, comprising a fixed pipeline support ( 12 ) and a movable pipeline support ( 12 ) configured for supporting a pipeline ( 10 ) which is suspended form the pipeline-laying vessel, —the movable pipeline support ( 12 ) comprising: —at least a first movable support member ( 20 A) configured for engaging a first collar ( 16 A) on the pipeline ( 10 ), —at least a second movable support member ( 20 B) configured for engaging a second collar ( 16 B) on the pipeline ( 10 ), —the fixed pipeline support ( 12 ) comprising: —at least a first fixed support member ( 20 A) configured for engaging a third collar on the pipeline ( 10 ), —at least a second fixed support member ( 20 B) configured for engaging a fourth collar on the pipeline ( 10 ), wherein the first ( 20 A) and second fixed support member ( 20 B) configured for engaging a fourth collar on the pipeline ( 10 ). | 5 |
RELATED APPLICATIONS
[0001] This application is related to the following co-pending applications entitled “Implantable Therapeutic Substance Infusion Device With Motor Stall Detector” by inventors Seifert et al. (attorney docket number P8905.00) and “Implantable Therapeutic Substance Infusion Device With Active Longevity Projection” by inventors Rogers et al. Ser. No. 09/809,809 Filed Mar. 16, 2001 (attorney docket number P8904.00), which are not admitted as prior art with respect to the present invention by its mention in this cross reference section.
FIELD OF THE INVENTION
[0002] This disclosure relates to a medical device and more particularly to an implantable therapeutic substance infusion device, also known as an implantable drug pump, optimized peristaltic pump motor drive circuit.
BACKGROUND OF THE INVENTION
[0003] The medical device industry produces a wide variety of electronic and mechanical devices for treating patient medical conditions. Depending upon medical condition, medical devices can be surgically implanted or connected externally to the patient receiving treatment. Clinicians use medical devices alone or in combination with therapeutic substance therapies and surgery to treat patient medical conditions. For some medical conditions, medical devices provide the best, and sometimes the only, therapy to restore an individual to a more healthful condition and a fuller life. One type of medical device is an implantable therapeutic substance infusion device.
[0004] An implantable therapeutic substance infusion device is implanted by a clinician into a patient at a location appropriate for the therapy. Typically, a therapeutic substance infusion catheter is connected to the device outlet and implanted to infuse the therapeutic substance such as a drug or infusate at a programmed infusion rate and predetermined location to treat a condition such as pain, spasticity, cancer, and other medical conditions. Many therapeutic substance infusion devices are configured so the device can be refilled with therapeutic substance through a septum while the device is implanted. Then the time the device can be implanted may not be limited by therapeutic substance stored capacity of the device. An example of an implantable therapeutic substance infusion is shown in Medtronic, Inc. product brochure entitled “SynchroMed® Infusion System” (1995).
[0005] Electrically powered implanted therapeutic substance infusion devices consume energy delivered typically by a battery, also called a power source, and can require replacement once implanted due to depletion of the battery. Typically the most significant power-consuming component in an implantable infusion device is the therapeutic substance metering motor such as a stepper motor.
[0006] A stepper motor is an electromechanical device whose rotor rotates a discrete angular amount when an electrical drive pulse is applied to the stator windings. The amplitude and the width of the electrical drive pulse must be tailored to the electromechanical properties of the motor in order to achieve rotation, stability, and optimal energy consumption. Examples of instability include the motor rotating backwards, stepping ahead then “flipping back” to its starting position, and not stepping at all. For a stepper motor to function normally and efficiently over a wide power source voltage range, the motor drive pulse needs to be adjusted proportional to the voltage change of the power source.
[0007] If all motor drive pulse parameters are held constant while the power source voltage decreases, a decrease due to normal consumption of power source energy, excess energy above that needed by the motor is delivered at the beginning of the service life of the device. This occurs because the pulse parameters needed for the end of service life, for example, pulse width, are greater than needed at the beginning.
[0008] Thus, unless the pulse parameters are appropriately varying as the power source voltage is varying, the excess energy drawn from the power source undesirably reduces the service life of the implantable pump. This may cause an early need to replace the pump which is undesirable.
[0009] Since replacement of the implanted device requires an invasive procedure of explanting the existing device and implanting a new device, it is desirable to extend battery life to the greatest extent practicable. Some previous implantable infusion devices have reduced power consumption by varying the pulse width of the motor drive signal, but stepper motors can become unstable or stall under some circumstance when the pulse width is varied from the optimal pulse width that the motor is typically designed to use. An example of a motor drive signal with a varying pulse width is shown in Japanese Patent 11,042,286 “Intracorporealy Embedded Type Liquid Medicine Supplying Apparatus” by Yamazaki (Feb. 16, 1999).
[0010] For the foregoing reasons, there is a need for an implantable therapeutic substance infusion device with optimized pump motor drive to increase the infusion device's effective service life. This increased service life reduces the overall cost of the medical therapy and the inconvenience to the patient and clinician for future device replacement surgeries.
BRIEF SUMMARY OF THE INVENTION
[0011] An implantable therapeutic substance infusion device embodiment with optimized peristaltic pump motor drive to maximize the service life of the power source while maintaining assurance that the energy needed to drive the pump motor is sufficient over the life of the power source and the life of the device. The slow continuous decrease of power source voltage versus time is periodically sampled and measured. A measurement circuit measures this voltage signal and this voltage value is used to continuously vary the motor drive parameters generated by the motor drive circuit to compensate for the decreasing voltage. The duty cycle of the short drive pulses increases as the power source voltage decreases thereby compensating for the reduced voltage drive amplitude to the motor. The electrical energy delivered by the motor drive circuit is substantially constant even when the power source voltage decreases. This invention avoids the waste of significant power source energy at the high initial power source voltage if the motor drive pulse width and repetition rate were constant over the service life of the pump and power source. The infusion device has a housing; a power source; a therapeutic substance reservoir configured for containing a therapeutic substance and being refilled with the therapeutic substance while implanted; a therapeutic substance pump fluidly coupled to the therapeutic substance reservoir, and electrically coupled to the power source; and, electronics electrically coupled to the power source and coupled to the therapeutic substance pump. The electronics include a processor; memory coupled to the processor; an infusion program residing in memory, the infusion program capable of being modified once the therapeutic substance infusion device is implanted; and, transceiver circuitry coupled to the processor for externally receiving and transmitting therapeutic substance infusion device information. Many embodiments of the therapeutic substance delivery device with optimized peristaltic pump motor drive and its methods of operation are possible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 shows the environment of an implantable therapeutic substance infusion device embodiment;
[0013] [0013]FIG. 2 shows an implantable therapeutic substance infusion device embodiment;
[0014] [0014]FIG. 3 shows an implantable therapeutic substance infusion device with catheter embodiment;
[0015] [0015]FIG. 4 shows an exploded view of an implantable therapeutic substance infusion device with peristaltic pump embodiment;
[0016] [0016]FIG. 5 shows a block diagram of an implantable therapeutic substance infusion device embodiment;
[0017] [0017]FIG. 6 shows flow diagram for the motor drive control embodiment;
[0018] [0018]FIG. 7 shows a schematic diagram of stepper motor control system embodiment;
[0019] [0019]FIG. 8 shows an electrical pulse diagram versus time for the chopper motor control embodiment;
[0020] [0020]FIG. 9 shows a diagram of the power source voltage versus depth of discharge of the power source superimposed with drive pulse duty cycle embodiment;
[0021] [0021]FIG. 10 shows the drive pulse duty cycle with varying duty cycles embodiment, and
[0022] [0022]FIG. 11 shows that the motor drive pulse energy is substantial constant over the useful voltage range of the power source embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] [0023]FIG. 1 shows the environment of an implantable medical device known as an implantable therapeutic substance delivery device 30 , also known as a drug pump, having a peristaltic pump with optimized peristaltic pump motor drive embodiment. The therapeutic substance delivery device 30 operates to infuse a therapeutic substance 36 stored in therapeutic substance reservoir 44 at a programmed flow rate into a patient 38 . The therapeutic substance delivery device 30 can be used for a wide variety of therapies such as pain, spasticity, cancer, and many other medical conditions.
[0024] The implantable therapeutic substance delivery device 30 is typically implanted by a surgeon in a sterile surgical procedure performed under local, regional, or general anesthesia Before implanting the therapeutic substance delivery device 30 , a catheter 32 is typically implanted with the distal end position at the desired therapeutic substance delivery site 34 and the proximal end tunneled to the location where the therapeutic substance delivery device 30 is to be implanted. The implantable therapeutic substance delivery device 30 is generally implanted subcutaneous about 2.5 cm (1.0 inch) beneath the skin where there is sufficient tissue to support the implanted system. Once the therapeutic substance delivery device 30 is implanted into the patient 38 , the incision can be sutured closed and the therapeutic substance delivery device 30 can begin operation.
[0025] [0025]FIG. 2 shows an implantable therapeutic substance delivery device 30 with optimized pump motor drive embodiment with housing 41 and fill port septum 40 . FIG. 3 shows implantable therapeutic substance delivery device 30 connected to catheter 32 prior to implantation into a patient 38 by a surgeon.
[0026] The therapeutic substance 36 in pump reservoir 44 inside the pump is a substance intended to have a therapeutic effect such as pharmaceutical compositions, genetic materials, biologics, and other substances. Pharmaceutical compositions are chemical formulations intended to have a therapeutic effect such as intrathecal antispasmodics, pain medications, chemotherapeutic agents, and the like. Pharmaceutical compositions are often configured to function in an implanted environment with characteristics such as stability at body temperature to retain therapeutic qualities, concentration to reduce the frequency of replenishment, and the like. Genetic materials are substances intended to have a direct or indirect genetic therapeutic effect such as genetic vectors, genetic regulator elements, genetic structural elements, DNA, and the like. Biologics are substances that are living matter or derived from living matter intended to have a therapeutic effect such as stem cells, platelets, hormones, biologically produced chemicals, and the like. Other substances are substances intended to have a therapeutic effect yet are not easily classified such as saline solution, fluoroscopy agents, and the like.
[0027] The therapeutic substance 36 in reservoir 44 can be replenished in some embodiments of the implanted therapeutic substance delivery device 30 by inserting a non-coring needle connected to a syringe filled with therapeutic substance 36 through the patient's skin into a fill port septum 40 on the therapeutic substance delivery device 30 to fill the implanted device. The contents of the syringe are then injected into the pump reservoir 44 .
[0028] If the therapeutic substance delivery device 30 requires replacement due to conditions such as power source depletion or other condition, an incision is made near the implanted therapeutic substance delivery device 30 , and the old therapeutic substance delivery device 30 is removed, also known as explanted. After the old therapeutic substance delivery device 30 has been explanted, typically a new therapeutic substance delivery device 30 is then implanted.
[0029] [0029]FIG. 4 shows an exploded view of an implantable therapeutic substance infusion device with optimized pump motor drive comprised of a housing 41 , a power source 42 , a therapeutic substance reservoir 44 , a therapeutic substance pump 46 , and electronics 48 .
[0030] The housing 41 is manufactured from a material that is biocompatible and hermetically sealed such as titanium, tantalum, stainless steel, plastic, ceramic, and the like. The power source 42 is carried in the housing 41 . The power source 42 , selected to operate the therapeutic substance pump 46 and electronics 48 , may be a lithium ion (Li+) battery, a capacitor, and the like.
[0031] The therapeutic substance reservoir 44 is carried in the housing 41 and is configured to contain therapeutic substance 36 . The therapeutic substance pump assembly 46 is carried in the housing 41 , and is fluidly coupled to the therapeutic substance reservoir 44 and electrically coupled to the power source 42 . The therapeutic substance pump assembly 46 is a pump sufficient for infusing therapeutic substance 36 such as the peristaltic pump with stepper motor drive that can be found in the SynchroMed& Infusion System available from Medtronic, Inc.
[0032] A stepper motor is an electromechanical device whose rotor rotates a discrete angular amount when an electrical drive pulse is applied to the stator windings. The amplitude and the width of the pulse must be tailored to the electromechanical properties of the motor in order to achieve rotation, rotational stability, and optimal energy consumption. An example is a motor that rotates 180 degrees with the application of a 3 volt, 11.2 millisecond, square pulse. A second pulse is then applied at minus 3 volts to rotate an additional 180 degrees making a complete revolution.
[0033] The stepper motor is mechanically coupled by gears to the peristaltic roller pump where the rollers rotate in such a way as to squeeze a compressible tube and drive liquid through the tube lumen in one direction. In effect the therapeutic substance 36 from the reservoir 44 flows in the tube and is metered to the patient 38 via catheter 32 to anatomical sight 34 .
[0034] Examples of instability include the motor rotating backwards, stepping ahead then “flipping back” to its starting position, and not stepping at all. For a stepper motor to function normally and efficiently over a wide power source voltage range, the motor drive pulse parameters need to be adjusted proportional to the voltage change of the power source.
[0035] [0035]FIG. 5 shows a block diagram device embodiment. The electronics 48 are carried in the housing 41 and coupled to the therapeutic substance pump 46 and the power source 42 . The electronics 48 include a processor, memory, an infusion program, and transceiver circuitry.
[0036] At the processor can be a microprocessor, an application specific integrated circuit (ASIC) state machine, a gate array, a controller, and the like. The electronics 48 are configured to control the therapeutic substance pump 46 infusion rate and can be configured to operate many other features such as patient alarms and the like. The infusion program and other device parameters and patient information reside in memory and are capable of being modified once the therapeutic substance infusion device is implanted. The transceiver circuitry is coupled to the processor for externally receiving and transmitting therapeutic substance infusion device information.
[0037] [0037]FIG. 6 shows a flow chart of a method for operating a therapeutic substance infusion device 30 with optimized pump motor drive. The method embodiment includes receiving an instruction to infuse a therapeutic substance 61 . Together with the elements of measuring, receiving and storing the power source voltage signal in 62 , the drive pulse duty cycle is calculated or provided by a look-up table in 63 . The drive pulse duty cycle is used for delivery of motor drive pulses 64 to the motor that generates the infusion of therapeutic substance from the pump 65 .
[0038] [0038]FIG. 7 shows a schematic diagram of stepper motor control system to illustrate the components of the preferred embodiment. The stepper motor 106 is connected to the power source 102 via the motor drive circuit 105 , and mechanically coupled with gears 107 to the therapeutic substance infusion pump 108 . The motor drive circuit 105 is configured with a drive interval timing circuit 105 a and a drive pulse circuit 105 b. The drive interval timing circuit 105 a specifies a substantially fixed drive interval for drive energy to be delivered to the motor 106 to operate a therapeutic substance pump 108 according to a therapy program. The drive pulse circuit 105 b is coupled to the power source measurement circuit 140 to generate a predetermined number of drive pulses within the drive interval according to the power supply 102 voltage to reduce motor 106 energy consumption. The duty cycle of short drive pulses varies according to the power source voltage 95 of FIG. 9 at terminal 103 as measured by the power source measurement circuit 140 to reduce motor energy consumption.
[0039] FIG. 8 shows the repetition rate of the long fixed drive period t2 varies dependent on the programmed pump flow rate in accordance with the therapy program. For example, the repetition rate is high for high therapy flow rates, and the repetition rate is low for low therapy flow rates.
[0040] In FIG. 7 the power source voltage 95 at terminal 103 is feed to the quad switches 111 , 112 , 113 , and 114 as well the power source measurement circuit 140 . The power source measurement circuit 140 is composed of a standard analog-to-digital converter as well as other electrical components. The power source measurement circuit 140 generates a signal or digital word proportional to the power source voltage that is fed to the processing unit 141 . The processing unit 141 produces a duty cycle control signal or digital word that is fed to the controller 104 in the motor drive circuit 105 . The controller 104 in the motor drive circuit is composed of standard digital logic, registers and other logic components to configure the motor drive pulses. Registers may include but are not limited to a pulse interval register, a drive pulse width register, a drive pulse duty cycle register, and a drive pulse expiration register.
[0041] The controller 104 outputs electrical pulses to drive the four motor drive switches 111 , 112 , 113 , and 114 . Outputs 116 and 118 of the quad switch assembly produce a motor drive pulse train that energizes the motor stator magnet 122 , in turn rotating the motor rotor 120 . The motor stator coil 124 is wound around the magnetic material stator 122 . The rotor 120 is mechanically coupled by gears 107 to the pump mechanism 108 . The rotor 120 of the stepper motor rotates in such a way as to propel and meter the therapeutic infusion substance 36 from the pump 30 to the patient 38 .
[0042] This invention achieves motor drive energy optimization by dividing the usual long drive pulse into numerous shorter pulses. For example, the long single drive pulse can be performed by 23 shorter pulses applied over the time period t 2 in FIG. 8.. Due to the large inductance of the motor's stator winding 124 , the flow of current is not significantly disrupted at each short pulse. The duty cycle, ratio of “on time” to “total time”, of the short pulses is directly proportional to the energy savings compared to a 100% “on time” drive pulse. The duty cycle changes in small discrete increments over the usable power source voltage range such that the energy that drives the motor is substantially constant and of proper amplitude for stable motor function. For example, the duty cycle increases in 1 / 16 steps as the power source voltage decreases and vice versa.
[0043] [0043]FIG. 8 illustrates how the stepper motor pulse duty cycle is achieved. The long pulse t2 is combined or commutated with chopper oscillator pulses 80 from chopper oscillator 110 in the controller 104 of the motor drive circuit 105 . The long motor drive pulse width t2 is fixed at 11.2 milliseconds. The 2048 hertz chopper oscillator 110 provides square wave pulses 80 that are used to achieve the short drive pulse t5. The duty cycle of the 2048 hertz pulses t5 in periods t2 and t4 are dependent on the power source voltage as described above. The predetermined number of short drive pulses t5 are about 23 pulses within the substantially fixed drive interval of 11.2 milliseconds of t2 and t4. The drive periods t2 and t4 have a duty cycle in the range from about 75% to about 100%. This combination of varying short pulse parameters achieves substantially constant motor drive energy to reliably operate a therapeutic substance pump according to a therapy program.
[0044] [0044]FIG. 9 illustrates the continuously varying power source voltage 95 versus the Depth of Power Source Discharge during the service life of the infusion device. Superimposed on FIG. 9 is the motor drive short pulse duty cycle 91 expressed in percent. As the power source voltage decreases, the duty cycle increases, ranging from 75% to 100%. The end of service life 92 of the power source 42 is where 100% duty cycle occurs. Until the end of service life is reached, the duty cycle of the stepper motor varies to compensate for the decreasing power source voltage.
[0045] [0045]FIG. 10 illustrates the duty cycle, defined as t5 divided by t6, as it varies depending on power source voltage 95 . At 100% duty cycle, the short drive pulses t5 are on during the entire 11.2 millisecond drive period t2 in FIG. 8. At 75% duty cycle, the long drive pulse is composed of 23 consecutive short drive pulses each at about 0.75/2048 hertz=0.366 milliseconds long.
[0046] [0046]FIG. 11 illustrates the long pulse motor drive energy 1100 is substantially constant versus power source voltage. This near constant delivered energy assures stable and reliable motor 120 rotation even when the power source voltage 95 decreases.
[0047] Many other related functions could be derived from this optimized motor drive invention. For example, if a motor stall is detected, the drive pulse duty cycle could be increased or decreased to overcome the motor stall or to do diagnostics of the stall. An intermittent motor stall might occur due to significant environmental magnetic field interactions such as experienced with magnetic resonance imaging technology.
[0048] In addition, if a very large change of power source current is needed, the resultant anticipated power source voltage reduction could be predicted using a power source forecast circuit. The power source forecast circuit identifies that the power source voltage will change abruptly and that the duty cycle must be adjusted. Typically the duty cycle is increased in anticipation of lower power source voltage. Such a dynamic prediction may be needed because of inherent time delays of the power source measuring or processing system. Large power source current changes might occur when the pump infusion rate is abruptly changed from a very low rate to a very high rate or an alarm is activated.
[0049] Thus, the implantable therapeutic substance infusion device 30 embodiments with optimized pump motor drive achieves the maximum service life of the power source while maintaining assurance that the stepper motor will function normally over the entire range of power source voltages. An energy efficient motor drive is achieved based on measuring power source voltage and continuously controlling the motor drive pulse parameters to minimize the electrical energy delivered to the pump motor. A predetermined number of drive pulses is selected to operate the stepper motor while substantially maintaining motor stability and avoid motor stall.
[0050] Thus, embodiments of the implantable infusion device with optimized peristaltic pump motor drive are disclosed to increase the infusion devices effective service life. One skilled in the art will appreciate that the present invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow. | A medical device known as an implantable therapeutic substance delivery device is configured for implanting in humans to deliver a therapeutic substance such as pharmaceutical compositions, genetic materials, and biologics to treat a variety of medical conditions such as pain, spasticity, cancer, and many other conditions. The infusion device incorporates a stepper motor that controls the infusion flow rate during the service life of the device. The stepper motor is controlled by continuously varying electrical pulse parameters based on the continuously decreasing power source voltage during the service life of the substance delivery device. In particular the stepper motor electrical pulse parameters, especially duty cycle, are selected to efficiently compensate for decreasing battery voltage thereby optimizing the motor performance while maximizing the power source service life. The infusion device has a housing, a power source, a therapeutic substance reservoir, a therapeutic substance pump, and electronics. Many embodiments of the therapeutic substance delivery device with optimized pump motor drive and its methods of operation are possible. | 0 |
PARTIAL WAIVER OF COPYRIGHT PURSUANT TO 1077 O.G. 22(MAR. 20, 1987)
© Copyright. 1996. Basic Resources, Inc. All of the material in this patent application is subject to copyright protection under the copyright laws of the United States and of other countries. As of the first effective filing date of the present application, this material is protected as unpublished material.
However, permission to copy this material is hereby granted to the extent that the owner of the copyright rights has no objection to the facsimile reproduction by anyone of the patent document or patent disclosure, as it appears in the United States Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
CROSS-REFERENCE TO RELATED APPLICATIONS
The following patent application, which are filed herewith, is incorporated by reference:
______________________________________Reference Number/Serial Number Title Author______________________________________TU-IP2003 Process Based James N. Earley Performance Jeffrey D. Hooper Management Systems Billy H. Stigall And Methods Used to John S. Stinson Monitor Performance Changes in Power Plant Equipment to Operate Power Plant at High Efficiency______________________________________
FIELD OF INVENTION
The present invention generally relates to the field of equipment and processes used in power plants by plant unit operators to generally monitor and control power production. The present invention particularly relates to equipment and processes used to monitor the operation of a power plant to maintain and/or to improve the efficiency of the power plant. The present invention also particularly relates to equipment and processes used to detect potential turbine water induction incidents in order to warn power plant operators of potential turbine water induction incidents, so that they can take preventive or corrective measures.
BACKGROUND
Traditional power plants can be improved in a number of ways. Specifically, traditional power plants lack sophisticated data collection and control systems that provide real time information in a format that can be easily understood and used by power plant operators to avoid certain types of emergencies and to operate the power plant at an increased efficiency. For instance, most power plants in the world are steam powered. In these power plants, condensation (e.g., water) is typically heated in some fashion to form steam. Steam is then channeled through various steam lines and passageways (e.g., pipes) throughout a power plant to drive or turn a turbine. The turbine then drives a generator, which is used to generate electricity. Regarding early warning systems, steam, however, may condense to form a liquid condensation, which is problematic and, in some cases, catastrophic, when too much condensation is formed and resides in the wrong location. Specifically, if condensation forms in or otherwise travels to the turbine, the turbine can be completely destroyed. In fact, the potential damage of such an event is so great that the mere presence of condensation in the turbine is generally viewed in the industry as a "single point failure" and grounds to shut down the entire power plant. Of course, shutting down the power plant introduces significant, additional costs that are associated with the actual loss of power production (e.g., loss of production, replacement power expense, repairs, startup expenses).
Consequently, an early warning system that alerts power plant operators of such a condition is desperately needed in the industry. Traditional power plant designs have typically positioned condensation level detectors that detect the actual presence of condensation in the turbine shell holding a turbine, in steam lines or other passageways that transport the steam from or to a turbine shell holding a turbine, or actually in peripheral equipment joined to a turbine (e.g., heaters). These level detectors are mechanical in nature and generally involve a mechanical float of some sort with electrical connections that are activated as the mechanical float rises past a series of electrical contacts. Since these level detectors have moving parts that are mechanical in nature and are constantly exposed to and/or immersed in purified water, they often corrode and, thus, do not always work as expected when needed. In addition, these level detectors are static detectors in that they are only activated when the condensation level rises to a dangerous level. As a result, it is difficult to test these types of detectors without significantly altering the operation of the power plant (e.g., shut down the plant). Similarly, temperature detectors are sometimes positioned inside the turbine shell holding the turbine and/or in steam lines linked to the turbine to detect changes in temperature over time at various locations. Unfortunately, however, information provided by these temperature detectors is seldom used or analyzed to accurately predict the presence of condensation in the turbine in a timely manner, because, in part, the information is not generally available. And, additionally, this temperature information is not generally available to power plant operators in real time, so that the power plant operator cannot use this information on an on-going, continuous basis. Moreover, additional information which is needed to make quick decisions, is not available, much less presented to the plant operator in a format allowing a quick analysis and review. As a result, at best, these temperature detectors provide only a last minute warning signal, which is not satisfactory. The need for an early warning system is especially critical in light of the fact that condensation in a typical power plant can back up into a turbine from peripheral equipment, such as a heater, in less than a few minutes, which provides very little time to diagnose a potential failure and to take corrective action. Thus, since condensation is already in the turbine or nearly in the turbine (e.g., in the steam lines connected to the turbine shell, which holds the turbine) before these temperature detectors detect a change in the temperature and, therefore, are not capable of providing any warning whatsoever, it is absolutely imperative that improved warning systems be provided to power plant operators in the future.
In addition, the lack of an early warning system is a consequence of the fact that sufficient, ongoing, continuous information is not available or routinely presented to the power plant operator. Static detectors and traditional control systems do not provide sufficient or timely feedback to enable the power plant operator to continuously monitor the overall power production cycle in order to keep a power plant operating at its highest efficiency, thereby reducing plant fuel costs. The efficiency or plant characteristics may vary with minor variances in the fuel (e.g., one load of coal verses another load of coal), outside weather conditions, and the load across the power plant, and the like. Immediate information that is continuously provided to the power plant operator would allow the power plant operator to better manage the operation of the plant, especially if such information is presented in a format that allows the power plant operator to review and analyze crucial information in a timely manner.
SUMMARY
The disclosed invention pertains to an apparatus and to related methods and systems that are used to monitor and control the operation of a power plant. Specifically, preferred embodiments continuously monitor certain thermodynamic properties of specific pieces of equipment that may potentially generate or otherwise hold excess amounts of condensation or feed water. Feed water is the term used to describe the liquid condensation that is heated by the power plant to produce steam. As discussed above, excess amounts of feed water in the wrong location may severely damage certain pieces of equipment (e.g., the turbine) and/or affect the efficiency of the overall power plant. When the thermodynamic properties approach particular, predefined values, preferred embodiments alert the power plant operator. This signal allows the power plant operator to initiate precautionary adjustments or actions that may depend upon other circumstances to avoid potential problems, such as a turbine water induction incident (feed water in the turbine), and/or to keep the power plant operating at peak efficiency.
Preferred embodiments of the steam powered electrical power generating station provide electricity and are comprised of a steam turbine positioned in a steam turbine shell, a piece of equipment, a first temperature detector, a second temperature detector, and a computer to evaluate various sorts of information. The steam turbine has at least one blade and a shaft joined to the at least one blade. The shaft is also joined to turn an electrical generator, so that the electrical generator can create electricity. Of course, the steam turbine shell is joined to receive steam to turn the at least one blade of the steam turbine. The piece of equipment (e.g., low pressure feed water heater, high pressure feed water heater, deaerator, auxiliary coolers condenser, and pumps) is joined to the steam turbine shell to receive steam from the steam turbine shell. The piece of equipment generally receives feed water through an entry port and releases feed water through an exit port. The piece of equipment performs certain operations on the feed water, such as pre-heating the feed water before the feed water is transferred to a boiler, which will be described below. The first temperature detector is positioned near the piece of equipment to detect a first temperature of the feed water prior to entering the first piece of equipment via the entry port, which is called the first temperature. The second temperature detector is positioned to detect another temperature of the feed water after exiting the piece of equipment via the exit port, which is called the second temperature. The computer is electrically coupled to the first temperature detector and to the second temperature detector and is programmed to evaluate the first and second temperatures in relation to one another. The computer compares the first temperature to the second temperature to generate a temperature difference and compares the temperature difference with a standard temperature difference. In other preferred embodiments, the computer can also perform a variety of other operations. Specifically, the computer can determine whether the piece of equipment is operating correctly and/or whether the piece of equipment has an excess amount of condensation that is in danger of traveling into the steam turbine shell. Preferred embodiments may also be comprised of additional equipment as well. Specifically, as referenced above, preferred embodiments may also be comprised of a burner and a boiler. The burner processes fuel (e.g., gas, pulverized coal, lignite) to generate heat, which is used to heat the boiler to convert feed water into steam, which, in turn, is transported to the steam turbine shell to turn the turbine.
Preferred embodiments also use additional detection and monitoring systems as an optional, secondary or back-up to the detection and monitoring system discussed above. For instance, preferred embodiments may further comprise at least one temperature detector in the steam turbine shell that is also electrically coupled to the computer, which is activated when condensation reaches the steam turbine shell. The computer continuously monitors the temperature detector(s) and triggers a warning signal to a plant operator operating the steam powered electrical power generating station when the temperature detector is activated. Differences in temperature detected by various temperature detectors in the turbine shell indicate or imply the presence of condensate in the turbine shell. In addition, preferred embodiments are also comprised of a level detector in the piece of equipment. This level detector is also electrically coupled to the computer and is activated when condensation in the piece of equipment reaches a certain, predefined level. Once again, the computer continuously monitors this level detector and triggers a warning signal to a plant operator when this level detector is activated. Also, additional temperature detectors can be positioned in mechanical passageway(s) that connect the steam turbine or the steam turbine shell to the first piece of equipment. These additional temperature detectors are also electrically coupled to the computer and compare the temperature detected by these temperature detectors to a standard temperature. The standard temperature may be associated with a normal operating condition or with an alarm condition. The computer may also compare temperature readings of a particular temperature detector over time to monitor the operation of the power plant. Either way, the computer continuously monitors the temperature and, if necessary, triggers a warning signal to the power plant operator.
Preferred methods are generally comprised of detecting a first temperature of feed water immediately before the feed water has entered heating equipment; detecting a second temperature of the feed water immediately after the feed water has exited the heating equipment; comparing the first temperature to the second temperature to generate a temperature difference between the first temperature and the second temperature; comparing the temperature difference with a preferred temperature difference to determine whether the temperature difference is within the approved range from the preferred temperature difference; and generating a warning signal to alert the power plant operator if the temperature difference is not within the approved range. Preferred processes may also be comprised of detecting a condensation level within the heating equipment; comparing the condensation level with a preferred condensation level to determine whether the condensation level exceeds the preferred condensation level; and generating a warning signal to alert the power plant operator if the condensation level exceeds the preferred condensation level. Similarly, preferred processes may also be comprised of detecting a third temperature of the steam in the mechanical passageway; and comparing the third temperature to a standard temperature to determine if steam is being transported via the mechanical passageway or whether condensation is present in the mechanical passageway. The first temperature is periodically detected at a first interval and the second temperature is periodically detected at a second interval. The first and second interval is preferably equal to two seconds. Note, as with the preferred system, once the preferred embodiment compares the measured readings, computes the temperature difference, and then compares the difference to a standard temperature difference, the warning signal generated can inform the plant operator that immediate, corrective action is needed to avoid imminent danger and/or that minor adjustments are needed to keep the power plant operating at peak efficiency.
Preferred embodiments provide a number of advantages. In particular, preferred embodiments continuously and periodically check the temperature measurements before and after the piece of equipment. Generally, preferred embodiments check the temperature at a preset interval (e.g., two (2) seconds). The interval that one temperature detector is checked may vary from the interval that a second temperature detector is checked. Temperature detectors and level detectors located elsewhere are preferably continuously (and periodically) checked as well. Preferred embodiments evaluate the heat rate of steam and condensation at various locations in the overall power plant. Additionally, preferred embodiments help diagnose problems at various locations in the overall power plant, such as in the low pressure and high pressure heaters. Preferred embodiments also provide an early warning of potential turbine water induction incidents, so that such incidents can be prevented. Moreover, preferred embodiments are reliable and accurate. Finally, preferred embodiments allow the power plant operator to control the overall power plant operations, specifically the feed water heater's performance, so that the overall power plant operation is at its highest efficiency, which significantly reduces the fuel costs of the power plant.
Other advantages of the invention and/or inventions described herein will be explained in greater detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present inventions. These drawings together with the description serve to explain the principles of the inventions. The drawings are only for the purpose of illustrating preferred and alternative examples of how the inventions can be made and used and are not to be construed as limiting the inventions to only the illustrated and described examples. Further features and advantages will become apparent from the following and more particular description of the various embodiments of the invention, as illustrated in the accompanying drawings, wherein:
FIG. 1 illustrates a general schematic system diagram of a steam-powered electric generating station 10, which, among other things, shows the general relationship of the main components of a preferred steam-powered electric generating station 10;
FIG. 2 illustrates a more detailed schematic view of steam-powered electric generating station 20, which, among other things, shows the use of steam from high pressure turbine 120 and intermediate pressure turbine 122 to enable high pressure feed water heaters 105 and low pressure feed water heaters 107 to heat feed water via steam lines 121 and 123;
FIG. 3 illustrates a detailed schematic view of steam-powered electric generating station 30, which, among other things, shows the specific equipment interconnections in a preferred embodiment, and the actual number of high pressure heaters 105A and 105B used to form high pressure heaters 105 (in FIGS. 1 and 2) and the actual number of low pressure heaters 107A, 107B, 107C, and 107D used to form low pressure heaters 107 (in FIGS. 1 and 2);
FIG. 4 illustrates a cross-sectional view of a typical preferred three-zone feed water heater, such as high pressure heater 105A or 105B (in FIG. 3) or low pressure heaters 107A, 107B, 107C, and 107D (in FIG. 3);
FIG. 5A illustrates a cross-sectional view of a typical bridle 500, which is comprised of various level detectors 501, 502, 503, 504, and 505 which are used to directly or indirectly monitor the water level 444 in heater 400;
FIG. 5B shows a chart of the levels detected or monitored by level detectors 501, 502, 503, 504, and 505 (in FIG. 5A);
FIG. 6 is an enlarged cross-sectional view of a typical temperature detector 60 used in the preferred embodiments shown in FIGS. 1, 2, and 3;
FIG. 7 is an enlarged view of cascaded high pressure feed water heaters 105 in FIGS. 1 and 2 and high pressure feed water heaters 105A and 105B in FIG. 3 with the temperature indicated at various locations;
FIG. 8 is a real time graph showing the difference in temperature (ΔT) for high pressure feed water heater 105A (T 11 ) in FIG. 7 over time in relation to two (2) limits L 1 and L 2 ;
FIG. 9A is a real time graph showing the difference in temperature (ΔT) for high pressure feed water heater 105B (T 10 ) in FIG. 7 over time in relation to two (2) limits L 3 and L 4 ;
FIG. 9B is a graph of the drain flow for high pressure feed water heater 105B in FIG. 7 verses Megawatts, allowing comparison of predicted verses actual performance;
FIGS. 10A and 10B are graphs of actual data from two (2) heaters that comprise high pressure feed water heaters 105, such as high pressure feed water heaters 105A and 105B in FIG. 3, during a turbine water induction incident, showing the difference in temperature of feed water across high pressure feed water heaters 105A and 105B;
FIG. 11 is a system level configuration of a preferred data collection and gathering system, having data collection system 1151 to collect sensor data 1120;
FIG. 12 is a graph of expected temperature measurements corresponding to low pressure feed water heater 107B in the power plant shown in FIG. 3 showing the relationship between the electrical load (MW) and the difference (A) in the temperature across low pressure feed water heater 107B, which is preferably used to determine the appropriate limits as well as the standard difference in temperature across low pressure feed water heater 107B; and
FIG. 13 is a graph of the actual temperature measurements corresponding to low pressure feed water heater 107D in the power plant shown in FIG. 3 showing the relationship between the electrical load (MW) and the difference (A) in the temperature across low pressure feed water heater 107D and the corresponding limits surrounding the difference (A) in the temperature across low pressure feed water heater 107B, as the electrical load changes.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment will be described by referring to apparatus and methods showing various examples of how the inventions can be made and used. When possible, like reference characters are used throughout the several views of the drawing to indicate like or corresponding parts.
Referring to FIG. 1, fuel (e.g., pulverized coal, gas, or lignite coal) and air are channeled into burner 113 to heat feed water in boiler 100 to a sufficient temperature to produce steam. Exhaust flue gas is directly or indirectly channeled to smoke stack 499. Although not shown in FIGS. 1 and 2, scrubbers and additional equipment may be used in preferred embodiments as well. Boiler feed water pump 109 supplies boiler 100 with slightly more than 4,000,000 pounds of pressured feed water per hour at a pressure of about 4300 psia. Economizer 102 preheats the feed water before the feed water is heated by the water walls of boiler 100. The steam is generally heated further with superheater 106 to produce "live" or "superheated" steam (hereafter "superheated steam"). The superheated steam is then passed through one or more turbines, such as high pressure turbine 120, intermediate pressure turbine 122, and low pressure turbine 124 (and/or other energy extraction mechanisms) to convert the energy present in the superheated steam into mechanical energy. The turbines drive electrical generator 126 to generate electricity, thereby converting the mechanical energy into electrical energy.
Specifically, superheated steam is typically passed through a number of turbine stages that are preferably positioned in series with one another, in order to extract as much energy as possible from the superheated steam. For instance, superheated steam at first heat and pressure point 11 (e.g., 1000° F. at 3675 psia), which is generally the highest heat and pressure point, will be used to drive high-pressure turbine 120. The exhaust from the high-pressure turbine 120 is superheated steam at the second heat and pressure point 13 (e.g., 1000° F. at 700 psia) and is generally at a lower heat and pressure than at first pressure point 11. The superheated steam at second heat and pressure point 13 drives intermediate pressure turbine 122. Note that reheater 108 may be used to boost the temperature of superheated steam at the second pressure point 13. Superheated steam at third heat and pressure point 15 (e.g., 160°-165° F. at 175 psia.) is at a lower temperature and pressure point than that of first and second heat and pressure points 11 and 13. The superheated steam at third heat and pressure point 15 drives low pressure turbine 124. The exhaust steam from the low-pressure turbine 124 varies with the load and is fed directly into condenser 130. Note low-pressure turbine 124, in the presently preferred embodiment, sits directly on top of condenser 130. The pressure at the exhaust of low pressure turbine 124 is slightly negative or less than the atmospheric pressure, due to the volumetric change which occurs in condenser 130. At hot well 132, the temperature will be no more than 140° F. (and typically about 125° F.) and the absolute pressure will be about 3 inches of Hg. Please note that this is a vacuum of about 13 psi relative to the atmosphere. Condensation created by condenser 130 is then pumped through auxiliary coolers 135 by condensate pump 134 and then into low-pressure feed water heaters 107 and deaerator 111. Feed water pump 109 pumps condensation from deaerator 111 through high pressure feed water heaters 105. Bottoming cycles, which extract the last economical bit of thermal energy from the superheated steam, and heat exchangers, which scavenge heat from the depleted steam for feed water heating, process heat and may also be used. For instance, although not shown, downcomer and waterwall tubes help scavenge heat generated by burner 113.
Referring to FIG. 2, in addition to the components and relationships discussed above, please note the additional detail showing steam lines 121, 123, 125, 127, and 129, which are used to transport steam to and from high pressure turbine 120, intermediate pressure turbine 122, and low pressure turbine 124. Steam is extracted from steam line 121 via steam line 121A to deaerator 111 and from steam line 121B to heat low pressure feed water heaters 107. Steam is also extracted from steam line 123 via steam line 123A to heat high pressure feed water heaters 105. Note that feed water is preferably heated by at least one feed water heater, such as low pressure feed water heaters 107 and high pressure feed water heaters 105, to a temperature as great as economically feasible. In addition, note, while most of feed water for boiler 100 is recycled condensation, which is stored in the hot well 132, condensation may be supplemented by raw water, that is processed through pretreatment 101 and demineralizer 103 and stored for use in condensation storage tank 133. Likewise, polishing demineralizer 136, along with a corresponding polishing demineralizer bypass, may also be used to demineralize condensation received from condensation pump 134.
FIG. 3 illustrates a detailed schematic view of steam-powered electric generating station 30, which, among other things, shows the specific equipment interconnections in a preferred embodiment. Note the actual number of high pressure feed water heaters 105A and 105B used to form high pressure feed water heaters 105 (in FIGS. 1 and 2) and the actual number of low pressure feed water heaters 107A, 107B, 107C, and 107D used to form low pressure feed water heaters 107 (in FIGS. 1 and 2) and the interconnections of the steam lines between these heaters.
A number of sensors are positioned throughout the plant at various locations to provide immediate and continuous sources of information to warn the power plant operator of potential problems and to generally monitor the operation of the power plant for efficiency purposes. For instance, referring to FIGS. 1 and 2, temperature detectors 60 are preferably positioned at various locations throughout a power plant. Specifically, as shown in FIG. 3, temperature detectors 60 are preferably positioned before and after low pressure feed water heaters 107 and before and after high pressure feed water heaters 105, as well as between high pressure feed water heaters 105A and 105B and between low pressure feed water heaters 107A, 107B, 107C and 107D. Likewise, as shown in FIGS. 1, 2, and 3, temperature detectors 60 may actually be positioned inside low pressure turbine 124, intermediate pressure turbine 122, and high pressure turbine 120. Also, as shown in FIGS. 2 and 3, temperature detectors may also be positioned in the passageways transferring steam extracted from the turbine to specific equipment, such as steam lines 123A and 121B. Similarly, level detectors 50 that detect the level of condensation are preferably placed in low pressure feed water heaters 107 and high pressure feed water heaters 105 to detect the level of condensation inside low pressure feed water heaters 107 and high pressure feed water heaters 105. Note level detectors 50 are actually labeled 50A, 50B, 50C, 50D, 50E, and 50F in FIG. 3 and temperature detectors 60 are actually labeled 60A, 60B, 60C, 60D, 60E, 60F, 60G, 60H, 60I, 60J, 60K, 60L, 60M, 60N, 60O, 60P, 60Q, and 60R in FIG. 3. Also, level detectors 50 and temperature detectors 60 are indicated by their location in FIGS. 1, 2, and 3, as opposed to a graphical symbol.
FIG. 4 illustrates a cross-sectional view of a typical three-zone feed water heater 400, such as high pressure heater 105A or 105B (in FIG. 3) or low pressure heater 107A, 107B, 107C, and 107D (in FIG. 3), which is used in preferred embodiments. A feed water heater's primary function is to capture latent heat from the steam extracted from a turbine, such as high pressure turbine 120, intermediate pressure turbine 122, and low pressure turbine 124, before the steam enters condenser 130, where the heat energy would be dissipated in a heat sink, such as an outdoor lake, cooling tower, etc. Steam extracted from the turbine is inputted into the feed water heater 400 via steam inlet 410, which fills voids 412 inside feed water heater 400. Vent 436 provides selective access to voids 412. Heater 400 is preferably surrounded with a shell skirt 428. A bolted shell joint 430 is optional. Feed water is directed into feed water heater 400 via feed water inlet 414 and through U-tubes 418 and eventually out feed water outlet 416. Heater 400 is designed to increase the temperature of the feed water entering heater 400 a specified, definite amount for a given turbine loading and feed water flow. Note channel 420 is preferably divided into two partitions 420A and 420B by partition plate 439, so that the incoming feed water is not directly mixed with the outgoing feed water.
In addition, while FIG. 4 symbolically represents U-tubes 418 as two (2) actual tubes that extend out into inner chamber 422, please note that U-tubes 418 are in fact an intricate array or bundle of tubes that hold feed water. U-tubes 418 form a condensing zone in which most of the steam is condensed and most of the heat transfer takes place. Baffles and tube supports 424 are used to support U-tubes 418 and to provide control fluid flow across the outside surfaces of all tubes in the condensing zone. Desuperheating zone baffles 426 and desuperheating zone shroud 429 combine to provide a separator counterflow heat exchanger that is contained within the heater sheet. The purpose of the desuperheating zone is to remove superheat from the steam. Drains subcooling zone enclosure 430, drains subcooling zone baffles 432, and drains outlet 434 combine to form another counterflow, the purpose of which is to subcool incoming drains. As a general rule, most subcooling zones are employed to reduce the saturation temperature of the condensate in the shell of the drain outlet to approach 10° F. above the feed water inlet temperature. Desuperheating zones and subcooling zones generally involve sensible heat transfer, in which both the temperature and the pressure of the fluid flowing on the shell side are reduced. Consequently, condensation is released, which forms inside the inner chamber 422, as the steam transports heat to the feed water in U-tubes 418 and cools and condenses into liquid form.
Condensation generally flows to the bottom surface of inner chamber 422 and rises to condensation level 444. In addition, although not desired, U-tubes 418 sometimes develop a leak and leak feed water into the inner chamber 422 as well. Of course, condensation level 444 is variable and, if it is too high, it is problematic, as condensation can flow out of steam inlet 410 into one or more turbines (e.g., high-pressure turbine 120, intermediate pressure turbine 122, and low-pressure turbine 124 in FIGS. 1, 2, and 3). When combined with drain inlet 438, drain subcooling zone enclosure 431, drain subcooling zone baffles 432, and drain outlet 434 enable the power plant operator to control the internal temperature in inner chamber 422 and thereby control the actual heating of the feed water in U-tubes 418, since the degree of water affects the overall temperature in the inner chamber 422, which provides the heat to heat U-tubes 418, and, if in contact with U-tubes 418, affects the transfer of heat to feed water in U-tubes 418.
A feed water heater is preferably designed to increase the temperature of the feed water a definite amount for a given turbine loading and feed water flow. Note that in certain types of boilers, such as in a "once through" boiler, turbine loading and feed water flow are proportional. The temperature of the feed water and changes in the temperature of the feed water are affected by any one of a number of factors by itself or in combination with one or more other factors. Significant factors include (i) changes in the steam flow to heater 400 through steam inlet 410; (ii) changes in feed water flow to heater 400 through feed water inlet 414; (iii) changes in the condensing surface area around inner chamber 422 of heater 400; (iv) changes in the temperature of the incoming feed water entering heater 400 via feed water inlet 414; (v) changes in the temperature of the steam entering heater 400 via steam inlet 410; and/or (vi) mechanical failure of heater 400 (e.g., U-tubes 418 develop a leak or inner chamber 422 is punctured).
Specifically, regarding the first factor, a change in steam flow to heater 400 can be attributed to a mechanical restriction in steam line(s) 123 and/or 121 (in FIG. 2), a temperature change of the feed water, or a load change. A mechanical restriction in steam line(s) 121 and/or 123 (in FIG. 2) may be simply a closed valve or line blockage. Temperature changes of feed water may be due to the fact that cooler feed water will draw more extraction steam into heater 400 and warmer feed water will restrict extraction steam to heater 400. Load changes affect the turbine steam requirements, which, in turn, affects the amount of steam that is available to be extracted.
Regarding the second factor, a change in feed water flow to heater 400 can be attributed to mechanical restriction of the feed water supply line and/or load reduction. A change in the condensing surface around U-tubes 418 of heater 400 can be attributed to a change in the heater water level. A high water level in heater 400 corresponds to additional U-tubes 418 being submerged in water. As more U-tubes 418 are covered by condensation, fewer U-tubes 418 can be utilized to condense extraction steam. A high condensation level can be caused from leaking U-tubes 418 in heater 400 and/or a stuck, blocked, or malfunctioning drain valve in drain subcooling zone baffles 432, drain subcooling zone enclosure 430, or drain outlet 434. A low water level in heater 400 does not correspond to fewer U-tubes 418 being submerged in condensation, but a lower water level in heater 400 will reduce the performance of heater 400.
Regarding the third factor, a change in the condensing surface area around inner chamber 422 of heater 400 may be attributed to the fact that over time portions of U-tubes 418 may be cut off or disconnected from the rest of the bundle of U-tubes 418, as leaks develop, etc. It is generally cheaper to merely seal off one tube from the bundle, than to remove the leaking U-tube 418. As more and more U-tubes are sealed off, the operational characteristics of the feed water heater 400 will vary.
Regarding the fourth factor, a change in the inlet temperature of feed water entering feed water inlet 414 can be attributed to a problem with an upstream heater (e.g., the feed water heater prior in the feed water cycle), except for the first feed water heater in the cycle or in the series of feed water heaters. Referring to FIG. 3, feed water flow is from right to left through the various heaters. For example, low pressure feed water heater 107D is upstream from low pressure feed water heater 107C and vice versa (feed water heater 107C is down stream from low pressure feed water heater 107D). As a general rule, the temperature of feed water in condenser 130 or hot well 132 will not have a significant effect on any of the other heaters in the cycle, except for the first heater (low pressure feed water heater 107D) in the cycle. When the performance of heater 400 changes for any reason, however, the temperature of feed water at the feed water outlet 416 will change as well. And, since the temperature of feed water at the feed water outlet 416 of one heater 400 is the temperature of the feed water at the feed water inlet 414 of the next heater when the two heaters 400 are in series with one another, the next heater's performance will be affected, as the temperature of the feed water at its feed water inlet 414 is changed. FIGS. 10A and 10B, which will be discussed below, are graphs of actual data from two (2) heaters that comprise high pressure feed water heaters 105, such as high pressure feed water heaters 105A and 105B, in FIG. 3, during a turbine water induction incident showing the delta temperature of high pressure feed water.
Regarding the fifth factor, a change in the temperature of the steam extracted from the turbine that enters heater 400 via steam inlet 410 can be attributed to a problem with boiler 100 (in FIGS. 1 and 2) or one of the turbines (e.g., high pressure turbine 120, intermediate pressure turbine 122, or low pressure turbine 124). As a result, preferred embodiments should be designed to detect a problem with the steam temperature with instrumentation monitoring one or all of the turbines 120, 122, and 124 and/or boiler 100, before the problem affects the performance of heater 400, but, if detectors monitoring turbines 120, 122, and 124 or boiler 100 fail, monitoring heater 400 may alert the plant operator of a potential problem in turbines 120, 122, and 125 or in boiler 100.
Regarding the sixth factor, a mechanical failure of heater 400 can be attributed to a leak in U-tubes 418 or in the partition plate 439. Failure in the partition plate will result in lower than design temperature rise of the feed water temperature, reduced drain flow of the condensed extraction steam, and a greater than design temperature rise of the downstream heater (the next sequential feed water heater in the feed water cycle). Failures in U-tubes 418 will result in a lower rise of temperature across heater 400 than that intended when heater 400 was designed, increased drain flow of the condensed extraction steam and leaking feed water, and a greater than design temperature rise of the downstream heater (which will be discussed below in reference to FIGS. 10A and 10B). As discussed above, the performance of heater 400 will deteriorate to a less than the original installed design condition as failed U-tubes 418 are repaired by plugging them. This plugging procedure will reduce the total heat exchange surface area of heater 400, but performance degradation is fixed and can be measured to establish a new `off design` norm.
Preferred embodiments monitor the effects of all of these factors by monitoring the temperature difference of the feed water across heater 400. With plant design information (plant design heat balance calculations) and/or unit historical data, the expected temperature rise across each heater 400 can be ascertained. With feed water flow, unit load, actual temperature rise for each heater 400, extraction steam pressures, extraction steam condensation temperatures, and heater performance can be calculated and audited against expected performance. For instance, FIG. 12 is a graph of expected temperature measurements corresponding to low pressure feed water heater 107B in the power plant shown in FIG. 3 showing the relationship between the electrical load (MW) and the difference (A) in the temperature across low pressure feed water heater 107B. This graph is used to model the performance of the low pressure feed water heater 107B in order to accurately define the standard difference in temperature for low pressure feed water heater 107B and to set the limits that will be discussed below. When the preferred embodiment detects a variation of a predetermined magnitude between actual and expected performance, the unit operator is alarmed by a plant data acquisition system, so that the power plant operator will respond by auditing the feed water heater process against design to determine the necessary action to remedy the situation.
FIG. 5A illustrates a typical process instructional diagram of a feed water heater, illustrating a cross-sectional view of bundle 500, which is comprised of various level detectors 50 (in FIGS. 1 and 2) which are used to directly or indirectly monitor the water level 444 in heater 400. In particular, level detectors 501, 502, 503, 504, and 505 monitor the position of water level 444. Also, note emergency drain value assembly 511 and the normal drain valve 514. Note "TW" stands for thermal well; "TE" stands for thermal element; "TI" stands for temperature indicator; "LV" stands for level valve; "LS" stands for level switch; "LC" stands for level controller; "LG" stands for level glass; and "PP" stands for pressure port. FIG. 5B shows the levels detected or monitored by level detectors 501, 502, 503, 504, and 505. In a preferred embodiment, these levels are generally defined by the following Table 1:
TABLE 1______________________________________FEED WATER HEATER WATER LEVEL LIMITS Inches below ShellWater Levels Centerline Comments______________________________________Normal Water Level 131/4 31/2 Tube Rows SubmergedLow Water Level 147/8 11/2 Tube Rows SubmergedHigh Water Level 12 5 Tube Rows SubmergedEmergency Isolation 10 5 Tubes Rows Submerged______________________________________
FIG. 6 is an enlarged cross-sectional view of a typical temperature detector 60. Note that thermocouple 62 is actually positioned inside a sheath or funnel, which is called a thermowell 64, that protects thermocouple 62 from the steam or feed water being tested and is electrically coupled to thermocouple head 68 to the data acquisition system. Note the exterior surface 66 of the steam duct or feed water passageway in which the temperature detector 60 is positioned.
FIG. 7 is an enlarged view of cascaded high pressure feed water heaters 105 in FIGS. 1 and 2 and high pressure feed water heaters 105A and 105B in FIG. 3 with the temperature indicated at various locations. Note that preferred embodiments focus on high pressure feed water heaters 105 to monitor the overall operation of the power plant and to especially provide an early warning of potential problems. This is important, because the potential differences in pressure between the condensation and steam in high pressure feed water heaters 105A and/or 105B are such that problems in these high pressure feed water heaters 105A and/or 105B have a significantly smaller response time during which power plant operators can take corrective action. In particular, as discussed above, the steam or condensation pressure in the high pressure feed water heater 105 is less than 600 psig, whereas the pressure of the feed water in the high pressure feed water heater 105 is greater than 4,000 psig, so excess feed water (e.g., from a leak in the U-tubes 418 of high pressure feed water heater 105A or 105B) easily overwhelms the steam being extracted from high pressure turbine 120 or intermediate pressure turbine 122 (in FIG. 3) and, therefore, can reach high pressure turbine 120 and/or intermediate pressure turbine 122 via the steam line(s) 60M or 60N (in FIG. 3) that are intended to carry the steam from high pressure turbine 120 and intermediate pressure turbine 122 to high pressure feed water heaters 105.
Referring again to FIGS. 3 and 7, T 1 corresponds to the temperature detected by temperature detector 60C of the feed water at feed water inlet 414 (in FIG. 4) of high pressure feed water heater 105B as the feed water enters high pressure feed water heaters 105. T 2 corresponds to the temperature detected by temperature detector 60B of the feed water at feed water outlet 416 (in FIG. 4) of high pressure feed water heater 105B as feed water leaves high pressure feed water heater 105B and subsequently enters high pressure feed water heater 105A via the feed water inlet 414 (in FIG. 4) of high pressure feed water heater 105A. T 3 corresponds to the temperature detected by temperature detector 60A of the feed water at feed water outlet 416 (in FIG. 4) of high pressure feed water heater 105A as the feed water leaves high pressure feed water heater 105A. T 4 corresponds to the temperature detected by temperature detector 60M of the extraction steam used to heat feed water in high pressure feed water heater 105A, as the extraction steam enters high pressure feed water heater 105A via steam inlet 410 (in FIG. 4). T 5 corresponds to the temperature detected by temperature detector 60S of the condensate drained from high pressure feed water heater 105A to high pressure feed water heater 105B, as condensation leaves high pressure feed water heater 105B via normal condensate drain and/or drain control valves. T 6 corresponds to the temperature detected by temperature detector 60N of the extraction steam used to heat feed water in high pressure feed water heater 105B, as the extraction steam enters high pressure feed water heater 105B via steam inlet 410 (in FIG. 4). T 7 corresponds to the temperature detected by temperature detector 60T of the heater drain used to heat feed water in high pressure feed water heater 105B, as the steam condensation leaves high pressure feed water heater 105B via the normal condensate drain and/or drain control valves to upstream deaerator 111. Differences in temperature are computed at various points throughout high pressure feed water heaters 105A and 105B to monitor the operation of high pressure feed water heaters 105A and 105B, individually and collectively. For instance, preferred embodiments calculate the difference in the temperature across high pressure feed water heater 105B (between T 2 and T 1 ., which is defined as T 10 ) and between T 1 and T 7 , which is defined as T 8 . Preferred embodiments also calculate the difference in temperature across high pressure feed water heater 105A (between T 2 and T 3 , which is defined as T 11 ) and between T 2 and T 5 , which is defined as T 9 . In addition, these differences in temperature are also archived over time at a predefined interval (e.g., 2 seconds).
FIG. 8 is a real time graph showing T 11 , which is the difference across high pressure feed water heater 105A over time in relation to two limits L 1 and L 2 . As discussed above, preferred embodiments determine the appropriate T 11 by reviewing system designs, manufacturer specifications, and imply historical readings from high pressure feed water heater 105A, which is, in this example, approximately 94° F. Then, a specified amount (e.g., 5° F.) was subtracted from and added to 94° F. to create L 1 (89° F.) and L 2 (99° F.). The end user may establish alternate appropriate L 1 and L 2 for the specific application. An example of preferred embodiments use a computer with the proper software to compare T 11 to L 1 and L 2 on an on-going basis (e.g., every two seconds) to determine whether high pressure heater 105A is working properly. Foxboro IA Distributed Control System is a preferred computerized data collection and gathering system 1150 (in FIG. 11) used, but alternate distributed control systems could be used. In addition, since Foxboro is equipped with computer hardware and software along with a printer(s) 1152, terminal(s) 1153, and data collection system 1151, the Foxboro system provides a way to collect and analyze the data collected in a real time fashion. FIG. 11 is a system level configuration of a preferred data collection and gathering system. Data collection system 1151 gathers sensor data 1120 associated with feed water heaters 1180, turbine 1160, generator 1126, and boiler 1100. Data collection system 1150 creates the graph shown in FIG. 8, T 11 , L 1 and L 2 , so that a plant operator can review the information on an on-going basis.
Likewise, FIG. 9A is a real time graph showing the difference (A) in temperature for high pressure feed water heater 105B in FIG. 7 over time in relation to two limits L 3 and L 4 . Once again, as discussed above, preferred embodiments determined the appropriate T 10 by reviewing system designs, manufacturer specifications, and historical readings from high pressure feed water heater 105B, which is approximately 28° F. Then, once again, a specified amount (5° F.) was subtracted off and added to 28° F. to create L 3 (23° F.) and L 4 (33° F.). Preferred embodiments use the FoxBoro system to compare T 10 to L 3 and L 4 on an on-going basis (every two seconds) to determine whether high pressure heater 105B is working properly. Foxboro creates the graph shown in FIG. 9A, and presents T 10 , L 3 and L 4 , so that the power plant operator can review the information on an on-going basis. Alternatively, as shown in FIG. 9B, alternate preferred embodiments could also graph the relationship between drain flow verses Megawatts and specify location 800, which is the sample corresponding to high pressure feed water heater 105B at a specific point in time. If high pressure feed water heaters 105A and 105B are operating correctly, the sample should reside somewhere on the relationship graphed in FIG. 9B. FIG. 9B is used in part to determine L 3 and L 4 . Although not shown, please note that a graph similar to that shown in FIG. 9B could be created that corresponded to FIG. 8 and could be used in part to determine L 1 and L 2 . Also, as shown in FIG. 13 in reference to low pressure feed water heater 107D, the standard difference (Δ) in the temperature and the corresponding limits surrounding the standard difference (Δ) in the temperature may vary as the electrical load changes.
If T 10 and/or T 11 (in FIGS. 9A and 9B, respectively) exceed their respective preset limits, it is an indication that high pressure feed water heater 105A and/or high pressure feed water heater 105B are not working correctly or that there might be excess of condensation therein. And, if there is excess water in high pressure feed water heater 105A and/or in high pressure feed water heater 105B, there is greater risk, if not an immediate danger, of there being feed water in the turbines. Consequently, drains, such as drain outlet 434 in FIG. 4, on high pressure feed water heater 105A and/or high pressure feed water heater 105B need to be opened to release any excess liquid. The power plant operator can directly open the drains or have them opened or, in some instances, an operating system, such as Foxboro, may automatically open the drains to release additional liquid. At any rate, the warning provided by monitoring the temperature is sufficiently earlier (and more reliable) than any warning provided by level detectors inside high pressure feed water heater 105A and/or high pressure feed water heater 105B (in FIG. 3) or other detectors or sensors in steam lines 121 or 123 (in FIG. 2) or in turbines 120, 122, or 124 (in FIGS. 1 and 2) themselves. However, these detectors and sensors do provide a secondary or back-up notification system.
FIGS. 10A and 10B show a graph of the T 1 , T 2 , T 3 , T 10 and T 11 over time, as high pressure feed water heaters 105S and 105B operate normally and as one high pressure feed water heater, high pressure feed water heater 105B, is filled with liquid. Region 1001 corresponds to a typical transient condition. Region 1002 corresponds to a steady state condition when both high pressure feed water heaters 105A and 105B are operating correctly. Region 1003 corresponds to a condition when high pressure feed water heater 105B is filled with liquid. Note the speed and degree to which the temperature difference across high pressure feed water heater 105B, T 10 , dropped. Also, as described above, note how the down-stream heater, high pressure feed water heater 105A, attempted to compensate for the effects of the excess liquid in high pressure feed water heater 105B. The difference across high pressure feed water heater 105A actually increased, as the incoming water temperature T 2 dropped and more steam was extracted from the turbine. Region 1004 corresponds to a condition in which drains were opened to drain excess liquid from high pressure heater 105B. Note both differences appeared to return to a normal operating range. Finally, region 1005 corresponds to another condition in which high pressure feed water heater 105B is again being filled with liquid and high pressure feed water heater 105A is attempting to compensate. Also, note that temperature detectors before and after each high pressure feed water heaters 105A and 105B are preferred, as shown in FIGS. 3 and 7, because temperature detectors before and after both high pressure feed water heaters 105 might not be able to detect a problem with one heater or locate the exact heater having the problem due to the interactive relationship of high pressure feed water heaters 105A and 105B shown in FIGS. 10A and 10B.
Note that the limits L 1 , L 2 , L 3 , and L 4 are flexible and may need to be adjusted or recalibrated from time to time, as the operational characteristics of the high pressure feed water heaters 105 and/or of the feed water change. As discussed above, the operational characteristics of the high pressure feed water heaters 105 may change, as leaks are detected in a specific U-tube of U-tubes 418 and that specific U-tube 418 is sealed off. In addition, the outside temperature or the electrical load on the power plant may affect the operational characteristics of the high pressure feed water heaters 105 as well. Also, note that graphs similar to the graphs shown in FIGS. 8, 9A, and 9B can be created for low pressure feed water heaters 107 or other pieces of equipment. Similarly, FIG. 13 is a graph of the actual temperature measurements corresponding to low pressure feed water heater 107D in the power plant shown in FIG. 3 showing the relationship between the electrical load (MW) ("ELECTRICAL LOAD") and the difference in the temperature (Δ) (DT) across low pressure feed water heater 107D and the corresponding limits (L A and L B )surrounding the difference in the temperature (Δ) across low pressure feed water heater 107B, as the electrical load changes.
Moreover, preferred embodiments take advantage of the realization that with plant design information (e.g., plant design heat balance calculations) and/or unit historical data, the expected temperature rise across each high pressure feed water heater 105 (in FIGS. 1 and 2) can be ascertained and accurately predicted. As shown in FIG. 12, with feed water flow, unit load, actual temperature rise for each heater, extraction steam pressures, and extraction steam condensation temperatures, heater performance can be calculated and audited against expected performance. When the preferred embodiment detects a variation of a predetermined magnitude between actual and expected performance, the power plant operator is alarmed by the plant data acquisition system. The power plant operator will respond by auditing the feed water heater process against design to determine the necessary action to remedy the situation.
FURTHER MODIFICATIONS AND VARIATIONS
Although the invention has been described with reference to a specific embodiment, this description is not meant to be construed in a limiting sense. The example embodiments shown and described above are only intended as an example. Various modifications of the disclosed embodiment as well as alternate embodiments of the invention will become apparent to persons skilled in the art upon reference to the description of the invention. For instance, while the preferred embodiment described above was described in reference to high pressure feed water heaters 105, the described techniques are preferably applied to other power plant equipment as well, especially other power plant equipment that is directly or indirectly coupled to at least one turbine, such as low pressure feed water heaters 107, auxiliary coolers 135, deaerator 111 (in FIGS. 1, 2, and 3). The systems and methods described above may also be applied to the high pressure turbines 120, intermediate pressure turbine 122, and low pressure turbine 124 themselves. In addition, alternate data collection and gathering systems may be used in place of or in lieu of the Foxboro System, such as a Honeywell or Bailey Distributed Control System.
Thus, even though numerous characteristics and advantages of the present inventions have been set forth in the foregoing description, together with details of the structure and function of the inventions, the disclosure is illustrative only, and changes may be made in the detail, especially in matters of shape, size and arrangement of the parts within the principles of the inventions to the full extent indicated by the broad general meaning of the terms used in the attached claims. Accordingly, it should be understood that the modifications and variations suggested above and below are not intended to be exhaustive. These examples help show the scope of the inventive concepts, which are covered in the appended claims. The appended claims are intended to cover these modifications and alternate embodiments.
In short, the description and drawings of the specific examples above are not intended to point out what an infringement of this patent would be, but are to provide at least one explanation of how to make and use the inventions contained herein. The limits of the inventions and the bounds of the patent protection are measured by and defined in the following claims. | A steam powered electric power generating station to provide electricity comprises a steam turbine positioned in a steam turbine shell, equipment, such as a heater, a first and a second temperature detectors, and a computer. The steam turbine has necessary blades and a shaft to turn an electrical generator to create electricity. The steam turbine shell mechanically coupled to receive steam to turn the at least one blade steam turbine. The equipment is mechanically coupled to the steam turbine shell to receive steam from the steam turbine shell and receives feed water through an entry port and releases feed water through an exit port. The first temperature detector is positioned to detect a first temperature of the feed water prior to entering the equipment via the entry port. The second temperature detector is positioned to detect a second temperature of the feed water after exiting the equipment via the exit port. The computer is electrically coupled to the first temperature detector and to the second temperature detector and compares the first temperature to the second temperature to generate a temperature difference. Related processes comprise detecting a first temperature of feed water immediately before the feed water has exited the heating equipment; detecting a second temperature of the feed water immediately after the feed water has entered the heating equipment; (c) comparing the first temperature to the second temperature to generate a temperature difference between the first temperature and the second temperature; (d) comparing the temperature difference with a preferred temperature difference to determine whether the temperature difference is within an approved range from the preferred temperature difference; and (e) generating a warning signal to alert the power plant operator if the temperature difference is not within the approved range. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a circularly polarized antenna and, more particularly, to a small-sized circularly polarized antenna for transmitting and receiving a circularly polarized signal.
2. Description of Related Art
In some electrical devices, such as the reader device of an RFID system, the antenna module of which must be able to transmit and receive a circularly polarized signal, in order to ensure that the electrical devices can operate normally in any kind of attitude. Besides, since the antenna module must be small enough to be portable, the size of the antenna module of the electrical device is also limited.
Generally, the circularly polarized antenna of the prior art uses a straight coupling line to couple the electrical signal to the antenna unit, in order to transform the electrical signal into a circularly polarized signal. Then, the circularly polarized signal is transmitted outside. Thus, the substrate of the circularly polarized antenna of the prior art must have a size large enough to enclose the straight coupling line on the surface thereof. Moreover, since the length of the side of the antenna unit must be about half of the wavelength of the circularly polarized signal being transmitted, so if the frequency of the circularly polarized signal being transmitted is 915 MHz, the length of the antenna unit should be 164 mm in the free space.
The methods to reduce the length of the side of the antenna unit are (1) forming some slots on the surface of the antenna unit or (2) changing the shape of the antenna unit, in order to increase current path. But, both the aforementioned methods are too complex. As a result, the structure of the circularly polarized antenna of the prior art is too complex to reach the requirement of easy-design.
Therefore, it is desirable for the industries to provide a circularly polarized antenna with a small size, which can not only have the simple structure (the standard shape of square and circle), but also have same function to apply in any kind of the antenna module of the portable electrical device.
SUMMARY OF THE INVENTION
The circularly polarized antenna for transmitting and receiving a circularly polarized signal of the present invention comprises a substrate having an upper surface and a lower surface; a signal distributor; an antenna for transmitting and receiving the circularly polarized signal; and a plurality of support units for supporting the antenna and maintaining a predetermined distance between the antenna and the upper surface of the substrate. The upper surface of the substrate comprises a plurality of slots, wherein one end of each slot overlaps with the respective ends of the other slots at a central region. The lower surface of the substrate comprises a coupling unit being electrically connected with the signal distributor, and the center of the coupling unit corresponds to the central region.
Therefore, in the same range of the operating frequency (i.e. the operating frequency of the RFID ranges from 902 MHz to 928 MHz), the circularly polarized antenna of the present invention can reduce the size of the antenna and the substrate by forming some slots on the upper surface of the substrate and by changing the size of the coupling portion, so as to maintain the same operating ability as the circularly polarized antenna of the prior art (i.e. having the same return loss and the operating frequency bandwidth). Therefore, the circularly polarized antenna of the present invention can be compact and keep the shape of antenna simple, so as to facilitate the development of a small-sized, more convenient and portable electrical device having the circularly polarized antenna of the present invention, such as the reader device of an RFID system.
The coupling unit of the circularly polarized antenna of the present invention can comprise any kind of coupling portion, but preferably the coupling portion is a coupling-ring portion with an opening or a polygon-shaped ring having fewer than thirty-six sides with an opening. The substrate of the circularly polarized antenna of the present invention can be made as any suitable printed circuit board, but preferably the printed circuit board is an FR-4 microwave substrate, a Duroid™ microwave substrate, or a Teflon™ microwave substrate. The signal distributor of the circularly polarized antenna of the present invention can use any kind of signal distributor, but preferably it is a coaxial cable connector. The signal distributor of the circularly polarized antenna of the present invention can be electrically connected with any kind of signal transmitting line, but preferably the signal transmitting line is a coaxial cable, or a copper strand wire. The upper surface of the substrate of the circularly polarized antenna of the present invention can have formed therein any quantity of the slots, but preferably the quantity of the slots ranges from 4 to 36. Besides, each slot formed on the upper surface of the substrate of the circularly polarized antenna of the present invention preferably has the same width. The size of the coupling portion of the lower surface of the substrate of the circularly polarized antenna of the present invention is not restricted, but preferably the width of the coupling portion is equal to the width of each slot. The shape of the end of each slot is preferably dumbbell-shaped or having a lateral pool. The antenna of the circularly polarized antenna of the present invention can be composed of any kind of metals, but preferably the antenna is composed of a copper alloy containing more than ninety-eight percent copper. The substrate of the circularly polarized antenna of the present can be formed in any kind of shape, but preferably the substrate is a square plate, a rectangular plate or a circular plate. The antenna of the circularly polarized antenna of the present invention preferably is a square plate, a rectangular plate, a square plate with chamfered corners, a rectangular plate with chamfered corners, a polygon-shaped plate, or a circular plate. The supporting unit of the circularly polarized antenna of the present invention preferably is composed of plastics or any electrically insulating materials. The circularly polarized signal of the present invention can transmit or receive circularly polarized signals in any frequency range, but preferably, the frequency ranges from 900 MHz to 930 MHz or from 400 MHz to 600 MHz. The length of the side-length of the antenna of the circularly polarized antenna of the present invention is not restricted, but preferably, the side-length of the antenna ranges from the one-quarter to three-quarters of the wavelength of the circularly polarized signal being transmitted or received by the circularly polarized antenna of the present invention.
Other objects, advantages, and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic drawing of the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 2A is a schematic drawing of the substrate of the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 2B is a schematic drawing of the substrate of the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 3 is a schematic drawing showing the relation between the diameter of the coupling-ring and resonant frequency of the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 4A shows the simulated result and the measured result of the axial ratio of the circularly polarized signal transmitted by the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 4B shows the simulated result and the measured result of the gain of the circularly polarized antenna according to the first preferred embodiment of the present invention.
FIG. 5A is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the second preferred embodiment of the present invention, wherein the quantity of the slots is 16.
FIG. 5B is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the third preferred embodiment of the present invention, wherein the quantity of the slots is 36.
FIG. 6A shows the variation of the return loss of the circularly polarized antenna of the present invention regarding the changing of the operating frequency.
FIG. 6B shows the variation of the axial ratio of the circularly polarized antenna of the present invention regarding the changing of the operating frequency.
FIG. 7 is a schematic drawing of the circularly polarized antenna according to the fourth preferred embodiment of the present invention.
FIG. 8A is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the fourth preferred embodiment of the present invention.
FIG. 8B is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the fourth preferred embodiment of the present invention.
FIG. 9 shows the variation of the axial ratio of the circularly polarized signal and the gain of the circularly polarized antenna regarding the changing of the operating frequency.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic diagram of the circularly polarized antenna according to the first preferred embodiment of the present invention. The substrate 21 is an FR-4 microwave substrate with the thickness of 0.8 mm, and the antenna 22 is composed of a copper alloy containing more than ninety-eight percent copper. Referring to FIG. 1 , the antenna 21 connects with the supporting structure 24 supported by a first supporting rod 231 , a second supporting rod 232 , a third supporting 233 , and a fourth supporting rod 234 . Therefore, the antenna 22 maintains a predetermined distance between it and the upper surface 211 of the substrate 21 . By adjusting the predetermined distance, the gain of the circularly polarized antenna of the present invention can be raised and the circularly polarized characteristics of the circularly polarized antenna can also be improved.
Since the predetermined distance between the antenna 22 and the upper surface 211 of the substrate 21 is essential for designing the operating frequency of the circularly polarized antenna 1 , when the operating frequency of the circularly polarized antenna 1 needs to be changed, the first supporting rod 231 , the second supporting rod 232 , the third supporting 233 , and the fourth supporting rod 234 must be adjusted to change the predetermined distance between the antenna 22 and the upper surface 211 of the substrate 21 .
FIG. 2A is a schematic diagram of the upper surface 211 of substrate 21 of the circularly polarized antenna according to the first preferred embodiment of the present invention. FIG. 2B is a schematic diagram of the lower surface 212 of substrate 21 of the circularly polarized antenna according to the first preferred embodiment of the present invention. Referring to FIG. 2A , the upper surface 211 of the substrate 21 comprises eight slots 213 , and one end of each slot 213 overlaps with the respective ends of the other slots at a central region 214 . In addition, referring to FIG. 2B , the lower surface 212 of the substrate 21 comprises a coupling-ring line 215 and a straight coupling line 216 , wherein the coupling-ring line 215 has an opening 217 on the edge. That is, the coupling-ring line 215 is not completely closed. In addition, the center of the coupling-ring line 215 corresponds to the center region 214 of the upper surface 211 of the substrate 21 , and the coupling-ring line 215 is electrically connected with a coaxial cable connector 25 through the straight coupling line 216 .
Moreover, the frequency range of the circularly polarized signal being transmitted and received (i.e. the resonant frequency) by the circularly polarized antenna 1 can be controller by adjusting the diameter of the coupling-ring line 215 , while the shape of the antenna 21 still remains simple.
Referring to FIG. 3 , when the size of the antenna size of the present invention is equal to that of the prior art circularly polarized antenna. That is, the diameter of the coupling-ring line is about 138 mm, the resonant frequency of the circularly polarized antenna according to the first preferred embodiment of the present invention is about 500 MHz, which is suitable for the application of digital television. Besides, this resonance frequency is obviously lower than that of the circularly polarized antenna of the prior art (about 915 MHZ). Therefore, when the diameter of the coupling-ring line of the antenna of the present invention becomes shorter, the resonant frequency of the circularly polarized antenna will become larger, toward the high-frequency range. For this reason, the circularly polarized antenna of the present invention can use a substrate with smaller size to have the same resonant frequency range as the circularly polarized antenna of the prior art.
In the present embodiment, the circularly polarized antenna of the present invention only uses the substrate (FR-4 microwave substrate) with a dimension of 130 mm×130 mm and the antenna (copper plate) with a dimension of 108 mm×108 mm to transmit and receive the circularly polarized signal, the frequency of which ranges from 902 MHz to 928 MHz. Obviously, the size of the antenna of the circularly polarized antenna of the present invention is smaller than that of the antenna of the circularly polarized antenna of the prior art (i.e., 164 mm×164 mm). Furthermore, the resonant distance between the substrate and the antenna of the circularly polarized antenna of the present invention is only 11.4 mm.
Referring to FIG. 2A , the upper surface of the substrate 21 of the circularly polarized antenna of the present invention comprises eight slots 213 , and one end of each slot overlaps with the respective ends of the other slots at a central region 214 . The width of each slot is 4 mm. In another aspect, referring to FIG. 2B , the coupling-ring line 215 is electrically connected with the coaxial cable connector 25 through the straight coupling line 216 , wherein the width of the coupling-ring line 215 and the width of the straight coupling line 216 are both 4 mm, and the diameter of the coupling-ring line is 72 mm.
Therefore, when the circularly polarized antenna of the present invention is in its “transmitting state”, the coaxial cable connector 25 receives an electrical signal from a coaxial cable (not shown), so as to transmit the electrical signal to the coupling-ring line 215 with an opening via the straight coupling line 216 . Then, the coupling-ring line 215 and the slots 213 on the upper surface 211 of the substrate 21 transform the electrical signal into a circularly polarized signal and then transmit it outside. In addition, while the circularly polarized antenna of the present invention is in its “receiving state”, the coupling-ring line 215 and the slots 213 on the upper surface 211 of the substrate 21 receive a circularly polarized signal and transform the circularly polarized signal into an electrical signal, Then, the electric signal is transmitted to a coaxial cable (not shown) via the straight coupling line 216 and the coaxial cable connector 25 for further signal processing processes.
FIG. 4A shows the simulated result and the measured result of the axial ratio of the circularly polarized signal transmitted by the circularly polarized antenna according to the first preferred embodiment of the present invention, wherein the simulated result and the measured result are represented by triangular dots and square dots, respectively. Referring to FIG. 4A , the measured result of the center frequency of the circularly polarized signal (about 0.91 GHz) is slightly smaller than the simulated result of the center frequency of the circularly polarized signal (about 0.95 GHz). Besides, the impedance bandwidth (the −10 dB bandwidth) of the circularly polarized antenna according to the first preferred embodiment of the present invention is about 126 MHz, while the 3 dB axial ratio thereof is about 2.5%.
FIG. 4B shows the simulated result and measured result of the gain of the circularly polarized antenna according to the first preferred embodiment of the present invention, wherein the simulated result and the measured result are represented by triangular dots and square dots, respectively. Referring to FIG. 4B , the simulated result of the gain of the circularly polarized antenna according to the first preferred embodiment of the present invention is bigger than the measured result of the gain of the circularly polarized antenna according to the first preferred embodiment of the present invention, since the simulated result is based on an assumption that the substrate is a substrate without any return loss.
In addition, the substrate of the circularly polarized antenna of the present invention can have any quantity of the slots on the upper surface thereof, i.e., the quantity can be 12, 16, 36, and even 64.
FIG. 5A is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the second preferred embodiment of the present invention, wherein there are 16 slots 51 formed on the upper surface of the substrate thereof. One end of each slot overlaps with the respective ends of the other slots at a central region 52 . FIG. 5B is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the third preferred embodiment of the present invention, wherein there are 36 slots 53 formed on the upper surface of the substrate thereof. One end of each slot 53 overlaps with respective ends of the other slots at a central region 54 . By comparing FIG. 5A with 5 B, it is shown that as the quantity of the slots is raised (from 16 to 36), and the area of the center region has become larger. In addition, the characteristics of the circularly polarized antenna of the present invention, such as the return loss, and the characteristics of the circularly polarized signal being transmitted by the circularly polarized antenna of the present invention will be affected by the different quantities of the slots formed on the upper surface of the substrate, as described below.
FIG. 6A shows the variation of the return loss of the circularly polarized antenna of the present invention regarding the changing of the operating frequency, wherein the upper surface of the substrate comprises different quantities of slots (4, 8, 12, 16 and 36). FIG. 6B shows the variation of the axial ratio of the circularly polarized antenna of the present invention regarding the changing of the operating frequency, wherein the upper surface of the substrate comprises different quantities of slots (4, 8, and 36).
As shown in FIG. 6A , when the quantity of the slots is raised, the return loss of the circularly polarized antenna of the present invention becomes smaller. That is, the circularly polarized antenna of the present invention can transform the electrical signal into the circularly polarized signal more efficiently. As shown in FIG. 6B , the signals transmitted by the circularly polarized antenna of the circularly polarized antenna are all circularly polarized, regardless of the quantity of the slots formed on the upper surface of the substrate thereof. Therefore, once the quantity of the slots is more than 8, the circularly polarized antenna of the present invention can have enough efficiency to transmit or receive the circularly polarized signals, without the need of forming too many slots on the upper surface of the substrate of the circularly polarized antenna of the present invention.
FIG. 7 is a schematic drawing of the circularly polarized antenna according to the fourth preferred embodiment of the present invention. In this preferred embodiment, the substrate 71 is an FR-4 microwave substrate with the thickness of 0.8 mm, and having a coaxial cable connector 75 mounting at the edge. The antenna 72 is composed of a copper alloy containing more than ninety-eight percent copper, and two of the corresponding corners are chamfered. As shown in FIG. 7 , the antenna 71 connects with a supporting structure 74 which is supported by a first supporting rod 731 , a second supporting rod 732 , a third supporting 733 , and a fourth supporting rod 734 . Therefore, the antenna 72 maintains a predetermined between it and the upper surface 711 of the substrate 71 . By adjusting the predetermined distance, the gain of the circularly polarized antenna of the present invention can be raised and the circularly polarized characteristics of the circularly polarized antenna can also be improved.
Since the predetermined distance between the antenna 72 and the upper surface 711 of the substrate 71 is essential for designing the operating frequency of the circularly polarized antenna 7 , while the circularly polarized antenna 7 is required to change its operating frequency, the first supporting rod 731 , the second supporting rod 732 , the third supporting 733 , and the fourth supporting rod 734 must be adjusted to change the predetermined distance between the antenna 72 and the upper surface 711 of the substrate 21 . Besides, in the present embodiment, the slots formed on the upper surface of the substrate of the circularly polarized antenna can have any kind of shape. Moreover, after the “end treatment” is executed on the ends, the ends of the slots formed on the upper surface of the substrate of the circularly polarized antenna can have any kind of shape, as shown in FIG. 8A and FIG. 8B .
FIG. 8A is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the fourth preferred embodiment of the present invention, wherein each slot 81 has a lateral slot 82 at one end, and the opposing end of each slot 81 overlaps with the respective ends of the other slots at a central region 83 . FIG. 8B is a schematic diagram of the upper surface of substrate of the circularly polarized antenna according to the fourth preferred embodiment of the present invention, wherein each slot 81 has a dumbbell-shaped part 85 at one end, and the opposing end of each slot 84 overlaps with the respective ends of the other slots at a central region 86 . In addition, the characteristics of the circularly polarized antenna of the present invention, such as the return loss, and the characteristics of the circularly polarized signal being transmitted by the circularly polarized antenna of the present invention will be affected by the different shape of the ends of the slots formed on the upper surface of the substrate, as described below.
FIG. 9 shows the variation of the axial ratio of the circularly polarized signal and the gain of the circularly polarized antenna regarding the changing of the operating frequency, wherein the curve connecting the square points is the axial ratio curve and the curve connecting the circle points is the gain curve.
Referring still to FIG. 9 , in the present preferred embodiment, the center frequency of the circularly polarized signal is slightly higher than the operating frequency of an RFID system. Besides, the 3-dB bandwidth of the axial ratio of the circular polarized signal transmitted by the circularly polarized antenna according to the fourth preferred embodiment is wider than the 3-dB bandwidth of the axial ratio of the circular polarized signal transmitted by the circularly polarized antenna according to the first preferred embodiment. In addition, the gain of the circularly polarized antenna according to the fourth embodiment in the operating frequency range of an RFID system is always larger than 4 dB. Therefore, the circularly polarized antenna according to the fourth preferred embodiment of the present invention can be used in most of the applications of the circularly polarized antenna.
In summary, in the same range of the operating frequency (i.e. the operating frequency of the RFID ranges from 902 MHz to 928 MHz), the circularly polarized antenna of the present invention can reduce the size of the antenna and the substrate by forming some slots on the upper and lower surface of the substrate and by changing the size of the coupling portion, so as to maintain the same operating ability as the circularly polarized antenna of the prior art (i.e. having the same return loss and the operating frequency bandwidth). Therefore, the circularly polarized antenna of the present invention can have a compact size and keep antenna as simple, so as to facilitate the development of a small-sized, more convenient and portable electrical device having the circularly polarized antenna of the present invention, such as the reader device of an RFID system.
Although the present invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the scope of the invention as hereinafter claimed. | The present invention relates to a circularly polarized antenna and, more particularly, to a compact circularly polarized antenna for transmitting and receiving a circularly polarized signal. The circularly polarized antenna comprises a substrate having an upper surface and a lower surface; a signal distributor; an antenna for transmitting and receiving the circularly polarized signal; and a plurality of support units. The upper surface of the substrate comprises a plurality of slots. One end of each slot overlaps with the respective ends of the other slots at a central region. The lower surface of the substrate comprises a coupling unit being electrically connected with the signal distributor, and the center of the coupling unit corresponds to the central region. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to German Patent Application No. 102014011263.2, filed Jul. 28, 2014, which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present disclosure pertains to a framework of multiple components, e.g., a motor vehicle body, and more particularly to a framework having different material components which reduces thermal stresses that otherwise occur with changing temperatures between components consisting of different materials when these are connected to one another in a fixed manner at multiple points that are distant from one another.
BACKGROUND
DE 10 2011 107 035 A1 discloses a method for joining components with different heat expansion coefficients, in which the components are preheated to a temperature which is in the middle of a temperature interval in which the finished framework is to keep its shape so that the framework although being under stress at both limits of the temperature interval, but these stresses do not become so severe that they deform the framework. For a motor vehicle body this implies that since in practice the ambient temperature forms the lower limit of the temperature interval, the body during the use of the motor vehicle is constantly subjected to stress and when it is damaged during an accident yield to these stresses through abrupt deformation under certain conditions. In addition, this method requires a major expenditure of time, energy and material since the required tools for heating the components to be connected have to be made available and operated, and the time spent for joining the body is extended at least by the time needed for tempering the components.
SUMMARY
In accordance with the present disclosure, a framework of components with different heat expansion coefficients is created, which does not tend to a stress-induced deformation even with major temperature fluctuations. In particular, a framework, such as a motor vehicle body, is provided with at least two components in the form of a frame member fastened to one another on an elongated overlap zone of materials with different heat expansion coefficients on at least a first of the two components. The overlap zone is subdivided by weak points oriented in a transverse direction into sections following one another in longitudinal direction. In that the first component locally deforms at the weak points, the occurrence of stresses which globally deform the framework can be prevented. A time-consuming temperature controlling step is not necessary Creating the weak points can be integrated with little effort in the production of the first component, in particular by cutting to size, punching out, deep drawing or the like.
A fixed connection to the second component should be formed in multiple of these sections. Preferably, each of these sections should have a fixed connection for when a section remains unconnected to the second component, it and the weak points limiting it could be replaced by a single possibly wider weak point and the structure of the first component simplified in this way. The fixed connection can be of any type which immovably fixes the components locally to one another such as for example a welded, riveted, clinching or gluing connection.
In that the weak points become narrower with rising temperature and wider with decreasing temperature, they can adapt the heat expansion behavior of the first component in the overlap zone to that of the second component, so that deformation similar to the known bi-metallic effect does not occur. When the component with the higher heat expansion coefficient is selected as first component, the heat expansion of the entire framework will substantially orient itself towards the lower expansion coefficient of the second component.
According to a simple and practical configuration, the weak points are formed as slots oriented in transverse direction of the overlap zone. At least the first component should be a cutting of flat material in particular sheet metal. The overlap zone can then extend along an edge of the flat material cutting. This facilitates the first component yielding to the stress acting in the overlap zone without being irreversibly deformed by this. Obviously, the second component can also be a flat material cutting and the overlap zone can also run at the edge of this cutting.
Reversible or elastic yielding of the first component upon thermal stress can be facilitated in particular in that the slots are open towards the edge of the flat material cutting of the first component. Widening at an end of the slots that is distant from an edge contributes to spatially distributing the thermal stresses that occur in the first component and counteract the risk of the formation of stress cracks in the first component, in particular at the end of the slots that are distant from the edge. A further contribution to avoiding excessive stresses at the ends of the slots that are distant from the edge that could possibly be material damaging can be that their distance from the edge is greater than the distance of the fixed connections from the edge.
In order to avoid leakage of the framework the slots should be completely covered by the second component. In order to prevent that dirt or moisture can accumulate in the slots these can be filled out with a permanently elastic sealing compound. When the first component has the lower thermal expansion coefficient, the filling out of the slots with the sealing compound should take place at low temperature. In this way it can be ensured that the sealing compound is subjected to pressure, but not tensile loading which could result in a tearing-open of the connection of the sealing compound to the flanks of the first component limiting the slots.
According to a possible application, the two components together form a hollow profile, in the case of a motor vehicle body, in particular a body side or cross member or a sill. According to a preferred application, one of the two components is a roof panel of a vehicle body and the other one is a side beam, which extends laterally of the roof panel, in particular above a door aperture of the body. With a typical application, the first component consists of aluminum while the second component can consist of steel.
During the drying of an applied paint layer, a framework such as for example a motor vehicle body is mostly exposed to high temperatures so that in particular during the drying of the paint layer major thermal stresses can occur. Such painted frameworks form a preferred area of application of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements.
FIG. 1 is a perspective view of an extract of the frame structure of a motor vehicle body;
FIG. 2 is an enlarged detail from the frame structure of FIG. 1 in perspective view;
FIG. 3 shows the detail of FIG. 2 in top view;
FIG. 4 is a top view analogous to FIG. 3 according to a modified configuration;
FIG. 5 shown an upper part of a motor vehicle body;
FIG. 6 is a section along the plane VI-VI from FIG. 5 ; and
FIG. 7 shows an overlap zone between two components according to a further configuration of the present disclosure.
DETAILED DESCRIPTION
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description.
As a first application example of the present disclosure, FIG. 1 shows an extract from a frame structure forming a lower part of a motor vehicle body. The frame structure includes a side member 1 , which substantially extends over the entire length of the vehicle body and of which merely a rear part is shown here, which extends from a heel plate 2 in the direction of the vehicle rear. The frame structure is mirror-symmetrical with respect to a symmetry plane marked in FIG. 1 by a dash-dotted line 3 . The halves of the heel plate 2 extending on the other side of the symmetry plane and of cross members 4 , 5 originating from the side member 1 are not shown in the figure.
The side member 1 is assembled from multiple panels, which in overlap zones extending in vehicle longitudinal direction are connected to one another. Elongated flanges formed at the edges of the panels are welded, glued or in another manner fastened to one another. Two such panels which are connected to one another in overlap zones 6 , 7 and which complement one another at least at a front end of the shown portion of the side member it to form a closed hollow profile are marked with 8 and 9 respectively.
A further elongated panel 10 , which in front of the heel plate 2 has an inverted hat-shaped cross section and runs below a floor panel (not shown) of the passenger cell, merges with the panels 8 , 9 at the height of a rear wheel housing recess 11 and is connected to the panel 9 in an overlap zone 12 . The cross members 4 , 5 are each also assembled from two elongated panels which are connected to one another on overlap zones 13 .
The panels which are connected to one another along the overlap zones 6 , 7 , 12 or 13 may have different materials, e.g., one of the panels may be steel and the other panel may be aluminum.
In the overlap zones, two flanges each of the two panels touch one another, as is exemplarily shown in an enlarged manner for the panels 8 , 9 in FIG. 2 . In order to prevent the panels which are connected to one another from distorted at high temperature, in particular when after the painting of the body the same is dried at high temperature, the flange 15 with one of the two panels, in this case the aluminum panel 9 is divided into tongue-like portions 17 by a multitude of slots 16 which are open towards the edge of the panel. Each individual portion 17 is fastened to the opposite flange 14 of the steel panel 8 by connections 18 in the form of welded spots or glued spots, rivets or the like. The heat expansion of the aluminum which is higher compared to steel results in that the slots 16 at high temperature become slightly narrower. Accordingly, stresses between the panels 8 , 9 , which could otherwise lead to bending or tearing-open of the connections 18 are avoided. Expansions 19 at the ends of the slots 16 that are distant from the edge facilitate the required deformation of the panel 9 and prevent that the stresses in the panel 9 , in particular at the ends of the slots 16 , are concentrated over a narrow space in such a manner that buckling or tearing of the panel 9 can occur there.
The slots 16 are shown empty in FIGS. 2 and 3 . In practice, however, they may be practically filled out with a permanently elastic sealing compound when there is the possibility of contact with corrosion-promoting substances such as precipitation water or dirt swirled up from the road. The sealing compound prevents these substances from accumulating in the slots 16 and imparts the flange 15 on its top side facing away from the flange 14 , preferably with a flat surface that is difficult for substances to adhere to.
FIG. 4 shows a top view of flanges 14 , 15 of the two panels 8 , 9 which are connected to one another analogously to FIG. 3 . The connection in this case is formed by an adhesive bead 20 that is continuously applied onto the non-slotted flange 14 of the panel 8 . During the pressing-together and gluing together of the flanges 14 , 15 , the adhesive enters a small distance into the slots 16 of the panel 9 but is resilient enough even in the cured state so as not to obstruct a narrowing of the slots 16 at high temperature. Here, too, the slots 16 can be filled out with the sealing compound mentioned above provided they have not already been filled out by the adhesive.
FIG. 5 shows a perspective view of a top part of a motor vehicle body. A roof panel 21 in this case is flanked by side beams 22 on both sides, which connect A pillar 25 and C-pillar 26 of the body to one another above door apertures 23 , 24 . FIG. 6 shows in section along the plane marked VI-VI in FIG. 5 , a partial section through one of the side beams 22 and the adjacent roof panel 21 . The side beam 22 is joined together from an outer panel 27 , an inner panel 28 , which are connected to one another via flanges 30 , 31 which are elongated in vehicle longitudinal direction projecting into a roof aperture 29 that is limited on both sides by the side beams 22 and via flanges on the upper edge of the door aperture 24 which is not shown in FIG. 6 . A reinforcing panel 32 extends through the hollow space limited by the outer and inner panel 27 , 28 and engages between the flanges of outer and inner panel 27 , 28 which are each connected to one another.
On its lateral edge, the roof panel 21 is bent C-like with an approximately upright flank 33 , which is located opposite a rising flank of the outer panel 27 , and an approximately horizontally oriented flange 34 following the flank 33 . The flanges 30 , 31 and 34 form an overlap zone in which the flange 34 of the roof panel 21 supports itself on the flanges 30 , 31 of the side beam 22 and is fastened to the same by an adhesive bead 20 running in vehicle longitudinal direction analogously to the representation of FIG. 4 . Here, too, the flange 34 of the roof panel 24 consisting of aluminum is subdivided in longitudinal direction by numerous slots 16 which, by getting narrower at high temperature, prevent the occurrence of deforming stresses between the roof panel 23 and the steel panels 27 , 28 , 32 of the side beam 22 .
In a perspective view, FIG. 7 shows an extract of two flanges 14 , 15 which are connected to one another, analogous to those of the FIGS. 3 and 4 . While, however, in FIGS. 3 and 4 slots 16 weaken the flange 15 of the panel 9 , beads 35 are stamped into the panel 9 in FIG. 7 for this purpose. When the portions 17 located between them expand more greatly at high temperature than the opposite panel 8 , these beads can also absorb stresses by becoming narrower. As a further example of a possible fixed connection 18 between the panels 8 and 9 , clinch connections in the portions 17 are indicated in FIG. 7 .
It is to be understood that the above detailed description and the drawings represent certain exemplary configurations of the present disclosure but that they are only intended for illustration and should not be interpreted as being restrictive of the scope of the present disclosure. Various modifications of the described configurations are possible without leaving the scope of the following claims and their range of equivalents. In particular, the mentioned panels may include metals other than steel and/or aluminum, pairings of metal with composite materials such as for example “Organoplate” or pairings of composite materials among them are possible.
While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims and their legal equivalents. | A framework such as a vehicle body is disclosed and includes at least two components of materials with different heat expansion coefficients fastened to one another on an elongated overlap zone. The overlap zone on a first component is subdivided by weak points oriented in its transverse direction into portions following one another in longitudinal direction. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to optical circulators and, more particularly, to circulators using latchable garnet components as Faraday rotators.
DESCRIPTION OF THE PRIOR ART
In the heart of all practical fiber optic non-reciprocal devices (e.g., isolators and circulators) there is at least one Faraday rotation region. Particularly in many circulator designs, Faraday rotation regions are immediately preceded or followed by "reciprocal" polarization changers, often half-wave plates. In polarization-independent optical circulators using walk-off plates to separate the polarizations, there is a need to form a "cluster" of these components. One exemplary arrangement using such a "cluster" is disclosed in U.S. Pat. No. 5,204,771 issued to M. Koga on Apr. 20, 1993. As disclosed by Koga, an exemplary rotator comprises a "cluster" consisting of a pair of reciprocal rotators (half wave plates) disposed adjacent to one another and oriented such that one provides a clockwise rotation and the other provides a counterclockwise rotation, followed by a conventional single sheet of Faraday rotator material, the Faraday rotator material surrounded by a permanent magnet.
One problem with such a design is the necessity to maintain the external magnetic field to provide the requisite Faraday effect. Additionally, the orientation of the pair of reciprocal rotators needs to be carefully controlled to ensure that each provides the necessary rotation in the same plane.
SUMMARY OF THE INVENTION
The need remaining in the prior art is addressed by the present invention, which relates to optical circulators and, more particularly, to circulators using latchable garnet components as Faraday rotators.
In accordance with the present invention, an exemplary optical circulator utilizes a "cluster" consisting of a single half-wave plate followed by a pair of latchable garnet Faraday rotators. Latchable garnet exhibits the required non-reciprocal 45° rotation without the need to apply an external magnetic field. A pair of such latchable garnets are disposed side-by-side so that a first latchable garnet provides a clockwise rotation and a second garnet provides a counterclockwise rotation. This combination provides the same isolation capabilities as various prior art designs.
An advantage of the arrangement of the present invention is that latchable garnet has no "axis" (only designations of "front" and "back"). Therefore, there is no orientation/alignment problems as there is in prior art arrangements using pairs of half wave plates.
Another advantage of the present invention is the reduction in the number of components required to form a circulator, particularly the removal of the permanent magnet from the arrangement.
Other and further advantages of the present invention will become apparent during the course of the following discussion and by reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
Referring now to the drawings,
FIGS. 1-3 illustrate an exemplary optical circulator utilizing pairs of latchable garnet as Faraday rotations, where
FIG. 1 illustrates a forward-propagating signal passing from a first port to a second port,
FIG. 2 illustrates a reverse-propagating signal passing from the second port to a third port, and
FIG. 3 illustrates a forward-propagating signal passing from the third port to a fourth port.
DETAILED DESCRIPTION
An exemplary optical circulator 10 utilizing pairs of latchable garnet is illustrated in FIG. 1. Optical circulator 10 comprises four separate ports, labeled "A", "B", "C", and "D". As illustrated in FIG. 1, an optical signal may be coupled into port A (via an optical fiber or waveguide that is coupled, via a collimating means such as a GRIN lens or molded aspheric lens, to circulator 10), propagate in the forward direction through circulator 10 and, as will be described in detail below, exit port B. FIG. 2 illustrates the same circulator 10, with an optical signal illustrated as entering port B and thereafter propagating in the reverse direction through circulator 10 so as to exit at port C. A signal introduced into port C, as shown in FIG. 3, will propagate through circulator 10 in the forward direction and exit at port D.
Referring back to FIG. 1, an optical signal L 1 is coupled into port A of circulator 10, in particular, into a first walk-off device 12 of circulator 10. As shown, signal L 1 comprises polarization components along both the "O" (ordinary) and "E" (extraordinary) optical polarization directions. As is well-known in the art, "ordinary"/"O"-polarized light propagates through a birefringent device (such as walk-off device 12) as if the medium is not birefringent, but is effectively isotropic with an index of refraction defined as no, where the value of no is dependent upon the crystalline medium and wavelength, but not on the direction of propagation. In contrast, the "extraordinary"/"E" light propagates in an "extraordinary" way; that is, deflecting sideways in a manner not easily described by Snell's Law. Walk-off device 12, which may comprise a rutile element, functions to separate these orthogonal components, as shown, so that the O and E components of signal L 1 exit rutile 12 along separate paths. The separated O and E components (referred to, respectively, as L 1A and L 1B ) next pass through a polarization changer 14, such as a suitably-oriented half-wave plate or an optically active material, where polarization changer 14 functions to transform both principle polarization components L 1A and L 1B 45° in the clockwise direction. In accordance with the present invention, a pair of latchable garnet Faraday rotators 16, 18 are next used to provide non-reciprocal rotation to each of the L 1A and L 1B components. The use of latchable garnet in an isolator is disclosed in U.S. Pat. No. 5,608,570, where it explains that a particular composition of garnet may be initially saturated to constitute an essentially single magnetic domain. Thereafter, the domain will remain essentially constant and does not require the constant application of a magnetic field to maintain the non-reciprocal property of the material. Referring back to FIG. 1, a first section of latchable garnet 16 is oriented along the optical axis of circulator 10 so as to provide a clockwise rotation to the L 1A component of input optical signal L 1 . The second section of latchable garnet 18 is disposed adjacent to first section 16, but is turned in the opposite direction, so as to provide for a counterclockwise rotation to the signal component passing therethrough. In the arrangement of FIG. 1, the L 1B component of input optical signal L 1 will pass through second garnet section 18. Upon exiting latchable garnet pair 16,18, therefore, the L 1A and L 1B component polarizations will be parallel (since the L 1A component has been rotated 45° twice in the clockwise direction, and the L 1B component has been rotated 45° once in he clockwise direction, then rotated 45° once in the counterclockwise direction).
These parallel L 1A and L 1B components next propagate in parallel paths through a second walk-off device 20, with its optical axis oriented as shown in FIG. 1. With this particular orientation, parallel components L 1A and L 1B are both O-polarized with respect to device 20 and therefore propagate as expected by a simple application of Snell's Law, emerging from device 20 in their same positions, as shown. Thereafter, components L 1A and L 1B propagate through a second pair of latchable garnet rotators 22,24. In this pair of non-reciprocal rotators, first rotator 22 will perform a counterclockwise 45° rotation upon the L 1A component of the signal and second rotator 24 will perform a clockwise 45° rotation upon the L 1B component of signal L 1 . The rotated L 1A and L 1B components next pass through a second polarization changer (e.g., half-wave plate) 26, which imparts an additional 45° clockwise polarization rotation upon each component. Thus, the L 1A and L 1B components will again be orthogonal to one another as they exit plate 26, as shown in FIG. 1. These orthogonal components next pass through a third walk-off device 28 (with its optical axis as shown in FIG. 1), where device 28 functions to re-combine these components such that optical signal L 1 will exit circulator 10 at port B, as shown.
In operation as a circulator, an optical signal that is coupled into port B will propagate in the reverse direction through circulator 10, as mentioned above, and exit through port C, where port C is disposed below port A, as shown. Referring to FIG. 2, input signal L 2 is coupled as an input signal into port B at third walk-off device 28. Input signal L 2 propagates through walk-off device 28 in the direction shown, where walk-off device 28 (for example, a rutile component) functions to split input signal L 2 into its orthogonal O and E components (denoted L 2A and L 2B in FIG. 2). Thereafter, the separate L 2A and L 2B components of signal L 2 will pass through second polarization changer 26. As is well-known in the art, signals propagating through such a device in the reverse direction will experience a rotation opposite (when viewed from the same position) that of a signal passing through in the forward direction. In particular, referring back to FIG. 1, a signal passing from left to right through device 26 experienced a 45° clockwise rotation. When used as shown in a FIG. 2, the L 2A and L 2B components of signal L 2 in the right to left direction will experience a 45° counterclockwise rotation (when viewed from the left side of the arrangement, as illustrated in FIG. 2). Subsequent to this counterclockwise rotation, the L 2A and L 2B components of signal L 2 will propagate through latched garnet rotators 22,24. Since latched garnet produces a non-reciprocal rotation (that is, the rotation is independent of the signal's propagation direction), the L 2A component will experience a 45° counterclockwise rotation and the L 2B component will experience a 45° clockwise rotation. As a result of these differences in rotation direction, the L 2A and L 2B components will now be parallel, as shown along face 30 of second walkoff device 20.
These parallel L 2A and L 2B components, which are both E-polarized components with respect to device 20, will next propagate through second walk-off device 20, moving along the length of device 20 so as to exit (remaining as separate parallel polarized components) in the bottom region of device 20. The parallel L 2A and L 2B components next pass through latched garnet devices 16, 18; latched garnet 16 providing a 45° clockwise rotation to the L 2A component and latched garnet 18 providing a 45° counterclockwise rotation to the L 2B component. The rotated components then pass through first polarization changer 14 (which in this direction provides a 45° counterclockwise rotation). This last rotation thus returns the L 2A and L 2B components to their orthogonal orientation, as shown at face 32 of first walk-off device 12. These separate polarizations will then be combined as the signals pass through first walk-off device 12, exiting circulator 10 at port C, as shown.
Referring to both FIGS. 1 and 2, it has now been shown that an optical signal entering port A will propagate through circulator 10 so as to exit at port B, and an optical signal entering port B will propagate through circulator 10 (in the reverse direction) to exit circulator 10 at port C. Lastly, FIG. 3 will illustrate the propagation of a third optical signal, L 3 , applied as an input to port C. As shown, input signal L 3 will be split, by first walk-off device 12, into its orthogonally polarized L 3A and L 3B components. As these components pass through the combination of first polarization changer 14 and latched garnet sections 16, 18 (the L 3A component passing through garnet 16 and the L 3B component passing through garnet 18), the components will be parallel, as shown at face 52 of second walk-off device 20.
As a result of the optical orientation of second walk-off device 20, parallel polarized components L 3A and L 3B are O-polarized with respect to device 20 will pass through as expected by Snell's Law, exiting as shown along face 30 of device 20. Thereafter, the parallel polarized L 3A and L 3B components of signal L 3 will propagate through latched garnet rotators 22,24 and second polarization changer 26, resulting in re-orienting the polarizations in an orthogonal relationship, as shown at face 36 of third walk-off device 28. These orthogonal L 3A and L 3B components will be re-combined as they propagate through device 28 and exit device 28 at port D. Although not shown in any of the drawings, a signal applied as an input to port D would be deflected further down when traversing through device 20 and either be lost or coupled into a lower port (not shown).
It is to be understood that although quartz was mentioned as a preferred material for the polarization changers, various other suitable changers/rotators may be used. | An optical circulator is disclosed that utilizes a polarization rotator comprising a polarization changer (e.g., a properly-oriented half-wave plate) in combination with a pair of latched garnet Faraday rotators. The latched garnet rotators are positioned next to each other and oriented so that one latched garnet rotator provides clockwise rotation and the other provides counterclockwise rotation. The use of latched garnet with a single half wave plate results in an arrangement that is reduced in overall size and does not require epoxy to interconnection the various piece parts. | 8 |
BACKGROUND OF THE INVENTION
Automated vehicle control over a highway or pathway has long been desirable. In the simplest application, the warehouse setting, such systems are relatively common. In existing systems utilized in warehouses and offices, a vehicle is usually guided over a desired path by sensing an electric current, or sensing a magnetic field. Other systems include optical sensing, radar, acoustic or video sensing systems. All of these systems are for relatively slow vehicles as they merely react to changes in direction. Each of the aforesaid systems include serious drawbacks to the development of a control system for use in a relatively high speed highway situation.
Generally stated, existing systems sense the vehicle's position relative to a desired pathway, usually the center line of the desired track, and then compensate for the vehicle being off the pathway. As a consequence, for a smooth ride the vehicle is limited to a relatively slow speed because there is no indication as to the upcoming road or path geometry. Further drawbacks particularly associated with electro magnetic systems wherein a cable is buried or located in the path, include power requirements to maintain a current in the cable. In particular power loss in the cable requires infusion of power along the pathway even in relatively short systems. Further should the cable be broken or should it become necessary to relocate the path, at least the broken section of the cable must be taken out of the pathway and the cable repositioned or relocated at some expense to the user. Finally, it has been found that insects such as termites will eat the insulation off buried cables resulting in the system shorting out. In the case of the optical systems, where a reflective path is placed in the center line of the desired track, the path may become dirty over a period of time and thus degrade operation of the system.
Existing electro-magnetic systems usually use a plurality of sensors, up to seven, mounted transversely across the vehicle to determine the track deviation. Most commonly the sensors are coil type, however, in some instances magnetometers have been used.
While radar sensing is possible along with sonar or sound sensing, one is limited in correctly reading and interpreting radar or sonar echoes to insure obstacles are avoided and turns are made properly. Video sensing techniques based on current technology, using video cameras, may operate satisfactorily in daylight and in periods of good visibility but at night and in periods of poor visibility video systems are of little or no value. Even in good visibility, video sensing systems must correctly interpret the video return. At least one echo sensing system uses a "side looking" system requiring a wall along one side of the path.
One advantage of video, radar and acoustic sensing techniques include the ability to "predict" upcoming road geometry and possibly smooth some of the vehicle corrections to maintain the desired path, however terrain recognition remains a limiting factor.
All existing systems suffer from insufficient intelligence on upcoming road geometry thus these present systems usually "react" to an off course signal when a turn occurs rather than "planning" ahead.
These different approaches may be characterized as "direct" sensing and "indirect" sensing. In direct sensing, the capabilities could include a "smart" on- board sensing system that could objectively or directly "perceive" the road geometry and the vehicle state thereby not requiring a specially designed roadway. On the other hand, an on-board sensing system that could read both vehicle state and road information indirectly from a specially designed roadway or roadside information system may be characterized as the "indirect" sensing approach.
The direct sensing approach can be analogized to video sensing which utilizes a video camera to sense the image of the upcoming road frame by frame. The data is processed and analyzed using an image processing technique. In the indirect sensing approach on the other hand, road geometry information is abstracted by several characteristic parameters and then stored in a roadway or roadside information system. Both the vehicle state and road information can be interrogated via on-board vehicle sensors or communications tools.
While the advantages of a direct sensing approach are fairly obvious, since the system essentially replicates human driving perception, it is limited by the fact that computer and image processing techniques are difficult to accomplish in "real time" using a practical size computer. On the other hand, the indirect sensing approach provides a relatively easy means of acquiring required road information as well as vehicle position relative to the center line of the desired path (lateral deviation).
In the interrogation of roadside references for stored information, only limited information need be transmitted to the vehicle, thus the amount of data to be processed is minimized. Therefore, both the on-board sensors and the roadway reference systems can be reasonably simple and economical for a large scale operation. Finally, due to the serial nature of the data, operation at relatively high speeds (80-120 km/hour) is possible. In short, it is an object of this invention to provide an indirect sensing system for vehicle control.
It is a further object of this invention to provide an indirect sensing system that provides roadway geometry or characteristics to the vehicle.
It is still another object of this invention to provide a control system in the vehicle that is responsive to both lateral deviation from a pathway obtained from the indirect sensing system and responsive to roadway characteristics which may be contained in the roadway or roadside reference systems.
It is a further object of this invention to provide an economical vehicle guidance/control system.
It is an object of this invention to provide a vehicle guidance and control system where roadway geometry information is permanently embedded in the pavement and further the roadway geometry information is safe in that it is not dependant on any outside power source.
It is still another object of this invention to provide a vehicle guidance and control system that effectively eliminates variations in signal interpretation from vertical movement caused by vehicle bounce.
It is also an object of this invention to provide a vehicle guidance and control system that based on interpreted roadway geometry provides steering signals either to a vehicle operator by way of a display or alternatively provides steering signals to the vehicle steering mechanism.
It is still another object of this invention to provide a roadway guidance/control system wherein the pathway may be readily altered.
It is another object of this invention to provide a roadway vehicle guidance/control system that utilizes passive markers.
It is still another object of this invention to provide a vehicle roadway guidance/control system wherein the passive markers may be serially oriented so that a binary code is formed by passage over the passive markers.
SUMMARY OF THE INVENTION
This invention is a vehicle direction sensing system for use with discreet magnetic markers wherein each magnetic marker, having a magnetic field associated therewith is embedded along a predetermined line in a pathway. The invention includes a first magnetic field strength sensing device positioned in the vehicle for determining the vertical component of the field strength of one of the discreet magnetic markers. Also included is a second magnetic field strength second sensing device positioned in the vehicle for determining the horizontal component of the field strength of the same one of the discreet magnetic markers. A computer is included for comparing the vertical component of the magnetic field strength and the horizontal component of the magnetic field strength of one of the markers to obtain the lateral deviation of the vehicle from the predetermined line.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic of a vehicle with the vehicle sensing system mounted therein traveling along a pathway with the markers embedded therein.
FIG. 2 is a block diagram of the magnetic sensing system in the vehicle.
FIG. 3 is a graphical representation of the field strength of the horizontal and vertical field strengths of a magnetic marker embedded in the pavement of a pathway.
FIG. 3A is a representation of the force fields and the force vectors of a magnet placed with the north pole in the uppermost position.
FIG. 3B is a representation of the force fields and force vectors of a magnet with the south pole placed in an uppermost position.
FIG. 4 is a graphical representation of the deviation of the pair of orthogonal magnetic force sensors from the center line of the pathway, such deviation determined by force strength.
FIGS. 5A-5C are flow charts representative of the computer program used to provide vehicle guidance/control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a vehicle 10 is schematically shown in perspective. Vehicle 10 is shown on a roadway 12 that has embedded therein a series of magnets 14. Preferably magnets 14 are on the center line of the pathway although they may be adjacent to the side. By varying the orientation, that is whether the north or south pole is up in the vertically placed magnets, one can send "binary" information to a remote sensor by encoding "1's" and "0's" with the serially placed magnets. It will be seen that deviation is not degraded by such placement.
Vehicle 10 may be conventional in construction having two rear wheels 16 and two front wheels 18. The front wheels 18 are controllable by conventional steering mechanism 20 which may be operated by the vehicle operator in the manner of a private automobile or a truck. Vehicle 10 may be powered in the conventional manner by an internal combustion engine (not shown) or any other appropriate type of motive power. The drive may be accomplished through the rear wheels 16 or through the front wheels 18. Such configuration is not critical to the invention described herein and it is specifically pointed out that the invention described herein is applicable to any type of vehicle be it a four-wheel vehicle, a three-wheel vehicle or a multi-wheel vehicle. One portion of the invention deals with steering control of the vehicle hence the vehicle should be provided with steerable wheels. In the embodiment described, the front wheels are steerable. In the event the vehicle is a three-wheel vehicle then a single steerable type wheel could be used in lieu of a conventional rack and pinion steering mechanism of a four-wheel vehicle.
Having described the vehicle environment, it is appropriate to pass on to particular features of the invention. Located at or near the front of vehicle 10 is a sensing unit or sensor 22. Sensor 22 contains a pair of orthoganaly oriented probes 24 and 26 (see FIG. 3). The probes are preferably mounted in the center line of the vehicle and should be longitudinally adjacent one to the other, that is with one in front of the other. Other mounting positions on the vehicle are possible, so long as the orthoganally adjacent relation is maintained. For example if magnets are embedded near the side of the pathway, the sensor with its probes may be mounted at the side of the vehicle.
Probes 24 and 26 are magnetometers capable of sensing not only the force of a magnetic field but also the direction of the field. The probes or magnetometers are mounted so that one (24) is vertical relative to the roadway and the other (26) is mounted horizontally with its axis perpendicular to the direction of travel of the vehicle and therefore perpendicular to the path center line. It is noted in FIG. 3 that the horizontal probe 26 is oriented so that a positive indication would be indicated to the left for a north-type of polarity. In like manner polarity of probe 24 is upwardly on the paper thus the positive direction is up. In FIG. 3, a signal strength diagram is shown in a plane coincident with the axis of a imbedded magnet parallel to the axis of the magnetometer probes 24 and 26, and perpendicular to the center line of the roadway 12 along with the probes. It should be understood that the signal strengths determined by the probes are schematic but the importance of the field strength will become apparent in the ensuing discussion. It should also be understood that the graph shown in FIG. 3 is from experimental and empirical data and from analysis in a test.
Referring still to FIG. 3 and to FIG. 3A, the vertical component or curve 28 in FIG. 3 results from movement of the magnetometer 24 from left to right (normal to the vehicle direction which is into or out of the paper) as it passes over a magnet 14 embedded in the pavement 12. As can be seen the lines of force 32 are represented as moving from the north pole to the south pole in the conventional manner. Breaking the line of force or vector 32 into its horizontal and vertical components 34 and 36 respectively, the vertical component 34 of the vector 32 is in the positive direction while the horizontal component 36 (with the magnetometer oriented as shown in FIG. 3) is in the negative direction. While movement of the magnetometer further to the left would theoretically reverse the vertical component 34, it has been shown by experimentation that deviation beyond a certain point, approximately 25 cm, from the magnets used in the present invention will result in a fall-off to the point there will be no signal received much beyond that point. Of course it is understood that stronger or larger magnets could increase this 25 cm distance.
In like manner, the horizontal component 36, goes from a positive indication on the left side of the magnet to a negative indication on the right side of the magnet.
The purpose of this discussion is to show that the positioning of the two magnetometers 24 and 26 at right angles to one another and generally coincident with each other will result in intelligence to indicate which side of the magnetic marker 14 the magnetometers (and of course the vehicle) are on no matter whether the north pole of the magnet is up as shown in FIG. 3A, or whether the south pole is up as shown in FIG. 3B. An examination of FIGS. 3A and 3B will show that if the magnetometers, oriented as they are shown in FIGS. 3A and 3B, are to the left of the center line of the path of the embedded magnets 14 whether or not the north or south pole is oriented upwardly will result in polarity indications from the magnetometers of the same sign. In FIG. 3A wherein the north pole is up, the polarity indications would be positive or northward with the magnetometers to the left of the center line and in opposite directions, that is the vertical polarity will be positive and the horizontal polarity will be negative when the magnetometers are to the right of the center line. In a similar fashion the polarity indications of the magnetometers would be negative for the vertical component in FIG. 3B when the magnetometers are to the left, just as the horizontal polarity indication would be negative to the left of the center line of the magnets. When the magnetometers are moved to the right, the polarities are different, that is the horizontal polarity is positive and the vertical polarity is negative. This factor will be taken into account to determine the deviation to the right or the left of the line of magnets 14 in the path roadway 12.
Referring now to FIG. 2, the signals from the sensors or probes 24 and 26 (which are represented in FIG. 2 as a single sensor 22) are then filtered in a low pass filter 38. The purpose of the low pass filter 38 is to filter out noise in the form of high frequency magnetic fields generated by the various electrical and mechanical components of vehicle 10.
The resulting signal emanating from filter 38 is passed on to an analogue-to-digital converter 40 so that a digital signal may be passed to computer 42 for information processing. Computer 42 compares the horizontal and vertical components of the signals received as a vehicle passes over the embedded magnets 14 to determine first, whether the vehicle is to the right or the left of the center lines of the magnets 14 and second, to enter into a "table look-up" of the two field strengths to determine how far from the center line of the path the vehicle may be. Since the horizontal and vertical field strengths of the embedded magnets are relative, the underlying strength of the earth field must also be known. As will be shown, the earth's field is likewise determined when the probes are generally midway between two embedded magnets. In addition, the polar orientation of several contiguous magnets may be used to provide roadside geometry.
Referring to FIG. 4, one can see the results of test data obtained from the measurement of the field strength of a series of magnets 14 placed in a pathway.
It is emphasized again that coil type sensors, which have been used in other magnetic sensing devices loose their capability as a vehicle speed approaches zero simply because such loop sensors must be moving through the magnetic field in order to determine the field strength. Magnetometer-type sensors, which are utilized herein, will operate at a stopped condition and thus are much more appropriate for the present embodiment.
Magnetometers which are appropriate for this invention are available from Macyntyre Electronic Design Associates at 11260 Roger Bacon Drive in Reston, Va. In like manner, the embedded magnets utilized herein are ceramic magnetic bars having a diameter of 2.5 cm and 10 cm long. In fact, four cylindrical magnets 2 1/5 cm in diameter and 2 1/2 cm long are stacked one upon the other and placed in a bored hole in the pavement. The sensor, with the probes 24 and 26 is positioned on the vehicle somewhere between 10 and 20 cm above the pavement with preferred distance being approximately 15 cm.
It would be assumed that the vertical movement of the car due to the springing and the like would cause wide variations in field strength. It has been found however that the problem of vertical displacement sensitivity can be overcome following the reasoning set forth below.
If the lateral position from the center is denoted as Y then using the magnetic field or M-field, measurements can be accomplished by using the relationship between the vehicle's deviation and the magnetic field strength B as defined as
y=F(B) (1).
Efforts have been conducted to mathematically describe the M-field using the theory of magnetic fields. Several models have been developed. The simplest approach is to refer to a magnetic marker as a magnetic dipole, then the M-field B at an observation point P(x, y, z) is where ##EQU1## μ is the permeability of free space M is the magnetic moment
Equation (2) represents the M-field by its three components, B x , B y , B z , therefore, the Equation can be expressed as
B=(B.sub.x, B.sub.y, B.sub.z) (3)
where B x and B y are in the road surface and oriented tangent to and normal to the road center line respectively, while B z is perpendicular to the road surface. Analysis is focused on the M-field at x=0, where only two nonzero components exist, defined as the horizontal component B h (y,z)=B y (0,y,z) and vertical component B v (y,z)=B z (0,y,z), Let s=B| x=0 , then the M-field strength at x=0 is
s=(B.sub.h (y,z),B.sub.v (y,z)) (4)
and expression (1) can be rewritten as
y=f(s) (5)
FIG. 3 gives both the test data and the analytical predictions of the magnetic field components. It was found that the analysis result has slight deviations from the test data. These deviations would cause errors if the vehicle position processing were dependent on equation (2).
In order to derive (5), the properties of an input-output relationship of the function f were analyzed. Let S be a signal set, S={2 i |s=(B h (y,z), B v (y,z))}, and U be a deviation set, Y={y|(-y max <y<y max )}. The function f can be interpreted as a rule which specifies a deviation y for each signal element s, that is, f maps s ε S to a corresponding deviation y ε Y, written as
f:S→Y (6)
The mapping relationship given in section (6) implies that any signal measurement s must have a unique deviation value y ε Y. A sensor that is located in the M-field, when x=0 and y=y i , will acquire only one signal measurement s i =f(y i ) (s i ε S). However, the signal s i may not be unique because of variations in the vertical displacement of the vehicle, which cause the sensor height to change. These variations s are bounded because of the limits of the vehicle suspension travel, therefore the signal s is within a certain range. If a signal subset S i S could be defined, which includes all the possible signal measurements s i ε S i , then a map f i could be given as
f.sub.i : if s.sub.i εS.sub.i then y=y.sub.i
The function f i denotes the transformation from s i to y i . If the vehicle deviation value is digitized and y={y 1 , y 2 , . . . Y n | Y 1 =y max . y n =y max }, function f can be specified by a set of rules f=(f i ). Clearly, this approach provides an alternative algorithm for solving the problem by defining the signal subsets S i .
The signal subset S i can be specified by defining the domain of the subset. Suppose that a plane specified by B h (y i , Z) and B v (y i , z) exists, then all the signal measurements s i will constitute a curve on the plane when the height of the sensor varies from 8 cm to 20 cm (the allowable vertical displacement). This curve is called the s curve and is given by
B.sub.v (y.sub.i, z)=g(B.sub.h (y.sub.i, z)
An optimal fit of the s curve can be found by a regression of samples of the measurements which gives
B=g'(a.sub.1, a.sub.2, , ,a.sub.k ;B.sub.h)
Conveniently, the s curve has very good linearity (FIG. 4 gives several s curves in the B h -B v plane). Thus, S i can be defined as:
S.sub.i ={s.sub.i | s.sub.i is defined by B.sub.v (y.sub.1, z)=a.sub.1 ·B.sub.h (y.sub.i, z)+b.sub.i }
where a i and b i can be calculated directly from the empirical data by regression.
After obtaining the signal subsets, a set of rules {f i }, which cover the complete sensing range, can be defined. The rule f i is rewritten as
f.sub.i : when B.sub.h =B.sub.hi, if B.sub.vi+1 <B.sub.v <B.sub.vi then y.sub.i+1 <y.sub.i (i=,2,. . .n)
By applying these rules, an algorithm can be constructed which finds each acquired signal s i its belonging subset S i , and then transforms it to a lateral deviation value. For instance, when s q =(B hg ,B vg ) is acquired, based on B hg , the algorithm calculates B v (5 cm, z) <B vg <B v (6.3 cm,z) is reached. This indicates that the vehicle's deviation is in a range between 5 cm and 6.3 cm as shown by the letter q in FIG. 4.
FIGS. 5A through 5C are a flow chart of a representative computer program that may be used in computer 42 to receive and process the signals from the analog-to-digital converter 40 and then pass on the information to the steering control unit 44 or for display on a visual display tube 43 for human intervention. Switch 45, shown in FIG. 2 is operative to actuate automatic steering by the steering actuator 44 or to permit human steering based on the visual display.
Program 46 starts with an initializing operation 48 which can include ordinary housekeeping functions of any micro-computer-type operation including an automatic execution of the impending program.
Once the program is in operation, then based on command from the computer the magnetometers 24 and 26 each read the magnetic field Bh and Bv that is the horizontal and vertical components first of the earth's field as indicated in decision block 50. The purpose of establishing the earth field is so that the background information caused by the earth's magnetic field is known before the variations or more properly anomalies in the earth's field caused by passing over the magnets 14 can be determined. The earth field is determined by noting over a period of time, i.e., clock cycles, that the horizontal and vertical components have remained unchanged. Once this occurs then the earth value is recorded as indicated at block 52 and a flag set to indicate that the earth value has been established. Since the field strength of the embedded magnets effectively drops to zero 25 cm from the magnet, a separation of 1 meter between embedded magnets 14 gives more than adequate time to establish the earth field. If, on the other hand, at decision block 50 there are variations between two consecutive horizontal and vertical components then one jumps to decision block 54 to record the peak value of that variation, which variation then becomes the field strengths used to determine deviation.
Referring back to FIG. 3A, one should envision travelling into the paper thus the z component of the magnetic field comes into effect. As one approaches the axis of the magnet, the vertical component 28 will rise in the same manner as shown in FIG. 3A. Thus, the three dimensional relationship of the magnetic field is in effect symmetrical. Once the peak value is reached, it is apparent that the vehicle and its associated sensing unit is at its closest point of approach to an individual magnet 14, which in this instance would be on a line normal to the axis of magnet 14 or immediately above magnet 14. This peak value, if an earth field has been determined, will be recorded and as indicated in operation block 56, along with the time taken from the computer clock. Simultaneously a peak flag is set to one and the polarity of both the horizontal and vertical magnetometers are recorded to determine the direction, right or left of center line, the binary value of the magnet (as previously explained) with reference to FIGS. 3A and 3B. Following the determination of the polarity of the embedded magnet, the relative values of the field strength are then compared to a table look-up based on the material included in FIG. 4. Once this is determined, the amount of deviation right or left of the center line is determined. Reference is made to the section above describing FIG. 4 wherein the location q is found to be between 5 and 6.3 cm from the center line of the desired path.
Passing on to FIG. 5B, the drive speed V may be determined by comparing the times between the recording the peak values as previously noted. It has been found in practice that three to four magnets should be passed in determining the speed due to variations in placement of the magnets.
The next step is to determine if the binary information encoded in the serially embedded magnets is complete as indicated in decision block 58. This can be accomplished in one of several manners. A predetermined word length can be utilized so that passage of eight or sixteen or thirty-two magnets would indicate a word which may take on a certain function or, alternatively, a coded character set can be developed so that distance to a turn will be represented in one manner and the length of the turn in a second manner. This type of information is described as road geometry information and may be required for example, to preview curves.
In this embodiment, road curves are represented with several parameters. A circular curve, is represented by its radius of curvature while a spiral curve, which usually leads into a circular curve, can be specified by a transition parameter which gives the relationship between the radius of curvature and the distance in the spiral section. Several parameters such as the length, direction and elevation of curvature are generally applied to all types of horizontal curves.
The amount of information to be provided to a sensing system such as described herein depends on the required precision of information. For example, eight bits of information can represent a 1275 meter radius with a precision of five meters while it may represent a 255 meter radius with one meter precision. In a system such as envisioned herein, it is appropriate to not only use a conventional header code to indicate the type of information that is forthcoming but also error detection and correction codes. Such codes are relatively well-known in the art having been first defined by R. W. Hamming and as a consequence taking on the term Hamming codes. Most commonly known are the parity bits utilized in information transfer in practically every computer manufactured today. As is also well-known in the computer science field, additional check bits can be added to the coding structure to correct up to a certain of number errors. Suffice it to say that in this application error correcting can be accomplished in two manners. First, additional bits can be added to the word for detection and correction of errors in the manner of Hamming and secondly, redundancy can be built-in into the system. By redundancy it is meant that the road geometry information can be repeated two or three times. Thus, as a vehicle approaches a turn the road geometry information including the radius, the direction of the turn, and the length of the turn will be provided to the vehicle for example, three times. Should there be inconsistencies between all three receptions, a warning signal can be transmitted to the vehicle operator or the vehicle slowed and ultimately halted. On the other hand, if a match occurs, control of the vehicle may continue to take place. Again it is pointed out that the magnets are placed with the north or south pole up depending upon representation of either a binary one or a binary zero. The information is then passed in serial fashion to the on-board computer for the decoding as indicated in FIG. 5B, block 60.
Subsequent to decoding, the decoded information may be displayed to the operator on a video display terminal 43 mounted in the vehicle. In addition to road geometry, such information as speed limit, stop lights or the like and other road information may be provided for appropriate control of the vehicle.
Once the information is decoded and checked, the binary information register should be zeroed (operation block 62) while the decoded information is passed on to the operating section of the computer to develop steering corrections and subsequently execute the steering commands (operation blocks 64 and 66). Finally, the flags are reset to zero and the program returned to read the next magnetic field from the next subsequent magnet.
It has been found that a spacing of one meter between the magnets in the road is sufficient to provide information for operating speeds up to 100k. For example, a curve having a radius of 1097 meters and the length of 709 meters requires less than 50 bits of binary code if the desired precisions for radius and length are one meter. Eleven bits are used for representing radius, ten bits are used for representing the length and twenty-five bits are applied to headers in correction codes. Thus, in a space of less than fifty meters one can transmit the road information to the on-board computer. Further, it has been found that with a system utilizing a twenty megahertz clock there will be ample time for processing the information set forth above. Specifically, at 80k per hour the vehicle will pass slightly more than twenty-two markers per second. With the twenty megahertz clock there will be about 900,000 clock cycles per marker. In a standard microprocessor the average instruction takes between ten and twelve clock cycles to execute. Thus there is adequate time to process a large number of instructions between each marker without overpowering the system.
OPERATION OF THE PREFERRED EMBODIMENT
It should be apparent to those skilled in the art how this system operates however, for clarity the following points are made.
The system is envisioned for being used with a vehicle 10 being equipped with the sensor 22. Vehicle 10 passes over a series of magnetic markers 14 embedded in the roadway. The magnetic markers 14 are oriented so that coded information can be passed to the on-board computer system using the principals set forth above. Specifically, if the magnet is oriented with the north pole facing upwardly then it represents a binary 1 while if it is placed with the south pole facing upwardly it represents a binary 0.
As a vehicle passes down the roadway or pathway, the sensor 22 records first the earth field, which can include magnetic influence from the vehicle, and then records the anomaly to the earth field caused by each individual embedded magnet 14. Both the vertical and horizontal field strength is recorded so that subsequent operations in the on-board computer 42 can determine the deviation right or left from the center line of the roadway. Concurrently, information is decoded based on the binary information in the embedded magnetic markers for the control and guidance of the vehicle. Computer generated steering commands based on deviation and on road geometry are used to guide the vehicle along the desired marked path.
Variations in the pathway can be accomplished simply by removing a series of magnetic markers and relocating the pathway to a different route. In like manner, lane information can be embedded into the roadway so that a vehicle is apprised of which lane in a multi-laned roadway it is operating in. This facilitates positioning the vehicle for an upcoming exit. For example, if the vehicle were operating in the center lane and there was a required right lane exit in a three-laned road, the vehicle could be easily moved rightwardly to exit at the appropriate exit point. The invention is considered particularly useful and appropriate where lane marker or roadway boundaries are covered by rain or snow.
While this invention has been described in relation to a particular embodiment, it is not to be so considered, rather it is to be limited only by the following claims. | An intelligent vehicle highway system requires a multi-functional roadway reference system to help the vehicle locate its lateral and longitudinal position along a highway. This information at a minimum is required to control the vehicle. The present invention consists of a roadway reference system in which discrete markers installed in the center of a traffic lane code one or more bits of information. An on-board sensing system acquires the information when the vehicle passes over the reference markers and thereby determines vehicle deviation and upcoming road geometry. Other coded information may be provided through the passive discrete markers to include such items as geographical position, warning of future conditions and the like. | 6 |
RELATED APPLICATIONS
This is a Continuation-In-Part of Application 07/531,981, filed Jun. 1, 1990 now U.S. Pat. No. 5,179,076.
FIELD OF THE INVENTION
This invention pertains to water-based drilling fluids that retain rheological stability over a range of temperatures from ambient to in excess of 475° F.
DESCRIPTION OF THE RELATED ART
It is well known in the art that drilling fluids must be used in connection with the drilling of wells, such as those in the oil and gas industry. Such fluids, or "muds," serve several functions in the drilling process. These functions include: removal of drilled cuttings, suspension of high specific gravity weight material and fine cuttings, sealing of the sides of the wellbore so as to minimize drilling fluid loss into the formation, provision of a hydrostatic head to prevent blowouts from high pressure fluids into the wellbore or up through the wellbore to the surface, creation of a low-friction surface on the wellbore to facilitate rotation and removal of the drill string as operational conditions require, cooling of the drill bit and lubrication to prevent the drill pipe from sticking during rotation.
Drilling muds are typically colloidal suspensions of certain viscosifiers and filtration control materials, such as clays, as well as of fine drilled solids, in either oil or water. Typical clay concentrations in drilling muds range from about 10 to about 50 lb/bbl. Various chemicals are added to alter, enhance, influence or modify the properties of the suspension, as is well known in the art. For example, a weighting agent, such as barium sulfate, or "barite," is added to increase the density of the mud. Viscosifiers are used to increase viscosity and gel strength. Deflocculants, such as lignosulfonates, prevent the clay particles from forming, which flocs contribute to an increase in viscosity. Filtration control materials, such as soluble polymers or starch, are added to encourage the development of the filter cake on the sides of the wellbore so that a minimal amount of the drilling fluid will enter a permeable formation.
The search for oil and gas has led to the drilling of deeper wells in recent years. Because of the temperature gradient in the earth's crust, deeper wells have higher bottomhole temperatures. As is well known in the art and confirmed by Remont et al., there is a need for a drilling fluid which retains rheological stability throughout a broad temperature range for efficient drilling of these deeper wells. Additionally, as is known in the art, formations which have relatively high pore pressures require corresponding denser drilling fluids to provide a hydrostatic head to prevent blowouts from high pressure fluids into the wellbore or up through the wellbore to the surface.
Because of their better thermal stability as compared to water-based fluids, oil-based fluids typically have been used in high temperature applications. However, as the environmental impact of the disposal of these spent slurries, and the drilled cuttings carried in these slurries, has become increasingly scrutinized, water-based fluids have become more and more the fluid of choice in the industry. Water-based fluids are also preferable in high pressure applications, such as deep wells, because oil-based fluids are more compressible than water-based fluids. This increased compressibility results in increased viscosity. A third advantage for water-based drilling fluids considers safety in well-control situations. Since gas is much more soluble in oil, an unanticipated influx of gas into the well cannot be detected as well at the surface in oil based drilling fluids until it is near the surface and very dangerous. On the other hand, with water-based drilling fluids, since gas is only sparingly soluble, such an influx can be detected more easily, the well shut-in, and the influx more safely handled at the surface.
For a mud to work well in high temperature bottomhole conditions, it must be rheologically stable over the entire range of temperatures to which it will be exposed. This range is generally from the flowline temperature which is 0° to 90° F. above ambient temperature to bottomhole temperature. For high temperature fluids, the flowline temperature is at the upper limit. The rheological stability of a mud is monitored by measuring its yield point and gel strengths, in accordance with standard drilling fluid tests, before and after circulation down the wellbore. These standard tests, which include the tests for yield point and gel strengths, are well known in the industry and are described in "Recommended Practice Standard Procedure for Field Testing Water-Based Drilling Fluids," Recommended Practice 13B-1 (1st ed. Jun. 1, 1990), American Petroleum Institute (hereinafter referred to as "RP 13B-1").
The major operational difficulty presented by a typical water-based mud at higher temperatures is that at such temperatures it degrades and becomes too viscous to be circulated easily. This circulation difficulty arises because the clays used in the muds are susceptible to temperature-induced gellation at temperatures as low as about 250° F. The circulation problems caused by the increased viscosity of the muds at higher temperatures are exacerbated during those time periods when drilling and circulation must be discontinued.
The prior art has several partial solutions to this high temperature difficulty, none of which is completely satisfactory. These solutions include: excessive dilution and dumping of spent fluids, addition of rheology-modifying chemicals, use of polymers instead of clay as viscosifiers, and use of foam drilling fluid. Dilution and dumping is not acceptable because it is expensive, requiring rebuilding of substantial fractions of the fluid system, and resulting in potentially large disposal costs. Addition of rheology-modifying chemicals only marginally elevates the temperature at which gellation initiates. Polymers used as viscosifiers are not acceptable in applications above approximately 250° F. to 300° F. due to the extreme degradation of the polymers, resulting in substantial loss of viscosity. Finally, water soluble foams are sometimes used for high temperature applications, but due to their low density they are ineffective for weighting or sealing and thus are not practical for use in situations where there is a large amount of water intrusion. They also have poor lubricating qualities and tend to be corrosive.
Recently, U. S. Pat. No. 4,629,575 to Weibel, which patent is incorporated herein by reference, has disclosed that parenchymal cell cellulose ("PCC") can be beneficially used in high temperature drilling fluids as a viscosifier; however, Weibel teaches that, due to thermal degradation, PCC is not effective as the sole viscosifier of a drilling fluid in high temperature applications above about 350° F. Therefore, there remains a need for a drilling fluid which remains rheologically stable through a wide temperature range, from ambient temperature to above about 475° F.
SUMMARY OF THE INVENTION
This invention relates to water-based drilling fluids which display rheological stability throughout a wide temperature range. This continuation-in-part of U.S. Pat. No. 07/531,981 focuses on the use of sulfate salts, as well as lower chlorides, the use of calcium chloride as the source for the chloride anion, and high density applications. For the purpose of this invention, "high-density" is deemed to be greater than about 16.0 lbs/gal. Although throughout this disclosure the phrase "the mud of this invention," or similar phrases, are used, it is to be understood that this invention encompasses a broad range of muds. Such phrases indicate a drilling fluid prepared in accordance with the methods taught herein. "Rheological stability" means that the effective viscosity at annular shear rate of the mud remains within an effective, relatively narrow range, between about 25 cp. and about 150 cp., but preferably between about 50 cp. and about 100 cp., over a broad temperature range, from the circulating flowline temperature to at least 475° F. This rheological stability enables the fluid to carry drilled cuttings efficiently at ambient temperatures. It also provides a sufficiently fluid viscosity at higher (bottomhole) temperatures to provide ease of circulation downhole. This invention also teaches the method for preparing and mixing the critical components of such a fluid, and a method for this fluid's use as a drilling mud.
The preferred drilling fluid comprises three components: clay, inorganic salt such as a chloride salt or a sulfate salt (or other such inorganic salts as are known in the art), and PCC. PCC was discussed above. The three components are preferably pretreated and then combined in proportions which result in a high density drilling fluid having the following characteristics: a yield point of about 10 lb/100ft 2 to about 30 lb/100ft 2 ; gel strengths of about 3 lb/100ft 2 to about 10 lb/100ft 2 for the 10-second measurement, about 15 lb/100ft 2 to about 30 lb/100ft 2 for the 10-minute measurement, and about 20 lb/100ft 2 to about 50 lb/100ft 2 for the 30-minute measurement; a high-temperature high-pressure (HTHP) filtration rate of less than about 50 cc/30 min. at 500 psi and 300° F.; and a pH between about 9.0 and about 11.5. These yield point, gel strength, HTHP filtration rate, and pH specifications set forth above relate to measurements made using standard tests for drilling fluids. Such standard tests are set forth in RP 13B-1. The respective characteristics for sulfate salt drilling fluids, as well as low chlorides and for calcium chlorides yield point of about 10 to about 25 lb/100 ft. 2 , and gel strengths of 3 to 10, 10 to 30 and 20 to 35 lb/100 ft. 2 for the 10-second, 10-minute and 30-minute readings, respectively.
Applicant's laboratory tests have shown that muds having the above characteristics generally comprise: about 2 to about 15 lb/bbl clay; about 2,000 to about 125,000 parts chloride, or a corresponding amount of the other anionic salt species such as sulfate, per million parts fluid; and about 1 to about 8 lb/bbl PCC.
The economic impact of this invention is most directly realized by the reduced circulating and conditioning times, hence shortened drilling times, realized because of the ease of circulating the drilling fluid at elevated temperatures. Further, use of the drilling fluid of this invention results in reduced dilution, dumping and makeup. This reduced dilution, dumping and makeup results in savings not only in the purchase of components for this fluid, but also in the cost of disposal of the spent fluid. This reduced disposal volume makes this fluid not only economically but also environmentally attractive. Another significant benefit of the mud of this invention is that its preparation is simpler than the preparation of a typical mud of the prior art. Additionally, the toxicity of the spent fluid is lower than that of those fluids typically used in high temperature applications, especially oil-based fluids. Furthermore, the mud of this invention typically lays down a filter cake one-half to one-third as thick as the filter cakes typically laid down by the muds of the prior art, minimizing the potential for the drill pipe to become stuck. Finally, the mud of this invention is a mud with reduced potential for temperature-induced carbonate gellation.
These and other benefits of this invention will be apparent in reviewing this disclosure, the descriptions of the various embodiments of this invention, and the claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
All Five FIGURES herein are plots showing the viscosities in centipoise of the various fluids in the Examples as functions of temperature in degrees Farenheit.
FIGS. 1A and 1B summarize the fluids 1A and 1B, respectively, of Example 1. FIG. 2 summarizes the fluid of Example 2. FIGS. 3A and 3B summarize the fluids 3A and 3B, respectively, of Example 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
For years there has been a need for a water-based, rheologically stable drilling fluid for high temperature applications. Applicant's invention is a water-based slurry comprising three essential components, resulting in a drilling fluid having rheological stability. This broad temperature stability is created from the synergistic combination of the three components, and makes it unnecessary to add significant amounts of other rheology-modifying additives, except in the high-density version of this invention where rheology modifying additives are needed to work on the extremely high concentration of weighting material. However, deflocculants and other additives typically used in drilling muds can be beneficially added where needed, using techniques commonly known in the art. This invention is directed to adjusting and stabilizing the rheology and filtration of the drillingfluid with respect to temperature.
The three essential components are:
1. Good quality clay, such as bentonite, or any other clays as are used in the art, at about 2 to about 15 lb/bbl. The specifications for bentonite as used in drilling fluids are set forth in "Specification for Oil-Well Drilling-Fluid Materials," API Specification 13A (12th ed. October, 1988), American Petroleum Institute (hereinafter referred to as "Spec 13A"). Spec 13A sets forth specifications for both bentonite and nontreated bentonite. Either of these, as well as other clays as are used in the art, can be used in the mud of this invention. In the preferred embodiment, nontreated bentonite should be used in a concentration of 5 to 10 lb/bbl. This nontreated bentonite should be prehydrated in fresh water, in a concentration of 20 to 25 lb/bbl, preferably with no additives, for a minimum of four hours. Prehydration can also be accomplished outside of this concentration range or in a different amount of time.
2. A PCC viscosifier at about 1 to about 8 lb/bbl. In the preferred embodiment, presheared PCC should be used in a concentration of 1 to 3 lb/bbl. Preshearing of the PCC is best accomplished in the laboratory by mixing 20 lb/bbl of PCC with fresh water or sea water, then using a laboratory grade blender at high speed for 15 to 30 minutes until the yield point of the slurry is at least about 70 lb/100ft 2 . For applications in the field, PCC is best presheared by mixing 20 lb/bbl PCC with fresh water or sea water, then circulating this slurry through a colloid mill or a modified homogenizer pump for a minimum of two hours, until the yield point of the slurry is at least about 70 lb/100ft 2 , as measured by the yield point test of RP 13B-1. A small version of the modified homogenizer pump can also be used for preparation in the laboratory. Preshearing can also be accomplished outside of this concentration range in a different amount of time, to a lower yield point or with different equipment; the method described above is the preferred embodiment.
3. An inorganic salt, such as a sulfate salt or a chloride salt or other such salts or any combination thereof, at about 2,000 to 125,000 parts chloride, or a corresponding amount of other anionic salt species per million parts of fluid. In the preferred embodiment, a chloride salt essentially comprising sodium chloride is used and the range is 10,000 to 30,000 parts of chloride per million parts of fluid. Extensive testing of chlorides has been performed and set forth in the parent application. These test have confirmed the applicable ranges of chloride concentration for typical-density (up to about 15 pounds per gallon) drilling fluids. Additional testing since filing of the parent application has allowed a broadening of the chloride range from 5,000 to 110,000 ppm to 2,000 to 125,000 ppm.
The corresponding ranges for sulfates can be calculated by one skilled in the art using DLVO theory, which relates the "thickness" of the double layer to the ionic strength, I, of the medium. To a first approximation, colloidal materials (that is, drilling fluids) will exhibit similar behavior in aqueous media that have similar ionic strength. Ionic strength is calculated by means of a sum:
I=1/2 Σm.sub.i ×Z.sub.i 2, where m is molality (moles/kg water) and Z is ionic charge
Therefore, 2,000 ppm of chloride corresponds to an ionic strength of about 0.056m. This translates to about 1,800 ppm of sulfate anion. Similarly, 125,000 ppm of chloride (ionic strength of about 4.29m) translates to about 114,500 ppm sulfate anion. For the narrower limits, 10,000 ppm of chloride is equivalent to about 9,150 ppm sulfate (ionic strength of 0.29m), and 30,000 ppm of chloride is equivalent to about 28,300 ppm of sulfate (ionic strength of 0.85m). An Example showing a drilling fluid with 27,500 ppm of sulfate is given. (Example 2) As is known in the art, the appropriate concentrations of other anions may be calculated using the DLVO theory.
The concentration of each component is customized to the particular application as a function of the drilling fluid density and the bottomhole temperature. Once the bottomhole temperature is known, the necessary density is determined, and a base mud is built using techniques commonly known in the art. This base mud is then customized using the following guidelines:
1. The yield point of the fluid is raised to between about 10 lb/100ft 2 and about 25 (30 for high-density) lbs/100ft 2 , using the standard yield point test of RP 13B-1. In the preferred embodiment, this range is between 15 lbs/100ft 2 and 20 lbs/100ft 2 . Achieving this yield point is accomplished by the addition of clay (preferably prehydrated) as long as the clay concentration is less than 10 lbs/bbl and the gel strengths are within the prescribed range set forth herein. If the clay concentration is greater than about 10 lbs/bbl or the gel strengths are at the maximum of the prescribed range, PCC (preferably presheared), and not clay, is added to raise the yield point.
2. The 10-second, 10-minute and 30-minute gel strengths are measured and adjusted to between about 3 lbs/100 ft 2 and about 10 (15 for high-density) lbs/100ft 2 , between about 10 lbs/100ft 2 and about 30 lbs/100ft 2 , and between about 20 lbs/100ft 2 and about 35 (50 for high-density lbs/100ft 2 , respectively. In the preferred embodiment, these ranges are 4 lbs/100ft 2 to 8 (10 for high-density) lbs/100 ft 2 , 15 lbs/100 ft 2 to 25 lbs/100 ft 2 , and 20 lbs/100ft 2 to 30 lbs/100ft 2 , respectively. This adjustment of gel strength is accomplished by the addition of clay, preferably prehydrated clay. The gel strengths are measured in accordance with the standard test set forth in RP 13B-1. As a practical matter, bringing the 10-second gel strength within range will generally result in acceptable 10-minute and 30-minute gel strengths with the mud of this invention. Therefore, it is usually sufficient to measure and adjust only the 10-second gel strength.
3. The filtration rate is adjusted so that the HTHP filtration test yields a value of less than 50 cc/30 min. at 500 psi and 300° F. In the preferred embodiment, the HTHP filtration rate should be lowered to less than 20 (30 for high-density) cc/30 min. at 500 psi and 300° F. This adjustment is accomplished by addition of clay, preferably prehydrated clay, if clay content is low (less than about 4 lbs/bbl), or with a temperature stable filtration polymer, such as Therma-Chek, Hostadrill, KemSeal, or other similar materials, otherwise. The HTHP filtration rate is measured via the standard test set forth in RP 13B-1.
4. The pH is adjusted to between about 9.0 and about 11.5. In the preferred embodiment, this range is generally 10.0 to 11.0. This adjustment is accomplished by the addition of alkalinity control materials such as caustic soda or soda ash or other similar materials as are well known in the art. The pH is measured via the standard test set forth in RP 13B-1.
5. The concentration of the anionic salt species is adjusted to between about 2,000 and about 125,000 parts of the chloride per million parts of the fluid, or the corresponding amount of other anion as calculated by the DLVO theory. In the preferred embodiment, this range is between 10,000 and 30,000 parts of chloride per million parts of the fluid, where the chloride originates from a chloride salt substantially comprising sodium chloride or from sea water or other brine. This adjustment of the salt concentration is accomplished by addition of an inorganic salt, such as sodium chloride or potassium chloride or sodium sulfate or calcium chloride or such other soluble inorganic salts, alone or in combination, as are commonly known in the art. The adjustment can also be accomplished by using sea water or other brine as the base fluid. Where chlorides are used, concentration of the chloride is measured via the standard test set forth in RP 13B-1. Where other inorganic salts are used, concentration of the anionic salt species is determined by use of Merck test strips, a testing method which is well known in the art, or any other analytical method for determination of concentration of anionic salt species.
These guidelines may be performed in any order, and the adjustment of any one of these critical properties as described above will not materially affect any of the other critical properties. For example, once the HTHP filtration rate is within range, adjustment of any or all of the other properties in accordance with these guidelines will not place the HTHP filtration rate substantially out of range. This is also true with the yield point, gel strengths, pH, and anionic salt species concentration. In fact, it is a significant benefit of this invention that the adjustment of filtration control, which filtration control is necessary to seal the wellbore and thus minimize fluid loss, is independent of the adjustment of the rheology of the mud of this invention. This benefit substantially simplifies the building of this mud over the building of the muds of the prior art.
As a general matter, as the bottomhole temperature increases, the circulating fluid will require the addition of more filtration control product to maintain the desired HTHP filtration rate. Further, as the density and the temperature of the fluid increase, less clay must be added to the circulating mud to maintain the yield point and/or gel strength within the desired range. Such increases in temperature and density also typically result in the fluid's requiring a different concentration of inorganic salt to maintain the synergistic effect of this invention.
Unlike the method of preparation of other fluids prepared in accordance with the prior art, no further guidelines are required for the preparation of the mud of this invention. Standard drilling fluid tests, such as Marsh funnel viscosity (FV), Bingham plastic viscosity (PV), room temperature filtration rate (API), filtrate alkalinity tests (Pm, Pf, Mf), and tests of the concentrations of calcium and carbonate, as are set forth in RP 13B-1, may also be performed; however, these measurements are not needed to control the performance of the mud of this invention.
As confirmed by the laboratory tests described in the Examples, clay (preferably prehydrated clay), inorganic salt, and PCC (preferably presheared PCC) must all be present to impart high temperature rheological stability. Fluids missing one or more of these three ingredients, or fluids containing all three ingredients but with one or more of these ingredients outside the prescribed ranges, generally do not exhibit the desirable rheological profile.
The benefit achieved from the addition of some level of salt as measured by chlorides and/or other anionic salt species is particularly surprising, as it has long been recognized in the blending of muds that salt intrusion tends to destabilize, rather than stabilize, mud rheology. The prior art frequently focuses on minimizing the concentration of salt in the mud. By sharp contrast, chloride salts and/or other anionic salt species are not only beneficial but also necessary for the stability of the mud of this invention.
It is believed that the key to improved temperature stability lies in minimizing the effect of the temperature-induced dispersion of clay packets. High temperature clay dispersion is apparently reduced by reducing the concentration of clay and by deliberately introducing salinity in the form of inorganic salts, the introduction of salinity being contrary to the teaching of prior art. Additional viscosity and filtration control is provided by polymers using techniques well known to one versed in the prior art.
Maintaining the concentration of the clay within a low range (about 2 to about 15 lb/bbl, but in the preferred embodiment 5 to 10 lb/bbl) results in good carrying capacity and suspension under the typical bottomhole conditions. Maintaining a low clay concentration further results in a reduction in the tendency to induce carbonate gellation in the fluid. It is believed that dispersion resistance for both drilled solids and clay is attained by the presence of the salt species in the mud of this invention. Finally, surface rheology and stability is provided by clay (preferably prehydrated) and PCC (preferably presheared), while filtration is controlled by high-temperature filtration polymers interacting with the clay.
Further testing since the filing of the parent application has taught that the salinity levels for high-density drilling fluids can be somewhat lower without a loss of rheological stability. For the purpose of this discussion, a drilling fluid will be considered to be high-density where it is denser than about 16.0 pounds per gallon. Examples are presented suggesting that the lower end of the range should be about 2,000 ppm chloride (or about 1,800 ppm sulfate) in such high-density applications.
In such high density applications, the use of a temperature-stable deflocculant is necessary in the best mode of this invention, at a concentration of between about 0.5 lb/bbl and 5.0 lb/bbl, as is seen in the Examples.
EXAMPLES
The following materials were employed in preparing the fluids discussed in the Examples:
Prehydrated Clay: Aquagel Gold Seal, a nontreated bentonite clay manufactured according to Spec 13A, manufactured by Baroid Drilling Fluids, Inc., prehydrated using the technique specified above.
Presheared PCC: HP-007, manufactured by Aqualon Company, presheared using the technique described above.
Drilled Solids: Rev-Dust, manufactured by Milwhite Co.
Deflocculants: Miltemp, manufactured by Milpark Drilling Fluids; or Therma-Thin, manufactured by Baroid Drilling Fluids, Inc.
Filtration Control Materials: Therma-Chek, sold by Baroid Drilling Fluids, Inc.; Filtrex or Pyrotrol, both manufactured by Milpark Drilling Fluids; Driscal D, sold by Drilling Specialties Company; low viscosity polyanionic cellulose (Pac-L), sold by Baroid; or Dextrid, premium stabilized non-fermentable starch, sold by Baroid.
Inorganic Salt: Industrial grade sack salt comprising substantially sodium chloride, or Sea-Salt, manufactured by Lake Chemical Company, or sodium sulfate or calcium chloride industrial grade (anhydrite or dihydrate).
Barite: A commercial API specification grade of barium sulfate, meeting the specifications of Spec 13A, used as a weighting agent in downhole fluids.
All other reagents, additives or chemicals are commercial grades obtained through retail chemical distributors.
Samples for the tests described in Examples 1 through 4 herein were prepared on a standard Hamilton Beach mixer as is typically used by persons practicing the art. Materials in the proportions set forth in the Examples were added to water in the following order: prehydrated clay, presheared PCC, inorganic salt, drilled solids, deflocculants, filtration control materials, caustic for pH adjustment, and barite in an amount sufficient to achieve the target fluid density. After each addition, the sample was stirred in the mixer for about 5 to 10 minutes or until well mixed. After all materials were added, the sample was then equilibrated by heating for about 16 hours at 150° F. in a roller oven, which oven is well known to practitioners of the art. After equilibration, the sample was stirred in the mixer for 10 to 30 minutes and the pH was readjusted with caustic addition as necessary. The sample was then aged for about 16 hours to between 375° F. and 400° F., as set forth in the pertinent Example, in a roller oven. The sample was stirred for 10 to 30 minutes in the mixer and the pH was again readjusted with caustic addition as necessary.
The following test was performed upon samples of the fluids in the Examples to obtain the rheological profiles: Using a Fann 50C Viscometer, a room temperature sample was inserted into the instrument and pressurized to 500 psi with nitrogen. The sample was sheared continuously at a shear rate of 102 sec -1 , corresponding to an instrument reading of 60 rpm. The temperature of the sample was increased at a rate of 2 F.°/minute from room temperature to 120° F. While the temperature of the sample was maintained at I20° F., measurements of plastic viscosity, yield point and gel strengths were taken in accordance with the procedures set forth in RP 13B-1. The temperature of the sample was then increased from 120° F. to a peak temperature of roughly 400° F, as further set forth in the Examples, at 2 F.°/minute. At this peak temperature, plastic viscosity, yield point and gel strengths were measured in accordance with RP 13B-1, while the temperature of the sample was maintained at the peak temperature. Finally, the sample was cooled from the peak temperature to 120° F. at 6 F.°/minute. At 120° F., the plastic viscosity, yield point and gel strengths were again determined in accordance with RP 13B-1 while the temperature of the sample was maintained at 120° F. While the sample was in the process of being heated or cooled, readings of shear stress as a function of temperature were taken at one minute intervals. Shear stress is converted to effective viscosity at 102 sec -1 by multiplying the output by 5.0. The heating curve was graphed as a series of closely spaced dots representing the data points; the cooling curve was graphed as a solid line connecting the data points collected during the cooling phase. These curves are the curves depicted throughout the FIGURES herein for each of the fluids tested.
Each of the remaining tests which were performed upon the samples of the drilling fluids discussed in the Examples were standard tests for drilling fluids, which tests are set forth in RP 13B-1.
EXAMPLE 1
One water-based field sample, Fluid 1A with elevated calcium and chloride levels, was taken and measured. This is a field sample which was being circulated (and therefore aged) near 300° F. Its composition and physical properties are set forth in Table 1. Although the rheological properties are stable, within the invention, the particular filtration materials either have not been optimized for calcium chloride brine, or are unstable near 300° F. FIG. 1A shows its rheological stability from 75° F. through 400° F., and confirms that it can tolerate calcium salts. Another water-based sample, Fluid 1B, is an example from laboratory tests using a calcium-tolerant filtration material such as Driscal D. This sample was aged overnight at 375° F. Its composition and physical properties are set forth in Table 1. This table demonstrates that, even in the presence of calcium as the cationic species, the fluid maintains both acceptable rheological and filtration control. FIG. 1B shows its rheological stability (after aging in the field at about 375° F.) from 75° F. through 400° F. FIG. 1B confirms that even with calcium as the cation the fluid maintains a similar rheological profile. Thus, this invention should include calcium chloride.
EXAMPLE 2
A field test was run using sodium sulfate as the inorganic salt in combination with the sodium chloride of the best mode. This sample, Fluid 2, came from a well being drilled at 21,850 ft., with a bottomhole temperature of about 390° F., which is equivalent to aging at 390° F. Table 2 sets forth pertinent lab data regarding the rheological and filtration characteristics of this sample, and FIG. 2 illustrates its rheological stability from about 75° F. to about 400° F.
EXAMPLE 3
Three high-density drilling fluids, 3A, 3B and 3C were prepared; their compositions and relevant properties are set forth in Table 3. FIGS. 3A and 3B present rheological stabilities for two of the fluids. All samples were aged at 400° F. before the measurements These fluids demonstrate that, in high-density applications, salinities as low as 2,000 ppm of chloride (or the equivalent) can be used without loss of rheological stability. Fluid 3C has less acceptable rheological properties than 3A and 3B, due to the lower deflocculant level and the particular filtration material that was selected. For that reason, no temperature profile was performed on Fluid 3C.
TABLE 1______________________________________Presence of Calcium Cation Sample A Sample B______________________________________Bentonite equivalent, lbs/bbl 10.5Presheared PCC, lb/bbl 3.0 2.5Drilled Solids, vol. % 5-6 5-6Deflocculant -- 0.40Miltemp, lb/bblFiltration Material, lb/bblTherma-Chek 1.0 2.0Driscal D -- 3.0Low viscosity PAC 2.0 --Dextrid 3.0 --Chloride, ppm 83,071 34,820Calcium, ppm 9,486 7,180Fluid Density, lb/gal 12.2 10.4pH 9.8 10.0Yield Point, (lbs/100 ft.sup.2) 13 28Gel Strengths, (lbs/100 ft.sup.2)10 seconds 8 2910 minutes 14 3530 minutes 22 44HTHP Filtration Rate 190 26@ 300° F. (cc/30 min.)______________________________________
TABLE 2______________________________________Presence of Sodium Sulfate______________________________________Bentonite equivalent (lbs/bbl) 9.5Presheared PCC, lb/bbl 2Drilled Solids, vol. % 5-6Deflocculant 0.30Miltemp, lb/bblFiltration Material 4.0Therma-Chek, lb/bblChloride (ppm) 12,000Sulfate (mg/L) 27,500Fluid Density, lb/gal 11.0pH 11.2Yield Point (lbs/100 ft.sup.2) 18Gel Strengths (lbs/100 ft.sup.2)10 seconds 810 minutes 1830 minutes 22HTHP Filtration Rate cc/30 min) 30.0(@ 300° F.)______________________________________
TABLE 3______________________________________Low Bentonite Concentration with High Density Fluids 3A 3B 3C______________________________________Prehydrated Aquagel, lb/bbl 5 5 5Presheared PCC (lb/bbl) 2 2 1Drilled Solids vol. % 5 5 3Deflocculant 3 3 2.5Therma-Thin lb/bblFiltration MaterialPyrotrol, bl/bbl 3 -- --Therma-Chek, lb/bbl -- 5 --Filtrex, lb/bbl -- -- 6.5Chloride, ppm 2057 2127 2623Fluid Density, lb/gal 17.9 17.9 18.2pH 11.06 11.03 11.1Yield Point, lb/100 ft.sup.2 15 28 8Gel Strengths, lb/100 ft.sup.210 Seconds 4 5 310 minutes 5 12 3930 minutes 9 24 52HTHP Filtration Rate, 44 47 48Rate, cc/30 min (@ 300° F.)______________________________________ | A water-based fluid for use in the drilling of wells is disclosed. This fluid: is rheologically stable over a wide temperature range, from room temperature to at least about 475° F., thus reducing drilling time in high temperature applications; typically necessitates minimal disposal rates in operation; is resistant to temperature-induced carbonate gellation; creates a thin filter cake; and combines the low toxicity of a water-based fluid with the performance stability of an oil-based fluid.
As further disclosed herein, this drilling fluid comprises a water-based colloidal suspension of certain readily available drilling fluid components, including clay, an inorganic salt, and parenchymal cell cellulose ("PCC"). | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a tangential indexable cutting insert for use in metal cutting processes in general and for radial and axial turning of a stepped square shoulder in particular.
BACKGROUND OF THE INVENTION
[0002] Tangential cutting inserts, also known as on-edge, or lay down, cutting inserts, are oriented in an insert holder in such a manner that during a cutting operation on a workpiece the cutting forces are directed along a major (thicker) dimension of the cutting insert. An advantage of such an arrangement being that the cutting insert can withstand greater cutting forces than when oriented in such a manner that the cutting forces are directed along a minor (thinner) dimension of the cutting insert. Another advantage of such an arrangement is that with the minor dimension directed perpendicular to the cutting forces it is possible to manoeuvre the cutting insert between obstacles close to the workpiece.
[0003] For turning a stepped square shoulder on a workpiece, a cutting tool assembly requires a cutting insert with an acute operative insert cutting corner, a tool back clearance angle along its inoperative cutting edge and an obtuse entering angle along its operative cutting edge. Such an entering angle enables an outwardly directed feed out movement to square out a shoulder, in particular, an outwardly directed radial feed out movement in the case of external axial turning operations and an outwardly directed axial feed out movement in the case of radial turning operations.
[0004] In view of these restrictions, cutting inserts for turning stepped square shoulders are usually either rhomboidal or triangular; thereby having respectively, two or three indexable insert cutting corners for single-sided cutting inserts. Such cutting inserts are, for example, as illustrated and described in U.S. Pat. No. 4,632,608, each insert cutting corner being formed as a protruding nose portion at the junction between centrally depressed insert sides. The cutting inserts are preferably double sided so as to be respectively formed with four or six indexable insert cutting corners.
[0005] With a view to increasing the number of cutting corners, a fully indexable non-tangential cutting insert is described in U.S. Pat. No. 6,074,137. The cutting insert comprises four substantially concave side edges extending between substantially square opposing upper and lower surfaces. Adjacent side edges meet at a cutting corner having an angle in the range of about 83°±5°. Although the cutting insert is substantially square and although it offers eight cutting corners, its depth of cut is limited. In fact, the maximal depth of cut is limited to less than the length of a side of an imaginary square, in which the insert is inscribed, in a top view of the insert. Furthermore, it is not a tangential cutting insert.
[0006] [0006]FIGS. 1 and 2, show a cutting tool 20 with a tangentially seated cutting insert 22 for both axial and radial turning operations, also known as longitudinal and face turning operations. The cutting insert 22 is oriented with relief angles γ 1 and γ 2 for radial and axial turning operations, respectively. The cutting insert 22 has one operative cutting corner 24 , a first trailing non-operative cutting corner 26 during axial turning operations and a second trailing non-operative cutting corner 28 during radial turning operations. Major and minor cutting edges 30 , 32 extend between the operative cutting corner 24 and non-operative cutting corners 28 , 26 .
[0007] [0007]FIG. 3 is an illustrative drawing showing the cutting tool 20 during either radial or axial turning operations of a workpiece 33 . Dashed lines 34 show an ideal square shoulder and the dash-dot line 35 is an imaginary extension of the worked face 36 of the workpiece 33 . As can be seen, for a radial turning operation, the second trailing non-operative cutting corner 28 and a portion of the major cutting edge 30 are oriented such that they “extend beyond” the imaginary extension 35 of the worked face 36 and would engage the workpiece 33 if an attempt were made to increase the depth of cut beyond a depth of cut, d, where the dashed line intersects the major cutting edge 30 . Thus, the depth of cut is limited during radial turning of a square shoulder. For axial turning in the configuration shown in FIG. 3, the depth of cut is also limited to d. Any increase in the depth of cut would lead to a non-square shoulder. Similarly, the insert could be configured with an orientation such that for an axial turning operation, the first trailing non-operative cutting corner 26 and a portion of the minor cutting edge 32 are disposed such that they have a limited depth of cut. Likewise, the insert could be configured with an orientation so that it has a limited depth of cut for both axial and radial turning operations due both to the first trailing non-operative cutting corner 26 and a portion of the minor cutting edge 32 and also to the second trailing non-operative cutting corner 28 and a portion of the major cutting edge 30 .
SUMMARY OF THE INVENTION
[0008] In accordance with the present invention there is provided an indexable cutting insert, for use in a cutting tool for turning operations, comprising:
[0009] two identical opposing end surfaces having 180° rotational symmetry about a first axis passing therethrough,
[0010] a peripheral side surface extending between the two opposing end surfaces, and
[0011] a peripheral edge formed at the intersection of each end surface and the peripheral side surface, at least two sections of each peripheral edge constituting cutting edges;
[0012] the peripheral side surface comprising:
[0013] two identical opposing major side surfaces having 180° rotational symmetry about a second axis passing therethrough, the second axis being perpendicular to the first axis;
[0014] two identical opposing minor side surfaces having 180° rotational symmetry about a third axis passing therethrough, the third axis being perpendicular to the first axis and the second axis;
[0015] a major plane defined by the first axis and the second axis;
[0016] a minor plane defined by the first axis and the third axis;
[0017] a median plane being defined by the second axis and the third axis;
[0018] each end surface having four corners, two lowered corners and two raised corners, the lowered corners being closer to the median plane than the raised corners;
[0019] in a side view of one of the minor side surfaces, all four corners are equidistant from the minor plane;
[0020] in a side view of one of the major side surfaces, all four corners are equidistant from the major plane.
[0021] In accordance with the present invention, the cutting insert has a maximum distance D1 between the minor side surfaces that is greater than a maximum distance D2 between the major side surfaces.
[0022] In accordance with the present invention, in an end view of the cutting insert, each major side surface is recessed.
[0023] In accordance with the preferred embodiment of the present invention, in an end view, the distance between the opposing major side surfaces varies from the maximum distance D2 adjacent the corners of the cutting insert to a minimum distance d2 at the intersection of the major side surfaces with the major plane.
[0024] In accordance with a specific application of the present invention, the minimum distance d2 is given by d2=D2−t, where the value t is given by 0.3 mm≦t≦0.4 mm.
[0025] In accordance with the present invention, in an end view of the cutting insert, each minor side surface is recessed.
[0026] In accordance with the preferred embodiment of the present invention, in an end view, the distance between the opposing minor side surfaces varies from the maximum distance D1 adjacent the corners of the cutting insert to a minimum distance d1 at the intersection of the minor side surfaces with the minor plane.
[0027] In accordance with a specific application of the present invention, the minimum distance d1 is given by d1=D1−s, where the value s is given by 0.05mm≦s≦0.25 mm.
[0028] In accordance with the present invention, each minor side surface merges with an adjacent major side surface at a corner side surface, wherein each corner side surface extends between a given raised corner of one of the two opposing end surfaces and a given lowered corner of the other of one of the two opposing end surfaces.
[0029] In accordance with the preferred embodiment of the present invention, each cutting edge comprises a major edge, a minor edge and a corner edge, therebetween.
[0030] In accordance with the present invention, each major edge, corner edge, and minor edge is formed at the intersection of adjacent major side surface, corner side surface, and minor side surface, respectively with an adjacent end surface.
[0031] In accordance with the preferred embodiment of the present invention, the major edges are recessed in an end view.
[0032] In accordance with the preferred embodiment of the present invention, the distance between the opposing major edges varies from the maximum distance D2 adjacent the corner edges to the minimum distance d2 at the intersection of the major edges with the major plane.
[0033] In accordance with the preferred embodiment of the present invention, the minor edges are recessed in an end view.
[0034] In accordance with the preferred embodiment of the present invention, the distance between the opposing minor edges varies from the maximum distance D1 adjacent the corner edges to the minimum distance d1 at the intersection of the minor edges with the minor plane.
[0035] In accordance with the preferred embodiment of the invention, each raised corner forms a corner cutting edge and adjacent major and minor edges form major and minor cutting edges, respectively.
[0036] Generally, the major cutting edge has a length L1 that is greater than half the distance D1.
[0037] Generally, the minor cutting edge has a length L2 that is approximately half the distance D2.
[0038] In accordance with the preferred embodiment of the present invention, the cutting insert further comprises an insert through bore extending between the major side surfaces and having a bore axis coinciding with the second axis.
[0039] In accordance with the present invention there is provided a cutting tool comprising: the cutting insert in accordance with the present invention, a shim, and an insert holder having an insert pocket in which the shim and the cutting insert are securely retained.
[0040] In the cutting tool, the insert pocket comprises: a base surface, the base surface being abutted by a given major side surface of the cutting insert, a first side wall extending uprightly from the base surface, the first side wall being abutted by a given minor side surface of the cutting insert, and a second side wall extending uprightly from the base surface, the first side wall being adjacent the major side surface and transverse thereto;
[0041] the shim comprises a top surface that is abutted by a non-operative end surface of the cutting insert, an opposing bottom surface that abuts the first side wall, and a perimeter surface extending therebetween;
[0042] a shim screw, extending through the shim through bore and threadingly engaged with a threaded second bore of the second side wall, secures the shim to the insert pocket; and
[0043] a securing screw, extending through the insert through bore, threadingly engaged with a threaded receiving bore of the base surface, secures the cutting insert to the insert pocket, the securing screw.
[0044] If desired, each end surface of the cutting insert further comprises two frustums extending away from the median plane located on either side of the major plane, and the top surface of the shim, in accordance with the present invention, further comprises a raised area being a portion of the top surface of the shim protruding from the top surface of the shim; wherein
[0045] the two frustums of the non-operative end surface abut the raised area of the top surface of the shim.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] For a better understanding, the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0047] [0047]FIG. 1 is of a side view of a typical prior art cutting tool;
[0048] [0048]FIG. 2 is an end view of the cutting tool in FIG. 1;
[0049] [0049]FIG. 3 is a plan view of the cutting tool in FIG. 1 in a turning operation.
[0050] [0050]FIG. 4 is a perspective view of the cutting insert in accordance with the present invention;
[0051] [0051]FIG. 5 is a first side view of the cutting insert in FIG. 4;
[0052] [0052]FIG. 6 is a second side view of the cutting insert shown in FIG. 4;
[0053] [0053]FIG. 7 is a cross-sectional view of the cutting insert shown in FIG. 6 taken along C-C;
[0054] [0054]FIG. 8 is an end view of the cutting insert shown in FIG. 4;
[0055] [0055]FIG. 9 is a side view of a cutting tool in accordance with the present invention;
[0056] [0056]FIG. 10 is an end view of the cutting tool in FIG. 9;
[0057] [0057]FIG. 11 is a plan view of the cutting tool in accordance with the present invention in an axial turning operation;
[0058] [0058]FIG. 12 is a detailed view of FIG. 11;
[0059] [0059]FIG. 13 is a plan view of the cutting tool in accordance with the present invention in a radial turning operation;
[0060] [0060]FIG. 14 is a detailed view of FIG. 13;
[0061] [0061]FIG. 15 is a perspective exploded view of cutting tool in accordance with the present invention; and
[0062] [0062]FIG. 16 is an end view of a cutting insert shown insert in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0063] Attention is first drawn to FIGS. 4 to 8 , showing a tangential indexable cutting insert 38 in accordance with present invention. The cutting insert 38 is generally manufactured by form pressing and sintering a cemented carbide, such as tungsten carbide, and can be coated or uncoated. The cutting insert 38 is generally rectangular in an end view and comprises two identical end surfaces 40 , and a peripheral side surface 42 extending between the end surfaces 40 . The cutting insert 38 and the end surfaces 40 have 180° rotational symmetry about a first axis R 1 that passes through the end surfaces 40 . Since the end surfaces 40 are identical, only one will be described, it being understood that the other end surface 40 has identical structure.
[0064] The peripheral side surface 42 comprises two opposed identical minor side surfaces 44 , two opposed identical major side surfaces 46 , and four opposed corner side surfaces 48 . Adjacent major and minor side surfaces 46 , 44 merge at a common corner side surface 48 . The cutting insert 38 and the major side surface 46 have 180° rotational symmetry about a second axis R 2 perpendicular to the first axis of rotational symmetry RI and passing through the major side surfaces 46 . The cutting insert 38 and the minor side surface 44 also has 180° rotational symmetry about a third axis R 3 that passes through the minor side surfaces 44 and is perpendicular to both the first and second axis of 180° rotational symmetry R 1 , R 2 .
[0065] The peripheral side surface 42 intersects each end surface 40 at a peripheral edge 50 . The peripheral edge 50 comprises two identical opposed major edges 52 , two identical opposed minor edges 54 , and four opposed corner edges 56 . Adjacent major and minor edges 52 , 54 merge at a common corner edge 56 . The major edges 52 are formed at the intersection of the major side surfaces 46 with the end surfaces 40 , the minor edges 54 are formed at the intersection of the minor side surfaces 44 with the end surfaces 40 , and the corner edges 56 are formed at the intersection of the corner side surfaces 48 with the end surfaces 40 .
[0066] For further description of the geometrical properties of the cutting insert 38 , a minor plane P 1 , to which the major edges 52 are generally parallel in an end view of the cutting insert 38 , is defined by the first and third axis of rotational symmetry R 1 , R 3 . A major plane P 2 , to which the minor edges 54 are generally parallel in an end view of the cutting insert 38 , is defined by the first and second axis of rotational symmetry R 1 , R 2 . A median plane M, which is perpendicular to both the first and major plane P 1 , P 2 , is defined by the second and third axis of rotational symmetry R 2 , R 3 . A width dimension D1 of the cutting insert 38 is defined as a maximum distance dimension between the minor side surfaces 44 measured parallel to the third axis R 3 . A length dimension D2 of the cutting insert 38 is defined as a maximum distance dimension between the major side surfaces 46 measured parallel to the second axis R 2 . For the tangential cutting insert 38 , the width dimension D1 is greater than the length dimension D2.
[0067] Associated with each of the four corner edges 56 of a given end surface are four corners comprising two diametrically opposed raised corners 58 and two diametrically opposed lowered corners 60 . The lowered corners 60 are closer to the median plane M than are the raised corners 58 . In a side view of either of the minor side surfaces 44 , all four corners 58 , 60 are equidistant from the minor plane P 1 . In a side view of either of the major side surfaces 46 , all four corners 58 , 60 are equidistant from the major plane P 2 . Each corner side surfaces 48 extends between a given raised corner 58 of one end surface 40 and an adjacent lowered corner 60 on the opposing end surface 40 . Each corner side surface 48 has uniform radius of curvature along its length, and typically forms an arc angle of 95°±3°. The alternating raised and lowered corners 58 , 60 enable the cutting insert 38 to have four same-handed raised corners 58 for indexing.
[0068] Adjacent major and minor edges 52 , 54 extend from the corner edge 56 of a given raised corner 58 with a variable slope to a respective lowered corner 60 . In a side view of the cutting insert 38 , adjacent each raised corner 58 , the slope of each major edge 52 (see FIG. 6) is generally constant with the major edge 52 substantially parallel to the median plane M. Moving along the major edge 52 towards an adjacent lowered corner 60 , the slope gradually increases and finally decreases adjacent the lowered corner 60 . As can be seen in FIG. 5 each minor edge 54 has a generally similar form to that of the major edges 52 . Thus in a respective side view, each major and minor edge 52 , 54 , has a similar wavy elongated “S”-shape.
[0069] In an end view of the cutting insert 38 , the major edges 52 are concave. In other words, the major edges 52 are recessed in an end view wherein, the distance between the opposed major edges 52 varies from approximately D2 adjacent the corner edges 56 to a minimum distance d2 at the intersection of the major edges 52 with the major plane P 2 . The minimum distance d2 is defined by D2−t. In a non-binding example, t is greater than or equal to 0.3 mm and less than or equal 0.4 mm. In an end view of the cutting insert 38 , each major side surface 46 is also concave, being recessed in the same manner as its associated major edge 52 . It should be noted that the variation of the distance between the opposed major edges 52 (and likewise the opposed major side surfaces 46 ) need not decrease uniformly from the maximum value D2 to the minimum value d2.
[0070] In an end view of the cutting insert 38 , the minor edges 54 are also concave, in a similar manner to the major edges 52 . The distance between the opposed minor edges 54 in an end view, varies from approximately D1 adjacent the corner edges 56 to a minimum distance d1 at the intersection of the minor edges 54 with the minor plane P 1 . The minimum distance d1 is defined by D1−s. In a non-binding example, s is greater than or equal to 0.05 mm and less than or equal 0.25 mm. Likewise, in an end view of the cutting insert 38 , each minor side surface 44 is concave, being recessed in the same manner as its associated minor edge 54 . The variation of the distance between the opposed minor edges 54 (and likewise the opposed minor side surfaces 44 ) need not decrease uniformly from the maximum value D1 to the minimum value d1.
[0071] It will be appreciated that whereas the whole of the peripheral edge 50 can function as a cutting edge, in practice, sections of the peripheral edge 50 adjacent the lowered corners 60 will not function as cutting edges. In a accordance with a specific application of the present invention, each given peripheral edge 50 has an effective major cutting edge 66 that extends from an associated given raised corner 58 along the given corner edge 56 and the given major edge 52 for a given major cutting edge length L1, which is greater than one half of the width dimension D1. Additionally, in accordance with the specific application of the present invention, each peripheral edge 50 has an effective minor cutting edge 68 that extends from an associated given raised corner 58 along the given corner edge 56 and the given minor edge 54 for a given minor cutting edge length, L2, which is approximately one half of the length dimension D2.
[0072] Attention is now drawn to FIGS. 9 and 10, showing side views of a cutting tool 70 in accordance with the present invention. The cutting insert 38 has relief angles γ1, γ2 and presents an operative raised corner 58 ′ outwardy projecting from the cutting tool 70 .
[0073] Attention is now drawn to FIGS. 11 and 12, showing the cutting insert 38 in an insert holder 72 in a plan view during an axial turning operation of a stepped square shoulder 74 of a workpiece 76 rotating about an axis A. Adjacent the stepped square shoulder 74 is an operative major edge 52 ′, an operative corner edge 56 ′ of an operative raised corner 58 ′ an operative minor edge 54 ′, and a trailing lowered corner edge 78 ′. It will be appreciated that an operative minor edge 54 ′ constitutes a secondary cutting edge or wiper and that only a small section of it adjacent the operative corner edge 56 ′ contacts the workpiece 76 . Due to the relief angles γ1, γ2 and any other required orientation of the cutting insert 38 , an entering angle K is formed between the major edge 52 and the feed direction F 1 , and a back clearance angle Kn is formed between the operative minor edge 54 ′ and a cylindrical surface 80 of the workpiece 76 . As can be seen, the trailing lowered corner edge 78 ′ is completely relieved from the cylindrical surface 80 of the workpiece 76 , whereby the depth of cut for axial turning is unlimited.
[0074] Attention is now drawn to FIGS. 13 and 14, showing the cutting insert 38 in an insert holder 72 in a plan view during an radial turning operation of a cylindrical surface 80 of a workpiece 76 rotating about an axis A. Adjacent the cylindrical surface 80 is an operative major edge 52 ′, an operative corner edge 56 ′ of the operative corner edge 58 ′ an operative minor edge 54 ′, and a trailing lowered corner edge 78 ″. It will be appreciated that that an operative major edge 52 ′ constitutes a secondary cutting edge or wiper and that only a small section of it adjacent the operative corner edge 56 ′ contacts the workpiece 76 . Due to the relief angles γ1, γ2 and any other required orientation of the cutting insert 38 , an entering angle K is formed between the operative minor edge 54 ′ and the feed direction F 2 , and a back clearance angle Kn is formed between the operative major edge 52 ′ and a stepped square shoulder 74 of the workpiece 76 . As can be seen, the trailing lowered corner edge 78 ″ is completely relieved from the stepped square shoulder 74 of the workpiece 76 , whereby the depth of cut for radial turning is unlimited.
[0075] The seating and securing of the cutting insert 38 will now be described with reference to FIG. 15, showing various elements not mentioned above. These elements include two frustums 82 on each end surface 40 , an insert pocket 84 of the insert holder 72 , an insert through bore 86 , a securing screw 88 , a shim 90 , and a shim screw 92 .
[0076] The insert pocket 84 comprises first and second side walls 94 , 96 uprightly extending from a base surface 98 of the insert pocket 84 . The shim 90 comprises a top surface 100 , a flat opposing bottom surface 102 , and a perimeter surface 104 extending therebetween. The top surface 100 of the shim 90 comprises a raised area 106 extending away from the bottom surface 102 of the shim 90 . A shim through bore 108 extends between the top surface 100 and the bottom surface 102 . The two frustums 82 of each end surface 40 extend away from the median plane M and are located on either side of the major plane P 2 . The frustums 82 are likely to impede chip flow, thereby limiting the lengths L1, L2 of the major and minor cutting edges 66 , 68 .
[0077] The shim 90 is secured in the insert pocket 84 with its bottom surface 102 abutting the second side wall 96 . The shim screw 92 , extends through the shim through bore 108 and threadingly engages with a threaded second bore 110 passing through the second side wall 96 , securing the shim 90 to the insert pocket 84 . The cutting insert 38 is secured in the insert pocket 84 with a non-operative end surface 40 adjacent the top surface 100 of the shim 90 . The first side wall 94 abuts the minor side surface 44 of the cutting insert 38 , and the base surface 98 abuts the major side surface 46 . The two frustums 82 of a non-operative end surface 40 abut the raised area 106 of the top surface 100 of the shim 90 . The securing screw 88 extends through the insert through bore 86 and threadingly engages a threaded receiving bore 112 in the base surface 98 of the insert pocket 84 .
[0078] It will be appreciated that the particular form of the end surfaces 40 will depend on the design factors that take into account various working conditions. For example, in order to increase the effective cutting wedge angle, a land 114 is provided adjacent the peripheral edge 50 (see FIG. 7). A rake surface 116 slopes downwardly and inwardly from the land 114 . If desired the rake surface can be provided with suitable chip control elements.
[0079] It is advantageous to have recessed side surfaces and side edges to take into consideration manufacturing tolerances so that the sides will not become convex or partially convex, when viewed in an end view, and interfere with the workpiece. It is possible to use straight side edges, i.e., the major side surface 46 and the major edges 52 could be straight, as in FIG. 16, either by tight manufacturing tolerances during pressing and sintering or by additional steps of grinding.
[0080] Although the present invention has been described to a certain degree of particularity, it should be understood that various alterations and modifications could be made without departing from the spirit or scope of the invention as hereinafter claimed. | A tangential indexable cutting insert can be used for metal cutting processes in general and for radial and axial turning of a stepped square shoulder in particular. The cutting insert exhibits 180° rotational symmetry about three mutually perpendicular axes. The cutting insert has generally “S”-shaped cutting edges extending between raised and lowered corners. The cutting edges and side surfaces are concave in an end view of the cutting insert. The cutting insert enables radial and axial turning operations of a square shoulder with unlimited depth of cut. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to secure data disposal (SDD) for disk drives.
BACKGROUND OF THE INVENTION
[0002] During the retirement phase of the PC life cycle, many users dispose of PCs without properly removing confidential data. This is a serious concern, since the information on these hard disks can then be retrieved by unauthorized people.
[0003] Many users think that formatting a hard disk removes and destroys its data, when in fact this data, which can be highly confidential, can still be retrieved from these systems. With most operating systems, files that are deleted are not necessarily erased. In many cases, the only thing erased is the logical link to the file.
SUMMARY OF THE INVENTION
[0004] To ensure that data cannot be retrieved even if a disk is removed from the drive and residual magnetic fields read by sophisticated data thieves, SDD is executed only on data regions that have been written to at least once during the lifetime of a disk drive. In some hard disk drive implementations up to fourteen overwrite cycles may be conducted as part of the SDD to ensure that any residual magnetic fields from the original data write are effectively eliminated, but as understood herein, absent present principles over twenty four hours may be required for such a comprehensive and repetitive overwrite process.
[0005] A method is disclosed for secure data disposal (SDD) of a disk drive having at least one data storage disk defining data regions. The method includes, for each data region to which data is written, indicating that the data region has been written to. The method then includes executing SDD only of data regions indicated to have been written to, and not executing SDD in data regions that have never been written to.
[0006] SDD may be executed only at end of life of the disk drive but only on all data regions indicated as having been written to at least once. Alternatively, SDD may be executed during operational life of the disk drive, e.g., on a previously written data region immediately after the previously written data region is indicated as being a free data region, or on a previously written data region during an idle period of the drive subsequent to an indication that the previously written data region is a free data region.
[0007] In one example, the data region can be a disk sector and the SDD includes writing a first pattern into substantially all bit locations of a sector, then writing at least a second pattern different from the first pattern into substantially all bit locations of the same sector. For some hard disk drive applications up to fourteen patterns may be written one on top of the other.
[0008] In another aspect, a tangible computer readable medium bears instructions to cause a processor, when a data storage disk sector is written to, to set a bit for the sector indicating that the sector will require secure data disposal (SDD) to be run on it. The processor executes SDD only on sectors whose bits indicate that they have been written to.
[0009] In another aspect, a disk drive includes one or more data storage disks and a processor writing data to sectors of the disk. A tangible program storage device bears instructions to cause the processor, pursuant to writing data to a sector, to set an indicator bit associated with the sector indicating that data has been written thereto. The instructions also cause the processor to execute secure data disposal (SDD) only on sectors whose respective indicator bits indicate the sectors have been written to.
[0010] In another aspect, a disk drive includes one or more data storage disks and a processor writing data to sectors of the disk. A tangible program storage device bears instructions to cause the processor, pursuant to writing data to a sector, determine whether another sector has been designated as being a free sector as a result. The instructions cause the processor to execute secure data disposal (SDD) only on the free sector.
[0011] The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram of one non-limiting system in accordance with present principles;
[0013] FIG. 2 is a flow chart of one example logic that may be employed in accordance with present principles; and
[0014] FIG. 3 is a flow chart of another example logic that may be employed in accordance with present principles.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Referring initially to FIG. 1 , a disk drive 10 such as, in one example, a hard disk drive can be used by a host computer 12 such as a notebook computer or desk top computer or any device that uses a disk drive to store data. The disk drive 10 typically includes a drive controller 14 that can be implemented by a processor. The disk drive 10 also includes a tangible computer readable medium such as but not limited to a solid state data cache 16 that, among other things, can store logic disclosed herein. The logic is executable by the drive controller 14 or other processor in the disk drive 10 .
[0016] The controller 14 can also control one or more head position mechanisms 18 that move one or more suspensions 20 bearing read and write heads 22 . The heads 22 read information from and write information to one or more rotatable data storage disks 24 . Typically, data is written to discrete areas of the disk 24 referred to herein as “sectors” 26 , it being understood that “sector” is not limited to a particular geometry such as a ring or wedge but more generally refers to a portion of the disk 24 that is regarded as a discrete storage area unit for purposes of secure data disposal (SDD).
[0017] SDD typically involves writing plural unique patterns of “ones” and “zeroes” into each sector of the disk, one pattern on top of another. More specifically, a first pattern is written into substantially all bit locations of a sector, then at least a second pattern different from the first is written into substantially all bit locations of the same sector to effect SDD. Additional patterns may be overwritten on top of the first two if desired. This is true of hard disk drives and other storages that rely on magnetic principles to store data. In the case of optical drives, flash memory, and other true digital devices, only one overwrite pattern may be required.
[0018] FIG. 2 shows one embodiment of logic that may be implemented in accordance with present principles. Commencing at block 28 , for each new drive, each sector is designated as “clean”, i.e., as never having been written. This designation may be accomplished by establishing the value of an indicator bit, referred to herein for convenience as a SDD bit, as appropriate, e.g., to be “zero” for “clean” and “one” for “dirty”. The SDD bit for a sector may reside in the sector or it may reside elsewhere, e.g., in a SDD bit table stored in the cache 16 .
[0019] The drive is then sold for use and subsequently during its operational lifetime, at block 30 for each write to a sector the SDD bit of the sector is set to a value indicating “dirty” at block 32 . At the end of the operational life of the disk drive when it is intended to be securely disposed of at block 34 , for each sector at block 36 it is determined at decision diamond 38 whether the respective SDD bit indicates that the sector is dirty. If it does, SDD is executed on the sector at block 40 , and upon completion of SDD the next sector is retrieved for test at block 42 , with the logic looping back to decision diamond 38 to test the SDD bit of the next sector. On the other hand, if the test at decision diamond 38 is negative, SDD is not executed on the sector, and the logic proceeds immediately to block 42 . In this way, SDD is performed only on sectors requiring it, saving execution time.
[0020] An alternate implementation is shown in FIG. 3 . Commencing at block 44 , for each new drive, each sector is designated as “clean”, i.e., as never having been written. This designation may be accomplished by establishing the value of an indicator bit, referred to herein for convenience as a SDD bit, as appropriate, e.g., to be “zero” for “clean” and “one” for “dirty”. The SDD bit for a sector may reside in the sector or it may reside elsewhere, e.g., in a SDD bit table stored in the cache 16 .
[0021] The drive is then sold for use and subsequently during its operational lifetime, at block 46 for each write to a sector the SDD bit of the sector is set to a value indicating “dirty” at block 48 . However, unlike the logic of FIG. 2 , the logic of FIG. 3 implements SDD during the operational life of the disk to further reduce the amount of time required at end of life to secure the disk.
[0022] Specifically, when a write is executed, a previously written sector might be designated as being “free” as a result when, for instance, data in the previously written sector is updated but owing to space constraints the updated version is written into another sector. When this occurs at decision diamond 50 , SDD is executed on the newly freed sector at block 52 and the SDD bit reset to “clean” at block 54 . SDD may be executed on the free sector immediately after the free sector is indicated as being a free sector, or SDD can be executed on the free sector during the next subsequent idle period of the drive after the free sector has been designated as such.
[0023] While the particular SECURE DATA DISPOSAL FOR DISK DRIVE is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. | When a disk sector is written to, a bit for the sector is set indicating that the sector will require secure data disposal (SDD) to be run on it. To save time during end of life disposal, SDD is executed only on sectors whose bits indicate that they have been written to. SDD can be executed on each dirty sector in one operation at end of life or incrementally during use as disk activity permits. | 6 |
[0001] This application is a continuation in part of U.S. patent application Ser. No. 13/228,404, “METHOD OF VISUALIZING THE COLLECTIVE OPINION OF A GROUP”, inventor Alexander L Davids, filed Sep. 8, 2011; application Ser. No. 13/228,404 in turn claimed the priority benefit of provisional patent application 61/393,283, “METHOD OF VISUALIZING THE COLLECTIVE OPINION OF A GROUP”, inventor Alexander L. Davids, filed Oct. 14, 2010, the contents of both applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention is in the general field of computerized decision-making tools, in particular tools for qualitative analysis of issues such as corporate, product, service or cause branding, marketing, business strategy and communications messaging.
[0004] 2. Description of the Related Art
[0005] In some areas of group decision making, particularly areas relating to taste or subjective opinions or qualitative assessment, often the collective opinions of a large group of individuals are viewed as the most optimal or “best” solution.
[0006] In the business world, this sort of statistical averaging approach is somewhat related to problems encountered in certain types of group decision-making, here exemplified by brand management. Branding, (e.g. a corporate, product, service or cause branding) essentially is a way for a business to identify a product, range of products, or organization that, on the one hand, helps identify unique aspects of the product(s) or organization that will be useful to consumers, help make the product or organization attractive to consumers, and also helps distinguish the product or organization from competitors.
[0007] As a result, the disciplines of branding, brand analysis, brand strategy, marketing and business strategy have emerged that attempt to capture these considerations, and distil them into a unique message, statement, idea, set of ideas or attributes like a positioning statement, personality traits, brand promise, values, vision statement, purpose or mission statement that best represents the offer or organization in question. Here, the perspectives from a large number of different individuals who are familiar with the issues, subject, work, offer, solution, values, characteristics, traits, attributes, features, benefits, disadvantages, weaknesses, messages, statements, positions, personalities, promises, values, visions, purposes or missions (collectively referred to as “issues”) can be very valuable, because each individual will bring to the analysis their own way of looking at things, and a larger diversity of opinions will, in general, be more likely to capture the many different opinion and views that the outside world of individuals may have or will have about the issues or offer.
[0008] Unfortunately, prior art methods of group decision making, brand analysis and brand strategy tended to not effectively harness the diversity of opinions and insight that larger groups can bring to a particular problem. Group meetings, for example, quickly tend to become dominated by a few individuals, with the rest of the group often eventually deferring to a formal or informal leader, thus harnessing only a fraction of the group brainpower. Prior art computerized group decision methods, exemplified by U.S. Pat. Nos. 7,177,851; 7,308,418 and U.S. patent application Ser. Nos. 10/848,989; 10/874,806; 11/181,644; 11/672,930; 11/672,930 and others tended to be cumbersome and difficult for non-expert users to use, and as a result failed to fully capture group insights into brand marketing and other types of group decision making.
[0009] For example, Saaty, US patent publication 2008/0103880 taught a computer implemented method and a system for collecting votes in a decision model. His methods, however, apparently focus on an analytic network process (ANP) model that weights factors such as goals, benefits, costs, risks and opportunities based on input from as few as one user.
[0010] By contrast, for the purpose of group decision making with respect to brand marketing issues, the resolution requires processing of opinion, subjective and creative factors, in addition to the more analytically quantifiable objective factors, such as the goals, benefits, costs, risks, and opportunities of the different outcomes. As a result, such ANP methods would appear to have limited applicability.
[0011] Bayer, in U.S. Pat. No. 6,311,190 taught a system for conducting surveys in different languages over a network with survey voter registration. This patent teaches various computerized survey methods useful for producing multilingual surveys, useful for working with voters speaking different languages and possibly located in different countries, but is also otherwise silent with regards to the problems encountered in typical branding exercises, where usually the study participants all speak the same language and may even be in the same location.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention is a simplified method of determining group collective viewpoint on various qualitative problems, here exemplified by brand marketing problems, which utilizes a software program and method with a simple graphical user interface, suitable for unskilled users. This simplified graphical user interface is used to capture input from a plurality of individuals, and this input data is then mathematically prioritized, clustered, and displayed in the form of simple graphical output, as well as supplemental mathematical output for more detailed analysis. The simplified user graphical data entry interface and simple graphical data output interface, along with supplemental detailed data as requested, help make the group decision making process both transparent, effective, and fast.
[0013] In one embodiment, the invention may be a computerized method of determining a group viewpoint on qualitative issues, such as brand marketing issues. Here the N highest importance aspects of the issue are selected by the group and often assigned images and titles. The system will typically present each user with one or more graphical user interface screens wherein the individual users will vote on the relative importance and degree of relationship between the N aspects (Data Points), often using drag and drop methods. The software will compute N×N similarity matrices and cluster the various aspects into groups of greater and lesser similarity and importance, and present the results to the user in the form of easy to read relationship tree diagrams (or other relationship diagrams such as nodal maps) where the relative importance of the issues may be designated by size and other markers such as graphic markers or numeric ratings. The software may reside on a network server and present these display screens to web browsers running on user computerized devices.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A shows an example of a qualitative problem that requires a group consensus. Here the problem is one of capturing the knowledge of an informed group, and translating this knowledge into an appropriate marketing brand.
[0015] FIG. 1B shows an optional initial step in the process, which is giving the participants an array of images that may potentially relate to various issues, concerns, or features relating to the qualitative problem at hand, and requesting that the audience agree on a limited number (such as 10) of most important issues, and assign a suggestive image and title to these most important issues.
[0016] FIG. 1C shows a flowchart for the collaborative clustering process and software.
[0017] FIG. 2A shows a mockup of the software user interface for prioritization
[0018] FIG. 2B shows screen shots from two different users who are each voting on the relative importance of the top ten issues. User one (top) is partway through the process, but has still not assigned two issues (gives base plan, unlock treasure) as to importance. User two (bottom) has finished the process. Although there is some agreement between the assignments as to importance, the two votes are not identical.
[0019] FIG. 3A shows a mockup user interface for the voting process where users rank the top 10 issues or concerns or features as to similarity.
[0020] FIG. 3B shows screen shots from two different users who are each voting on the relative similarity, between the top ten issues. Here the first issue or Data Point is being voted on. Note that this first issue or Data Point “Captures vision” was previously assigned by both voters as being extremely important. User one (top) is partway through the process, but has still not assigned four issues (gives base plan, unlock treasure, provide guidance, med& biochem) as to similarity. User two (bottom) has finished the process. Again, although there is some agreement between the assignments as to similarity, the two votes are not identical.
[0021] FIG. 3C shows screen shots from two different users who are each voting on the relative similarity between the top ten issues or Data Points. Here the 9 th issue is being voted on. This 9 th issue or Data Point was previously rated as very unimportant by user one, and thus had an overall lower average importance rating. User one (top) is partway through the process, but has still not assigned four issues (gives base plan, unlock treasure, provide guidance, med& biochem) as to similarity. User two (bottom) has finished the process. Again, although there is some agreement between the assignments as to similarity, the two votes are not identical.
[0022] FIG. 4 shows a mockup user interface for summary of individual user's voting results.
[0023] FIG. 5 shows a sample user matrix (default).
[0024] FIG. 6 shows a sample similarity matrix for User A and User B.
[0025] FIG. 7 shows the actual similarity matrix produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C.
[0026] FIG. 8 shows a sample user similarity matrix of nine users.
[0027] FIG. 9 shows a similarity matrix transformed to positive scale.
[0028] FIG. 10 shows a single linkage hierarchical clustering—first iteration
[0029] FIG. 11 shows a sample display of a treemap.
[0030] FIG. 12A shows the actual treemap produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C, and who produced the actual similarity matrix shown in FIG. 6 .
[0031] FIG. 12B shows an alternate type of treemap for a different analysis. Here the relative importance of the various ratings is indicated by a numeric score in the lower righthand side of the various images.
[0032] FIG. 13 shows a sample display of a clustering recommendation
[0033] FIG. 14 shows the actual clustering recommendation diagram produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C, and who produced the actual similarity matrix shown in FIG. 6 , as well as the actual treemap shown in FIG. 12A .
[0034] FIG. 15 shows how the entire process may be used to facilitate complex group qualitative decisions, such as product branding, and produce high quality results within a single day.
[0035] FIG. 16 shows a summary of grouping results for all Data Points and voter modes
[0036] FIG. 17 shows a sample report of user grouping results
[0037] FIG. 18 shows a sample user matrix for user A.
[0038] FIG. 19 shows a sample overall similarity matrix.
[0039] FIG. 20 shows a sample difference matrix.
[0040] FIG. 21 shows a sample report of level of agreement.
[0041] FIG. 22 shows a sample display of clustering results for an individual user.
[0042] FIG. 23 shows a sample admin interface for setting up pre-defined groups.
[0043] FIG. 24 shows a sample display of clustering results for a pre-defined age group.
DETAILED DESCRIPTION OF THE INVENTION
[0044] The computer software and algorithms of this invention are typically designed to run under the control of one or more microprocessors and computer memory, accept input by one or more standard graphical user interfaces, and also provide output by one or more graphical user interfaces. In order to facilitate group interaction, often the software will be intended to run on a network enabled server (e.g. an Internet Web server) or service (e.g. an Internet service), connected to a plurality of user interface devices, such as Apple iPads, tablets, smartphones, laptop computers and the like, often running in web browsers or other network or internet enabled applications on these devices. Ideally, each participant in the process will have access to their own user interface device, although of course users may share user interface devices as needed. Often, to facilitate group collaboration and decision making, the output from the software will be projected onto large screens intended for group viewing, using standard video projectors and the like. Alternatively, of course, the output may itself be transmitted over a network, such as the Internet, and be viewed on, for example, web browsers running on various individual user computerized devices, or be displayed on the user interface devices. This later configuration will be useful when, for example, group collaboration between group members separated by a significant distance is desired.
[0045] At the broadest level, the invention is a method to provide insight on individual or group perceived differences between various concepts or issues. In order to provide a simple and convenient identifier for these various concepts or issue, according to the invention the various concepts or issues will often be identified by various visual and/or verbal Data Points. For purposes of providing a simple user interface, these visual and/or verbal Data Points that symbolize the concepts or issues will often be identified in the form of an image, usually with a short descriptive text name attached.
[0046] FIG. 1A shows an example of a complex qualitative problem that requires group input, along with an example of one embodiment of the decision making process that can be facilitated by the methods of this invention. Here the problem is one of capturing the knowledge of an informed group, and translating this knowledge into an appropriate marketing brand.
[0047] In this example, the process begins by first prompting the group participants ( 100 ) through verbal ( 102 ) and visual ( 104 ) stimuli to start identifying the various qualitative issues that are likely to be most relevant to the problem. In some embodiments, human facilitators ( 106 ) who are familiar with this basic process may be used to help guide the process, while in other embodiments, software “wizards”, expert systems, or help software may do the same thing. Here the participants are being asked to identify key qualitative issues relevant to branding, such as the brand personality ( 108 ) (here the personality of a brand of trendy clothes for teenage girls will clearly be quite different from the personality of a brand intended for the elderly), the needs of the audience of consumers of the product or services being potentially offered by the (to be) brand ( 110 ), which relates to the brand positioning, and also other relevant marketing issues such as the company or product values, vision, culture or history of the various products, services, or company behind the brand ( 112 ). From this analysis, with the aid of the invention, group consensus as to the top issues (here the top ten issues, facets or Data Points) are identified, their relative importance weighted, and the concepts are clustered in ways that, as will be discussed, will facilitate group decision making ( 114 ), here ultimately resulting in a brand strategy ( 116 ).
[0048] In order to harness the power of groups of individuals to focus on concepts or issues, often the various individuals will vote on the relative relationships and importance of these concepts or issues, and the software will then segment the results according to voter preference. The software will often also provide additional insight into the problem at hand by segmenting the various voters by results.
[0049] In order to provide a very simple user interface, which encourages transparent decision making and both individual and group focus, it will often be useful to further encourage users to link the key concepts, issues or Data Points to suggestive images or icons. Although not obligatory to the invention, this linkage to relevant visual images helps engage the visual centers of the participants' brains, and helps prevent confusion and reinforce attention on the problem at hand. The use of images facilitates a deeper level of collective understanding after words and phrases have been chosen by engaging the visual parts of each individual participant's brain. For example, if the word is “pure” a picture of a distilled glass of water is very different than the picture of an innocent child and the interface allows a collective precise meaning for each word to be defined. The group will have chosen a set of top text ideas and then assign images to each idea, or the group will choose images and then assign text labels or text ideas to each image. It is noted that in rare circumstances, a combination of text and images will be used and then images and text labels will be assigned, respectively.
[0050] FIG. 1B shows an optional initial step in the process, which is giving the participants an array of images that may potentially relate to various issues, concerns, or features relating to the qualitative problem at hand, and requesting that the audience agree on a limited number (such as ten) of most important issues, and assign a suggestive image and title to these most important issues.
[0051] Here, this type of method will be termed a “collaborative clustering process”, and a flow chart of one embodiment of this process is shown in FIG. 1C , and according to the invention, many or all steps of this process may be implemented in software, normally running on networked server systems, often communicating over either local networks or through larger networks such as the Internet.
[0052] In the specific embodiments and examples discussed herein, exemplified by the modules (e.g. program modules) shown in FIG. 1C , the Project Console and Voting Booth programming examples were web applications that were custom built on a Ruby framework. These were run on a RackSpace Cloudserver on CentOS, Apache, and MySQL. The Clustering module was a custom single-linkage clustering module built in the Ruby programming environment. The Cladogram and Dendrogram viewers were custom built using Adobe Flash AS3; and the data feed from the Project Console as XML. Other software systems and methods may also be used as desired.
[0053] In one embodiment, the invention may use modular data collection, pre-processing, core processing, post processing, and output approach to quickly and economically support the decision making process. The invention software will typically use hierarchical clustering algorithms to identify relationships between data elements (i.e. the concepts or issues, again usually identified with an image and short text description to facilitate user interaction). The invention software and method will typically use binary comparisons to generate objective data from subjective input data, and use images to assist in the (human) semantic conversion of data elements. The software and method will usually also use individual prioritization of data elements to assist with group prioritization, as well as use one or more types of graphical output display to help users visualize relationships. In order to avoid undue influence by a few real or self-appointed group leaders, the system will often use anonymous participation to remove group influenced biases during voting process.
[0054] This type of approach has a number of distinct advantages. The anonymous participation feature can help prevent or at least reduce the level of individual and group input bias, as well as help prevent prioritization bias.
[0055] The software also is scalable to large numbers of participants; helps significantly speed up the execution of the decision process, and helps maximizes the objectivity of the prioritization. The software also keeps track of each step of process, allowing users to review at anytime, and also allows the results from different sessions to be analyzed between sessions.
[0056] Often, it will be useful to implement the methods of the invention in the form of multiple software modules. These modules can include I) an initial setup module, II) a voting booth module, III) a module to summarize the individual voting results into a similarity matrix, IV) a clustering analysis module, V) a recommendation display module, and VI) a voting patterns analysis module. This voting patterns analysis module can, in turn analyze the various votes according to a) voting patterns analysis, b) comparison between individual user voting results matrix with the overall similarity matrix, and c) also analyze voting results on pre-defined groups. The function of these various software modules are described below.
Part I. Initial Setup Module
[0057] In one embodiment, the software will allow a user designated as an Administrator to log in, and present the Administrator with a list of previously executed projects. When the Administrator drills down on each project, a history of results from previous runs will be listed, each drilling into the results of each run. Typically each individual Administrator will have their own logins, but different Administrators in the same organization or division will often be able to share access to the projects list as authorized.
[0058] From the projects list, the Administrator can then select and launch a new voting project by entering and uploading relevant information for the project. Alternatively, the Administrator may choose a previously run project to launch an additional run. The Administrator may additionally be able to set a timer for the length of time the project is allowed to run for.
[0059] In order to simplify the user interface for the system, often it will be useful, as a preliminary exercise, to first have the group identify analyze the problem and select a relatively small number of concepts or issues, such as the top ten concepts or issues, to focus on. In some implementations, this initial analysis and identification will be done by the same group of people who later identify the top ten issues or concepts, and in other implementations this may be done by a different group of people. As previously discussed, to improve ease of visualization, often these top ten concepts or issues will be represented by images that symbolize that specific concept or issue, as well as a short text phrase or label that also identifies the concept or issue. This approach greatly simplifies the user interface, and makes it easier for larger groups to maintain a group focus on the problem. Again, these labeled images will be termed “Data Points”.
[0060] In some embodiments, it may be useful to first identify the top issues, such as the top ten issues, by a preliminary process that initially is based on a much larger issue list. This preliminary and optional “winnowing down” method may be performed by another computer implemented method, either as a stand-alone program, or as a program module integrated into the computer programs that implement the other aspects of the invention described herein. For example, each user may be provided with a much larger list of potential top issues on a computer screen, for example a scrolling list, which may be implemented in on a touch sensitive screen for ease of use. The user may be invited to pick his or her top eight or ten issues from this larger list. This computer generated list can also allow the user to get further information as to a more precise definition of that particular potential top issue. The participant may then optionally be presented with the popularity ranking data from the overall team as well. Then, after each participant has made this initial selection, the system administrator or facilitator may be presented with a summary screen that rank orders the various issues in terms of frequency of selection. The numeric ranking of the frequency of selection may also be presented. The facilitator may then view the summary scores, demote issues with fewer votes, and/or edit the various issue names and definitions as appropriate. The facilitator may also add issues and definitions to this summary list as appropriate. This process can then continue in an iterative manner with the participants getting the facilitator adjusted issue list, selecting and voting again as appropriate, until a final list of issues that will ideally have multiple votes for each issue is presented to the participants.
[0061] In this discussion, it is assumed that by one process or another, at a group consensus has been obtained as to what the most significant issues are or may be so as to narrow down the number of choices to a reasonable number, which again is often around ten.
[0062] Continuing, in one embodiment, the software will prompt the Administrator to enter or transfer the names of about ten top Data Points (here assumed to be previously derived) for the project. Here a simplified software user interface, such as a graphical user interface, may allow the Administrator to easily manipulate the symbolic images and text of the roughly ten most critical issues or points by intuitive methods, such as dragging-and-dropping images from an online image gallery (e.g. FIG. 1B ) to the associated Data Points. Often these symbolic images and text may be designated by Universal Resource Locators (URLs), and the software application may store the public URLs of the dropped-in images for a subsequent voting display. Additionally, to facilitate group interactions, the software may optionally also prompt to the Administrator to send email or social media invitations to various pre-determined voters (i.e. voters, group members, users or participants).
[0063] Part II. Voting Booth Module: The voting module will often begin in a starting state that presents all of the top selected Data Points. Typically each user (group member, voter) will then rate each Data Point based on their assessment of the Data Point's level of importance in relative to the other Data Points. However to prevent users from voting all Data Points as “important”, the voting module software may enforce preset constraints as to what percentage of the Data Points may be rated into one or more importance categories. This process is shown in FIG. 2A , which shows an abstracted version of a user prioritization user interface. Here the various boxes marked with an “X” ( 200 ) indicate the various images and text that are used to symbolize the various concepts or issues that are being analyzed by the group. In some embodiments, the software may additionally allow the Administrator to enter various objectives such as “core brand essence” or “concept” to help ensure that all users are using the same importance ranking scheme.
[0064] Real examples for a simplified two voter analysis are shown in FIG. 2B . FIG. 2B shows screen shots from two different users who are each voting on the relative importance of the top ten issues. User one (top) is partway through the process, but has still not assigned two issues (gives base plan, unlock treasure) ( 202 ) ( 204 ) as to importance. User two (bottom) has finished the process. Although there is some agreement between the assignments as to importance, the two votes are not identical.
[0065] After the relative importance of the various concepts or issues are determined and ranked by the group, the next step is to determine which of the various concepts or issues are really unique, and Which are really just alternate ways of stating or looking at the same concept or issue. To do this, the users will then vote to rank the various images and text according to degrees of similarity, such as very similar, similar, different, very different, and so on. Each user will make this determination on their own user interface, and the system will again accumulate group statistics. This voting process is shown in FIG. 3A . FIG. 3A shows a mockup user interface for the voting process where users rank the roughly top ten issues or concerns or features as to similarity.
[0066] Thus FIG. 3A shows an abstraction of a graphical user interface that the system may present to facilitate the voting process. In order to improve usability, the interface may allow users to skip to the next Data Point or go back to change their rating at anytime during the process. Group decision making processes can often be bogged down by users that take too much time to think, and to prevent this, the system may additionally show the time remaining and remind the individual user when it is close to the end. Often various other time management schemes, such as showing the three most important Data Points first, will be used to make sure that users have enough time to rate at least the most important Data Points.
[0067] Real examples for a simplified two voter analysis are shown in FIGS. 3B and 3C . FIG. 3B shows screen shots from two different users who are each voting on the relative similarity between the top ten issues. Here the first issue or Data Point ( 300 ) is being voted on. Note that this first issue or Data Point “Captures vision” was previously assigned by both voters as being extremely important. User one (top) is partway through the process, but has still not assigned four issues (gives base plan, unlock treasure, provide guidance, med& biochem.) ( 302 ) as to similarity. User two (bottom) has finished the process. Again, although there is some agreement between the assignments as to similarity, the two votes are not identical.
[0068] FIG. 3C shows screen shots from two different users who are each voting on the relative similarity between the top ten issues or Data Points. Here the 9 th issue ( 304 ) is being voted on. This 9 th issue or Data Point was previously rated as very unimportant by user one, and thus had an overall lower average importance rating. User one (top) is partway through the process, but has still not assigned two issues (unlock treasure, provide guidance) ( 306 ) as to similarity. User two (bottom) has finished the process. Again, although there is some agreement between the assignments as to similarity, the two votes are not identical.
[0069] When the voting process is completed, the system will then generate a graphical user interface that summarizes the individual user's vote, and this is shown in FIG. 4 .
[0070] FIG. 4 shows an abstract view of the user interface that summarizes that individual user's particular voting results. Again the boxes with “X” inside represent the images and descriptive text used to symbolize the concepts or issues being analyzed. In order to insure accurate results, usually the system will allow the users to examine this display, and allow the user to make final changes by suitable dragging and dropping operations. In some embodiments, to help ensure good user input data, the software may warn the user if, for example, over 70% of the Data Points are rated ‘similar’.
[0071] The data from multiple numbers of users, minimum of one, normally at least two, and often ten or more users, are then analyzed by the various matrix methods described below. In general, more users are better, and there is no upper limit on the maximum number of users that may be analyzed using these methods.
[0072] In some embodiments, the program will create a user matrix based upon a rating scale range, such as −2 (most dissimilar items or concepts) to 2 (most similar items or concepts). Often this particular scale will be fixed regardless of the number of Data Points and/or users being analyzed.
[0073] The software will typically create an N×N matrix for each user, where N is the number of Data Points selected. Thus, for example, if ten concepts or items are being analyzed by the group, and these items or concepts are represented by ten images and associated text, the N×N matrix will be a 10×10 matrix, where each row or column will represent a different concept or item, again referred to here as a “Data Point”. The rating results of each user will be stored in their own matrix. This is shown in FIG. 5 .
[0074] By default, all cell values in this matrix may initially be set to zero (which means the Data Point pair is neither similar or dissimilar), with the exception of the diagonal cells, since obviously any one given concept or item “Data Point” will be maximally similar to itself, and here maximal similarity is given a value of “2”.
[0075] Note that although this user matrix will be used to store rating results from a particular user, in order to preserve a simple user interface, this matrix will not usually be displayed to the user. Rather, the users will normally use a different type of interface to compare the Data Points, which will be discussed shortly in the part 2 voting booth module discussion.
[0076] The 10×10 matrix in FIG. 5 shows how the matrix should look like in the beginning of the rating process. In this example the matrix is created for clustering analysis of 10 Data Points.
[0077] Once the user started rating each Data Point pair, the corresponding cell values in the user matrix will be updated at the same time. As previously discussed, the values associated with each rating may be assigned as follows in Table 1 below.
[0000]
TABLE 1
Similarity ratings
Data Point Pair Rating
Cell Value
Very Similar
2
Similar
1
Dissimilar
−1
Very Dissimilar
−2
[0078] In order to force decision making, in some embodiments, a user may not be allowed to vote neutral, however, a user can choose not to rate a particular Data Point pair.
[0079] For example, if the user rated Data Point 1 and Data Point 2 as similar, the value in the corresponding cells will change from zero to one.
[0080] To check the data, the system will recognize that the valid cell values will be −2, −1, 0, 1, and 2 only, if a user did not finish the rating process in the given time period. When this happens, the cells corresponding to those Data Point pairs will remain zero by default.
[0081] Note that the user matrix is a symmetric matrix so the cell values are symmetric with respect to the main diagonal (top left to bottom right).
[0000] Part III. Summarize Individual Voting Results into a Similarity Matrix
[0082] Once all of the user matrices are filled, the software will then usually summarize the values into a similarity matrix by a simple summation operation where the value in any summation matrix cell i, j, is simply the sum of the individual user matrix cell i,j values. For example, in a circumstance where the voting results for two users (User A and User B) are being analyzed by the system, then the user matrixes of the two can be added or summed together, as is shown in FIG. 6 . Note that although for many applications, it is preferable to work with the voting results from multiple users; a single user can also use the system as desired.
[0083] Thus in a similarity matrix, the value in each cell is equal to the sum of the corresponding cells in the various user matrices. The diagonal cells will have a value that is equal to the total number of users multiplied by two. If, in the above example, User A gave a rating of one (i.e. similar) for Data Point A and Data Point B, while User B gave a rating of two (i.e. very similar) for Data Point A and Data Point B, then the corresponding cell in the similarity matrix will be: 2+1=3. This is shown as the circled cells in FIG. 6 .
[0084] Thus the minimum and maximum values allowed in a similarity matrix should be: minimum is: −2*number of users, and maximum is: 2*number of users
[0085] Any values outside of this minimum and maximum range would thus be considered as invalid values. This overall similarity matrix may then be used by the software to perform a clustering analysis, as described below.
[0086] FIG. 7 shows part of the actual similarity matrix produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C.
[0087] FIG. 8 shows a sample user similarity matrix of nine users.
Part IV. Clustering Analysis Module
[0088] In prior art clustering analysis, the data set was often constructed in a way that the observations (rows) are different than the variables (columns). The variables were then used to describe the observation, instead of showing the relationship between observations. Then the data set would usually then be converted to a distance matrix which would display the distance or closeness between the observations.
[0089] According to the invention, however, since we begin with building a similarity matrix, which in a way is already the ‘distance’ between Data Points, therefore we can skip the conversion step and instead use the similarity matrix itself as the distance matrix for the clustering process.
[0090] This process of hierarchical clustering can be defined by the following steps:
1. Assign each Data Point to a cluster, each cluster containing just one Data Point (thus a matrix with N Data Points should have N clusters to begin with). Let the distances (similarities) between the clusters be the same as the distances (similarities) between the Data Points they contain. 2. Find the closest (most similar) pair of clusters and merge them into a single cluster. 3. Compute the distances (similarities) between the new cluster and each of the old clusters. This can be done using single-linkage, average linkage and complete-linkage 4. Repeat steps 2 and 3 until all items are clustered into a single cluster of N Data Points.
Example
[0095] Suppose we have summarized the user ratings into the similarity matrix as shown in FIG. 8 .
[0096] For the ease of calculation, we will transform the values in this similarity matrix to show the similarity in a positive scale. The formula for transformation is:
[0000] −1*( X ij −maximum cell value), where X ij is value of row i and column j, i ε(1 ,N ) and j ε(1 ,N ), N is the total number of Data Points
[0097] In our example, the maximum cell value is Total # of Users*2=>9*2=18. This transformed matrix is shown in FIG. 9 , which shows the similarity matrix transformed to a positive scale.
[0098] In the transformed similarity matrix, the smaller values represent more similar Data Points, while the larger values represent more dissimilar Data Points. The closest (i.e. most similar) pair of Data Points in this example are Data Point 1 and Data Point 10, with a rating of ‘1’. They are merged into a new cluster called “Data Point 1/10”. The level of the new cluster is thus L (Data Point 1, Data Point 10)=1 and the new sequence number is m=1.
[0099] Then we compute the similarity from this new compound Data Point to all other Data Points. In single-linkage clustering, the rule is that the similarity from the compound Data Points to another Data Point is equal to the most similar rating from any member of the cluster to the outside Data Point. So the similarity rating from “Data Point 1/10” to “Data Point 2” is 8, which is the similarity rating between Data Point 10 and Data Point 2, and so on.
[0100] After merging Data Point 1 with Data Point 10 we obtain the matrix shown in FIG. 10 , Which shows the Single linkage hierarchical clustering first iteration.
[0101] The process then continues to find the next most similar pair. Here we have Min d(i,j)=d(Data Point 1/10, Data Point 8)=1, therefore we will merge Data Point 1/10 and Data Point 8 into a new cluster.
[0102] We (the software algorithm) then continue to find the next most similar pair of Data Points. Thus we have Min d(i,j)=d(Data Point 1/10/8, Data Point 6)=2, therefore we will merge “Data Point 1/10/8” and “Data Point 6” into a new cluster.
[0103] Next, Min d(i,j)=d(Data Point 4, Data Point 9)=2, therefore we will merge Data Point 4 and Data Point 9 into a new cluster.
[0104] Next, Min d(i,j)=d(Data Point 4/9, Data Point 7)=3, therefore we will merge Data Point 4/9 and Data Point 7 into a new cluster.
[0105] Next, Min d(i,j)=d(Data Point 2, Data Point 5)=3, therefore we will merge Data Point 2 and Data Point 5 into a new cluster.
[0106] Next, Min d(i,j)=d(Data Point 4/9/7, Data Point 2/5)=6, therefore we will merge Data Point 4/9/7 and Data Point 2/5 into a new cluster.
[0107] Next, Min d(i,j)=d(Data Point 2/5/4/9/7, Data Point 1/10/8/6)=7, therefore we will merge Data Point 2/5/4/9/7 and Data Point 1/10/8/6 into a new cluster.
[0108] Finally we will merge the last two clusters together and summarize the clustering results into a hierarchical tree (or treemap, FIG. 11 ). This treemap is discussed in more detail in the part V recommendation module, discussed below.
Part V. Display of Recommendation Module:
[0109] The Administrator (and the users as well as desired) can view the clustering results in different graphical display formats such as treemap (also known as a dendrogram), mindmap, heatmap, nodal plot, and other graphical representations.
[0110] In some embodiments, it will be useful to select the treemap graphical output mode to be the first (default) output that is graphically shown to the Administrator and optionally the users. If the software is being used in an interactive group setting, then the Administrator can then discuss the clustering results with the various users, using the treemap output as a convenient graphical display. Based upon group input, the level of significance of the various tree settings can be assigned, and various threshold cut-offs can be refined based either upon group discussion, or on preassigned algorithms as desired.
[0111] After discussion is over, the Administrator will enter the necessary threshold cutoff information to the system, or alternatively the system may do this automatically. The system may then display the recommendation with Data Points organized in pillars as indicated.
[0112] FIG. 11 shows an abstracted example of the treemap output. In this embodiment, the horizontal axis may display all of the data points (i.e. issues, concerns) involved in the process. In order to improve the usability of the treemap user interface, the data points (issues, concerns) that were voted by the group to be more important than the other data points (issues or concerns) may be represented by bigger boxes (i.e. the image symbolizing that particular issue or concern will be made larger), and the system will also weight these higher voted data points (issues or concerns) higher as well.
[0113] Alternatively other methods of priority visualization may also be implemented. For example, in alternative schemes, instead of designating priority by box size, other types of graphical methods may be used. For example, a priority score may be inserted in the corner of each image/text issue, or other graphical index such as number of stars (group favorites) may be employed. In some embodiments, the system may automatically judge when certain selections are clear winners, when all are rated about the same, or clearly show the least important issues.
[0114] FIG. 12A shows the actual treemap produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C, and who produced the actual similarity matrix shown in FIG. 6 . As can be seen, the images that correspond to the issues, concepts or Data Points considered most important by the two users are shown as larger images than the less important issues, concepts, or Data Points.
[0115] In addition to image size, other graphical methods for visual identification, such as numeric ratings or use of a color scale may also be used to show the average level of similarity, as determined by group consensus. Thus, for example, Data Points that are more similar to each other may be displayed in darker color, and Data Points that are less similar to each other may be displayed in lighter colors.
[0116] Alternatively, concepts or data points considered most important can be simply be shown by a numeric indicator on the images that correspond to the issues, concepts, or Data Points. This alternate method (here for a different analysis) is shown in FIG. 12B .
[0117] In FIGS. 11 and 12A , the vertical axis represents the distance between clusters. As was discussed in Part 4—Clustering Analysis Module, distance is computed during the clustering process. The definition of distance between clusters various depends on the method of calculation used. For single-linkage method, distance between two clusters may be defined by the closest similarity rating between them.
[0118] Continuing with the invention's user interface, in the tree map, the height of a branch may represent the distance between two clusters. Thus in the example tree map, the “height” between Data Point 1 and Data Point 10 is 1 and the height of Data Point 4/9/7 and Data Point 2/5/3 is 7.
[0119] This user interface may be used by the Administrator, the various users, or in a conference setting, by a conference facilitator and participants to extract further meaning from the analysis. Here the “height” on this user interface is a very good predictor of how easy or hard it will be to name a cluster. This is because if all the ideas are really very similar, we are looking at almost the same idea. If the ideas are very different, then likely the idea will probably need more discussion in order to understand and interpret the result. An example of the user interface display is shown in FIG. 13 .
[0120] FIG. 14 shows the actual clustering diagram produced by the users who were previously voting in FIGS. 2B , 3 B, and 3 C, and who produced the actual similarity matrix shown in FIG. 6 , as well as the actual treemap shown in FIG. 12A .
[0121] FIG. 15 shows how the entire process may be used to facilitate complex group qualitative decisions, such as product branding, to produce high quality results within a single day. Here either human facilitators, or alternatively automated wizard software can help move the process along by imposing time deadlines and providing supplemental help and assistance as needed. In some embodiments, such as when groups are assembled into a single room, it may be advantageous to use multiple high resolution image projectors or video screens or large format interactive display boards to keep a display of past steps in the process up on screen while work commences. The ongoing display assists facilitator to maintain group focus and motivation.
Part VI. Voting Patterns Analysis Module
[0122] In some embodiments, the system will also perform clustering on the user rating pattern and display grouping results to the Administrator and/or other users. This option allows different users to be assigned to different groups based on similarity of their rating patterns. For example, voting trends may show that men system users (voters) tend to have significant differences from women system users, or younger voters may have significant differences from older voters. In a branding context, for example, this information can be highly useful, particularly if the brand is being focused at certain specific consumer subgroups.
[0123] In some embodiments, the system will allow the Administrator to see the names of the users in each group, as well as the clustering results based on the specific user group. In other embodiments, specific names may be withheld to encourage candid voting and preserve user privacy.
[0124] This type of analysis may begin by extracting information from the various user matrices. Here each row in a user matrix represents the rating results of a Data Point versus the other Data Points. For each Data Point, the program may extract rating results (rows) from each user, and combine them into a single matrix. The column for Data Point X vs. Data Point X may be removed since the value is set to 2 by default (comparing to itself)
[0125] The system may then perform average linkage hierarchical clustering. After the analysis is completed, the system may then display an alternative tree map with users being categorized into different clusters.
[0126] The number of clusters we will get depends on a preset value or run time set value that may be varied according to the judgment of the system Administrator as to where best to “cut the tree”.
[0127] In alternative embodiments, the system software may be set to automatically force the output to display only a preset maximum number of tree clusters/pillars. For example, the system may automatically force cluster output into a maximum of two, three or four different clusters. This cluster upper limit option allows the Administrator or team to visualize the data as a smaller number of easier to understand branches. This automatic cluster upper limit option is particularly useful when working with larger numbers of concepts and ideas (e.g. 40 ideas) which otherwise (without automatic cluster forcing) could lead to an overly large number of branches, which in turn would make it more difficult for users to use to understand and extract meaning.
[0128] In the case where the system does not automatically impose a preset upper limit on the number of the clusters, if we set the system to cut off the tree at half of the longest distance between any clusters, we will get four clusters in results. We may name each cluster from left to right (group 1, group 2, group 3, etc.). For example, we have the following grouping results after the clustering analysis for Data Point X:
Group1: User A, User B, User C, User D, User H
Group2: User E
Group3: User G, User F
Group4: User I
[0129] This process may be repeated for the rest of the Data Points, and the system will keep track of the user groupings. After all the Data Points are analyzed, the system can then calculate the group a user most frequently belongs to (i.e. the mode). An example of such a table showing user grouping results for all Data Points and voter modes is shown in FIG. 16 .
[0130] Here, the overall grouping results may be summarized as below:
Group 1: User A, User C, User D
Group 2: User B, User F, User H
Group 3: User F, User G, User I
[0131] The system may then run cluster analysis on Group 1, 2, and 3 separately and display a comparison report on their clustering results.
[0132] For this analysis, the clustering process is similar to what we did previously for the overall cluster, but instead of combining the individual matrix of 9 users, the system may instead combine the individual matrix of users in Group 1 only (then do the same for group 2 and 3).
[0133] The overall clustering results may then be included in the display. If the program is being run in a group setting, the facilitator can then, for example, compare the difference between each user group and the overall results, as well as the difference between each user group. A sample report of such user grouping results is shown in FIG. 17 . Note that in FIG. 17 , the clustering results are only for display purposes, and are not actual data.
[0000] Voting Patterns Analysis Module Part B:—Compare Individual User Matrix with Overall Similarity Matrix
[0134] More insight may also be obtained by comparing how individual user choices compare with the group averages. This can be done by first calculating the percent of similarity between the similarity matrix belonging to the user of interest, versus the overall group similarity matrix. The user's can then be grouped by percent of similarity, and a level of confidence rating generated. For example, this level of confidence can determine how different a user result is from the majority, as well as determining if we have a group divided into factions, or even if a particular user is an extreme outlier who perhaps should be discarded from the analysis. In some embodiments, the system Administrator may, for example, be able to see the names of the users in each group and the % of total users, and also determine segmentation—i.e. the relationship (if any) between voting patterns and types of users.
[0135] This analysis may also begin by comparing an individual user matrix with the overall similarity matrix. Here the idea is to determine the differences in cell values between the user and overall matrices. The program can pick any user to start. In this example shown in FIG. 18 , we will begin with User A's matrix.
[0136] To do this, user A's matrix needs to be transformed to show similarity in a positive scale.
[0137] The formula for this transformation is:
[0000] −1*( X ij −2) Where X ij is value of row i and column j, i ε(1 ,N ) and j ε(1 ,N ), N is the total number of Data Points
[0138] As before, in this example, the maximum cell value is 2, which is the maximum value allowed in a user matrix.
[0139] To compare User A's matrix with the overall similarity matrix shown in FIG. 19 , we will need to transform the overall similarity matrix into a single user matrix.
[0140] For this comparison exercise, the formula for transforming an overall similarity matrix is shown as follows:
[0000] −1*(ROUND( X ij /N )−2) Where X ij is value of row i and column j, i ε(1 ,N ) and j ε(1 ,N ), N is the total number of Data Points
[0141] In our example the overall similarity matrix combined the results from nine users. Here we will transform it to a single user matrix by dividing the cell values by nine, which is the total number of users participated.
[0142] Then the above formula will transform the matrix to show similarity in a positive scale.
Comparison Between an Individual User Matrix and the Overall Similarity Matrix
[0143] Now that both matrices have the same scale, we can compare each cell in the user matrix to the corresponding cell in the overall similarity matrix. The comparison results will be stored in a new matrix, called the Difference Matrix. If the two cell values are identical, the corresponding cell in the difference matrix will be zero. Otherwise the difference matrix cell value will equal to the absolute value of the difference between the two cells.
[0144] The formulas are summarized as below:
[0000] If X ij =Y ij then Z ij =0
[0000] Otherwise if X ij ≠Y ij then Z ij =absolute( X ij −Y ij )
[0000] where X is the individual user matrix, Y is the overall similarity matrix and Z is the difference matrix.
[0145] Here Row iε(1,N) and column jε(1,N), N is the total number of Data Points
[0146] The difference matrix for user A's matrix vs. overall similarity matrix is shown in FIG. 20 .
[0147] Here the percentage of similarity is calculated by the inverse of the sum of all cells divided by 2 then divided by total number of cells in the difference matrix.
[0000] % of Similarity=100%−SUM of cells in Difference Matrix÷2÷Total Number of Cells in Different Matrix.
[0148] In this example, the sum of all cells in the difference matrix is 101 and there are 10×10=100 cells in the matrix so the % of similarity is:
[0000] 100%−(101/2/100)=49%
[0149] This lets the Administrator and users know, for example, that the voting pattern of user “A” is 49% similar to the overall voting results.
[0150] The system will perform the same calculation to the rest of the users and summarize the results into a level of agreement report, shown in FIG. 21 .
[0151] Using this report, the Administrator can then drill down to view the clustering results for an individual user. This is shown in FIG. 22 .
Part VII. Voting Patterns Analysis Module Voting Results on Pre-Defined Groups (Optional)
[0152] In some situations, the Administrator might also want to know if users with different backgrounds have voted differently. In this optional embodiment, the system may ask the Administrator to enter the name and predefined values of the user parameters (e.g. age range, sex, department, etc.) in various preset groups When users log in to their voting booth, they will have to select the best description from a drop-down list user interface, such as one shown in FIG. 23
[0153] For example, if we have the following pre-defined groups:
Group 1: User A, User C, User E, User G
Group 2: User B, User H
Group 3: User D, User F, User I
[0154] The system may then run clustering analysis for each group and display the results, such as those shown in FIG. 24 . Here FIG. 24 shows a sample display of clustering results for a pre-defined age group.
[0155] In some embodiments, the Administrator may also have the ability to compare voting results side by side between different groups.
[0156] This function may also allow Administrators to run clustering on specific selected group(s). For example, if the Administrator has decided not to look at clustering results from the executive group (or if the executive group has locked out this function) but rather may just want to look at results from the marketing and customer service groups, then the Administrator can exclude executive and combine marketing and customer service together and rerun clustering.
Additional Features and Embodiments
[0157] In addition to the previously described software features, additional software features may be added to the system as desired. Some of these additional features include:
1. Addition of third party participation input of Data Points. 2. Addition of third party participation in clustering Data Points. 3. Addition of alternative clustering methodologies. 4. Addition of alternative semantic data conversion methodologies. 5. Addition of input of Data Points as sounds, scents, 3D images, moving images and/or physical objects. 6. Addition of result display methods. 7. Addition of alternative analysis methods of voting patterns. 8. Addition of adaptive selection of pre-defined user group clustering. 9. Addition of tools to assist users in naming sub-clusters and clusters
Alternative Uses:
[0167] Although brand identification and analysis has been used throughout as a specific example and embodiment of the invention's methods, it should be understood that these specific examples and embodiments are not intended to be limiting. Rather, this is a general purpose process, as such it can be used anywhere users are trying to analyze and interpret the relationship between verbal and/or visual data elements.
[0168] Other areas where the methods of the invention may be used include:
1. A group of decision makers clustering decision options into groups, and sub-groups 2. A creative professional artist clustering ideas, images, objects and/or sounds into themes and sub-themes 3. A group of marketers collectively clustering ideas, images, sounds and/or objects into groups of creative categories 4. A group of product managers collectively clustering features into a feature set, and sub-sets 5. An author or group of authors clustering ideas into the themes or chapters of a published work 6. A group of customers collectively clustering products into groups, and sub-groups 7. An individual or group clustering personal ideas, images or objects into meaningful groups, and sub-groups 8. A sales person or team clustering ideas to present as different parts of a proposal 9. A group of friends clustering ideas to create a theme for an event 10. A group of fans clustering their favorite stories, shows, or events 11. An individual clustering the friends in their social network | A computerized method of visualizing the collective opinion of a group regarding one or more qualitative issues. The group initially selects N issues from the universe of potential issues and often assigns the issues images and titles. The system presents each user with graphical user interface screens wherein individual users vote on the relative importance and degree of relationship between the N aspects (Data Points) and issues, often using drag and drop methods. The software computes N×N similarity matrices based on users voting input and clusters various aspects into groups of greater and lesser similarity and importance, and presents results of users qualitative ranking in easy to read relationship tree diagrams where the relative importance and qualitative relationship of the issues may be designated by size and other graphical markers. The software may reside on a network server and present display screens to web browsers running on user's computerized devices. | 6 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a magnetic field enhanced sputtering arrangement having a drive housing which forms the arrangement housing, and a rotor which is connected to a magnet carrier arrangement in a torsion-tight or non-rotatable manner. The present invention also relates to a vacuum treatment apparatus equipped with the magnetic field enhanced sputtering arrangement of the invention.
It is known to sputter materials, be they electrically conducting or electrically insulating, in vacuo, wherein an electric field is generated in a reaction chamber, between the surface of the material to be sputtered, i.e., the target surface and a counter electrode. A plasma discharge is formed, and with the positive ions of a gas introduced into the reaction chamber, the surface of the material to be sputtered is sputtered. The material thus sputtered is used either directly for coating workpieces in the chamber, or in the form of a reaction product after reacting with a reactive gas supplied to the chamber.
Such sputtering processes are carried out in DC plasmas, HF plasmas, or in plasmas which are generated by DC and superimposed AC.
In spite of entirely different details in the mechanism of a sputtering process proper, for the stated case of plasma excitation, it is further known to increase the plasma density and therewith the sputtering rate by generating a magnetic field in the region of the target surface to be sputtered. A sputtering process of this type, which is enhanced by a magnetic field, is known for example by the term magnetron sputtering.
It is further known to close at least partially, the flux of this magnetic field, by forming a tunnel thereof over the target surface.
Moreover, it is known, such as for example for magnetron sputtering, from EP-0 399 710, U.S. Pat. No. 5,130,005, DE-A-33 31 245 or as depicted in DE-A-35 06 227, to move the flux of the magnetic field with respect to the target surface, and in this way to reach the range of the maximum sputtering rate, be this in order to sputter the target as uniformly as possible, or in order to achieve, on the work piece, a desired distribution of the rate of deposition of the material.
It is also known in reactive sputtering to move the flux relative to the sputtered surface.
Additionally, the provided target arrangements can be planar in this arrangement, as is the case with the known planar magnetron arrangement, or they can define volume surfaces, such as for example concave surfaces, in which connection, reference is made to the pot-shaped magnetron arrangement according to DE 35 06 227. This target arrangement can be implemented integrally or it can comprise several targets.
In its broadest aspect, the present invention relates to all stated sputtering techniques and appropriate magnetic field enhanced sputtering arrangements.
Regarding a planar magnetron, it is known from DE-A-33 31 245 as well as from U.S. Pat. No. 5,130,005, with respect to the realization of a relative motion between a magnetic field flux and a target surface, to move a magnet arrangement under the target arrangement. According to DE-A-33 31 245, for this purpose a magnet arrangement is moved along the target arrangement in a cooling medium chamber, which is closed off on one side from the target arrangement by holding plates. This magnet arrangement is moved eccentrically with respect to an axis of rotation or it is additionally guided by cams. In this way a tunnel-shaped magnetic field is generated, moving along the target surface to be sputtered. The rotational drive of the magnet arrangement takes place either through the flow of the cooling medium, namely water, through the cooling chamber, or via a drive shaft extending through the chamber wall.
A magnetic field enhanced sputtering arrangement of the above mentioned type and implemented as a planar magnetron, is known from U.S. Pat. No. 5,130,005. It comprises a housing, on the front face of which a target arrangement can be mounted, which here comprises exclusively the target and the target plate below it. This target arrangement can only be mounted or dismounted by dismantling the arrangement. The housing defines an annular chamber adjoining the mounting plate. A magnet carrier is movably supported about a hinge pin in the housing. The magnet in a magnet arrangement including the carrier, generates a magnetic field whose flux penetrates through the region of the target. The magnetic field is shifted by the relative rotational movement between the magnet carrier arrangement and the target, which is stationary in the housing.
Furthermore, an electric motor is provided which acts upon the magnet carrier arrangement via toothed belts and gearing via a pinion axle which extends through the wall of the chamber. In this arrangement, it is a disadvantage that the electric motor and the drive transmission provided between the magnet carrier and the electric motor, take up a great deal of space. Additionally, the drive motor is mounted at an offset position from the annular chamber which function as a cooling chamber. The drive motor thus must be cooled separately. A further disadvantage is that by means of an expensive electronic monitoring system, the movement of the magnet arrangement itself must be monitored in order to detect defects between the drive motor and the magnet arrangement.
SUMMARY OF THE INVENTION
It is the task of the present invention to eliminate these disadvantages in a magnetic field enhanced sputtering arrangement of the above mentioned type.
This is achieved through the invention, which comprises a magnetic field enhanced sputtering arrangement with an arrangement housing, on whose front face is mountable a target arrangement. A magnet carrier arrangement rotatably supported about an axis, is provided in the arrangement housing. Flux (Φ B ) of a magnet on the carrier penetrates through a region of the mounted target arrangement and is shifted through relative rotational motion. An electric motor drive with a drive housing connected to the arrangement housing so as to be torsion-tight, has a rotatably supported rotor which, in turn, acts upon the magnet carrier arrangement. According to the invention, the drive housing forms the arrangement housing and the rotor is connected to the magnet carrier arrangement so as to be torsion-tight or non-rotatable.
In this way, the drive housing simultaneously forms the housing for the rest of the arrangement and the rotor is connected in a non-rotatable manner, to the magnet carrier. An extremely compact construction results. Since, further, the target arrangement must be cooled effectively and is mounted in the arrangement housing, which in turn, is the housing for the drive, the basis is created for simultaneously cooling the target arrangement and the electric motor drive, using the same cooling system. The construction according to the invention also avoids gearing and thus makes possible a drastic reduction of the number of moving parts. This increases operating safety, reduces production cost, and leads to an extremely compact construction.
The term electric motor drive herein means a drive in which electromagnetic fields establish an operational linkage between a stator and a rotor.
The compact construction of the sputtering arrangement is further increased, preferably in that the electric motor transmission (φ M ) between the housing and rotor takes place via an annular air gap which is coaxial to the axle, and whose diameter is significantly greater than its axial extent. In a preferred embodiment that is implemented as a magnetron, preferably as a planar magnetron, wherein the magnetic field flux exits in tunnel-like fashion from the mounted target arrangement and enters it again.
According to another feature of the invention, the motion of the magnetic field flux along the target surface to be sputtered is laid out in the form of a preselected path, and preferably as a closed path. This is readily possible since magnets are disposed on the magnet carrier arrangement, which primarily carries out a rotational motion, and the magnets are controllably movable on the carrier and/or, if electromagnets are used, they are driven selectively in terms of time or angle of rotation and/or the magnets are disposed eccentrically.
Although it is entirely possible in a system which allows relative movement between the target and magnet carrier, and with respect to an apparatus on which the arrangement according to the invention is mounted, e.g. a system which is absolutely at rest, to move the target and leave the magnet carrier at absolute rest; in a highly preferred embodiment, the housing is implemented for mounting on a vacuum coating apparatus and therewith, to form the reference system which is at rest.
A vacuum treatment apparatus, according to the invention, is distinguished due to the stated advantages of the sputtering arrangement according to the invention, and those yet to be described, in particular by an extremely compact construction.
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 specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which the preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings:
FIG. 1 schematically illustrates the basic principle of the sputtering arrangement according to the invention, with the housing at rest and using a planar target;
FIG. 2 is a view which is analogous to FIG. 1, and schematically illustrates the fundamental arrangement according to the invention, in the form of a pot-shaped magnetron; and
FIG. 3 is a longitudinal sectional view of an embodiment which is preferred today and which comprises the magnetic field enhanced sputtering arrangement according to the invention, in which all advantageous partial aspects of the invention are used in combination.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically depicts a magnetic field enhanced sputtering arrangement according to the invention with planar target arrangement 1, which comprises, in particular, a target plate. The target arrangement 1 closes off housing 3 of the sputtering arrangement, against a process volume U and is connected to housing 3 at 18. Within the housing 3, and ina magnet carrier chamber 5a a magnet carrier arrangement 5 is rotatably supported about an axis A. The carrier arrangement includes permanent and/or electromagnets 7. The arrangement formed by magnets 7 can comprise permanent and/or electromagnets which are mounted to be stationary on the carrier 5 or, as shown schematically at r in dashed lines, the permanent and/or electromagnets, in addition to rotation about axis A, are movable with respect to the carrier 5, radially and/or azimuthally, generally in such a way that with respect to housing 3, the magnets travel on a given path. In this way, the region on the surface of the target arrangement 1 and to be sputtered, through which and along which the magnetic field flux Φ B is effective, is shifted along appropriate paths, which can also take place by driving electromagnets that are fixedly provided on themagnet carrier 5.
In FIG. 1 the course of the flux Φ B , with magnets disposed eccentrically to axis A (solid line and dashed line) and, with a tunnel-shaped flux over the target surface are shown purely schematically and qualitatively. A dot-dash line illustrates the flux which can also be used, in particular, with HF applications.
The magnetic field flux Φ B depicted schematically in FIG. 1, is atleast partially closed in a tunnel-shaped manner over the target surface tobe sputtered and/or is largely closed over structures in the proximity of the target, such as frames of the housing 3.
The magnet carrier arrangement 5, according to the invention, is coupled soas to be resistant to torsion (in a non-rotatable manner), to a rotor 9 of an electric motor drive, whose stator 10 is connected in a manner that is resistant to torsion, to the housing 3. A force-transmitting electromagnetic driving flux Φ M acts across an annular air gap 12. The depicted sputtering arrangement is DC operated or high frequency operated or is operated in a mixed form, with DC and AC as a magnetron andconsequently, a plasma discharge is generated via a counter electrode 14. As is customary, the process chamber 3a of the housing, together with counter electrode 14 can be connected to a reference potential, such as for example to ground potential. Further, as is known to the expert, the counter electrode 14 can be connected to a bias potential or a bias electrode can be provided separately.
In FIG. 1, the different options for electrically feeding the plasma discharge are depicted schematically on the power source unit 16.
FIG. 2 depicts the sputtering arrangement similar to FIG. 1, but for a non-planar target surface to be sputtered, namely, as an example, a cone-shaped target, wherein, as with the target arrangement according to FIG. 1 as, the surface to be sputtered can be formed by a single target orby several targets.
FIG. 3 depicts an embodiment of a sputtering source according to the invention which is preferred today, for example, in the form of a planar magnetron. The cathode arrangement 1 comprises the target plate 21 proper and here for example a rear backing plate 23, which plates, in the mountedstate, are closely thermally coupled, as well as also electrically coupled,such as through mutual prestressing or bonding.
The target arrangement 1, acting electrically as a block, is detachably mounted on the housing 3 of the arrangement, namely on a metal mounting flange 25. The target arrangement 1 is clamped on the mounting flange 25 with a vise, or forms, as in the present case, with the flange 25, a target replacement quick lock, such as a bayonet catch. A lock of this type is known from EP-A-0 512 456 which, in this respect, is an integral component of the present specification.
The mounting flange 25 is connected via an insulating flange 27 to the remaining parts of the housing 3, the housing being essentially in the form of a bell. At the side of the target arrangement, a wall 29 comprising essentially a rigid plastic material, defines together with thetarget arrangement 1, a cooling chamber 31. One side of the cooling chamber31 is defined directly by the target arrangement 1, or by a heat-conductingfoil 31a, which through the pressure in the cooling medium, is pressed against the target arrangement 1.
If the target arrangement 1 is exchangeable by means of a quick lock, the medium-activated foil according to EP-A-512 456 serves as a tension or tension-relief element for the lock, such as, for example, for a bayonet catch.
Wall 29 continues coaxially toward axis A and then forms a pipe 33, which, together with wall 29 in housing 3, define an annular magnet carrier chamber 35. A rotor 41 is rotatably supported on bearing 37, at a central housing portion 39, centrally supporting the pipe 33 or, generally, the central axis. A torsion-resistant, that is, non-rotatable stator 43 on housing 3 together with rotor 41, defines the annular air gap 12, which forms the electric motor drive of the rotor 41. The magnet carrier arrangement 5 is supported on the rotor 41 so as to be non-rotatable therewith. The magnet carrier arrangement 5 revolves in the magnet carrierarrangement chamber 35, when the rotor is driven. The diameter of ring-shaped gap 12 is substantially greater than the axial extent of the gap so that a precise and, in particular, sufficiently slow rotational driving of the rotor can take place and simultaneously the volume defined by the target arrangement 1 is optimally utilized in the sense of the compact construction of the arrangement, and thus a gearing can be omitted.
An asynchronous motor with stator windings 45 and winding-free rotor is preferably used as the drive. The motor has an optimum flat construction when viewed axially.
Depending on the use, another drive motor can also be used, for example, anelectronically commutated motor or a DC motor which is electronically driven.
The interior volume of pipe 33 comprising, as already stated, an electrically insulating material, preferably a synthetic material, is divided by means of an inner pipe 47 acting as a separating wall, into a feed line 49 and a return line 51 for circulating a cooling medium to and from the cooling chamber 31. The metal inner pipe 47 is connected electrically to a metal separating wall 53 which extends essentially parallel to wall 29 and to the target arrangement 1, through the cooling chamber 31. An outlet opening 55 is provided in a central region of the separating wall 53, through which the cooling medium flowing through the feed line 49 in the direction of the arrow, flows to the outside, along the target arrangement 1. Return flow openings 57 are provided on the periphery of the separating wall 53, by which the cooling medium flows radially back into the return line 51. If a foil 31a is provided and if itis electrically conducting, it ensures a contact region on the target arrangement, over a large area.
The feed line 49 in pipe 33 is connected via a connection line arrangement 59, to a flexible plastic tube 61, which, embedded in a plastic portion 63of housing 3, extends to the outside and there, loops several times around the outer surface of the housing 3. The return line 51 communicates with aline arrangement 65, leading radially to the outside.
Via pipe 33, wall 29 and plastic part 63 of the housing, the inner pipe 47,which extends as a separating wall through pipe 33, is electrically insulated from the metal parts of the housing 3, and is connected to an electric connection 67, to which is applied the electric signal for operating the target arrangement 1. Electrical contacting with the target arrangement takes place via the separating wall 53 which is peripherally connected to the metal holding frame 25, and potentially the foil 31a.
Water is preferably used as the cooling medium. From the connection 67 carrying high voltage for the target arrangement 1, the voltage drops along the section of the tube 61 extending radially to the outside, or thecontained water column, due to the impedance of water, so that on the outside of the housing 3, the reference potential, e.g. ground potential, is practically reached. The cooling chamber in the axial direction is optimally thin so that overall an optimum effect of the magnet system on the surface of the target arrangement to be sputtered, is effected.
By providing the electrically insulating pipe, preferably comprising a synthetic material, and implemented integrally with wall 29, the insulation between the voltage-carrying inner pipe 47 as electrical feed to the target arrangement, as well as plate 53 to the metal parts of the housing 3, is ensured without complicated insulation measures, which further reduces the volume of the sputtering arrangement according to the invention. Providing the separating wall 53 in combination with the feed and return lines for the cooling medium in pipe 33 results optimally in a flow of fresh cooling medium along the target arrangement and its flow back in the region of wall 29 wherein the separating walls for the feed and return lines for the cooling medium are simultaneously used as electrical connection lines for the target arrangement 1.
In FIG. 3, and only shown on the right side, a mounting flange 70 is provided on the vacuum chamber. 72 is a vacuum ring seal, 74 is a HF seal,and 76 is a shield.
The target arrangement 1 is provided with a bayonet lock which can be tightened via foil 31a through the pressure of the cooling medium, and is removed or replaced by rotation with respect to the mounting or bayonet flange 25, at the vacuum chamber side. The entire arrangement with drive and cooling chamber including the foil 31a in FIG. 3, can be dismounted downwardly, thus from the normal atmosphere, and be removed from flange 70.
Through these constructive measures, which drastically simplify the arrangement, compactness is also achieved and the volume of the sputteringarrangement is reduced significantly.
By providing the flexible tube 61, and therewith realizing the use of waterimpedance, on the one hand, a sufficient voltage drop with low electric loss between high-voltage carrying parts and the housing 3 is ensured and,on the other hand, simultaneously the housing 3 is cooled. Consequently, with the same system to be provided for the target arrangement, cooling ofthe housing of the drive system and therewith its stator is effected by heat conduction.
Due to the large diameter of the annular gap coupling between stator and rotor, the rotation of the rotor can be driven optimally slowly and uniformly so that expensive and voluminous gearing is avoided. The rotational behavior of the drive system can be simply controlled or regulated electronically. Viewed overall, the number of required constructional parts is drastically reduced compared to conventional constructions of sputtering sources, which increases reliability and reduces constructional expenditures.
While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A magnetic field enhanced sputtering arrangement and vacuum treatment apparatus includes an arrangement housing, on whose front face is mountable a target arrangement. A magnet carrier arrangement is rotatably supported about an axis in the arrangement housing. Magnetic flux of the magnet carrier penetrates through a region of the mounted target arrangement and the region is shifted through a relative rotational motion. An electric motor drive with a drive housing is connected to the arrangement housing so as to be torsion-tight therewith, and a rotor is rotatably supported in the drive housing, which, in turn, acts upon the magnet carrier arrangement. The drive housing forms the arrangement housing and the rotor is connected to the magnet carrier arrangement so as to be non-rotatable therewith, for a compact construction. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for "sighting in" rifles and more particularly, to a bench rest for accommodating a rifleman, immobilizing a rifle and "sighting in" the rifle in a highly efficient manner. In a preferred embodiment the bench rest is constructed of plastic pipe such as polyvinylchloride piping using various polyvinylchloride pipe fittings, a seat or platform is provided to support the rifleman and both fixed and adjustable cradles are sued to securely, yet adjustably, mount the rifle. In a most preferred embodiment the adjustable cradle is fitted with vertical and horizontally-oriented, threaded rods adjusted by crank or rod handles to facilitate positioning of the sights or rifle scope directly on the target. The polyvinylchloride (PVC) bench rest is light in weight, yet highly rigid and sturdy for the intended purpose.
2. Description of the Prior Art
One of the problems which is inherent in testing and sighting rifles for accuracy or in target shooting is that of immobilizing the rifle to a desired extent in order to adjust the iron sights or rifle scope to extreme accuracy at selected distances. This objective is typically accomplished by placing the rifle on a table, bench or other support and using sand bags to prop the rifle in a secure position and enable the shooter or rifleman to accurately focus the sights on the target and make the necessary adjustments to the sights or scope. Typical of devices which may be utilized of this purpose is the "Instrument-Supporting Tripod with Seat" detailed in U.S. Pat. No. 2,982,338, dated May 2, 1961, to W. Arthur Ernst. While the device is designed to support an electric generator for military usage and provides a seat for the operator of the hand cranked instrument, it might also be used to support a rifle for "sighting in" or target shooting purposes. U.S. Pat. No. 4,055,017, dated Oct. 25, 1977, to Harold Thompson, details a "Mini Bench Rest". The bench rest includes a mounting base adapted to permit articulation for both pitch and yaw and a bench having a beam mounted to a collar and fitted with a front support rest. The front support rest is adjustable for elevation with respect to the main plane of the beam and the beam also includes a detachably mounted rear support for long barrel guns such as rifles. A "Firearm Shooting Support Table" is detailed in U.S. Pat. No. 4,296,963, dated Oct. 27, 1981, to Kenneth G. Blanchard, et al. The shooting table includes a table portion for supporting a firearm and a seat portion for supporting the operator or rifleman while firing the firearm with the firearm resting on the table portion. The table has a pair of front legs to support the front of the table and the seat portion includes a pair of horizontally-extending support members extending from the seat and pivotally mounted to the front legs of the table to pivotally support the seat portion of the front of the table. The horizontally-extending support members telescope to adjust the seat toward or away from the table. The seat portion also has a pair of legs mounted to the seat portion of the rear of the table to support the rear end of the seat separate from the table and the table has a support leg at its rearward end to support the rearward end of the table. U.S. Pat. No. 4,501,082, dated Feb. 26, 1985, to F. Joseph Phillips, et al, details a "Portable Bench Rest". The bench rest includes an upper cross member having legs pivotally attached thereto to allow for collapsing of the legs for carrying the shooting bench and a brace secures one of the legs in an extended position during use of the bench. The other leg carries a rest member at its upper end, which rest member is adjustable for elevation by pivoting the leg about its pivotable attachment to the upper cross member. U.S. Pat. No. 4,506,466, dated Mar. 26, 1985, to Stanley J. Hall, details a "Portable Shooter's Bench". The bench includes top, front and rear leg assemblies pivotally connected thereto, which leg assemblies fold inwardly to provide a pocket for carrying a seat which is movably connected to the leg assemblies when they are folded outwardly at the point of use. The bench top is inclined and is vertically and angularly adjustable and also has a lateral recess which overlies the seat for accommodating the upper body of the shooter when seated on the seat. An adjustable gun rest is provided at the front of the bench top for supporting the forearm of the shooter's gun. U.S. Pat. No. 4,535,559, dated Aug. 20, 1985, to Michael F. Hall, details a "Portable Shooting Bench" which apparatus enables more accurate firing of rifles and other firearms and is particularly adapted for use for this purpose in hard-to-reach locations and/or over extended periods of use because of its lightness of weight and compactness when assembled for portage. A "Portable Blind" is detailed in U.S. Pat. No .4,788,997, dated Dec. 6, 1988, to L. M. Clopton. The lightweight, portable blind includes a quick adjustable combination armrest/shooting rail, roof and roof support members, all of which attach to a folding outdoor chair, using clamps. A camouflage slip cover encloses the entire blind to conceal the person inside.
It is an object of this invention to provide a new and improved bench rest for "sighting in" rifles, which bench rest includes a rigid frame having a platform or seat for supporting a rifleman and a pair of cradles for receiving the stock and forestock, or barrel, respectively, of a rifle to stabilize the rifle and facilitate adjusting the rifle sights or scope to impact a bullet on a target.
Another object of this invention is to provide a bench rest for receiving both a rifle and rifleman in a stabilized configuration and facilitate sighting in the rifle sights or scope on a target.
Yet another object of this invention is to provide a new and improved bench rest for "sighting in" rifles and patterning shotguns, which bench rest includes a rigid frame fitted with a fixed cradle for receiving and immobilizing the rifle or shotgun stock and an adjustable cradle for receiving the rifle or shotgun forestock or barrel and further provided with a seat or platform for supporting a rifleman to facilitate "sighting in" the rifle on a target or determining the shot pattern of a shotgun at various distances.
A still further object of this invention is to provide a plastic piping bench rest for supporting a rifle and rifleman in rigid, stable configuration, which bench rest includes a fixed cradle for receiving the stock of the rifle and an adjustable cradle for receiving the forestock or barrel of the rifle, which adjustable cradle is supported on a block and threaded rod apparatus which may be adjusted in both the horizontal and vertical directions to "sight in" the rifle.
SUMMARY OF THE INVENTION
These and other objects of the invention are provided in a new and improved bench rest for sighting in rifles, which bench rest includes a rigid, light frame constructed of polyvinylchloride pipe and suitable polyvinylchloride pipe fittings and includes a seat, a fixed cradle for receiving the stock of the rifle and an adjustable cradle for receiving the forestock of the rifle. The adjustable cradle is further provided with a support block that threadably receives horizontally and vertically oriented threaded rod and rod handles or cranks for adjusting the adjustable cradle and rifle barrel in the horizontal and vertical directions and sighting the rifle in on a target.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood by reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a preferred embodiment of the bench rest of this invention, with a rifleman and a rifle in functional shooting position;
FIG. 2 is a rear view of the bench rest illustrated in FIG. 1;
FIG. 3 is a front view of the bench rest illustrated in FIG. 1;
FIG. 4 is a left side view of the bench rest illustrated in FIG. 1;
FIG. 5 is a top view of the bench rest illustrated in FIG. 1;
FIG. 6 is a sectional view taken along line 6--6 in FIG. 1, of a preferred adjustable cradle assembly for vertically and horizontally adjusting the rifle barrel when the rifle is in the shooting position illustrated in FIG. 1;
FIG. 7 is a sectional view taken along line 7--7 in FIG. 1 of the adjustable cradle assembly illustrated in FIG. 6; and
FIG. 8 is a side view, partially in section, of the adjustable cradle illustrated in FIGS. 6 and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1-5 of the drawings, in a preferred embodiment the bench rest for rifle sighting of this invention is generally illustrated by reference numeral 1. In a most preferred embodiment of the invention the bench rest frame 2 of the bench rest 1 is characterized by conventional assembled and glued polyvinyl chloride (PVC) piping and fittings, including regular and angular tee fittings and elbow fittings, in non-exclusive particular. Typically, a set of support bars 3 and provided on each end of the bench rest frame 2 and each set of support bars 3 is connected by support bar couplers 3a and a brace coupler 6, and receives a bar foot 4 on each end. Each support bar coupler 3a and brace coupler 6 is characterized by a tee fitting, while each bar foot 4 is characterized by an elbow fitting, both constructed by PVC material. A bar brace 5 projects between each set of support bars 3 and projects into the tee leg of the brace coupler 6 on each of the sets of support bars 3, as illustrated. Spaced, parallel, vertical leg members 7 extend upwardly from the tee legs of the support bar couplers 3a, respectively, and are provided with leg brace couplers 10, characterized by offset PVC tee fittings, which leg brace couplers 10 also receive leg braces 9, projecting into the tee legs of corresponding leg brace couplers 10, installed on spaced, parallel, horizontal side members 8, respectively. The side members 8 are attached to the respective leg members 7 by side member couplers 11, which are characterized by PVC teel fittings. An additional leg brace 9 projects between the respective leg members 7 at the seat end of the bench rest frame 2 and is secured in position by additional tee fitting leg brace couplers 10, to further stabilize the bench rest 1. Accordingly, it will be appreciated from a consideration of FIG. 1 of the drawings that one set of leg braces 9 project upwardly from corresponding leg brace couplers 10 attached to the respective vertical leg members 7, while another set of leg braces 9 project downwardly from the upper end of the leg members 7 to the horizontal side members 8, where they are secured by additional leg brace couplers 10. A pair of top member couplers 14, which are characterized by PVC elbow fittings, secure the tops of the respective vertical leg members 7 to corresponding ends of the spaced, parallel, horizontal top members 13 and the top members 13 are vertically spaced from the parallel side members 8 by top member braces 15, secured in position by corresponding top member brace couplers 16, also characterized by PVC tee fittings. A horizontal angle member 18 is secured to one of the top members 13 by an angle member coupler 19, which is characterized by a PVC 45 degree elbow fitting and is secured to the opposite top member 13 by means of a 45 degree PVC top member brace coupler 16, as illustrated in FIG. 5. A platform or seat 21 rests on the parallel side members 8 at one end of the bench rest frame 2 and is secured in position by fasteners such as screws or bolts (not illustrated). Accordingly, it will be appreciated from a consideration of FIG. 1 that a rifleman 39 may straddle the seat 21 with one leg projecting over one of the side members 8 and the opposite leg projecting over the opposite side member 8 and his right arm resting on one of the top member 13, to grasp a rifle 35 in firing configuration. The stock 37 of the rifle 35 is cradled in a V-shaped fixed cradle 33, secured to the angle member 18 by means of a cradle bolt 34, and the forestock 36 in a V-shaped adjustable cradle 25 element of an adjustable support mechanism 23.
Referring now to FIGS. 1, 5 and 6-8 of the drawings, in a most preferred embodiment of the invention a support block 24 element of the adjustable support mechanism 23 is suspended horizontally between the top members 13 of the bench rest frame 2 on a pair of spaced cradle guide rods 29, which span a horizontal threaded rod 30, threaded through the support block 24 and fitted with horizontal rod crank 31. The horizontal threaded rod 30 is secured in position on the top members 13 by means of a rod bolt 32, which is threaded into a drilled and tapped receptacle (not illustrated) in one end of the horizontal threaded rod 30, as illustrated in FIGS. 1, 5, 6 and 7. Accordingly, the support block 24 is caused to move horizontally on the cradle guide rods 29 along the horizontal threaded rod 30 responsive to rotation of the horizontal rod cranks 31 to adjust the "yaw", or horizontal swing of the adjustable cradle 25 and rifle barrel 35a. Furthermore, as illustrated in FIGS. 1, 7 and 8 of the drawings the adjustable cradle 25 is vertically mounted above the support block 24 one end of a vertical threaded rod 27, threaded through the support block 24 and fitted with a vertical rod crank 28 mounted on the bottom end thereof. Accordingly, rotation of the vertical rod crank 28 adjusts the adjustable cradle 25 vertically to further adjust the "pitch" or vertical orientation of the rifle barrel 35a. In another preferred embodiment of the invention the forestock 36 of the rifle 35 rests in a cradle pad 26, fitted in the adjustable cradle 25, to securely, yet removably, immobilize the forestock 36 and yet prevent scratching of the finish on the forestock 36. Similarly, the stock 37 of the rifle 35 is designed to seat in a similar cradle pad 26 located in the fixed cradle 33, designed for the same purpose. The cradle pads 26 may typically be constructed of foam rubber of similar material, which serve to immobilize the stock 37 and forestock 36.
It will be appreciated from a consideration of FIGS. 1 and 6-8 of the drawings that the rifle 35 is pivotally mounted in the adjustable cradle 25 of the adjustable support mechanism 23 when the stock 37 is lifted from the fixed cradle 33, since the vertical threaded rod 27 is threadably mounted in the support block 24. Accordingly, the bench rest 1 can be utilized to fire the rifle at several horizontally-disposed targets by swinging the stock 37 of the rifle 35 in an arc after lifting the stock 37 from the fixed cradle 33. It will be further appreciated by those skilled in the art that the adjustable support mechanism 23 may be fixed and designed such that the adjustable cradle 25 is fixed between the top members 13 in the same manner as the fixed cradle 33, under circumstances where it is not desired to adjust the height and lateral movement of the rifle barrel 35a. Accordingly, under these circumstances, the bench rest 1 may be set up to face a target at a selected distance from the rifle 35, the rifle barrel 35a seated in a fixed version of the adjustable cradle 25 and the stock 37 then seated in the fixed cradle 33, to effect the desired rifle sighting. However, in a most preferred embodiment of the invention the adjustable support mechanism 23 is utilized to facilitate selective vertical and horizontal adjustment of the adjustable cradle 25 and therefore the rifle barrel 35a, to provide additional latitude in sighting of the rifle by the rifleman 39.
It will be further appreciated by those skilled in the art that in addition to serving as a support for rifle sighting, the bench rest can also be used to pattern shotguns. Furthermore, while the forestock of the rifle or shotgun is preferably placed in the adjustable cradle, the barrel can also be so positioned moreover, the bench rest 1 can be constructed of any desired material, including wool, metal, plastic, fiberglass or the like, according to the knowledge of those skilled in the art. However, in a most preferred embodiment, PVC plastic is preferred because of the rigidity, high strength-to-weight ratio and ease of assembly and adjustment of the respective structural members to accommodate a rifleman or shooter of desired size and weight. For example, under circumstances where the rifleman or shooter is extremely large, the distance between the top member braces 15 and leg members 7 might be extended during the construction of the bench rest 1 to better and more comfortably accommodate the rifleman or shooter. Under circumstances where the bench rest 1 is constructed of PVC material, the respective structural members can be assembled using a suitable PVC cement which is well known to those skilled in the art. Furthermore, due to the nature of the PVC material, the various structural components can be easily cut and shaped to fit in a desired configuration to effectuate the intents and purpose of the invention.
Accordingly, while the preferred embodiments of the invention have been described above, it will be recognized and understood that various modifications may be made therein and the appended claims are intended to cover all such modifications which may fall within the spirit and scope of the invention. | A bench rest for supporting both a rifle and a rifleman for accurately "sighting in" the rifle on a target. In a preferred embodiment the bench rest includes a frame constructed of plastic pipe such as polyvinylchloride pipe and fittings, having a seat for supporting the rifleman, a fixed cradle for receiving the stock of the rifle and an adjustable cradle for receiving the forestock or barrel of the rifle and mounting the rifle in secure, yet vertically and horizontally adjustable relationship. In a most preferred embodiment of the invention the adjustable cradle is moved vertically and horizontally by crank operation of threaded rods during the "sighting in" process. | 5 |
RELATED APPLICATION
This application claims priority as a continuation-in-part of U.S. Provisional Patent Application No. 62/120,940, entitled “Ternary Cycle Heat Recovery From Low Temperature Sources”, filed Feb. 26, 2015.
BACKGROUND OF THE INVENTION
1. Field of the Invention
Specifically, the present invention is a process to capture energy from available heat sources, heretofore not considered commercially attainable because of their low temperature levels. An indirect heat exchanger facilitates heat transfer from these low temperature sources to a refrigerating agent that enters the exchanger as a lower temperature sub-cooled liquid or saturated condition and exits it as a vapor. The vapor is then uniquely superheated to condition it for turbine expansion and to produce electricity in a connected generator.
Heat may be extracted from renewable energy sources such as solar heated water in tropical or desert areas, or from geothermal spots. Heat may be extracted from power plant condenser rejected heat or stack gas waste heat. Heat may be extracted from any available source, leaving the source at a lower temperature level.
This process can serve as a stand-alone plant or be integrated with a power plant to recover rejected heat from the plant's condenser and stack gas to significantly improve plant thermal efficiency. A conventional steam power plant using the Rankine Cycle rejects approximately 55% of the fuel heat input in the condenser and 10% from the stack, resulting in a plant thermal efficiency of 35-40%. This process can increase plant thermal efficiency up to 70%.
Another feature of this process includes its capability to produce a combination of electrical power and desalinated water, by including a unique steam flash tower with a top-mounted tube and shell condenser. Non-potable water such as sea or brackish water is introduced to the flash tower for vacuum distillation with the remaining water returned to its source at a lower temperature. The flashed steam is then condensed on the outside tube surfaces of the condenser to produce potable water and to maintain flash tower vacuum pressure. The steam heat of condensation is transferred to a refrigerating agent circulating inside the tubes to vaporize it and then produce electrical power as described above.
This process allows greater flexibility in new power plant location since it provides independence from a cooling water source. It is an economical replacement for a typical plant's cooling tower, which discharges rejected heat into the atmosphere, consumes large amounts of expensive water, and may create condensate drift problems. It would not be necessary for plants to return rejected heat in cooling water to its source, mitigating environmental bio-equilibrium problems. Plant seasonal load variations caused by changing cooling water or air temperatures are prevented since a consistently low water temperature is returned to the condenser all year. Alternately, greater plant revenues may be realized by selling condenser cooling water BTU's as a product.
Integrating this process with a Rankine cycle steam power plant can produce a significant increase in electrical output using the recovered rejected heat from the plant condenser. In addition, significant desalinated water output can be produced, which is environmentally friendly. Current desalination plants have high capital investments, high operating and maintenance costs, and leave a mark on the environment.
Retrofitting this process to existing plants can significantly increase plant thermal efficiencies, reduce fuel costs, and reduce stack emissions without adding air pollution equipment. Revenues can be generated from sales of electricity, desalinated water, or cooling water BTU's. Power output from less efficient plants can be proportionally reduced with corresponding credit for reductions in emission of pollutants and carbon dioxide (CO 2 ), without requiring the addition of high cost pollution collection equipment. Receiving of operating permits, monitoring of water discharge temperature for limit violations or load reductions, water intake fouling problems, environmental bio-equilibrium impacts, and forced load reductions during peak summer demand seasons would no longer be issues. Power plant efficiency can significantly improve by returning the cooling water to the plant condenser at a lower temperature than it receives through existing cooling equipment, producing more power output.
2. Prior Art Description
Current power plants operating on the Rankine cycle primarily uses condenser cooling water from nearby sources and cooling towers to reject low temperature energy causing low plant thermal efficiencies. Dissipation of condenser rejected heat from power plants is an environmental issue and various other ideas have been discussed such as using irrigation canals and holding ponds. Prior art has not disclosed a process that efficiently uses low temperature water as an energy source on a commercial scale.
This disclosed process can be applied in geothermal power plants, resulting in significantly higher thermal efficiencies of about 50% rather than currently demonstrated efficiencies of 7 to 10%. Application in tropical or desert areas would provide essential resources and greater outputs would be realized from sea water heated solar ponds. The capacity factor for this renewable energy process would be significantly higher than demonstrated with wind or solar cell energy.
Other than hydropower and geothermal, prior art has not disclosed an economical system to produce large amounts of renewable, clean electricity in a compact source at more locations. This disclosure includes these attributes.
SUMMARY OF THE INVENTION
This specification includes two applications for this innovative process as outlined below:
1. The first application integrates this process with a new or existing power plant to generate additional electric power by substituting a refrigerate condenser for the normal water or air cooled condenser to capture condenser rejected heat, and including a refrigeration loop to capture stack gas heat in an indirect heat exchanger. The refrigerate is vaporized by these rejected heats and then uniquely conditioned to produce electric power.
2. The second application integrates this process with a power plant, using the normal cooling water condenser with its cooling water discharge redirected to a unique vacuum flash tower to capture its rejected heat. The flash tower generated steam is condensed on a refrigerate condenser producing desalinated water and its heat of condensation providing input to vaporize the refrigerate, which is then uniquely conditioned to produce electrical power.
This invention consists of a ternary-cycle process, including a refrigerating agent with inherent capabilities of vaporizing at low temperature used in two concurrent cycles to produce work, and a third cycle such as a water-steam cycle to provide heat input. Since organic refrigerates are costly and environmentally unfriendly, carbon dioxide (CO 2 ) agent is used as an example in this disclosure. CO 2 is safely removed from the environment and provides a non-toxic workplace environment.
The first CO 2 cycle (path A) operates at sub-critical pressure, initially driven by a startup pump located in the tank storage area. Path A receives low temperature heat input from an indirect heat exchanger (evaporator), entering it as a sub-cooled liquid or saturated mixture condition and discharging as a saturated vapor. Heat input to the evaporator is provided from a low temperature heat source. Path A discharges from the evaporator as a vapor and is superheated in downstream indirect heat exchangers by the second CO 2 cycle (Path B). Path A is expanded through turbines with connected generators to produce electricity before exhausting as a low pressure superheated vapor.
The second CO 2 cycle (path B) receives subcritical saturated vapor and compresses it to supercritical pressure. The heat of compression (HOC) superheats path B, converting it to supercritical pressure-temperature fluid. Path B separated into two mass flow streams transfers its heat to path A in two stages of indirect heat exchangers, thereby uniquely superheating path A vapor to condition it for turbine expansion. As detailed below, the power consumption to compress path B is significantly less than the power produced by path A expansion.
Path B discharges from the exchangers, recombines, and discharges into an ejector as the motive stream to draw path A from the reheat turbine exhaust. Combined paths A and B mix in the ejector, compress path A, and discharge to a liquid-vapor separator, resulting in a saturated mixture of about 25% of path B inlet pressure, dependent on the ejector design. Assuming a 50% quality mixture, path A and B split into two equal mass flow streams from the separator. The top outlet of the separator discharges saturated vapor to the compressor to complete path B cycle. The bottom outlet of the separator discharges saturated liquid to a throttling valve, which controls inlet temperature to the evaporator, completing path A cycle.
During startup, path B receives subcritical pressure vapor from path A via a full turbine bypass and compresses it to supercritical pressure using a startup electric motor drive. After the vapor supply to the compressor is assumed by the separator and turbine startup temperature is achieved, turbine bypass flow is redirected through the superheat turbine and subsequent reheat exchanger and turbine placing them on line with their electric generators. The compressor may then be switched from its startup electric motor drive to turbine drive via hydraulic couplings and the compressor in path B takes over as the driving force for both path A and B.
The ejectors significantly reduce compressor power consumption since compression of path B starts from separator outlet pressure and not path A reheat turbine exhaust pressure. Additionally, isentropic compression occurs in the region on the pressure-enthalpy (P-H) diagram with nearly vertical isentrope lines as compared to the less vertical isentropic lines in the turbine expansion region, which helps minimize compressor power consumption.
The third cycle that provides heat input to the process is captured from low temperature sources currently considered not to be commercially available, and rejected heat by the Rankine cycle in a steam power plant is a prime example of this. This rejected heat may be captured as demonstrated by this disclosure, along with other available sources. Application 1 shows capturing of rejected heat directly from the low pressure turbine exhaust and stack gas. Application 2 shows capturing of rejected heat from the condenser cooling water.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an embodiment of the present invention to capture power plant rejected heat to produce additional electric power. The normal plant Rankine cycle is illustrated in thin black lines with feedwater heater train 16 , economizer 2 , boiler 2 a , boiler enclosure 2 b superheater 3 , high pressure turbine 4 , reheater 5 , intermediate pressure turbine 6 , low pressure turbine 7 , electric generators 8 , and water cooled condenser 12 . The conventional condensate, boiler feedwater, and condenser 12 cooling water pumps are omitted for clarity. The superimposed binary CO 2 cycle is illustrated in heavier solid and dotted black lines. Rankine cycle condenser 12 is removed from the cycle as depicted by cut-lines 9 and replaced by CO 2 cycle condenser 12 a to capture this rejected heat. Condenser 12 a is depicted with steam inlet piping 14 from turbine 7 exhaust, refrigerate inlet headers 24 , refrigerate outlet headers 25 , codensate piping 15 routed to feedwater heater train 16 , and refrigerate temperature control valve 34 - 1 . In a second loop, heat exchanger 30 - 3 is added to boiler gas exhaust duct 44 with refrigerate temperature control valve 34 - 2 to capture rejected heat before exhausting it to the atmosphere through stack 41 . The refrigerate from these two loops is recombined before routing to heat exchanger 30 - 1 .
FIG. 2 depicts an embodiment of the present invention to capture power plant rejected heat to produce additional electric power and desalinated water. Flash tower 2 is included with multiple levels of steam flash trays 3 a to reduce footprint area. In this application, normal plant condenser 12 is kept in-place and flash tower 2 and trays 3 a are supplied with warm cooling water discharge 13 from condenser 12 by the existing plant cooling water pump. Condenser-evaporator E 8 is located in the top section of flash tower 2 .
FIG. 3 is a CO 2 P-H diagram with English Units (referenced from 32° F.) marked to show the CO 2 binary cycle conditions and the basis of FIGS. 1 and 2 .
FIG. 4 shows a water and steam pressure-enthalpy (P-H) diagram, marked with a solid black line to show the conditions for this cycle.
DETAILED DESCRIPTION
The process is similar in relation to electric power production in both FIGS. 1 and 2 with each including separator 33 , compressor 31 , turbine 32 - 1 and 32 - 2 , electric generators 8 , heat exchangers 30 - 1 and 30 - 2 , and ejector 35 . The processes differ in that FIG. 1 heat exchanger 30 - 1 receives CO 2 vapor from condenser 12 a , which is superimposed into the Rankine cycle, and from stack gas heat exchanger 30 - 3 . In FIG. 2 CO 2 vapor to heat exchanger 30 - 1 is supplied from condenser-evaporator E 8 in flash tower 2 , formed by condensing flashed steam from Rankine cycle condenser 12 cooling water discharge 13 .
FIG. 1 illustrates condenser 12 a superimposed into the Rankine cycle. Since the CO 2 can enter condenser 12 a in a mixed phase condition, it is necessary to arrange the surface in one pass with the tubes sloped upwards from inlet header 24 to outlet header 25 . The total surface conductance of condenser 12 a is relatively high because of the condensing steam film conductance on the outside of the tubes and boiling film conductance on the inside of the tubes. Stack gas exchanger 30 - 3 may be arranged in one refrigerate vertical up-flow-pass with horizontal cross flow stack gas, allowing for collection and removal of condensed stack gas vapor by trap 42 to waste disposal. These exchangers may have other arrangements.
FIG. 2 illustrates flash tower 2 divided into two sections with the lower section serving as steam flash area 3 , and the upper section 5 serving as CO 2 evaporator-steam condensing area. Warm water piping 4 a is directly connected to flash area 3 via columns 21 . Direct connection of piping 4 a allows for increasing the height of tower 2 in proportion to the positive pressure head available from the plant's condenser cooling water pumps or other pumps that may be included with this or other processes. A higher tower 2 allows for more tray 3 a levels and more desalinated water and power output per footprint area.
For applications using natural circulation, warm water is supplied to a nearby reservoir, which is open to the atmosphere via a vent, so that the difference between atmospheric pressure and vacuum pressure inside tower 2 causes the water to be forced upwards to a level equivalent to about 33 feet, which facilitates the supply of warm water to columns 21 and stacked flash trays 3 a . Optionally, compressed gas may be introduced at the reservoir vent to produce more than 33 feet of head.
In flash tower 2 , cooling water 13 a is boiled at low vacuum pressure and corresponding saturation temperature, which is lower than the water inlet temperature. The boiling water takes its energy for heat of vaporization from the remaining water and reduces its temperature to saturation temperature for discharge through downcomer 23 b at a lower temperature than the water inlet temperature 13 a.
Cooling water 13 a entering flash tower 2 may be sea water, brackish water, river, or lake water. A fraction of this water is distilled from vapor and may be used as potable water 14 .
Flash area 3 and upper section 5 are sealed from the atmosphere and operate under vacuum pressure. Vacuum pump 10 serves to create the initial vacuum and then to intermittently vent non-condensable gasses. Vacuum pressure is maintained during operation at the condensing saturation temperature of the steam since the steam collapses into water and occupies less volume, causing the vacuum to be maintained.
From column 21 , the warm water 13 a enters flash trays 3 a through connecting piping and valves 21 a , which control tray 3 a water level using water level measuring and control instruments. The entering water 13 a boils at the saturation temperature of the vacuum pressure, taking its heat of vaporization energy from the water and cooling it to saturation water temperature. Steam 3 b flashed in trays 3 a is depicted by the white-filled curved arrows on FIG. 2 . Steam 3 b exits trays 3 a , enters up-flow section 3 c , passes through moisture separators 3 d , and enters heat exchanger E 8 . The cooled water 19 a is shown exiting the center of trays 3 a through connecting piping and valves 23 a into downcomer 23 for exiting tower 2 and returning to condenser 12 through piping 19 . Valves 23 a control tray 3 a outlet temperature via instruments and controls.
CO 2 evaporator-steam condenser heat exchanger E 8 is shown as one upward vertical pass of CO 2 with cross-flowing of steam around a 360 degree periphery, but it can have various arrangements. The water from condensed steam is collected in an under-pan as potable water 14 . The total surface conductance of exchanger E 8 is relatively high because of the condensing steam film conductance on the outside of the tubes and the boiling film conductance of CO 2 inside the tubes.
Integrating the desalination feature with a 200 megawatt power plant would require the diameter of tower 2 to be approximately 70 feet as set by the maximum allowable steam velocity leaving the water surface of 15 feet per second. The total height of tower 2 from its base to top would be about 80 feet as set by the required tray geometry. Marked FIG. 4 shows that about 2% of the plant's cooling water is flashed into steam, resulting in a desalinated water output of about 1 million pound per hour, equivalent to 9.3 acre-foot/day, or 11,500 cubic meters/day. Average size desalination plants range between 5,000 and 10,000 cubic meters/day.
Both FIGS. 1 and 2 schematically illustrate the CO 2 flow paths. CO 2 flows in parallel paths A and B through process 1 at two different pressure levels and sets of conditions with the only common mixing point being at ejector 35 and moisture separator 33 , where their mixed conditions create a quality mixture, which correspondingly separates the mixture into a ratio of saturated liquid path A and vapor path B.
An example cycle follows to demonstrate the process for producing desalinated water and electricity with reference to marked FIGS. 3 and 4 . Referring to FIG. 3 and starting with separator 33 , marked as a single point ( 1 ) at 975 psia and 50% quality mixture, the separated saturated liquid (path A) is marked with a solid heavy-weighted black line as it discharges separator 33 at point 2 A, flows through throttle valve 34 to the inlet of evaporator E 8 ( 3 A) as a low quality saturated mixture at 63° F., and then flows through evaporator E 8 absorbing the steam heat of condensation. It exits as a vapor ( 4 A) to exchanger E 30 - 1 for superheating ( 4 A to 5 A), followed by isentropic expansion in turbine 32 - 1 ( 5 A to 6 A). It exhausts to exchanger 30 - 2 for reheating ( 6 A to 7 A), followed by isentropic expansion through turbine 32 - 2 ( 7 A to 8 A) before it exhausts at 85 psia via ejector 35 for return to separator 33 ( 8 A to 1 ). Path B is marked by a short-dotted, heavy-weighted black line flowing as saturated vapor from separator 33 ( 1 to 2 B) to compressor 31 ( 2 B to 3 B). Path B exits compressor 31 as a superheated supercritical pressure fluid at 3900 psia pressure and splits into two mass flow streams to transfer its heat to path A as it passes through the two stages of heat exchangers (E 30 - 1 and E 30 - 2 ). Path B recombines ( 4 B) and flows to ejector 35 as the motive stream to induce path A flow from turbine exhaust 32 - 2 ( 4 B to 1 ). Path A and B mix in ejector 35 , compressing path A and discharging to separator 33 , resulting in a 50% quality mixture for re-splitting into path A and B, completing their cycles.
Referring to FIG. 4 , sub-cooled water at 85° F. near 14.6 psia pressure is introduced to flash tower 2 operating at 0.3 psia pressure. The water boils and about 2% is flashed into steam, which is removed as desalinated water in evaporator 8 where it is condensed as it transfers its heat of condensation to vaporize path A, and the remaining 98% water discharges flash tower 2 at 65° F., corresponding to saturation temperature at 0.3 psia.
Referring to FIG. 2 , path A is shown as a solid heavy-weighted black line discharging as a saturated liquid from the bottom of separator 33 and flowing to throttle valve 34 and to inlet header 24 of exchanger E 8 . Path B is shown as short-dotted, heavy-weighted black line discharging from the top of separator 33 as a vapor and entering compressor 31 , where it is compressed to 3900 psia/250° F. supercritical fluid. Compressor 31 heat of compression (HOC) superheats path B, which discharges and splits into two mass flow streams for transferring its heat to path A in superheater exchanger 30 - 1 and reheat exchanger 30 - 2 . Path B exits exchangers 30 - 1 and 30 - 2 as a sub-cooled liquid and mixes before entering ejector 35 as the motive stream to induce path A from turbine 30 - 2 exhaust.
Path A CO 2 saturated liquid pressure is throttled to 63° F. temperature by valve 34 before it flows through the evaporators, in this case exchanger E 8 , absorbing the steam heat of condensation from flash steam 3 b , converting path A to saturated vapor. Path A exits exchanger E 8 and flows through heat exchanger 30 - 1 where it is converted to 230° F. superheated vapor by heat transferred from path B. Path A then flows to superheat turbine 32 - 1 , where it is isentropically expanded to superheated vapor at 150 psia/45° F. Path A then flows through heat exchanger 30 - 2 , where it is reheated to 192° F. superheated vapor. It then enters reheat turbine 32 - 2 , where it isentropically expands to 85 psia/120° F. superheated vapor and exhausted to the suction connection of ejector 35 .
Path B transfers heat to path A in exchangers 30 - 1 and 30 - 2 before it enters ejector 35 as the motive stream for path A. Ejector 35 is designed with various ratios of motive flow to induced flow to compress Path A, in this case, resulting in a pressure regain to 975 psia entering separator 33 . The combination of path A and B through ejector 35 is shown as a broadly-dotted, heavy-weighted black line leaving ejector 35 resulting in vertical separator 33 conditions at a 50% quality mixture.
Ejector 35 considerably reduces the power consumption of compressor 31 since the pressure in path B is compressed to 3900 psia from separator 33 outlet pressure of 975 psia and not reheat turbine 32 - 2 exhaust pressure of 85 psia. Ejector 35 is available as current technology, but it has not been used in a power generation cycle as disclosed in this invention. Path B serves as the motive stream for ejector 35 in which it flows through an internal converging nozzle to increase its velocity and cause a sufficiently low pressure to be created at the inlet connection for path A. Path A and B mix in ejector 35 followed by flow through a diverging nozzle to help regain about 25% of path B initial inlet static pressure.
The ternary cycles shown are examples to demonstrate process 1 and may be modified to suit design conditions of manufacturers, including operating pressures and temperatures, design of turbines for other exhaust pressures or splitting path B into other mass flow proportions. As may be noted by the example cycle marked on FIG. 3 , compressor 31 enthalpy of compression (˜22 BTU/lb) is considerably less than the total enthalpy of expansion (˜40 BTU/lb) provided by turbines 32 - 1 and 32 - 2 , which is equivalent to recovering about 45% of rejected heat and resulting in a combined plant thermal efficiency of about 70%.
CO 2 storage and startup unit 50 , shown in dotted, light-weighted black lines, provides startup and shutdown services by receiving path A liquid during load reductions or shutdowns, and supplying path A liquid during startups or load increases. Unit 50 maintains path A CO 2 liquid condition by holding pressure and temperature during storage. Automatic CO 2 mass flow adjustments are facilitated from unit 50 to or from path A for each load change. | A unique method and ternary cycle process that captures heat from low temperature sources currently considered not commercially usable to produce electricity and desalinate water. In one cycle a novel flash tower operating at vacuum pressure causes a fraction of low temperature water to flash into steam. The steam passes to an indirect heat exchanger with a circulating refrigerating agent such as CO 2 , which condenses the steam on its outside surfaces to produce desalinated water product. The steam heat of condensation vaporizes the refrigerating agent, which is part of a binary refrigerate cycle that uniquely conditions it for turbine expansion to produce electricity in a connected electric generator. | 5 |
This is a divisional of copending application Ser. No. 07/425,015 filed on Oct. 23, 1989, now U.S. Pat. No. 5,031,596.
BACKGROUND OF THE INVENTION
a) Field of the invention
The present invention relates to an injection carburetor for internal combustion engines, and more particularly to a fuel supply system provided in a suction tube which can meter a flow rate of fuel to render an airfuel ratio of a gas mixture constant by balancing a difference between the negative pressure produced in the suction tube and the atmospheric pressure with a difference in fuel pressure between the upstream side and the downstream side of an orifice provided in a fuel passage.
b) Description of the prior art
In the past, a system metering a flow rate of fuel in accordance with relationship between the flow rate of fuel passing through an orifice and a difference in fuel pressure between the upstream side and the downstream side of the orifice, as in fuel injection systems of stationary venturi type carburetors and U.S. Pat. application Ser. NO. 341,827, has been designed so that only the fuel supplied to an engine passes through the orifice. When the passed fuel is metered by the orifice, as diagrammed in FIG. 1, the fuel pressure difference is proportional to the square of the fuel flow rate, with the result that, for example, if the fuel of the amount six times the minimum supply fuel flow rate of the system flows through the orifice, the fuel pressure difference will be increased as much as 36 times the difference at that time and reach a limit value in practical use. However, general engines for automobiles, which need to be capable of metering the fuel supply flow rate from the minimum to about 40 times that, cannot make use of such a conventional fuel injection system as in the foregoing. Accordingly, in order to solve this problem, as in U.S. Pat. application Ser. No. 352,299, a system has been proposed in the past which is constructed to arrange at least two fuel control units for a slow zone and a main zone. This system, however, has defects that its structure is complicated and the transition from the slow zone to the main zone is not performed smoothly. Further, although another system is available which is capable of covering such a wide metering range as is mentioned above in the fuel supply system with a single fuel control unit, like SU carburetors, this system brings about defects that since the arrangement is such that the fuel flow rate is metered by change of the sectional area of the fuel passage (i.e., change of channel resistance) according to the flow rate of air, metering accuracy is reduced.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a fuel supply system for injection carburetors capable of metering accurately a flow rate of fuel covering a wide range in a single fuel control unit.
Another object of the present invention is to provide an injection carburetor which is simple in structure and suitable to common engines for automobiles.
These objects are achieved, according to the present invention, by the arrangement including a first channel for returning only fuel of a predetermined flow rate from the fuel fed from a fuel supply source, to the fuel supply source through an orifice and a constant flow rate control means; a second channel branching off from the first channel between the orifice and the constant flow rate control means for injecting the fuel into a suction tube of the carburetor; an air flow rate detecting means detecting the flow rate of air flowing through the suction tube; and a fuel ejection control means calculating the flow rate of fuel to be ejected so that a difference between the negative pressure in the suction tube and the atmospheric pressure which is detected by the air flow rate detecting means is counterbalanced with a difference in fuel pressure between the upstream side and the downstream side of the orifice to maintain consistently an air-fuel ratio of a gas mixture.
Further, according to the present invention, these objects are also accomplished by the arrangement including a first channel for feeding fuel of a predetermined flow rate from a fuel supply source through a constant flow rate control means to return part of the fuel to the fuel supply source through an orifice; a second channel branching off from the first channel between the constant flow rate control means and the orifice for injecting the fuel into a suction tube of the carburetor; an air flow rate detecting means detecting the flow rate of air flowing through the suction tube; and a fuel ejection control means calculating the flow rate of fuel to be ejected so that a difference between the negative pressure in the suction tube and the atmospheric pressure which is detected by the air flow rate detecting means is counterbalanced with a difference in fuel pressure between the upstream side and the downstream side of the orifice to maintain consistently an air-fuel ratio of a gas mixture.
According to the present invention, the constant flow rate supply means is provided with a diaphragm constituting a partition between a fuel inlet chamber and a fuel outlet chamber; a valve connected with the diaphragm to be capable of opening and closing an inlet port of the fuel inlet chamber; an orifice communicating the fuel inlet chamber with the fuel outlet chamber; and a spring pressing the diaphragm in a direction to open the valve. Also, the air flow rate detecting means is provided with a piston valve advancing into or retracting from the suction tube in accordance with the flow rate of air sucked into the suction tube; a spring pressing the piston valve in an advancing direction thereof; a negative pressure passage opened in an internal wall of the suction tube which faces to an end face of the piston valve; and an air passage opened in an air horn.
According to the fuel supply system of the present invention, since the arrangement is made so that the fuel of the predetermined flow rate is returned to the fuel supply source through the orifice apart form the flow rate of fuel metered and ejected in accordance with the flow rate of air sucked into the suction tube, the relationship between the flow rate of the ejected fuel and the fuel pressure difference assumes virtually linear form, the measuring of the fuel flow rate with a high degree of accuracy can be materialized over a wide rage even in a single fuel control unit, and the transition from the slow zone to the main zone is very smoothly made.
These and other objects as well as the features and the advantages of the present invention will become apparent from the following detailed description of the preferred embodiments when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a characteristic diagram showing the relationship between a fuel flow rate and a fuel pressure difference in a conventional fuel supply system;
FIG. 2 is a schematic view showing a general arrangement of a fuel supply system according to the present invention;
FIG. 3A is a sectional view showing concrete structure of an air flow rate detecting means;
FIG. 3B is a schematic view of an end face of the air flow rate detecting means viewed in the direction of an arrow of FIG. 3A;
FIG. 4 is a sectional view showing concrete structure of a constant flow rate control means;
FIG. 5 is a sectional view showing concrete structure of a fuel ejection control means used in a first embodiment of the present invention;
FIG. 6 is a characteristic diagram showing the relationship between a fuel ejection flow rate and a fuel pressure difference in the first embodiment;
FIG. 7A is a characteristic diagram showing the relationship between a pressure difference between the upstream side and the downstream side of an orifice and a fuel ejection flow rate in the first embodiment;
FIG. 7B is a characteristic diagram showing the relationship required between an air flow rate and a pressure difference in the first embodiment;
FIGS. 8 and 9 are sectional views showing concrete structure of the fuel ejection control means used in second and third embodiments, respectively;
FIG. 10 is a sectional view showing concrete structure of the fuel ejection control means used in a fourth embodiment;
FIG. 11 is a characteristic diagram showing a fuel ejection flow rate and a fuel pressure difference in the fourth embodiment;
FIG. 12A is a characteristic diagram showing the relationship between a pressure difference between the upstream side and the downstream side of the orifice and a fuel ejection flow rate in the fourth embodiment;
FIG. 12B is a characteristic diagram showing the relationship required between an air flow rate and a pressure difference in the fourth embodiment; and
FIGS. 13,14 and 15 are sectional views showing concrete structure of the fuel ejection control means used in fifth, sixth and seventh embodiments, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First of all, referring to FIGS. 2 to 5, a first embodiment of the present invention will be described below. FIG. 2 shows an example of conceptional structure of a fuel supply system according to the present invention. In this figure, reference numeral 1 represents an air flow rate detecting detecting flow rate of air sucked into a suction tube 2, 3 a constant flow rate control means adapted to return only fuel of a constant flow rate, from the fuel fed from a fuel supply source 4 through a fuel pump 5 to a fuel ejection control means which will be mentioned later, to the fuel supply source 4, and 6 a fuel ejection control means injecting the fuel of the amount corresponding to the air flow rate defected by the air flow rate detecting means and discharging the remainder of the fuel fed from the fuel supply source 4 into the constant flow rate control means 3. FIG. 3A depicts an example of concrete structure to the air flow rate detecting means 1. In the figure, reference numeral 7 designates a piston valve having a through-hold 7a in its top face for sliding in a direction normal to the suction tube 2 to form a variable venturi section 2a in the suction tube 2, 8 a spring biasing the piston valve 7 in a direction to narrow the variable venturi section 2a, 9 an adjusting screw capable of adjusting the resilient force of the spring 8 through a receiver 9a, 10 an atmospheric chamber provided under a large diameter section of the piston valve 7 so that atmosphere of an air horn is conducted thereinto, 11 a negative pressure passage opened in the variable venturi section 2a for taking out negative pressure created in the venturi section 2a, and 12 an air passage opened in the air horn for taking out relatively high reference pressure (for instance, atmospheric pressure3). FIG. 4 shows concrete structure of the constant flow rate control means 3, in which reference numeral 13 represents an inlet chamber having a fuel inlet port 13a, 14 an outlet chamber separated form the inlet chamber 13 by a diaphragm 15, having a fuel outlet port 14a, 16 an orifice communicating the inlet chamber 13 with the outlet chamber 14, 17 a valve having an end portion connected to the diaphragm 15 to be capable of controlling an opening degree of the fuel inlet port 13a of the inlet chamber 13, 18 a spring urging the diaphragm 15 toward the inlet chamber 13, and 19 an adjusting screw capable of adjusting the resilient force of the spring 18 through a receiver 19a. FIG. 5 shows concrete structure of the fuel ejection control means used in the first embodiment of the present invention, in which reference numeral 20 represents an atmosphere chamber adapted to conduct the atmospheric pressure thereinto through the air passage 12 of the air flow rate detecting means, 21 a depression chamber adapted to conduct the negative pressure of the venturi section 2a thereinto through the negative pressure passage 11 of the air flow rate detecting means 1, 22 a diaphragm constituting a partition between the atmosphere chamber 20 and the depression chamber 21, 23 a fuel pressure chamber adapted to feed the fuel from the fuel supply source thereinto, 24 a fuel ejection chamber divided from the fuel pressure chamber 23 by a fuel diaphragm 25, having a fuel ejection port 24a open to the suction tube 2, and 26 an orifice communicating the fuel pressure chamber 23 with the fuel ejection chamber 24. Reference numeral 27 designates a connecting member connected between the diaphragms 22 and 25, having a fuel ejection valve 27a capable of opening and closing the fuel ejection port 24a, 28 a spring pressing the negative pressure diaphragm 22 to open the fuel ejection valve 27a, and 29 an adjusting screw adjusting the resilient force of the spring 28 through a receiver 29a. In the air flow rate detecting means 1 described above, the venturi section 2a is configured as depicted in FIG. 3B so that the difference of the pressure (the magnitude of the negative pressure) produced between the negative pressure passage 11 and the air passage 12 in accordance with the air flow rate can accommodate the relationship of the fuel flow rate and the fuel pressure difference between the upstream side and the downstream side of the orifice through which the fuel passes. Also, the constant flow rate control means 3 is constructed so that the opening degree of the valve 17 is adjusted by operating the adjusting screw 19 and thereby the flow rate of the fuel flowing through the fuel inlet chamber 13 and the fuel outlet chamber 14 is controlled. Further, in the fuel ejection control means 6, the flow rate of the fuel passing through the orifice 26 in the injection of the fuel is such that a variable ejection flow rate Qa of the fuel delivered from the ejection port 24a which is metered in response to the air flow rate is added to a predetermined flow rate Q A of the fuel returned to the fuel supply source through the constant flow rate control means 3. Now, when the fuel pressure difference between the upstream side and the downstream side of the orifice 26 is taken as P and that in the case where the ejection flow rate Qa=0 in particular is P O , the relationship between the ejection flow rate Qa and the fuel pressure difference (P - P O ), although dependent on the setting value of the predetermined flow rate Q A , will exhibit a characteristic curve, near a straight line, deflected slightly downward as shown in FIG. 6. Further, when the effective area of each of the diaphragms 22, 25 is taken as S, the resilient force of the spring 28 as Fs, and the differential pressure detected by the air flow rate detecting means 1 as Fa, a mutual relationship is given by
P×S+Fa×S+Fs=O (1)
and the function of the fuel ejection control means 6 is that the pressure differences are counterbalanced with each other as shown in this equation, resulting in the delivery of the fuel of the flow rate (ejection flow rate) according to the air flow rate. Also, FIG. 7A is a characteristic diagram showing the relationship of the fuel pressure difference P between the outstream the downstream side of the orifice 26 and the ejection flow rate Qa, and FIG. 7B the relationship of the air flow rate required accordingly for the air flow rate detecting means 1 and the pressure difference.
Next, the functions of the fuel supply system which has been mentioned will be explained below.
In this system, prior to an engine start, the fuel pump 5 is first started by an initial operation of a start key and the fuel is fed from the fuel supply source 4 to the fuel ejection control means 6 (refer to arrows of solid lines in FIG. 2). At this step that the engine is not started, since the pressure difference is not detected by the air flow rate detecting means 1, the fuel ejection valve 27a is in a closed state, and the fuel introduced into the fuel pressure chamber 23 flows into the fuel ejection chamber 24 at the predetermined flow rate Q A under the differential pressure P O and is returned to the fuel supply source 4 through the constant flow rate control means 3. That is, in the state that the engine is not yet started, the fuel of a constant flow rate is circulated by the fuel pump 5 within a closed channel constructed form the fuel supply source 4, the fuel ejection control means 6, and the constant flow rate control means. Next, when the engine is started by a further operation of the engine key, negative pressure corresponding to the flow rate of air sucked into the venturi section 2a of the suction tube 2 is produced. The negative pressure is introduced into the depression chamber 21 of the fuel ejection control means 6 through the negative pressure passage 11 and consequently the negative pressure diaphragm 22 will be displaced toward the depression chamber 21 in virtue of the pressure difference generated between the atmosphere chamber 20 and the depression chamber 21. Accordingly, the fuel ejection valve 27a is opened so that the fuel is injected into the suction tube 2 from the fuel ejection chamber 24. At the same time, the fuel pressure difference P between the upstream side and the downstream side of the orifice becomes greater than the differential pressure P O and the fuel of the flow rate Qa higher than the predetermined flow rate Q A is metered by the orifice 26 to be included in the fuel ejection chamber 24. Thus, the state that the differential pressure between the negative pressure according to the flow rate of air sucked into the suction passage 2 and the atmospheric pressure is balanced with the fuel pressure difference (P - P O ) between the upstream side and the downstream side of the orifice 26 renders an air-fuel ratio of a gas mixture constant, and the fuel pressure difference (P - P O ) and the flow rate Qa of the fuel to be ejected maintain the relationship such as is shown by a characteristic curve of FIG. 6, with the result that fuel flow rate control with a considerable degree of accuracy can be secured over a wide operation range.
FIG. 8 shows concrete structure of the fuel ejection control means used in a second embodiment of the present invention. In this figure, reference numeral 30 represents a first diaphragm constituting a partition between the fuel pressure chamber 23 and the atmosphere chamber 20, 31 a second diaphragm constituting a partition between the fuel ejection chamber 24 and the depression chamber 21, and 32 a partition wall dividing the atmosphere chamber 20 from the depression chamber 21 and having a small hole 32a into which the connecting member 27 is inserted. In such structure, a flow control valve 27b is configured at the upper end of the connecting rod 27, associated with a fuel inlet port 23a of the fuel pressure chamber 23, and actuated by the second diaphragm 31 displaced in response to the negative pressure of the venturi section 2a which is introduced into the depression chamber 21 to control the flow rate of the fuel introduced into the fuel pressure chamber 23. Even in the case where the negative pressure is not conducted into the depression chamber 21, however, the valve 27b is held to a predetermined opening degree by the spring 28 and the like to secure the predetermined flow rate Q A . Reference numeral 33 denotes an injection nozzle ejecting the fuel, through an ejection port 33a, supplied from a discharge port 24b of the fuel ejection chamber 24 and incorporating a diaphragm 34 connected with a needle valve 34a and a spring 35. Accordingly, when the negative pressure detected by the air flow rate detecting means 1 is conducted into the depression chamber 21, the valve 27a is moved in its opening direction and resultant increase of the amount of a fuel flow from the fuel supply source 4 causes the fuel pressure in each of the chambers 23, 24 to be raised, so that force acting upward on the diaphragm 34 of the injection nozzle 33 is increased to open the valve 34a against the resilient force of the spring 35, thereby injecting the fuel into the suction tube 2. Thus, the fuel pressure difference between the upstream side and the downstream side of the orifice 26 is increased so that the negative pressure accommodating the flow rate of air flowing through the suction tube 2 is balanced with the fuel pressure difference.
FIG. 9 shows concrete structure of the fuel ejection control means used in a third embodiment of the present invention. This embodiment is such that the fuel ejection valve 27a is configured at the lower end of the connecting member 27 to open and close the ejection port 24a of the fuel ejection chamber 24. Specifically, the fuel ejection valve 27a is actuated by the displacement of the second diaphragm 31 according to the negative pressure conducted into the depression chamber 21 for control of the amount of fuel injection. Reference numeral 36 denotes a spring arranged opposite to the spring 28 across the first diaphragm 30 to urge the valve 27a in its opening direction and the difference of the resilient force between the springs 28 and 36 corresponds to Fs of the equation (1) mentioned above.
FIG. 10 depicts concrete structure of the fuel ejection control means employed in a fourth embodiment of the present invention. Although this embodiment is different from the embodiment shown in FIG. 5 in that the fuel is fed from the fuel supply source 4 through the constant flow rate control means 3 into the fuel ejection chamber 24 (refer to arrows of broken lines in FIG. 2), that the fuel diaphragm 25 is pressed toward the fuel ejection chamber 24 by a spring 37, and that the fuel flowing from the fuel pressure chamber 23 is returned to the fuel supply source 4 through a regulator fuel section 38, like reference numerals are substantially used to like members and parts with the embodiment of FIG. 5. According to the fuel ejection control means of this type, the relation ship between the ejection flow rate Qa of the fuel and the fuel pressure difference (P O - P) is represented by a characteristic curve deflected somewhat upward as shown in FIG. 11. Also, when the effective area of each of the diaphragms 22, 25 is taken as S, the resilient force of the spring 37 as Fs, and the differential pressure detected by the air flow rate detecting means 1 as Fa, equation (1) described above will be accomplished. FIG. 12A shows the relationship between the fuel pressure difference P between the upstream side and the downstream side of the orifice 26 and the ejection flow rate Qa, and FIG. 12B depicts the relationship between the air flow rate required for the air flow rate detecting means 1 in response to the relationship of P and Qa and the differential pressure to be produced by air thereof. Since the functions of the fourth embodiment are the ramp as those of the embodiments mentioned already, their explanation will not be required.
FIG. 13 shows concrete structure of the fuel ejection control means used in a fifth embodiment of the present invention. This embodiment is different from the embodiment shown in FIG. 8 in that the fuel is fed from the fuel supply source 4 through the constant flow rate control means 3 into the fuel ejection chamber 24 (refer to arrows of broken lines in FIG. 2), that the fuel diaphragm 31 is provided, in addition to the spring 28, with a spring 39 opposite thereto, and that the connecting member 27 is provided with a valve 27 adjusting the opening degree of a fuel outlet port 23b of the fuel pressure chamber 23 to control a return flow rate of the fuel. In this case, the difference of the resilient force between the springs 28 and 39 corresponds to Fs in equation (1) given above. The fifth embodiment is such that when the second diaphragm 31 is displaced toward the depression chamber 21 in virtue of the differential pressure detected by the air flow rate detecting means 1 and the opening degree of the fuel outlet port 23b is reduced by the valve 27c, the fuel pressure in the fuel pressure chamber 23 is raised, with the result that the fuel is ejected from the injection nozzle into the suction tube 2 and the pressure difference caused by the air flow rate is counterbalanced with the fuel pressure difference between the upstream side and the downstream side of the orifice 26.
FIG. 14 shows concrete structure of the fuel ejection control means used in a sixth embodiment of the present invention. This fuel ejection control means is different from that shown in FIG. 9 in that the fuel is supplied from the fuel supply source 4 through the constant flow rate control means 3 into the fuel ejection chamber 24 (refer to arrows of broken lines in FIG. 2), that the first diaphragm 30 is pressed only by the spring 28 in the direction in which the fuel ejection valve 27a is closed, and that the fuel flowing from the fuel pressure chamber 23 is returned to the fuel supply source 4 through the regulator fuel section 38. Since its functions are the same as those described in reference to FIG. 10, the explanation is omitted.
FIG. 15 shows the fuel ejection control means used in a seventh embodiment. This fuel ejection control means 6 is different from that shown in FIG. 14 in that the fuel ejection chamber 24 is provided with the fuel inlet port 24b, which is connected to the injection nozzle 33 through a fuel passage 40, that the fuel is supplied from the fuel supply source 4 through the constant flow rate control means 3 into the fuel passage 40 (refer to arrows of broken lines in FIG. 2), that the connecting member 27 is provided with a valve 27d capable of controlling the opening degree of the fuel inlet port 24b, and that the fuel is directly returned from the fuel pressure chamber 23 to the fuel supply source 4. In this embodiment, when the negative pressure is introduced into the depression chamber 21 from the air flow rate detecting means 1, the valve 27d is moved in the direction in which the opening degree of the fuel inlet port 24b is diminished until the fuel pressure in the fuel ejection chamber 24 and the fuel pressure chamber 23 decreases. Accordingly, upward pressing force acting on the diaphragm 34 of the injection nozzle 33 increases to open the valve 34a. Thus, the fuel is injected into the suction tube 2 and as a result, the fuel pressure difference between the upstream side and the downstream side reduces so that it is counterbalanced with the pressure difference detected by the air flow rate detecting means 1.
In each embodiment described above, a bearing may be used to smooth the movement of the piston valve 7 in the air flow rate detecting means 1. | A fuel supply system for injection carburetors includes an orifice, a constant flow rate control device, and a fuel supply source and is provided with a first fuel channel circulating fuel of a predetermined flow rate, a second fuel channel branching off from the first fuel channel between the orifice and the constant flow rate control device for injecting the fuel into a suction tube of the carburetor, an air flow rate detecting device capable of detecting a flow rate of air flowing through the suction tube, and a fuel ejection control device capable of metering the flow rate of fuel to be ejected so that a pressure difference with atmospheric pressure which is detected by the air flow rate detecting device is balanced with a fuel pressure difference between the upstream side and the downstream side of the orifice. The fuel supply system is simple in structure and can hold an air-fuel ratio of a gas mixture with a high degree of accuracy to a desired constant value, over the entire operation region, through a single fuel control unit. | 5 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/356,994, filed Jan. 24, 2012, which claims the benefit of priority to United States Provisional Patent Application Ser. No. 61/491,009, filed May 27, 2011.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to viscous, low emission fuels, including those used to power marine engines.
[0004] 2. Summary of the Related Art
[0005] Large ships, such as oil tankers, cruise ships and container vessels, have historically had slow-speed engines designed to bum cheap, highly viscous “bunker fuels”; the bottom of the barrel from the petroleum distillation process. This has been economically driven, because fuel costs are estimated to amount to 35-65% of the operating costs of these large ships. As these ships approach populated areas, the combustion of bunker fuels causes harmful levels of particulate matter, nitrogen oxides and sulfur dioxide emissions that can travel inland causing severe respiratory illnesses.
[0006] In 2010, the Marine Environment Protection Committee of the International Maritime Organization (IMO) adopted detailed and stringent emissions rules for these so-called Sulfur Emission Control Areas (SECAs). Presently, SECAs include most of the coastal areas of the United States, Canada and Europe and are likely to expand. Enforcement of these SECA standards as well as proposed IMO global emission limits on new engine builds are expected to reduce sulfur emissions by 98%, particulate matter by 85% and nitrogen oxides by 80%. New sulfur standards will phase in beginning in 2012, and will reach a limit of 1,000 parts per million by 2015. In addition, beginning in 2016, newly constructed ships will be required to demonstrate advanced emission control technology in accordance to the IMO regulations.
[0007] There is, however, an enormous existing international fleet of vessels having engines that are not readily compatible with burning less viscous, lower emission fuels. These ships are expected to have serviceable lifetimes extending many additional decades until newer, cleaner fleets gradually replace them.
[0008] Approaches to lowering emissions from these large ship engines are complex and accomplish only partial emissions reductions. For example, spraying water into the fuel/air mixture during combustion reduces NOx emissions, but does not address the SOx emissions and lowers peak engine load. Another example is fuel switching to cleaner, low-sulfur diesel fuels when transiting the SECAs. This approach greatly reduces particulate matter and SOx emissions, but requires the ships to carry multiple fuel sources and does not address NOx emissions. Further, this approach presents a danger of fire and explosion when these less viscous, lower flash point fuels are used in traditional marine engine types.
[0009] There is, therefore, a need for new cleaner burning fuels having suitable viscosity and flash points for these existing engines that, once burned, offer satisfactory emission profiles. One possibility is to mix viscous chemicals having inherent heat content with cleaner fuel oils. However, such chemicals tend to phase separate from the fuel oil, requiring mixing immediately before combustion, which is inconvenient and can be dangerous if done improperly. The present invention addresses these difficult problems.
BRIEF SUMMARY OF THE INVENTION
[0010] The invention relates to fuel mixtures containing glycerol. The invention provides fuel mixtures containing glycerol that are homogeneous or chemically stable for extended periods of time. The invention further provides processes for making such fuel mixtures, as well as fuel mixtures produced according to these processes.
[0011] The fuel mixtures according to the invention provide an important improvement over the related art because the fuel mixtures according to this invention are homogeneous or chemically stable for extended periods of time, and thus do not have to be produced immediately prior to combustion, unlike previous fuel mixtures containing glycerol.
[0012] In a first aspect, the invention provides a fuel mixture including a fuel oil selected from the group consisting of, but not limited to, marine gas oil, marine diesel oil, intermediate fuel oil, low sulfur diesel, ultra-low sulfur diesel and residual fuel oil; glycerol; and a non-ionic surfactant, wherein the mixture remains homogeneous at room temperature for at least 24 hours, and chemically stable for up to six months or more.
[0013] In a second aspect, the invention provides a fuel mixture produced by a process combining fuel oil, crude glycerol and a non-ionic surfactant, heating the crude glycerol to a temperature from about 40 to about 70° C., and mixing the fuel oil with crude glycerol utilizing an ultrasonic processor at from about 40 to about 75 Watts for from about 15 to about 40 seconds at about 20 kHz, with a total energy input of about 2,000 J per 150 mL, wherein the resultant mixture remains homogeneous for at least 24 hours, and chemically stable up to six months or more.
[0014] In a third aspect, the invention provides a process for producing a homogeneous fuel mixture comprising a fuel oil, crude glycerol and a non-ionic surfactant; heating the crude glycerol to a temperature from about 40 to about 70° C., and mixing the oil, crude glycerol and non-ionic surfactant with an ultrasonic processor at from about 40 to about 75 Watts for from about 15 to about 40 seconds at about 20 kHz, with a total energy input of about 2,000 J per 150 mL, wherein the resultant mixture remains homogeneous for at least 24 hours and chemically stable up to six months or more.
[0015] An object of the invention is to provide a fuel mixture that has viscosity, heat content and flash point properties that are suitable for use in existing marine engines, but which, upon combustion, produces lower emissions of sulfur dioxide (SO 2 ) and nitrous oxides (NOx) than conventional “bunker fuels” currently used to power marine engines.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 shows a comparison of UV-VIS absorbance spectra for 10%, 20% and 30% glycerol in ultra-low sulfur diesel emulsions.
[0017] FIG. 2 shows (A) glycerol droplet size number distribution of the sample showing a 1-4 microns range; (B) statistically relevant glycerol droplet size number distribution showing that most droplets are 2 microns in diameter.
[0018] FIG. 3 shows an emulsion stability plot showing a gradual glycerol droplet sedimentation followed by long term emulsion stability of the flocculated droplets.
[0019] FIG. 4 shows the emissions evolution from a single cylinder diesel engine operating at 2,000 RPM and a nominal fuel rate of 12.2 kW for commercial ultra-low sulfur diesel compared to a fuel mixture consisting of 266.6 mL ultra-low sulfur diesel, 20 mL glycerol, 6.6 mL 2,5-bis(ethoxymethyl)furan, and 6.6 mL distilled water and 3 mL of technical grade mono-/di- and tri-glycerides surfactant.
[0020] FIG. 5 shows the relationship between (A) a homogeneous fuel mixture, (B) a chemically stable, but non-homogenous fuel mixture and (C) a fuel mixture that is neither chemically stable nor homogenous as were made according to Example 4.
[0021] FIG. 6 shows the fuel mixture produced in example 2 in A) prior to fuel mixture processing and B) 168 hours after fuel processing
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The invention relates to fuel mixtures containing glycerol. The invention provides fuel mixtures containing glycerol that are homogeneous or chemically stable for extended periods of time. The invention further provides processes for making such fuel mixtures, as well as fuel mixtures produced according to these processes.
[0023] The fuel mixtures according to the invention provide an important improvement over the related art because the fuel mixtures according to the invention are homogeneous or chemically stable for extended periods of time, and thus do not have to be produced immediately prior to combustion, unlike previous fuel mixtures containing a fuel oil and glycerol.
[0024] For purposes of the invention, the term “homogeneous” is intended to mean that the fuel mixture contains glycerol droplets of defined size that are evenly dispersed within the fuel oil, such that the fuel mixture has a physical appearance and physical properties that are characteristic of a homogeneous mixture. The physical properties of such a homogeneous mixture are further described below. The term “chemically stable” is intended to mean a fuel in which the fuel oil and glycerol may be phase separated, but in which the defined size of the glycerol droplets is maintained, such that the fuel mixture becomes homogeneous once again upon gentle mixing of the phases.
[0025] An object of the invention is to provide a fuel mixture that has viscosity, heat content and flash point properties that are suitable for use in existing marine engines, but which, upon combustion, produces lower emissions of sulfur dioxide (SO 2 ) and nitrous oxides (NOx) than conventional “bunker fuels” currently used to power marine engines.
[0026] In a first aspect, the invention provides a fuel mixture comprising a fuel oil selected from the group consisting of, but not limited to, marine gas oil, marine diesel oil, intermediate fuel oil, low sulfur diesel, ultra-low sulfur diesel and residual fuel oil; glycerol; and a non-ionic surfactant, wherein the mixture remains homogeneous or chemically stable at room temperature for at least 24 hours.
[0027] In some embodiments, the fuel oil is selected from low sulfur diesel and ultra-low sulfur diesel. In some embodiments, the mixture comprises from about 50% to about 99% oil (vol/vol). In some embodiments, the mixture comprises about 65% oil (vol/vol).
[0028] In some embodiments, the mixture comprises from about 1% to about 50% glycerol (vol/vol). In some embodiments, the mixture comprises about 35% glycerol (vol/vol). Most commercially available glycerol preparations contain certain contaminants, such as salts, methanol and water. It is preferred that these contaminants be present in the glycerol in such low quantities as to limit the total concentration of the contaminants in the fuel mixture to controlled levels. Thus, in some embodiments the glycerol contains less than about 5% salt (wt/wt). In some embodiments the glycerol contains about 1% salt (wt/wt). In some embodiments, the glycerol contains less than about 10% methanol (wt/wt). In some embodiments, the glycerol contains about 2-5% methanol (wt/wt). In some embodiments, the glycerol contains less than about 20% water (wt/wt). In some embodiments the glycerol contains about 1-5% water (wt/wt).
[0029] To improve the combustion properties of the glycerol, combustion improvers may be added to the glycerol. In some embodiments, the glycerol contains less than about 10% combustion improver (wt/wt). In some embodiments, the glycerol contains about 5-10% combustion improver (wt/wt). In some embodiments, the combustion improver is selected from ethers, peroxides, nitriles, and mixtures thereof.
[0030] The homogeneity or chemical stability of the fuel mixture is provided in part by controlling the size of the glycerol droplets. Controlling the size of the glycerol droplets is also useful to allow the glycerol droplets to pass through the fuel filters, which generally have a particle size cutoff of about 5-20 μm. In some embodiments, the glycerol has droplet sizes of from about 100 nm to about 10 μm. In some embodiments, the glycerol has droplet sizes of from about 1 μm to about 4 μm. Droplet size is readily measured by laser scattering at 633 nm wavelength.
[0031] The homogeneity or chemical stability of the fuel mixture can be further improved by the addition of one or more non-ionic surfactants to the fuel mixture. In some embodiments, the mixture comprises from about 0.1% to about 5% non-ionic surfactant (wt/wt). In some embodiments, the mixture comprises from about 0.1% to about 5% non-ionic surfactant (wt/wt). In some embodiments, the mixture comprises about 1% non-ionic surfactant (wt/wt). In some embodiments, the non-ionic surfactant is selected from, but not limited to, the group consisting of one or more of polyethylene glycol, polyoxyethylene, glycerides, polyglycerols, sorbitan glycosides, esters and acids, or mixtures thereof.
[0032] In some instances, the viscosity of the fuel mixture may be increased by adding viscosity enhancers to the fuel oil phase. Such viscosity enhancers include, without limitation, resins, resin acids, polyureas, nitroesters, polyolefins, elastomers, and mixtures thereof.
[0033] While not critical to the invention, it has been observed that in some embodiments of the fuel mixture, the mixture has a heating energy of from about 30 to about 44 kJoules per kilogram, typically about 38 kJoules per kilogram. Heating content can be measured using a bomb calorimeter.
[0034] As discussed above, it is an object of the invention to provide a fuel mixture that, when combusted, produces lower emissions of SO 2 and NOx than conventional bunker fuels used to power marine engines. In some embodiments, the mixture, when created, contains less than about 0.1% by mass elemental sulfur. Elemental sulfur in fuel oils can be measured by energy-dispersive x-ray fluorescence in the liquid phase. In some embodiments, the mixture, when combusted in a marine diesel engine, produces less than about 10 g/kwh NOx. NOx can be measured in the exhaust by standard procedures using a chemiluminescence analyzer.
[0035] These reduced emissions can be achieved by using in the fuel mixture a fuel oil that has lower sulfur and nitrogen content than conventional bunker fuels. However, such fuel oils generally have viscosities, specific gravities and flash points that are not suitable for commonly used marine diesel engines. The fuel mixture according to the invention overcomes these problems. In some embodiments, the mixture has a viscosity of from about 5 to about 200 cst at 40° C. In some embodiments, the mixture has a viscosity of from about 12 to about 20 cst at 40° C. Typically, viscosity is measured by standard procedures using an efflux cup. In some embodiments, the mixture has a specific gravity of from about 0.83 to about 1.2. In some embodiments, the mixture has a specific gravity of from about 0.9 to about 1.0. In some embodiments, the mixture has a flash point of from about 50° C. to about 160° C. In some embodiments, the mixture has a flash point of about 60° C.
[0036] Another complication in combusting heavy fuel residuals is the accumulation of carbon and ash deposits on exposed and mated surfaces within the engine due to low hydrogen saturation of the organic molecules. This situation is monitored through the heating of the fuel in an open flask and the residual content weighed and termed the ramsbottom carbon in accordance to ASTM-D524. In some embodiments, the mixture contains less than about 5% wt. ramsbottom carbon. In some embodiments, the mixture contains less than about 1% wt. rams bottom carbon. As discussed above, a significant advantage of the fuel mixture according to the invention is that it is homogeneous and remains homogeneous or chemically stable for extended periods of time, thereby obviating the need to produce the mixture immediately prior to combustion. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 2 weeks. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 3 months. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 6 months.
[0037] In a second aspect, the invention provides a fuel mixture produced by a process comprising fuel oil, crude glycerol and a non-ionic surfactant, heating the crude glycerol to a temperature from about 40 to about 70° C., and mixing the oil, crude glycerol (commercial grade) with an ultrasonic processor at from about 40 to about 75 Watts for from about 15 to about 40 seconds at about 20 kHz, with a total energy input of about 2,000 J per 150 mL, wherein the resultant mixture remains homogeneous or chemically stable for at least 24 hours. In some embodiments, the crude glycerol is heated to about 50° C.
[0038] A variety of fuel oils may be used to produce the fuel mixture according to this aspect of the invention. In some embodiments, the fuel oil is selected from the group consisting of marine gas oil, marine diesel oil, intermediate fuel oil, low sulfur diesel, ultra-low sulfur diesel and residual fuel oil. In some embodiments, the fuel oil is selected from low sulfur diesel and ultra-low sulfur diesel. In some embodiments, the mixture comprises from about 50% to about 99% oil (vol/vol). In some embodiments, the mixture comprises about 65% oil (vol/vol). In some embodiments, a mixture of intermediate fuel oil and marine gas oil is used. In some embodiments, the ratio of intermediate fuel oil and marine gas oil is about 2.5:1 (vol/vol) and the combination comprises about 50% of the total fuel mixture.
[0039] As described above, the fuel oil is mixed with glycerol to produce the fuel mixture according to this aspect of the invention. The mixture comprises from about 1% to about 50% glycerol (vol/vol). In some embodiments, the mixture comprises about 35% (vol/vol) glycerol. In some embodiments, the glycerol contains less than about 5% salt (wt/wt). In some embodiments, the glycerol contains about 1% salt (wt/wt). In some embodiments, the glycerol contains less than about 10% methanol (wt/wt). In some embodiments, the glycerol contains about 2-5% methanol (wt/wt). In some embodiments, the glycerol contains less than about 20% water (wt/wt). In some embodiments, the glycerol contains about 5-10% water (wt/wt).
[0040] In some embodiments, a combustion improver is added to the glycerol prior to mixing the glycerol and the fuel oil. In some embodiments, the glycerol contains less than about 10% combustion improver (wt/wt). In some embodiments, the glycerol contains about 5-10% combustion improver (wt/wt). In some embodiments, the combustion improver is selected from the group consisting of one or more ether, peroxide, nitrile, and mixtures thereof. During mixing, the glycerol forms droplets. In some embodiments, the glycerol forms droplet sizes of from about 100 nm to about 10 μm. In some embodiments, the glycerol forms droplet sizes of from about 1 μm to about 4 μm.
[0041] As discussed above, one or more non-ionic surfactants are mixed with the fuel oil and the glycerol. In some embodiments, the mixture comprises from about 0.1% to about 5% non-ionic surfactant (wt/wt). In some embodiments, the mixture comprises from about 0.1% to about 5% non-ionic surfactant (wt/wt). In some embodiments, the mixture comprises about 1% non-ionic surfactant (wt/wt). In some embodiments, the non-ionic surfactant is selected from, but not limited to, the group consisting of one or more of polyethylene glycol, polyoxyethylene, glycerides, polyglycerols, sorbitan glycosides, esters and acids, or mixtures thereof.
[0042] In some embodiments, a viscosity enhancer is mixed with the fuel oil, glycerol and non-ionic surfactant. In some embodiments, the viscosity enhancer is selected from, without limitation, the group consisting of resins, resin acids, polyureas, nitroesters, polyolefins, elastomers, and mixtures thereof.
[0043] In some embodiments, the mixture has a heating energy of from about 30 to about 44 kJoules per kilogram. In some embodiments, the mixture has a heating energy of about 38 kJoules per kilogram. In some embodiments, the mixture, when created, contains less than about 0.1% by mass elemental sulfur. In some embodiments, the mixture, when combusted in a marine diesel engine, produces less than about 10 g/kWh NOx.
[0044] In some embodiments, the mixture has a viscosity of from about 5 to about 200 cst at 40° C. In some embodiments, the mixture has a viscosity of from about 12 to about 20 cst at 40° C. In some embodiments, the mixture has a specific gravity of from about 0.83 to about 1.2. In some embodiments, the mixture has a specific gravity of from about 0.9 to about 1.0. In some embodiments, the mixture has a flash point of from about 50° C. to about 160° C. In some embodiments, the mixture has a flash point of about 60° C.
[0045] In some embodiments, the mixture contains less than about 5% wt. ramsbottom carbon. In some embodiments, the mixture contains less than about 1% wt. ramsbottom carbon.
[0046] The mixture is mixed to homogeneity. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 2 weeks. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 3 months. In some embodiments, the mixture remains homogeneous or chemically stable at room temperature for at least 6 months.
[0047] In a third aspect, the invention provides a process for producing a homogeneous fuel mixture comprising fuel oil, crude glycerol (commercial grade) and a non-ionic surfactant, heating the crude glycerol to a temperature from about 40 to about 70° C., and mixing the oil, crude glycerol with an ultrasonic processor at from about 40 to about 75 Watts for from about 15 to about 40 seconds at about 20 kHz, with a total energy input of about 2,000 J per 150 mL, wherein the resultant mixture remains homogeneous or chemically stable for at least 24 hours. In some embodiments, the crude glycerol is heated to about 50° C.
[0048] The following examples are intended to illustrate certain embodiments of the invention and are not intended to limit the scope of the invention.
EXAMPLE 1
Demonstration of Achievable Droplet Sizing
Reagent Grade Glycerol Ultrasonically Blended with ULSD with a Mixture of Span80 and Tween80.
[0049] 20 mL of reagent grade glycerol is placed in a 300 mL wide-mouth Pyrex beaker. 80 mL of ultra-low sulfur diesel, 15 ppm or less of sulfur, containing dissolved span 80 (2.4 g) and tween 80 (0.5 g) is then added. The mixture is placed in a water bath and brought to 50° C. The heated mixture is ultrasonically processed using a 20 kHz ultrasonic processor with a ½″ horn operating with an intensity of 55 Watts for 20 seconds for a total of 1,143 Joules of energy input. The resulting mixture is allowed to slowly cool to 21° C. in a thermally controlled environment. Upon cooling the sample obtains a homogeneous amber color and a viscosity of 11 cst. The blended sample containing the 20 mL glycerol (20% total mixture volume) is analyzed using a UV-Vis spectrophotometer as well as a laser droplet sizer which utilizes light at a wavelength of 633 nm to calculate the droplet size distribution. The resulting UV-Vis spectrophotometer spectra is shown in FIG. 1 and compared to spectra obtained at 10% volume and 30% volume of glycerol in ULSD at the same surfactant weight ratio. The spectra for the 20% vol. glycerol sample show an absorbance at 633 nm of 1.71. This sample was subsequently analyzed by a laser droplet sizer that demonstrated a resulting droplet size distribution spanning 1-4 microns is shown in FIG. 2 .
EXAMPLE 2
Demonstrated Emulsion Creation with Intermediate Fuel Oil 180, 99% Pure Glycerin, Marine Gas Oil, Span 80 and Span 85 Surfactants
[0050] In this experiment, 70 mL of 99% pure glycerin was placed in a 300 mL wide mouth Pyrex® bottle. Added onto of the glycerin was 60 mL of intermediate fuel oil 180, 25 mL of marine gas oil, 3 mL of span 80 surfactant and 2 mL of span 85 surfactant for a total sample volume of 160 mL. The mixture was place in a water bath and heated to a uniform temperature of 70° C. The mixture was then vigorously agitated by hand to create a uniform appearing mixture. The mixture was immediately emulsified using an ultrasonic processor which utilized a ½″ horn operated at a frequency of 20 kHz with a power output of 75 Watts for 20 seconds for a total power output of 1,523 Joules. The resulting emulsion was dark brown in color and uniform. The emulsion remained homogeneous in nature for over 168 hours at room temperature. This homogeneous mixture is shown in FIG. 6 . In the A) free glycerol layer is clearly present at the bottom with heavy fuel oil 180 and surfactant on top. After processing B) the glcycerol emulsion remains homogeneous for extended periods of time.
EXAMPLE 3
Demonstrated 24+ Hour Emulsion Homogeneity Using Ultra-Low Sulfur Diesel, Reagent Glycerol, Water and Technical Grade Mono-/di-/tri-glycerides
[0051] In this experiment, 100 mL of ultra-low sulfur diesel fuel, 15 ppm sulfur concentration, was placed in a 300 mL wide mouth Pyrex bottle along with 25 mL glycerol and 25 mL water. A surfactant consisting of a technical grade blend of mono-/di- and tri-glycerides was splashed into the mixture with a total volume of 4 mL. The entire contents were heated to 50° C. in a water bath. The sample was ultrasonically processed for 20 seconds using an ultrasonic processor operating at 20 kHz with a ½″ horn. The sonic power output was 50 Watts for a total of 1,077 J of energy applied to the fuel mixture. The final appearance of the emulsion is a homogeneous milky white viscous liquid with a viscosity of 9 cst. at 25° C. The sample was transferred to a 250 mL glass bottle and placed in a 25 ° C. water bath for observation. The sample remained homogeneous for over 24 hours at room temperature.
EXAMPLE 4
Demonstration of Long-Term Chemical Stability of MDO, Glycerol and Surfactant System
[0052] 97.5 mL of ULSD and 52.5 mL of reagent grade glycerol is placed in a 300 mL wide mouth Pyrex bottle. Surfactants consisting of Span 80 (6.6 g) and Span 85 (0.9 g) were splash blended with the MDO and glycerol. The sample was heated in a water bath to 50° C. and emulsified using a 20 kHz ultrasonic processor with an intensity of 50 Watts for 15 seconds with a resulting energy input into the fuel mixture of 813 J. The resulting mixture was a homogeneous amber color with a viscosity of 7.5 cst. at 50° C. The sample was allowed to slowly cool to room temperature and monitored for creaming/sedimentation and chemical stability over a period of 2 months. As shown in FIG. 3 , which details the time evolution of the sample for emulsion stability, the sample underwent complete sedimentation of the glycerol droplets after 6 days under ambient conditions. The emulsion character of the droplets is retained as apparent by the amber color of the glycerol fraction due to the presence of surfactant and MDO between the close packed glycerol droplets. The emulsion was allowed to remain in this configuration at room temperature for a further 2 months, in which the emulsion remained chemically stable. This was verified by agitating the sample by gently rolling the sample bottle, which reconstituted the emulsion to a homogeneous sample. Long term stability is demonstrated in FIG. 5 .
[0053] FIG. 5 also shows the relationship between (A) a homogeneous fuel mixture, (B) a chemically stable, but non-homogenous fuel mixture and (C) a fuel mixture that is neither chemically stable or homogenous as were made according to Example 4. In case (B), the denser glycerol droplets sediment out of the fuel oil phase, but glycerol droplets remain chemically stable and retain droplet size and surfactant interface coverage. In case (C), the glycerol droplets were not chemically stable and resulted in emulsion breaking as depicted by the free glycerol layer at the bottom of the bottle.
EXAMPLE 5
Combustion and Emissions Characterization of a Glycerol Added Fuel Blend
[0054] 30 mL of reagent grade glycerol is splash blended with 10 mL water and 10 mL 2,5-bis(ethoxymethyl)furan in a 300 mL wide-mouth Pyrex beaker. 100 mL of ultra-low sulfur diesel is followed with dissolved with technical grade mixed mono-/di- and triglycerides. The mixture is placed in a water bath and brought to 50° C. The heated mixture is ultrasonically processed using a 20 kHz ultrasonic processor with a ½″ horn operating with an intensity of 55 Watts for 40 seconds. The resulting mixture obtains a homogeneous cloudy white color. The blended fuel was subsequently diluted by splash blending an additional 200 mL ultra-low sulfur diesel to achieve 6.6% glycerol in fuel (vol/vol) and operated in an air-cooled, high speed, single-cylinder diesel engine with a bore of 80 mm, stroke of 69 mm, displacement of 0.347 liter and a compression ratio of 22:1. The engine was maintained at a speed of 2,000 revolutions per minutes using a water-brake dynamometer with a nominal fueling rate of 12.2 kW. NO, NO 2 , CO 2 , O 2 , CO where monitored using electrochemical sensors and PM emissions were monitored using traditional filter paper techniques. The resulting emissions for NO are reduced by 6.2% (ppm/ppm) and particular matter is reduced by 10.3% (FSN/FSN) as shown in FIG. 4 . | The invention provides fuel mixtures containing fuel oil, glycerol, glycerol impurities and non-ionic surfactants. The mixtures remain homogeneous longer and are more chemically stable than previous mixtures. Upon combustion, the mixtures generate reduced SOx, NOx and particulate matter emissions compared to residual fuels and offer improved engine performance over previous mixtures. | 2 |
FIELD OF THE INVENTION
[0001] The invention relates to polypropylene bags in general and to high strength polypropylene bags in particular.
PRIOR ART
[0002] Many different types of products are shipped and sold in bags. It is often desirable to make the bags out of a strong plastic such as polypropylene. Polypropylene is largely impervious to water. Thus, if a polypropylene bag is wetted, it can often be returned to a merchantable condition by wiping it off or simply allowing it to dry. Polypropylene is also impenetrable by most oils. Consumer packaged goods can be rendered unmerchantable by oily spots on the exterior of the package caused by seep through from oils in the product. Polypropylene bags are very good at keeping the oils in the product inside the bag and away from any exterior labels or artwork. Tears or rips in bags can also render goods unmerchantable. Additionally, such tears or rips can spill product on the floor of retail and other businesses, creating a potential slip and fall danger. Polypropylene, particularly axially oriented polypropylene, is very strong. Polypropylene bags are thus highly resistant to tears.
[0003] However, the features that make polypropylene such good bag material, also make it difficult to form bags from polypropylene, particularly a type of bag known as a gusseted pinch bag. Gusseted pinch bags offer numerous advantages over other bag styles. This closure method has a very low leak rate. Powders and oils cannot seep out of the closure. This can be contrasted with bags that are sewn closed, where there is always some space between the stitching through which liquids and fine powders can escape. Similarly, moisture laden air can reach the product through stitching and other common closure methods. This can lead to some products becoming stale, clumping or otherwise deteriorating. Likewise, insects can enter bags via gaps in stitching. Pinch bag closures substantially eliminate the risk of air, water, and insects reaching the product via the closure. When filled, there is also a delineation between the sides and faces of gusseted bags. This gives the bags a box-like quality that facilitates stacking and that can be advantageous both in shipping and for in-store displays. Gusseted bags are also easy to fill.
[0004] Gusseted pinch bags are typically manufactured by perforating a continuous sheet of material into bag shaped panels. Before the perforations are severed but after they are formed, the sheet is folded so that its outside edges overlap and are adhered together. This forms a “tube,” that will comprise a series of bag shaped segments connected by the perforations. Once the tube is formed, longitudinal pressure is applied to the terminal bag shaped segment. This causes the perforations to break, leaving an individual bag shaped segment with two open ends. The bottom end of each segment is closed by folding the end of the bag over and adhering it to itself, thereby creating a bag. These are stacked and sent to the packager, where the bag is filled and the opposite end closed.
[0005] Polypropylene presents two significant obstacles to the foregoing process. First, polypropylene's general imperviousness to water and most oils, makes it difficult for adhesives to bind effectively to it. Thus, adhesively sealing a polypropylene pinch bag is difficult. Nor are the standards for an acceptable seal easily met. Bags are often subjected to extreme variations in temperature during transit. Conditions in uninsulated truck and rail cars can vary from below freezing in the winter to well above 100° F. in the summer. Accordingly, industry standards require adhesive seams to maintain their integrity from 0° F. through 140° F. Testing to these standards are commonly referred to as the freeze test and the heat test.
[0006] Second, the high strength of axially oriented polypropylene makes it difficult to form workable perforations. When the material is being perforated, it cannot be completely severed. Rather, it must retain its identity as a sheet to allow the sheet to be folded into a tube. If the perforation line suffers even a partial failure prior to the separation of the bag segments, at a minimum, the particular bag is likely to be rendered unusable. More significantly and more commonly, the entire tubing process goes offline, jams have to be cleared, and material and most significantly, time is lost.
[0007] Once the tube is formed the terminal bag shaped segment must be removed cleanly. If a single strand of material does not break, the terminal bag remains attached to the tube, and the process jams up. The high linear strength of axially oriented polypropylene makes the creation of a fine enough perforation extremely challenging. If the perforations are too small and too close together, the perforation becomes a complete cut. If the perforations are too far apart, the bag segments will not separate cleanly and consistently. Therefore, a process for manufacturing axially oriented polypropylene gusseted pinch bags in accordance with the following objectives is desired.
OBJECTS OF THE INVENTION
[0008] It is an object of the invention to provide a method for manufacturing axially oriented polypropylene bags.
[0009] It is an additional object of the invention to provide a method for manufacturing axially oriented polypropylene pinch bags.
[0010] It is an additional object of the invention to provide a method for manufacturing axially oriented polypropylene gusseted pinch bags.
[0011] It is another object of the invention to provide a method of manufacturing bags that will be resistant to punctures.
[0012] It is yet another object of the invention to avoid or limit loss of product due to bag damage.
[0013] It is still another object of the invention to avoid or limit product spills due to bag damage.
SUMMARY OF THE INVENTION
[0014] A method of manufacturing a pinch bag, and preferably a gusseted pinch bag, from polypropylene is disclosed. A sheet of polypropylene is provided. The sheet is preferably comprised of one or more layers of axially and/or biaxially oriented polypropylene. Perforation lines in a pinch pattern are formed in the sheet. The perforation lines are preferably created with a laser that forms a series of small, closely spaced holes in the sheet along the perforation line. The laser heats the plastic surrounding the holes, causing the polypropylene molecules between the holes to lose their orientation. Thus, the polypropylene in the perforation line between the holes is substantially weakened. The sheet is then folded into a tube. The edges of the sheet are sealed together, thereby forming the tube. A lateral force is applied to the terminal tube in the sheet, breaking the perforation line and separating the terminal tube from the sheet. One end of the tube is then sealed, thereby forming a bag.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view showing a polypropylene matrix being laminated to a polypropylene sheet.
[0016] FIG. 2 is a perspective view of an example of a polypropylene weave.
[0017] FIG. 2A is an exploded view illustrating a preferred embodiment of a polypropylene weave being laminated to a polypropylene sheet.
[0018] FIG. 3 is a plan view of a preferred embodiment of a single detachable gusseted pinch bag section.
[0019] FIG. 3A is a plan view of a preferred embodiment of a single detachable pinch bag section.
[0020] FIG. 4 is a plan view of a polypropylene sheet segmented with perforations into a plurality of detachable gusseted pinch bag sections.
[0021] FIG. 4A is a close up view of the perforations circled in FIG. 4 .
[0022] FIG. 4B is a detailed view, including preferred dimensions, of the perforations circled in FIG. 4A .
[0023] FIG. 4C is a plan view of a polypropylene sheet segmented with perforations into a plurality of detachable pinch bag sections.
[0024] FIG. 5 is a perspective view of a preferred embodiment of a detachable bag section being folded into a gusseted tube.
[0025] FIG. 6A is a side view of a preferred embodiment of a gusseted tube.
[0026] FIG. 6B is a plan view of a preferred embodiment of a gusseted tube.
[0027] FIG. 6C is an end view of a preferred embodiment of a gusseted tube.
[0028] FIG. 7A is a perspective view of a preferred embodiment of a gusseted tube being folded closed at one end to form a bag.
[0029] FIG. 7B is a perspective view of a preferred embodiment of a bag.
[0030] FIG. 8A is a perspective view of a preferred embodiment of a detachable bag section being folded into a gusseted tube wherein the seam includes a vent.
[0031] FIG. 8B is a cut-away view of a preferred embodiment of a bag containing a vent.
[0032] FIG. 8C is a top view of a preferred embodiment of a bag containing a vent.
[0033] FIG. 9 is a perspective view of a dual layer of hot melt adhesive being applied.
[0034] FIG. 10 is a schematic illustration of a laser perforation module being used to perforate a polypropylene sheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0035] The invention relates to a method of making a bag 1 . In the preferred embodiment, bag 1 will be formed from a sheet 2 . Sheet 2 will preferably be comprised primarily of polypropylene. Most preferably, sheet 2 will have multiple layers that are laminated together.
[0036] In one preferred embodiment, one of the layers is matrix 3 . Matrix 3 may be a scrim or a net or any other conventional webbing pattern or combinations thereof. However, in the most preferred embodiment, matrix 3 is a weave 4 .
[0037] In the preferred embodiment of weave 4 , matrix 3 is comprised of a first layer of polypropylene fibers 5 positioned generally parallel to each other. A second layer of generally parallel polypropylene fibers 6 is also provided. Second layer of polypropylene fibers 6 is positioned at an angle to first layer 5 , and preferably at a right angle; however, which fiber is on top and which is on bottom will alternate at each intersection of fibers. That is, fibers 5 and 6 are woven together. The individual fibers are not physically connected to each other at the intersections.
[0038] In the preferred embodiment the polypropylene weave 4 that comprises matrix 3 has a mass of between about fifty grams per square meter (about 580 denier) and about one hundred twenty grams per square meter (about 1350 denier), and preferably about sixty-two grams per square meter (about 900 denier). In this embodiment, the polypropylene fibers are axially oriented via pre-stretching. When polypropylene is extruded, the molecules in the fibers are typically randomly oriented. In this configuration, polypropylene is relatively weak, such that a sudden impact applied parallel to the length of the fiber could easily break the fiber. However, if a force is slowly applied to the fiber, the polypropylene molecules will become aligned in the direction of the force. Such fibers are said to be axially aligned, with the alignment typically being parallel to the length of the fibers. Axially aligned polypropylene fibers are much stronger than non-aligned fibers of the same weight. Suitable axially aligned polypropylene weave may be obtained from Ciplas, S. A. of Bogata, Colombia.
[0039] In one preferred embodiment, matrix 3 is laminated to a solid layer 7 of polypropylene. Solid layer 7 is preferably a seventy gauge (0.7 mil) biaxially oriented polypropylene sheet. Biaxial orientation means that the polypropylene molecules are oriented along two axes. When laminated together, the axes of orientation of solid layer 7 will preferably run parallel to the length and width of sheet 2 while the axes of orientation of the fibers of matrix 3 will also run parallel to the length and width of sheet 2 . Thus, solid layer 7 and matrix 3 reinforce each other and give a great deal of strength to sheet 2 . Solid layer 7 will also close the inter-fiber apertures of matrix 3 , which will prevent water, powders, and most oils and vapors from passing through sheet 2 . Solid layer 7 is preferably clear and will lend itself to printing techniques that are common in consumer packaged goods. Suitable biaxially oriented polypropylene sheets may be obtained from Vifan, Inc. of Morristown, Tenn.
[0040] Solid layer 7 is preferably laminated to matrix 3 . The preferred laminate is transparent and preferably comprises a polypropylene base. Additionally, it will preferably contain between about fifteen to thirty percent polyethylene. Any printing will typically occur on solid layer 7 .
[0041] Printing will occur on either the interior surface or the exterior surface of solid layer 7 . When printing occurs on the interior surface of solid layer 7 , a reverse printing technique will typically be used, and the ink will be applied to the side of solid layer 7 that faces matrix 3 . In such cases, the ink can interfere with the adhesion of solid layer 7 to matrix 3 . Thus, when printing on the interior surface of solid layer 7 , the inventor contemplates adding a tackifier to the laminate to help solid layer 7 fully adhere to matrix 3 . When a tackifier is used, it will preferably comprise about fifteen percent of the laminate by weight.
[0042] In addition to the tackifier, it is preferable to treat the portions of solid layer 7 to which ink has been applied with a liquid primer. The primer will help ionize the ink which help form a bond between the ink and the polypropylene layers. The preferred primer is Mica A31X™, available from the Mica Corporation of Shelton, Conn. The inventor contemplates applying about 0.2 lbs of Mica A31X™ per ream of solid layer 7 to the surface of solid layer 7 . The primer will preferably only be applied where ink has been applied to sheet 7 . Thus, if a portion of sheet 7 contains no printing, preferably no primer would be applied to that portion of sheet 7 . The primer is preferably applied after the ink.
[0043] When printing is done on the exterior of solid layer 7 , there is no need for a tackifier or primer. However, in the preferred embodiment, the inventor contemplates applying a coat of clear lacquer over external printing. This will seal the ink, provide an increased gloss on the finished bag, and increase the coefficient of friction of the surface of the bag. Increasing the coefficient of friction is especially advantageous in that it can provide the finished filled bags with a higher angle of slide—essentially, allowing the bags to be stored, displayed, and transported at a greater angle without sliding off stacks, shelves and the like.
[0044] Regardless of whether the printing is to be performed on the interior or the exterior of solid layer 7 , heat resistant ink is preferably used. Suitable inks are available from the Sun Chemical Corp. of Parsippany, N.J., and from the Flint Group, N.A. of Plymouth, Mich.
[0045] In the preferred embodiment, a continuous layer of laminate 8 is applied to solid layer 7 at a rate of about 15 grams to about 30 grams per square meter. Matrix 3 is then brought into contact with laminate 8 and solid layer 7 to form a preferred embodiment of sheet 2 .
[0046] Solid layer 7 and matrix 3 will most preferably be provided in rolls. Suitable machinery to spool solid layer 7 and matrix 3 off of their respective rolls and into multilayer sheet 2 is available from the Davis Standard, Corp. of Somerville, N.J.; Windomeller & Hoelscher K G of Lengerich, Germany; or the Starlinger Corp. of Weissenbach, Austria. Equipment suitable for extruding a molten laminate 8 onto solid layer 7 may be obtained from the Davis Standard, Corp., Windomeller & Hoelscher or the Starlinger, Corp.
[0047] In the preferred embodiment, laminate 8 is extruded at about 510° F. and will hit the solid layer 7 at about 400° F. Solid layer 7 and matrix 3 are brought into contact with each other immediately after the extrusion of laminate 8 and chilled with a water chiller to 68° F. Immediate chilling will prevent the high temperatures from degrading the polypropylene. Suitable chillers are available from the Davis Standard, Corp. and Windomeller & Hoelscher.
[0048] Although the preferred embodiment of sheet 2 has been described as consisting of three layers, it will be appreciated that fewer or greater numbers of layers of varying densities and strengths may be provided according to nature of product being packaged and the conditions to which it will be subjected.
[0049] Once sheet 2 is formed, it will be cut into detachable bag sections 9 . In one preferred embodiment, bag sections 9 will form gusseted pinch bags. This is preferably performed by forming a plurality of staggered perforated lines 10 extending across sheet 2 . Perforated lines 10 will preferably be comprised of several staggered sections.
[0050] Beginning at outer edges 11 of multi-layer sheet 2 , a first section 10 A is cut on both sides of sheet 2 . Sections 10 A are preferably cut substantially perpendicular to edges 11 .
[0051] At the ends of sections 10 A distal from edges 11 , a second section 10 B is cut on both sides of sheet 2 . Sections 10 B are preferably cut substantially parallel to outer edge 11 .
[0052] Beginning at the ends of sections 10 B distal from their respective sections 10 A, a third section 10 C is cut on both sides of sheet 2 . Sections 10 C are preferably cut substantially perpendicular to sides 11 .
[0053] At the ends of sections 10 C distal from sections 10 B, a fourth section 10 D is preferably cut on both sides of sheet 2 . Sections 10 D are preferably cut substantially parallel to edges 11 .
[0054] At the ends of sections 10 D distal from sections 10 C, a fifth section 10 E is preferably cut on both sides of sheet 2 . Sections 10 E are preferably cut substantially perpendicular to edges 11 . At the ends of sections 10 E distal from sections 10 D, a sixth section 10 F is preferably cut on both sides of sheet 2 . Sections 10 F are preferably cut substantially parallel to edges 11 .
[0055] At the ends of sections 10 F distal from their respective sections 10 E, a seventh section 10 G is cut. Section 10 G is preferably cut substantially perpendicular to edges 11 . Section 10 G will preferably connect opposite sections 10 F.
[0056] From the foregoing, it will be appreciated that perforated line 10 will extend across sheet 2 and will contain seven horizontal (perpendicular to edges 11 ) sections and six vertical (parallel to edges 11 ) sections. Horizontal sections 10 G should be approximately the same length as or slightly shorter than the combined length of horizontal sections 10 A. Horizontal sections 10 C and 10 E will be approximately the same length. Vertical sections 10 B, 10 D, and 10 E can vary in length depending on how much stagger is desired in finished bag 1 . However, each pair of vertical sections 10 B will preferably be the same length. Likewise, with pairs of vertical sections 10 D and 10 F.
[0057] As noted above, a plurality of perforated lines 10 will be formed across sheet 2 . Each pair of perforated lines 10 will delineate detachable bag sections 12 , with one line 10 forming the upper edge 13 of bag section 12 and the other line 10 forming the lower edge 14 of bag section 12 . However, in the preferred embodiment cutting perforated lines 10 will not separate sheet 2 . Rather, sheet 2 will only have been perforated. It will still be possible to handle sheet 2 as a unit. However, perforated lines 10 will make it possible to separate bag sections 12 from sheet 2 by applying a lateral force to sections 12 , when desired.
[0058] Perforated lines 10 are preferably formed using a laser perforator module 15 . Laser perforator module 15 will preferably consist of a laser source 15 A which will preferably be a carbon-dioxide laser of which the laser energy output can be continuous in nature (CW), or preferably can be modulated, resulting in discrete bursts or pulses of energy. The bursts or pulses of laser energy will be focused and directed by a focus/steering module 15 B. The focus/steering module 15 B will preferably be galvanometer-based and can be a pre-objective or post-objective scanning system used to create a two-dimensional focal plane 15 C (or field-of-view) at the surface of sheet 2 . The pulsed laser energy 15 D will be focused by and directed by the focus/steering module 15 B to anywhere within the focal plane, to a spot 15 E small enough to result in an energy density sufficient to create a small hole or perforation 16 in sheet 2 .
[0059] The output energy of laser source 15 A shall be modulated in coordination with focus/steering module 15 B and the motion of sheet 2 to create a perforated line 10 across the width W of sheet 2 while sheet 2 is in a motion parallel to its length L. Multiple laser perforator modules 15 may be positioned across the width W of sheet 2 and used simultaneously to improve processing efficiency.
[0060] In the preferred embodiment, each pulse from the laser source 15 A will create a small circular perforation 16 in sheet 2 . Each perforation 16 is preferably about 0.2 millimeters in diameter. Perforations 16 are preferably spaced on approximately 0.4 millimeter centers—i.e., the center of one perforation 16 is about 0.4 millimeters from the center of each adjacent perforation 16 . As will be appreciated, the narrowest distance between each perforation 16 will be about 0.2 millimeters.
[0061] Using laser perforator module 15 to form perforations 16 provides at least one advantage over using mechanical cutters to form similarly sized and spaced perforations. Laser perforator module 15 essentially burns or melts each perforation 16 through sheet 2 . However, in addition to creating these perforations 16 , the laser will also heat a small area 301 immediately surrounding each perforation 16 . Heating axially oriented polypropylene to near its melting point will cause the oriented molecules to become randomized, substantially weakening the polypropylene. Thus, by using laser perforator module 15 to form perforation line 10 , the material in the preferred perforation line 10 remaining after line 10 has been cut will be a series of polypropylene strips 17 about 0.2 millimeters wide separated by 0.2 millimeter wide holes. However, rather than being axially oriented polypropylene, as would be the case if perforations 16 were formed mechanically, strips 17 will be comprised substantially, if not exclusively, of randomly oriented polypropylene molecules. This will make perforation line 10 much weaker than would be the case if perforation line 10 were formed by simply mechanically cutting the same series of holes in sheet 2 .
[0062] Suitable laser perforator modules 15 are available from Preco, Inc. of Lenexa, Kans.
[0063] Although the principal manner of forming perforation line 10 described herein involves laser perforation, the inventors do contemplate mechanical formation of perforation line 10 . In this alternate embodiment, sheet 2 would be scored along a line having the same pattern described above with respect to lines 10 . A die cutter would be used in this embodiment. In the matrix/laminate/solid layer embodiment of sheet 2 , the die would cut sheet 2 from the matrix 3 side. The die would completely sever matrix 3 across the entire length of line 10 . However, the die would alternate between completely severing solid layer 7 and leaving strips of solid layer 7 either completely uncut or only scored. Suitable die cutters are believed to be available from Madern USA, Inc. of Apex, N.C.
[0064] However perforated line 10 is formed, it should preferably break cleanly and completely upon the application of about eight to about nineteen pounds of force per inch of width W of sheet 2 , applied substantially linearly in a direction substantially parallel to the length L of sheet 2 . To facilitate this, it may be preferable to completely sever the portions of perforated line 10 corresponding to vertical sections 10 B, 10 D, and 10 F as well as the corners that transition between the vertical sections and the horizontal sections of line 10 . These corners will preferably be cut on a radius of ⅛ th to 1/32 nd and preferably 1/16 th of an inch, rather than ninety degree angles, to facilitate separation.
[0065] After perforated lines 10 are formed, a gusseted tube 18 will preferably be formed from sheet 2 . Sheet 2 will be folded along fold lines 19 that extend from upper edge 13 to lower edge 14 along lines that include vertical sections 10 F. Sheet 2 will also be folded along fold lines 20 that extend from upper edge 13 to lower edge 14 along lines that include vertical sections 10 D. Finally, sheet 2 will be folded along fold lines 21 that extend from upper edge 13 to lower edge 14 along lines that include vertical sections 10 B. Equipment suitable for folding sheet 2 is available from Windomeller & Hoelscher or the Strong-Robinette Machine Corporation of Bristol, Tenn.
[0066] The folds made along fold lines 19 will preferably be made in a direction that will fold the interior surface of sheet 2 toward the interior surface of sheet 2 in the region of sheet 2 proximate fold line 19 . The folds made along fold lines 20 will preferably be made in a direction that will fold the exterior of sheet 2 toward the exterior of sheet 2 in the region of sheet 2 proximate to fold line 20 . The folds made along fold lines 21 will preferably be made in a direction that will fold the interior surface of sheet 2 toward the interior surface of sheet 2 in the region of sheet 2 proximate to fold lines 21 .
[0067] Folding sheet 2 in the foregoing fashion will create a front face section 22 between sections 10 G of upper and lower edges 13 , 14 and between fold lines 19 . It will also create first sidewall sections 23 A between sections 10 E of upper and lower edges 13 , 14 and between fold lines 19 and 20 . Second sidewall sections 23 B will be formed between sections 10 C of upper and lower edges 13 , 14 and between fold lines 20 and 21 . Folding sheet 2 in this manner will also create first and second rear face sections 24 A and 24 B between sections 10 A of upper and lower edges 13 , 14 and between fold lines 21 and edges 11 . In all of the foregoing sections, the vertical dimension will be that dimension that is perpendicular to both upper and lower edges 13 , 14 .
[0068] When sheet 12 is folded in the foregoing fashion, rear face sections 24 A and 24 B will be substantially parallel to front face section 22 and will be positioned so that edges 11 meet. Gusseted tube 18 is formed when edges 11 are joined.
[0069] The foregoing explanation describes the formation of a gusseted bag. However, a flat pinch bag could be formed in substantially the same fashion. In this embodiment, staggered perforated lines 10 will be cut in a simple pinch pattern.
[0070] In this embodiment, beginning at outer edges 11 of multi-layer sheet 2 , a first section 401 is cut on both sides of sheet 2 . Sections 401 are preferably cut substantially perpendicular to edges 11 .
[0071] At the ends of sections 401 distal from edges 11 , a second section 402 is cut on both sides of sheet 2 . Sections 402 are preferably cut substantially parallel to outer edge 11 .
[0072] At the ends of sections 402 distal from their respective sections 401 , a third section 403 is cut. Section 403 is preferably cut substantially perpendicular to edges 11 . Section 403 will preferably connect opposite sections 402 .
[0073] After perforated lines 10 are formed, a tube 18 will preferably be formed from sheet 2 . Sheet 2 will be folded along fold lines 404 that extend from upper edge 13 to lower edge 14 along lines that include sections 402 . Equipment suitable for folding sheet 2 is available from Windomeller & Hoelscher or the Strong-Robinette Machine Corporation of Bristol, Tenn.
[0074] The inventors contemplate joining edges 11 by applying adhesive to the exterior surface of 24 A and the facing, interior surface of 24 B. In all of the foregoing conditions, the inventor contemplates using a polypropylene base hot melt adhesive, preferably hot melt number 2903 available from the H. B. Fuller Co. of St. Paul, Minn.
[0075] Most relevant polypropylenes melt at around 335° F. and they begin to deteriorate substantially between around 325° F. and 335° F. However, hot melt should contact sheet 2 at a temperature high enough to soften the polypropylene and make it more susceptible to bonding but not so high that the adhesive substantially weakens the polypropylene in the vicinity of the seam that is being formed. Ideally, the hot melt will contact the surface of sheet 2 at about 285° F. to 300° F. and most preferably at about 290° F.
[0076] It will be appreciated that applying the adhesive to one edge 11 and then pressing the second edge 11 onto the adhesive that is resting on the first edge 11 will result in the adhesive contacting the second edge 11 at a cooler temperature than the adhesive had when it was initially applied to the first edge 11 . This can result in a less than ideal bond to the second edge 11 . This problem may be addressed by minimizing the time between when the adhesive is applied to the first edge 11 and when the second edge 11 is pressed into contact with the adhesive. Although delays between when the adhesive is applied and when the second edge 11 is brought into contact with the adhesive should be minimized in any event, the inventor has found that applying a double layer of hot melt to the first edge 11 achieves the best results.
[0077] In the preferred embodiment, the adhesive is applied to first edge 11 in a first continuous swirl pattern 101 . Adhesive in a second continuous swirl pattern 102 is laid down immediately on top of first swirl pattern 101 . Each swirl will preferably have a diameter of about ¼ to ¾ of an inch and most preferably ½ of an inch. First swirl pattern 101 is believed to help insulate second swirl pattern 102 by separating second swirl pattern 102 from first edge 11 . Immediately after second swirl pattern 102 is applied, second edge 11 is brought into contact with first edge 11 and the double layer of adhesive that has been deposited on first edge 11 . This will result in second swirl pattern 102 contacting second edge 11 at substantially the same temperature that first swirl pattern 101 contacted first edge 11 . The bonds with each edge 11 will thus be substantially identical.
[0078] To achieve the preferred double swirl patterns 101 , 102 adhesive is applied using a dual headed nozzle, such as die no. 1054730 (orifice diameter 0.018 inches) available from the Nordson Corporation of Westlake, Ohio. In the preferred embodiment, the nozzles are positioned about eight inches apart. Each nozzle is preferably positioned about 1 inch to about 4 inches above first edge 11 of sheet 2 and most preferably about 1.5 inches above first edge 11 . The adhesive is preferably heated to about 325+ F. when it leaves the nozzles. The nozzles extrude strands of adhesive having a diameter of about 0.018 inches. The adhesive preferably leaves the nozzles at between about 80 psi and about 460 psi, depending upon the speed at which sheet 2 is moving. The swirl patterns 101 , 102 are created with air heated to at least 325° F. and applied within the nozzle between about five and about twenty-four pounds per square inch (psi). All of the foregoing results in the adhesive reaching sheet 2 at the preferred temperature of 290° F. The inventor has found that applying adhesive in the foregoing fashion results in seams that meet both the heat test and freeze test, discussed above.
[0079] In another sealing option, edges 11 are configured to overlap about one inch. Two double layer swirl lines of adhesive 201 , 202 are laid down on first edge 11 , each swirl line 201 , 202 being formed in substantially the same fashion described above. Swirl lines 201 , 202 will be substantially parallel and separated by about ½ inch. When second edge 11 is brought into contact with swirl lines 201 , 202 , this will create a channel 203 in seam 204 wherein edges 11 will be joined at swirl lines 201 , 202 , but not in the approximate ½ inch between swirl lines 201 , 202 . During the cutting stage, a first hole 205 will have been formed in first edge 11 proximate either upper edge 13 or lower edge 14 of bag 1 , preferably using a die cutter such as model no. CPS-6100 available from the Park Air Corporation of Brockton, Mass. Hole 205 will preferably be about 1/16 th to about 5/16 th of an inch in diameter and will preferably be positioned between swirl lines 201 , 202 . Hole 205 will thus provide fluid communication between the interior of bag 1 and channel 203 . A second hole 206 is also provided in second edge 11 during the cutting stage, preferably with laser perforation module 15 . Second hole 206 is also preferably about 1/16 th to about 5/16 th of an inch in diameter and is positioned between swirl lines 201 , 202 . Thus, second hole 206 will provide fluid communication between the exterior of bag 1 and channel 203 . Like first hole 205 , second hole 206 is also positioned proximate to either upper edge 13 or lower edge 14 of bag 1 ; however, second hole 206 should preferably be positioned at substantially the opposite end of bag 1 from first hole 205 . While holes 205 , 206 are preferably positioned close to edges 13 , 14 , they should not be positioned so close that closing bag 1 closes either hole 205 or 206 .
[0080] When formed in the foregoing fashion, holes 205 , 206 and channel 203 form a vent 207 in bag 1 . This configuration will make it difficult for water to enter bag 1 via vent 207 . The longer the space in channel 203 between holes 205 , 206 , the more difficult it will be for water vapor to enter bag 1 via vent 207 . The same holds true for insects. However, gases within bag 1 can easily escape bag 1 anytime there is positive pressure inside bag 1 . Positive pressure within bag 1 can commonly occur in at least two situations. First, certain products naturally evolve gases. High fat content dog foods are an example of such a product. Vent 207 would allow these gases to escape, avoiding the bloated appearance they can create in bags 1 . Allowing these gases to escape gradually can also avoid odor problems associated with their accumulation. Gases, namely air, can also be introduced into bag 1 during filling. As bags 1 are stacked, the pressure applied to bags 1 by the stack will force air out via vent 207 . This has two principle positive effects. First, it facilitates stacking, by allowing bags 1 to lie flatter, and second, it helps prevent the contents of bag 1 from becoming stale by limiting the exposure of those contents to air.
[0081] Beside the hot melt adhesive described above, other sealing options for seam 204 include thermal welding and radio frequency welding. Suitable thermal welding equipment may be obtained from the Miller Weldmaster Corporation of Navarre, Ohio. Another sealing mechanism would be extruded polypropylene. This would preferably be applied using a bead extruder, in which the molten polypropylene would be deposited onto first edge 11 in a bead.
[0082] Once edges 11 are joined together, rear face sections 24 A and 24 B will form a rear face section 24 . Gusseted sidewalls 23 will also be formed by sidewall sections 23 A and 23 B, the gusseted version of bag 1 . Sidewalls 23 will connect front face section 22 to rear face section 24 .
[0083] It will be appreciated that staggering lines 10 in the manner described above will cause lower edge 14 of front face 22 to be vertically displaced from lower edge 14 of rear face 24 . Similarly, staggering lines 10 will also cause each lower edge 14 of sidewall sections 23 A and 23 B to be vertically offset relative to each other and with respect to lower edges 14 of front and rear faces 22 , 24 . It will also cause lower edge 14 of sidewall sections 23 A, 23 B to be vertically positioned between lower edge 14 of front face 22 and lower edge 14 of rear face 24 .
[0084] Once tubes 18 are formed, they will be separated from sheet 2 . As discussed above, this is preferably done by applying a lateral force to the terminal tube 18 strong enough to break perforated line 10 that forms upper edge 13 of the terminal tube 18 . Equipment suitable for detaching each tube 18 is available from Windomeller & Hoelscher K G or the Strong-Robinette Machine Corporation.
[0085] Bag 1 may be formed from gusseted tube 18 by closing one end of gusseted tube 18 . This is preferably accomplished by applying a polypropylene based hot melt adhesive, such as H. B. Fuller's hot melt number 2903, to the interior surface of rear face 24 at a point below lower edge 14 of front face 22 . Tube 18 would then be folded along a line 25 generally parallel and proximate to lower edge 14 of front face 22 . This will place a portion of the exterior of front face 22 into contact with itself. It will also place a portion of the interior of rear face 24 into contact with front face 22 . Additionally, it will place a portion of the interior and exterior surfaces of sidewalls 23 into contact with front face 22 . The adhesive will secure all of the foregoing together, securely closing one end of tube 18 and forming bag 1 . It should be noted that this closure method results in seams that are substantially impermeable to water, insects, and most oils. Bags that close in the foregoing manner are sometimes known as “pinch bags.” Equipment suitable for sealing one end of tube 18 is available from Windomeller & Hoelscher K G or the Strong-Robinette Machine Corporation.
[0086] Alternatively, either end of bag 1 may be closed by folding it in the same or substantially the same manner described above and sealing the end together using thermal welding equipment available from the Miller Weldmaster Corporation of Navarre, Ohio.
[0087] Once bag 1 has been formed, it may be filled with whatever bag 1 is intended to hold and the other end sealed in substantially the same fashion as described above with respect to the first end.
[0088] The finished bag 1 will be resistant to punctures and tears by virtue of the high strength polypropylene that comprises bag 1 . This will protect bag 1 from damage during shipping and while stored in a retail environment. The polypropylene will also minimize spillage and/or leakage from bag 1 , reducing the potential for slip and fall injuries. The polypropylene will also protect the exterior of bag 1 from discoloration caused by the contents of bag 1 . Similarly, the polypropylene will protect the contents of bag 1 from deterioration due to elements in the environment.
[0089] Although the discussion of the invention has focused on polypropylene bag material, the present invention is not limited to bags 1 made exclusively from polypropylene. Rather, bags 1 may contain non-polypropylene elements, such as laminates, inks, adhesives and even plastic combinations that comprise polypropylene blended or interwoven with non-polypropylene minority components, and still be considered a polypropylene bag or sheet.
[0090] These and other modifications for the manufacture of bag 1 will be apparent to those of skill in the art from the foregoing disclosure and drawings and are intended to be encompassed by the scope and spirit of the following claims. | An improved belt-clip holder for various objects is disclosed. The holder may be of unitary construction and includes a belt-clip for securely attaching the holder to a user's belt or other suitable item. The unitary construction reduces the cost and complexity of the holder. The holder has front, back and side panels to hold and protect an object, such as a dipping tobacco tin, or a group of objects, such as a group of credit cards. The holder also may have bottom panels in some embodiments. A retainer, having an integral retaining lip, secures the held object or objects in the holder. A cavity formed by the lower edges of the front, back, and side panels, allows a user to push a held object upward in order to remove the object from the holder. The retainer is configured so that a user my disengage the integral retaining lip using the same hand used to push the held object upward via the cavity. In this manner, the holder allows for the secure retention of an object within the holder, and also for easy, single-handed, removal of the object by a user when such removal is desired. | 1 |
BACKGROUND
The present invention relates to the maintenance operations and the functional tests performed in aircraft and more particularly to a method and a device for securely automating the procedures for verifying equipment items in an aircraft from a remote station, on the assembly line or during operation of the aircraft, by using the on-board information system as well as its topology.
To optimize the reliability of aircraft and to increase their profitability, on-line maintenance operations are frequently employed between the phases of flight.
In general, such operations consist, for example, in the case of maintenance operators, in verifying the hardware and software configuration of the aircraft systems, in analyzing the data stored in memory during the flight (continuous monitoring), in modifying certain aircraft parameters or certain software data, in launching test software applications and/or in checking the change of software configuration following a downloading operation.
The analyzed data are often obtained from transducers and stored in memory in a central diagnosis and storage device accessible via a man-machine interface of MCDU (initials for Multi-Control Display Unit in English terminology) or OMT (initials for Onboard Maintenance Terminal in English terminology) type. This interface, via which interactive operations can be launched, makes it possible to analyze data stored in memory, to access parameters of the aircraft and more generally to execute test and maintenance functions. By way of illustration, the Airbus A320, A330 and A340 are equipped with MCDUs and the Airbus A380 is equipped with an OMT (Airbus, A320, A330, A340 and A380 are trademarks).
Access to the maintenance systems of the aircraft is generally limited to fixed physical stations installed on board in the cockpit. Thus, when the aircraft is on the ground, a maintenance operator is able to board the aircraft to access and analyze the data stored in memory, to modify the parameters thereof if necessary and to launch test applications.
In order to ensure optimized sequencing of tasks, the current devices generally require the continuous presence of an operator to verify that the operations are being conducted properly.
Alternatively, mobile stations are being used to respond to an increasing demand of the airline companies in order to shorten the time for on-line maintenance operations. Such stations, whose function is similar to that of the interfaces of MCDU or OMT type, are connected to the central diagnosis and storage device via connection ports connected to the network of the aircraft.
FIG. 1 illustrates an example of an aircraft 100 comprising a central diagnosis and storage device 105 connected via a communication interface (not illustrated) to a fixed on-line maintenance station 110 installed in the cockpit.
Device 105 is connected to all systems of the aircraft that generate maintenance messages, for example to control transducers (not illustrated) of the engines and to actuators of the landing gear and control surfaces.
Thus, when aircraft 100 is on the ground, a maintenance operator is able, with the aid of fixed station 110 , to analyze the flight data of the aircraft and to modify the parameters thereof.
Although this solution meets the expectations of the airline companies, it is necessary to use a hard-wired link between an aircraft and a station to achieve on-line maintenance operations. Such a constraint has the effect in particular of prolonging the duration of maintenance operations and consequently increasing the costs of operating the aircraft.
To alleviate these disadvantages, there exist diagnosis systems that use a wireless communication technology, wherein the data obtained from transducers can be transmitted directly to the mobile on-line maintenance station. For example European Patent 1306305 discloses a system in which the transducers are connected to data storage and transmission devices. In this way, a mobile station is able to obtain flight data on request.
However, such a system is limited to accessing data without permitting modification of the parameters of an aircraft, and it necessitates the use of several storage and transmission devices.
Similarly, during assembly of the aircraft, the final assembly line teams rely on interactive maintenance tools to achieve all or part of the functional tests of the aircraft and configuration tracking throughout the manufacturing process until delivery of the aircraft.
However, despite the performances of the maintenance stations, means for automating certain tests do not exist.
In fact, although certain maintenance stations installed on board aircraft can be connected to a communication network for exchange of data between the aircraft and remote equipment, the network connection does not permit remote control of the applications implemented on board the aircraft or transmission of data to these applications, for security reasons.
BRIEF SUMMARY
The invention makes it possible to solve at least one of the problems mentioned in the foregoing.
The object of the invention is therefore a method for testing or evaluating the configuration of at least one equipment item in an aircraft, the said aircraft comprising an on-board information system, the said information system comprising a secured part and a less secured part, the said less secured part comprising a network interface capable of exchanging data with an information system external to the said aircraft, the said secured part comprising at least one maintenance function, this method comprising the following steps,
receiving at least one command to test or evaluate the configuration of the said at least one equipment item via the said network interface;
encoding the said at least one received command;
transmitting the said encoded command to the said secured part of the said information system of the said aircraft;
in response to reception of the said encoded command, filtering the said at least one encoded test command; and
in response to the said filtering step, translating and executing the said encoded command in relation to the said at least one maintenance function.
In this way the method according to the invention makes it possible to execute a maintenance function in a secured part of an information system of an aircraft from a remote station, without affecting the security of this part of the information system, by using the existing information system and its topology.
Advantageously, the method additionally comprises a step of determining a result in response to the said execution of the said at least one command and a step of transmitting the said result to the said information system external to the said aircraft via the said communication interface, to permit a remote station to receive and analyze the result of a function executed in a secured part of an information system of an aircraft.
According to a particular embodiment, the said step of transmitting the said result comprises a step of transmitting the said result from the said secured part of the said information system of the said aircraft to the said less secured part of the said information system of the said aircraft, and a step of transmitting the said result from the said less secured part of the said information system of the said aircraft to the said information system external to the said aircraft. In this way the method according to the invention makes it possible to use the existing information system and topology of an aircraft to execute a maintenance function in a secured part of an information system of an aircraft and to obtain the result of this execution.
According to another particular embodiment, the said less secured part comprises at least one second maintenance function, distinct from the said at least one maintenance function, referred to as at least one first maintenance function, the method additionally comprising a step of evaluating the said at least one command capable of determining if the said at least one command is intended for the said secured part or for the said less secured part of the said information system of the said aircraft, the said steps of encoding, of transmitting, of filtering, of translating and of executing the said at least one command being executed if the said at least one command is intended for the said secured part of the said information system of the said aircraft. In this way the method according to the invention makes it possible to optimize the processing of commands to execute maintenance functions according to the intended recipient of these commands.
Advantageously, the method additionally comprises, if the said at least one command is intended for the said less secured part of the said information system of the said aircraft, a step of executing the said at least one received command in relation to the said at least one second maintenance function. The said at least one received command is preferably encoded prior to execution thereof.
According to a particular embodiment, the method additionally comprises an initial step of establishing a secured communication channel between the said information system of the said aircraft and the said information system external to the said aircraft in order to permit data exchange and to improve the security of data transmissions between a remote station and the information system of the aircraft.
Another object of the invention is a computer program comprising instructions capable of employing each of the steps of the method described in the foregoing, a device comprising means capable of employing each of the steps of the method described in the foregoing, as well as an aircraft comprising such a device.
BRIEF DESCRIPTION OF THE DRAWINGS
Other advantages, objectives and characteristics of the present invention become apparent from the detailed description provided hereinafter by way of non-limitative example, with reference to the attached drawings, wherein:
FIG. 1 shows an aircraft comprising a fixed maintenance station making it possible to analyze the flight data thereof and to modify the parameters of those data according to a standard plan;
FIG. 2 schematically shows an example of an environment in which the present invention may be employed;
FIG. 3 illustrates the architecture of devices employed in the environment shown in FIG. 2 ;
FIG. 4 schematically illustrates the algorithm employed in the information system of an aircraft, in accordance with the invention, in order to permit automation of final assembly-line tests of the aircraft and/or automation of periodic verification operations executed by the airline company that operates the aircraft;
FIG. 5 partially shows an Ethernet frame used to transmit a command that can be subjected to filtering;
FIG. 6 shows an ASCII table and more particularly characters that can be used to transmit a command from the non-secured part to the secured part of an information system of an aircraft without compromising the security thereof;
FIG. 7 illustrates an example of a correspondence table that can be used by a conversion module to establish correspondence links between commands and instructions; and
FIG. 8 illustrates an example of a device capable of employing the invention or part of the invention.
DETAILED DESCRIPTION
According to a particular embodiment, the invention employs a system composed of the information system of the aircraft, comprising communication means such as IP communications means (initials for Internet Protocol in English terminology), and a remote station or an automatic test station situated, for example, on the ground. This system makes it possible to assure automation of tests and verification of the configuration of the logical systems of an aircraft.
The remote station or the automatic test station is connected to the on-board information system via a secured network such as an Ethernet network.
Securing of the connection can be assured, for example, by an element on the ground integrated in the network of the airline company and capable of employing a secured tunnel. The technology used preferably should make it possible to maintain a high level of security throughout the useful life of the aircraft.
To access the on-board maintenance functions from a remote station or test station, it is necessary to establish a secured connection between a server on the ground and the on-board component that is managing the communication means of the aircraft. When the tunnel is established, activities may be handled from the remote station or the test station.
FIG. 2 schematically shows an example of an environment in which the present invention can be employed. Illustrated here is an aircraft 200 comprising a maintenance device 205 containing, for example, centralized diagnosis and storage tools, connected to a network connection port 210 , in this example accessible from outside the aircraft. In this case, network connection port 210 is connected to network 215 , using, for example, the IP protocol.
Device 205 is connected to all of the aircraft systems that generate maintenance messages, for example control transducers (not shown) of the engines and to actuators of the landing gear and control surfaces.
An on-line remote maintenance station 220 , located in a maintenance center 225 , for example, is connected to device 205 by a communication network 215 and port 210 .
Thus, when aircraft 200 is on the ground, during assembly or during operation thereof, a maintenance operator is able, with the aid of remote station 220 , to analyze the data of the aircraft, to modify the parameters thereof and/or to monitor the execution of maintenance application modules implemented therein.
Although the connection between aircraft 200 and network 215 is hard-wired in this case, wireless communication technologies such as WiMax and/or WiFi may be used. In this case, the aircraft comprises wireless communication means capable of establishing a communication with a compatible device located on the ground, in a satellite or in any type of vehicle, this device itself being connected to network 215 .
FIG. 3 illustrates more precisely the architecture of devices employed in the environment represented in FIG. 2 . In this case reference 300 denotes the systems installed on board the aircraft, while reference 305 denotes the remote systems belonging, for example, to the maintenance control center, also known as MCC (initials for Maintenance Control Center in English terminology), to the maintenance information system, also known as MIS (acronym for Maintenance Information System in English terminology) or to the final assembly center.
The remote system comprises a remote station or a test station 310 , such as a portable computer of the PC type (initials for Personal Computer in English terminology), and a server 315 , making it possible to establish a data communication with the on-board information system 320 of the aircraft via network 325 .
Two types of data can be processed by the remote station or the test station: the data originating from the aircraft and the command data for managing the tests.
On-board information system 320 of the aircraft is connected to avionic systems 330 , for example the flight control systems, the automatic pilot and the environment monitoring systems, and to the systems 335 of the commercial world, known as “open” systems, as opposed to the avionic world, by virtue of the origin of the processed data.
Furthermore, on-board information system 320 comprises two parts, a highly secured part 340 , known as confidence world, and a less secured part 345 , known as connected world.
Less secured part 345 comprises a communication module 350 capable of receiving and transmitting data from and to network 325 . Communication module 350 is connected to a maintenance application module 355 , which itself comprises an encoding module 360 used for encoding data to be transmitted to secured part 340 of on-board information system 320 .
Secured part 340 comprises a filtering module 365 capable of monitoring the data transmitted by less secured part 345 .
Secured part 340 additionally comprises a maintenance application module 370 , itself comprising a conversion module 375 capable of converting the data received from filtering module 365 so that they will be processable by maintenance application module 370 .
As illustrated, maintenance application module 355 of less secured part 345 is connected to the systems of commercial world 335 , while maintenance application module 370 of secured part 340 is connected to the systems of avionic world 330 .
FIG. 4 schematically illustrates the algorithm employed in the information system of an aircraft, in accordance with the invention, to permit automation of final assembly-line tests of the aircraft and/or automation of periodic verification operations executed by the airline company that operates the aircraft.
Reference {circle around ( 1 )} in this case denotes the part of the algorithm employed in the non-secured part of the information system of the aircraft, reference {circle around ( 2 )} denotes the part of the algorithm employed in the secured part of the information system of the aircraft, reference {circle around ( 3 )} denotes the functions employed in the confidence world, or in other words the avionics in this case, and reference {circle around ( 4 )} denotes the functions employed in the commercial world.
After a command (step 400 ) has been received from a remote station or from a test station via, for example, a previously established, secured communication tunnel, a test is performed (step 405 ) to identify the intended recipient of the received command.
If the intended recipient of the received command is situated in the confidence world, the command is encoded (step 410 ) to make it compatible with the filter used at the input of the secured part, then is transmitted thereto (step 415 ). The exchange of a command and/or of data between the secured and non-secured parts is preferably achieved via a dedicated internal network.
The encoding consists, for example, in encoding the commands in the form of frames having a predetermined format and/or characteristics. The filtering then consists in verifying this format and/or these characteristics.
As indicated in the foregoing, when the secured part of the information system of the aircraft receives a command from the non-secured part, the received command is filtered (step 420 ) by means of a robust filter. The commands not conforming to the predetermined criteria of the filter are rejected. The filtered commands are converted or translated (step 425 ) by a translation module of the secured part to permit their execution by the intended maintenance function.
The requested maintenance function, for example a module for management of interactive tests or a module for management of test configuration, executes the received command or manages the execution thereof, and preferably sends a response, such as a configuration or a result, to the command translation module, which constructs a corresponding file. This file is then transmitted (step 430 ) to the maintenance function of the non-secured part of the information system of the aircraft, which transfers the received information items to the remote station (step 435 ).
If the intended recipient of the received command is situated in the connected world, the command is encoded (step 440 ) in standard manner, to make it compatible with the protocols used in the systems of the connected world.
The requested maintenance function, for example a module for management of interactive tests, executes the received command (step 445 ) or manages the execution thereof. If a response is determined, for example a configuration or a result, it is transmitted to the remote station (step 435 ).
The algorithm illustrated in FIG. 4 makes it possible to employ different test and/or verification scenarios during final assembly and/or during operation of the aircraft.
According to a first example, the mode of operation for achieving a sequence of automatic tests in the avionics is the following (although such a sequence of tests is performed in this case on the final assembly line of the aircraft, an equivalent sequence many be used during operation of the aircraft).
A test application hosted by the remote station first sends an initialization command over the network to an element of the maintenance function hosted in the connected world. After this command has been received (step 400 ) and the determination has been made that it is intended for the secured part of the information system of the aircraft (step 405 ), the element of the maintenance function encodes the command to make it compatible with the robust filter (step 410 ). The encoded command is then transmitted to the filter of the secured part (step 415 ).
After the command has been filtered (step 420 ), and if it has not been rejected, it is translated and transmitted to the corresponding maintenance function of the secured part in order to be executed (step 425 ). The requested maintenance function, in this case the module for management of interactive testing, executes the received command and, in response to the initialization command, transmits its configuration to the command translator, which constructs, for example, a corresponding file.
The file is then sent to the maintenance function of the connected world (step 430 ), which in turn transmits the file to the remote station (step 435 ).
The remote station verifies that the resulting file conforms to the initialization command. In the affirmative, the remote station constructs the following command to initiate a test action and transmits it to the information system of the aircraft. If the result does not conform, an error message is recorded.
After a first test command has been received (step 400 ) and the determination has been made that it is intended for the avionics (step 405 ), the maintenance function of the non-secured part of the information system of the aircraft encodes the command (step 410 ) to make it compatible with the filter of the secured part and transmits it thereto (step 415 ).
After the command has been filtered (step 420 ), it is translated in order to permit the maintenance function, in this case the module for management of interactive testing or the module for management of configuration of equipment items of the aircraft, to launch the test (step 425 ). The target or targets executes or execute the test and, as the case may be, the maintenance function calculates the test result. The result is transmitted via the command translator, which constructs, for example, a corresponding file, to the maintenance function of the non-secured part of the information system of the aircraft ( 430 ), which retransmits it to the remote station (step 435 ).
The remote station then can analyze the test result file and record it.
To automate all of the tests of a scenario, the sequence hereinabove must be repeated for all targets in question.
The test command transmitted to the avionics may relate in particular to a test as such, for example a functional test of an equipment item of the aircraft, or to management of the configuration of equipment items of the aircraft, especially an element of the avionics.
It should be noted that several methods exist for determining the configuration of equipment items of the aircraft. A first solution consists in interrogating each target, or in other words each element being tested. Alternatively, a second solution consists in accessing a configuration file determined and recorded by the maintenance function. According to this second solution, it is not necessary to analyze the configurations of the equipment items during the test.
According to a second example, the operating mode for achievement of a sequence of automatic tests in the systems of the connected mode and commercial mode is the following (once again, such a sequence of tests is executed in this case on the final assembly line of the aircraft).
As in the foregoing, a test command comprising a test application is transmitted over the network by the remote station, to an element of the maintenance function hosted in the non-secured part of the information system of the aircraft. After the command has been received (step 400 ) and the determination has been made that the received command is intended for the systems of the connected world (step 405 ), the element of the maintenance function encodes the command (step 440 ) in order to make it compatible with the protocols of the connected world.
The target of the connected world executes the test ( 445 ). If a result is expected, the element of the maintenance function recovers the test result and transmits it to the remote station (step 435 ), which can analyze the test result and record it.
In order to automate all of the tests of a scenario, the foregoing sequence is repeated for each intended target.
As indicated in the foregoing, the purpose of the filter is to filter the data received from the network, in order to transmit only the correctly formatted data to the secured part of the information system of the aircraft.
The filtering module is preferably based on the sieve principle, or in other words on an iterative mechanism, wherein several levels of filters are used to optimize the processing times. Thus it is composed of several elements making it possible to filter the received data increasingly finely in order to allow passage of only the data corresponding to valid commands.
The filtering module necessitates that a command format be defined in order that only a certain type of network frames is processed. The format and the associated transport protocol can be defined in the form of parameters, accessible to the filtering module. For example, such parameters may stipulate that the commands be received in the form of Ethernet frames, indicate the sources authorized to transmit such commands, allocate a maximum lifetime to the frames, beyond which the frames are not taken into account, and indicate the characters that can be validly used to encode a command in a frame.
By way of illustration, the filtering of Ethernet frames can be achieved in three steps.
FIG. 5 partially shows an Ethernet frame 500 to which filtering can be applied according to these three steps.
Firstly, each frame is analyzed by verifying, for example, source physical address 505 and destination physical address 510 , especially the MAC addresses (acronym for Media Access Control in English terminology), protocol type 515 and signature 525 of the complete frame. Data 520 of the frame are not analyzed in this first step.
If source physical address 505 and destination physical address 510 , protocol type 515 and signature 525 do not conform to the parameters of the filtering module, the frame is rejected.
On the other hand, if source physical address 505 and destination physical address 510 , protocol type 515 and signature 525 conform to the parameters of the filtering module, a second filtering step is employed.
It should be noted here that the first filtering step can be applied to data other than those cited, or on the other hand to fewer data.
The second step consists, for example, in analyzing data header 520 . In particular, this second filtering step may consist in verifying IP version 525 (initials for Internet Protocol in English terminology), header length 530 , service type 535 , total data length 540 , identification 545 used to reconstitute the fragments, lifetime 550 , also known as TTL (initials for Time To Live in English terminology), protocol 555 and source address 560 and destination address 565 .
Once again, if all of these information items do not conform to the parameters of the filtering module, the frame is rejected. On the other hand, if all of these information items conform to the parameters of the filtering module, a third filtering step is employed.
It should be noted here also that the second filtering step may be applied to data other than those cited, or on the other hand to fewer data.
The third step consists in this case in analyzing the characters of useful data 570 of the frame. Thus this step makes it possible to verify that the characters necessary for construction of the command cannot be used to construct the executable code. Advantageously, all the characters of the useful data must be chosen from the ASCII table, within the values between 032 and 090, as illustrated in FIG. 6 .
If a character of useful data 570 does not belong to the ASCII table, between the values 032 and 090, the frame is rejected. On the other hand, if all the characters of useful data 570 belong to the ASCII table, between the values 032 and 090, the frame is transmitted to the secured part of the information system of the aircraft to be processed therein.
Naturally the third step of filtering may be applied to other criteria, especially more restrictive criteria.
The purpose of translation of the filtered commands is to establish an interface between the maintenance functions and the network.
This module is preferably developed in such a way that only the commands pertaining to instructions corresponding to maintenance functions implemented in the secured part of the information system of the aircraft have an action. This means that this module knows the instructions that may be executed by each application. In other words, a list of instructions or of a sequence of instructions is preferably stored in memory beforehand. Such a list defines a set of configurations of possible sequencings of instructions. This list may also define prohibited combinations.
This configuration is constructed in such a way that the sequencing of instructions of an application is known a priori. This permits the conversion module to verify that the commands that it receives and the sequencing of the associated instructions conforms to what the application is supposed to execute. This verification permits the conversion module to reject any unexpected sequencing and in this way to ensure that dangerous operations cannot be executed.
In a particular embodiment, the conversion module uses a table of correspondence between command names and the effective functions, or in other words instruction sequences, in order to associate one or more instructions with the command names received from the remote station. It should be noted here that the instructions may have several forms. For example, they may be pointers to functions or commands interfaced with the operating system of the maintenance device. The instructions make it possible in particular to simulate an action entered by a user at the maintenance-device interface accessible in the aircraft.
FIG. 7 illustrates an example of a correspondence table 700 that can be used by the conversion module.
In this case correspondence table 700 comprises two columns: a column 705 containing the command names and a column 710 containing the list of instructions associated with each command.
Line 715 illustrates an example of a command to test a flight management device, referred to as FMU (initials for Flight Management Unit in English terminology). In this case the name of the command that can be used by a maintenance operator from a remote station is TEST:FMU. As shown, this command corresponds to execution of the instruction sequence comprising the instructions Set_Param(a, b, c), AutoTest_FMU 1 and AutoTest_FMU 2 .
After a command has been analyzed and declared to be in conformity, the conversion module transmits the corresponding instructions to the application in question. The application executes the instructions and in general returns a response. This response is received by the conversion module, which constructs a response message, preferably signed.
By way of illustration, returning to the example illustrated in FIG. 7 , the operating mode for execution of instructions corresponding to the command TEST:FMU is the following,
the operator enters the command TEST:FMU at the remote station;
the command TEST:FMU is transmitted to the information system of the aircraft via a communication network;
the command received by the aircraft is encoded then filtered;
the instruction sequence corresponding to the filtered command is identified, in this case being the instructions Set_Param(a, b, c), AutoTest_FMU 1 and AutoTest_FMU 2 ;
these instructions are transmitted by a software layer of API type (initials for Application Programming Interface in English terminology) to the intended applications (as if the command had been generated by keystrokes at a fixed station);
the intended applications execute the instructions in conformity with the command and transmit the results to the conversion module via the software layer of API type; and,
the conversion module forms a response message, for example by constructing a screen page or part of a screen page comprising the results, signs the response message to attest to the origin and integrity of the furnished information, and transmits the response message to the remote station via the communication network.
In the case of automatic tests, it is also possible to use a software application implemented on the remote station to generate a concatenation of commands in order to create a complete test scenario.
A device adapted for employment of the invention or part of the invention is illustrated in FIG. 8 . Device 800 is, for example, a computer or a microcomputer.
In the present case, device 800 is provided with a communication bus 802 , to which there are connected:
a central processing unit or microprocessor 803 (CPU, Central Processing Unit);
a read-only memory 804 (ROM, the acronym for Read Only Memory in English terminology), which may be provided with the programs “Prog”, “Prog 1 ” and “Prog 2 ”;
a random-access memory or cache memory 806 (RAM, the acronym for Random Access Memory in English terminology), comprising registers capable of recording variables and parameters created and modified in the course of execution of the aforesaid programs; and
a communication interface 818 , capable of transmitting and receiving data.
Optionally, device 800 may also be provided with:
a screen 808 , for visualizing data and/or for acting as a graphical interface with the user who will be able to interact with the programs according to the invention, with the aid of a keyboard and of a mouse 810 , or of another pointing device such as a light pen, a touch screen or a remote control;
a hard disk 812 , which can comprise the aforesaid programs “Prog”, “Prog 1 ” and “Prog 2 ” and data processed or to be processed according to the invention; and
a memory card reader 814 capable of receiving a memory card 816 and reading or writing therein data processed or to be processed according to the invention.
The communication bus permits communication and interoperability among the different elements included in device 800 or connected thereto. The depiction of the bus is not limitative and, in particular, the central unit is capable of communicating instructions to any element of device 800 directly or via another element of device 800 .
The executable code of each program permitting the programmable device to employ the process according to the invention may be stored, for example, on hard disk 812 or in read-only memory 804 .
According to one variant, memory card 816 may contain data, especially signature keys, as well as the executable code of the aforesaid programs, which code will be stored on hard disk 812 once it has been read by device 800 .
According to another variant, it will be possible for the executable code of the programs to be received at least partly via interface 818 to be stored in a manner identical to that described in the foregoing.
More generally, it will be possible for the program or programs to be loaded into one of the storage means of device 800 before being executed.
Central unit 803 will command and direct the execution of the instructions or portions of software code of the program or programs according to the invention, which instructions are stored on hard disk 812 or in read-only memory 804 or else in the other aforesaid storage elements. During boot-up, the program or programs stored in a non-volatile memory, such as hard disk 812 or read-only memory 804 , are transferred to random-access memory 806 , which then contains the executable code of the program or programs according to the invention as well as registers for storing in memory the variables and parameters necessary for employment of the invention.
The communication apparatus containing the device according to the invention may also be a programmed apparatus. This apparatus then contains the code of the computer program or programs resident, for example, in an application-specific integrated circuit (ASIC).
It should be noted that the maintenance application modules of the avionics, just as all the on-board software applications of the secured part of the information system of the aircraft, are developed in accordance with strict aeronautical standards, making it possible to guarantee a certain level of security and to demonstrate a level of prediction of the behavior of the system.
By way of illustration, the hosting platform of the maintenance application modules of the avionics, for which the desired software quality assurance level is DAL C, is developed in such a way that the level of control of the on-board code ensures in particular the integrity of the generated information items (the hosting platform, for example, is developed according to the DO-178B aeronautical standard).
Thus the employment of the invention in such a context makes it possible to guarantee a certain level of integrity of the data and results transmitted to the remote station.
Naturally, to satisfy specific needs, a person competent in the field of the invention will be able to apply modifications in the foregoing description. | A method for testing or evaluating the configuration of at least one equipment item in an aircraft includes receiving at least one command to test or evaluate the configuration of the at least one equipment item via a network interface of a less secure part of an on-board information system of the aircraft. The network interface is capable of exchanging data with an information system external to the aircraft. The method also includes encoding the at least one received command and transmitting the encoded command to the secured part of the information system of the aircraft. In response to reception of the encoded command, the at least one encoded test command is filtered. In response to the filtering, the encoded command is translated and executed in relation to at least one first maintenance function of the secured part. | 6 |
The present application is a 371 of International application PCT/DE2012/200008, filed Feb. 13, 2012, which claims priority of DE 10 2011 011 112.3, filed Feb. 12, 2011, the priority of these applications is hereby claimed and these applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention pertains to a method for producing a strand or cable, in which fibers and/or wires are twisted at a cabling point to form the strand or cable. The invention also pertains to a device for carrying out the method and to a cable which can be produced by the method.
Such methods by means of which wire strands or cables are produced from natural fibers, plastic fibers, or wires are known from a history of use and are usually carried out with a cabling machine. Spools onto which the fiber strands or wires to be cabled are wound are arranged on the rotor of the cabling machine. The fiber strands or wires are guided under rotation to the cabling point, where they are twisted to form the strand or cable, and the formed strand or cable is then wound up onto a cable drum.
Such methods are also used in particular to produce strands and cables which comprise high-strength plastic fibers of aramid, for example. Such strands and cables are very strong for their weight and volume.
For this reason, plastic fiber cables are used in mountain climbing to ensure the safety of the climbers. The advantage of such plastic fibers is also manifest when they are used in wire cables of considerable length for use in suspended applications, e.g., for hoist cables in mining or for deep-sea cables. In applications such as this, the weight of the wire cable itself uses up a large percentage of the load-bearing capacity of the cable; the useful load is reduced to a corresponding extent.
The problem with plastic fibers is that, although they are very strong in the longitudinal direction, they are quite weak in the transverse direction, and there is therefore a considerable danger of breakage under certain types of load.
The plastic fiber cables used to ensure the safety of mountain climbers normally comprise a core-jacket structure, in which the core consists of fiber strands which have been twisted together. The cabled fiber strands are protected from damage by a jacket, which is braided around them and which thus holds them together.
The method indicated above is also used to produce composite cables in which the core cable consists of high-strength plastic fibers and the external strands consist of steel wire. For example, in the case of the cable known from U.S. Pat. No. 6,563,054 B1, a jacket of thermoplastic material is applied around a core cable of parallel plastic fibers, and the steel wire strands are cabled on top of that.
SUMMARY OF THE INVENTION
The invention is based on the goal of creating a method of the type indicated above by means of which strands or cables can be produced which offer mechanical properties superior to those of the known strands or cables.
According to the invention, the goal is achieved in that the fibers and/or the wires are coated with a liquefied matrix material before and/or at the cabling point and are embedded in the matrix material as they are being cabled.
By means of the method, a strand or cable can be produced in which the fibers or, insofar as the fibers are in the form of monofilament bundles, the monofilament bundles or wires in the strand or cable are surrounded by the matrix material, and in which the spaces between the fibers, monofilament bundles, or wires twisted to form the strand or cable are filled by the matrix material. The properties of the strands or cables are especially advantageous when at least the sections of the strand or cable in which the fibers, monofilament bundles, or wires are not at the surface of the strand or cable are completely surrounded by the matrix material. An especially homogeneous strand or an especially homogeneous cable can be produced in this way. The strand or cable, furthermore, can be jacketed with the matrix material at the same time.
The matrix material protects the fibers or wires, bonds them to each other, and transmits the prevailing forces to them. A composite cable with improved mechanical properties is obtained.
Through the choice of the matrix material, furthermore, the mechanical properties of the strand or cable can also be advantageously influenced. Thus the strength will be greater when a high-strength matrix material is chosen then when a less-strong matrix material is selected.
It is also possible, as the fibers or wires are being twisted into a cable, to embed them in the matrix material in the positions which they are intended to assume in the strand or cable. There will then be no need for any further treatment of the cable for the purpose of bringing the fibers or wires into the intended positions.
If the strand is produced by the cabling of preferably twisted monofilament bundles of individual fibers, each of the monofilament bundles is coated with the matrix material and embedded in the matrix material during the cabling process itself, wherein each monofilament bundle remains surrounded by the matrix material. Depending on, for example, the viscosity of the matrix material and on the ability of the matrix material to wet the fiber material, the method also makes it possible for at least individual fibers of the monofilament bundle lying on the outside of the monofilament bundle to be surrounded by the matrix material.
It is advantageous for the monofilament bundles and possibly the individual fibers to be separated from each other by the matrix material, so that the load which they exert on each other in the direction perpendicular to the longitudinal direction is reduced. The danger of breakage is thus significantly decreased. The strands or cables are more resistant than the known strands or cables and have a longer service life.
Whereas the use of natural fibers, metal fibers, mineral fibers, glass fibers, and/or carbon fibers could be imagined as materials for the production of the strand or cable, synthetic fibers such as aramid or polyethylene fibers are used in the preferred embodiment of the invention.
A thermoplastic is advisably used as the matrix material. In addition to the preferred polypropylene, it is also possible to consider the use of polycarbonate, polyamide, polyethylene, or PEEK.
In the inventive cable, the fibers embedded in the matrix material can form the core of a composite strand, which comprises an external layer of steel wire.
In addition, the embedded fibers can be the core cable of the cable, and the cable can comprise an external layer of strands, preferably of steel wire strands or of the previously mentioned composite strands with a core of fibers and an external layer of steel wire.
The strand or cable is advisably embedded completely in the matrix material. The matrix material then forms a jacket and thus provides protection from the outside. When a strand or a core cable is being produced, furthermore, the strands surrounding the strand or core cable can be embedded in this jacket.
It is obvious that the inventive method can also be used to produce a cable from wires and/or fibers which have already been twisted into strands. In this case, the strands to be cabled are embedded in the matrix material, wherein the matrix material can fill up the voids which may be present in the strands. Strands produced by the method described here can be used to produce the cable.
The method is also advantageous in that it makes it easier to produce cables with a core-jacket structure. Whereas, for the embedding of the core cable, it has been necessary until now to conduct the method in two steps, namely, first, the jacketing of the core cable and then the cabling of the strands onto the core, this can now be carried out in a single step by means of the inventive method.
It is advisable to provide a device for coating the fibers or wires on a cabling machine which can both produce the core cable and twist the strands around the core cable (tandem cabling machine). The core cable is coated with the matrix material at least by the time at which the strands are wound onto the core. In certain cases, the fibers, wires, and/or strands used to produce the core cable will have already been embedded in the matrix material.
Whereas it would be possible to imagine that the fibers, wires, and/or strands could be sprayed with the matrix material, they are, in an especially preferred embodiment of the invention, immersed in the liquefied matrix material before and/or at the cabling point.
In one embodiment of the invention, a heatable container is preferably provided to hold the liquefied matrix material, which container surrounds the fibers and/or wires and/or strands before or at the cabling point.
Alternatively, it is also possible to provide a spray device to spray the liquefied matrix material. It is advisable for the device used to implement the method to be provided with protective walls, at least in the area in which the matrix material is sprayed, to close off the device from the outside and thus to prevent sprayed matrix material from reaching the environment. The space formed by the protective walls can be provided with an exhaust system and an appropriate filter.
It is advisable for the container or the spray device to be connected to an extruder, by means of which the matrix material is liquefied and conveyed toward the spray device or container.
It is advisable for a device for measuring the temperature of the container to be provided to ensure that the container is heated in such a way that the matrix material in the container remains liquid. Adjusting the temperature also makes it possible to change the viscosity of the matrix material and to influence the wetting of the fibers or wires.
In an especially preferred embodiment of the invention, the container comprises a rotatable end wall, which is provided with openings, through which the fibers, wires, and/or strands are guided to the cabling point. The rotatable end wall can be rotated at the same rotational speed as the rotor over which the fibers, wires, and/or strands are guided to the cabling point. The openings are advisably provided with seals, which prevent the matrix material from escaping from the container.
At the end of the container opposite the rotatable wall, another opening is provided, through which the formed strand or the formed cable is to be guided.
It is advisable for the diameter of the additional opening to be the same as the outside diameter of the strand to be formed or of the cable to be formed. As it leaves the container, the strand or the cable is thus brought into the shape intended for it.
Whereas it could be imagined that the rotation of the end wall could be synchronized electromechanically with the rotation of the rotor, in a preferred embodiment of the invention, the rotatable end wall and the rotor are connected to each other The rotor thus carries the end wall along with it as it rotates.
It is advisable for the container to be closed except for the previously mentioned openings. In certain cases, the matrix material can be under increased pressure in the container, so that it wets the fibers more effectively or can penetrate more effectively into any voids which may be present.
After the cable-forming process, especially after the strand or cable has left the container through the previously mentioned opening, it is advisable to cool the strand or the cable, preferably in air or in a cooling fluid such as water, to solidify the matrix material.
In one embodiment of the invention, a calibration ring is arranged in the container, through the opening of which the strand to be formed or the cable to be formed is pulled during the cabling process. The fibers and/or the wires of the strand or of the cable can thus be given the desired shape while still inside the container.
This proves to be especially advantageous when the diameter of the additional opening of the container is larger than the opening of the calibration ring. It is then possible to apply a jacketing of matrix material to the strand or cable during the cabling process itself. This is possible in particular in cases where the viscosity of the matrix material at the previously mentioned additional opening is such that the material retains its form after leaving the opening.
To make this possible, the container is advisably provided with a section of pipe at the end where the formed strand or the formed cable is pulled out, the inside diameter of this section of pipe being larger than the opening of the calibration ring and in which pipe section the matrix material cools and solidifies. For this purpose the pipe section can be provided with a cooling device such as a water cooling device.
In a further embodiment of the invention, the fibers are stretched as they are being cabled and embedded in the matrix material and as the matrix material is cooled until it has solidified, with the result that the fibers are held by the matrix material in the position which they have assumed in the stretched state. It is advisable to stretch the fibers to such an extent that they are brought into a position which they assume when absorbing load, preferably to such an extent that, when load is absorbed by the strand or cable, they undergo plastic stretching precisely according to Hooke's law.
The load absorption can be improved by this measure. The actual absorption of load by strands or cables made of fibers which have not been prestretched begins only after a certain delay, because every time the fibers are subjected to load they must first “settle”, that is, arrive at a final spatial arrangement in which they form a stable cross section. This applies in particular to plastic fibers in the form of monofilament bundles. If the fibers have already been stretched while they are being cabled, and as long as they are held in the stretched state until the matrix material has solidified, they are held in the stretched state by the matrix material. The fibers are “frozen” in this stretched condition. This offers the advantage that, in the case of a cable structure consisting of a core cable of fibers and strands of steel, the stretching behavior of the core cable can be adapted to the stretching behavior of the wire strands, and the core cable can thus absorb a significant percentage of a load.
In an elaboration of the invention, it is provided that an additional jacketing is applied after the cabling onto the strand or the cable. If the jacketing, which is preferably formed by a surrounding layer of braid, is put under tension, it can serve to hold the fibers in the above-described pretensioned state or it can at least serve to help hold them in this state.
If the jacketing is also embedded in the matrix material, an especially good bond can be created between the fibers and the jacketing. The problem which occurs in the case of known cables, namely, that a jacketed core strand or a jacketed core cable becomes detached from the rest of the cable or from the rest of the strand is therefore eliminated.
An especially strong bond can be achieved when the surrounding braid is formed out of fibers of different thicknesses and/or when it is formed with mesh openings, through which the matrix material penetrates.
The invention is explained in greater detail below on the basis of exemplary embodiments and the attached drawings, which relate to the exemplary embodiments:
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows a schematic diagram of an inventive device;
FIG. 2 shows a detail of the inventive device in the form of an isometric diagram;
FIG. 3 shows a detail of another inventive device in the form of an isometric diagram;
FIG. 4 shows a schematic diagram of another inventive device;
FIG. 5 shows a detail of the inventive device according to FIG. 4 in the form of an isometric diagram;
FIG. 6 shows a cross section of an inventive cable;
FIG. 7 shows a cross section of another inventive cable;
FIG. 8 a shows a cross-section of an inventive strand;
FIG. 8 b shows the strand of FIG. 8 a after compacting;
FIG. 9 shows a cross section of another inventive cable;
FIG. 10 shows a cross section of another inventive cable;
FIG. 11 shows a cross section of another inventive cable;
FIG. 12 shows a cross section of another inventive cable; and
FIG. 13 shows a cross section of another inventive cable.
DETAILED DESCRIPTION OF THE INVENTION
An inventive device shown in FIG. 1 for the production of cables or strands comprises a rotor 9 , over which twisted monofilament bundles 2 or aramid fibers are guided to a cabling point 3 . On the rotor 9 , spools of the type known in themselves (not shown) are arranged, on which the monofilament bundles are wound. During the cable-forming process, the monofilament bundles 2 are unwound continuously from the spools as the rotor 9 turns in the direction of the arrow P. At the cabling point 3 , the monofilament bundles 2 are formed into a cable 20 in the manner known in itself. By means of rollers 15 , the cable 20 is pulled from the cabling point 3 and wound up on a cable drum.
At the cabling point 3 , a container 7 , which is shown in more detail in FIG. 2 , surrounds the monofilament bundles 2 and the cable 20 . The container 7 has a conical shape and is provided at the end facing the rotor 9 with a rotatable end wall 10 , which has several openings 11 and which is rigidly connected to the rotor 9 by a connecting web 16 . The twisted monofilament bundles 2 are guided from the rotor 9 through the openings 11 to the cable-forming point 3 . Only four monofilament bundles 2 are shown in FIG. 2 to serve as an example. Depending on the application, various numbers of openings 11 suitable for the number of monofilament bundles 2 to be formed into a cable can be provided.
The device can form cables not only out of twisted monofilament bundles 2 but also out of previously formed strands. The monofilament bundles 2 can also be formed into cables in combination with previously formed strands.
Another opening 12 , through which the cable 20 is guided out of the container 7 , is provided at the end of the container 7 opposite the end wall 10 . The opening 12 has a diameter which corresponds to the diameter of the cable 20 to be formed. Instead of a circular shape for the opening 12 , it is also possible to use some other shape, preferably an asymmetric, angled-oval, or polygonal (e.g., three-sided, four-sided, or five-sided) shape or the shape of a section of a circle (e.g., a semi-circle or quarter-circle).
The container 7 is connected by a heated pipe 13 to an extruder 8 , by means of which polypropylene is continuously liquefied and supplied to the container 7 . So that the polypropylene 4 remains liquid in the container 7 , the container 7 is provided with heating tapes (not shown) in its lateral surface so that it can be heated to a temperature of 200-300° C. A temperature sensor is provided in the container to monitor the temperature.
To produce the inventive cable 20 , the monofilament bundles 2 are drawn continuously to the cabling point 3 . When the rotor 9 turns, the end wall 10 is turned along as well by the connecting web 16 at the same rotational speed, so that the monofilament bundles 2 are guided continuously through the openings 11 to the cabling point 3 . The seals (not shown) provided on the openings 11 prevent polypropylene 4 supplied through the connecting pipe 13 from escaping from the container 7 .
In the container 7 , the monofilament bundles 2 are coated with the polypropylene 4 before they reach the cabling point 3 . The cable-forming process at the cabling point 3 also takes place completely in the polypropylene 4 . During the cabling process, the polypropylene 4 is supplied continuously to the container by the extruder 8 .
The formed cable is guided out of the container 7 through the opening 12 and into a water bath 14 , in which the polypropylene 4 is cooled and solidified. By means of a tensioning device (not shown) to stretch the cable, the cable can be prestretched in such a way that the monofilament bundles 2 assume the position in the cable which they assume under the load which the cable is intended to absorb during use. The monofilament bundles 2 are held by the polypropylene 4 in the stretched state. They are “frozen” in this stretched condition.
FIG. 6 shows a cable 20 of aramid fibers produced by means of the method described above. Several fiber strands 21 , 22 , wound from several twisted monofilament bundles, have been formed into the cable 20 . The monofilament bundles, shown as black dots, are surrounded by the polypropylene 4 .
Reference is made in the following to FIGS. 3-5 and 7-12 , where the same parts or parts of similar function are designated by the same reference numbers as those used in FIGS. 1, 2, and 6 , a letter being appended to each of the associated reference numbers.
An inventive device shown in FIG. 3 differs from those according to FIGS. 1 and 2 in that a connecting web 16 a , which is connected to the rotor, is hollow on the inside, and in that a core cable 23 is guided through the connecting web 16 a to the cabling point 3 a . At the cabling point 3 a , the core cable 23 is formed into a cable 20 a with the external strands 24 and coated with polypropylene 4 a as described above.
As an option, the device can also comprise a braiding device 35 , indicated only schematically here, by means of which a layer of braid 27 can be applied to the core cable 23 and embedded in the polypropylene 4 a . The surrounding layer of braid forms a braided cable 20 a ′ out of the cable 20 a.
Another inventive device, shown in FIGS. 4 and 5 , comprises, in its container 7 b , a calibration ring 30 , formed by a ring mounted in the container 7 b , through which a core cable 22 b to be formed, is pulled to give it its shape after fibers 2 b have been wound around the core cable 22 b . At one end of the container 7 b , namely, the end from which the core cable 22 b leaves the container 7 b , a section of pipe 31 is arranged. The inside diameter of the pipe section 31 , in the walls of which a water cooling circuit is provided, is larger than the opening of the calibration ring 30 . Polypropylene 4 b , with which the fibers 2 b are coated, is cooled in the pipe section 31 to a viscosity such that, upon emergence from the pipe section 31 , it retains its shape but still remains soft.
The device according to FIG. 5 can be used to provide the core cable 22 b with a jacketing 26 of polypropylene 4 b on the fibers.
FIG. 7 shows a composite cable 20 a , which comprises a core cable 22 a , which corresponds to the cable 20 described above. The core cable 22 a is surrounded by a jacketing 26 of the polypropylene 4 a forming the matrix material. Steel strands 24 have been wound around the core cable 22 a and thus embedded in the jacket 26 . The steel strands were pressed into the matrix material 4 a of the jacket 26 while the material was still soft.
FIG. 4 shows a schematic diagram of optional enhancements to the part of the device shown in FIG. 5 . Downstream in the cable-forming direction from the pipe section 31 , a braiding device 26 b can be provided, by means of which a layer of braid can be applied to the core cable 22 b.
In addition, another cabling device 36 can be provided, by means of which external strands 24 b can be wound onto the core cable 22 b , the strands 24 b thus becoming embedded in the matrix material 4 b.
FIG. 8 a shows a strand 1 , the core strand 22 b of which has been produced by the inventive method and consists of aramid fiber strands embedded in polypropylene. Steel wire 24 b , shown only schematically here, has been pressed directly into the core cable 22 b as the core cable 22 b was being heated during the cable-forming process. FIG. 8 b shows a strand 1 ′, which is constructed like that according to FIG. 8 a but which has been compacted by hammering, for example.
A composite cable 20 c shown in FIG. 9 comprises a core cable consisting of three twisted, polypropylene-embedded fiber strands 21 c of monofilament bundles of aramid fibers, into which, during the cabling process, external strands 1 c have been pressed. The external strands 1 , only one of which is shown in detail, comprise, as a core, polypropylene-embedded aramid fibers 23 . In the polypropylene 4 c , steel wire strands 24 c are arranged around the aramid fibers 23 .
FIG. 10 shows a composite cable 20 d , which comprises a core cable embedded in polypropylene 4 d . The core cable comprises a core 21 d of polypropylene-embedded monofilament bundles 21 d of aramid fibers, in which steel wire strands 24 c are embedded, and around which an additional layer of steel wire strands 25 is wound. External strands 1 d are seated in the polypropylene 4 d ; these have the same structure as that described above for the strands 24 c of the exemplary embodiment according to FIG. 9 .
An inventive composite cable 20 e shown in FIG. 11 differs from the cables of the previous exemplary embodiments in that the external strands 1 e are completely embedded in a matrix material of polypropylene 4 e . A core cable of the cable 20 e comprises a core strand 32 of steel wire and strands 24 e , 25 e wound around it, which comprise here a core (not shown) of aramid fibers embedded in polypropylene. The core strand 32 and the strands 24 e , 25 e are surrounded by a lubricant 33 . Around the lubricant 33 and the core cable, the method described above is used to cable the external strands 1 e onto the core cable, and as this is done the core cable with the lubricant 33 is completely embedded together with the external strands 1 e in the polypropylene 4 e.
A cable shown in cross section in FIG. 12 can be produced by using the previously mentioned braiding device 31 to apply a layer of braid 27 into the jacketing 26 around the fibers 22 f of a core cable. The layer of braid 27 is also embedded in the matrix material 4 f surrounding the fibers 22 f , and a good bond is achieved between the fibers on the one side and the braid 27 on the other. A jacket 26 of matrix material 4 f is formed around the braiding 27 . As shown in FIG. 13 , external strands 24 g can be embedded in this jacket 26 .
It is obvious that the examples described here can be carried out with matrix materials other than the polypropylene mentioned. For example, polycarbonate, polyamide, polyethylene, or PEEK could be used instead.
In should also be obvious that the individual steps of the method described here can be combined with each other in any way desired depending on the cable structure to be produced. In corresponding fashion, individual components of the production device such as the container, the device for winding the external strands onto the cable, and the braiding device, possibly even several devices of the same type, can also be combined with each other in accordance with the method to be applied. | A method for producing a strand or cable, in which fibers and/or wires are twisted at a twisting point to form the strand or cable. The fibers and/or wires are coated with a liquefied matrix material before and/or at the twisting point and are embedded in the matrix material during twisting. The fibers and/or wires are immersed in the matrix material before and/or at the twisting point and the formed strand or the formed cable is cooled after the twisting in order for the matrix material to solidify, preferably by air or in a cooling liquid, for example water. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to the field of filling aerosol spray paint cans or similar items. When an aerosol spray paint can is charged, it is necessary to place a ball inside the can. This ball permits the user to stir the contents of the can by shaking the can with the ball inside.
Aerosol spray paint cans and the like are normally filled and sealed by automatic mass production. A conveyor belt type arrangement is used whereby the cans are placed on a conveyor belt which has placer tabs for each can and receive charges of contents. The cans are eventually crimped and sealed for transportation and sale. During this charging process it is necessary for the manufacturer to insert a ball inside of each can. Should a ball fail to be inserted in the can the finished product would not be marketable. It is therefore important in the industry to insure that each can receives a ball before the can is sealed.
Other manufacturing processes also require that balls be inserted into a can before it is permanently sealed. Any industry which utilizes a ball inside of a sealed container would benefit from this device and the method for using same.
One major problem which exists in automatically checking the insertion of a ball into a can is that the spray paint industry (and other related industries) use highly volatile chemicals in filling the contents of the can prior to the insertion of the ball. For example, in the spray paint industry, acetone and methyl chloride must be placed into the can before it is sealed. Both of these chemicals are highly volatile and the use of electrically powered checking devices is severely restricted and quite hazardous.
It is an object of this invention to provide an automatic ball drop checking device which utilizes only pneumatic sensing devices and pneumatic power for its operation. The use of air pressure rather than electricity greatly enhances the safety of the instant automatic checking device.
It is another object of this invention to provide a method which may be universally adapted for use in counting materials when electronic counters or other electronic devices would be impractical or hazardous.
BRIEF SUMMARY OF THE INVENTION
In the aerosol spray paint can industry, and related industries, an assembly line is utilized to charge the contents of the aerosol can with the appropriate fluids. Once the cans have been filled, a ball is inserted into the can and the can is then crimped and sealed. A series of dispensing nozzles and apparatus are applied to each can as the filling and sealing operations progress. The cans ride on a conveyor belt and an indexing system forwards each can to the next station as the operation in the previous station is completed. A crucial part of this operation involves dropping a ball from a ball drop plate into each can in turn.
The instant device relates to an automatic means for determining when a ball has been inserted into a can. The device incorporates a unique checker arm for controlling a proximity switch sensor. The proximity switch sensor works on pneumatic air pressure.
The device comprises an essentially rectangular base having two holes in the top. A first hole is used to bolt the entire device to the appropriate position in the automated line. A second and larger hole is provided for receiving the drop tube. A drop tube with an essentially cylindrical inner diameter is attached perpendicularly to the base. The drop tube has a small slot in the side of it.
Next to the drop tube and perpendicularly attached to the bottom of the base is an essentially L-shaped bracket. Pivotably attached to the short arm of the L is a sensor arm which protrudes slightly into the inner cylinder of the drop tube. In the long portion of the L-shaped bracket is a void which consists of the proximity switch sensor outlet. When a ball is dropped down the drop tube it will contact the protruding part of the sensor arm thus rotating the protruding part of the arm downward and the opposite end of the sensor arm upward. This upward motion of the sensor arm blocks the proximity switch sensor port thus creating a back pressure to the sensor switch. When that occurs a signal is sent through a fluid amplifier indicating that the ball has dropped and the various mechanisms required to activate the movement of the conveyor belt so that the cans move to the next station occurs.
The new method for using this device comprises supplying a signal to a four-way valve which locks down a Humphrey valve and simultaneously sends a signal to an indicator and regulator. The regulator reduces the line pressure to 5-10 pounds per square inch and supplies pressure to the proximity switch sensor. When a ball drops past the sensor arm a back pressure is created in the proximity switch sensor. That signal is then amplified and sent back to the four-way valve to open the Humphrey lock-out valve and indicate that a ball has dropped, moving the can to the next station.
Since it is impossible for a ball to drop through to a can without activating the sensor arm, the device is very reliable. Because the entire device operates on a mechanical signal (the ball dropping) which is then converted into an air pressure signal through various regulators and sensing devices, the operation is simple, inexpensive, and highly reliable.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective exploded view of the device. FIG. 1 is the most representative figure of the device.
FIG. 2 is a perspective view of the device as assembled with the drop tube section cut away.
FIG. 3 is a top view of the device showing the drop tube, sensor bracket, and sensor arm protruding into the drop ball cylinder.
FIG. 4 is a front cut away view of the device showing particularly the inner cylinder of the drop tube.
FIG. 5 is a schematic diagram showing the various paths of the air pressure and the devices which are used to practice the method of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the assembly line manufacture of aerosol paint cans, or related articles, an inner lock valve is located on the drive cylinder to a chain driven continuous belt. At the end of each indexed stroke, each can is moved forward to the next station to receive more fluid, to receive a ball, to be sealed, or to have various functions performed upon the article. At the end of each indexed stroke, the inner lock valve sends a pulse of air to the track switch on the supply line. Simultaneously, a signal is sent to the four-way control valve on the drive cylinder. This signal is then routed through a Humphrey inter-lock valve at each station to insure that each station has fired before the four-way control valve on the drive has a chance to reverse the drive cylinder and release the inner-lock valve on the drive which would de-energize the track switch supply line.
In the operation of this device, as shown schematically in FIG. 5, the track switch supply line is energized to signify that the ball drop station is ready to accomplish its function, which is to drop a ball down a drop cylinder and into a can. Since the Humphrey lock-out valve on the ball drop circuit is in the normally open position it is necessary for the checker track switch to send a signal to the Humphrey lock-out valve to close simultaneously with sending a signal to the ball drop circuit to drop a ball. With the checker track switch 1 supply line energized and the station on-off valve in the "on" position and with a container in place to actuate the track switch, the track switch sends an air signal to the pilot of the four-way control valve for the ball feed. Simultaneously through a tee in the pilot air feed line a signal is sent to the pilot of the four-way valve 2 for the ball feed drop checker for the ball drop circuit. The four-way valve used herein is standard in the industry and may be purchased, for example from LHB Industries, part #152-JJ-4150. The four-way control valve 2 for the ball feed drop circuit then shifts, feeding supply air to the input of the regulator 3 (LHB part # MAR-1) which is mounted on the ball drop checker control panel. Simultaneously through a tee, a signal is sent to a pressure indicator 4 (LHB part # IND-3-RD) which is also mounted in the control panel. The pressure indicator shows that the ball drop circuit has been energized. When the initial signal from the checker track switch 1 is fed into the four-way valve 2 it also shifts the Humphrey inner-lock valve 5 which is located on the four-way manifold. The normally open Humphrey inner-lock valve is then closed blocking the supply air to the pilot on the drive indexing control valve. This mode for the Humphrey lock out valve is shown schematically on FIG. 5 as "stop."
In actual production and charging of aerosol spray paint cans or the like, a series of HumphreY inner-look valves control the entire indexing of the drive cylinder and drive chain. Each station at which a function is performed has a Humphrey inner-lock valve. These inner-lock valves are connected in series so that any station not completing its cycle will block supply air to the indexing drive pilot on the indexing chain and keep the chain from advancing the cans to the next cycle. In the particular field involving aerosol spray paint cans, nine separate stations are involved. Nine functions are thus performed. The instant device deals with the station concerning the ball drop checker. Other mechanisms which would be used in conjunction with this device include a ball drop plate rotator, toluene filling head, acetone filling head, paint head, methyl chloride head, crimping the valve in the can, checking to insure that a vacuum is maintained in the can, and charging heads. A vacuum is commonly measured in inches of mercury drawn. The vacuum drawn by the crimping procedure should measure at least five (5) inches of mercury The charging heads only fill half the can at one station, the other half at a separate station. Should all of these functions be satisfactorily performed, all Humphrey lock-out valves (which are connected in series) would be open and an output signal to the four-way valve on the drive cylinder would index the drive chain and advance the cans. In standard operation, these stations are in pairs so that two cans may receive each operation simultaneously. The drive belt would then advance the cans two stations to receive the next operation.
Referring back to FIG. 5, it can be seen that the signal from the four-way valve (which is at a line pressure of approximately 60 pounds per square inch) activates the indicator 4 and is fed into the regulator 3. The regulator then reduces the pressure to 5-10 pounds per square inch in order to operate the proximity switch sensor (LHB #1022). In practice it has been found that the preferred pressure is between five (5) and ten (10) pounds to give the desired reliability for the proximity switch sensor 6. A tee in the signal line between the regulator and proximity switch sensor feeds gauge 7 so that the pressure to the sensor switch may be monitored. This proximity switch sensor 6 is mounted on the ball feed drop checker as shown in FIG. 1.
As the four-way valve 2 for the ball drop circuit shifts, a four-way valve for the ball drop plate rotator also shifts so that the Humphrey inner-lock on the ball drop plate rotator is in the closed position. The ball drop plate rotator receives supply air from its four-way valve which enters the air cylinder through the speed control valve on the ball drop plate rotator. That cylinder then moves forward turning the ball feeder disc or ball drop plate rotator which drops a ball into the ball feed drop tube 8. As the cylinder for the ball drop plate rotator reaches the end of its forward stroke, it contacts a station return valve which sends a signal to the opposite pilot on its four-way control valve shifting it and the inner-lock valve back to their normal position and allowing the air to be exhausted from the cylinder, at which point the spring in the cylinder returns it to its ready position.
As a ball drops through the ball drop tube 8 it contacts the drop checker sensor arm 10 (FIG. 1). The ball drop tube 8 is inserted into the large hole 9' on the sensor base 11 so that the inner cylindrical passage center 9 for the ball located within the ball drop tube 8 is perpendicular to the sensor base 11.
Also attached to the bottom of the sensor base is an essentially L-shaped bracket 12. This L-shaped bracket is attached to the bottom of the sensor base 11 and is perpendicular thereto. The long portion of the L-shaped bracket has a port 13 cut therethrough. To the far side 14 of this port is attached the proximity switch sensor device. The port 13 thus communicates with the proximity switch sensor 6.
To the short side of the L-shaped bracket is pivotably attached a sensor arm 10. The short side of the L-shaped bracket has an essentially rectangular slot 15 cut therein. The sensor arm 10 is pivotably attached in the sensor arm slot 15 by means of a pin 16. When the device is assembled, as best shown in FIGS. 2, 3 and 4, the sensor arm protrudes into the inner diameter of the drop tube 8. This inner diameter or ball cylinder 17 is the passageway which guides the ball from the ball drop plate rotator to the can. In order to allow the sensor arm 10 to rotate about its pivot pin 16, a ball drop slot 18 is cut into the ball drop tube 8. When appropriately assembled, as shown in FIGS. 2 and 4, it can be seen that one end 19 of the sensor arm protrudes inwardly into the center of the drop tube cylinder 17. The outward end 20 of the sensor arm 10 extends past the proximity switch mounting port 13.
In operation, when it is desired to drop a ball into a can, the ball drop plate rotator dispenses a ball through the hole in the base of the device. The ball then drops down through the inner cylindrical passage for the ball 9 and down the inner ball cylinder 17. As it contacts the inner end 19 of the sensor arm near the bottom of the cylinder, the sensor arm pivots allowing the ball to fall past it and into the container. (The sensor arm may be located anywhere along the length of the drop tube.) As the inner arm moves downward with the force of the dropping ball, the outer end 20 of the sensing arm moves upward to pass in front of the energized proximity switch exhaust port 13. In the preferred embodiment, the sensing arm is adjusted to provide approximately 1/16" of clearance between the proximity switch port base and the body of the pivot arm. As the arm passes in front of the proximity switch port, the exhaust port of the proximity switch is closed thus creating a back pressure and energizing the output of the proximity switch. Output air from the proximity switch is then fed to the signal input of the fluid amplifier valve 21 (see FIG. 5). The fluid amplifier valve (LHB #2010) is located on the control panel.
Once the ball has been dropped and sensed by the sensor arm and proximity switch sensor, the fluid amplifier amplifies the five (5) to ten (10) pounds per square inch signal from the proximity switch sensor and sends line pressure to the four-way valve 2. The signal fluid amplifier 21 has line pressure supplied to it by a line air input from a separate air supply line on the filling table. When a signal is supplied by the proximity switch sensor 6 to the input of the fluid amplifier valve, it energizes the output. This energized output air feeds the opposite pilot on the ball drop station four-way control valve 2. This control valve thus shifts its inter-lock valve (Humphrey lock-out valve 5) to its normal position and then de-energizes the ball drop checker proximity switch and fluid amplifier valve. Once the signal fluid amplifier 21 sends a signal through the four-way valve 2 to the Humphrey lock-out valve to return to its normally "on" position (symbolized by "GO" on the schematic) the inter-lock air signal continues through the remaining inner-lock stations through a series of Humphrey valves and ultimately reaches the drive pilot which causes the line to index and begin another cycle.
In the event that the ball feed station cycles but fails to drop a ball (due to a jam or an empty hopper) the ball drop checker indicator and gauge will both show the energized condition and the inter-lock will prevent the line from indexing to the next cycle. After the problem has been resolved, the ball feed can be manually operated. Once a ball drops, the ball drop checker will clear and the line will resume the normal indexing cycle.
This entire device may be attached in the appropriate manner to the automated assembly line process by means of the bolt hole 22. Alternatively, the bolt hole may be eliminated and the device may be attached by means of brackets or other standard and ordinary methods of attachment. In order to insure easy inspection and repair of the device, both the sensor arm and drop tube are made so that they may be removed by means of removing the holding pins (16 and 23). The ball drop tube 8 is held in place by means of the set pin 23; the sensing arm by pin 16.
While the preferred embodiment has been described herein, it can be seen that minor variations or equivalent interchange of parts may be used in order to practice this invention. While parts listed from LHB Industries have been drawn, any parts which function equivalently are acceptable. It is believed that the use of pneumatic air pressure rather than any electronic or electrical devices greatly enhances the safety and reliability of the counting devices. It is to be appreciated that the instant invention encompasses not only the embodiment of the sensor arm bracket and mechanism but also the method of practicing the use of this device in that the unique pneumatic air sensing mechanism is new and novel. | A pneumatic sensing device is presented which automatically senses the motion of a ball falling into a can. A sensing arm protrudes into the pathway of the dropping ball. When the ball hits one end of the arm, the other end of the arm rotates upward and closes off an exhaust port, creating a back pressure in a proximity switch. The proximity switch then sends a pneumatic signal to a four-way valve that allows the now filled can to move on to the next work station. Also presented is a method of using the sensing arm which uses a regulator and indicator to display when the ball drop station has been energized but the ball has failed to drop. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part application of U.S. application Ser. No. 11/982,067 which was filed on Oct. 31, 2007 to which application this inventor claims domestic priority.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to fasteners and threaded workpieces, and more particularly to affixing an internally threaded insert within a workpiece so that a threaded fastener may be made up to the workpiece utilizing the threads of the insert.
[0003] For a variety of reasons it is desirable to dispose a self-tapping sleeve within a workpiece. Most, but not all of the time, the self-tapping sleeve will have internal threads and will be utilized for thread replacement. For example, if pre-existing threads of the workpiece are damaged, the damaged threads may be replaced with the threads of the insert. One type of internally-threaded insert is self-tapping, such that the insert may be driven into a bore of the workpiece, cutting threads in the bore as the insert is driven. The self-tapping inserts have both internal threads for receiving a fastener and external threads. A first group of external threads cuts new threads in the bore, and a second group of external threads makes up into the new threads, thereby advancing and securing the self-tapping insert within the bore and thus providing new threads within the workpiece.
[0004] The most common use of self-tapping inserts is to provide replacement threads where the original threads of the workpiece have become damaged, and to stabilize the matrix material to prevent cracks from continuing or propagating. When the original threads become damaged, they can sometimes be repaired by chasing the damaged thread with a tap to restore the original thread shape. However, if the original thread shape cannot be restored by this measure, the thread must be replaced. One means of replacing the threads is to bore the hole to a larger diameter than the original thread diameter and to rethread the hole. However, a disadvantage of this procedure is that it requires a change in the fastener size from the original. If the equipment utilizes multiple fasteners of the original size, the different size fastener complicates maintenance and repair of the equipment because different tools are required, and correlating fasteners with the matching threads made more difficult. It is therefore desirable in some cases to be able to replace the original threads with threads of the same size so that the same size fastener may be utilized. In these cases, self-tapping inserts may be employed.
[0005] Self-tapping inserts are hardened steel cylinders, threaded on the exterior and, usually, in the interior. The interior thread diameter and pitch of the internal threads are those of the fastener to be installed. The exterior of the self-tapping insert comprises a section which cuts new threads (the “cutting section”) and a section of threads which make up into the newly cut threads. The cutting section of the known self-tapping inserts is tapered and usually comprises three or more slots or holes, which interrupt the tapered threads, thereby forming teeth similar to those of a conventional thread tap. Typically a bolt (the “drive bolt”) is used to drive the self-tapping insert into a pilot hole in the base metal. This pilot hole is usually made by drilling out the damaged threads as described above to form a bore hole in the base metal. As the insert is turned, the teeth of the cutting section engage and remove the base metal until the insert is fully installed and flush with the exterior surface of the workpiece. The insert remains in place within the workpiece by an interference fit between the newly cut threads in the workpiece and the exterior threads on the insert.
[0006] While in a well-equipped shop it is possible to correctly install known varieties of self-tapping inserts with shop equipment such as mills and drill presses, field installation of such devices with hand tools presents several disadvantages for the known self-tapping inserts. Because the known self-tapping inserts are tapered on the tapping end (i.e., the end which is first inserted into the bore hole), the inserts have a tendency to start tapping crookedly. The person performing the tapping procedure has no simple way other than by visual inspection to ascertain whether the insert is entering the bore hole straight—i.e., whether the longitudinal axis of the insert coincides with the longitudinal axis of the bore hole. The only way to ensure that the prior-art insert enters the bore straight is to utilize a magnetic drill (“mag drill”) which attaches to the work-piece with an electromagnet. An example of such a mag drill is disclosed in U.S. Pat. No. 3,969,036 (Hougen). The procedure requires: (1) positioning the mag drill by means of a centering tool; (2) replacing the centering tool with a drill bit and drilling out the damaged threads; (3) customizing the drive bolt by removing its head so that it can be fitted to the chuck of the mag drill; (4) with the mag drill maintained in exactly the same location as established in step (1), threading the prior art insert onto the modified drive bolt and installing the modified drive bolt into the chuck of the mag drill; (5) driving the prior art insert two to three rotations with the mag drill, until it has started to cut new threads; and (6) completing the installation with a wrench, socket wrench, pneumatic impact wrench, mechanical torque multiplier, or hydraulic torque multiplier, depending upon the torque required to install the prior art insert.
[0007] It is important that the insert be installed straight, which means it must be correctly aligned at the initiation of the installation procedure. If the insert is too crooked during installation, the insert may shatter when partially installed because of the hardness of the insert. If the insert is installed crooked and does not shatter, the fastener will often not align correctly with the insert. The alignment problem becomes more severe for larger inserts. In recognition of this problem, one manufacturer of self-tapping inserts requires that the installation method for larger diameter inserts (such as larger than ¾ inch) include counter-boring or partially pre-tapping the pilot hole for the insert such that the insert will be properly aligned within the hole. Counter-boring or pre-tapping the pilot holes are demanding, time-consuming and expensive procedures requiring large-diameter drill bits and/or taps, often under difficult field conditions.
[0008] A need therefore exists for a self-tapping insert which aligns itself correctly to the axis of the workpiece's borehole, without the need to counter-bore or pre-tap, and without the aid of magnetic drills, mills, drill presses, vises, collets, or similar devices.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to embodiments of a self-tapping insert which meets one or more of the needs identified above. The disclosed self-tapping insert is utilized to provide new threads within the smooth bore of a workpiece. If the insert is utilized to provide new threads to replace damaged threads, the damaged threads are drilled out to provide the smooth bore.
[0010] An embodiment of the disclosed self-tapping threaded insert comprises a cylindrical body having a top, a bottom, an interior portion and an exterior portion, where the cylindrical body defines a central axis. The interior portion of the insert may comprise a first set of threads. The exterior portion comprises tapping or cutting threads and engagement threads. In relative order from the bottom of the cylindrical body (i.e., the end of the insert first inserted within the borehole), the exterior portion of the insert comprises a plurality of cutting threads and a plurality of engagement threads.
[0011] An embodiment of the self-tapping insert further comprises a pilot extension member which is removeably attached to the device. The pilot extension member increases the effective length of the self-tapping insert to allow greater penetration of the insert within the pilot hole, thereby reducing the angle of deflection between the longitudinal axis of the smooth bore and the central axis of the self-tapping insert
[0012] The cutting threads comprise means for cutting threads in the smooth bore which are used for locking the insert within the bore. The engagement threads thereafter engage the insert locking threads as the insert is made up into the bore. A driving means is required to drive the body of the insert into the bore until the insert is completely seated within the bore.
[0013] Embodiments of the apparatus comprise means for cutting threads in the smooth bore. The thread cutting means may comprise one or more apertures in the cylindrical body where the apertures extend from the exterior portion to the interior portion of the insert, where each aperture comprises at the exterior portion a leading edge and a trailing edge. The apertures may be circular, oval, or elongated slots.
[0014] Embodiments of the apparatus may comprise means to drive the self-tapping insert into the borehole. The driving means may consist of a threaded bolt, whose threads match those of the self-tapping insert's interior threads, and whose constituent parts include, in order from its top, a hexagonal drive head, a threaded shank, and a threaded stem whose diameter is smaller than the diameter of the self-tapping insert's internal threads, and whose threads may be left-handed threads.
[0015] A means for aligning the self-tapping insert to the axis of the borehole comprises a pilot removeably attached to the drive bolt's threaded stem. An embodiment of the pilot comprises, at its top, a threaded bore centered upon the detachable pilot's longitudinal axis, and threaded with left-handed threads which match those of the drive bolt's threaded stem. The detachable pilot has a substantially cylindrical body having a top, a bottom, and exterior portion, where the cylindrical body defines a central axis. The detachable pilot may further comprise, centered on its bottom, a recessed broached hexagon, or other polygonal shapes suitable for a driver, whose point-to-point dimension and depth typically equal one-third to one-half of the detachable pilot's outside diameter. The broached hexagon serves as the receptacle for an Allen key or similar device, which is used to break free the pilot from the drive bolt's stem.
[0016] The detachable pilot's top, that is to say the part that threads onto the drive bolt's threaded stem and shoulders against the bottom of the self-tapping insert, comprises a threaded bore centered in the top of the pilot, where the diameter and thread pitch of the threaded bore are compatible with those of the drive bolt's stem, and the depth being such as to allow the detachable pilot to shoulder up against the bottom of the self-tapping insert.
[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a prior art self-tapping insert.
[0019] FIG. 2 is a side view of the prior art self-tapping insert depicted in FIG. 1 .
[0020] FIG. 3 is a perspective view of the prior art self-tapping insert shown in FIG. 1 attached to a drive bolt and utilizing a nut and washers for spacers.
[0021] FIG. 4 is a side view of the prior art self-tapping insert and drive bolt combination shown in FIG. 3 .
[0022] FIG. 5 schematically shows a prior art self-tapping insert, as ideally disposed within the bore hole of a workpiece prior to the removal of the drive bolt.
[0023] FIG. 6 shows an embodiment of the presently disclosed invention being inserted into the bore of work piece.
[0024] FIG. 7 shows an exploded view of the presently disclosed invention.
[0025] FIG. 8 shows a side view of an embodiment of the presently disclosed invention being inserted into the bore of a work piece.
[0026] FIG. 9 shows a detailed view of the insert and detachable guide of an embodiment of the presently disclosed invention.
[0027] FIG. 10 shows a bottom view of the detachable guide.
[0028] FIGS. 11A through 11G show the installation procedure for an embodiment of the presently disclosed invention in a workpiece.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0029] When the threads of a workpiece cannot be repaired by chasing the damaged thread with a tap to restore the original thread shape, replacement of the threads with a self-tapping insert provides an alternative method of repair. The pilot hole is usually made by drilling out the damaged threads to form a smooth walled bore hole in the base metal, and the prior art insert is placed within the bore hole.
[0030] Referring now specifically to the drawings, FIGS. 1 through 4 show a prior art self-tapping insert 20 , which is a hardened steel cylinder, threaded on the exterior and interior. The prior art insert 20 comprises external threads 22 , internal threads 24 and apertures 26 . The prior art self-tapping insert 20 is generally installed with drive bolt 28 which makes up into internal threads 24 of the insert. The diameter and pitch of interior threads 24 are those of the fastener to be installed. The exterior of the self-tapping insert 20 comprises a first section 30 which cuts new threads (the “cutting section”) and a second section 32 which comprises threads which make up into the newly cut threads.
[0031] Drive bolt 28 is used to drive the prior art self-tapping insert 20 into a pilot hole in the workpiece 44 as schematically shown in FIG. 5 . The cutting section 30 of the known self-tapping inserts is tapered and usually comprises three or more apertures 26 which interrupt the tapered threads. As the drive bolt 28 is rotated clock-wise (turned right-handed), the leading edges 34 of the apertures 26 engage and remove the base metal until the insert is fully installed and flush with the top surface 42 of the workpiece 44 . Referring to FIG. 3 , the term “leading edge” is defined as the edge of the aperture 26 which, as the insert 20 is rotated clock-wise, is the cutting edge.
[0032] The insert remains in place within the workpiece 44 by an interference fit between the newly cut threads in the workpiece and the threads of the second section 32 of the insert 20 . Spacers, such as washers 36 or nut 38 are utilized to allow the top of the prior art insert 20 , once installed, to be flush with the top surface 42 of the workpiece. However, as illustrated in FIG. 5 , the larger diameter of the head of drive bolt 28 , the washers 36 , and nut 38 , prevent setting the top 40 of the insert 20 below the top surface 42 of the workpiece 44 without substantial modifications to the tool configuration. It is to be appreciated that FIG. 5 depicts the ideal installation of a prior art self-tapping insert 20 into a workpiece 44 , i.e., where the insert is straight with respect to the borehole such that the longitudinal axis of the insert is generally aligned with the axis of the bore hole.
[0033] FIG. 6 shows an embodiment of the disclosed self-tapping self-guided insert 210 and components thereof. As best shown in the exploded view of FIG. 7 , this embodiment may comprise a cylindrical body 212 , a driving means, such as bolt 214 , and a detachable pilot extension member 216 . The components of the disclosed self-tapping self-guided insert 210 may be fabricated from various materials having the requisite mechanical properties based upon the material of the workpiece 244 . Suitable materials comprise steel and various alloy steels. The hardness of self-tapping insert 210 will be higher than the hardness of the material of the workpiece. As discussed above, various features of embodiments of the disclosed apparatus, and the methods for installing the apparatus, allow the use of harder metals for the self-tapping insert, because the torque required to install the disclosed self-tapping insert is not as high as for the known self-tapping inserts. Instead of being limited to hardness values of approximately 54RC, the disclosed self-tapping insert have a greater hardness value because of the reduced risk of shattering during installation.
[0034] Cylindrical body 212 has a top 218 which, as shown in FIG. 10G , is the end which will be approximately flush with the top surface 242 of the work piece 244 and a bottom 220 which end directly abuts extension member 216 . Cylindrical body 212 is shown in the figures to have interior threads 222 .
[0035] The interior threads 222 will typically conform to the size and type of the damaged threads being replaced. The interior threads 222 will have standard threads to match those of the drive bolt 214 , i.e. USS, SAE, and metric straight threads.
[0036] Cylindrical body 212 also has an exterior portion which term refers to all surfaces and structures on the exterior of the cylindrical body. As shown on FIG. 8 , the cylindrical body 212 defines a central axis A. The exterior portion comprises, in relative order from the bottom 120 of the cylindrical body, a plurality of cutting threads 230 , and a plurality of engagement threads 232 .
[0037] Cylindrical body 212 has an exterior thread diameter D o and an internal diameter D. Removeably attached to the cylindrical body 212 is detachable pilot extension member 216 . The maximum diameter D of the pilot extension member 216 section 128 defines a plane which is perpendicular to the central axis A of the cylindrical body 212 . Diameter D is sized to penetrate the smooth bore of the pilot hole, which is usually made by drilling out damaged threads. The length of the detachable pilot extension member 216 is configured to maintain the central axis A of the self-tapping insert in general alignment with the longitudinal axis of the smooth bore, as shown in FIG. 8 . Detachable pilot extension member 216 may have a constant diameter D along its entire length. Alternatively, as indicated in the figures, the diameter of the pilot extension member may taper toward the connection to the cylindrical body 212 . Diameter D is sized such that the detachable pilot extension member 216 penetrates the smooth bore, but the tolerances between the smooth bore and pilot member are relatively close. For example the tolerance between the internal diameter of the smooth bore and diameter D may range from 0.003 to 0.006 inches per side.
[0038] Cylindrical body 212 comprises a plurality of apertures 234 which extend from the exterior to the interior of the cylindrical body. The sides of the apertures 234 on the exterior of the cylindrical body 212 are bounded on opposing sides of the aperture by a leading edge 236 and a trailing edge 238 , wherein, as the self-tapping insert is rotated into the smooth bore, the leading edge 236 will tap new threads as it progresses through the smooth bore. In one embodiment of the present self-tapping insert, the leading edge 236 is the same radial distance from the center of the insert as the trailing edge 238 , i.e., the opposing side of the aperture. This embodiment may be the preferred embodiment in cases where the insert is a small diameter, such as less than 1 centimeter, where the amount of waste material created by the cutting of the thread is relatively small, and the torque required to install is relatively low.
[0039] As an alternative embodiment, the disclosed apparatus may also comprise a leading edge 236 which has a greater radial distance from the center of the insert than the trailing edge 238 . The “height” (i.e., the radial extension) of the leading edge may be greater than that of the trailing edge. In other words, if a first diameter is defined by the rotation of the leading edge 236 about the central axis A and a second diameter is defined by the rotation of the trailing edge 238 about the central axis, the first diameter will be greater than the second diameter.
[0040] This feature, known as “chip relief”, serves to direct chips to the interior of the insert rather than forcing chips into the newly cut threads. The resulting reduction of galling and binding reduces the torque required to seat the insert into the bore hole.
[0041] The disclosed self-tapping insert further comprises drive means, such as a drive bolt 214 made up into the internal threads 222 of cylindrical body 212 . Drive bolt 214 may comprise various head configuration for attaching a desired socket or wrench for rotating the self-tapping insert 210 . However, in contrast to prior art self-tapping inserts, the drive bolt 214 utilized in the present invention may provide means for attaching the detachable pilot extension member 216 to the self-tapping insert 210 . In this embodiment, drive bolt 214 may comprise, in relative order from the top of the drive bolt, a polygonal head 250 , a threaded shank 252 , which has threads compatible with the interior threads 222 and a threaded stem 254 having a diameter less than the diameter of the threaded shank. Threaded stem 254 is made up into internal threads 256 of the detachable pilot extension member 216 , and will be made up by rotation which is opposite of the make up direction of the threaded shank 252 into interior threads 222 . For example, if threaded shank 252 is made up to internal threads 222 by right hand rotation, then detachable pilot extension member 216 would make up to threaded stem 254 by left hand rotation and vice-versa.
[0042] As shown in FIGS. 11A through 11G , a driving means, such as drive bolt 214 , is utilized to rotate the self-tapping insert 210 . The first step in the process is to drill a smooth bore hole 200 in the work piece 244 with drill 202 . As best shown in FIG. 7 , a nut 258 and washer 260 may be used to facilitate installation of the cylindrical body 212 , which is the only part of the apparatus left in the bore hole 200 once installation has been completed. Once the bore hole 200 has been drilled, the self-tapping insert 210 is rotated several full turns to form several guide threads 204 in the bore hole 200 as shown in FIGS. 11B-11C . The entire self-tapping insert 210 is removed from the bore hole 200 and the detachable pilot extension member 216 is removed from the threaded stem 254 with an appropriate tool, such as Allen wrench 206 , as shown in FIG. 11D . As shown in FIGS. 11E-11F , the self-tapping insert 210 , with the detachable extension member 216 removed, is reinserted into the partially threaded bore hole 200 and rotated until nut 258 abuts the top surface 242 of work piece 244 . Once the nut 258 abuts or shoulders against the top surface 242 , the nut 258 is secured with a tool and the drive bolt 214 is removed.
[0043] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings. While the above is a description of various embodiments of the present invention, further modifications may be employed without departing from the spirit and scope of the present invention. For example, the size, shape, and/or material of the various components may be changed as desired. Thus the scope of the invention should not be limited by the specific structures disclosed. Instead the true scope of the invention should be determined by the following claims. | A self-tapping insert is installed in a pre-existing bore hole in a workpiece by rotating the insert, causing cutting threads on the exterior of the self-tapping insert to cut new threads. Engagement threads on the exterior of the self-tapping insert engage the new threads to retain the self-tapping insert within the workpiece. The self-tapping insert may comprise internal threads which are used to replace damaged threads in the workpiece. The means of installing the self-tapping insert may include a drive bolt having threads which make up into those of the self-tapping insert's internal threads. The self-tapping insert is aligned within the bore hole by means of a detachable pilot, which is connected to the insert with attachment means. The attachment means include the pilot being attached to the drive bolt. The pilot may be attached to the drive bolt means of left-handed threads in an axially-centered aperture of the pilot and matching left-handed threads on the end of the drive bolt. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a United States National Phase Application of International Application PCT/EP2013/060236 filed May 17, 2013 and claims the benefit of priority under 35 U.S.C. §119 of German Patent Application DE 10 2012 011 515.6 filed Jun. 1, 2012, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to a locking unit for a vehicle seat with a pivotably mounted rotary latch for locking with a bolt, the rotary latch having a rotary latch hole for pivotably mounting on a bearing bolt protruding through the rotary latch hole, and a latching pawl which, in the event of a crash, secures a locked state of the locking unit by the rotary latch being supported on a first contact point on the latching pawl. The invention also relates to a vehicle seat with the locking unit.
BACKGROUND OF THE INVENTION
[0003] DE 10 2008 051 832 A1 discloses a locking unit of the type in question for a vehicle seat. A locking unit of this type comprises a pivotably mounted rotary latch for locking with a bolt. A latching pawl which is mounted pivotably about another pivot axis secures the rotary latch in the locked state. A tensioning element which is referred to as a tolerance-compensating pawl exerts a closing moment on the rotary latch and thereby eliminates play present between the rotary latch and the bolt.
[0004] DE 20 2011 100 040 U1 likewise discloses a locking unit for a vehicle seat. The rotary latch of this locking unit has a recess which differs from the circular shape and is approximately in the shape of an elongated hole and by means of which said rotary latch is mounted pivotably on a bush or a bearing bolt.
[0005] The latching pawl and the tensioning element are arranged so as to be pivotable about the same axis and axially offset next to each other on a bearing bolt and interact with the rotary latch. In the event of a crash, first of all only the latching pawl secures the rotary latch by the rotary latch being supported on a contact point on the latching pawl. The crash load which is transmitted by the bolt to the rotary latch in the event of a crash is absorbed here by the contact point of the rotary latch with the latching pawl.
[0006] In the event of a high crash load, the rotary latch is displaced relative to the bearing bolt along the recess which is approximately in the shape of an elongated hole until it comes to bear against the housing of the locking unit. This gives rise to a second contact point which can additionally absorb the crash load.
SUMMARY OF THE INVENTION
[0007] The invention is based on an object of improving a locking unit of the type mentioned at the beginning, in particular of specifying an alternative possibility for increasing the load-absorption capacity in the event of a crash, in order to increase the crash safety of a vehicle seat.
[0008] A locking unit of the type in question for a vehicle seat comprises a pivotably mounted rotary latch for locking with a bolt, wherein the rotary latch has a rotary latch hole for pivotably mounting on a bearing bolt protruding through the rotary latch hole, and a latching pawl which, in the event of a crash, secures a locked state of the locking unit by the rotary latch being supported on a contact point on the latching pawl.
[0009] According to the invention, it is provided that the rotary latch of the locking unit has at least one cutout region which, in the event of a crash, permits a deformation of the rotary latch, wherein the cutout region is arranged spaced apart in the radial direction from the rotary latch hole. The cutout region is therefore formed separately from the rotary latch hole and is separated therefrom, for example, by a web.
[0010] Owing to the fact that the rotary latch has a cutout region which, in the event of a crash, permits a deformation, and which is arranged spaced apart in the radial direction from the rotary latch hole, the rotary latch can be displaced in the event of a crash until said rotary latch comes to bear against the housing of the locking unit, thus producing a second contact point which can additionally absorb the crash load.
[0011] Owing to the deformation in the event of a crash, the rotary latch advantageously executes a displacement of this type, i.e. a translatory movement and/or a tilting movement, in order to reach the housing.
[0012] According to an advantageous refinement, the cutout region is designed as a continuous opening in the axial direction. A cutout region designed in such a manner can be produced relatively simply, for example, by means of punching.
[0013] According to an alternative refinement, the cutout region is designed as a notch.
[0014] The rotary latch advantageously has a hook mouth for receiving the bolt.
[0015] It is particularly advantageous here if the cutout region is arranged on that side of the rotary latch hole which faces away from the hook mouth.
[0016] According to an advantageous development of the invention, the rotary latch has at least one load-relieving region which is provided on that side of the rotary latch hole which is opposite the cutout region. The load-relieving region assists the deformation of the rotary latch.
[0017] If, in the locked state, a tensioning element exerts a closing moment on the rotary latch, a play present between the rotary latch and the bolt can thereby be eliminated.
[0018] According to an advantageous refinement of the invention, the rotary latch and the latching pawl are arranged within an at least partially closed housing.
[0019] The cutout region preferably runs approximately in a semicircle around the rotary latch hole.
[0020] The object is also achieved by a vehicle seat comprising at least one locking unit according to the invention.
[0021] The invention is explained in more detail below with reference to an advantageous exemplary embodiment illustrated in the drawings. However, the invention is not restricted to said exemplary embodiment.
[0022] 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 specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In the drawings:
[0024] FIG. 1 is an exploded illustration of a locking unit;
[0025] FIG. 2 is a schematized illustration of a vehicle seat;
[0026] FIG. 3 is a top view of parts of the locking unit according to a first exemplary embodiment in the locked state;
[0027] FIG. 4 is a top view of parts of the locking unit according to the first exemplary embodiment in the event of a crash; and
[0028] FIG. 5 is a top view of parts of the locking unit according to a second exemplary embodiment in the locked state.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] Referring to the drawings in particular, in a motor vehicle, a locking unit 10 for connecting a backrest 3 of a vehicle seat 1 , in particular a rear seat, to a vehicle structure is provided. The backrest 3 here is attached to a seat part 5 so as to be pivotable from a use position into a not-in-use position.
[0030] However, the locking unit 10 can also be used at different locations, for example for fastening the seat part 5 of the vehicle seat 1 to the floor structure of the motor vehicle, or in a door lock.
[0031] The arrangement of the vehicle seat 1 within the vehicle and the customary direction of travel thereof define the directional details used below. A direction oriented perpendicularly to the ground is referred to below as the vertical direction and a direction perpendicular to the vertical direction and perpendicular to the direction of travel is referred to below as the transverse direction.
[0032] The locking unit 10 has a lock housing which comprises a first side plate 16 and a second side plate 18 . In the present case, the basic surfaces of the side plates 16 , 18 are of flat configuration and are arranged in a plane defined by the direction of travel and the vertical direction, i.e. perpendicularly to the transverse direction. Each of the side plates 16 , 18 comprises two bearing bores 13 which, in the present case, are of circular design.
[0033] The first side plate 16 and the second side plate 18 form a receptacle which opens in the direction of a bolt 12 in order to receive the latter for locking purposes. The locking unit 10 in the present case is fastened to the backrest 3 and the bolt 12 is fastened to the vehicle structure. It is also conceivable for the locking unit 10 to be fastened to the vehicle structure and for the bolt 12 to be fastened to the backrest 3 . That portion of the bolt 12 which is to be received by the receptacle generally runs horizontally in the transverse direction.
[0034] A rotary latch 20 is mounted pivotably on a first bearing bolt 51 which, in turn, is fastened to the first side plate 16 and to the second side plate 18 . For this purpose, the rotary latch 20 has a rotary latch hole 24 through which the first bearing bolt 51 protrudes. The rotary latch 20 furthermore has a hook mouth 21 for interaction with the bolt 12 . The rotary latch 20 is pretensioned in the opening direction by means of a first spring 71 .
[0035] The rotary latch 20 has a functional surface 22 which partially laterally bounds the hook mouth 21 . In the locked state, the functional surface 22 approximately faces in the direction of a second bearing bolt 52 which is arranged parallel to the first bearing bolt 51 and therefore likewise runs in the transverse direction. In the present case, the functional surface 22 is of planar design, but can also be, for example, curved in the shape of an arc of a circle and of concave design.
[0036] On that side of the hook mouth 21 which faces away from the rotary latch hole 24 and is opposite the functional surface 22 , the hook mouth 21 is bounded laterally by a lug 28 of the rotary latch 20 .
[0037] The rotary latch 20 has a basic body which is bounded in the axial direction by a flat basic surface in each case. The width of the functional surface 22 corresponds to the thickness of the basic body of the rotary latch 20 , i.e. to the extent of the basic body in the axial direction.
[0038] The first bearing bolt 51 is inserted into respective bearing bores 13 in the side plates 16 , 18 and protrudes perpendicularly from the basic surfaces of the side plates 16 , 18 . The first bearing bolt 51 therefore runs horizontally in the transverse direction. In the present case, the preferably metallic first bearing bolt 51 is riveted or calked to the side plates 16 , 18 . The first bearing bolt 51 is preferably designed in the form of a hollow cylinder in order to receive a fastening means, for example a screw, by means of which the locking unit 10 is fastened to the backrest 3 during the installation.
[0039] The second bearing bolt 52 is also inserted into respective bearing bores 13 in the side plates 16 , 18 and protrudes perpendicularly from the basic surfaces of the side plates 16 , 18 . The second bearing bolt 52 therefore likewise runs horizontally in the transverse direction. In the present case, the preferably metallic second bearing bolt 52 is riveted or calked to the side plates 16 , 18 . In the same manner as the first bearing bolt 51 , the second bearing bolt 52 is preferably designed in the form of a hollow cylinder in order to receive a fastening means, for example a screw, by means of which the locking unit 10 is fastened to the backrest 3 during the installation.
[0040] A tensioning element 40 is mounted pivotably on the second bearing bolt 52 . For this purpose, the tensioning element 40 has a tensioning element hole 44 which, in the present case, is circular and is penetrated by the second bearing bolt 52 . The tensioning element 40 is pretensioned toward the rotary latch 20 by means of a third spring 73 .
[0041] In the locked state, when the hook mouth 21 of the rotary latch 20 receives the bolt 12 , the tensioning element 40 exerts a closing moment on the rotary latch 20 owing to the pretensioning by the third spring 73 as a securing element. For this purpose, the tensioning element 40 has a tensioning surface 41 which is curved eccentrically with respect to the second bearing bolt 52 and is in non-self-locking contact with the functional surface 22 of the rotary latch 20 . In the present case, the tensioning surface 41 is curved in the shape of an arc of a circle and is of convex design.
[0042] A latching pawl 30 is arranged on the second bearing bolt 52 axially next to the tensioning element 40 and is likewise mounted pivotably on the second bearing bolt 52 , i.e. in alignment with the tensioning element 40 . For this purpose, the latching pawl 30 has a latching pawl hole 34 which, in the present case, is circular and is penetrated by the second bearing bolt 52 . The latching pawl 30 is pretensioned toward the rotary latch 20 by means of a second spring 72 .
[0043] In the present case, the latching pawl 30 is arranged adjacent to the first side plate 16 and, in the present case, the tensioning element 40 is arranged adjacent to the second side plate 18 . The latching pawl 30 and the tensioning element 40 are coupled by empty travel for carrying-along purposes, for example by means of a slot and pin guide or by means of an axially protruding driver.
[0044] The latching pawl 30 has a latching surface 31 which is in the vicinity of the tensioning surface 41 of the tensioning element 40 . In the locked state, the latching surface 31 is positioned spaced apart from the functional surface 22 of the rotary latch 20 . In the present case, the latching surface 31 is curved in the shape of an arc of a circle and is of convex design, but may also be planar.
[0045] The width of the functional surface 22 , which corresponds to the thickness of the basic body of the rotary latch 20 , also approximately corresponds to the total of the thickness of the latching pawl 30 and the thickness of the tensioning element 40 . The rotary latch 20 therefore has approximately the same material thickness as the latching pawl 30 and the tensioning element 25 together.
[0046] According to a first exemplary embodiment, the rotary latch 20 has a cutout region 25 on that side of the rotary latch hole 24 which faces away from the hook mouth 21 . In the present case, the cutout region 25 is designed as a continuous opening in the axial direction and runs approximately in a semicircle around the rotary latch hole 24 . The cutout region 25 therefore completely penetrates the basic body of the rotary latch 20 in the axial direction, parallel to the rotary latch hole 24 which, in the present case, is designed as a circular bore.
[0047] The cutout region 25 here is arranged spaced apart in the radial direction from the rotary latch hole 24 . The cutout region 25 is therefore formed separately from the rotary latch hole 24 and, in the present case, is separated therefrom by a web. The cutout region 25 therefore does not have any connection with the rotary latch hole 24 .
[0048] However, the cutout region 25 may also be designed in a different manner. For example, the cutout region 25 can be designed as a notch which extends from the surface of the basic body of the rotary latch 20 into the basic body, but not through the latter. The semicircular cutout region 25 can also be interrupted by one or more webs. Furthermore, the cutout region 25 can have a design differing from the semicircular shape, for example a rectangular, circular or oval shape. Similarly, a plurality of rectangular, circular, oval or differently designed cutout regions 25 can be provided next to one another and/or separated from one another by webs.
[0049] In the present case, two load-relieving regions 27 are provided on that side of the rotary latch hole 24 which is opposite the cutout region 25 . The load-relieving regions 27 are therefore arranged approximately between the rotary latch hole 24 and the hook mouth 21 of the rotary latch 20 . In the present case, the load-relieving regions 27 are formed in the shape of a segment of a circle and are separated from one another by a web running in the radial direction. In the present case, the load-relieving regions 27 are likewise designed as a continuous opening in the axial direction and completely penetrate the basic body of the rotary latch 20 in the axial direction, parallel to the rotary latch hole 24 .
[0050] The load-relieving regions 27 can also be designed so as to differ from the shape shown here, for example can be designed as a notch or with a different design, in a similar manner to the cutout region. It is also conceivable for only one load-relieving region 27 to be provided or for the latter also to be entirely omitted.
[0051] According to a second exemplary embodiment, which is illustrated in FIG. 5 , there is no load-relieving region.
[0052] FIG. 3 illustrates the positions of the rotary latch 20 and the latching pawl 30 of the locking unit 10 according to the first exemplary embodiment in the locked state.
[0053] The bolt 12 bears against the lug 28 of the rotary latch 20 in the hook mouth 21 . In the event of a crash, the rotary latch 20 experiences an opening moment by means of the bolt 12 and pushes the tensioning element 40 (not illustrated here) away. As a result, the latching surface 31 of the latching pawl 30 first of all enters into contact with the functional surface 22 of the rotary latch 20 . The latching pawl 30 thus serves to support the rotary latch 20 and, as a securing element, prevents a further rotation of the rotary latch 20 in the opening direction. The latching pawl 30 therefore prevents the rotary latch 20 from opening.
[0054] If, on account of the crash, the bolt 12 exerts a further load on the lug 28 of the rotary latch 20 , the rotary latch 20 undergoes a translatory movement approximately in the loading direction. In the process, the bearing bolt 51 (not illustrated in FIG. 3 ), on the side facing away from the hook mouth 21 presses against the wall of the rotary latch hole 24 . In the process, the cutout region 25 of the rotary latch 20 is compressed and the rotary latch 20 is deformed. The rotary latch 20 migrates here in the loading direction mentioned.
[0055] The movement of the rotary latch 20 in the loading direction ends when the rotary latch 20 enters into contact with one of the housing parts 16 , 18 or when the rotary latch has covered a distance which corresponds to the radial extent of the cutout region 25 . This position is illustrated in FIG. 4 .
[0056] During the movement described here of the rotary latch 20 , the load-relieving regions 27 also assist the deformation of the rotary latch 20 . The load-relieving regions 27 are expanded here, as a result of which the radial extent thereof is increased. The material of the rotary latch 20 in the region between the load-relieving regions 27 and the rotary latch hole 24 can also tear off in the process, as can the web between the load-relieving regions 27 .
[0057] In all of the exemplary embodiments described here, the first bearing bolt 51 , as illustrated in FIG. 1 , is encased by a first slide bush 61 . The first slide bush 61 is also designed in the form of a hollow cylinder. The first slide bush 61 is therefore located in the radial direction between the first bearing bolt 51 and the rotary latch 20 .
[0058] As illustrated in FIG. 1 , the second bearing bolt 52 is encased by a second slide bush 62 . The second slide bush 62 is also designed in the form of a hollow cylinder. The second slide bush 62 is therefore located in the radial direction between the first bearing bolt 51 and the latching pawl 30 and also the tensioning element 40 .
[0059] The first sliding bush 61 and the second sliding bush 62 can also be omitted or formed integrally with the first bearing bolt 51 and the second bearing bolt 52 .
[0060] In the locked state of the locking unit 10 , the bolt 12 is located in the receptacle formed by the side plates 16 , 18 and in the hook mouth 21 of the closed rotary latch 20 . The tensioning element 40 secures the rotary latch 20 by interaction of the tensioning surface 41 with the cam 26 . The latching surface 31 of the latching pawl 30 is slightly spaced apart from the functional surface 22 of the rotary latch 20 .
[0061] In order to open the locking unit 10 , the latching pawl 30 is pivoted away from the rotary latch 20 , as a result of which the latching surface 31 of the latching pawl 30 is further away from the functional surface 22 of the rotary latch 20 . The latching pawl 30 carries along the tensioning element 40 owing to the carrying-along coupling, and therefore the rotary latch 20 is no longer secured.
[0062] By means of the pretensioning on account of the first spring 71 , the rotary latch 20 opens, i.e. pivots in the opening direction. Alternatively or in addition to the pretensioning by the first spring 71 , the rotary latch 20 can also be carried along for opening purposes by the latching pawl 30 or by the tensioning element 40 .
[0063] Owing to the pivoting movement of the rotary latch 20 , the hook mouth 21 draws back from the receptacle formed by the side plates 16 , 18 and releases the bolt 12 which moves away from the locking unit 10 counter to the pivoting-in direction. If the bolt 12 has left the hook mouth 12 , the locking unit 10 is in the unlocked state.
[0064] If, in said unlocked state, the bolt 12 passes again into the receptacle formed by the side plates 16 , 18 and enters into contact with the border of the hook mouth 21 , the bolt 12 pushes the rotary latch 20 into the closed position thereof. The tensioning element 40 , owing to the pretensioning thereof by the third spring 73 , moves along the cam 26 . Carried along by the tensioning element 40 or owing to the pretensioning by the second spring 72 , the latching pawl 30 pivots toward the rotary latch 20 , with the latching surface 31 approaching the functional surface 22 of the rotary latch 20 . The locking unit 10 is then in the locked state again.
[0065] The features disclosed in the above description, the claims and the drawings can be of importance both individually and in combination for realizing the invention in the various configurations thereof.
[0066] While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A locking unit ( 10 ) for a vehicle seat ( 1 ) includes a pivotally mounted rotary latch ( 20 ) for locking to a bolt ( 12 ). The rotary latch ( 20 ) includes a rotary latch hole ( 24 ) for pivotably mounting on a bearing pin ( 51 ) which protrudes through the rotary latch hole ( 24 ). A detent ( 30 ) secures the locking unit ( 10 ) in the locked state in the event of a crash. The rotary latch ( 20 ) supports itself on a first contact point against the detent ( 30 ). The rotary latch ( 20 ) includes at least one recess area ( 25 ) which enables the rotary latch ( 20 ) to deform in the event of a crash. The recess area ( 25 ) is arranged at a distance from the rotary latch hole ( 24 ) in the radial direction. | 8 |
FIELD OF THE INVENTION
This invention relates generally to fishing equipment. More particularly the present invention is directed to an electronic fishing device that may tow a lure or another element and apply information about water temperature and depth for device control purposes and optionally for determining the thermocline and seeking the right depth for desired species.
BACKGROUND OF THE INVENTION
Recreational and sport fishing has great global markets. Millions of anglers are counted throughout the world and their number is still growing. The invention described in this document relates closely to fishing with a lure or e.g. a baited hook trolled behind the boat. The number of trolling anglers in Europe, the USA and Canada is estimated to be over 40 millions. Typically, the anglers are fishing for a specific species and it is known that fish are active in varying temperatures species-specifically, as can be seen in FIG. 1 , and also the richest area of various species in general may be determined.
However, while fishing for particular species, the control over the depth of the lure in water is a major problem. Typically, the means that the anglers are using for depth control is such as a downrigger, see FIG. 2 and entity 202 therein, a submersible temperature/depth transducer and monitor and a diver. Alternatively, the depth of the lure can be controlled by different lure types or by adjusting the length of the fishing line and trolling speed. A downrigger, which is bolted to the stern of a fishing vessel, consists of an electrical or mechanical reel and a short rod. The reel is filled with strong line\wire, which is attached to a lead weight. A submersible temperature/depth transducer and monitor, attached to the downrigger line instead of a conventional weight, is used for reading the temperature and speed through a coaxial cable to the LCD screen located in a boat. However, the handling of a downrigger is difficult and usually, when the fish strikes, one more person is needed to wind up the downrigger. Further, a small disk known as a diver is attached to the fishing line to make a lure dive deeper. Any of the means mentioned above are merely adapted to track a predetermined depth disregarding various other factors truly affecting the actual position of fishes. In addition, e.g. a downrigger with a submersible temperature/depth transducer and monitor is an expensive piece of equipment and yet, a depth chart is also needed. Moreover, the diver is generally not accurate and it does not offer any method of measuring the temperature in real time.
U.S. Pat. No. 6,760,995B2 discloses a submersible device for controlling the depth and the azimuth heading of the device. However, the publication mainly concentrates on the remote control part of the suggested arrangement despite the cursory disclosure of sensors for sensing the characteristics of the underwater environment.
Thus the objective of the present invention is to at least alleviate the aforesaid defects of prior art solutions when it comes to the usability and fish tracking capability thereof.
SUMMARY OF THE INVENTION
The objective is met by an electronic fishing device, hereafter also referred as “the device”, which may be configured to track a predetermined depth, a predetermined temperature and/or the thermocline, and in connection with thermocline tracking, preferably configured to remain therein or on a predetermined level relative thereto.
Accordingly, in one aspect of the present invention an electronic fishing device for facilitating trolling a fish-catching element in water comprises:
a first sensing means for obtaining a first indication relating to water temperature, a second sensing means for obtaining a second indication relating to the depth of the device, a steering means for adjusting the depth of the device, and a processing means for controlling, via said first and/or second indication provided by said first and second sensing means, the steering means so as to guide the device relative to at least one element selected from the group consisting of: the position of the thermocline layer, a predetermined depth, and a predetermined temperature.
In an embodiment of the present invention a system comprising the above electronic fishing device is characterized by at least one further element being designed as remote therefrom, when in use, and selected from the group consisting of: a remote controller, a data analyzer, a data forwarding entity, and a data storage.
In another aspect of the present invention is provided a method of fishing by using the electronic fishing device or the system.
Yet a further aspect of the present invention includes the use of the electronic fishing device or the system in marine or other underwater research.
In one embodiment the device may be controlled to gravitate towards and reside within the thermocline in general, or to maintain a certain level or layer inside or at least relative, e.g. within a predetermined distance according to predetermined or adaptive criteria, to the thermocline. The processing means may be thus configured to determine, via said first and second indications provided by said first and second sensing means, the position of the thermocline layer so as to control the steering means to guide the device relative to the thermocline layer.
In another aspect, the aforesaid device is used in marine or other type of underwater research as to be described in more detail hereinafter.
The device further optionally comprises a data transfer means for changing the settings of the device while or prior to/after using it, or for other remote control, e.g. steering, purposes, a remote device means for e.g. remote storage, management, processing, transfer, or analysis of the information sent by the device and/or for transmitting distant control data towards the device. The device may also comprise a memory means such as one or more memories for e.g. preprogrammed routines and/or for storing of e.g. the temperature and/or the depth data as well as the data from the optional sensors for future reference, a bottom detection means, e.g. one or multiple sensors, for preventing the device or the lure to hit the bottom of sea or a lake, a light intensity measuring means, e.g. one or multiple sensors, for detecting the lightness circumstances, a camera for the real time monitoring of the device and a velocity measuring means, e.g. one or multiple sensors, for detecting the trolling speed, for instance. The aforementioned means may alternatively or additionally be used for other purposes. Yet, the device may comprise a position adjustment means such as a hydrofoil of preferred shape, size, material, and/or optionally color. One or more elements of the device may be embedded at least partly in a body portion that may be of substantially cylindrical shape, for instance.
The processing means may refer to one or more electronic elements such as (micro)processors, microcontrollers, digital signal processors (DSPs), programmable logic chips, or any desired combination thereof.
Likewise, the first sensing means for obtaining a first indication of water (or generally surrounding liquid) temperature may refer e.g. to one or more electronic sensor elements such as thermistors, thermocouples, RTDs, or a combination thereof.
Respectively, the second sensing means for obtaining a second indication of (device) depth may refer e.g. to one or more electronic sensor elements such as pressure sensors implemented with semiconductor piezoresistive or microelectromechanical systems technique, for example.
Further, a storage means may refer to non-volatile memory, such as PROM, EEPROM or flash memory, for instance. Also volatile memory such as RAM may be included.
The data (e.g. control or other, e.g. measurement, data) transfer means may be implemented by using sound waves, i.e. a sonic data link, and/or by sending pulses along the fishing line. The remote device means may be implemented accordingly to enable co-operation, i.e. one or two-way information transfer, with the data transfer means of the device. Use of both the data transfer means (in connection with the electronic fishing device) and the remote device means (residing elsewhere, e.g. on a boat or ship towing the device) preferably enables two-way communication between the device and the user. Both the aforesaid means may include processing and/or memory means in addition to communication means such as a transmitter, a receiver, or a transceiver.
In addition, a bottom detection means may be implemented with e.g. echo sounder or ultra sound, or the detection of the bottom may also be implemented inductively.
In different embodiments, the device may have independent steering and the device may track the thermocline by scanning the area and calculating the limits. In some embodiments, the device may also have a sideways trim or a sideways control used to direct the device more to alongside with the trolling vessel, for instance. In addition, some embodiments may arrange the devices for shallow or deep water, or the device may be castable. The other embodiments may include a combination of any of the characteristics mentioned above.
The utility of the invention is based on multiple issues. First, the provided device is simple to use and manufacture, affordable, small in size, light, and versatile. The device is feasible for both shallow and deep water and it is practical with both slow and faster towing speeds. Tracking the thermocline by using e.g. the temperature gradient, instead of simple temperature and/or pressure sensing, provides a more accurate method of locating the wanted species. The thermocline typically contains more fishes than the surrounding other layers, which makes tracking thereof desirable in trolling. Preferred species may be further monitored by temperature-based tracking.
The thermocline (see FIG. 3 for illustrative example) is generally a designation for a specific layer in a lake or sea. The determination of the thermocline can be based on the temperature and it can be detected by monitoring the drop of the water temperature with depth, e.g. the gradient of the temperature as a function of depth. The range of the water temperature in the thermocline is often approximately 4° C.-10° C. and the thickness of the thermocline can considerably vary from only few meters to e.g. a hundred meters in tropic. For example, the place and the thickness of the thermocline may typically vary with latitude and season. E.g. in Finland the thermocline is strongest during the summer when the difference between the temperature of the surface water and the bottom water is widest and nonexistent during the winter when the water in the sea and lakes is cold from the surface to the bottom. Instead, the thermocline is permanent in the tropics throughout the year. It is believed that the thermocline prevents the warm surface water from mixing with the cold bottom water and thus oxygen, nutrient and other substances are isolated into it. As a result, fish gravitate towards the thermocline after nourishment.
Further, the configurable and adjustable device for various circumstances in accordance with an embodiment of the present invention may be achieved by using repairable and/or replaceable parts defining e.g. different sizes, shapes and/or colors of the hydrofoil and the front fins, for instance. Further, additional features may be purchased or otherwise obtained (e.g. user-made). Optionally, the device may have extension/additional slots or corresponding locations or fasteners e.g. for electronic and/or mechanical supplementary components such as extra sensors or components related to the programmability or fishing, for example.
Various embodiments are disclosed in the attached dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Next the invention will be described in more detail with reference to the following drawings:
FIG. 1 illustrates depth-specific zones for different fish species.
FIG. 2 discloses shortcomings of a prior art downrigger solution.
FIG. 3 illustrates a position of an exemplary thermocline in relation to the water temperature and depth.
FIG. 4 a illustrates an isometric view of one embodiment of an electronic fishing device in accordance with the present invention.
FIG. 4 b illustrates a top view of one embodiment of an electronic fishing device in accordance with the present invention.
FIG. 4 c illustrates a side view of one embodiment of an electronic fishing device in accordance with the present invention.
FIG. 4 d illustrates a front view of one embodiment of an electronic fishing device in accordance with the present invention.
FIG. 4 e illustrates a rear view of one embodiment of an electronic fishing device in accordance with the present invention.
FIGS. 5 a and 5 b illustrate one alternative hydrofoil shape.
FIG. 6 a illustrates a side view of one embodiment of an adjustable means to change the towing/trolling point location and a connection ring for a lure line.
FIG. 6 b illustrates a top view of one embodiment of an adjustable means to change the towing/trolling point location and a connection ring for a lure line.
FIG. 7 a illustrates a side view of one possible use scenario of an embodiment of the present invention.
FIG. 7 b presents a method diagram of one possible use scenario of an embodiment of the present invention.
FIG. 8 is a block diagram of an embodiment of fishing device internals according to the present invention.
FIG. 9 presents a flow diagram of the functional description of the thermocline tracking and associated device steering and/or depth control.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIGS. 1-3 have already been reviewed in connection with introducing the background and summary of the invention. FIG. 4 a illustrates a perspective view of one embodiment of an electronic fishing (aid) device in accordance with the present invention. The submersible device 402 comprises a control body 404 , a hydrofoil 406 preferably assembled on the rear end of the control body 404 , front fins 408 assembled in both of the front sides of the control body 404 , a preferably adjustable towing/trolling point 410 with e.g. a hook, a ring, a projection, etc, on the front top of the control body 404 , and a connection point, e.g. a hook or ring etc, for a lure 412 in the rear end of the control body 404 . Although FIG. 4 provides one configuration, it should be understood that the device 402 may be in wide variety of sides, shapes and colors although the functionality of the equipment carried by the device 402 remains substantially the same.
The control body 404 , best shown in Figures from 4 a to 4 c , is preferably made of transparent acrylic tube with the bow piece, or substantial frontal part of the device, 414 , battery cover (not shown) and fastener of the hydrofoil 416 made of die-casted plastic or some other feasible material. In the depicted example the control body 404 is substantially of cylindrical shape, i.e. a cylinder or “tube”-like. The control body 404 may include the electronics of the device (not shown) such as the first sensing means, the second sensing means, steering means and storage means. In one preferable embodiment the first sensing means and the second sensing means are implemented with the temperature and the pressure sensors configured to the same component or entity. The control of the electronic fishing device may be produced e.g. by a microcontroller. The display of the device is preferably an LCD (Liquid Chrystal Display) and controlling the device is enabled, for example, with one or more internal and/or at least partially surface mounted and watertight microswitches or e.g. push-buttons whereby e.g. a magnetic pencil or other tool may be applied for remotely, e.g. through the body 404 shell in the case of internal switch, controlling the device in order to minimize the possibility of water leaks via the switches/buttons upon activation, for instance. In addition, the control body 404 of the device includes a power source, typically e.g. two AAA batteries.
With reference to FIGS. 4 a and 4 b as well as FIGS. 4 d and 4 e , the features of the front fins 408 will now be explained. The front fins 408 are preferably used to at least partially control the depth of the device 402 by changing the angle of attack of the hydrofoil. Typically, the control of the front fin angle is enabled e.g. with an actuation means such as a servo motor or an electromagnet (not shown). The device may be configured to detect the angle of the front fins by using the feedback coupling, for example, and to adjust the angle due to achieve and maintain desired depth in water. In another embodiment, the angle of the front fins can be set asymmetrically due to direct the device more alongside with the trolling vessel. In some embodiments, the front fins 408 may be implemented by using one large fin connected to above or below of the control body 404 or articulated to the centre or other desired portion of the control body 404 .
With reference to Figures from 4 a to 4 e , the features of the hydrofoil 406 will now be explained. The function of the hydrofoil 406 is based on the shape of the hydrofoil's wing. Normally, the hydrofoils are used to raise the hull of a boat up and out of the water. As the effect of the boat speed, the hydrofoil creates the lift and at a certain speed, the lift produced by the hydrofoils is big enough to compensate the weight of the boat and its cargo. In this invention, the traditional hydrofoil is utilized upside down so as to help the device to dive.
The hydrofoil 406 is preferably placed above of the center of mass of the device 402 at the rear end of the control body 404 . The place, the size and the shape of the hydrofoil 406 may have an effect of correcting a wrong intersecting angle and/or balancing the movement of the device 402 while steering the front fins 408 and/or while changing the towing direction. The balancing characteristics of the hydrofoil 406 are applicable to both low and high trolling speed.
The hydrofoil 406 is preferably made of buoyant material such as balsa, rotational molded plastic or acrylic, where the buoyancy characteristic may be enhanced by adding air bubbles therein. In one embodiment, the density of the hydrofoil is about 0.49 kg/m 3 . The aim of the low density of the hydrofoil is to ensure the buoyancy of the device in case of loosing it, which leads finally to the stopping of the device, and to keep the device in the right position when it is laid down on the surface of water prior to initiation of actual trolling.
Different hydrofoils (shape, buoyancy, color) may be obtained and assembled for different purposes and circumstances as well as the preferences of the user.
Various shapes of the hydrofoil 406 may be especially appropriate for shallow water and for deep water, for example. Preferably, the hydrofoil shape is a disc shaped with a substantially elliptical cross sectional shape, for example. The other possible hydrofoil shapes may be similar to airfoil structures used in aircraft and to dagger-board used in sailing crafts; the usage position is then turned upside down in this invention. The other alternate shapes may be U-shaped, T-shaped and triangle shaped hydrofoils, for example. In the case of airfoil structures, the cross section of the hydrofoil is cambered with the mean-line concaved downwards when in use position. Instead, in the case of a dagger-board, the cross section is symmetrical.
In FIGS. 5 a and 5 b one alternative hydrofoil shape for deep water are illustrated. For deep water, the hydrofoil 406 may have more wing profile to achieve more efficient diving force and to improve the movement of the device in deep water. The shape of this hydrofoil style resembles the U-shaped hydrofoil with an airfoil structure cross section. The opening 502 illustrated in the top view of FIG. 5 b is turned on the direction of motion and the purpose of said opening is to give more space to the fishing line, for instance. However, in spite of the hydrofoil shape the buoyancy feature is preferably retained with every utilized shape.
FIGS. 6 a and 6 b illustrate one embodiment of an adjustable means to changing the towing/trolling point 410 location. A fishing line to the trolling rod is referred with number 602 and a line to the lure with 604 . The advantages of the adjustable towing/trolling point 410 may come up while using lures of different weights, for example. Although the hydrofoil 406 balances the device 402 while trolling, the heavy lure may complicate the stabilization of the device. By adjusting the towing/trolling point 410 towards the back of the device the stability of the device is more effortless to achieve. With light lure the towing/trolling point 410 may be adjusted towards the front since the lighter lure affects the device 402 lesser.
In some advanced embodiments the towing/trolling point 410 may be, even dynamically, adjusted by the software. In this case, the software can be configured to detect the stabilization features depending on the weight of the lure and the trolling speed and to adjust the towing/trolling point 410 automatically to the adequate point.
FIG. 7 a illustrates one possible use scenario of an embodiment of the present invention. The device 402 is connected from the trolling point to the rod with a line portion 602 . The lure is connected to the connection ring 412 for the lure line of the device with a line portion 604 . The portions 602 , 604 may belong to the same, e.g. variable width, line as illustrated, or they may be separate lines. In the former case, the line portion 604 may be made thicker such that it does not freely slide through the connection ring and therefore functionally maintains the lure and the device separate during trolling operation. In alternative embodiment, a single constant-width line may be used, in which case the lure may be kept distant from the device by adding a local widening means such as a knot or a clip to the line portion 604 located between the connection ring and the lure. Still in a further alternative, a tension means may be provided in connection with the trolling point and/or connection ring such that during trolling the tension keeps the lure physically separated from the device body. The line 604 from the device to the lure is advantageously set short, e.g. about 0.5-2 m thus the depth of the lure remains the same with the device and the breaking of the line is more unlikely. Anyway, if the line 602 between the rod and the device breaks, the device rises to buoy on the surface of water (i.e. the buoyancy of the device also compensates for the weight of the lure), since the velocity of the device decreases and finally drops to zero, as described above. When a single line extends between the fishing rod and the lure such that it substantially freely passes via the trolling and connection rings, the device may surface in the case the lure or the line 604 gets stuck resulting a stop in horizontal speed.
Accordingly, FIG. 7 b illustrates one possible method diagram of an embodiment of the present invention. Phase 702 refers to obtaining the device. In phase 704 the device is connected to the rod and the lure. In phase 706 the settings are adjusted and a desired trolling mode is selected. Next, see phase 708 , the device is laid to the surface of the water and the trolling will be started. In phase 710 the towing of the device and the lure is performed. In the final phase 712 the device is reeled in and picked up from the water upon catching a fish or quitting fishing, for example. Dotted line from/to phase 714 refers to the optional data transmission between the device and the user via the remote control.
FIG. 8 is a block diagram of an embodiment of the electronic fishing device internals according to the present invention. The depicted example introduces certain internals of the device mainly from a functional standpoint and the actual implementations may vary, i.e. various elements may be physically integrated together or separated into multiple entities. The mode and the values for the CPU (Central Processing Unit) may be adjusted by the user via the control buttons. The steering means provide information about the fin position for CPU and the CPU controls the steering means, which controls the motor of the fin position, for example. The first sensing means, the second sensing means and the optional supplementary components provide the data that the CPU reads at intervals. The read data is stored to the memory as well as the settings and the programs of the device, e.g. preprogrammed routines. The instructions and information for the user may be presented on the display. Optionally, the display may be a touch display for obtaining control information from the user. The optional data transfer means provides two-way communications between the user and the device.
The second sensing means is preferably a pressure sensor that provides the indication of the depth by using e.g. the formula of hydrostatic pressure P=ρgh, where ρ is the liquid density, g is gravitational acceleration and h is the height of liquid above, as known as depth hereafter. Normally, since the approximated depth is satisfactory, the constants ρ and g may be set according to freshwater density 1.00·10 3 kg/m 3 and standard gravity 9.80665 m/s 2 . However, the constant g may be set depending on the position of the device on Earth and respectively, the constant ρ may be set depending on water density according to the environment the device produced for, since the density of the salty sea water is greater than freshwater.
With reference to FIG. 9 , the actual functional description of the thermocline tracking and associated device steering and/or depth control may be introduced by software, for example.
At first, the processing means may be optionally configured to deduce, note reference numeral 904 , based on the information sent by the sensing function at 902 that the device is laid down to the surface of water. Depending on the settings set by the user the processing means may be configured to at least track the thermocline 906 , perform the preprogrammed routine 908 , dive to a preset depth and/or temperature or wait for the instructions sent by the user via the data transfer means. It will be apparent to those skilled in the art that the processing means may be configured to send the information about its state to a remote device in any phase.
If the thermocline tracking is selected, the processing means may be configured to scan the area from the surface e.g. to 20 m or some other predetermined depth, or e.g. to the depth the user sets via the data transfer means 910 . Alternatively, a predetermined range may be utilized within which the thermocline is supposed to reside. Instead of scanning the area downwards from the surface, the scanning procedure may also be performed from some particular depth upwards. Said processing means is configured to control the steering means to dive into the set depth. The scanning is performed to the set depth unless the optional bottom detection means detects the bottom of sea or a lake first, for example. In that case, said processing means is preferably configured to control the steering means to interrupt diving when the distance from the bottom is less than a predetermined value. During the scanning, the processing means is configured to read the temperature and/or depth data transmitted by the first sensing means and the second sensing means, respectively, with the sampling frequency of 10 times per second, for example, or with some other predetermined sampling frequency 912 . The sampling frequency may also be determined by software depending on the sinking (vertical) and/or horizontal speed of the device, for instance. In addition, the data of the optional supplementary components may be read and during the scanning. The processing means is configured to calculate the average out of ten data points, i.e. the time period of one second, for instance, or out of some other predetermined data points and compare the data with the previous values 914 . Further, said processing means is configured to store the data to the storing means. The data may also be sent to the remote device via the data transfer means.
The analyzed temperature to depth ratio R=ΔT/Δh, is the average change of the temperature over the change of the depth. The ratio may also be the other way around, i.e. the depth to temperature ratio or some other relation with these or corresponding parameters such as associated tables, for instance. The thermocline is assumed to begin when the ratio exceeds the threshold value e.g. about 2-2.5 C/m and to end when the ratio again remains under the threshold value. In some other embodiments, the tracking of the thermocline may also be implemented with an algorithm that determines the upper and the lower border of the thermocline by detecting the change of the temperature derivative. The upper border is identified when the change of the derivative becomes near to about zero and, respectively, the lower border when the change of the derivative becomes negative. Thus the device may thus drift within the thermocline and remain therein without a more sophisticated scanning procedure. Note the FIG. 3 , wherein three different acceleration points or areas have been highlighted and the acceleration term is used to refer to the aforesaid change of the temperature derivative.
After the area scanning has been performed said processing means may evaluate if the thermocline has been tracked 916 . If the diving was interrupted, said processing means may use the data from the area scanned before the interruption. If the tracking of the thermocline has succeeded, said processing means is preferably configured to store the position of the thermocline layer in the storage means 918 and to control the steering means to rise to the preset level, e.g. layer, therein 920 or just to remain within the thermocline. Additionally, a preprogrammed routine may be performed in this phase 908 . The processing means is configured to detect the environmental circumstances, e.g. the temperature and/or the depth, in the layer to control the steering means to stay within the layer/thermocline 922 . Additionally, the processing means may be configured to perform the second scanning of the thermocline 906 or to wait for more instructions, for instance. Also, the processing means may be configured to continue the data reading and storing from the first sensing means and the second sensing means as well as from the optional supplementary devices 924 .
If the tracking of the thermocline fails, the processing means may be configured to perform a preprogrammed routine 908 or a rescan 906 . In case of rescanning said processing means controls the steering means to resurface 926 and starts the scanning again, for example. The sampling frequency and the averaging may also be adjusted for the rescanning, for instance. If the tracking of the thermocline fails, possibly again or repeatedly for a certain number of times, the processing means may be configured to control the steering means to dive or to rise to the preset temperature layer or to the preset depth 928 or to resurface 926 . Alternatively, the processing means may be configured to use some default thermocline configuration 930 or to control the steering means to resurface 926 . In some embodiments with the optional data transfer means, the device may be configured to send information to the remote device about the failing of the tracking and to wait the user's new instructions.
Further, the processing means may be configured to rescan the area 906 with predetermined time intervals or if e.g. the preset layer in the thermocline disappears. Alternatively, the instruction for the area scanning may be given by the remote controlling means. The area scanning 906 may also be performed after every resurface.
Moreover, the preprogrammed routine 908 performed before, after or instead of the thermocline tracking, for instance, may include some fish imitating movements or some other (pseudo-) random behavior to attract fish. In addition, the routine may be configured to control the device to set for a predetermined time period e.g. to a preset depth and/or temperature layer and switch the depth and/or the temperature layer periodically, for example.
Trolling may be finished by sending a termination request that is obtained by the device via the data transfer means, for instance, or simply by reeling in the fishing line that makes the device to resurface. The control means may be configured e.g. to recognize the forced rising attempt and to control the steering means to resurface.
In addition to or instead of fishing applications, the device in accordance with one or more embodiments of the present invention may be used for marine or other type of underwater research purposes. For example, the fish-catching element to be towed may be replaced with a measurement device and/or a sample gathering device or a measurement and/or a sample gathering devices may be included in the fish-catching element. Further, the measurement device and/or the sample gathering device may be configured to measure, for example, underwater light density and/or salinity to depth ratio or light intensity and/or salinity at various depths and/or to gather e.g. plankton samples. The measuring and/or sample gathering may be performed while tracking the thermocline and/or trolling or the measuring, and/or sample gathering may be performed by using e.g. some other preprogrammed routine or a remote control. The measured data may be further utilized when controlling the device and/or tracking the thermocline or performing some other procedures. In addition, the device may be configured to measure and/or gather samples continuously or the measuring and/or sample gathering may be user-adjustable, e.g. triggerable, and/or timed.
The scope of the patent will be defined by the appended claims. Skilled persons will appreciate the fact that various changes and modifications may be made to the explicitly disclosed embodiments and features thereof without diverging from the scope as set forth in the claims. | An electronic fishing device for facilitating trolling a fish-catching element in water and a related system, method, and use, the fishing device including: a first sensing element for obtaining a first indication relating to water temperature, a second sensing element for obtaining a second indication relating to the depth of the device, a steering member for adjusting the depth of the device, a processing unit for controlling, via the first and/or second indication provided by the first and second sensing elements, the steering member so as to guide the device relative to at least one element selected from the group consisting of: the position of the thermocline layer, a predetermined depth, and a predetermined temperature. In addition to fishing the disclosed device may be utilized in marine or other underwater research. | 0 |
The invention herein described was made in the course of or under a contract or subcontract thereunder with the Department of the Air Force.
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 327,856 filed Dec. 7, 1981 now U.S. Pat. No. 4,456,337.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to the field of electrically tunable optical or light filters and values in which a filter element is caused to change or switch color or is caused to switch between light transmissive and opaque in response to a chemically transmitted electrical signal.
2. Description of the Prior Art
Optical filters for light in the visible range ordinarily contain colored compounds or thin layers of materials that achieve wavelength specificity through interference effects. These conventional filters have fixed absorption characteristics which cannot be varied, or "tuned," once the filter is constructed.
Rare-earth diphthalocyanines are known from prior publications to have electrochromic properties in which the color of the diphthalocyanine can change over a period of about eight seconds upon application of a potential difference across an electrochemical cell having a diphthalocyanine film on one of the electrodes. P. N. Moskalev and I. S. Kirin, "Effect of the Electrode Potential on the Absorption Spectrum of a Rare-Earth Diphthalocyanine Layer," Opt. i Spektrosk, 29, 414 (1970) and P. N. Moskalev and I. S. Kirin, "The Electrochromism of Lanthanide Diphthalocyanines," Russian J. Phys. Chem., 46, 1019 (1972).
U.S. Pat. No. 4,184,751 of M. M. Nicholson, the inventor herein, describes the use of metal diphthalocyanine complexes as the electrochromically active material in an electrochromic display cell. Rapid color changes in less than 50 milliseconds are achieved, thus alleviating the slow switching time previously reported for rare-earth diphthalocyanine complexes. Power requirements are small because of the low power switching characteristics of the material and because the device exhibits an open circuit memory of from several minutes to several hours, depending on its construction. A multi-color, i.e., more than one color, device is achieved through use of a range of voltages applied between generator and counter electrodes. Color reversal of displayed information and the background against which it is displayed is achieved through use of display electrodes in the background portions of the viewing area as well as in the character segments.
SUMMARY OF THE INVENTION
Briefly, and in general terms, the invention is concerned with a color filter for light wherein the color of the filter is electronically tunable. The filter element is an electronically isolated, light transmissive film of an insoluble material which is capable of reversibly changing or switching its color by reaction with soluble oxidizing and reducing agents. The soluble reactants are electrochemically generated at a generator electrode and are transported to the filter element by diffusion through a thin layer of electrolyte.
A film of the color-changing filter material used in this invention is preferably supported on an inert, insulative and transparent substrate of a fully compatible material. There is no need to dispose the color-changing material on a conductive transparent material such as tin oxide. Furthermore, by matching the thermal expansion coefficient of the substrate to that of the filter material, the adhesion between them should be relatively high. This factor will tend to increase the useful life of a filter device in accord with the invention.
Since a transparent plastic can be used for the insulative substrate instead of glass, resistance to breakage can be increased.
When filter material is disposed directly on an electrode, certain deleterious effects can occur. For example, cathodic hydrogen evolution can cause a lutetium diphthalocyanine film to peel away from a tin oxide electrode. If, as in the invention, the color-changing material is not on an electrode surface, this problem cannot occur. In the present invention, the filter material can be on any suitable substrate, whether nonconductive or conductive.
Since a device in accord with the invention uses an insoluble color-changing material rather than a soluble one, refreshing is not required. Hence the average power is low. Furthermore, due to its retention feature the most recently selected filter color is not lost in the event of a power failure.
The rare-earth diphthalocyanines are useful as electrochromic materials disposed directly on electrodes due, in part, to their relatively high solid-state conductivities. Of course, these materials are also expected to be well-suited for use in this invention. However, depending on the chemical kinetics, it is believed that it may be possible to use in this invention many other materials that can change color reversibly but which lack high solid-state conductivity or other properties favorable to a direct electrochromic response. This broad aspect of the invention exists because the color change reactions therein are essentially chemical rather than electrochemical.
A limiting case of this filter results in an electronically switchable light valve which will be realized when the material of the filter element is capable of reversibly changing its light transmission characteristic from light transmissive in one state to opaque in another state.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section of an optical filter in accord with the invention.
FIG. 2 is an exploded view in perspective of an alternative embodiment of an optical filter in accord with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there are shown the essential parts of a chemically coupled, color-changing, optical filter 10. As shown, a cell housing for the filter 10 includes an upper portion 14 and a lower portion 112 enclosing a cell housing cavity 15. A filter element 12 comprising a light-transmissive film of an insoluble color-changing material is disposed on an interior surface of the upper cell housing portion 14. The filter element 12 may be of any insoluble color-changing material such as, for example, a multicolor rare-earth diphthalocyanine, a two-color (blue and white) indigo dye or other insoluble dye which is capable of reversibly changing color by reaction with soluble oxidizing and reducing agents that are electrochemically generated. As the thickness of a film of indigo is increased, it will reach a point where it is essentially opaque in its blue optical state while it will remain capable of transmitting a substantial amount of light in its white optical state. This latter characteristic of indigo makes it suitable for use in a light valve.
The upper cell housing portion 14 may be of any material which is compatible with the color-changing material such as, for example, a plastic, glass or alumina.
The housing material and the color-changing material preferably have substantially the same thermal expansion coefficient so as to promote good adhesion. The better the adhesion, the longer will be the life of the device 10.
In order for the device 10 to act as a light filter, both the upper portion 14 and the lower portion 112 of the cell housing must be transparent, at least in the region between dotted vertical lines 114 and 116 which are disposed to indicate the extent of the filter element 12. Dotted vertical lines 114 and 116 thus indicate the region traversed by a beam of light passing through the filter 10.
The remainder of the device parts in FIG. 1 comprise the drive means for electrochemically generating the reactants, i.e., the soluble oxidizing and reducing agents. The reactants interact with the color-changing material to alter its color.
The drive means includes a generator electrode film 16 of a transparent conductive material such as, for example, tin oxide formed on the inner surface of the lower portion 112 of the cell housing. Generator electrode film 16 is disposed substantially parallel to, spaced apart from and coextensive with the filter element 12.
Electrical contact with the generator electrode film 16 is preferably made everywhere along the outer edge of the film through a peripheral strip of metal 118 and a conductor 120 extending external to the cell housing through a seal. Such geometry limits the ohmic resistance of the conductive film 16 to less than that of one square of the conductive material, even where the total area of the film 16 is large. This limitation on the electrical resistance of the generator electrode favors uniform and rapid response over the entire area of the filter element 12.
A counter electrode 18 is shown disposed on the interior side of the upper portion 14 of the cell housing. Since the central portion of the cell is shown occupied by the filter element 12, the counter electrode 18 is shown disposed around the outer portion of the cell housing cavity 15. A conductor 122 provides an electrical path leading from the counter electrode 18 external to the cell housing through a seal.
The cell housing cavity 15 is filled with a body of electrolyte solution 26 in contact with the generator electrode 16, the filter element 12 and the counter electrode 18.
Interposed between the generator electrode 16 and the counter electrode 18 is a selective separator 24 which, in effect, divides the cell housing cavity 15 into two compartments. The first or central compartment 34 contains the generator electrode 16 and the filter element 12 while the second or outer compartment 36 contains the counter electrode 18. The selective separator 24 prevents loss of electrochemically generated reactant species from the compartment 34 containing the generator electrode 16 and the filter element 12. Stated alternatively, the separator 24 excludes or confines the electrochemically generated reactant species away from the compartment 36 containing the counter electrode 18. Thus, the generated reactants are preserved for reaction with color-changing material only. In addition, the separator 24 is required to confine certain soluble chemical species to the compartment of the generator electrode 16 and filter element 12 and prevent contamination of the counter electrode 18 where these species could interfere with the operation of the counter electrode 18. Similarly, the separator 24 is required to confine certain other soluble chemical species to the compartment 36 of the counter electrode 18 and prevent contamination of the generator electrode 16 and of the color-changing material of the filter element 12 where these other species could interfere with the operation of the generator electrode 16 or with the operation of the color-changing material. However, the separator 24 does permit the passage of current-carrying ions between the generator and counter electrodes 16 and 18. A semi-permeable separator 24 made of, for example, an ion exchange resin is preferred but a retentive diffusion barrier containing electrolyte may serve as an adequate separator 24 in some cases. An ion exchange resin exhibits selective permeability due to its ability to transport primarily cations or anions. A retentive diffusion barrier retards the undesired passage of chemical species because of its microporous structure. The diffusion barrier can be a microporous structure of inert material fabricated by screening. Alternatively, the separator 24 may be a molecular filter having selective permeability due to its ability to transport only chemical species smaller than a certain size.
As has been indicated, the generator electrode 16 is preferably of a conductive, inert material such as, for example, tin oxide. The counter electrode 18 preferably includes an electrochemical couple with insoluble active components, such as silver-silver bromide, which will not impose special requirements on the separator 24. Soluble counter electrode couples such as iodide-triiodide are not ruled out, however, if an appropriate separator 24 is used. If both members of the counter-electrode couple are soluble, as in the case of iodide-triiodide, the separator 24 must be retentive enough to exclude the more active member, such as triiodide, from the region of the filter element 12.
The portion of the electrolyte solution 26 in contact with the filter element 12 and the generator electrode 16 initially contains a component of each of two redox couples. As indicated above, any components of the redox couples that would interfere with the operation of the counter electrode 18 are excluded or confined away from the region of the counter electrode 18 by the separator 24. The initial component of one redox couple is in the reduced form while the initial component of the other redox couple is in the oxidized form. The electrolyte solution 26 may also include an inert supporting electrolyte. This may be a simple inorganic salt such as, for example, potassium chloride. The initial redox couple components must be compatible with one another and with the color-changing material of the filter element 12 so that no color change or other change occurs until an electrical signal is applied to the device.
Chemically, the operation of the device 10 is similar to that of indirect coulometry, a technique developed for the investigation of redox processes in biological materials that are sterically unable to react directly at an electrode surface. See F. M. Hawkridge and T. Kuwana, "Indirect Coulometric Titration of Biological Electron Transport Components," Anal. Chem., 45, 1021 (1973).
When a current is passed in the drive means with the generator electrode 16 as the anode and the counter electrode 18 as the cathode, an oxidizing agent is formed at the surface of the generator electrode 16. This reactant diffuses across the layer of electrolyte solution 26 from the generator electrode 16 to the color-changing material in the filter element 12. The oxidizing agent reacts with the color-changing material to change its color and, in the process, is regenerated as the initial redox component in the reduced state. Thus, the soluble redox system mediates, or couples, the color-changing material in the filter element 12 to the generator electrode 16 without being consumed itself. In the device 10, the anodic charge passed at the generator electrode 16 should be that required to completely convert the amount of color-changing material present in the filter element 12. On controlled electrolysis in the opposite direction, the component of the other redox couple generates a reducing agent which reacts with the oxidized color-changing material and brings it back to its initial color state. It is apparent that there is no net change in the color-changing material or the reactants. Thus, the cycle should be repeatable many times. With some color-changing materials, if the reverse electrolysis is carried further by the passage of additional cathodic charge, the color-changing material may be reduced beyond its original color state to a third or even a fourth color state. Hence, in addition to being applicable to two-color displays, the scheme of this invention is adaptable to the operation of multicolor displays wherein the color-changing material has more than two color states.
As will be apparent to those skilled in the art, the above-recited process may be reversed in that the first reactant generated may be a reducing agent to react with a suitable color-changing material to switch the material from its initial color state by reduction rather than by oxidation. It will also be apparent that further oxidized states may exist to provide additional colors.
By way of example, a suitable color-changing material for a device 10 in accordance with the invention is lutetium diphthalocyanine, often abbreviated LuH(Pc) 2 , initially in a green color state. The initial soluble redox component in the reduced form may be the bromide anion, Br - . When a current is passed in the drive means with the generator electrode 16 as the anode and the counter electrode 18 as the cathode, the bromide anion is oxidized at the generator electrode 16 to form bromine, Br 2 . The bromine reactant diffuses across the electrolyte 26 to the filter element 12 where the lutetium diphthalocyuanine is switched from its initial green color to a red color state by oxidation. In the process, the initial redox component, the bromide anion Br - , is regenerated.
The initial soluble redox component in the oxidized form may be the colorless methyl viologen (1,1'-dimethyl-4,4'-bipyridyl) cation, abbreviated MV ++ . On controlled electrolysis in the reverse direction, a current is passed in the drive means with the generator electrode 16 as the cathode and the counter electrode 18 as the anode. The methyl viologen cation is reduced at the generator electrode 16 to form MV + . This reactant diffuses across the electrolyte 26 to the filter element 12 where the lutetium diphthalocyanine is switched from the red color state to its initial green color state by reduction. In the process, the initial redox component, the colorless methyl viologen cation MV ++ , is regenerated. Although the MV + species is strongly colored, it is present only during the switching process. Hence, it should not significantly alter the subsequent appearance of the device.
If the reverse electrolysis is carried further by the passage of additional cathodic charge, the lutetium diphthalocyanine may be further reduced beyond the green state to a blue form. The reaction sequence below illustrates the type of chemical process involved in this additional reduction.
At Generator Electrode (Generation of Reducing Agent)
2MV.sup.++ +2e→2MV.sup.+
At Filter Element 12 Surface (Chemical Switching of Color-Changing Material from Green to Blue) ##STR1##
In principal, only two redox couples are needed to cycle a diphthalocyanine film through all of its oxidation states, or colors. One redox couple should have an equilibrium potential more negative than any in the color-changing material system, and the other should have an equilibrium potential more positive than any of those for the color-changing material. It is further desired that different states of the color-changing material within a given film be capable of interacting with one another to reach equilibrium fairly quickly after passage of a switching charge. For example, in converting a lutetium diphthalocyanine film from red to green, any overdriving of the outer surface to blue should be only temporary. From observations of lutetium diphthalocyanine, it is anticipated that such equilibration can occur easily across several thousand angstroms of film thickness. Some practical relations of color and absorption spectra to potential are given in M. M. Nicholson and R. V. Galiardi, "Investigation of Lutetium Diphthalocyanine as an Electrochromic Display Material," Final Report, Contract N62269-76-C-0574, C77-215/501, NADC-76283-30, May 1977, Electronics Research Center, Rockwell International, Anaheim, Calif.
More detailed relationships between color, absorption spectra, potential, and the hydrogen ion activity of the electrolyte are given in M. M. Nicholson and T. P. Weismuller, "A Study of Colors in Lutetium Diphthalocyanine Electrochromic Displays," Final Report, Contract N00014-81-C-0264, C82-268/201, October 1982, Rockwell International Corporation, Anaheim, Calif.
Certain color conversions of lutetium diphthalocyanine have been observed. MV ++ has been electrochemically reduced to MV + which then reacted with this material to switch its color to blue from green. Br - has been electrochemically oxidized to form Br 2 which then reacted with this material to switch its color from green to red. With mixtures containing both couples (MV + /MV ++ and Br - /Br 2 ), reversible switching has been observed.
The compartment 34 of cell housing cavity 15 contains that portion of the body of electrolyte 26 having the redox components therein which are needed to react at the generator electrode 16. The compartment 36 contains that portion of the body of electrolyte 26 from which redox components are excluded unless some of them happen to be common to the counter electrode 18 system. For example, a component such as bromide ion can be one of the main redox components, so that
2Br.sup.- →Br.sub.2 +2e
at the generator electrode. Sometimes the same component can be part of the counter electrode system:
AgBr+e→Ag+Br.sup.-.
In this case, one can use a separator 24 which is permeable to bromide ion.
The compartments 34 and 36 are shown in FIG. 1 to have substantial size for the purpose of providing an excess of reactants. Longer device life is thereby provided in the event of gradual depletion of the reactants when the device 10 is put in service. Where depletion is not a factor, the device 10 can be made more compact by making the compartments 34 and 36 smaller.
In the device 10 of FIG. 1, the displacement between the filter element 12 and the generator electrode 16 is made small relative to the other dimensions of the cell housing cavity 15 by forming an internal pedestal 124 of appropriate height on the inner side of the upper portion 14 of the cell housing.
The displacement or distance between the filter element 12 and the generator electrode 16 is preferably made very small. This is necessary for rapid switching of color, since a reactant must travel by diffusion from its generation site across the layer of the electrolyte 26 to filter element 12. For example, if the reactant has a diffusion coefficient of 1×10 -5 cm 2 /sec in the liquid phase, and a switching time of one hundred milliseconds is desired, the distance between the generator electrode 16 and the surface of filter element 12 should be approximately fourteen microns. This estimate is made from the relationship (cut & paste) where Δt is the transport time across a layer of thicknesses ΔX and D is the diffusion coefficient. With a five-micron separation distance, the response time would be reduced to approximately twelve milliseconds. These estimates are made with the assumption that the chemical color-change reaction is faster than the diffusion process.
It is convenient to cause a color change in the filter element 12 with a current pulse, rather than a voltage pulse, since it is the amount of charge passed in generating a given amount of reactant which is most closely related to the amount of color-changing material to be switched. However, a voltage pulse of suitably controlled amplitude and duration may also be used.
In the device 10 of FIG. 1, the electrical path through the electrolyte 26 from the generator electrode 16 to the counter electrode 18 may have a substantial amount of electrical resistance. Where fast response of the filter is essential, an alternative arrangement may be made as in FIG. 2. In FIG. 2, ohmic voltage drop in the electrolyte is minimized by forming the device 10 as a stack of layers, sandwich fashion, with the counter electrode 18 and separator 24 disposed parallel to the planar filter element 12 of color-changing material.
Although the body of electrolyte 26 is shown as a distinct layer in the exploded view of FIG. 2, it will be understood that the electrolyte 26 is in contact with and extends from the filter element 12, disposed on the underside of upper cell housing portion 14, to the counter electrode 18, disposed on the upper side of lower cell housing portion 112. The generator electrode 16 may be, for example, of mesh to facilitate light transmission.
Although it is important to control the various thicknesses in the multilayer device structure 10 of FIG. 2, this control is not as difficult to achieve as in the fabrication of liquid crystal display devices wherein relatively large rigid plates must be positioned close together. The layer thicknesses in the present device can be achieved by screening or lamination techniques.
While the invention has been described with respect to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | A device usable as a tunable light filter or as a light valve having an electronically isolated element of a solid, insoluble material capable of reversibly changing state by reaction with soluble reactants. The state-changing element receives the reactants by diffusion through an electrolyte from a generator electrode. | 6 |
TECHNICAL FIELD
The present invention generally relates to surface mount electronic devices. More particularly, this invention relates to a semiconductor device having a micromachine and capable of being surface mounted as a package to a circuit board.
BACKGROUND OF THE INVENTION
A variety of semiconductor micromachines are known, including yaw (angular rate) sensors, angular and linear accelerometers, pressure sensors, thermal sensors, and actuators such as nozzles and valves. Each of these devices typically involves one or more micromachined structures (micromachines) formed in or on a silicon chip (referred to herein as a device chip). The device chip is often placed within a protective subpackage and then wire bonded to electrically connect the device to bond pads on the subpackage. The bond pads of the subpackage can then be reflow soldered to conductors on a circuit board, electrically and physically interconnecting the device to the board circuitry. Alternatively, device chips can be glued to a ceramic substrate, and then wire bonded to a circuit board after other surface mount components have been reflow soldered to the board.
Another packaging alternative involves wafer bonding methods, in which the micromachine of a device chip is enclosed by a second chip (referred to herein as a capping chip), which is bonded to the device chip. A cavity is often formed in the capping chip to receive and/or provide clearance for the micromachine of the device chip. Absolute pressure sensors require that the cavity be evacuated and hermetically sealed, while the performance of yaw sensors and accelerometers with resonating and tunneling micromachines generally benefit if the cavity is evacuated so that the micromachine operates in a vacuum. Bonding is typically achieved by forming the capping chip of silicon or glass (e.g., Pyrex), which can be bonded to the silicon device chip by such known techniques as anodic bonding and silicon fusion bonding, or with the use of glass frit, adhesives and solder. An example of this method is represented in FIG. 1, in which a micromachine sensor 110 is shown to include a device chip 112 with a surface micromachine 114 , and a capping chip 116 with a cavity 118 in which the micromachine 114 is received. A portion of the capping chip 116 is removed by cutting or etching to allow for wire bonding of bond pads 120 on the device chip 112 to a ceramic substrate (not shown) to which the sensor 110 is attached by glueing or another suitable method. The substrate is then placed in a cavity package and mounted to a circuit board.
From the above, it can be appreciated that semiconductor micromachines have required various packaging and bonding steps that add significant cost. Accordingly, it would be desirable if semiconductor micromachines could be produced and packaged with reduced material and processing requirements, yet were produced in a form that protects the delicate micromachine from potential hazards within its operating environment.
SUMMARY OF THE INVENTION
The present invention is directed to a semiconductor device and method by which a device chip with a micromachine is directly surface mounted to a circuit board. Semiconductor devices in accordance with this invention generally entail a device chip with a micromachine and electrically-conductive runners that electrically connect the micromachine to appropriate signal conditioning circuitry. A capping chip is bonded to the device chip and encloses the micromachine. The capping chip has a first surface facing the device chip, an oppositely-disposed second surface, and electrical interconnects through the capping chip between the first and second surfaces. The electrical interconnects electrically communicate with the runners on the device chip, thereby providing a signal path from the micromachine to the exterior of the device. The capping chip further includes bond pads in electrical communication with the electrical interconnects. With the bond pads, the capping chip can be surface mounted to a circuit board by reflowing solder bumps formed on the bond pads. Depending on the placement of the bond pads on the capping chip, the semiconductor device can be mounted to the circuit board with the capping chip between the device chip and circuit board, or the semiconductor device can be mounted with one side of the device attached to the circuit board.
The method of this invention generally entails forming the device and capping chips in accordance with the above, and then bonding the capping chip to the device chip so as to enclose the micromachine within the semiconductor device and electrically connect the micromachine to the bond pads on the exterior of the capping chip. Bonding is preferably performed with solder bumps formed on the capping chip. The solder bumps are located on the capping chip so as to register with the runners on the device chip when the capping and device chips are mated. Reflowing causes the solder bumps to form solder connections that physically interconnect the runners to the electrical interconnects, and thereby electrically interconnect the micromachine to the bond pads of the semiconductor device.
In view of the above, a semiconductor device with a micromachine element can be manufactured and surface mounted to a circuit board without the additional steps of wire and adhesive bonding, without a chip for the sole purpose of enclosing the micromachine, and without a subpackage or cavity package to protect the micromachine.
Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 is a cross-sectional view of a wafer-bonded semiconductor micromachine sensor in accordance with the prior art.
FIG. 2 is a cross-sectional view of a wafer-bonded semiconductor micromachine sensor in accordance with a first embodiment of the present invention.
FIG. 3 is a cross-sectional view of the sensor of FIG. 2 surface mounted to a circuit board in accordance with a method of this invention.
FIG. 4 is a cross-sectional view of the sensor of FIG. 2 that has been surface mounted to a circuit board in accordance with an alternative method of this invention.
FIGS. 5 and 6 are cross-sectional views of wafer-bonded semiconductor micromachine devices in accordance with second and third embodiments of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 2 through 6 illustrate examples of semiconductor devices that can be fabricated and surface mounted in accordance with this invention. Each device is shown as being formed by solder bonding a device chip to a capping chip, such that a micromachine is protected in some manner by the capping chip, e.g., a micromachine is formed on the device chip and enclosed within a cavity formed by a recess in the capping chip. As evidenced from the Figures, the micromachine can have a variety of transduction configurations, including that of an actuator or a sensing element for motion, pressure, heat, light or chemical sensing. The device chips are preferably silicon, more preferably monocrystallographic silicon, though it is foreseeable that other materials could be used. The capping chips can be formed of ceramic, glass, silicon or another semiconducting material through which electrically conductive interconnects can be formed. Suitable ceramic materials include low temperature cofired ceramic (LTCC), high temperature cofired ceramic (HTCC), thick film ceramic with punched vias, thick or thin film on glass (e.g., Pyrex, etc.) or ceramic with machined vias. To better match the expansion coefficients of a ceramic capping chip with a silicon device chip, the composition of the ceramic can be modified with the addition of Pyrex or a glass frit mixed into the ceramic prior to green sheet fabrication. By matching the expansion coefficient of the device and capping chips, a more stable and durable device is produced.
Referring to FIG. 2, a semiconductor sensing device 10 is shown with a device chip 12 solder bonded to a capping chip 16 . A micromachine 14 formed on the device chip 12 is enclosed within a cavity 18 formed by a recess in a lower surface 22 of the capping chip 16 . The recess can be fabricated during the green tape portion of LTCC or HTCC fabrication, or formed by machining or etching after the material for the capping chip 16 is fired. As depicted, the micromachine 14 may be a resonating micromachine of a type used to sense motion, such as angular rate sensors for monitoring yaw, pitch or roll, angular and linear acceleration, and vibration sensors, as disclosed in U.S. Pat. No. 5,831,162 to Sparks et al., commonly assigned with this invention. Other types of sensing micromachines are also possible with the general configuration shown in FIG. 2, including but not limited to micromachined cantilevers for sensing motion. As known in the art, capacitive or piezoresistive sensing elements (not shown) can be used to sense motion of the micromachine 14 .
The micromachine 14 is shown as being electrically interconnected to bond pads 20 on the capping chip 16 by conductive runners 26 on the enclosed surface of the device chip 12 and by metal vias 28 through the thickness of the capping chip 16 , i.e., between the lower surface 22 and the upper surface 24 of the capping chip 16 . The runners 26 and metal vias 28 can be formed by any suitable method. As an example, the vias 28 may be formed during the green tape portion of LTCC or HTCC fabrication of the capping chip 16 . Alternatively, if the chip 16 is formed of thick-film ceramic, the vias 28 can be produced by punching or machining the chip 16 , and then filling with a suitable conductor material. With the bond pads 20 , the micromachine 14 and its corresponding sensing elements can be electrically interconnected with circuitry on a substrate to which the device 10 is mounted, as will be discussed in reference to FIGS. 3 and 4 below. Signal conditioning circuitry for the sensing elements can be formed on the device or capping chips 12 or 16 .
As shown in FIG. 2 . in a preferred embodiment of the invention, the metal vias 28 are physically and electrically connected to the runners 26 with solder connections 30 within the cavity 18 , and the capping chip 16 is attached to the device chip 12 with a solder seal ring 32 that surrounds the cavity 18 and the solder connections 30 , so that the solder connections 30 as well as micromachine 14 are protectively enclosed between the chips 12 and 16 . The chips 12 and 16 can be solder bonded in a vacuum with the seal ring 32 , with the result that the micromachine 14 is hermetically vacuum sealed within the cavity 18 to enhance the performance of the micromachine 14 if operated as a resonating or tunneling element of a yaw sensor or accelerometer. If a hermetic seal is not required, the seal ring 32 need not be continuous or even a ring. The solder bonding process by which the ring 32 bonds the chips 12 and 16 entails depositing a suitable solder composition on solderable regions of the device and capping chips 12 and 16 . These solderable regions are necessary as solder will not wet or metallurgically bond to the substrates of the chips 12 and 16 . A suitable process and materials for the solderable regions are disclosed in U.S. Pat. No. 6,062,461 to Sparks et al., commonly assigned with this invention.
Finally, solder bumps 34 are shown as being located on the bond pads 20 , allowing for the device 10 to be “flip-chip” mounted to an appropriate substrate, as depicted in FIGS. 3 and 4. In order to avoid remelting the solder connections 30 and seal ring 32 during solder bonding of the device 10 , the solder compositions for the solder connections 30 and seal ring 32 preferably have a higher melting or liquidus temperature than that of the solder bumps 34 . The device 10 can then be placed on a circuit board and reflowed along with other surface-mount components. In FIG. 3, the device 10 is shown placed next to a conventional surface-mount component 36 on a circuit board 38 of any suitable construction. The solder bumps 34 on the capping chip 16 are shown as having been reflowed to form solder connections 40 that physically and electrical connect the device 10 to the board 38 , so that the capping chip 16 is between the device chip 12 and the board 38 .
In FIG. 4, an alternative mounting orientation for the device 10 is shown, by which a side or the device 10 is attached to the circuit board 38 . By mounting the device 10 as depicted in FIG. 4, the device 10 can be oriented to respond in any axis (x, y or z) of motion. This embodiment of the invention is preferably achieved by forming wide electrical vias in the saw street of the wafer material from which the capping chip 14 is cut. The resulting metal regions 42 (one of which is shown in FIG. 4) can be plated with solder or a solderable material, and then joined with solder 44 to the circuit board 38 , so that the metal regions 42 are between the capping chip 16 and the board 38 . The metal regions 42 preferably do not contact the device chip 12 because the body of the chip 12 is typically at electrical ground. Conductive runners 46 arc shown on the surface of the capping chip 16 as electrically connecting the metal vias 28 to the metal regions 42 , in order to electrically interconnect the micromachine 14 to the circuit board 38 . Though not shown in FIG. 4, the bond pads or FIGS. 2 and 3 may also be present on the exposed (lefthand) surface of the capping chip 16 . so that the device 10 can be mounted in either manner shown in FIGS. 3 and 4. FIG. 4 also shows an optional plate 48 attached to the device chip 12 and joined with solder 50 to the circuit board 38 to provide greater stability for the device 10 . The plate 48 can be formed of any suitable, preferably nonconducting material, and may attached to the device chip 12 by gluing, solder or other suitable methods.
FIGS. 5 and 6 illustrate other sensing applications for a semiconductor micromachine device in accordance with this invention. In FIG. 5, a fluid-handling actuator 60 is shown mounted to a circuit board 88 in which an opening 86 has been formed through which a fluid passes before entering the actuator 60 . As shown, the actuator 60 is structured similarly to the sensing device 10 of FIGS. 2 through 4, including device and capping chips 62 and 66 , a solder seal ring 82 attaching the device chip 62 to the capping chip 66 , metal vias 78 through the capping chip 66 , and solder connections 70 and 80 by which the actuator 60 and its sensing elements are electrically interconnected with circuitry on the circuit board 88 . As with the previous embodiments, the solder connections 70 and 80 are originally in the form of solder bumps, enabling reflow soldering of the device chip 12 to the capping chip 16 , and enabling the device 60 to be “flip-chip” mounted to the circuit board 88 . In addition, the capping chip 66 is shown as being attached to the circuit board 88 with a second solder seal ring 84 that isolates the solder connections 70 and circuitry on the circuit board 88 from the fluid flowing through the actuator 60 .
The actuator 60 differs primarily from the sensing device 10 of FIGS. 2 through 4 by the presence of passages 64 and 68 formed in the device and capping chips 62 and 66 , respectively, which permit fluid flow to actuator elements 74 and 76 formed or attached to the device chip 62 . Suitable applications for the actuator 60 include but are not limited to ink jet printing, medical and chemical fluid analysis, and gas sensing.
Finally, FIG. 6 depicts an absolute pressure sensor 90 in accordance with this invention, by which a capping chip 96 is used to surface-mount a device chip 92 to a substrate, shown as the circuit board 88 of FIG. 5 . The device chip 92 is shown to have a thinned section that defines a diaphragm 94 for sensing pressure to which the thinned section is subjected. A solder seal ring 102 attaches the device chip 92 to the capping chip 96 , and defines a chamber 98 between the chips 92 and 96 that is evacuated during solder bonding and thereafter hermetically sealed under vacuum by the ring 102 , as required for sensing absolute pressure. As with the previous sensing devices of FIGS. 2-5, the sensor 90 is equipped with metal vias 108 through the capping chip 96 and solder connections 100 and 106 by which the sensor 90 and its associated sensing elements (not shown) are electrically interconnected with circuitry on the circuit board 88 . Signal conditioning circuitry for the sensing elements can be formed on the device chip 12 or a separate chip on the board 88 . The sensing elements can be of any suitable type, including capacitive and piezoresistive sensing elements of types known in the art. As with the actuator 60 of FIG. 5, the capping chip 96 is shown as being attached to the circuit board 88 with the solder connections 106 and a second solder seal ring 104 , the latter of which can be used to form an evacuated or otherwise protected region on the capping chip 96 in or on which circuits (not shown) can be formed. While described as sensing pressure, the diaphragm 94 can be equipped with heat sensing elements to provide a thermal sensing capability for such applications as bolometers and other temperature sensors, thermopiles and IR sensors.
Each of the semiconductor devices described above share the features of having a micromachine element and the ability to be manufactured and surface mounted to a circuit board without the additional steps of wire and adhesive bonding, without the use of a chip whose sole purpose is to enclose the micromachine, and without conventional subpackages or cavity packages for protecting the micromachine. Devices in accordance with the present invention achieve these advantages by employing a capping chip that not only provides support and protection for its device chip and micromachine, but also provides electrical interconnects that enable the device chip to be directly surface mounted (i.e., solder bonded, preferably flip-chip mounted) to a substrate without the requirement for additional packaging or bonding steps. The features of this invention are applicable to a variety of semiconductor micromachine applications in addition to those described above, and can be achieved with devices that differ in appearance from those shown in the Figures.
Additional advantages of this invention include the ability to stack sensing devices so that multiple devices are mounted to a substrate with a single solder-bonding operation. Another option is to enlarge the capping chip so that discrete components, such as capacitors, inductors and resistors, can be simultaneously solder-bonded to the capping chip with the device chip, or subsequently wire-bonded to the capping chip. An organic coating or soldered metal cap may be used to encapsulate or enclose the components on the capping wafer, to permit handling as a single surface-mount package.
While the invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. Accordingly, the scope of the invention is to be limited only by the following claims. | A semiconductor device and method by which a device chip with a micromachine is directly surface mounted to a circuit board. A capping chip is bonded to the device chip and encloses the micromachine. The capping chip has a first surface facing the device chip, an oppositely-disposed second surface, and electrical interconnects through the capping chip between the first and second surfaces. The electrical interconnects electrically communicate with runners on the device chip that are electrically connected to the micromachine, thereby providing a signal path from the micromachine to the exterior of the device. The capping chip further includes bond pads for electrical communication with the electrical interconnects. With the bond pads, the capping chip can be surface mounted to a circuit board by reflowing solder bumps formed on the bond pads. Depending on the placement of the bond pads on the capping chip, the semiconductor device can be mounted to the circuit board with the capping chip between the device chip and circuit board, or the semiconductor device can be mounted with one side of the device attached to the circuit board. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation application of my application Ser. No. 11/593,407 filed on Nov. 7, 2006 now U.S. Pat. No. 7,468,129 and entitled “Oil-Water Separator,” which is a divisional application of my application Ser. No. 10/999,543 filed on Nov. 30, 2004 entitled “Oil-Water Separator,” now U.S. Pat. No. 7,160,467, the full disclosures of which are incorporated by reference herein and priority of which is hereby claimed.”
BACKGROUND OF THE INVENTION
The present invention relates to oilfield equipment, and more particularly to an apparatus for separating water and oil that can be used in-situ.
Conventionally, an oil well is encompassed with a water-retaining moat, or ditch designed to drain water washed away from the area surrounding the drilling or production rig. The ditch is formed about the periphery of a zone defined by the governmental regulations for the protection of the environment. When small amounts of oil escape from the well bore or are spilled by trucks, the rain water tends to carry the oil droplets, along with the rain water into the ditch, wherein the oil-water mixture is retained. A levee is constructed on the outer edge of the ditch to prevent the water from the ditch escaping outside of the defined zone.
Despite all efforts, heavy rains and sometimes flood waters fill the ditch to capacity and cause the water mixed with the suspended oil to flow over the levee, thereby contaminating the surrounding area. From time to time, the ditch is inspected to make sure that the level of liquids in the trench has not exceeded the allowable value. A part of the ditch is made intentionally at a lower level to created the so-called sump. Even the best inspections may miss a critical increase in the liquid level within the sump, which may quickly fill to capacity and overflow if not carefully monitored. From time to time, the water with suspended oil particles is pumped out and transported away from the site to a de-contamination facility, where the oil may be recovered. Naturally, such transportation increases the cost of the oilfield operation.
The present invention contemplates provision of an oil-water separator that can be installed in the trench surrounding the oil well to capture oil and prevent it from being carried over the levee by rising water.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide an in situ apparatus for separating oil from water that can be installed in an oilfield ditch.
It is another object of the present invention to provide an oil-water separator that has oil-absorbing means for retaining a quantity of oil within the apparatus, thereby preventing escape of the oil and contamination of the surrounding areas.
These and other objects of the present invention are achieved through a provision of an oil-water separator that is adapted for positioning in the ground next to the trench surrounding an oilfield. A portion of the separator housing is buried below the trench bottom, while the inlet conduit is positioned at about the same level as the trench bottom.
A plurality of buoyant oil-absorbing members are positioned in the housing; the trench water with oil particles suspended therein is admitted through the inlet conduit. The oil particles contact the oil-absorbing members and adhere thereto. An outlet conduit is positioned downstream from the oil-absorbing members. The outlet conduit is connectable to a pump to allow removal of the oil-free trench water from the housing. A diverting pipe coupled to the outlet of the pump diverts the water away from the housing and the trench. The water can be diverted over the levee surrounding the trench or to other desired location. As a result the oil is removed from the trench water, and the level of liquid in the trench is controlled.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the drawings, wherein like parts are designated by like numerals and wherein
FIG. 1 is a perspective view of the oil-water separator in accordance with the present invention.
FIG. 2 is a perspective view of the oil-water separator apparatus in accordance with the present invention transported to or from the job site.
FIG. 3 is a schematic view of the separator apparatus in accordance with the present invention positioned in the trench adjacent an oilfield, with the ditch not having any water.
FIG. 4 is a schematic view similar to FIG. 3 , with the ditch half full of water.
FIG. 5 is a schematic view similar to FIGS. 3 and 4 , with the ditch being full of water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings in more detail, numeral 10 designates the oil-water separator apparatus in accordance with the present invention. As can be seen in the drawings, the separator 10 comprises a separator housing 12 having a closed bottom 14 , vertical front wall 16 , back wall 20 , a pair of side walls 18 and 22 , and an open top 24 . The walls 16 , 18 , 20 , and 22 and the bottom 14 define an interior hollow chamber of the housing 12 . The side wall 22 is provided with an inlet conduit 26 extending outwardly in a transverse relationship to the vertical wall 22 . The inlet conduit 26 has an inlet opening 28 for admitting liquid into the separator housing 12 .
An opening 30 is formed in the upper part of the wall 22 , and the conduit 26 is positioned therein. The inlet conduit 26 communicates with an interior chamber of the housing 12 through the opening 30 . A water-permeable mesh screen 32 is positioned in the opening 30 to prevent floating debris, such as sticks, leaves, and other such undesirable objects from entering the interior chamber of the housing 12 .
A vertical dividing plate 40 is positioned inside the housing 12 , dividing the interior chamber of the housing into two distinct portions, an inlet portion 42 and an outlet portion 44 . The dividing plate 40 is secured and extends from a top edge 46 of the front wall 16 and the back wall 20 . The vertical dimensions of the dividing plate 40 are smaller than the height of the vertical walls 16 and 20 , such that a channel 48 is formed below a lower edge 50 of the separating plate 40 . The horizontal dimensions of the plate 40 are slightly smaller or equal to the distance between the front wall 16 and the back wall 20 .
A slot 52 is formed in the plate 40 at a level approximately co-planar with the bottom of the inlet conduit 26 . An inner water permeable mesh screen 54 is inserted through the slot 52 to extend substantially across the width of the housing 12 , from the side wall 18 to the side wall 22 . An outlet conduit 56 is positioned in the outlet portion 44 of the interior chamber to allow removal of liquid from the interior of the housing 12 . The outlet conduit 56 has an outlet opening 58 . The conduit 56 is operationally connected to a pump 60 to facilitate removal of the liquid form the housing 12 . The open top 24 of the housing 12 is protected by a pair of hinged covers 62 and 64 which are secured to extension plates 66 , 68 , which are mounted on the upper edge of the walls 16 and 20 . The securing plates 66 and 68 extend vertically outwardly from the edge 46 , allowing pivotal movement of the covers 62 and 64 . A cutout 70 is formed in the cover 64 to accommodate extension of the outlet conduit 56 from the chamber portion 44 outside of the housing 12 . The bottom, inlet end 72 of the outlet conduit 56 rests on the screen 54 , as can be seen in FIG. 1 .
The present invention provides for the use of a plurality of oil absorbing members 80 , which are positioned in the chamber portion 42 above the screen 54 . The absorbent members 80 are formed from porous material suitable for attracting and retaining as much oil particles as possible. The absorbent members 80 , which can be two or more in number, are buoyant; they float close to the surface of the liquid inside the chamber portion 42 , as will be described in more detail hereinafter.
Turning now to FIGS. 3-5 , the oil-water separator 10 in accordance with the present invention is seen positioned in an oilfield adjacent an oil well 82 . A ditch, or trench, 84 surrounds the oil well 82 . The separator 10 is partially buried in the soil wherein a hole 86 has been formed. Most of the separator housing 12 is below the ground level 83 . The hole 86 is immediately adjacent to the ditch 84 , preferably close to the lowest, sump area of the ditch 84 . The inlet conduit 26 is positioned close to the bottom 88 of the ditch 84 so as to receive water through the opening 28 .
A certain quantity of water is initially deposited into the housing 12 , with the level of preloaded water 90 reaching about the level of the mesh screen 54 . The absorbent members 80 rest on the screen 54 , initially above the water level 90 . The outlet conduit 56 is connected to the pump 60 , and the outlet of the pump 60 is connected to a diverting conduit 92 . An outlet 94 of the diverting conduit 92 extends above a levee 96 formed around the ditch 84 .
Gradually, the rainwater and run-off collect in the ditch 84 . When the level of water reaches the inlet conduit 26 , the water is allowed to freely enter the conduit 26 and flow into the housing. The direction of the water flow is schematically illustrated by arrows 98 . The water, with the oil particles suspended therein enters the inlet portion 42 of the interior chamber. The absorbent members 80 attract the oil particles that tend to float on the water surface. Water, substantially free from the oil particles, floats under the dividing plate 40 , along the channel 48 into the chamber portion 44 . The liquid level substantially equalizes in the portion 42 and the portion 44 of the interior chamber with the level of water in the trench 84 . Any debris that entered the chamber portions 42 and 44 through the screen 32 is additionally screened by the screen 54 on its path upwardly in the chamber portion 44 .
The water, now substantially free from oil and debris, enters the outlet conduit 56 . When the pump 60 is activated, the water is pumped out of the separator housing 12 and into the diverting conduit 92 . From there, the water can be pumped over the levee 96 . When the ditch 84 becomes full with water, as schematically shown in FIG. 5 , the pump 60 may be turned on either manually or automatically, to be activated based on the water level predetermined by the operator. The water is pumped from the ditch 84 through the separator 10 and over the levee 96 , thereby preventing oil accumulated in the ditch 84 from being released into the surrounding areas outside of the levee 96 .
If desired, the level of water in the ditch 84 can be continuously monitored and controlled by the automatic operation of the pump 60 . In the alternative, an operator may inspect the level of liquid in the ditch 84 and start operation of the pump 60 to remove a portion of water from the ditch 84 . From time to time, the operator can inspect the status of the absorbent members 80 by opening the cover 62 and visually inspecting the absorbent members. When the absorbent members 80 become saturated with oil, they can be easily removed from the interior of the housing 12 and new absorbent members can be positioned by dropping them on the screen 54 . Should the screen 54 become clogged with small leaves or other particles, the operator can clean the screen by lifting the covers 62 and 64 and obtaining access to the interior chamber and the screen 54 .
The separator apparatus 10 of the present invention requires little monitoring and can function for a long time without repairs or adjustments. When the job in the oilfield is complete, the apparatus 10 can be removed from the ground and transported to the new job site after the water from the housing 12 has been drained.
Many changes and modifications can be made in the design of the present invention without departing from the spirit thereof. I therefore pray that my rights to the present invention be limited only by the scope of the appended claims. | An oil-water separator for use in a trench, which surrounds an oilfield. The separator is positioned in the ground such that an inlet conduit extends at about the same level as the bottom of the trench. The trench water is admitted into the housing, where it contacts a plurality of buoyant oil-absorbing members, causing the oil particles to adhere to the surface of the oil-absorbing members. An outlet conduit located downstream from the oil-absorbing members is connectable to a pump to cause the oil-free water to be pumped from the housing and diverted away from the trench. | 2 |
This application is a continuation-in-part, division, of application Ser. No. 08/237,679, filed May 5, 1994 now abandoned.
FIELD OF THE INVENTION
The present invention relates to work stations and more particularly to height adjustable work surfaces associated with such stations.
BACKGROUND OF THE INVENTION
In a modern office or workplace, it is common to provide work stations utilized by numerous personnel. Each station will include one or more work surfaces for ordinary paper work, or to accommodate a typewriter, control panels or computer keyboards and related accessories such as a mouse. It is desirable for these work surfaces to be vertically adjustable to adapt to the varying requirements of different users. Conventional work stations are not designed with this facility in mind.
Various mechanisms have been introduced into the workplace to attempt to overcome this deficiency. However, many are expensive and cumbersome to install and use, and many fail to provide uniform lift when the balance or load at the lift points supporting the work surface is uneven.
To overcome these problems, a number of different solutions have been proposed, most of which involve the use of cables, fixed position pulleys and centrally mounted drive units. For example, in Canadian Patent 1,258,288 dated Aug. 8, 1989, a work surface height adjustment mechanism includes left and right side cable lift mechanisms, means to mount each of the lift mechanisms to a supporting surface such as a wall, pulleys connected to the vertically adjustable supports to which the work surface is mounted, and a central drive mechanism connected to the underside of the work surface at the exact midpoint thereof.
In addition to requiring numerous parts and components, including at least six pulleys, a complicated cable takeup system and mounting means to secure the cable lift mechanisms to a supporting wall panel, all of which add substantially to manufacturing and installation costs, there is virtually no flexibility permitted with respect to the positioning of the drive unit which must be mounted at the center of the work surface's lower surface. This is not always the most desirable or even practical location for the drive unit and the system as a whole is therefore rigid and non-adaptive to varying situations and requirements.
As cost and flexibility are major factors to customer acceptance of height adjustment mechanisms, there is a need for a system providing the advantages of systems such as taught in the '288 patent, without the rigidity and relative complexity thereof.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a work surface height adjustment mechanism that obviates and mitigates from the disadvantages of the prior art.
It is a further object of the present invention to provide a height adjustment mechanism of substantially simplified construction and wherein the drive unit need not be located centrally relative to the work surface.
It is yet another object of the present invention to provide a height adjustment mechanism wherein the drive unit may be operated manually or with a powered assist.
According to the present invention then, there is provided a mechanism for adjusting the height of a work surface, comprising vertically movable shaft means for supporting a work surface thereon for up and down movement, actuator means operable for selectively raising or lowering said shaft means, cable means interconnecting said shaft and actuator means, said cable means being displaceable to raise and lower said shaft means in response to operation of said actuator means, and compression resistant sleeve means surrounding said cable means between said shaft means and said actuator means.
According to another aspect of the present invention, there is also provided a work surface height adjustment mechanism, comprising at least two horizontally spaced apart parallel shafts supported for reciprocating movement along the longitudinal axes thereof, said shafts being adapted to support a work surface thereon, actuator means operable for generating a force causing said reciprocating movement of said shaft means to selectively raise or lower a work surface, flexible cable means operatively connecting said actuator means and each of said shafts for respectively transmitting said force generated by said actuator means to said shafts, and compression-resistant sleeve means jacketing said cable means substantially continuously between said actuator means and said shafts.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the present invention will now be described in greater detail and will be better understood when read in conjunction with the following drawings in which:
FIG. 1 is a perspective, partially exploded view of a height adjustable work surface in accordance with the present invention;
FIG. 2 is a schematical, front elevational, partially sectional view of the lift columns supporting the work surface and the drive unit therefor, the drive unit being shown in plan;
FIG. 3 is a front elevational, partially sectional view of an alternate lift column;
FIG. 4 is a side elevational, partially sectional more detailed view of a lift column;
FIG. 5 is a rear perspective, partially sectional view of the upper part of the column shown in FIG. 4;
FIG. 6 is a partially sectional, more detailed plan view of a hand cranked drive unit;
FIG. 7 is a partially sectional plan view of a power assisted actuator; and
FIG. 8 is a perspective view of an alternate actuator including a gear motor assembly.
FIG. 9 is a perspective view of a modification to the support mechanism for the height adjustable work surface of FIG. 1;
FIG. 10 is a side elevational view of the modified support mechanism of FIG. 9; and
FIG. 11 is a perspecyive view of a further modification to part of the support mechanism of FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, there is shown generally a height adjusting mechanism 10 useful to raise and lower a work surface 4. The height adjustment mechanism generally comprises spaced apart, telescopic lift columns 8 which support work surface 4 by means of horizontally extending brackets 7 attached to the tops of each column, a drive unit or actuator 15 and jacketed cables 16 extending between the actuator and the lift columns, the cables being displaceable to raise and lower the columns as will be described in greater detail below.
With reference to FIG. 2, each of lift columns 8 comprises an outer housing 18 adapted for connection to a supporting surface 2 (FIG. 1) and a telescopically associated shaft 19. Shaft 19 is slidably supported for vertically axial movement in and out of the housing by means of a bottom bushing 20 at the lower end of the shaft and a suitable bearing or low friction sleeve 21 at the upper end of housing 18.
Actuator 15 as shown in a simplified form in FIG. 2 comprises a power screw 26 journalled at its opposite ends into an actuator housing 30. One end of the power screw includes an extension 27 protruding through housing 30 for connection to a handle or hand crank (not shown) by means of which the screw can be turned in either a clockwise or a counter-clockwise direction.
Threadedly connected to power screw 26 is a cable carrying bushing or nut 28 which will move back and forth along the power screw within housing 30 depending upon whether the power screw is being turned clockwise or counterclockwise.
Connecting the actuator to each of the lift columns, or more particularly to each of shafts 19, is a flexible cable 35 sheathed within a flexible but compression resistant jacket or sleeve 36. Each sleeve 36 is preferably compression loaded between its respective points of connection at one end to the actuator and at the other end to housing 18 of each lift column or to some other convenient point just prior to cable 35's point of connection to shaft 19. Each cable 35 is connected at one of its ends to bushing 28 and at its other end to bottom bushing 20 at the lower end of shaft 19.
As will be obvious, any movement of bushing 28 back and forth along the power screw will be automatically translated into a corresponding up or down movement of shafts 19 as a result of the interconnection between the two by cables 35. More specifically, movement of bushing 28 in the direction of arrow A will cause an equal upward movement of shafts 19 in the direction of arrow B, with the amount of movement of each shaft 19 being exactly equal notwithstanding any unequal loading of work surface 4. Causing the movement of bushing 28 in the opposite direction will result in the lowering (by gravity) of shafts 19, again in substantially equal and coordinated increments.
In the system described above, the location of and point of mounting for the actuator is immaterial and in an extreme example, it can even be left to dangle. If preferred, the actuator can be mounted beneath the work surface, but where this is neither desired nor practical, it can be mounted anywhere else for easy access having regard to the lack of need for any fixed positioning, externally mounted and exposed pulleys or means to guide the cables 35 along a predetermined path. It will be appreciated as well that cables 16 need not be of equal length.
With reference to FIG. 3, there is shown an alternately configured lift column wherein cable 35 engages a small pulley 38 provided at the bottom of shaft 19 and is then fixedly connected to housing 18 such as at point 39.
With reference now to FIG. 4, an exemplary lift column assembly is shown in greater detail. Like numerals to those used in the previous figures have been used for like elements. The column shown in FIG. 4 is an elongated version adapted to engage the ground or floor by means of an adjustable foot or leveller 60 threadedly received into a bottom cap 61 press fit into the lower end of housing 18.
Shaft 19 is supported at its lower end by means of a bottom bushing 62 having chamfered peripheral edges 63 to facilitate its sliding movement along the inner walls of housing 18. A threaded bolt 64 and a washer 65 are used to securely connect the bushing and shaft together, with both the bushing and washer including aligned slots or apertures 66 to receive cable 35 therethrough.
The upper end of shaft 19 is slidably supported such as by means of a metallic sleeve 70 with an inner TEFLON (trade-mark) liner 72 and, optionally, a shaft seal 71.
As seen most easily in FIG. 5, a cable stop plate 73 is fitted through the horizontal portion 76 of a T-shaped slot 74 formed in the rear surface 17 of housing 18. Plate 73 extends partially into the annulus 19 between the inner surface 14 of housing 18 and shaft 19 to engage bottom bushing 62 to limit the shaft's total predetermined upward travel. Plate 73 also provides a convenient point of attachment for a connector 46 that couples with the associated end of sleeve 36. The vertical portion 75 of T-shaped slot 74 provides clearance for the ingress of cable 16.
With reference to FIG. 6, an exemplary hand cracked actuator assembly is shown in greater detail. Once again, like reference numerals to those used in the previous figures have been used for like elements.
As shown, the actuator comprises a cylindrical housing 30 and a power screw 26 aligned axially therein. The power screw is narrowed at its rearward end 34 and is journalled through a thrust plate 33 and bearings (e.g. brass bushings) 37 and 37a. Rearwardly protruding end 34 of the power screw is threaded for connection to a retaining nut (not shown for clarity). The forward end of the power screw is telescopically inserted into the rearwardly extending cylindrical end of a crank handle adaptor 40 which in turn is rotatably supported in axial alignment with housing 30 by means of a front end support block 41. The block may be made of any tough but low friction material such as nylon or DELRIN (trade-mark). Block 41 can be fitted into the leading end 32 of housing 30 and secured into place by means of, for example, a pair of screws (not shown).
Crank handle adaptor 40 includes a forwardly extending narrowed portion 44 for connection to a handle 45.
Adaptor 40 and the power screw are connected together for mutual rotation by means of a pin 47 or any other suitable connector. The adaptor additionally includes a longitudinally extending slot 48 to slidably engage pin 47, thus permitting the handle to be retracted into the position shown in dotted lines which is a convenient feature in certain installations.
A pair of threaded apertures 43 in thrust plate 33 are provided to engage cooperatively threaded cylindrical connectors 46 that couple with the respective ends of sleeves 36 and provide a passage for cables 35. As will be seen, cables 35 pass through connectors 46 for connection with carrier bushing 28 and a cable retaining washer 49. Preferably, both the bushing and the washer include at least one co-aligned threaded aperture 52 for a threaded fastener (not shown) connecting the two together. Bushing 28 includes chamfered peripheral edges 29 to facilitate its back-and-forth movement within the housing, and a small radially extending screw or pin 23 that tracks within a longitudinally extending slot 25 in the housing 30's outer wall to prevent the bushing from rotating relative to the housing. A small nylon sleeve 22 around the screw is provided to reduce friction and prevent binding of the pin within slot 25. Cables 35 may be retained in place by means of beads 50 connected to the cables at their respective ends.
A power-assisted actuator 80 is shown with reference to FIG. 7. As before, like numerals are used to identify like elements.
Actuator 80 generally includes an outer housing 81 supporting the power screw 26 and a DC motor 83. The power screw is journalled at one of its ends into a sleeve bearing 84 and at its opposite end into a ball bearing 85 and bearing cap 86.
A rearward extension 26(a) of the power screw supports a cogged pulley 90 and a timing belt 91 connects this pulley to a similar but smaller cogged pulley 93 on the motor's impeller 94.
A carrier flange 96 is threadedly connected to the power screw for back and forth movement with the clockwise or counterclockwise rotation of the screw and of course the carrier flange is adapted for connection to cables 35 (not shown in this view).
FIG. 8 shows another alternate power assisted actuator making use of a gear motor assembly 100 and a drum 101 which reciprocates back and forth to actuate cables 35 connected thereto. As will be appreciated, this particular embodiment eliminates the need for a power screw 26.
It has been found that the weight of work surface 4 is sufficient by itself to allow its lowering due to gravity as the actuator is turned in the appropriate direction. It is contemplated however that compression springs or other suitable means can be added to columns 8 to assist more positively in downward adjustments to the surface's position.
With reference to FIGS. 9 and 10, there is shown an alternative support mechanism which is potentially more economical to manufacture although the principles of operation remain much the same in relation to the use of telescopic lift column 8. Thus, rather than using a telescopic column, the support means comprise a bracket 100 that can be attached directly by any suitable means, such as screws, rivets, weldments or glue, to a structural member 101 or other part of the work station. The outer edge 103 of bracket 100 is provided with a glide 105 preferably made from a low friction material such as plastic, Nylon®, Teflon® or other materials, a number of which will be readily apparent to those skilled in the art.
Glide 105 is slidably received into a channel member 110 which will typically be either an extruded or forged plastic or metal component. As will be appreciated, channel 110 is adapted to move up and down relative to the guide in response to movement of cable 35 within jacket 36. As shown in the figures, a connector 46 is conveniently provided on bracket 100 to couple with the co-operating end of sleeve 36. Cable 35 connects to channel 110 in any suitable fashion such as by means of, for example, an eyelet 115 provided at the channel's lower edge which captures a bead 50 at the cable's end.
A support bracket 107 is provided at the upper end of channel 110 to support a work surface 4 (not shown). In most instances, a pair of spaced apart channels will be used to support a work surface although more can be used for a longer surface, and indeed, a single channel can be used in relation to a shorter surface, particularly one not expected to bear heavy loads or subjected to differential loading at opposite ends thereof.
With reference to FIG. 11, a further modification is shown in which glides 105 are replaced with rollers 120. Other possibilities will occur to those skilled in the art.
It will be obvious to those skilled in the art that the scope of the present invention is not restricted to the embodiments disclosed above, but may instead be varied within the scope of the following claims without departing from the spirit and scope of the invention. | There is described an improved mechanism for adjusting the height of a work surface, comprising vertically movable shafts for supporting a work surface thereon for up and down movement, an actuator operable for selectively raising or lowering the shafts, cables interconnecting the shafts and the actuator, the cables being displaceable to raise and lower the shafts in response to operation of the actuator and a compression resistant sleeve surrounding each of the cables between the shafts and the actuator. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of aptitude testing, including apparatus and methods for testing the aptitude of subjects to mental tasks and assessing subjects thinking style.
BACKGROUND OF THE INVENTION
[0002] Existing commonly-used aptitude tests attempt to measure a subject's current abilities using a standardised test appropriate to the subject's age, language, culture and educational background. The tests do not necessarily identify potential aptitude in subjects who do not meet a basic requirement of the tests such as a particular educational background or for whom no standardised test exists or is appropriate. For example, as existing tests require a minimum level of knowledge before aptitude can be assessed, those subjects with natural abilities not meeting the minimum requirements would generally not be identified as potential candidates. Furthermore, minorities may consider certain tests to be unfair and discriminatory. There is a need for a new test which can be used to assess potential aptitude as well as current aptitude levels.
[0003] Aptitude and thinking style are closely related and thus a test that can identify aptitude can also be used to identify a subject's thinking style. Knowledge of a subject's thinking style can also be used to identify the optimum teaching and training approach for the subject.
[0004] U.S. Pat. Nos. 4,955,938 and 5,331,969 (the contents of which are hereby incorporated herein by reference) disclose techniques for obtaining a steady state visually evoked potential (SSVEP) from a subject. These patents disclose the use of Fourier analysis in order to rapidly obtain the SSVEP's and changes thereto.
SUMMARY OF THE INVENTION
[0005] It is now appreciated that these techniques can be utilized to measure brain activity and assess the aptitude of an individual.
[0006] More particularly the invention provides a method of assessing the cognitive aptitude of a subject to a predetermined task, the method including the steps of:
[0007] (i) presenting to the subject a group of cognitive tasks;
[0008] (ii) detecting brain response signals from the subject during presentation of said group of cognitive tasks;
[0009] (iii) calculating amplitude, phase and/or coherence SSVEP responses from said brain response signals; and
[0010] (iv) comparing said SSVEP responses to known SSVEP responses obtained from individuals with high and/or low aptitudes to said predetermined task in order to assess the subject's aptitude for said predetermined task.
[0011] The invention also provides an apparatus for assessing the cognitive aptitude of a subject to a predetermined task, the apparatus including:
[0012] (i) means for presenting to the subject a group of cognitive tasks;
[0013] (ii) means for detecting brain response signals from the subject during presentation of said group of cognitive tasks;
[0014] (iii) means for calculating amplitude, phase and/or coherence SSVEP responses from said brain response signals; and
[0015] (iv) means for comparing said SSVEP responses to known SSVEP responses obtained from individuals with high and/or low aptitudes to said predetermined task in order to assess the subject's aptitude for said predetermined task.
[0016] The present invention can utilise Steady State Probe Topology (SSPT), a brain imaging technique based on the brain's response to a continuous sinusoidal visual flicker or the SSVEP to examine changes in the activity in various brain regions while an individual undertakes a number of cognitive tasks. The cognitive aptitude will be indicated by specific changes in SSVEP amplitude, phase and coherence during a given cognitive task. The changes in SSVEP amplitude, phase and coherence can also indicate different thinking styles associated with different patterns of brain activity. Subjects that score high, on a test of analytical thinking show greater left hemisphere phase advance that is interpreted as greater activation of this area during the analytical task. By contrast, subjects that score low on the test of analytical thinking do not show this pattern. In addition, subjects that score high on a test of holistic thinking show greater SSVEP pahse advance at right hemisphere sites. These results are consistent with neuropsychological research indicating a specialised role for the left hemisphere in analytical thinking and the right hemisphere for holistic thinking.
[0017] More generally, SSVEP can be used to identify aptitude in specific cognitive domains known to be associated with performance and training aptitude. For example, trainee aircraft pilots need aptitude in visualizing their environment in three dimensions. A test for this ability could involve SSVEP measurements while the subject undertakes the Mental Rotation Task where they are required to rotate images of three dimensional shapes. Specific changes in SSVEP amplitude, phase and coherence are associated with a high aptitude for this task and these changes may be used to identify individuals with a high ability to manipulate three dimensional images. Studies undertaken by the inventor reveal that individuals with a high aptitude for the manipulation of three dimensional images exhibit a greater phase advance at left prefrontal cortical sites and reduced coherence between central and parietal cortical sites. By contrast, subjects with a high ability show increased SSVEP coherence between right prefrontal and central sites during the time that the image was held in short term memory without manipulation.
[0018] More particularly, the techniques of the invention can be used in a number of different fields including:
(i) identifying cognitive aptitude in specific domains; (ii) identifying an individual's thinking style and hence the optimum teaching/training approach; (iii) identifying the suitability of an individual for specific training; and (iv) identifying the suitability of an individual for specific employment.
[0023] The changes in SSVEP amplitude, phase and/or coherence can be an increase or decrease. Also, the magnitude of the change may vary from case to case. One way of determining whether there has been a significant change in SSVEP amplitude, phase and/or coherence is by reference to statistical analyses where a change is regarded as significant at the p<0.05 level where p represents the probability of a Type 1 statistical error (i.e. wrongly rejecting the null hypothesis). Statistical significance can be tested using a number of methods including student's t-test, Hotellig's T2 and the multivariate permutation test. For a discussion of these methods used to analyse the SSVEP see Silberstein R. B., Danieli F., Nunez P. L. (2003) Frontoparietal evoked potential synchronisation is increased during mental rotation. Neuroreport, 14:67-71, Silberstein R. B., Farrow M. A., Levy F., Pipingas A., Hay D. A., Jarman F. C. (1998). Functional brain electrical; activity mapping in boys with attention deficit hyperactivity disorder. Archives of General Psychiatry 1998; 55:1105-12.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will now be further described with reference to the accompanying drawings, in which:
[0025] FIG. 1 is a schematic diagram of a system of the invention;
[0026] FIG. 2 is a schematic plan view showing in more detail the manner in which visual flicker signals are presented to a subject;
[0027] FIG. 3 is a schematic view showing one of the half silvered mirrors and LED array;
[0028] FIG. 4 diagrammatically illustrates SSVEP phase distribution for a subject with high analytical aptitude;
[0029] FIG. 5 diagrammatically illustrates SSVEP phase distribution where the subject has a low analytical aptitude;
[0030] FIG. 6 diagrammatically illustrates SSVEP phase distribution for subjects with high holistic thinking capacity;
[0031] FIG. 7 diagrammatically illustrates SSVEP phase distribution for subjects with low holistic thinking capacity;
[0032] FIG. 8 diagrammatically illustrates SSVEP coherence at frontal sites for subjects having high verbal IQ; and
[0033] FIG. 9 diagrammatically illustrates SSVEP coherence in subjects having high conceptual and visualisation skills.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 schematically illustrates a system 20 for determining the response of a subject 6 to a cognitive task which can be presented to the subject 6 on a video screen 1 and loudspeaker 11 . The system includes a computer 2 which controls various parts of the hardware and also performs computation on signals derived from the brain activity of the subject 6 , as will be described below. The computer 2 also holds the cognitive task which can be presented to the subject 6 on the screen 1 and/or through the loudspeaker 11 .
[0035] The subject 6 to be tested is fitted with a helmet 7 which includes a plurality of electrodes for obtaining brain electrical activity from various sites on the scalp of the subject 6 . The helmet includes a visor 8 which includes half silvered mirrors 17 and 18 and LED arrays 19 and 21 , as shown in FIG. 2 . The half silvered mirrors are arranged to direct light from the LED arrays 19 and 21 towards the eyes of the subject. The LED arrays 19 and 21 are controlled so that the light intensity therefrom varies sinusoidally under the control of control circuitry 5 . The control circuitry 5 includes a waveform generator for generating the sinusoidal signal. The circuitry 5 also includes amplifiers, filters, analogue to digital converters and a USB interface for coupling the various electrode signals into the computer 2 .
[0036] The system also includes a microphone 9 for recording voice signals from the subject 6 . The microphone 9 is coupled to the computer 2 via a microphone interface circuit 10 . The system also includes a switch 4 which can be manually operated by the subject as a part of the response to the cognitive task. The switch 4 is coupled to the computer 2 via a switch interface circuit 3 .
[0037] The computer 2 includes software which calculates SSVEP amplitude phase and/or coherence from each of the electrodes in the helmet 7 .
[0038] Details of the hardware and software required for generating SSVEP are well known and need not be described in detail. In this respect reference is made to the aforementioned United States patent specifications which disclose details of the hardware and techniques for computation of SSVEP. Briefly, the subject 6 views the video screen 1 through the visor 8 which delivers a continuous background flicker to the peripheral vision. The frequency of the background flicker is typically 13 Hz but may be selected to be between 3 Hz and 50 Hz. Brain electrical activity will be recorded using specialised electronic hardware that filters and amplifies the signal, digitises it in the circuitry 5 where it is then transferred to the computer 2 for storage and analysis. SSPT is used to ascertain regional brain activity at the scalp sites using SSPT analysis software.
[0039] The cognitive tasks are presented on the video screen 1 and/or via the loudspeaker 11 . The subject 6 is required to make a response that may comprise a button push on the switch 4 and/or a verbal response which is detected by the microphone 9 . The topographic distribution of the SSVEP amplitude, SSVEP phase and SSVEP coherence during the performance of the cognitive tasks can be correlated with the aptitude and thinking style of the subject. The microphone 9 generates audio signals which are amplified, filtered and digitised via the interface 10 and stored as sound files on the computer 2 . This enables the timing of the verbal responses to be determined within an accuracy of say 10 microseconds. Alternatively, the subject may respond to the cognitive task via a motor response such as a button push via the switch 4 . In all cases, the precise timing of all events presented to the subject 6 are preferably determined with an accuracy of no less than 10 microseconds.
[0040] As mentioned above, the visor 8 includes LED arrays 19 and 21 . In one embodiment, the light therefrom is varied sinusoidally. An alternative approach utilises pulse width modulation where the light emitting sources are driven by 1-10 Khz pulses where the pulse duration is proportional to the brightness of the sight emitting sources. In this embodiment, the control circuitry 5 receives a digital input stream from the computer 2 and outputs pulse width modulated pulses at a frequency of 1-10 Khz. The time of each positive going zero-crossing from the sinusoidal stimulus waveform is determined to an accuracy of 10 microsecond and stored in the memory of the computer 2 .
[0041] Brain electrical activity is recorded using multiple electrodes in helmet 7 or another commercially available multi-electrode system such as Electro-cap (ECI Inc., Eaton, Ohio USA). The number of electrodes is normally not less than 16 and normally not more than 256, and is typically 64.
[0042] Brain activity at each of the electrodes is conducted to the control circuitry 5 . The circuitry 5 includes multistage fixed gain amplification, band pass filtering and sample-and-hold circuitry for each channel associated with an electrode of the helmet. Amplified/filtered brain activity is digitised to 16 bit accuracy at a rate not less than 300 Hz and transferred to the computer 2 for storage on hard disk. The timing of each brain electrical sample together with the time of presentation of different components of the cognitive task are also registered and stored to an accuracy of 10 microseconds.
[0000] SSVEP Amplitude, Phase and Coherence
[0043] The digitised brain electrical activity (EEG) together with timing of the stimulus zero crossings enables calculation of the SSVEP from the recorded EEG or from EEG data that has been pre-processed using Independent Components Analysis to remove artefacts and increase the signal to noise ratio. [Bell A. J. and Sejnowski T. J. 1995 . An Information Maximisation Approach to Blind Separation and Blind Deconvolution , Neural Computation, 7, 6, 1129-1159; T-P. Jung, S. Makeig, M. Westerfield, J. Townsend, E. Courchesne and T. J. Sejnowskik, Independent Component Analysis of Single - Trial Event - Related Potential Human Brain Mapping, 14(3):168-85, 2001.]
[0044] Calculation of SSVEP amplitude and phase for each stimulus cycle can be accomplished using Fourier techniques using equations 1.0 and 1.1 below:
a n = 1 S Δ τ ∑ i = 0 S - 1 f ( n T + ⅈ Δ τ ) cos ( 2 π T ( n T + ⅈ Δ τ ) )
b n = 1 S Δ τ ∑ i = 0 S - 1 f ( n T + ⅈ Δ τ ) sin ( 2 π T ( n T + ⅈ Δ τ ) ) Equation 1.0
[0045] Where a n and b n are the cosine and sine Fourier coefficients respectively. n represents the nth stimulus cycle, S is the number of samples per stimulus cycle (16), Δτ is the time interval between samples, T is the period of one cycle and f(nT+iΔτ) is the EEG signal (raw or pre-processed using ICA).
SSVEP amplitude = ( a n 2 + b n 2 ) SSVEP phase = a tan ( b n a n ) Equation 1.1
[0046] Amplitude and phase components can be calculated using either single cycle Fourier coefficients or coefficients that have been calculated by integrating across multiple cycles.
[0047] Two types of coherence functions are calculated from the SSVEP sine and cosine Fourier coefficients while subjects undertake the cognitive task. One will be termed the SSVEP Coherence (“SSVEPC”) and the other, Event Related SSVEP Coherence (“ER-SSVEPC”).
[0000] SSVEPC
[0048] The SSVEP sine and cosine coefficients can be expressed as complex numbers
C n =(a n ,b n )
where a n and b n have been previously defined.
[0049] The nomenclature is generalised to take into account multiple tasks and multiple electrodes.
C g,e,n =(a g,e,n ,b g,e,n )
where
[0050] g=the task number
[0051] e=the electrode
[0052] n=the point in time
The following functions are defined:
γ g , e1 , e2 = H g , e1 , e2 T g , e1 , e2
H g , e1 , e2 = ∑ n = 1 n = T C g , e1 , n · C g , e2 , n * Equation 1.2
Where C* is the complex conjugate of C and
T g , e1 , e2 = ( ∑ n = 1 T C g , e1 , n · C g , e1 , n * ) ( ∑ n = 1 T C g , e2 , n · C g , e2 , n * ) Equation 1.3
The SSVEPC is then given by
γ 2 g,e1,e2 =|H g,e1,e2 | 2 /T 2 g,e1,e2 Equation 1.4
And the phase of the SSVEPC is given by ER-SSVEPC
ϕ g , e1 , e2 = Tan - 1 ( Im ( H g , e1 , e2 ) Re ( H g , e1 , e2 ) ) Equation 1.5
[0053] In this case, the coherence across trials in a particular task can be calculated. This yields coherence as a function of time. The nomenclature can be generalised to take into account multiple tasks and multiple electrodes.
C g,d,e,n =(a g,d,e,n ,b g,d,e,n )
where
[0054] g=the task number
[0055] d=the trial within a particular task, eg a specific response
[0056] e=the electrode
[0057] n=the point in time
The following functions are defined:
γ g , e1 , e2 , n = H g , e1 , e2 , n T g , e1 , e2 , n Equation 1.6 H g , e1 , e2 , n = ∑ d = 1 d = D C g , e1 , d , n · C g , e2 , d , n * and T g , e1 , e2 , n = ( ∑ d = 1 D C g , e1 , d , n · C g , e1 , d , n * ) ( ∑ d = 1 D C g , e2 , d , n · C g , e2 , d , n * ) Equation 1.7
The SSVEPC is then given by
γ 2 g,e1,e2,n =|H g,e1,e2,n | 2 /T 2 g,e1,e2,n Equation 1.8
And the phase of the SSVEPC is given by
ϕ g , e1 , e2 , n = Tan - 1 ( Im ( H g , e1 , e2 , n ) Re ( H g , e1 , e2 , n ) ) Equation 1.9
[0058] The above equations apply to scalp recorded data as well as brain electrical activity inferred at the cortical surface adjacent to the skull and deeper such as the anterior cingulate cortex. Activity in deeper regions of the brain such as the anterior cingulate or ventro-medial cortex can be determined using a number of available inverse mapping techniques such as BESA (Scherg M, Ebersole J S., Brain Source Imaging of Focal and Multifocal Epileptiform EEG Activity. Neurophysiol Clin. 1994 January; 24(1):51-60); LORETA (Pascual-Marqui RD, Esslen M, Kochi K, Lehmann D. Functional Imaging with Low - Resolution Brain Electromagnetic Tomography ( LORETA ): A Review . Methods Find Exp Clin Pharmacol. 2002; 24 Suppl C:91-5); or EMSE Information (Source Signal Imaging Inc. 2323 Broadway, Suite 102, San Diego, Calif. 92102).
[0059] While the subject 6 is performing the cognitive and emotional tasks, the visual flicker is switched on in the visor 8 and brain electrical activity is recorded continuously on the computer 2 .
[0060] At the end of the tests, the SSVEP responses associated with the various tasks can be calculated and separately averaged. For specific tasks, the SSVEP amplitude, phase and coherence can be compared with a database of results for groups of subjects with high aptitude and specific thinking styles. The comparison will identify the individuals specific thinking style and aptitude. For example, individuals with an aptitude for computer software development may demonstrate increased SSVEP phase lag at prefrontal sites and reduced left frontal SSVEP coherence while performing Raven's Progressive Matrices (a task used in IQ tests). By contrast, an individual suited as an aircraft pilot may demonstrate reduced left temporal SSVEP coherence when performing the mental rotation task. For security purposes, the database can be situated on a remote computer (not shown) accessed via the internet through a modem 12 .
EXAMPLE 1
[0061] The system illustrated in FIGS. 1 to 3 was used for testing subjects using an analytical test known as the Hidden Figures Test. Data from the electrode sites was analysed using the SSPT technique based on computer algorithms listed in Equation 1.1 and the SSVEP phase distribution was displayed graphically.
[0062] FIG. 4 illustrates the SSVEP phase from a subject having high analytical aptitude. In this Figure, the lighter areas represent SSVEP phase advance or regions of increased brain processing speed. In this diagram, the darker shades represent SSVEP phase lag or regions of reduced brain processing speed. The light area 50 delineated in broken lines demonstrates and area of greater activation. This area is situated in the posterior left hemisphere in the region of the temporal and parietel cortex. This indicates that the subject has a high analytical aptitude.
[0063] FIG. 5 graphically represents the SSVEP phase distribution for a subject carrying out the same test. It will be noted that there are no light areas in the distribution and this distribution is interpreted as demonstrating that the subject has low analytical aptitude.
EXAMPLE 2
[0064] The same equipment was used as in Example 1 above but the subjects were made to perform the Gestalt Completion Test. The Gestalt Completion Test places demands on holistic thinking. Electrical activity from the electrode sites was analysed using the SSPT technique based on computer algorithms listed in Equation 1.1 and the results displayed graphically.
[0065] FIG. 6 diagrammatically shows SSVEP phase distribution. The results include a light area 52 bounded by broken lines. This light area demonstrates increased activity in the right temporal and right frontal areas which is consistent with the importance of right hemisphere activity in holistic recognition. This is interpreted as indicating that the subject has high holistic thinking ability.
[0066] FIG. 7 in contrast shows the results of a subject performing the same test for a subject having low holistic thinking abilities. The SSVEP phase distribution shows reduced left temporal activity and enhanced left parietal, left posterior activity as indicated by the light area 54 bounded by broken lines.
EXAMPLE 3
[0067] The system shown in FIGS. 1 to 3 was used to test subjects carrying out a computerised version of Raven's Progressive Matrices. Electrical activity was again processed using the SSPT technique based on computer algorithms listed in Equation 1.8. The results are displayed graphically in FIGS. 8 and 9 .
[0068] The graph of FIG. 8 shows event related SSVEP coherence between activity recording sites 56 . The display includes a plurality of lines 58 between frontal sites. This result was produced from statistically significant differences in event related SSVEP coherence recorded from participants having high verbal IQ scores.
[0069] FIG. 9 graphically illustrates statistically significant differences in event related SSVEP coherence recorded from participants having high conceptual and visualisation skills (performance IQ). The results graphically shown in FIG. 9 include lines 60 demonstrating increased event related SSVEP coherence between right parieto-temporal regions and other scalp sites. The activity was measured whilst the subjects were preparing to make decisions while undertaking a computerised version of Raven's Progressive Matrices.
[0070] With the techniques of the invention, by examining the scalp distribution of the SSVEP phase and amplitude and SSVEP event related coherence during a range of thinking tasks and by comparing these distributions with a database of known SSVEP amplitude, phase and coherence patterns, it is possible to infer the aptitude of a specific participant to various tasks.
[0071] Many modifications will be apparent to those skilled in the art without departing from the spirit and scope of the invention. | A method of assessing the cognitive aptitude of a subject to a predetermined task, the method including the steps of: (i) presenting to the subject a group of cognitive tasks; (ii) detecting brain response signals from the subject during presentation of the group of cognitive tasks; (iii) calculating SSVEP amplitude, phase and/or coherence responses from the brain response signals; and (iv) comparing the SSVEP responses to known SSVEP responses obtained from individuals with high and/or low aptitudes to the predetermined task in order to assess the subject's aptitude for the predetermined task. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority, under 35 U.S.C. § 119, of U.S. Provisional Patent Application No. 60/851,035 filed Oct. 11, 2006, the entire disclosure of which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a turbulence minimizing connector for allowing multiple streams of liquid to enter the connector, flow together therein, and exit the connector with minimal mixing.
[0004] 2. Description of the Prior Art
[0005] Heretofore, multiple fluid-carrying lumens (also referred to as extensions, catheters or multi-lumen catheters) have been proposed for mixing components therein prior to delivery of the mixture to a patient, i.e., a human body.
[0006] FIG. 1 depicts an intravenous extension system 10 described in U.S. Pat. No. 6,780,167 issued to the inventor of the instant application on Aug. 24, 2004 (the “'167 Patent” or “'167”). The '167 Patent includes a multi-lumen intravenous extension 12 having a connector 14 at the proximal end 16 thereof. Connected to the proximal end 16 of the extension 12 is a main infusion conduit or tubing 18 . The tubing 18 is connected to an upstream connector 20 that, in turn, is fluidically connected to tubing 22 extending from a fluid source 24 (e.g., a bag of saline solution). Also connected to the connector 14 are first and second tubes 26 , 27 , which are connected to first and second fluid sources 28 , 29 , respectively (e.g., syringes). Each of the fluid sources 28 , 29 can contain a selected drug, medication, or liquid in a predetermined amount that is to be infused into a body 28 .
[0007] At a distal end 30 of the extension 12 is a coupling connector 32 that includes a mixing or “common” chamber 33 illustrated in FIGS. 2 to 4 . Distal connectors existing prior to the '167 Patent were realized by an industry standard connector, referred to as a luer connector 32 . The '167 Patent supplied the connector 32 to provide a fluidic interface between the extension 16 and an infusion needle or intravenous catheter 34 . The outlet of the connector 32 is connected to the needle/catheter 34 , which is inserted into the body 38 and is, typically, held therein by a wing tape or bandage 40 .
[0008] FIGS. 2 to 4 illustrate that the mixing chamber 33 in the connector 32 has an outer cylindrical wall or tubular portion 42 that is received over the distal end 30 of the multi-lumen intravenous extension tubing 12 .
[0009] FIG. 3 , in particular, shows that the tubular portion 42 of the connector 32 has a larger diameter to fit over the distal end 30 of the extension tubing 12 . The exit portion 44 at the distal end of the connector 32 fits over or is connected to a proximal end 46 of the catheter 34 or needle. As such, the connector 32 provides the mixing chamber 33 for liquids, including a main liquid such as a saline solution and one or more medications or other liquids provided through the tubes 26 , 27 . This mixing chamber 33 is smooth-bored throughout. The diameter abruptly changes between the tubular portion 42 and the exit portion 44 at an interface 35 (indicated by dashed lines in FIG. 3 ).
[0010] With multi-lumen medical tubing (e.g., the multi-lumen intravenous extension 12 of the '167 Patent), fluids exit the connector 14 (or the extension 16 ) along with the fluid passing through the main lumen 52 . It would be beneficial to have these fluids not intermix and remain separated for as long as possible, prior to vascular entry. If such intermixing is prevented, then the intended additionally added medication is administered with a minimal degree of dilution and/or interaction with other medications until it enters the vessel intended to receive such medications. As such, unwanted boluses of medication and interactions are avoided. It is known that medications, especially, injected anesthesia, should be administered with constancy and control, and not with randomly sized or chaotic boluses because differential administration of such medicines can have serious, if not deadly, consequences.
[0011] Based upon the above considerations, it would be beneficial to provide a device that minimizes turbulence of the co-delivered fluids.
SUMMARY OF THE INVENTION
[0012] It is accordingly an object of the invention to provide a turbulence minimizing device for multi-lumen fluid delivery systems and a method for minimizing turbulence in such systems that overcome the hereinafore mentioned disadvantages of the heretofore-known devices and methods of this general type and that are configured to integrate with existing standardized infusion systems to minimize chaotic admixing of fluids that are to be transfused concomitantly.
[0013] The present invention is an improvement upon prior art connectors for infusion systems. In one exemplary embodiment, the present invention improves upon the multi-lumen intravenous extension described in the '167 Patent. This extension is used for transmitting liquids in a body and for infusing the fluids individually undiluted and unprecipitated as close as possible to the point where they are injected into the blood stream, for example. While the turbulence minimizing device of the present invention can be used with the multi-lumen extension of the '167 Patent, it is not limited to use with this device. The present invention, however, is particularly useful when combined with the '167 device and, therefore, portions of the '167 disclosure are included herein. For clarity, the '167 disclosure is incorporated by reference herein in its entirety. Inclusion of the '167 catheter herein should not be taken as applicable only to this exemplary embodiment of a medical fluid infusing device. Those having ordinary skill in the art of such devices will appreciate the improvement that the present invention may provide to other prior art devices that deliver medicinal fluids.
[0014] The connector of the present invention is positioned between an intra-vascular or intravenous access site and an infusion system typically including a steady supply of saline and syringes or syringe connectors or medicinal fluid pumps predetermined for injecting amounts of drugs, medications, or other liquids. The connector of the present invention allows for organized and controllable delivery and administration of a wide variety of medications and pharmaceutical agents with a minimal amount of medication intermixing prior to entry into a body.
[0015] The mixing connector forms the male half of a luer lock connector. The mixing connector has a size equal to the medical industry standard for insertion into a vascular access device. The term “standard,” as it is used herein, relates to the industry standard corresponding to ISO 594-1:1986.
[0016] When used with the multi-lumen intravenous extension of the '167 Patent, the connector of the present invention replaces the connector 32 , which is positioned between the intra-vascular or intravenous access site and the multi-lumen intravenous extension 12 .
[0017] The Coanda Effect, also known as “boundary layer attachment”, is the tendency of a stream of fluid to stay attached to a convex surface, rather than follow a straight line in its original direction even if the surface's direction of curvature is directed away from the axis of the stream of fluid. The mixing connector of the invention utilizes the Coanda Effect when directing the stream of liquids exiting a multi-lumen interface (such as the distal end 30 ). In particular, the fluids exiting secondary lumens that are disposed adjacent the inner wall of the mixing connector will travel along that surface and remain substantially coherent along the convex surface with little or no mixing with the fluid exiting the primary lumen or other fluid(s) exiting secondary lumen(s). This laminar flow is maintained most or all of the way through the mixing connector. It can be appreciated that this laminar flow is enhanced when guiding fins project inwardly from the surface over which the fluids travel. The mixing connector contains features to take advantage of the Coanda Effect. In this way, different medications can be kept separate, independent of carrier flow rate and boluses. Because differing drugs are sometimes incompatible, e.g., due to differing drug solubilities that can cause undesirable precipitant or can cause drug inactivation, it is desirable to keep the drugs separate before introduction into a patient. Such separation is important to drugs like Dilantin/phenytoin, which precipitates when piggybacked into any dextrose-containing solution. The phenomenon relates, often, to the solute and the solvent (pH, concentration, temperature in solution, protein binding, etc.). Amphotericin B (Fungizone) similarly precipitates with solutions containing sodium chloride and Dopamine (Intropin, Revimine) is inactivated in solutions with a high pH and must not be piggybacked into any solution containing sodium bicarbonate. The mixing connector of the invention reduces the possibility of drug incompatibility to a point where mixture and common exposure is substantially eliminated and the possibility of drug precipitation is minimized.
[0018] The mixing connector can be used in a number of medical applications, such as with delivery of anesthesia during operations. The mixing connector allows for infusion of anesthetic agents, vaso-active agents, antibiotics, and antiarrhymics, whether in adults or children (both neonatal and pediatric) and can be used with a patient controlled analgesia (PCA) pump. Also, the mixing connector can be used in an intensive care unit for vaso-active medications, antiarrhymics, potassium, antibiotics, insulin, etc.
[0019] The '167 Patent describes an over-pressure danger that exists at a vascular entry point when fluid is being introduced into a patient. As can be understood from the description of the mixing connector herein, replacement of the '167 connector 32 with the mixing connector does not adversely impact the over-pressure protection that exists when the mixing connector is utilized with the '167 system 10 and, therefore, is particularly suited for improving that system 10 .
[0020] Because turbulence of the intermixed fluids at the mixing connector is minimized, all of the advantages provided by the '167 system remain with the connector of the present invention. More specifically, delivering the pharmaceutical agents with less change to the normal fluid dynamics improves patient safety as compared to prior art infusion systems. Additionally, the infusion of liquid agents through the satellite lumens remains independent upon carrier fluid rates for delivery. Because the liquids from the satellite lumens are delivered with greater control in volume, time of onset of the action of the agents delivered is decreased and the concentration of those agents remains virtually constant. Less intermixing of the fluids also means that delivery of the agents infused through the satellite lumens will not be altered by the carrier fluid rate. Like the '167 system, the mixing connector decreases priming volume even more by further reducing the “tubing dead space.” The mixing connector also allows and enhances independent infusion of multiple agents and reduces carrier fluid rate requirements.
[0021] Other features that are considered as characteristic for the invention are set forth in the appended claims.
[0022] Although the invention is illustrated and described herein as embodied in a turbulence minimizing device for multi-lumen fluid infusing devices and a method for minimizing turbulence in such systems, it is, nevertheless, not intended to be limited to the details shown because various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0023] The construction and method of operation of the invention, however, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following, the invention will be described in more detail by exemplary embodiments and the corresponding figures. By schematic illustrations that are not true to scale, the figures show different exemplary embodiments of the invention. The same or equally functioning parts are characterized with the same reference numerals. Shown are sections in schematic cross-section.
[0025] FIG. 1 is a fragmentary, perspective and partially cut-away view of a prior art multi-lumen intravenous extension coupled at its input to a bag of saline solution and to two syringes and coupled at its output end to an infusion catheter inserted into a body;
[0026] FIG. 2 is a cross-sectional view of a mixing chamber connector of FIG. 1 along section line 2 - 2 ;
[0027] FIG. 3 is a cross-sectional view of the mixing chamber connector of FIG. 2 along section line 3 - 3 ;
[0028] FIG. 4 is a cross-sectional view of a mixing chamber connector according to the present invention viewed along section line 4 - 4 with a fluid supply input having a main lumen and two satellite lumens;
[0029] FIG. 5 is a fragmentary, cross-sectional view of a connector according to the invention coupled to a downstream female luer connector;
[0030] FIG. 6 is a cross-sectional view of a first alternative exemplary embodiment of a portion of the connector of FIG. 5 with two satellite lumens and a primary lumen with fins separating the openings of the two satellite lumens from one another;
[0031] FIG. 7 is a cross-sectional view of a second alternative exemplary embodiment of a portion of the connector of FIG. 5 with two satellite lumens and a primary lumen with fins separating the openings of the two satellite lumens from one another;
[0032] FIG. 8 is a cross-sectional view of a third alternative exemplary embodiment of a portion of the connector of FIG. 5 with three satellite lumens and a primary lumen with fins separating the openings of the three satellite lumens from one another;
[0033] FIG. 9 is a cross-sectional view of a fourth alternative exemplary embodiment of a portion of the connector of FIG. 5 with four satellite lumens and a primary lumen with fins separating the openings of the four satellite lumens from one another;
[0034] FIG. 10 is a cross-sectional view of a fifth alternative exemplary embodiment of a portion of the connector of FIG. 5 with four satellite lumens and a primary lumen with fins separating the openings of the four satellite lumens from one another;
[0035] FIG. 11 is a cross-sectional view of a sixth alternative exemplary embodiment of a portion of the connector of FIG. 5 with six satellite lumens and a primary lumen with fins separating the openings of the six satellite lumens from one another;
[0036] FIG. 12 is a cross-sectional view of a seventh alternative exemplary embodiment of a portion of the connector of FIG. 5 with two satellite lumens and a primary lumen with fins bisecting the openings of the satellite lumens;
[0037] FIG. 13 is a cross-sectional view of a eighth alternative exemplary embodiment of a portion of the connector of FIG. 5 with six satellite lumens and a primary lumen with fins bisecting the openings of the satellite lumens;
[0038] FIG. 14 is a fragmentary, cross-sectional view of an alternative embodiment of the connector according to the invention along section line 14 - 14 in FIG. 15 and coupled to a downstream female luer connector;
[0039] FIG. 15 is a cross-sectional view of the connector of FIG. 14 along section line 15 - 15 in FIG. 14 ;
[0040] FIG. 16 is a side elevational view of the connector of FIG. 14 ;
[0041] FIG. 17 is a fragmentary, cross-sectional view of another alternative embodiment of the connector according to the invention coupled to a downstream female luer connector;
[0042] FIG. 18 is a fragmentary, cross-sectional view of still another alternative embodiment of the connector according to the invention coupled to a downstream female luer connector; and
[0043] FIG. 19 is a fragmentary, enlarged cross-sectional view of a portion of the connector of FIG. 18 with a bi-curved flow chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] As shown in FIG. 3 , the different fluids entering the chamber 33 of the connector 32 from input lumen 18 , 26 , 27 travel towards the catheter 34 and contact the inner distal face 36 of the chamber 33 . These fluids, therefore, are forced to interface together on their way into and through the entry orifice 39 of the catheter 34 . This uncontrolled mixing is turbulent and transitory and cannot assure a constant and controlled delivery of each of the differing fluids being delivered simultaneously. This is especially true where the fluids have similar viscosities. In some circumstances, gravity could have a pronounced affect on the denser fluids being concomitantly delivered, especially as the diameter of the chamber 33 increases.
[0045] Referring now to the drawings in greater detail, there is illustrated in FIG. 5 , a fluid intermixing connector 100 that minimizes or substantially avoids unnecessary or undesired mixing of any combination of the secondary lumen fluids and the primary lumen fluid before being co-delivered, for example, through the intravenous needle/catheter 34 to a patient.
[0046] The connector 100 has an outer diameter that can be of a standard size to fit multi-lumen supply lines such as the three-lumen configuration 18 , 26 , 27 illustrated in FIG. 1 . One exemplary size for the outer diameter of the connector 100 has the same outer shape of connector 14 . Of course, as long as the fluid supplying lumens can be inserted into the inflow side of the connector 100 , the outer diameter of the connector 100 can be any desired size.
[0047] The body of the connector 100 defines an interior chamber 110 having two parts, a proximal connection portion 120 and a distal intermixing portion 130 .
[0048] The proximal connection portion 120 has a substantially cylindrical interior cavity 122 for receiving therein one or more of the fluid supplying lumens, for example, the primary and secondary lumens 18 , 26 , 27 illustrated in FIG. 1 or the catheters illustrated in U.S. Pat. Nos. 4,968,308 to Dake et al. or 5,833,652 to Preissman et al. If the distal ends of the fluid supplying lumens do not, together, have a cylindrical outer shape, then the interior cavity 122 can be of any shape for receiving these ends. The fluid supplying lumens can be separately inserted into the proximal connection portion 120 or can be bundled into an integral distal end 140 shown, for example, in FIG. 5 and having an outer shape substantially corresponding to the interior shape of the proximal interior cavity 122 . In either configuration, these lumens are fluid-tightly fixed to the proximal connection portion 120 within the proximal cavity 122 so that all fluid flow therefrom travels from the input side 102 to the output side 104 of the connector 100 .
[0049] The interface between the proximal cavity 122 and the distal intermixing portion 130 can include a limiting shelf 124 having an internally projecting radial extent less than or equal to a distance D between the outer circumference of the distal end of the multi-lumen tube assembly and the radially outer-most edge of an opening of any of the lumens within the distal end 140 . For example, if there is a distal end 140 with three lumens aligned along a single diameter as shown in FIG. 5 (secondary 144 , primary 142 , secondary 144 ), then the shelf 124 can be as thick as the distance D between the outer-most edge of the secondary lumen 142 and the outer edge of the distal end 140 . In such a configuration, the outer-mist lumen 144 would not be obstructed in any way by either the shelf 122 or the internal cavity 132 of the distal intermixing portion 130 .
[0050] The distal intermixing portion 130 is the downstream portion of the chamber 110 . This region receives the fluids that exit the fluid supplying lumens. In one exemplary embodiment illustrated in FIG. 5 , the distal intermixing portion 130 is a conical- or funnel-shaped chamber that directs fluid flow from the primary and secondary lumen(s) to the single output bore 106 of the connector 100 . In this exemplary embodiment, the distal intermixing portion 130 has a longitudinal length greater than a longitudinal length of the proximal intermixing portion 120 . Alternatively, as shown in FIG. 13 , the longitudinal length of the distal intermixing portion 130 can be approximately equal to the longitudinal length of the proximal intermixing portion 120 or it can be even shorter than the proximal portion 120 , as is illustrated in FIGS. 17 and 18 . In cross-section, the cavity 132 can be paraboloid, spherical, or polygonal in its funnel shape. In the latter configuration, the polygonal funnel can have a number of sides equal to, less than, or greater than the number of lumens supplying fluid into the cavity 132 . FIG. 17 , for example, shows a paraboloidal-shaped funnel.
[0051] Consistent with the Coanda Effect, the fluids exiting secondary lumens that are disposed adjacent the inner wall 132 of the funnel will travel along that surface and remain substantially coherent along the inwardly curved/slanted wall 132 with little or no mixing with the primary lumen fluid (or other secondary fluids). This laminar flow is maintained due to the streamlining (described as the Coanda Effect above) that is created by the wall 132 of the proximal intermixing portion 130 from the lumen exit to the bore 106 .
[0052] It can be appreciated that laminar flow can be enhanced if guiding fins 134 project inwardly from the inner wall 132 . Such fins 134 are illustrated, first, within the distal cavity 132 of the connector 100 illustrated in FIG. 5 . By extending radially into the funnel shaped chamber, these fins 134 partition the flows. If the number of fins 134 is equal to the number of fluid supplying lumens, then the distal cavity 132 can be divided into portions that enhance the laminar flow of each fluid being supplied by the lumens. FIG. 6 , for example, shows such a configuration. In this exemplary embodiment, the fins have a trapezoidal cross-sectional shape. Of course, any cross-sectional shape can be used, such as the rectangular shape of the fins 134 in FIGS. 10 and 11 , the curved I-beam shape of the fins 134 in FIG. 7 , or the complex-curved flower-like shape the fins 134 create in FIG. 13 .
[0053] In the exemplary embodiment of FIG. 5 , the fins 134 have a height that is approximately equal to the radial distance between the inner surface of the cavity 132 and the inner-most edge of the secondary lumen 54 , 56 . These fins 134 can be any height and can even touch at a center point between the three lumens 52 , 54 , 56 as shown in FIG. 6 , for example. The touching/connection of the fins 134 at the center point can occur either only at the distal end of the fins 134 or can extend most of the way to the exit 135 of the distal cavity 132 so that, when viewed from a downstream end of the connector 100 , the bore 106 has a pie-chart cross-section as illustrated in FIG. 6 .
[0054] The fins 134 have differing configurations depending upon the spatial orientation of the primary and secondary lumens. FIGS. 6 to 13 illustrate various exemplary configurations of the fins 134 within the distal cavity 132 numbering fins from 2 to 6. Of course, manufacturing limitations and needs of the user will determine whether or not a given number of fins 134 is practical for the desired use.
[0055] The interior edges of the fins 134 can be sharpened with a beveled edge 136 like a knife to improve segregation and decrease turbulence thereat. Such an embodiment is shown, for example, in FIGS. 5 and 19 .
[0056] Each of the fins 134 in FIGS. 6 to 11 and 13 are illustrated as being disposed to a side of a secondary lumen. If desired, one or more fins 134 can bisect one or more of the secondary lumens. FIG. 12 illustrates a bisection of two secondary lumens 54 , 56 . Such a configuration may be useful where the viscosity(ies) of one or more of the fluids to be delivered through the connector 100 make the fluids difficult to intermix. If, for example, the first fluid of the primary lumen 52 is significantly less viscous than the second and third fluids exiting from the secondary lumens 54 , 56 , it may be desirable to “pre-mix” portions of the second and third fluids with the first fluid and, thereby, “increase” the viscosity of the first fluid. In this way, when the mixtures at the distal end of the fins 134 approach the exit 135 of the distal cavity, the less viscous fluid does not “beat out” the other fluids in the “race” through the exit and, thereby, prevent the more viscous fluid(s) from exiting the connector 100 .
[0057] The shape of the sides of the fins 134 can take many forms, triangular, rectangular, polygonal, blade- or knife-shaped, and/or a combination of one or more shapes. FIG. 5 , for example, shows a triangular blade-shaped side in the lower of the two fins 134 and a curvilinear blade-shaped side in the upper of the two fins 134 . One particularly well-performing fin configuration is shown in FIG. 13 .
[0058] In the fins 134 extend all the way to the distal surface 146 of the distal end 140 of the fluid supplying lumens, then the fins 134 can abut the distal surface 146 (as shown at the lower of the two fins 134 of FIG. 5 ) and entirely replace the limiting shelf 124 . In such a configuration, the proximal surfaces of the fins 134 will form the limiting shelf 124 that prevents the distal end 140 from entering the cavity 132 of the distal portion 130 . Of course, if the fins 134 extend any part of the way towards the center of the cavity 132 at the interface 126 of the proximal 122 and distal 132 cavities, the proximal surface of the fins 134 lying in a plane transverse to the longitudinal extent of the connector 100 will prevent further movement of the distal end 140 into the cavity 132 .
[0059] FIGS. 14 to 16 illustrate another alternative embodiment of a connector 200 of the present invention. FIG. 14 is a cross-section through the section line illustrated in FIG. 15 . The connector 200 has an interior chamber 210 with two parts, a proximal connection portion 220 and a distal intermixing portion 230 . The connector 200 has an input side 202 for receiving the distal end 140 in the proximal cavity 222 and an output side 204 for delivering the intermixed fluids out from the exit bore 206 . The configuration of FIGS. 14 to 16 has a distal cavity 232 with a smaller longitudinal extent than the cavity 132 of the connector 100 shown in FIG. 5 . The proximal portion 220 has a cylindrical proximal cavity 222 with a distal stopping shelf 224 that prevents distal insertion of the distal end 140 into the distal cavity 232 . Of course, the fins 234 can provide the distal stopping shelf on their upstream side.
[0060] FIG. 17 illustrates a further alternative embodiment of a connector 300 of the present invention. The connector 300 has an interior chamber 310 having two parts, a proximal connection portion 320 and a distal intermixing portion 330 . The connector 300 has an input side 302 for receiving the distal end 140 in the proximal cavity 322 and an output side 304 for delivering the intermixed fluids out from the exit bore 306 . In this cross-section, the distal cavity 332 has a smaller longitudinal extent than the cavity 132 of the connector 100 shown in FIG. 5 . The distal cavity 332 does not have fins and is funnel shaped with a linear inwardly sloping wall 334 . The proximal portion 320 has a cylindrical proximal cavity 322 with a distal stopping shelf 324 that prevents distal insertion of the distal end 140 into the distal cavity 332 .
[0061] FIG. 18 is the connector 300 of FIG. 17 but with eight fins 334 spaced evenly about a non-curvilinear funnel-shaped cavity 332 . FIG. 19 is an enlarged portion of one of the fins 334 and illustrates a height of the fins 334 that is increasing from the proximal side of the distal cavity 332 towards the distal side thereof. This fin 334 also illustrates a distal cavity 332 that is paraboloidal concave with a convex exit to create a smooth transition at the exit of the cavity 332 .
[0062] The desired orientation of the multi-lumens with respect to the fins 134 , 234 , 334 , may require exact placement of the distal end 140 of the multiple lumens. Exact rotational orientation can be assured by providing at least one recess on the exterior surface of the distal end 140 of the multi-lumen plug that is to be inserted into the proximal cavity 132 , 232 , 332 of the connector 100 , 200 , 300 . If the proximal cavity 132 , 232 , 332 is provided with at least one protrusion extending radially inward into the center of the cavity 132 , 232 , 332 , then the distal end 140 of the lumens to be inserted therein will not occur unless the protrusion is aligned with the recess—much like a key and keyhole. Of course, this configuration can be reversed if desired. If only one recess and only one protrusion is provided according to such a configuration, then the distal end 140 cannot enter the proximal cavity 132 , 232 , 332 except in proper rotational alignment. An example of this single recess/protrusion assembly 400 is illustrated in the cross-section of FIG. 12 . When there exist more than one accepted rotational orientation of the distal end, such as the symmetric configurations of FIGS. 7, 8 , 9 , and 11 , it is possible to include more than one recess/protrusion. For example, the configuration of FIG. 7 can have two symmetrical recesses/protrusions, the configuration of FIG. 8 can have three symmetrical recesses/protrusions, the configuration of FIG. 9 can have four symmetrical recesses/protrusions, and the configuration of FIG. 11 can have six symmetrical recesses/protrusions.
[0063] The protrusion on the inside of the chamber 132 , 232 , 332 can be displayed to the user, if desired, in directions for use or can be permanently marked on the connector 100 , 200 , 300 .
[0064] There are many kinds of luer connector fittings that can be used with the connector 100 , 200 , 300 . Only a few exemplary embodiments are illustrated in the figures of the drawings and, therefore, the possible luer fittings should not be limited to that which is shown. The fittings typically include round male and female interlocking tubes, slightly tapered to hold together better with a simple pressure or twist fit, referred to in the art as a luer slip and a luer lock. In the latter configuration, an outer threading rim improves the secure, fluid-tight connection of the luer connector.
[0065] One advantage to each of the above-mentioned configurations over the '167 device is that the volume of the intermixing chamber 132 , 232 , 332 is smaller than the pill-shaped chamber 32 . Therefore, the amount of medicinal fluid necessary to fill the chamber 132 , 232 , 332 is reduced, thereby, decreasing the time for any injectate to exit the connector and enter the catheter 34 . Also the volume of priming/flushing fluids is reduced as well as the time taken to prime or flush.
[0066] The connector 100 of the present invention can be used in a number of medical applications. For example, it can be used in anesthesia during operations for infusion of anesthetic agents, vaso-active agents, antibiotics, and antiarrhymics, whether in adults or children (both neonatal and pediatric). The connector 100 , 200 , 300 also can be used with a PCA pump and can be used in an intensive care unit for vaso-active meds, antiarrhymics, potassium, antibiotics, insulin, etc.
[0067] The '167 Patent describes an over-pressure danger that exists at a vascular entry point when fluid is being introduced into a patient. As can be understood from the description of the connector 100 , 200 , 300 , replacement of the '167 connector 32 with the connector 100 , 200 , 300 does not adversely impact the over-pressure protection that exists when the connector 100 , 200 , 300 is utilized with the '167 system 10 and, therefore, is particularly suited for improving that system 10 .
[0068] Because turbulence of the intermixed fluids at the connector 100 , 200 , 300 is minimized, all of the advantages provided by the '167 system remain with the connector 100 , 200 , 300 . More specifically, delivering the pharmaceutical agents with fewer changes to the normal fluid dynamics improves patient safety as compared to prior art infusion systems. Additionally, the infusion of liquid agents through the satellite lumens remains independent of carrier fluid rates for delivery. Because the liquids from the satellite lumens are delivered with greater control in volume, the time of the onset of the action of the agents delivered is decreased and the concentration of those agents remains virtually constant. Less intermixing of the fluids also means that delivery of the agents infused through the satellite lumens will not be altered by the carrier fluid rate. Like the '167 system, the connector 100 , 200 , 300 of the present invention decreases priming volume even more by further reducing the “tubing dead space.” The connector 100 , 200 , 300 also allows and enhances independent infusion of multiple agents and reduces carrier fluid rate requirements.
[0069] From the foregoing description, it will be appreciated that the connector of the present invention provides a number of advantages, some of which have been described above and others of which are inherent in the invention. | A fluid turbulence minimizing device includes a connection portion defining a connection cavity shaped to receive a tertiary fluid-supply conduit including a primary fluid-supply lumen and two secondary fluid-supply lumens and an intermixing portion having a longitudinal flow axis and defining an intermixing cavity that has an input orifice fluidically communicating with the connection cavity and a given area, an exit orifice having an area less than the given area, an inner surface having an upstream side adjacent the connection portion, a downstream side at a distance from the connection portion, and a cross-sectional area decreasing from the input orifice to the exit orifice to convey fluid supplied from the conduit to the connection cavity through the intermixing cavity and out the exit orifice, and guide fins inwardly projecting from the inner surface of the intermixing portion toward the longitudinal flow axis and having a longitudinal extent aligned substantially parallel with the longitudinal flow axis. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND
[0003] The present invention relates generally to equipment for handing pipe in an oilfield environment. More particularly, the present invention relates to elevators used to engage and lift vertically oriented tubular members.
[0004] Many different types of tubular members are handled during drilling, completion, and workover of wells. Among the tubular members used in well construction and servicing are drill pipe, drill collars, casing and tubing. Many different specialized types of equipment are used in handling tubular members during various phases of the drilling, completion, and workover processes.
[0005] Elevators are often used when handling tubular members when the tubular members are in or being moved to a vertical, or close to vertical, orientation. Most elevators are configured to interface with a shoulder, or upset, on the outer surface of the tubular member. The engagement of the elevator with this shoulder allows the elevator to support the weight of the tubular member and prevents the tubular member from falling through the elevator.
[0006] Many elevators are equipped with swinging doors that open to allow the tubular member to be received in the elevator and are then secured in a closed position to retain the member. These doors are often characterized by hinges that support the swinging doors and lock assemblies that keep the doors closed. These doors and lock assemblies are often manually operated and have thus been a focus of efforts to improve the safety and operation of these devices.
[0007] There remains a need to develop methods and apparatus for pipe elevators that overcome some of the foregoing difficulties while providing more advantageous overall results.
SUMMARY OF THE PREFERRED EMBODIMENTS
[0008] The embodiments of the present invention are directed toward an elevator comprising a body having a longitudinal axis therethrough. The body is operable to at least partially surround and support a tubular member aligned with the longitudinal axis. The body also has a longitudinal opening that is sized so as to allow the tubular member to pass therethrough. A door is rotatable about the longitudinal axis of the body and has a closed position wherein the tubular member is retained within the body and an opened position wherein the tubular member can pass through the longitudinal opening.
[0009] Thus, the present invention comprises a combination of features and advantages that enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more detailed description of the preferred embodiment of the present invention, reference will now be made to the accompanying drawings, wherein:
[0011] FIG. 1 shows a top view of an elevator constructed in accordance with embodiments of the invention;
[0012] FIG. 2 shows a partial sectional view of the elevator of FIG. 1 ;
[0013] FIG. 3 shows a partial sectional view of an open elevator constructed in accordance with embodiments of the invention;
[0014] FIG. 4 shows a cross-section view of the locking pin of the elevator of FIG. 3 ;
[0015] FIG. 5 shows a partial sectional view of a closed elevator constructed in accordance with embodiments of the invention;
[0016] FIG. 6 shows a cross-section view of the locking pin of the elevator of FIG. 5 ;
[0017] FIG. 7 shows a tubular member being received by an elevator constructed in accordance with embodiments of the invention;
[0018] FIG. 8 shows a tubular member fully engaged by an elevator constructed in accordance with embodiments of the invention;
[0019] FIG. 9 shows a cross-sectional view of the engaged elevator of FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring now to FIGS. 1 and 2 , elevator assembly 1 0 comprises body 12 , bottom ring 14 , door 16 , top ring 18 , and locking pin 20 . FIG. 2 is a sectional view of elevator assembly 10 taken along section line A-A of FIG. 1 . Body 12 comprises lower shoulder 22 , upper shoulder 24 , bail pins 26 , handle 28 , and locking slot 30 . Bottom ring 14 and top ring are rotatably fixed relative to body 12 by pins 32 and 33 , respectively. Locking pin 20 is coupled to door 16 and is guided by locking slot 30 . Snap ring 32 engages body 12 and holds top ring 18 , door 16 , and bottom ring 14 within the body.
[0021] Body 12 has a substantially cylindrical shape having an opening 34 on one side. Bail pins 26 are arranged on opposite sides of body 12 for attaching to bails, or other lifting members. In certain embodiments, bail pins 26 may be replaced by lugs, lifting ears, or other means for connecting elevator 10 to a lifting appliance. Locking slot 30 extends through body 12 and includes counterbore 36 sized so as to interface with locking pin 20 .
[0022] FIGS. 3 and 5 show a cross-section of elevator assembly 10 , taken along section line B-B of FIG. 2 . FIG. 3 shows elevator assembly 10 is shown in an open position wherein door opening 38 is aligned with body opening 34 . In the open position, bushing 40 of locking pin 20 is retracted and rests against body 12 . Referring now to FIG. 4 , locking pin 20 comprises bushing 40 , rod 42 , bushing spring 44 , lock button 46 , and button spring 48 . Bushing 40 comprises shoulder 50 and counterbore 52 . Rod 42 comprises T-shaped front end 54 that engages door 16 and flanged back end 56 that slidably engages lock button 46 , such as with a dove-tail slot. Bushing spring 44 is disposed between shoulder 50 and back end 56 so as to bias bushing 40 toward front end 54 of rod 42 . In order to move bushing 40 toward back end 56 , lock button 46 must be centered so as to move past counterbore 52 . Lock button 46 is biased to an offset position by button spring 48 .
[0023] Door 16 is rotated to a closed position, as shown in FIG. 5 , by moving locking pin 20 through slot 30 until locking pin 20 engages counterbore 36 . The engaged locking pin is shown in FIG. 6 . In the closed position, door 16 completely closes body opening 34 and locking pin 20 is disposed at the end of slot 30 . Bushing 40 is urged into counterbore 36 by bushing spring 44 . As bushing 40 moves into counterbore 36 , lock button 46 enters bushing counterbore 52 and is urged to one side by button spring 48 .
[0024] From the locked position the only way to unlock and rotate door 16 is to follow the steps described below. First, lock button 46 us centered within bushing 40 . This allows bushing 40 to be pulled out of counterbore 36 . Once bushing 40 is out of counterbore 36 , door 16 can be rotated by moving locking pin 20 through slot 30 to the open position shown in FIG. 4 .
[0025] FIGS. 7-9 illustrate the engagement of a tubular member 100 with elevator assembly 10 . As shown in FIG. 7 , elevator assembly 10 is in the open position wherein door opening 38 is aligned with body opening 34 . Tubular member 100 is inserted into openings 34 , 38 such that elevator 10 is disposed close to tool joint 104 . Elevator 10 may be attached to tubular member 100 when the tubular member is vertical, horizontal, or at any angle in between. Once tubular member 100 is received in elevator 10 , locking pin 20 is moved through slot 30 such that door 16 rotates to capture the tubular member.
[0026] Once in the closed position, as shown in FIGS. 8 and 9 , angled surface of top ring 18 engages the tapered shoulder of tool joint 102 . Door 16 holds tubular member 100 in close engagement with top ring 18 and bottom ring 14 . Thus, tubular member 100 is securely fastened within elevator 10 and ready to be lifted up. Once the handling of tubular member 100 is completed, door 16 is rotated back to the open position of FIG. 7 and elevator 10 can be removed from the tubular member.
[0027] As can be seen in FIG. 8 , the relationship between top ring 18 , door 16 , and bottom ring 14 and tubular member 100 is critical to the performance of elevator 10 . As the diameter and type of tubular member changes, one or more of bottom ring 14 , door 16 , and top ring 18 may have to be changed so as to properly engage pipes with different diameters or tool joint shoulders. Many of the other components of elevator 10 , such as body 12 and locking pin 20 may be used for a wide range of pipe sizes without replacement. Thus, elevator 10 may be designed to allow for simple assembly and disassembly.
[0028] Referring back to FIGS. 2 and 3 , elevator 10 can be disassembled by first removing snap ring 32 , allowing top ring 18 to be removed from body. Door 16 can then be lifted up through body 12 . As door 16 is lifted locking pin 20 will slide out of the T-shaped slot in the door, thus allowing the locking pin to be removed from slot 30 . After door 16 is removed, bottom ring 14 can then be removed from body 12 .
[0029] In the above described embodiments, locking pin 20 is used to manually open and close elevator 10 . In other embodiments, the door could have gear teeth cut on its outside surface and the locking pin could be replace by pinion and hydraulic motor which would rotate the door. The hydraulically actuated elevator may find particular usefulness in allowing for remote control of the elevator and for larger elevator sizes where manual operation would be difficult.
[0030] While preferred embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. For example, elevators capable of handling a wide array of sizes and tubular members can be constructed in accordance with the embodiments discussed herein. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | An elevator comprising a body having a longitudinal axis therethrough. The body is operable to at least partially surround and support a tubular member aligned with the longitudinal axis. The body also has a longitudinal opening that is sized so as to allow the tubular member to pass therethrough. A door is rotatable about the longitudinal axis of the body and has a closed position wherein the tubular member is retained within the body and an opened position wherein the tubular member can pass through the longitudinal opening. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This patent application claims the benefit of Provisional U.S. Pat. Application Ser. No. 60/029,742 filed Nov. 8, 1996.
BACKGROUND OF THE INVENTION
This invention provides novel benzoylphenylurea insecticides and novel methods of control cockroaches, ants, fleas, and termites.
A broad class of benzoylphenylurea insecticides is disclosed in U.S. Pat. No. 3,748,356. Hexaflumuron, a commercially significant benzoylphenylurea, is disclosed in U.S. Pat. No. 4,468,405. Use of hexaflumuron in methods of controlling termites is disclosed in WO 93/24011. Use of hexaflumuron to control cockroaches is disclosed in WO 94/03066.
We have discovered that certain novel benzoylpheylureas have substantially greater activity against cockroaches, ants, fleas, and termites than would have been expected based on comparison with the closest prior art, i.e., hexaflumuron.
SUMMARY OF THE INVENTION
The invention provides new compounds of formula (I): ##STR2## wherein R 1 is --CF=CFCF 3 or --CF 2 CF=CFCF 3 .
The invention also provides a method of controlling cockroaches, ants, fleas, or termites which comprises delivering an effective amount of a compound of the formula (I) to a location where control of cockroaches, ants, fleas, or termites is desired.
DETAILED DESCRIPTION OF THE INVENTION
Intermediate 1:2,6-difluorobenzoyl isocyanate ##STR3##
A mixture of 0.52 g of 2,6-difluorobenzamide and 0.33 ml of oxalyl chloride was stirred under reflux in 15 ml 1,2-dichloroethane overnight. Solvent was removed under vacuum and 10 ml 1,2-dichloroethane was added. Solvent was removed under vacuum to leave the title intermediate, which could be used directly or dissolved in 1,2- dichloroethane and stored for future use.
Intermediate 2:3,5-dichloro-4-(1,2,3,3,3-pentafluoropropenoxy)aniline ##STR4##
To 1.1 liters of tetrahydrofuran containing 44.5 g of 2,6-dichloro-4-aminophenol and 3.2 g potassium hydroxide, was added subsurface 38.7 g of hexafluoropropene. The addition was complete in 25 minutes at a temperature of 8°-11° C. Analysis by liquid chromatography indicates no starting aniline present. Most of the THF was removed under vacuum, 500 mL water was added and the resulting mixture was extracted 3×500 mL ethyl ether. The combined extracts were washed with 2×100 mL 1N NaOH, 2×200 mL brine, dried over anhydrous sodium sulfate, filtered and the solvent removed under vacuum to give a mixture. This mixture was separated by prep LC to give 46.8 g of 3,5-dichloro-4-(1,1,2,3,3,3-hexafluoropropoxy)aniline and ˜4 g of 3,5-dichloro-4-(1 ,2,3,3,3-pentafluoropropenoxy) aniline . Proton and 19 F nmr and mass spectra were consistent with the proposed structures.
Intermediate 3:3,5-Dichloro-4-trans-(1,1,2,3,4,4,4-hettafluorobut-2-enoxy)aniline
A. Preparation of Sodium Perfluoropentanoate ##STR5##
26 g Perfluoropentanoic acid was stirred magnetically as 2N aqueous sodium hydroxide was added dropwise until the pH reached 5. The water was removed under vacuum to yield 28.2 g white solid product, mp 256-7ο. The 19 F nmr was consistent with the proposed structure. Anal. Calcd C 5 F 9 NaO 2 : C, 21.0. Found: C, 20.89, H, 0.06, N, 0.02.
B. Preparation of Octafluoro-1-butene ##STR6##
28 g of sodium perfluoropentanoate was placed in a 100 ml round-bottom flask and heated with a mantle with no stirring. The flask was fitted with a tube which went through a trap, a 30% aqueous sodium hydroxide bubbler (containing some Dow Corning Antifoam A to control foaming), and a Drierite tube before the product was allowed to bubble into a reaction mixture. Heating was controlled so as to maintain a steady, but not too vigorous rate of bubbling through the trap.
C. Preparation of 3,5-Dichloro-4-trans-(1,1,2,3,4,4,4-heptafluorobut-2-enoxy)aniline ##STR7##
The butene generated in the above reaction was bubbled in subsurface to 14 g 4-amino-3,5-dichlorophenol in 175 ml THF containing 5.15 g 87% powdered potassium hydroxide pellets cooled in an ice bath over 2.5 hours. Stirring was continued while the mixture was allowed to warm to room temperature. The solvent was removed under vacuum and 300 ml dichloromethane was added. This solution was washed with 100 ml water, 100 ml 1N sodium hydroxide, 100 ml 1N HCl, and again with 50 ml 1N NaOH before drying over anhydrous magnesium sulfate. Removed solvent under vacuum to leave a dark oil. This was chromatographed over silica gel starting with 1:1 hexane-dichloromethane and eluting product with dichloromethane. The total yield of nearly colorless oil was 15 g. Anal. calcd C 10 H 4 Cl 2 F 7 NO: C, 33.55; H, 1.13; N, 3.91. Found: C, 33.32; H, 1.12; N, 3.81. Proton and 19 F nmr confirm the olefinic structure as shown with a trans configuration around the double bond.
PREPERATION OF PRODUCTS
Compound 1: N- 3,5-Dichloro-4-(1,2,3,3,3-pentafluoropropenoxy)phenyl!-N'-(2,6-difluorobenzoyl) urea ##STR8##
Dissolve 0.77 g 3,5-dichloro-4-(1,2,3,3,3-pentafluoropropenoxy) aniline in 8 mL 1,2-dichloroethane under an atmosphere of nitrogen at room temperature. Add 0.50 g 2,6-difluorobenzoyl isocyanate dissolved in 5.8 mL dichloroethane dropwise over a 10 minute period. Stir and warm to 40° C. for a 2 hour period. Chill in ice water bath and filter the white solid 0.93 g, mp 177°-80° C. Proton nmr and mass spectra were consistent with the proposed structure. Anal. calcd C 17 H 7 Cl 2 F 7 N 2 O 3 :C, 41.57; H, 1.44; N, 5.70. Found: C, 41.65; H, 1.31; N, 5.59.
Compound 2:1-(2.6-Difluorobenzoyl)-3- 3,5-dichloro-4-trans-(1,1,2,3,4,4,4-heptafluorobut-2-enoxy) phenyl!urea ##STR9##
2,6-Difluorobenzoyl isocyanate made from 0.52 g 2,6-difluorobenzamide was stirred in 10 ml 1,2-dichloroethane while 1.08 g of the amine made above in 5 ml 1,2-dichloroethane was added in portions. The mixture was heated to reflux and then cooled. The solvent was removed under vacuum and the resulting solid recrystallized from methanol to give 0.95 g white crystals, mp 153-4ο. The proton and 19 F nmr's were consistent with the proposed structure. Anal. calcd C 18 H 7 Cl 2 F 9 N 2 O 3 : C, 39.95; H, 1.30; N, 5.18. Found: C, 39.65; H, 1.36; N, 5.19.
BIOLOGICAL ACTIVITY
German Cockroach 2nd Instars (Blattella Germanica)
Continuous, low-dose ingestion exposure (treated cornmeal) Rates: (0.19), 0.78, 3.12, 12.5, 50, 200 ppm
______________________________________ LC.sub.50 (ppm) 21 days 42 days______________________________________Compound 2 <1.03 <0.78Compound 1 <0.78 <0.78hexaflumuron >200 >200______________________________________
Under continuous exposure, Compounds 1 and 2 were far superior to hexaflumuron.
German Cockroach 2nd Instars (Blattella Germanica)
Limited ingestion exposure (48 hr) to treated cornmeal Rates: 1, 10, 1,000, 10,000 ppm
______________________________________ LC.sub.50 (ppm) 21 days 42 daysCompound low high low high______________________________________Compound 2 60.8 1768 162.7Compound 1 80.2 36.1hexaflumuron >10,000 >10,000______________________________________
Under limited exposure, Compounds 1 and 2 were far more potent than hexaflumuron.
Cat Flea (Ctenocephalides felis)
Continuous exposure of larvae to treated media, impact on subsequent adult emergence Rates: 0.1, 1.0, 10, 100, 1,000 ppm
______________________________________ LC.sub.50 (ppm) LC.sub.90 (ppm)______________________________________Compound 2 4.5 27.2Compound 1 29.2 77.3hexaflumuron 65.7 333.5______________________________________
Compounds 1 and 2 were far more active against fleas than was hexaflumuron.
Subterranean Termite (Reticulitermes flavipes)
Limited exposure (7 days) with mortality determined at 14, 28, 42, and 56 days
______________________________________Compound LT.sub.50 (days) for 10000 ppm treatment______________________________________Compound 1 36.8Compound 2 35.5hexaflumuron 40.6______________________________________
Under limited exposure to termites, Compounds 1 and 2 had more rapid action than did hexaflumuron.
Ant Studies
Laboratory ant bait studies were carried out with Red Imported Fire Ant (RIFA) (Solenopsis invicta) and Pharaoh Ant (Monomorium pharaonis). Chitin synthesis inhibitors, such as the compounds of the invention, control ants by killing the molting larvae and/or pupae and potentially preventing the hatching of eggs. Because adult workers are not affected, control is measured by effects on the brood. The studies involved 3-day exposure to bait. These limited exposure studies more accurately represent real world bait availability than continuous exposure.
______________________________________ Time to Time to Achieve Achieve Concentration 50% Brood 90% BroodCompound tested Species Reduction Reduction*______________________________________Compound 1 0.07% RIFA 2 wks 3 wks 0.07% Pharaoh NA NAHexaflumuron 0.1% RIFA NA NA 0.25% RIFA 4 wks 10 wks 0.1% Pharaoh NA NA______________________________________ *Only concentration tested. NA = did not achieve specified percent brood reduction.
Compound 1 is significantly more potent than hexaflumuron based on a short exposure study with RIFA.
FORMULATIONS
In order to facilitate the application of the compounds of formula (I) to the desired locus, or to facilitate storage, transport or handling, the compound is normally formulated with a carrier and/or a surface-active agent.
A carrier in the present context is any material with which the compound of formula (1) (active ingredient) is formulated to facilitate application to the locus, or storage, transport or handling. A carrier may be a solid or a liquid, including a material which is normally gaseous but which has been compressed to form a liquid. Any of the carriers normally used or known to be usable in formulating insecticidal compositions may be used.
Compositions according to the invention contain 0.0001 to 99.9% by weight active ingredient. Preferably, compositions according to the invention contain 0.001 to 10.0% by weight of active ingredient though proportions as low as 0.0001% may be useful in some circumstances.
Suitable solid carriers include natural and synthetic clays and silicates, for example natural silicas such as diatomaceous earths; magnesium silicates, for example talcs; magnesium aluminium silicates, for example attapulgites and vermiculites; aluminium silicates, for example kaolinites, montmorillonites and micas; calcium carbonate; calcium sulphate; ammonium sulphate; synthetic hydrated silicon oxides and synthetic calcium or aluminium silicates; elements, for example carbon and sulfur; natural and synthetic resins, for example coumaronne resins, polyvinyl chloride, and styrene polymers and copolymers; solid polychlorophenols; bitumen; waxes; agar; and solid fertilizers, for example superphosphates. Cellulose based materials, for example wood, sawdust, agar, paper products, cotton linter, or Methocel®, as well as the other solid carriers that are themselves attractive to or at least non-repellant to termites are particularly suitable and preferable. Mixtures of different solids are often suitable. For example, a mixture of wood flour and agar formulated as a moisture containing solid would be preferable.
Suitable liquid carriers include water; alcohols, for example isopropanol and glycols; ketones, for example acetone, methyl ethyl ketone, methyl isobutyl ketone, isophorone and cyclohexanone; ethers; aromatic or aliphatic hydrocarbons, for example benzene, toluene and xylene; petroleum fractions, for example kerosene and light mineral oils; chlorinated hydrocarbons, for example carbon tetrachloride, perchloroethylene and trichloroethane; polar organic liquids, such as dimethyl formamide, dimethyl acetamide, dimethyl sulfoxide and N-methylpyrrolidone; oils derived from plants, such as corn oil and peanut oil. Mixtures of different liquids are often suitable, for example a mixture of isophorone with a polar organic solvent such as N-methylpyrrolidone, as are mixtures of solid and liquid carriers.
Pesticidal compositions are often formulated and transported in a concentrated form which is subsequently diluted by the user before application. The presence of small amounts of a carrier which is a surface-active agent facilitates this process of dilution. Thus it is suitable to use at least one carrier in such a composition which is a surface-active agent. For example, the composition may contain at least two carriers, at least one of which is a surface-active agent.
A surface-active agent may be an emulsifying agent, a dispersing agent or a wetting agent; it may be nonionic or ionic. Examples of suitable surface-active agents include the sodium or calcium salts of polyacrylic acids and lignin sufonic acids; the condensation of fatty acids or aliphatic amines or amides containing at least 12 carbon atoms in the molecule with ethylene oxide and/or propylene oxide; fatty acid esters of glycerol, sorbitol, sucrose or pentaerythritol; condensates of these with ethylene oxide and/or propylene oxide; condensates of these with ethylene oxide and/or propylene oxide; condensation products of fatty alcohol or alkyl phenols, for example p-octylphenol or p-octylcresol, with ethylene oxide and/or propylene oxide; sulfates or sulfonates of these condensation products; alkali or alkaline earth metal salts, preferably sodium salts, or sulfuric or sulfonic acid esters containing at least 10 carbon atoms in the molecule, for example sodium lauryl sulphate, sodium secondary alkyl sulfates, sodium salts of sulfinated castor oil, and sodium alkylaryl sulfonates such as dodecylbenzene sulfonate; and polymers of ethylene oxide and copolymers of ethylene oxide and propylene oxide.
Pesticidal compositions may for example be formulated as wettable powders, dusts, granules, baits, solutions, emulsifiable concentrates, emulsions, suspension concentrates and aerosols.
Wettable powders usually contain 25, 50 or 75% weight of active ingredient and usually contain in addition to solid inert carrier, 3-10% weight of a dispersing agent and, where necessary, 0-10% weight of stabilizer(s) and/or other additives such as penetrants or stickers.
Dusts are usually formulated as a dust concentrate having a similar composition to that of a wettable powder but without a dispersant, and are diluted in the field with further solid carrier to give a composition usually containing 0.5-10% weight of active ingredient.
Granules are usually prepared to have a size between 10 and 100 BS mesh (1.676-0.152 mm), and may be manufactured by, for example, agglomeration or impregnation techniques. Generally, granules will contain 0.01-75% weight active ingredient and 0-10% weight of additives such as stabilizers, surfactants, slow release modifiers and binding agents. The so-called "dry flowable powders" consist of relatively small granules having a relatively high concentration of active ingredient. Of particular interest in current practice are the water dispersible granular formulations. These are in the form of dry, hard granules that are essentially dust-free, and are resistant to attrition on handling, thus minimizing the formation of dust. On contact with water, the granules readily disintegrate to form stable suspensions of the particles of active material. Such formulation contain 90% or more by weight of finely divided active material, 3-7% by weight of a blend of surfactants, which act as wetting dispersing, suspending and binding agents, and 1-3% by weight of a finely divided carrier, which acts as a resuspending agent.
Baits are prepared by, for example, combining a mixture of a suitable food source, such as sawdust for termites or grain or meal for cockroaches, with an amount of active ingredient sufficient to provide the desired result; for example, from about 0.001% to about 20% weight active ingredient and forming the mixture into a paste by the addition of about 1% to 5% of a water based binder such as agar. The paste-like mixture may be applied as is or may be packed into a housing such as a hollowed out wooden dowel or a plastic tube or bait station. In other embodiments, sheets of paper or cardboard can be sprayed with or dipped in a diluted formulation containing the active ingredient. Baits are a preferable embodiment of the present invention.
Emulsifiable concentrates usually contain, in addition to a solvent and, when necessary, co-solvent, 10-50% weight per volume active ingredient, 2-20% weight per volume emulsifiers and 0-20% weight per volume of other additives such as stabilizers, penetrants and corrosion inhibitors.
Suspension concentrates are usually compounded so as to obtain a stable, non-sedimenting flowable product and usually contain 10-75% weight active ingredient, 0.5-15% weight of dispersing agents, 0.1-10% weight of suspending agents such as protective colloids and thixotropic agents, 0-10% weight of other additives such as defoamers, corrosion inhibitors, stabilizers, penetrants and stickers, and water or an organic liquid in which the active ingredient is substantially insoluble; certain organic solids or inorganic salts may be present dissolved in the formulation to assist in preventing sedimentation or as anti-freeze agents for water.
Aqueous dispersions and emulsions are compositions which may be obtained by diluting a wettable powder or a concentrate with water. The said emulsions may be of the water-in-oil or of the oil-in-water type, and may have a thick `mayonnaise`-like consistency.
The method of applying a compound of Formula (I) to combat termites comprises applying the compound, conveniently in a composition comprising the compound of Formula (I) and a carrier as described above, to a locus or area to be treated for the termites, such as soil or timber, already subject to infestation or attack by termites or intended to be protected from infestation by termites. The active ingredient is, of course, applied in an amount sufficient to effect the desired action of combatting termite infestation. This dosage is dependent upon many factors, including the carrier employed, the method and conditions of the application, whether the formulation is present at the locus in the form of a film, or as discrete particles or as a bait, the thickness of film or size of particles, the degree of termite infestation, and the like.
Proper consideration and resolution of these factors to provide the necessary dosage of the active ingredient at the locus to be protected are within the skill of those versed in the art. In general, however, the effective dosage of the compound of the invention at the locus to be protected--i.e., the dosage to which the termite has access--is of the order of 0.001 to 1.0% based on the total weight of the composition, though under some circumstances the effective concentration may be as little as 0.0001% or as much as 2%, on the same basis.
When used to control cockroaches, it is preferred to use the active ingredient in a treated bait or as a surface treatment.
When used to control ants, it is preferred to use the active ingredient in a liquid bait or granular bait.
When used to control termites, it is preferred to use the active ingredient in a cellulose based bait.
When used to control fleas, it is preferred to use the active ingredient on a treated substrate.
Suitable formulations include granular, paste, or dust cockroach bait, SP or WP cockroach and/or flea sprayables, cellulose-based termite baits, liquid or granular ant baits, feed-through or topical animal treatment for fleas. | Compounds of formula (I): ##STR1## wherein R 1 is --CF=CFCF 3 or --CF 2 CF=CFCF 3 are useful in control of cockroaches, ants, fleas, or termites. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a easily transportable ladder, and more specifically to a ladder with a fixed wheel on one side of the base of the ladder.
Maintenance personnel commonly utilize one or more ladders for various tasks. Such ladders may be foldable (or step) ladders, or extension ladders. Step ladders may range from typical household step ladders which are generally six feet high, to maintenance step ladders which may be up to twelve feet high and weigh as much as forty five pounds or more. Extension ladders may similarly vary in length and weight, and may weigh over one hundred pounds.
Maintenance personnel may be required to frequently relocate ladders from one work site to the next, along with moving tools, fixtures, lights, etc. Carrying heavy ladders may prove both difficult and tiring, and therefore fatiguing to a worker, who must then climb the ladder to perform tasks. Such fatigue may result in slower performance of work, or in injury. Further, due to their length, ladders are generally only be carried on the right or left side, and as such, create an uneven load on the carrier's spinal column. In some cases, long term uneven loading may injure the spinal column and/or create liability for an employer.
Attempts have been made to reduce the effort required to move ladders, such as the removable castors taught in U.S. Pat. No. 6,592,134 issued Jul. 15, 2003 for “Ladder Transport Systems.” The '134 patent teaches a removable caster held to a ladder by a “C Clamp” type device. While the device of the '134 patent address some of the needs, it does not allow the use of a large non-obtrusive or stable wheel for ladder transportation. A caster type wheel disadvantageously allows a ladder base to run down a slope, creating possibly dangerous situations. Also, the wheel of the '134 patent is entirely outside the profile of the ladder, which either limits the wheel size, or creates an undesirably large extension from the ladder.
Thus, a need remains for maintenance ladders which are easily and steadily transportable and reduce fatigue and injury resulting from carrying heavy ladders between job sites.
BRIEF SUMMARY OF THE INVENTION
The present invention addresses the above and other needs by providing a ladder with at least one fixed axle (i.e., not a caster-type wheel) base wheel adapted to facilitate relocating the ladder. The ladder may be a step ladder or an extension ladder. The ladder includes a ladder base adapted to reside on a support surface, a ladder top opposite the ladder base, and ladder sides connected by steps, the ladder side extending between the ladder base and the ladder top. The base wheel is attached to one of the sides near the ladder base, and is adapted to rollably support the ladder base when the ladder is moved. The base wheel may be recessed into an opening on the ladder side to allow a larger diameter wheel to be used, or may be attached to the ladder using a surface mount bracket.
In accordance with one aspect of the invention, there is provided a ladder comprising a step portion with a fixed axle base wheel. The step portion comprises, a ladder base adapted to reside on a ladder support surface when the ladder is in use, a ladder top opposite the ladder base, first and second ladder sides extending between the ladder base and the ladder top, and steps connecting the ladder sides. The fixed axle base wheel preferably has an outside diameter between approximately three inches and approximately six inches, and more preferably approximately five inches, and is mounted to one of the ladder sides, proximal to the ladder base, and is preferably a roller scooter or a shopping cart type wheel, and more preferably a shopping cart type wheel. Advantageously, an opening may be provided in the ladder side to allow the wheel to partially intrude into the ladder to allow a larger wheel diameter without the wheel extending too far beyond the ladder side. The fixed axle base wheel is adapted to stably rollably support the ladder base when the ladder is being carried near the ladder top with steps nearly vertical (i.e., steps nearly perpendicular to the support surface or floor) and the ladder base, instead of being dragged, is rolled on the base wheel.
The ladder may be a step ladder having a hinged portion is connected to the step portion by a hinge at the ladder top, or an extension ladder with an extension portion slidably attached to the step portion. It is further contemplated to provide a second wheel, which is preferably a caster-type wheel, mounted to the same ladder side as the base wheel, proximal to the ladder top. If a second wheel is included, the ladder may similarly be rolled on the base wheel and second wheel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The above and other aspects, features and advantages of the present invention will be more apparent from the following more particular description thereof, presented in conjunction with the following drawings wherein:
FIG. 1A is a front view of a prior art step ladder positioned for use.
FIG. 1B is an edge view of the prior art step ladder positioned for use.
FIG. 2 is a view of the prior art step ladder positioned for carrying.
FIG. 3 is a view of a step ladder with a base wheel according to the present invention added to aid in transporting the ladder, with the ladder angled as it might be while being transported.
FIG. 4 is an edge view of the step ladder including the base wheel.
FIG. 5 is a view of an extension ladder with a base wheel according to the present invention added to aid in transporting the ladder, with the ladder angled as it might be while being transported.
FIG. 6 is an edge view of the extension ladder including the base wheel.
FIG. 7A is a detailed edge view of a base wheel assembly of the ladder.
FIG. 7B is a detailed side view of a base wheel assembly of the ladder.
FIG. 7C is a detailed side view of a base wheel assembly of the ladder wherein the wheel is attached to the ladder using a stand-off.
FIG. 8 is a second embodiment of the present invention with a caster wheel added near the ladder top of a step ladder.
FIG. 9 is the second embodiment of the present invention with a caster wheel added near the ladder top of an extension ladder.
FIG. 10 is a detailed view of the caster wheel assembly on the step ladder.
FIG. 11A is a side view of the wheel attached to the ladder using a riveted surface mount.
FIG. 11B is a bottom view of the wheel attached to the ladder using the riveted surface mount.
FIG. 12 is an edge view of a ladder having two base wheels.
Corresponding reference characters indicate corresponding components throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
The following description is of the best mode presently contemplated for carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.
A typical prior art step ladder is shown in FIG. 1A , and an edge view of the prior art ladder is shown in FIG. 1B . The prior art ladder is typically six to twelve feet high, and weighs up to forty five pounds or more. Such ladders are commonly used for painting, changing light bulbs, repairs to plumbing, etc. A view of the prior art step ladder 10 positioned for carrying is shown in FIG. 2 . Extensive carrying of a twelve foot long prior art ladder is both fatiguing and may lead to spinal column injury.
The present invention provides a easily transportable step ladder 12 adapted to facilitate stable carrying, as shown in FIG. 3 . The ladder 12 includes a ladder base 12 a adapted to rest on a support surface (or floor) 11 when the ladder 12 is in use, a ladder top 12 b opposite the ladder base 12 a , and ladder sides 14 a and 14 b with steps 13 attached thereto, ladder sides 14 a , 14 b extending between the ladder base 12 a and the ladder top 12 b . A fixed axle base wheel assembly 16 is attached to the ladder side 14 a near the ladder base 12 a , but may alternatively be attached to ladder side 14 b . The ladder 12 is shown angled relative to the support surface 11 (i.e., ladder steps 13 nearly perpendicular to the support surface and said ladder top 12 b lifted away from the floor), as the ladder 12 might be transported by carrying the ladder top 12 b , and letting the ladder base 12 a roll on the base wheel assembly 16 .
An edge view of the ladder 12 is shown in FIG. 4 , comprising a first step portion 20 a and a hinged portion 22 . The step portion 20 a is fixedly attached to the ladder top 12 b , and the hinged portion 22 is pivotally attached to the ladder top 12 b by a hinged portion pivot 24 , and may alternatively be attached by hinges. The step portion 20 a and hinged portion 22 may be constructed from wood, fiberglass, or metal, and are generally tapered being wider at the base and narrower at the top.
An extension ladder 48 according to the present invention is shown in FIG. 5 and in edge view in FIG. 6 . The ladder 48 comprises a second step portion 20 b , an extension portion 50 , and the fixed axle base wheel assembly 16 . The extension portion 50 slidably cooperates with the step portion 20 b to extend the ladder 48 . The ladder 48 is shown in FIG. 5 angled relative to the support surface 11 , as the ladder 48 might be transported by carrying the ladder top, and letting the base wheel assembly 16 roll on the support surface 11 .
The present invention may further be applied to a ladder having a single portion (i.e., without a hinged portion or an extension portion), or a ladder with three or more hinged portions, or a combination of hinged and extension portions, and any ladder including at least one wheel assembly 16 as described above, is intended to come within the scope of the present invention.
A detailed edge view of the fixed axle (i.e., not a caster-type wheel) base wheel assembly 16 of the ladders 12 or 48 is shown in FIG. 7A and an edge view is provided in FIG. 7B . The wheel assembly 16 includes a base wheel 26 with a base wheel fixed axle 30 . The fixed axle 30 is supported by first and second axle supports 32 a and 32 b , and the major axis of the fixed axle 30 is substantially perpendicular to a plane parallel to the step portion 20 a , i.e., perpendicular to a plane the steps 13 (see FIG. 3 ) lie in. The axle 30 is shown in FIG. 7B held in intimate contact with the ladder side 14 a or 14 b , as seen in FIG. 7B . The axle supports 32 a , 32 b are attached to the ladder side 14 a by axle support bolts 34 . The wheel 26 protrudes partially through a wheel opening 28 in the ladder side 14 a . The base wheel assembly 16 is adapted to rollably support the ladder base 12 a when either ladder 12 or 48 is being carried with steps 13 nearly perpendicular to the support surface 11 and the ladder base 12 a , instead of being dragged, is rolled on the base wheel 26 , and the ladder sides 14 a and 14 b are at a small angle to the relative to the support surface 11 . For additional strength, a boot 35 may be extended past the wheel opening 28 . Such boot 35 is preferably metal, and is shown in FIGS. 7A and 7B .
An alternative embodiment of the wheel assembly is shown in FIG. 7C wherein the wheel 26 is attached to the ladder side 14 a or 14 b using a stand-off 33 to obtain greater ground clearance for the ladder 12 when being transported.
The base wheel 26 is preferably between approximately three inches in diameter and approximately six inches in diameter, and more preferably five inches in diameter. The base wheel 26 is preferably of the type commonly used on roller blades, roller scooters (i.e., is a roller-blade type wheel), or a shopping-cart type wheel, and more preferably a shopping-cart type wheel. The fixed axle 30 is between approximately two inches and approximately ten inches from said ladder base (i.e., measured along the length of the ladder).
A step ladder 12 including a second caster-type wheel assembly 18 is shown in FIG. 8 . The wheels assembly 18 is mounted on the same ladder side 14 a or 14 b as the base wheel assembly 16 , but is mounted near the ladder top 12 b . Thus mounted, the second wheel assembly 18 allows the ladder 12 to be guided without requiring lifting, thus further reducing fatigue. A view of the caster-type wheel assembly 18 mounted on the extension ladder 48 is shown in FIG. 9 .
A detailed view of the second wheel assembly 18 mounted to the ladder 12 is shown in FIG. 10 . The wheel assembly 18 includes a second wheel 36 riding on a second wheel axle 38 . The axle 38 is attached to a rearward sloping second axle support 40 , which axle support 40 is typically a “U” shaped bracket. The axle support 40 is attached to a castor swivel 42 , which caster swivel 42 is rotationally attached to a caster base 44 . The caster base 44 is attached to the ladder side 14 a by caster base bolts 46 . The second wheel 36 is adapted to rollably support the ladder top 12 b when the base wheel 26 and the second wheel 36 are in contact with the support surface 11 . The wheel 36 is between approximately three inches in diameter and approximately six inches in diameter.
A side view of the wheel 26 mounted to the ladder side 14 a using a surface mount 60 is shown in FIG. 11A . A corresponding bottom view of the wheel 26 mounted using the surface mount 60 is shown in FUG. 11 B. The surface mount 60 is preferably attached to the ladder side 14 a using rivets 62 , and more preferably using four rivets 62 .
An edge view of a two sided ladder 70 including a thick hinged portion 22 b which includes a wheel assembly 16 adjacent to the wheel assembly 16 mounted to the stepping portion 20 a , is shown in FIG. 12 . Wheel assemblies 16 are included on each portion of the two sided ladder 70 to support the two similarly heavy portions of the two sided ladder 70 . The hinged portion 22 b may be a stepped hinged portion having thickness substantially similar to the stepping portion 20 a.
While the invention herein disclosed has been described by means of specific embodiments and applications thereof, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims. | A ladder with a fixed axle wheel adapted to facilitate relocating the ladder. The ladder may be a step ladder or an extension ladder. The ladder includes a ladder base adapted to reside on a support surface, a ladder top opposite the ladder base, and ladder sides connected by steps, the ladder sides extending between the ladder base and the ladder top. The wheel is attached to one of the sides near the ladder base and is adapted to rollably support the ladder base when the ladder is moved. The wheel may be recessed into an opening on the ladder side to allow a larger diameter wheel to be used. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to a transconductance stage with improved linearity, and more particularly, to a transconductance stage with low distortion for providing an output signal that is free from parasitic components linked to third order intermodulation products. The invention has applications in transmitters and receivers, and in particular, in communication equipment such as portable phones.
BACKGROUND OF THE INVENTION
[0002] A transconductance stage, also called a transconductor, is an electronic device that converts an input voltage into an output current. The voltage can be a voltage referenced relative to a potential or to a differential voltage. In the same way, the current can be a differential current.
[0003] [0003]FIG. 1 shows a possible embodiment of a very simple transconductance stage mounted around a bipolar transistor 10 . A voltage V in is applied to the base of the transistor, while a current I out circulates in the collector linked to an output terminal 14 . The transistor emitter is linked to a supply terminal 16 (e.g., ground) through a resistor, or more generally, a degeneracy impedance 20 .
[0004] By naming the variations of the voltage of the transistor base v, and the variations in the collector current they produce i, the transconductance stage of FIG. 1 shows an equivalent transconductance gm eq such that:
gm eq = i v = gm 1 + gm * Ze ( 1 )
[0005] In this equation gm is the transconductance of the isolated transistor in the absence of degeneracy resistance. This is such that:
gm=I O /V T (2)
[0006] where I O is the quiescent current of the transistor, and V T is the thermal voltage. The thermal voltage V T is such that V T =kT/q, where T is the absolute operating temperature (expressed in Kelvin), k is Boltzmann's constant, and q is the electron charge.
[0007] When the transconductance stage is connected by its collector to a load impedance Z OUT , that is, by terminal 14 in the figure, a voltage gain G V is obtained such that:
G V =gm eq *Z OUT (3)
[0008] In a receiver or transmitter, the transconductance stage transmits the frequency components of a signal applied to it, but also other components among which include the intermodulation product components. These components, generated by the transconductance stage, are due in particular, to a linearity defect.
[0009] As an illustration, if a signal received by the stage comprises two frequency components F 1 and F 2 , the output signal comprises the fundamental components F 1 and F 2 , and also their harmonics 2F 1 ,2F 2 , 3F 1 , 3F 2 , etc., of the second order intermodulation components of the type F 1 −F 2 and F 1 +F 2 , as well as the third order intermodulation components of the type 2F 1 −F 2 or 2F 2 −F 1 , for example.
[0010] The components of the intermodulation products, which are the parasitic components of the output signal, generally have low amplitudes compared to the components of the frequencies from which they are derived. Nonetheless, they are undesirable when their frequency coincides with the frequency of the desired signal.
[0011] For example, a frequency component F of low amplitude risks being in competition with a parasitic component of the identical 2F 1 −F 2 type. If F−F 2 =F 2 −F 1 , these difficulties appear, in particular, in the domains such as that of Hertzian (i.e., radio waves) telecommunications, where certain channels, whose reception is very weak, risk being distorted by neighboring strong channels.
[0012] To augment the linearity of the transconductance stages, and thus reduce the amplitude of the parasitic components which may be generated, the stages are equipped with feedback. The feedback includes, for example, an emitter degeneracy resistor such as resistor 20 described in reference to FIG. 1. A higher resistance value improves the linearity of the stage.
[0013] The gain in linearity is obtained at the expense of an equivalent transconductance or a lower voltage gain. Concerning this subject, one can refer to equations (1) and (3) above. Thus, to obtain an output signal of the same amplitude as that which would be obtained without feedback, the supply power has to be raised. This requires raising the quiescent current crossing the transistor or the supply voltage. However, it turns out that for portable communication equipment, such as cellular phones operating on a portable energy source (an electrical battery, for example), increased energy consumption has a very negative influence on autonomy.
[0014] Another feedback possibility directed at improving the linearity of a transconductance stage is shown in FIG. 2. FIG. 2 shows a transconductance stage mounted around a transistor 10 associated with a parallel feedback branch 22 connected between the collector and the base. The input terminal 12 and the output terminal 14 correspond, as for the device in FIG. 1, to the base and to the collector. The emitter is linked directly to a supply terminal 16 (ground).
[0015] A feedback branch 22 , connected between the input and output terminals, makes it possible to extract a fraction α of the output voltage from the input voltage. The equivalent transconductance gm eq of the stage of FIG. 2 is thus reduced. An increase in the feedback proportion α results in better linearity, but also a weaker equivalent transconductance. Thus, as in the device of FIG. 1, increasing the linearity is at the expense of greater electrical consumption. U.S. Pat. No. 5,826,182 discloses a transconductor operating in class AB and not in class A, like the stages of FIGS. 1 and 2.
[0016] The device described in the referenced U.S. patent has the advantage of reducing the third order components of the intermodulation product by significant proportions. However, a common base structure provides the device with a very low input impedance. Thus, means for adapting the impedance to a value of 50 Ω, normal for high frequency transmitters-receivers, would consequently reduce the transconductance significantly relative to an assembly of the same type as shown in FIGS. 1 and 2 to which the same adaptation impedance has been applied. The assemblies in FIGS. 1 and 2 benefit from the naturally high impedance of the assembly.
SUMMARY OF THE INVENTION
[0017] An object of the invention is to provide a transconductance stage which has none of the limitations of the devices described above.
[0018] Another object of the invention is to provide a transconductance stage with good linearity and low distortion, free from third order intermodulation product components, and having a high transconductance.
[0019] A further object of the invention is also to provide such a transconductance stage with low energy consumption.
[0020] Another object of the invention is to provide such a stage with a reduced influence on third order intermodulation components.
[0021] Yet another object of the invention is to provide a transconductance stage with an input impedance capable of being adapted easily to a value approaching 50 Ω.
[0022] These and other objects, advantages and features of the invention are provided by a transconductance stage comprising at least one principal bipolar transistor having a base linked to an input terminal, a collector linked to an output terminal, and an emitter linked to a supply terminal through the intermediary of a degeneracy resistor.
[0023] At least one compensation bipolar transistor is connected in parallel to the principal transistor and linked to the supply terminal without going through the degeneracy resistor. The value R E of the degeneracy resistance of the principal transistor is chosen such that R E *I 0 >V T /2, where V T is the thermodynamic voltage and I 0 is the quiescent current of the principal transistor. The choice of the degeneracy resistance R E is preferably made such that R E >>V T /2I 0 , for example, R E >10V T /2I 0 .
[0024] According to the invention, the compensation transistor is without degeneracy resistance when the electrical liaison resistance in the emitter of this transistor at the supply terminal is sufficiently weak to be neglected compared to the degeneracy resistance of the principal transistor. In other words, with r representing the value of a degeneracy resistance of the compensation transistor, the value r should be such that r<<V T /2I′ 0 *I′ 0 is the quiescent current of the compensation transistor.
[0025] Moreover, it is understood that supply terminal means a terminal used for the polarization of transistors, that is, for setting their quiescent currents. The supply terminal can be a supply source potential, for example, or ground.
[0026] Based upon the choice of the degeneracy resistance of the principal transistor indicated above, the phase of the third order intermodulation product components, generated by the principal transistor and the compensation transistor, have opposite signs and oppose each other. The resulting amplitude of the third order components is thus lower than that of the third order components which each of the transistors considered separately would have generated.
[0027] A suitable polarization of the compensation transistor, and an adjustment of its quiescent current, makes it possible to generate third order harmonics with this transistor which are also equal in amplitude to those generated by the principal transistor. In this case, the third order harmonics of the two transistors not only oppose each other but are cancelled.
[0028] In a particular embodiment of the transconductance stage, an inductor links the principal transistor and the compensation transistor to the supply terminal. The inductor is connected in series with the degeneracy resistor between the emitter of the principal transistor and the supply terminal.
[0029] This inductor raises the input impedance of the stage. Its value can be chosen as a function of a desired input impedance, in such a way as to adjust this impedance closer to the usual value of 50 106 . An impedance adaptation can be made by associating a resistor or other suitable passive components at the base of the transistor.
[0030] According to the invention, the transconductance stage can further comprise an inductor, called a parallel inductor, connected in parallel to the degeneracy resistor of the principal transistor. The parallel inductor has a value L E such that:
L E <<R E /2πΔ F and L E >>R E /2π F
[0031] F is a central operating frequency of the transconductance stage, and ΔF is the width of a band of frequencies capable of containing third order intermodulation product components generated by the stage.
[0032] The first condition indicated for choosing the value of the parallel inductance makes it possible for the inductor to operate like a short-circuit towards the supply terminal to filter the frequency components whose value corresponds to the chosen frequency band ΔF. These frequencies correspond to second order intermodulation components, of the type F 1 −F 2 or F 2 −F 1 , with reference to the example chosen in the introductory part of the description.
[0033] The second order intermodulation components combine with the fundamental components to generate new third order components. The filtering carried out by the parallel inductor makes it possible to limit or to eliminate this phenomenon. The second condition for choosing the value L E of the parallel inductance makes it possible to provide the inductor with an impedance very much higher than that of the degeneracy resistance such that it does not disturb the value of this resistance at the operational frequencies around the value F.
[0034] The transconductance stage of the invention can be a simple stage or a differential stage. In the second case, it comprises first and second principal transistors and first and second compensation transistors connected in parallel respectively to the first and second principal transistors. The bases of the first and second principal transistors are linked respectively to the first and second input terminals forming a differential input. The collectors of the first and second principal transistors are linked respectively to the first and second output terminals. The emitters of the first and second principal transistors are linked respectively to a supply terminal through the intermediary of a first and second degeneracy resistor.
[0035] Moreover, the first and second compensation transistors are linked without degeneracy resistance to the supply terminal. The first and second degeneracy resistors of the principal transistors have the values R E1 and R E2 such that:
R E1 *I 1 >V T /2 and R E2 *I 2 >V T /2
[0036] The terms I 1 and I 2 refer to the quiescent currents of the first and second principal transistors and where V T refers to the thermodynamic voltage.
[0037] The criteria for selection of the degeneracy resistances for each part of the differential stage are the same as for the single stage described above. Preferably:
R E1 *I 1 >>V T /2 and R E2 *I 2 >>V T /2.
[0038] In the same way, the transconductance stage can be equipped with inductors for facilitating impedance adaptation of the inputs. The transconductance stage then comprises first and second inductors linking respectively the first and second principal and compensation transistors to the supply terminal. The first and second inductors are connected in series with the first and second degeneracy resistors between the emitters of the principal transistors and the supply terminal.
[0039] Furthermore, the transconductance stage can comprise an inductor of value L connected between the emitters of the principal transistors. The value of the inductance is chosen such that it presents a high impedance for the signal corresponding closely to the working frequency, so that it does not distort the operation for these frequencies. It is also chosen so that it has a low impedance for the components of the second order intermodulation product in order to filter them.
[0040] Considering that the degeneracy resistances of the first and second principal transistors are equal, both having the same value R E , and L can be chosen such that:
L 2 * 2 π * Δ F << R E and L 2 * 2 π * F >> R E
[0041] The values ΔF and F are the same as those taken into consideration above.
[0042] The invention relates not only to a transconductance stage but also to a transmission or reception stage comprising, between an antenna and a modulator or demodulator, a low noise amplifier and a frequency translation device equipped with a mixer, in which at least one of the mixers and amplifiers comprises a transconductance stage as described above. The invention also concerns the use of a transconductance stage in a portable phone.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] Other characteristics and advantages of the invention will be understood from the following description. This is provided as a purely illustrative and non-limiting example.
[0044] [0044]FIG. 1 is a diagram of a transconductance stage with a series feedback according to the prior art;
[0045] [0045]FIG. 2 is a diagram of a transconductance stage with a parallel feedback according to the prior art;
[0046] [0046]FIGS. 3A and 3B are diagrams of a single transconductance stage according to the present invention;
[0047] [0047]FIG. 4 is a diagram of a differential transconductance stage according to the present invention;
[0048] [0048]FIGS. 5 and 6 are diagrams of another embodiment of the transconductance stages illustrated in FIGS. 3A and 4;
[0049] [0049]FIGS. 7 and 8 are diagrams of yet another embodiment of the transconductance stages illustrated in FIGS. 3A and 4; and
[0050] [0050]FIGS. 9A and 9B are simplified drawings of a receiver and a transmitter equipped with a transconductance stage according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] In the following description, identical, equivalent or similar elements of the different figures are marked with the same reference numbers. The transconductance stage of FIG. 3A comprises a first transistor 110 , called the principal transistor, and a second transistor 130 , called the compensation transistor, connected in parallel with the principal transistor. Even though this is not a necessary condition for the operation of the stage, the two transistors preferably have the same specifications.
[0052] The transistor bases are connected to an input terminal 112 to which an input voltage V in is applied. The transistor collectors are linked to an output terminal 114 for connecting to a load (not shown) for the stage. The current crossing this load is called I out . The quiescent currents of the compensation transistor and the principal transistor are called, respectively, I 1 and I 0 . These currents are fixed by the specifications of the transistors and possibly by polarization resistors (not shown).
[0053] The emitters of the transistors are linked to a supply terminal 116 which, in this figure, corresponds to ground. The emitter of the compensation transistor is connected directly to the supply terminal in such a way that it is not degenerate. The emitter of the principal transistor is connected to the supply terminal through the intermediary of a degeneracy resistor 120 , of value R E . The resistor 120 can be formed from a single resistive component or can comprise several resistive components. As stated above, the value of the resistance R E is chosen such that R E *I 0 is greater than V T /2, and may even be very much greater.
[0054] The phase of the harmonic of the third order intermodulation product, as far as the principal transistor is concerned, depends on the value of the degeneracy resistance. This phase reverses around a value of R E which is exactly V T /2I 0 . As an example, if the phase of the third order harmonic is 180° for a value zero or close to zero for the degeneracy resistance, it is 90° for a value R E =V T /2I 0 and zero (0°) for a high value of R E compared with V T /2I 0 . Thus, the case of a phase equal to 180° corresponds to the compensation transistor whose emitter is not degenerate, whereas the case of a phase of 0° corresponds to the principal transistor.
[0055] Since the phases of the components of the third order intermodulation products are opposed, these components, coming from the principal transistor and the compensation transistor, cancel each other. When the amplitude of the third order components is almost the same for the two transistors, the compensation can attain complete elimination of these components. This ideal case can be approached, for example, by using transistors with almost identical specifications and by adjusting the quiescent current I 1 of the compensation transistor.
[0056] TABLE I below provides, for comparison, the output amplitudes of a desired signal at a frequency of 2 GHz, and the amplitude measured in dBc relative to the amplitude of the fundamental, called Imd3, of the components of the third order intermodulation products for a transconductance stage according to FIG. 1 of the prior art, and for a transconductance stage according to the invention and to FIG. 3A. In the two cases, the frequency offset of the component of the third order intermodulation products is ΔF=1 MHz, the input voltage V in is 10 mV, and the value of the degeneracy resistance is 20 Ω.
TABLE I Specification/ Prior art/ Invention/ Performance FIG. 3A Degeneracy R E = 20Ω R E = 20Ω resistance Quiescent current I 0 = 2.947 mA I 0 = 2.947 mA I 1 = 26.8 μA I out −69.59 dBI −69.28 dBI Imd3 (attenuation) −65.64 dBc −103.0 dBc
[0057] It can be seen from consulting TABLE I, that for almost identical quiescent currents (close to 26.8 μA), that is, for almost identical electrical consumption, the components of the intermodulation products undergo very high attenuation in the transconductance stage according to the invention (−103 dB instead of −65 dB).
[0058] In comparison, to obtain such an attenuation with the transconductance stage of the prior art, the value R E would have had to of been raised to 27.5 Ω and the quiescent current I 0 of the degeneracy resistor would have had to have been raised to 14.8 mA. These measures would thus have led to a significant increase in the consumption of electrical energy.
[0059] [0059]FIG. 3A shows a stage mounted according to the invention, built around transistors of the NPN type. An almost identical stage can be produced, as shown in FIG. 3B, from PNP transistors. The output terminal 114 remains connected to the transistor collectors. The supply terminal 116 is no longer the ground terminal as in the above example, but is a supply terminal with a potential Vcc. The potential Vcc is positive relative to ground. As for the rest, and in particular the choice of the degeneracy resistance, one can refer to the description relating to FIG. 3A.
[0060] [0060]FIG. 4 shows another possibility for mounting a transconductance stage according to the invention. It concerns a differential stage. Two principal transistors 110 a and 110 b , in with their emitter degeneracy are associated with two compensation transistors 130 a and 130 b , are without degeneracy. The two compensation transistors 130 a and 130 b are respectively connected in parallel to the principal transistors. The transistors may be identical or different. The differential stage arises from the association of two single stages according to FIG. 3A or 3 B.
[0061] The specifications corresponding to the device of FIG. 3A are not described completely here. The values R Ea and R Eb of the degeneracy resistors 120 a and 120 b , connected to the emitters of the principal transistors can be identical or different. However, they are both chosen according to the criteria mentioned above, that is, higher and preferably very much higher than V T /2I 0 a or V T /2I 0 b, where I 0 a and I 0 b are the quiescent currents of the principal transistor under consideration.
[0062] The transconductance stage has two output terminals 114 a and 114 b which deliver the output currents I out and I xout . The dynamic currents must not be confused with the currents I 1 a, I 1 b, I 0 a and I 0 b shown in the figure. The currents I 1 a, I 1 b, I 0 a and I 0 b are the quiescent currents of the principal and compensation transistors. The stage input comprises two input terminals which, in FIG. 4, are the terminals 112 a and 112 b . These terminals receive the input voltages V ina and V inb .
[0063] Although it is not described in detail here, the symmetrical transconductance stage can also be produced from PNP transistors. Concerning this, reference can be made to FIG. 3B and to the corresponding description.
[0064] When the transconductance stage is to be used in a transmitter or receiver, its input is adapted to a real impedance on the order of 50 Ω. The impedance adaptation can take place, for example, by a series connection with the stage input of an appropriate resistance. However, the transconductance stage according to FIGS. 3A, 3B or 4 still shows, in the absence of special adaptation, a relatively low resistive impedance. This makes adaptation to 50 Ω more difficult.
[0065] [0065]FIG. 5 shows a development of the transconductance stage of FIG. 3A, making it possible, without inserting any supplementary resistor, to raise the resistive value of its high frequency input impedance. According to the mounting illustrated in FIG. 5, an inductance 118 of value L is inserted between the emitter of the compensation transistor and the supply terminal 116 . The inductance is also linked to the emitter of the principal transistor through the intermediary of the degeneracy resistor 120 . Thus, the inductance 118 is in series with this resistor between the emitter of the principal transistor and the supply terminal.
[0066] The value of the inductance 118 can be chosen, for example, as a function of a transition pulse of the stage, in such a way that the real part of the input impedance is on the order of 50 Ω. As an example, a value of 0.8 nH can be chosen.
[0067] TABLE II below demonstrates the influence of the inductance 118 in the transconductance stage of FIG. 5, in comparison with that of FIG. 3A.
TABLE II Specifications without 118 with 118 I 1 400 μA 400 μA I 0 5 mA 5 mA R E 5 Ω 5 Ω L (118) without (0 nH) with (1 nH) input impedance 9-66 80-63 at 2 GHz
[0068] In this table I 1 , I 0 , R E and L correspond respectively to the quiescent current of the compensation transistor 130 , that of the principal transistor 110 , the value of the degeneracy resistor 120 , and the value of the inductor 118 . It is evident that the real part of the input impedance is greatly improved.
[0069] [0069]FIG. 6 shows the use of impedance adaptation inductors in a differential stage. The degeneracy resistors of the two principal transistors are no longer linked together to the supply terminal 116 , but are each linked to the supply terminal 116 by an impedance adaptation inductor. These inductors, references 118 a and 118 b , are respectively in series with the degeneracy resistors between the emitters of the principal transistors and the supply terminal. Moreover, they are linked directly to the emitters of the compensation transistors.
[0070] As noted in the introductory part of the text, the signal comprises not only third order intermodulation products but also second order intermodulation products. The latter, combined with the fundamental components, are capable of generating supplementary third order components.
[0071] [0071]FIG. 7 shows a development of the transconductance stage of the invention which is directed to eliminating or reducing the second order components, and hence, those of the third order. The stage in FIG. 7 comprises the components of FIG. 5 with an added inductor 122 connected in parallel to the degeneracy resistor terminals 120 . In general, it is considered that the parallel inductor 122 is connected in parallel to the degeneracy resistor 120 when it is connected in parallel to all or part of this resistor.
[0072] The value L E of the parallel inductor 122 is chosen such that it is transparent, that is, it has a very high impedance for the components corresponding to the fundamental frequencies F of the desired signal.
[0073] It is also chosen to filter, that is, to present a low impedance for a frequency band ΔF corresponding to second order intermodulation. The orders of magnitude of the frequencies F and ΔF are very different. The fundamental frequencies F of the desired signal are on the order of 1 GHz, for example, whereas the intermodulation frequencies ΔF (for example, F 2 −F 1 ) are on the order of 1 MHz.
[0074] As mentioned above, the parallel inductor 122 is thus chosen such that:
L E <<R E /2 πΔF and L E >>R E /2πF.
[0075] [0075]FIG. 8 shows the application of this development for a differential transconductance stage according to FIG. 6. An inductor 122 is connected between the emitters of the principal transistors 110 a and 110 b . The value of this inductance is determined according to the same criteria as those mentioned above.
[0076] The impedance adaptation inductors 118 , 118 a and 118 b are shown in dotted lines in FIGS. 7 and 8.
[0077] Even though they are part of the illustrated circuit, they are not indispensable. Moreover, the voltage supplies 200 and the impedance adaptation components 202 , 202 a and 202 b are also shown, linked to the input terminals of the stages of FIGS. 7 and 8. The impedance adaptation components comprise an inductor and/or a capacitor in series. They also are shown in dotted lines since they are optional.
[0078] [0078]FIGS. 9A and 9B show the respective principal elements of a receiver stage and a transmitter stage of a portable phone, or another communication device. In particular, it concerns an antenna 300 , an amplifier 302 , a mixer 304 and a demodulator 306 (FIG. 9A) or a modulator 307 (FIG. 9B). The mixer 304 , associated with a local oscillator (not shown), is part of a frequency translation device. A transconductance stage according to the invention and such as described above, can be used in particular in the mixer 304 or in the amplifier 302 as input stage, for example. | A transconductance stage includes at least one principal bipolar transistor having a base linked to an input terminal, a collector linked to an output terminal, and an emitter linked to a supply terminal through a resistor. At least one bipolar compensation transistor is connected in parallel to the principal transistor and linked without going through the resistor to the supply terminal. The value R E of the resistance is chosen so that R E *I 0 >V T /2, where V T is the thermal voltage and I 0 is the quiescent current of the principal transistor. | 7 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates generally to bumper assemblies for automotive vehicles and more particularly to reinforcement attachments for securing an outer fascia member to an inner structural bumper member.
Many typical automotive bumper designs include an outer decorative fascia member, which can be of a color and trim scheme that is complementary to that of the automotive vehicle body. Such a fascia is secured to, and substantially covers, a structural reinforcement bumper member adapted to absorb impacts from low-speed collisions. The bumper reinforcement member is designed to absorb the energy of such a collision while the vehicle itself remains undamaged, often with little or no damage to the decorative outer fascia member itself. Typically, in such designs, the outer fascia member is composed of a flexible and resilient synthetic material that is molded to a desired shape and configuration. Conventional fasteners arc typically inserted through the top of the bumper reinforcement member and into or through a portion of the fascia member that extends between the bumper reinforcement member and the radiator or radiator support structure such that the fasteners are not exposed and do not, therefore, detract from the appearance of the fascia member or the vehicle. However, in many vehicles equipped with such bumper assemblies, the engine-cooling radiator or the radiator's support structure does not allow adequate clearance for the use of such conventional fasteners to attach the fascia member to the structural bumper reinforcement member.
In accordance with the present invention, this problem of inadequate fastener clearance is addressed by the use of an attachment strip (preferably composed of a resilient plastic or other strong but lightweight synthetic material) having at least one resilient finger member with a preferably hook-shaped discontinuity that mates with a corresponding discontinuity (also preferably hook-shaped) on the fascia member. This allows the fascia member to be securely snapped into place on the bumper reinforcement member after the attachment strip has been mounted thereon. Although the discontinuities on the attachment strip finger members and on the fascia member can each be a single continuous discontinuity extending along substantially the entire length of the attachment strip and the fascia member, respectively, the preferred arrangement is a series of discrete finger members and fascia discontinuities spaced apart along the fascia and bumper reinforcement members.
In its preferred form, the attachment strip has a series of windows that are longitudinally aligned and substantially coextensive with the resilient finger members in order to allow the attachment strip to be fabricated with a conventional two-piece mold apparatus. Also in a preferred form of the invention, the attachment member has a centered locator lug or other such locator protrusion that is adapted to be received by a corresponding centered locator opening or notch in the fascia member when the two are snapped together. This allows the fascia to be easily and conveniently located centered on the attachment strip (and thus on the bumper reinforcement member) during assembly.
Additional objects, advantages, and features of the present invention will become apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an exemplary automotive vehicle with one or both of its bumper assemblies in accordance with the present invention.
FIG. 2 is a partial exploded bottom perspective view, illustrating the components of a bumper assembly according to the present invention.
FIG. 3 is a bottom view of a bumper assembly according to the present invention, just prior to the fascia being snapped into place.
FIG. 4 is a partial bottom perspective view of an assembled bumper assembly according to the present invention.
FIG. 5 is a partial cross-sectional view of the assembled bumper apparatus, taken generally along line 5--5 of FIG. 4.
FIG. 6 is a partial cross-sectional view of the assembled bumper apparatus, taken generally along line 6--6 of FIG. 4.
FIG. 7 is a partial cross-sectional view of the assembled bumper apparatus, taken generally along line 7--7 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 through 7 depict exemplary and illustrative embodiments of an automotive bumper assembly according to the present invention. One skilled in the art will readily recognize from the following discussion that the principles of the present invention are equally applicable to bumper assemblies having shapes or configurations other than those depicted for purposes of illustration in the drawings. It should also be noted that the shape of the bumper assembly components illustrated in FIGS. 2 through 7 does not exactly match that of the front and rear bumper assemblies shown on the vehicle illustrated in FIG. 1. For purposes of clarity, however, the shape of the bumper assembly components in FIGS. 2 through 7 has been simplified.
In FIG. 1, a vehicle 10 includes a front bumper assembly 12 and a rear bumper assembly 14. Although the illustrations of FIGS. 2 through 7 depict a simplified front bumper assembly 12, it should be recognized that the principles of the invention shown in FIGS. 2 through 7 are equally applicable to the rear bumper assembly 14. Also, it should be recognized that the fascia attachment illustrated in the drawings can be employed on either the upper or the lower flanges (or on both) of the fascia member and the inner structural bumper member.
In FIGS. 2 through 7, the bumper assembly 12 includes an inner structural bumper member 16, having a lower bumper flange 20 and an upper bumper flange 22 thereon. The bumper assembly 12 also includes an outer fascia member 18 similarly having a lower fascia flange 24 and an upper fascia flange 26. A preferred series of discrete fascia discontinuities 28 (which are preferably of a generally hooked-shaped cross-sectional configuration) are spaced apart along substantially the entire length of an edge of the lower fascia flange 24.
An attachment strip 30, which is preferably composed of a resilient plastic or other similar high-strength lightweight material, extends along an inner side of the lower bumper flange 20. The attachment strip 30 has a preferred series of discrete finger portions 32, which extend outwardly and upwardly from an edge portion of the attachment strip 30 and are generally parallel to, but spaced-apart from, the main body portion of the attachment strip 30. The resilient fingers 30 each include preferably hook-shaped finger discontinuities 34 along their free edges, with the hook-shaped finger discontinuities 34 oriented in an opposite direction from the hook-shaped fascia discontinuities 28, with the corresponding discontinuities facing generally toward each other. As can perhaps best be seen in FIGS. 2 through 4, this arrangement allows the lower fascia flange 24 of the fascia member 18 to be snapped into a secure engagement with the attachment strip 30.
The attachment strip 30 can be secured to the lower bumper flange 20 by way of conventional threaded male fasteners 38, for example. The fasteners 38 extend through a series of openings 42 in the lower bumper flange 20 and a corresponding series of openings 44 in the attachment strip 30, where the fasteners 38 threadably engage conventional U-nut clips that resiliently grip the main body portion of the attachment strip 30, as illustrated, for example, in the cross-sectional view of FIG. 5. In this regard, the lower fascia flange 24 preferably includes a series of spaced-apart cut-out recesses 46, which provide clearance for the head portions of the illustrated male fasteners 38. Thus, as can be seen in FIGS. 4 through 7, both the lower bumper flange 20 and the lower fascia flange 24 are sandwiched between the main body portion of the attachment strip 30 and the attachment strip's resiliently deflectable fingers 32 when the fascia 18 is snapped into place. This provides for a secure, rattle-free attachment of the fascia member 18 to the inner structural bumper members 16, with no fasteners visible from the exterior of the vehicle 10, when viewed from a normal viewing perspective. It should be noted, however, that other well-known fastener types can alternately be used to secure the attachment strip 30 onto the inner bumper member 16.
In order to facilitate the ease and economy of the fabrication of the attachment strip 30, the attachment strip's main body portion preferably includes a series of finger windows or other openings 36 that correspond with the number of resiliently-deflectable fingers 32. The finger windows 36 are generally aligned with, and substantially coextensive with, the fingers 32. This configuration allows the attachment strip 30 to be easily and economically fabricated in a conventional two-piece molding apparatus.
Also for purposes of ease and economy of assembly, a locator lug 50 is provided, preferably on one of the fingers 32 and preferably at the center of the length of the attachment strip 30. Correspondingly, a locator opening or notch 52 is provided on the corresponding (preferably center) location of the lower fascia flange 24. The locator opening 52 on the fascia member 18 is configured to receive the locator lug 50 on the central finger 32 of the attachment strip 30, thus providing for easy and convenient alignment of the fascia member 18 with the attachment strip 30 and the inner structural bumper member 16 when the fascia member 18 is securely snapped into place.
The foregoing discussion discloses and describes merely exemplary embodiments of the present invention for purposes of illustration. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications, and variations can be made therein without departing from the spirit and scope of the invention as defined in the following claims. | An automotive bumper assembly preferably includes a resilient attachment strip secured to the bumper assembly's inner structural bumper member. The attachment strip includes resilient fingers with preferably hook-shaped edge portions that mate and interlock with preferably hook-shaped edge portions of an outer decorative fascia member. This configuration allows the fascia member to be conveniently snapped into place on the structural inner bumper member with only minimal clearance being needed for a secure attachment. | 1 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional application 61/391,464, filed on Oct. 8, 2010, the contents of which are incorporated in its entirety.
TECHNICAL FIELD OF THE INVENTION
This invention relates to novel pyridazine derivatives, their salts, solvates, hydrates and polymorphs thereof. The invention also provides compositions comprising a compound of this invention and the use of such compositions in methods of treating diseases and conditions associated with protein kinase modulation.
BACKGROUND OF THE INVENTION
Protein kinases are enzymes that catalyze the phosphorylation of hydroxyl groups of tyrosine, serine, and threonine residues of proteins. Many aspects of cell life (for example, cell growth, differentiation, proliferation, cell cycle and survival) depend on protein kinase activities. Furthermore, abnormal protein kinase activity has been related to a host of disorders such as cancer and inflammation. Therefore, considerable effort has been directed to identifying ways to modulate protein kinase activities. In particular, many attempts have been made to identify small molecules that act as protein kinase inhibitors.
The c-Met proto-oncogene encodes the Met receptor tyrosine kinase. The Met receptor is a 190 kDa glycosylated dimeric complex composed of a 50 kDa alpha chain disulfide-linked to a 145 kDa beta chain. The alpha chain is found extracellularly while the beta chain contains transmembrane and cytosolic domains. Met is synthesized as a precursor and is proteolytically cleaved to yield mature alpha and beta subunits. It displays structural similarities to semaphorins and plexins, a ligand-receptor family that is involved in cell-cell interaction. The ligand for Met is hepatocyte growth factor (HGF), a member of the scatter factor family and has some homology to plasminogen (Longati, P. et al., Curr. Drug Targets 2001, 2, 41-55); Trusolino, L. and Comoglio, P. Nature Rev. Cancer 2002, 2, 289-300].
Met functions in tumorigenesis and tumor metastasis. Expression of Met along with its ligand HGF is transforming, tumorigenic, and metastatic (Jeffers, M. et al., Oncogene 1996, 13, 853-856; Michieli, P. et al., Oncogene 1999, 18, 5221-5231). MET is overexpressed in a significant percentage of human cancers and is amplified during the transition between primary tumors and metastasis. Numerous studies have correlated the expression of c-MET and/or HGF/SF with the state of disease progression of different types of cancer (including lung, colon, breast, prostate, liver, pancreas, brain, kidney, ovaries, stomach, skin, and bone cancers). Furthermore, the overexpression of c-MET or HGF have been shown to correlate with poor prognosis and disease outcome in a number of major human cancers including lung, liver, gastric, and breast. c-MET has also been directly implicated in cancers without a successful treatment regimen such as pancreatic cancer, glioma, and hepatocellular carcinoma.
Met mutants exhibiting enhanced kinase activity have been identified in both hereditary and sporadic forms of papillary renal carcinoma (Schmidt, L. et al., Nat. Genet. 1997, 16, 68-73; Jeffers, M. et al., Proc. Nat. Acad. Sci. 1997, 94, 11445-11500). HGF/Met has been shown to inhibit anoikis, suspension-induced programmed cell death (apoptosis), in head and neck squamous cell carcinoma cells. Anoikis resistance or anchorage-independent survival is a hallmark of oncogenic transformation of epithelial cells (Zeng, Q. et al., J. Biol. Chem. 2002, 277, 25203-25208).
Increased expression of Met/HGF is seen in many metastatic tumors including colon (Fazekas, K. et al., Clin. Exp. Metastasis 2000, 18, 639-649), breast (Elliott, B. E. et al., 2002, Can. J. Physiol. Pharmacol. 80, 91-102), prostate (Knudsen, B. S. et al., Urology 2002, 60, 1113-1117), lung (Siegfried, J. M. et al., Ann. Thorac. Surg. 1998, 66, 1915-1918), and gastric (Amemiya, H. et al., Oncology 2002, 63, 286-296). HGF-Met signaling has also been associated with increased risk of atherosclerosis (Yamamoto, Y. et al., J. Hypertens. 2001, 19, 1975-1979; Morishita, R. et al., Endocr. J. 2002, 49, 273-284) and increased fibrosis of the lung (Crestani, B. et al., Lab. Invest. 2002, 82, 1015-1022).
2-amino-pyridines, such as PF-2341066, have been reported as potent inhibitors of the HGF receptor tyrosine kinase (c-Met) and ALK (J. G. Christensen, et al. Abstract LB-271, AACR 2006 meeting; H. Y. Zou et al. Cancer Res 2007; 67: 4408; patent disclosures: WO 2004076412, WO 2006021881, WO 2006021886).
Previously, we described the substituted pyridazine carboxamide compounds as protein kinase inhibitors (WO 2009/154769). Most of these compounds potently inhibit c-Met and ALK with IC50 of <100 nM. This invention discloses the unsaturated heterocycle substituted pyridazine carboxamide as more selective c-Met inhibitors.
SUMMARY OF THE INVENTION
The invention relates to pyridazine derivative compounds (e.g., any of the formulae herein), compositions comprising the compounds, and methods of using the compounds and compound compositions. The compounds and compositions comprising them are useful for treating or preventing disease or disease symptoms, including those mediated by or associated with protein kinase modulation activity.
The present invention solves the problems set forth above by providing an isolated compound of Formula I
or a salt thereof; or a prodrug, or a salt of a prodrug thereof; or a hydrate, solvate, or polymorph thereof; wherein:
R 1 , R 2 , R 3 , and R 4 each are independently H, alkyl, or Z 1 ;
R 6 is an unsaturated heterocyclyl, wherein R 6 is optionally substituted by 1-3 groups independently selected from alkyl, cycloalkyl, heterocyclyl, alkoxy, hydroxyalkyl, and Z 1 ;
Each Z 1 is halogen, CN, NO 2 , OR 15 , SR 15 , S(O) 2 OR 1 , NR 15 R 16 , C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, 1,2-methylenedioxy, C(O)OR 15 , C(O)NR 15 R 16 OC(O)NR 15 R 16 , NR 15 C(O)NR 15 R 16 , C(NR 16 )NR 15 R 16 , NR 15 C(NR 16 )NR 15 R 16 , S(O) 2 NR 15 R 16 , R 17 , C(O)R 17 , NR 15 C(O)R 17 , S(O)R 17 , S(O) 2 R 17 , R 16 , oxo, C(O)R 16 , C(O)(CH 2 )nOH, (CH 2 )nOR 15 , (CH 2 )nC(O)NR 15 R 16 , NR 15 S(O) 2 R 17 , where each n is independently 0-6;
Each R 15 is independently hydrogen, C 1 -C 4 alkyl or C 3 -C 6 cycloalkyl;
Each R 16 is independently hydrogen, alkenyl, alkynyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl; and
Each R 17 is independently C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl.
The compounds of this invention, and compositions comprising them, are useful for treating or lessening the severity of protein kinase modulated diseases, disorders, or symptoms thereof, i.e., disorders effectively treated by inhibitors of protein kinases, especially c-met.
In another aspect, the invention relates to a method of treating a disease or disease symptom in a subject in need thereof including administering to the subject an effective amount of a compound of any formulae herein, or pharmaceutical salt, solvate or hydrate thereof (or composition thereof). The disease or disease symptom can be any of those modulated by a protein kinase (e.g. c-met). The disease or disease symptom can be, for example, cancer or proliferation disease or disorder (e.g., including those delineated herein).
DETAILED DESCRIPTION OF THE INVENTION
Description of the Drawings
FIG. 1 showed c-Met expression in all these cell lines. U87MG, PC3 and Caki cells expressed phosphorylated high level of c-Met. Compared to total c-Met expression level, U87-MG showed the most elevated phospho-c-Met level and thus it was selected for in vivo studies.
FIG. 2 . Growth inhibition of EXAMPLE 1 on U-87 MG xenograft tumor model. The data graph shows the tumor volume of U-87 MG in Balb/c nude mice. Lines, mean tumor volume for each group, bars, ±S.E.
DEFINITIONS
The terms “ameliorate” and “treat” are used interchangeably and both mean decrease, suppress, attenuate, diminish, arrest, or stabilize the development or progression of a disease (e.g., a disease or disorder delineated herein).
By “disease” is meant any condition or disorder that damages or interferes with the normal function of a cell, tissue, or organ.
By “marker” is meant any alteration that is associated with a disease or disorder.
For example, any protein or polynucleotide having an alteration in expression level or activity that is associated with a disease or disorder.
In this disclosure, “comprises,” “comprising,” “containing” and “having” and the like can have the meaning ascribed to them in U.S. patent law and can mean “includes,” “including,” and the like; “consisting essentially of” or “consists essentially” likewise has the meaning ascribed in U.S. patent law and the term is open-ended, allowing for the presence of more than that which is recited so long as basic or novel characteristics of that which is recited is not changed by the presence of more than that which is recited, but excludes prior art embodiments.
The term “compound” as used herein, is also intended to include salts, prodrugs, and prodrug salts of a compound of formulae herein. The term also includes any solvates, hydrates, and polymorphs of any of the foregoing. The specific recitation of “prodrug,” “prodrug salt,” “solvate,” “hydrate,” or “polymorph” in certain aspects of the invention described in this application shall not be interpreted as an intended omission of these forms in other aspects of the invention where the term “compound” is used without recitation of these other forms.
A salt of a compound of this invention is formed between an acid and a basic group of the compound, such as an amino functional group, or a base and an acidic group of the compound, such as a carboxyl functional group. According to another preferred embodiment, the compound is a pharmaceutically acceptable acid addition salt.
As used herein and unless otherwise indicated, the term “prodrug” means a derivative of a compound that can hydrolyze, oxidize, or otherwise react under biological conditions (in vitro or in vivo) to provide a compound of this invention. Prodrugs may only become active upon such reaction under biological conditions, or they may have activity in their unreacted forms. Examples of prodrugs contemplated in this invention include, but are not limited to, analogs or derivatives of compounds of any one of the formulae disclosed herein that comprise biohydrolyzable moieties such as amides, esters, carbamates, carbonates, and phosphate analogues. Prodrugs can typically be prepared using well-known methods, such as those described by Burger's Medicinal Chemistry and Drug Discovery (1995) 172-178, 949-982 (Manfred E. Wolff ed., 5th ed); see also Goodman and Gilman's, The Pharmacological basis of Therapeutics, 8th ed., McGraw-Hill, Int. Ed. 1992, “Biotransformation of Drugs”.
As used herein and unless otherwise indicated, the term “biohydrolyzable moiety” means a functional group (e.g., amide, ester, carbamate, carbonate, or phosphate analogue, that either: 1) does not destroy the biological activity of the compound and confers upon that compound advantageous properties in vivo, such as uptake, duration of action, or onset of action; or 2) is itself biologically inactive but is converted in vivo to a biologically active compound.
A prodrug salt is a compound formed between an acid and a basic group of the prodrug, such as an amino functional group, or a base and an acidic group of the prodrug, such as a carboxyl functional group. In a one embodiment, the prodrug salt is a pharmaceutically acceptable salt.
Particularly favored prodrugs and prodrug salts are those that increase the bioavailability of the compounds of this invention when such compounds are administered to a mammal (e.g., by allowing an orally administered compound to be more readily absorbed into the blood) or which enhance delivery of the parent compound to a biological compartment (e.g., the brain or central nervous system) relative to the parent species. Preferred prodrugs include derivatives where a group that enhances aqueous solubility or active transport through the gut membrane is appended to the structure of formulae described herein. See, e.g., Alexander, J. et al. Journal of Medicinal Chemistry 1988, 31, 318-322; Bundgaard, H. Design of Prodrugs; Elsevier: Amsterdam, 1985; pp 1-92; Bundgaard, H.; Nielsen, N. M. Journal of Medicinal Chemistry 1987, 30, 451-454; Bundgaard, H. A Textbook of Drug Design and Development; Harwood Academic Publ.: Switzerland, 1991; pp 113-191; Digenis, G. A. et al. Handbook of Experimental Pharmacology 1975, 28, 86-112; Friis, G. J.; Bundgaard, H. A Textbook of Drug Design and Development; 2 ed.; Overseas Publ.: Amsterdam, 1996; pp 351-385; Pitman, I. H. Medicinal Research Reviews 1981, 1, 189-214.
The term “pharmaceutically acceptable,” as used herein, refers to a component that is, within the scope of sound medical judgment, suitable for use in contact with the tissues of humans and other mammals without undue toxicity, irritation, allergic response and the like, and are commensurate with a reasonable benefit/risk ratio. A “pharmaceutically acceptable salt” means any non-toxic salt that, upon administration to a recipient, is capable of providing, either directly or indirectly, a compound or a prodrug of a compound of this invention.
Acids commonly employed to form pharmaceutically acceptable salts include inorganic acids such as hydrogen bisulfide, hydrochloric, hydrobromic, hydroiodic, sulfuric and phosphoric acid, as well as organic acids such as para-toluenesulfonic, salicylic, tartaric, bitartaric, ascorbic, maleic, besylic, fumaric, gluconic, glucuronic, formic, glutamic, methanesulfonic, ethanesulfonic, benzenesulfonic, lactic, oxalic, para-bromophenylsulfonic, carbonic, succinic, citric, benzoic and acetic acid, and related inorganic and organic acids. Such pharmaceutically acceptable salts thus include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, decanoate, caprylate, acrylate, formate, isobutyrate, caprate, heptanoate, propiolate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, butyne-1,4-dioate, hexyne-1,6-dioate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, hydroxybenzoate, methoxybenzoate, phthalate, terephathalate, sulfonate, xylenesulfonate, phenylacetate, phenylpropionate, phenylbutyrate, citrate, lactate, β-hydroxybutyrate, glycolate, maleate, tartrate, methanesulfonate, propanesulfonate, naphthalene-1-sulfonate, naphthalene-2-sulfonate, mandelate and the like salts. Preferred pharmaceutically acceptable acid addition salts include those formed with mineral acids such as hydrochloric acid and hydrobromic acid, and especially those formed with organic acids such as maleic acid.
Suitable bases for forming pharmaceutically acceptable salts with acidic functional groups of prodrugs of this invention include, but are not limited to, hydroxides of alkali metals such as sodium, potassium, and lithium; hydroxides of alkaline earth metal such as calcium and magnesium; hydroxides of other metals, such as aluminum and zinc; ammonia, and organic amines, such as unsubstituted or hydroxy-substituted mono-, di-, or trialkylamines; dicyclohexylamine; tributyl amine; pyridine; N-methyl,N-ethylamine; diethylamine; triethylamine; mono-, bis-, or tris-(2-hydroxy-lower alkyl amines), such as mono-, bis-, or tris-(2-hydroxyethyl)amine, 2-hydroxy-tert-butylamine, or tris-(hydroxymethyl)methylamine, N,N,-di-lower alkyl-N-(hydroxy lower alkyl)-amines, such as N,N-dimethyl-N-(2-hydroxyethyl)amine, or tri-(2-hydroxyethyl)amine; N-methyl-D-glucamine; and amino acids such as arginine, lysine, and the like.
As used herein, the term “hydrate” means a compound which further includes a stoichiometric or non-stoichiometric amount of water bound by non-covalent intermolecular forces.
As used herein, the term “solvate” means a compound which further includes a stoichiometric or non-stoichiometric amount of solvent such as water, acetone, ethanol, methanol, dichloromethane, 2-propanol, or the like, bound by non-covalent intermolecular forces.
As used herein, the term “polymorph” means solid crystalline forms of a compound or complex thereof which may be characterized by physical means such as, for instance, X-ray powder diffraction patterns or infrared spectroscopy. Different polymorphs of the same compound can exhibit different physical, chemical and/or spectroscopic properties. Different physical properties include, but are not limited to stability (e.g., to heat, light or moisture), compressibility and density (important in formulation and product manufacturing), hygroscopicity, solubility, and dissolution rates (which can affect bioavailability). Differences in stability can result from changes in chemical reactivity (e.g., differential oxidation, such that a dosage form discolors more rapidly when comprised of one polymorph than when comprised of another polymorph) or mechanical characteristics (e.g., tablets crumble on storage as a kinetically favored polymorph converts to thermodynamically more stable polymorph) or both (e.g., tablets of one polymorph are more susceptible to breakdown at high humidity). Different physical properties of polymorphs can affect their processing. For example, one polymorph might be more likely to form solvates or might be more difficult to filter or wash free of impurities than another due to, for example, the shape or size distribution of particles of it.
The term “substantially free of other stereoisomers” as used herein means less than 25% of other stereoisomers, preferably less than 10% of other stereoisomers, more preferably less than 5% of other stereoisomers and most preferably less than 2% of other stereoisomers, or less than “X” % of other stereoisomers (wherein X is a number between 0 and 100, inclusive) are present. Methods of obtaining or synthesizing diastereomers are well known in the art and may be applied as practicable to final compounds or to starting material or intermediates. Other embodiments are those wherein the compound is an isolated compound. The term “at least X % enantiomerically enriched” as used herein means that at least X % of the compound is a single enantiomeric form, wherein X is a number between 0 and 100, inclusive.
The term “stable compounds”, as used herein, refers to compounds which possess stability sufficient to allow manufacture and which maintain the integrity of the compound for a sufficient period of time to be useful for the purposes detailed herein (e.g., formulation into therapeutic products, intermediates for use in production of therapeutic compounds, isolatable or storable intermediate compounds, treating a disease or condition responsive to therapeutic agents).
“Stereoisomer” refers to both enantiomers and diastereomers.
As used herein, the term “halo” or “halogen” refers to any radical of fluorine, chlorine, bromine or iodine.
The terms “alk” or “alkyl” refer to straight or branched chain hydrocarbon groups having 1 to 12 carbon atoms, preferably 1 to 8 carbon atoms. The expression “lower alkyl” refers to alkyl groups of 1 to 4 carbon atoms (inclusive).
The term “arylalkyl” refers to a moiety in which an alkyl hydrogen atom is replaced by an aryl group.
The term “alkenyl” refers to straight or branched chain hydrocarbon groups of 2 to 10, preferably 2 to 4, carbon atoms having at least one double bond. Where an alkenyl group is bonded to a nitrogen atom, it is preferred that such group not be bonded directly through a carbon bearing a double bond.
The term “alkoxy” refers to an —O-alkyl radical. The term “alkylenedioxo” refers to a divalent species of the structure —O—R—O—, in which R represents an alkylene.
The term “alkynyl” refers to straight or branched chain hydrocarbon groups of 2 to 10, preferably 2 to 4, carbon atoms having at least one triple bond. Where an alkynyl group is bonded to a nitrogen atom, it is preferred that such group not be bonded directly through a carbon bearing a triple bond.
The term “alkylene” refers to a divalent straight chain bridge of 1 to 5 carbon atoms connected by single bonds (e.g., —(CH 2 ) x —, wherein x is 1 to 5), which may be substituted with 1 to 3 lower alkyl groups.
The term “alkenylene” refers to a straight chain bridge of 2 to 5 carbon atoms having one or two double bonds that is connected by single bonds and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkenylene groups are —CH═CH—CH═CH—, —CH 2 —CH═CH—, —CH 2 —CH═CH—CH 2 —, —C(CH 3 ) 2 CH═CH— and —CH(C 2 H 5 )—CH═CH—.
The term “alkynylene” refers to a straight chain bridge of 2 to 5 carbon atoms that has a triple bond therein, is connected by single bonds, and may be substituted with 1 to 3 lower alkyl groups. Exemplary alkynylene groups are —C≡C—, —CH 2 —C≡C—, —CH(CH 3 )C≡C— and —C≡C—CH(C 2 H 5 )CH 2 —.
The terms “cycloalkyl” and “cycloalkenyl” as employed herein includes saturated and partially unsaturated cyclic, respectively, hydrocarbon groups having 3 to 12 carbons, preferably 3 to 8 carbons, and more preferably 3 to 6 carbon.
The terms “Ar” or “aryl” refer to aromatic cyclic groups (for example 6 membered monocyclic, 10 membered bicyclic or 14 membered tricyclic ring systems) which contain 6 to 14 carbon atoms. Exemplary aryl groups include phenyl, naphthyl, biphenyl and anthracene.
“Heteroaryl” refers to a monocyclic or fused ring (i.e., rings which share an adjacent pair of atoms) group of 5 to 12 ring atoms containing one, two, three or four ring heteroatoms selected from N, O, or S, the remaining ring atoms being C, and, in addition, having a completely conjugated pi-electron system, wherein 0, 1, 2, 3, or 4 atoms of each ring may be substituted by a substituent. Examples, without limitation, of heteroaryl groups are pyrrole, furan, thiophene, imidazole, oxazole, thiazole, pyrazole, pyridine, pyrimidine, quinoline, quinazoline, isoquinoline, purine and carbazole.
The terms “heterocycle”, “heterocyclic” or “heterocyclo” refer to fully saturated or partially unsaturated cyclic groups, for example, 3 to 7 membered monocyclic, 7 to 12 membered bicyclic, or 10 to 15 membered tricyclic ring systems, which have at least one heteroatom in at least one ring, wherein 0, 1, 2 or 3 atoms of each ring may be substituted by a substituent. Each ring of the heterocyclic group containing a heteroatom may have 1, 2, 3 or 4 heteroatoms selected from nitrogen atoms, oxygen atoms and/or sulfur atoms, where the nitrogen and sulfur heteroatoms may optionally be oxidized and the nitrogen heteroatoms may optionally be quaternized. The heterocyclic group may be attached at any heteroatom or carbon atom of the ring or ring system.
The term “heterocyclyl” refers to fully saturated or partially unsaturated cyclic groups, for example, 3 to 7 membered monocyclic, 7 to 12 membered bicyclic, or 10 to 15 membered tricyclic ring systems, which have at least one heteroatom in at least one ring, wherein 0, 1, 2 or 3 atoms of each ring may be substituted by a substituent. Each ring of the heterocyclyl group containing a heteroatom may have 1, 2, 3 or 4 heteroatoms selected from nitrogen atoms, oxygen atoms and/or sulfur atoms, where the nitrogen and sulfur heteroatoms may optionally be oxidized and the nitrogen heteroatoms may optionally be quaternized. The heterocyclyl group may be attached at any heteroatom or carbon atom of the ring or ring system.
The term “substituents” refers to a group “substituted” on any functional group delineated herein, e.g., alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl, heterocyclyl, or heteroaryl group at any atom of that group. Suitable substituents include, without limitation halogen, CN, NO 2 , OR 15 , SR 15 , S(O) 2 OR 15 , NR 15 R 16 , C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, 1,2-methylenedioxy, C(O)OR 15 , C(O)NR 15 R 16 , OC(O)NR 15 R 16 , NR 15 C(O)NR 15 R 16 , C(NR 16 )NR 15 R 16 NR 15 C(NR 16 )NR 15 R 16 , S(O) 2 NR 15 R 16 , R 17 , C(O)R 17 , NR 15 C(O)R 17 , S(O)R 17 , S(O) 2 R 17 , R 16 , oxo, C(O)R 16 , C(O)(CH 2 )nOH, (CH 2 )nOR 15 , (CH 2 )nC(O)NR 15 R 16 , NR 15 S(O) 2 R 17 , where n is independently 0-6 inclusive. Each R 15 is independently hydrogen, C 1 -C 4 alkyl or C 3 -C 6 cycloalkyl. Each R 16 is independently hydrogen, alkenyl, alkynyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl. Each R 17 is independently C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl. Each C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl and C 1 -C 4 alkyl in each R 5 , R 16 and R 17 can optionally be substituted with halogen, CN, C 1 -C 4 alkyl, OH, C 1 -C 4 alkoxy, NH 2 , C 1 -C 4 alkylamino, C 1 -C 4 dialkylamino, C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, or 1,2-methylenedioxy.
The term “oxo” refers to an oxygen atom, which forms a carbonyl when attached to carbon, an N-oxide when attached to nitrogen, and a sulfoxide or sulfone when attached to sulfur.
The term “acyl” refers to an alkylcarbonyl, cycloalkylcarbonyl, arylcarbonyl, heterocyclylcarbonyl, or heteroarylcarbonyl substituent, any of which may be further substituted by substituents.
The recitation of a listing of chemical groups in any definition of a variable herein includes definitions of that variable as any single group or combination of listed groups. The recitation of an embodiment for a variable herein includes that embodiment as any single embodiment or in combination with any other embodiments or portions thereof. The recitation of an embodiment herein includes that embodiment as any single embodiment or in combination with any other embodiments or portions thereof.
The compounds of this invention may contain one or more asymmetric centers and thus occur as racemates and racemic mixtures, single enantiomers, individual diastereomers and diastereomeric mixtures. All such isomeric forms of these compounds are expressly included in the present invention. The compounds of this invention may also be represented in multiple tautomeric forms, in such instances, the invention expressly includes all tautomeric forms of the compounds described herein. All such isomeric forms of such compounds are expressly included in the present invention. All crystal forms of the compounds described herein are expressly included in the present invention.
Compounds of the Invention
In one aspect, the present invention provides a compound of Formula I:
or a salt thereof; or a prodrug, or a salt of a prodrug thereof; or a hydrate, solvate, or polymorph thereof; wherein:
R 1 , R 2 , R 3 , and R 4 each are independently H, alkyl, or Z 1 ;
R 6 is an unsaturated heterocyclyl, wherein R 6 is optionally substituted by 1-3 groups, independently selected from alkyl, cycloalkyl, heterocyclyl, alkoxy, hydroxyalkyl, and Z 1 ;
Each Z 1 is halogen, CN, NO 2 , OR 15 , SR 15 , S(O) 2 OR 15 , NR 15 R 16 , C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, 1,2-methylenedioxy, C(O)OR 15 , C(O)NR 15 R 16 OC(O)NR 15 R 16 , NR 15 C(O)NR 15 R 16 , C(NR 16 )NR 15 R 16 , NR 15 C(NR 16 )NR 15 R 16 , S(O) 2 NR 15 R 16 , R 17 , C(O)R 17 , NR 15 C(O)R 17 , S(O)R 17 , S(O) 2 R 17 , R 16 , oxo, C(O)R 16 , C(O)(CH 2 )nOH, (CH 2 )nOR 15 , (CH 2 )nC(O)NR 15 R 16 , NR 15 S(O) 2 R 17 , where each n is independently 0-6;
Each R 15 is independently hydrogen, C 1 -C 4 alkyl or C 3 -C 6 cycloalkyl;
Each R 16 is independently hydrogen, alkenyl, alkynyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl; and
Each R 17 is independently C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl.
In one embodiment, the invention provides for a compound of formula II:
or a salt thereof; or a prodrug, or a salt of a prodrug thereof; or a hydrate, solvate, or polymorph thereof; wherein R 1 , R 2 , R 3 , R 4 , R 7 and R 8 each are independently H, alkyl or Z 1 ;
Each Z 1 is halogen, CN, NO 2 , OR 15 , SR 15 , S(O) 2 OR 5 , NR 15 R 16 , C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, 1,2-methylenedioxy, C(O)OR 15 , C(O)NR 15 R 16 OC(O)NR 15 R 16 , NR 15 C(O)NR 15 R 16 , C(NR 16 )NR 15 R 16 , NR 15 C(NR 16 )NR 15 R 16 , S(O) 2 NR 15 R 16 , R 17 , C(O)R 17 , NR 15 C(O)R 17 , S(O)R 17 , S(O) 2 R 17 , R 16 , oxo, C(O)R 16 , C(O)(CH 2 )nOH, (CH 2 )nOR 15 , (CH 2 )nC(O)NR 15 R 16 , NR 15 S(O) 2 R 17 , where each n is independently 0-6;
Each R 15 is independently hydrogen, C 1 -C 4 alkyl or C 3 -C 6 cycloalkyl;
Each R 16 is independently hydrogen, alkenyl, alkynyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl; and
Each R 17 is independently C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl.
In another embodiment, the invention provides for a compound of formula III:
or a salt thereof; or a prodrug, or a salt of a prodrug thereof; or a hydrate, solvate, or polymorph thereof; wherein R 7 and R 8 each are independently H, alkyl or Z 1 ;
Each Z 1 is halogen, CN, NO 2 , OR 15 , SR 15 , S(O) 2 OR 5 , NR 15 R 16 , C 1 -C 2 perfluoroalkyl, C 1 -C 2 perfluoroalkoxy, 1,2-methylenedioxy, C(O)OR 5 , C(O)NR 15 R 16 OC(O)NR 15 R 16 , NR 15 C(O)NR 15 R 16 , C(NR 16 )NR 15 R 16 , NR 15 C(NR 16 )NR 15 R 16 , S(O) 2 NR 15 R 16 , R 17 , C(O)R 17 , NR 15 C(O)R 17 , S(O)R 17 , S(O) 2 R 17 , R 16 , oxo, C(O)R 16 , C(O)(CH 2 )nOH, (CH 2 )nOR 15 , (CH 2 )nC(O)NR 15 R 16 , NR 15 S(O) 2 R 17 , where each n is independently 0-6;
Each R 15 is independently hydrogen, C 1 -C 4 alkyl or C 3 -C 6 cycloalkyl;
Each R 16 is independently hydrogen, alkenyl, alkynyl, C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl; and
Each R 17 is independently C 3 -C 6 cycloalkyl, aryl, heterocyclyl, heteroaryl, C 1 -C 4 alkyl or C 1 -C 4 alkyl substituted with C 3 -C 6 cycloalkyl, aryl, heterocyclyl or heteroaryl.
Representative compounds of the invention are depicted in Table 1. In these examples the stereochemistry at the chiral carbon atoms is independently either RS, R, or S, unless specified. The structures depicted herein, including the Table 1 structures, may contain certain —NH—, —NH 2 (amino) and —OH (hydroxyl) groups where the corresponding hydrogen atom(s) do not explicitly appear; however they are to be read as —NH—, —NH 2 or —OH as the case may be. In certain structures, a stick bond is drawn and is meant to depict a methyl group.
TABLE 1
1
2
3
5
6
7
Representative compounds of the invention are listed below:
{5-[(1R)-1-(2,6-dichloro-3-fluorophenyl)ethoxy]-6-aminopyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide; {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide; {5-[(1S)-1-(2,6-dichloro-3-fluorophenyl)ethoxy]-6-aminopyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide; {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide; {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-[1-(2-methoxyethyl)-6-oxo-1,6-dihydro-pyridin-3-yl]carboxamide; {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(1-ethyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide.
The synthesis of compounds of the formulae herein can be readily effected by synthetic chemists of ordinary skill. Relevant procedures and intermediates are disclosed, for instance, herein. Each of the patents, patent applications, and publications, whether in traditional journals or available only through the internet, referred to herein, is incorporated in its entirety by reference.
Other approaches to synthesizing compounds of the formulae herein can readily be adapted from references cited herein. Variations of these procedures and their optimization are within the skill of the ordinary practitioner.
The specific approaches and compounds shown above are not intended to be limiting. The chemical structures in the schemes herein depict variables that are hereby defined commensurately with chemical group definitions (moieties, atoms, etc.) of the corresponding position in the compound formulae herein, whether identified by the same variable name (e.g., R 1 , R 2 , R, R′, X, etc.) or not. The suitability of a chemical group in a compound structure for use in synthesis of another compound structure is within the knowledge of one of ordinary skill in the art. Additional methods of synthesizing compounds of the formulae herein and their synthetic precursors, including those within routes not explicitly shown in schemes herein, are within the means of chemists of ordinary skill in the art. Methods for optimizing reaction conditions, if necessary minimizing competing by-products, are known in the art. The methods described herein may also additionally include steps, either before or after the steps described specifically herein, to add or remove suitable protecting groups in order to ultimately allow synthesis of the compounds herein. In addition, various synthetic steps may be performed in an alternate sequence or order to give the desired compounds. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing the applicable compounds are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 3 rd Ed., John Wiley and Sons (1999); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
The methods delineated herein contemplate converting compounds of one formula to compounds of another formula. The process of converting refers to one or more chemical transformations, which can be performed in situ, or with isolation of intermediate compounds. The transformations can include reacting the starting compounds or intermediates with additional reagents using techniques and protocols known in the art, including those in the references cited herein. Intermediates can be used with or without purification (e.g., filtration, distillation, sublimation, crystallization, trituration, solid phase extraction, and chromatography).
Combinations of substituents and variables envisioned by this invention are only those that result in the formation of stable compounds.
The invention also provides compositions comprising an effective amount of a compound of any of the formulae herein, or a pharmaceutically acceptable salt, solvate, hydrate, polymorph or prodrug, if applicable, of said compound; and an acceptable carrier. Preferably, a composition of this invention is formulated for pharmaceutical use (“a pharmaceutical composition”), wherein the carrier is a pharmaceutically acceptable carrier. The carrier(s) must be “acceptable” in the sense of being compatible with the other ingredients of the formulation and, in the case of a pharmaceutically acceptable carrier, not deleterious to the recipient thereof in amounts typically used in medicaments.
Pharmaceutically acceptable carriers, adjuvants and vehicles that may be used in the pharmaceutical compositions of this invention include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
The pharmaceutical compositions of the invention include those suitable for oral, rectal, nasal, topical (including buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous and intradermal) administration. In certain embodiments, the compound of the formulae herein is administered transdermally (e.g., using a transdermal patch). Other formulations may conveniently be presented in unit dosage form, e.g., tablets and sustained release capsules, and in liposomes, and may be prepared by any methods well known in the art of pharmacy. See, for example, Remington's Pharmaceutical Sciences, Mack Publishing Company, Philadelphia, Pa. (17th ed. 1985).
Such preparative methods include the step of bringing into association with the molecule to be administered ingredients such as the carrier that constitutes one or more accessory ingredients. In general, the compositions are prepared by uniformly and intimately bringing into association the active ingredients with liquid carriers, liposomes or finely divided solid carriers or both, and then if necessary shaping the product.
In certain preferred embodiments, the compound is administered orally. Compositions of the present invention suitable for oral administration may be presented as discrete units such as capsules, sachets or tablets each containing a predetermined amount of the active ingredient; as a powder or granules; as a solution or a suspension in an aqueous liquid or a non-aqueous liquid; or as an oil-in-water liquid emulsion or a water-in-oil liquid emulsion, or packed in liposomes and as a bolus, etc. Soft gelatin capsules can be useful for containing such suspensions, which may beneficially increase the rate of compound absorption.
A tablet may be made by compression or molding, optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing in a suitable machine the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, preservative, surface-active or dispersing agent. Molded tablets may be made by molding in a suitable machine a mixture of the powdered compound moistened with an inert liquid diluent. The tablets optionally may be coated or scored and may be formulated so as to provide slow or controlled release of the active ingredient therein. Methods of formulating such slow or controlled release compositions of pharmaceutically active ingredients, such as those herein and other compounds known in the art, are known in the art and described in several issued US patents, some of which include, but are not limited to, U.S. Pat. Nos. 4,369,172; and 4,842,866, and references cited therein. Coatings can be used for delivery of compounds to the intestine (see, e.g., U.S. Pat. Nos. 6,638,534, 5,217,720, and 6,569,457, 6,461,631, 6,528,080, 6,800,663, and references cited therein). A useful formulation for the compounds of this invention is the form of enteric pellets of which the enteric layer comprises hydroxypropylmethylcellulose acetate succinate.
In the case of tablets for oral use, carriers that are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried cornstarch. When aqueous suspensions are administered orally, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening and/or flavoring and/or coloring agents may be added.
Compositions suitable for topical administration include lozenges comprising the ingredients in a flavored basis, usually sucrose and acacia or tragacanth; and pastilles comprising the active ingredient in an inert basis such as gelatin and glycerin, or sucrose and acacia.
Compositions suitable for parenteral administration include aqueous and non-aqueous sterile injection solutions which may contain anti-oxidants, buffers, bacteriostats and solutes which render the formulation isotonic with the blood of the intended recipient; and aqueous and non-aqueous sterile suspensions which may include suspending agents and thickening agents. The formulations may be presented in unit-dose or multi-dose containers, for example, sealed ampules and vials, and may be stored in a freeze dried (lyophilized) condition requiring only the addition of the sterile liquid carrier, for example water for injections, immediately prior to use. Extemporaneous injection solutions and suspensions may be prepared from sterile powders, granules and tablets.
Such injection solutions may be in the form, for example, of a sterile injectable aqueous or oleaginous suspension. This suspension may be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as, for example, Tween 80) and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or diglycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant.
The pharmaceutical compositions of this invention may be administered in the form of suppositories for rectal administration. These compositions can be prepared by mixing a compound of this invention with a suitable non-irritating excipient which is solid at room temperature but liquid at the rectal temperature and therefore will melt in the rectum to release the active components. Such materials include, but are not limited to, cocoa butter, beeswax and polyethylene glycols.
The pharmaceutical compositions of this invention may be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art.
Topical administration of the pharmaceutical compositions of this invention is especially useful when the desired treatment involves areas or organs readily accessible by topical application. For application topically to the skin, the pharmaceutical composition should be formulated with a suitable ointment containing the active components suspended or dissolved in a carrier. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petroleum, white petroleum, propylene glycol, polyoxyethylene polyoxypropylene compound, emulsifying wax and water. Alternatively, the pharmaceutical composition can be formulated with a suitable lotion or cream containing the active compound suspended or dissolved in a carrier. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water. The pharmaceutical compositions of this invention may also be topically applied to the lower intestinal tract by rectal suppository formulation or in a suitable enema formulation. Topically-transdermal patches and iontophoretic administration are also included in this invention.
Particularly favored derivatives and prodrugs are those that increase the bioavailability of the compounds of this invention when such compounds are administered to a mammal (e.g., by allowing an orally administered compound to be more readily absorbed into the blood) or which enhance delivery of the parent compound to a biological compartment (e.g., the brain or central nervous system) relative to the parent species. Preferred prodrugs include derivatives where a group that enhances aqueous solubility or active transport through the gut membrane is appended to the structure of formulae described herein. See, e.g., Alexander, J. et al. Journal of Medicinal Chemistry 1988, 31, 318-322; Bundgaard, H. Design of Prodrugs ; Elsevier: Amsterdam, 1985; pp 1-92; Bundgaard, H.; Nielsen, N. M. Journal of Medicinal Chemistry 1987, 30, 451-454; Bundgaard, H. A Textbook of Drug Design and Development ; Harwood Academic Publ.: Switzerland, 1991; pp 113-191; Digenis, G. A. et al. Handbook of Experimental Pharmacology 1975, 28, 86-112; Friis, G. J.; Bundgaard, H. A Textbook of Drug Design and Development; 2 ed.; Overseas Publ.: Amsterdam, 1996; pp 351-385; Pitman, I. H. Medicinal Research Reviews 1981, 1, 189-214.
Application of the subject therapeutics may be local, so as to be administered at the site of interest. Various techniques can be used for providing the subject compositions at the site of interest, such as injection, use of catheters, trocars, projectiles, pluronic gel, stents, sustained drug release polymers or other device which provides for internal access.
According to another embodiment, the invention provides a method of impregnating an implantable drug release device comprising the step of contacting said drug release device with a compound or composition of this invention. Implantable drug release devices include, but are not limited to, biodegradable polymer capsules or bullets, non-degradable, diffusible polymer capsules and biodegradable polymer wafers.
According to another embodiment, the invention provides an implantable medical device coated with a compound or a composition comprising a compound of this invention, such that said compound is therapeutically active.
In another embodiment, a composition of the present invention further comprises a second therapeutic agent. The second therapeutic agent includes any compound or therapeutic agent known to have or that demonstrates advantageous properties when administered alone or with a compound of any of the formulae herein. Drugs that could be usefully combined with these compounds include other kinase inhibitors and/or other chemotherapeutic agents for the treatment of the diseases and disorders discussed above.
Such agents are described in detail in the art. Preferably, the second therapeutic agent is an agent useful in the treatment or prevention of a disease or condition selected from cancer.
Even more preferably the second therapeutic agent co-formulated with a compound of this invention is an agent useful in the treatment of c-met, ron, or ALK and its fusion proteins such as EML4-ALK and NPM-ALK mediated disease/disorders. Even more preferably the second therapeutic agent co-formulated with a compound of this invention is an agent useful in the treatment of c-met mediated disorder.
In another embodiment, the invention provides separate dosage forms of a compound of this invention and a second therapeutic agent that are associated with one another. The term “associated with one another” as used herein means that the separate dosage forms are packaged together or otherwise attached to one another such that it is readily apparent that the separate dosage forms are intended to be sold and administered together (within less than 24 hours of one another, consecutively or simultaneously).
In the pharmaceutical compositions of the invention, the compound of the present invention is present in an effective amount. As used herein, the term “effective amount” refers to an amount which, when administered in a proper dosing regimen, is sufficient to reduce or ameliorate the severity, duration or progression of the disorder being treated, prevent the advancement of the disorder being treated, cause the regression of the disorder being treated, or enhance or improve the prophylactic or therapeutic effect(s) of another therapy.
The interrelationship of dosages for animals and humans (based on milligrams per meter squared of body surface) is described in Freireich et al., (1966) Cancer Chemother Rep 50: 219. Body surface area may be approximately determined from height and weight of the patient. See, e.g., Scientific Tables, Geigy Pharmaceuticals, Ardley, N.Y., 1970, 537. An effective amount of a compound of this invention can range from about 0.001 mg/kg to about 500 mg/kg, more preferably 0.01 mg/kg to about 50 mg/kg, more preferably 0.1 mg/kg to about 2.5 mg/kg. Effective doses will also vary, as recognized by those skilled in the art, depending on the diseases treated, the severity of the disease, the route of administration, the sex, age and general health condition of the patient, excipient usage, the possibility of co-usage with other therapeutic treatments such as use of other agents and the judgment of the treating physician.
For pharmaceutical compositions that comprise a second therapeutic agent, an effective amount of the second therapeutic agent is between about 20% and 100% of the dosage normally utilized in a monotherapy regime using just that agent. Preferably, an effective amount is between about 70% and 100% of the normal monotherapeutic dose. The normal monotherapeutic dosages of these second therapeutic agents are well known in the art. See, e.g., Wells et al., eds., Pharmacotherapy Handbook, 2nd Edition, Appleton and Lange, Stamford, Conn. (2000); PDR Pharmacopoeia, Tarascon Pocket Pharmacopoeia 2000, Deluxe Edition, Tarascon Publishing, Loma Linda, Calif. (2000), each of which references are entirely incorporated herein by reference.
It is expected that some of the second therapeutic agents referenced above will act synergistically with the compounds of this invention. When this occurs, its will allow the effective dosage of the second therapeutic agent and/or the compound of this invention to be reduced from that required in a monotherapy. This has the advantage of minimizing toxic side effects of either the second therapeutic agent of a compound of this invention, synergistic improvements in efficacy, improved ease of administration or use and/or reduced overall expense of compound preparation or formulation.
Methods of Treatment
According to another embodiment, the invention provides a method of treating a subject suffering from or susceptible to a disease or disorder or symptom thereof (e.g., those delineated herein) comprising the step of administering to said subject an effective amount of a compound or a composition of this invention. Such diseases are well known in the art and are also disclosed herein.
In one aspect, the method of treating involves treatment of a disorder that is mediated by the protein kinase, e.g. c-met, ron.
In another aspect, the invention provides a method of treating a disease in a subject comprising administering to the subject a compound of any of the formulae herein.
In another aspect, invention provides a method of treating a disease in a subject comprising administering to the subject a composition comprising a compound of any of the formulae herein.
In certain embodiments, the disease is mediated by the c-met or ron kinases.
In another embodiment, the disease is cancer or a proliferation disease.
In yet another embodiment, the disease is cancer of the lung, colon, breast, prostate, liver, pancreas, brain, kidney, ovaries, stomach, or skin, or bone cancers, gastric cancer, breast cancer, pancreatic cancer, glioma, and hepatocellular carcinoma, papillary renal carcinoma, or head and neck squamous cell carcinoma.
In a one embodiment, the method of this invention is used to treat a subject suffering from or susceptible to a disease or condition. Such diseases, disorders or symptoms thereof include, for example, those modulated by a protein kinase (e.g., c-met, ron). The disease or disease symptom can be, for example, cancer or proliferation disease or disorder. The disease or disease symptom can be lung, colon, breast, prostate, liver, pancreas, brain, kidney, ovaries, stomach, skin, and bone cancers, gastric cancer, breast cancer, pancreatic cancer, glioma, and hepatocellular carcinoma, papillary renal carcinoma, or head and neck squamous cell carcinoma. Methods delineated herein include those wherein the subject is identified as in need of a particular stated treatment. Identifying a subject in need of such treatment can be in the judgment of a subject or a health care professional and can be subjective (e.g. opinion) or objective (e.g. measurable by a test or diagnostic method).
In another embodiment, the invention provides a method of modulating the activity of a protein kinase (e.g. protein tyrosine kinase, kinases listed herein) in a cell comprising contacting a cell with one or more compounds of any of the formulae herein.
In another embodiment, the above method of treatment comprises the further step of co-administering to said patient one or more second therapeutic agents. The choice of second therapeutic agent may be made from any second therapeutic agent known to be useful for indications herein. Additional therapeutic agents include but are not limited to agents for treatment of diseases, disorders or symptoms thereof including for example, anticancer agents, antiproliferative agents, antineoplastic agents, antitumor agents, antimetabolite-type/thymidilate synthase inhibitor antineoplastic agents, alkylating-type antineoplastic agents, antibiotic-type antineoplastic agents, or, any other agent typically administered as a primary or adjuvant agent in cancer treatment protocols (e.g., antinausea, antianemia, etc.), including for example, vinblastine sulfate, vincristine, vindesine, vinestramide, vinorelbine, vintriptol, vinzolidine, tamoxifen, toremifen, raloxifene, droloxifene, iodoxyfene, megestrol acetate, anastrozole, letrazole, borazole, exemestane, flutamide, nilutamide, bicalutamide, cyproterone acetate, goserelin acetate, luprolide, finasteride, herceptin, methotrexate, 5-fluorouracil, cytosine arabinoside, doxorubicin, daunomycin, epirubicin, idarubicin, mitomycin-C, dactinomycin, mithramycin, cisplatin, carboplatin, melphalan, chlorambucil, busulphan, cyclophosphamide, ifosfamide, nitrosoureas, thiotephan, vincristine, taxol, taxotere, etoposide, teniposide, amsacrine, irinotecan, topotecan, an epothilone, Iressa, Avastin, OSI-774, angiogenesis inhibitors, EGFR inhibitors, MEK inhibitors, VEGFR inhibitors, CDK inhibitors, Her1 and Her2 inhibitors and monoclonal antibodies.
The term “co-administered” as used herein means that the second therapeutic agent may be administered together with a compound of this invention as part of a single dosage form (such as a composition of this invention comprising a compound of the invention and an second therapeutic agent as described above) or as separate, multiple dosage forms. Alternatively, the additional agent may be administered prior to, consecutively with, or following the administration of a compound of this invention. In such combination therapy treatment, both the compounds of this invention and the second therapeutic agent(s) are administered by conventional methods. The administration of a composition of this invention comprising both a compound of the invention and a second therapeutic agent to a subject does not preclude the separate administration of that same therapeutic agent, any other second therapeutic agent or any compound of this invention to said subject at another time during a course of treatment.
Effective amounts of these second therapeutic agents are well known to those skilled in the art and guidance for dosing may be found in patents and published patent applications referenced herein, as well as in Wells et al., eds., Pharmacotherapy Handbook, 2nd Edition, Appleton and Lange, Stamford, Conn. (2000); PDR Pharmacopoeia, Tarascon Pocket Pharmacopoeia 2000, Deluxe Edition, Tarascon Publishing, Loma Linda, Calif. (2000), and other medical texts. However, it is well within the skilled artisan's purview to determine the second therapeutic agent's optimal effective-amount range.
In one embodiment of the invention where a second therapeutic agent is administered to a subject, the effective amount of the compound of this invention is less than its effective amount would be where the second therapeutic agent is not administered. In another embodiment, the effective amount of the second therapeutic agent is less than its effective amount would be where the compound of this invention is not administered. In this way, undesired side effects associated with high doses of either agent may be minimized. Other potential advantages (including without limitation improved dosing regimens and/or reduced drug cost) will be apparent to those of skill in the art.
In yet another aspect, the invention provides the use of a compound of any of the formulae herein alone or together with one or more of the above-described second therapeutic agents in the manufacture of a medicament, either as a single composition or as separate dosage forms, for treatment or prevention in a subject of a disease, disorder or symptom set forth above. Another aspect of the invention is a compound of the formulae herein for use in the treatment or prevention in a subject of a disease, disorder or symptom thereof delineated herein.
In other aspects, the methods herein include those further comprising monitoring subject response to the treatment administrations. Such monitoring may include periodic sampling of subject tissue, fluids, specimens, cells, proteins, chemical markers, genetic materials, etc. as markers or indicators of the treatment regimen. In other methods, the subject is prescreened or identified as in need of such treatment by assessment for a relevant marker or indicator of suitability for such treatment.
In one embodiment, the invention provides a method of monitoring treatment progress. The method includes the step of determining a level of diagnostic marker (Marker) (e.g., any target or cell type delineated herein modulated by a compound herein) or diagnostic measurement (e.g., screen, assay) in a subject suffering from or susceptible to a disorder or symptoms thereof delineated herein, in which the subject has been administered a therapeutic amount of a compound herein sufficient to treat the disease or symptoms thereof. The level of Marker determined in the method can be compared to known levels of Marker in either healthy normal controls or in other afflicted patients to establish the subject's disease status. In preferred embodiments, a second level of Marker in the subject is determined at a time point later than the determination of the first level, and the two levels are compared to monitor the course of disease or the efficacy of the therapy. In certain preferred embodiments, a pre-treatment level of Marker in the subject is determined prior to beginning treatment according to this invention; this pre-treatment level of Marker can then be compared to the level of Marker in the subject after the treatment commences, to determine the efficacy of the treatment.
In certain method embodiments, a level of Marker or Marker activity in a subject is determined at least once. Comparison of Marker levels, e.g., to another measurement of Marker level obtained previously or subsequently from the same patient, another patient, or a normal subject, may be useful in determining whether therapy according to the invention is having the desired effect, and thereby permitting adjustment of dosage levels as appropriate. Determination of Marker levels may be performed using any suitable sampling/expression assay method known in the art or described herein. Preferably, a tissue or fluid sample is first removed from a subject. Examples of suitable samples include blood, urine, tissue, mouth or cheek cells, and hair samples containing roots. Other suitable samples would be known to the person skilled in the art. Determination of protein levels and/or mRNA levels (e.g., Marker levels) in the sample can be performed using any suitable technique known in the art, including, but not limited to, enzyme immunoassay, ELISA, radiolabelling/assay techniques, blotting/chemiluminescence methods, real-time PCR, and the like.
The present invention also provides kits for use to treat diseases, disorders, or symptoms thereof, including those delineated herein. These kits comprise: a) a pharmaceutical composition comprising a compound of any of the formula herein or a salt thereof; or a prodrug, or a salt of a prodrug thereof; or a hydrate, solvate, or polymorph thereof, wherein said pharmaceutical composition is in a container; and b) instructions describing a method of using the pharmaceutical composition to treat the disease, disorder, or symptoms thereof, including those delineated herein.
The container may be any vessel or other sealed or sealable apparatus that can hold said pharmaceutical composition. Examples include bottles, divided or multi-chambered holders bottles, wherein each division or chamber comprises a single dose of said composition, a divided foil packet wherein each division comprises a single dose of said composition, or a dispenser that dispenses single doses of said composition. The container can be in any conventional shape or form as known in the art which is made of a pharmaceutically acceptable material, for example a paper or cardboard box, a glass or plastic bottle or jar, a re-sealable bag (for example, to hold a “refill” of tablets for placement into a different container), or a blister pack with individual doses for pressing out of the pack according to a therapeutic schedule. The container employed can depend on the exact dosage form involved, for example a conventional cardboard box would not generally be used to hold a liquid suspension. It is feasible that more than one container can be used together in a single package to market a single dosage form. For example, tablets may be contained in a bottle, which is in turn contained within a box. Preferably, the container is a blister pack.
The kit may additionally comprising information and/or instructions for the physician, pharmacist or subject. Such memory aids include numbers printed on each chamber or division containing a dosage that corresponds with the days of the regimen which the tablets or capsules so specified should be ingested, or days of the week printed on each chamber or division, or a card which contains the same type of information.
The compounds delineated herein can be assessed for their biological activity using protocols known in the art, including for example, those delineated herein. Certain of the compounds herein demonstrate unexpectedly superior attributes (e.g., inhibition of P450, Met, Ron, etc.; pharmacokinetic properties, etc.) making them superior candidates as potential therapeutic agents.
All references cited herein, whether in print, electronic, computer readable storage media or other form, are expressly incorporated by reference in their entirety, including but not limited to, abstracts, articles, journals, publications, texts, treatises, technical data sheets, internet web sites, databases, patents, patent applications, and patent publications.
EXAMPLES
Synthesis of 5-[(2,6-dichloro-3-fluorophenyl)ethoxy]-6-{(tert-butoxy)-N-[(tert-butyl)oxycarbonyl]carbonylamino}pyridazine-3-carboxylic acid (A)
Step 1: A suspension of A1 (400 g, 2.68 mol) in 25% ammonium hydroxide (3 L) was heated at 130° C. for 12 h in a sealed stainless autoclave. After the tube was cooled to 0° C., the mixture was filtered. The resulting solid was washed with water for several times and dried under vacuo to provide A2 (284 g, 82%).
Step 2: To a solution of A2 (284 g, 2.19 mol) in methanol (3.5 L) was added NaHCO 3 (368.4 g, 4.38 mol) at room temperature, followed by bromine (350 g, 2.19 mol) drop-wise. After the addition was complete, the mixture was stirred for 20 h, then filtered and washed by methanol for several times. The filtrate was concentrated and the residue was dissolved in water (2 L) and extracted with ethyl acetate (2 L×3). The combined organic phase was washed with 10% sodium thiosulfate aq. (2 L), sat. sodium bicarbonate aq. (2 L) and brine (2 L), dried over anhydrous magnesium sulfate and evaporated. The residue was purified by column chromatography (EA:PE=2:1) to provide A3 (159.8 g, 35%).
Step 3: To a solution of A4 (150 g, 0.72 mol) in methanol (800 mL) cooled to 0° C., was added NaBH 4 (66 g, 1.74 mol) in portions. The resulting mixture was stirred at r.t. for about 1 h and evaporated. Water (1 L) was added to the residue at 0° C., followed by 3N HCl until pH=6. The resulting mixture was extracted with ethyl acetate (400 mL×4). The combined organic phase was dried over anhydrous sodium sulfate, filtered and concentrated to give A5 (148.6 g, 98%).
Step 4: To a solution of A5 (147.6 g, 0.71 mol) in THF (3 L) was added 60% NaH (28.4 g, 0.71 mol) at 0° C., the resulting mixture was stirred at that temperature for 30 min, was then added A3 (147 g, 0.71 mmol) quickly. The resulting mixture was heated under reflux overnight and evaporated. The residue was purified by column chromatography (PE:EA=4:1) to provide the advanced intermediate A6 (89.3 g, 37.6%).
Step 5: To a solution of A6 (97 g, 0.288 mol) in DMF (1 L) was added Boc 2 O (113 g, 0.519 mol) and DMAP (7 g, 58 mmol). The mixture was stirred at r.t. overnight and evaporated. The residue was purified by column chromatography (PE:EA=10:1) to afford A7 (136 g, 88%).
Step 6: Sodium acetate (41 g, 0.50 mol) was added to a solution of A7 (136 g, 0.25 mol) in ethanol/DMF [(5:1) (1200 mL)]. The mixture was degassed, then added Pd(dppf)Cl 2 .CH 2 Cl 2 (18.63 g, 22.5 mmol). The resulting mixture was heated at CO atmosphere at 90° C. for 1.5 h, then evaporated. The residue was purified by column chromatography (PE:EA=1:4) to afford A8 (141 g, 97%).
Step 7: To the solution of A8 (141 g, 0.246 mol) in THF (650 mL) was added 1N LiOH aq. (390 mL). The resulting mixture was stirred at r.t. over weekend, then acidified by 2N HCl to pH=5, extracted with ethyl acetate (300 mL×5). The combined organic phase was dried over Na 2 SO 4 , filtrated and concentrated to give A (134 g, 99%).
Synthesis of 6-[bis(tert-butoxycarbonyl)amino]-5-[(1R)-1-(2,6-dichloro-3-fluoro-phenyl)ethoxy]pyridazine-3-carboxylic acid (B)
Step 1: To a solution of A5 (219 g, 1.05 mol) in 1,2-dichloroethane (3500 mL) was added Boc-D-Pro (141 g, 0.65 mol) followed by EDCI (163 g, 0.85 mol) and DMAP (21.57 g, 0.18 mol) at 0° C. The resulting mixture was stirred at r.t. overnight and then water (3500 mL) was added and separated, the water phase was extracted with DCM (1500 mL×3), dried over MgSO 4 , concentrated and purified by column chromatography to (PE:EA=30:1) to give B1 (55.96 g, yield: 51.1%)
Step 2: To a solution of B1 (59.96 g, 268 mmol) in THF (1200 mL) was added 60% NaH (10.71 g, 268 mmol) at 0° C., the resulting mixture was stirred at that temperature for 30 min, was then added A3 (55.82 g, 268 mmol) quickly. The resulting mixture was heated under reflux overnight and evaporated. The residue was purified by column chromatography (PE:EA=4:1) to provide the advanced intermediate B2 (33.95 g, 37.7%). 1H-NMR (300 MHz, CDCl 3 ): δ=1.87 (d, 3H), 5.08 (s, 2H), 6.03-6.09 (m, 1H), 6.42 (s, 1H), 7.14 (t, 1H), 7.35 (dd, 1H). LC-MS [M+H] + : 336.0.
Step 3: To a solution of B2 (33.95 g, 101 mmol) in DMF (400 mL) was added BOC 2 O (39.59 g, 182 mmol) and DMAP (2.46 g, 20.2 mmol). The mixture was stirred at r.t. overnight and evaporated. The residue was purified by column chromatography (PE:EA=10:1) and the residue was treated with PE:EA=10:1 to afford B3 (46.9 g, 86.7%).
Step 4: Sodium acetate (14.34 g, 175 mmol) was added to a solution of B3 (46.9 g, 87.4 mmol) in ethanol/DMF [(5:1) (480 mL)]. The mixture was degassed, then added Pd(dppf)Cl 2 .CH 2 Cl 2 (7.14 g, 8.74 mmol). The resulting mixture was heated at CO atmosphere at 90° C. overnight, then evaporated. The residue was purified by column chromatography (PE:EA=4:1) to afford B4 (47.1 g, 94.0%). 1H-NMR (300 MHz, CDCl 3 ): δ=1.38 (s, 18H), 1.46 (t, 3H), 1.88 (d, 3H), 4.45-4.53 (m, 2H), 6.18 (q, 1H), 7.13 (t, 1H), 7.34 (dd, 1H), 7.57 (s, 1H). LC-MS [M+H] + : 574.0.
Step 5: To the solution of B4 (47.1 g, 82.1 mmol) in THF (400 mL) was added 1N LiOH aq. (98.5 mL). The resulting mixture was stirred at r.t. over weekend, then acidified by 2N HCl to pH=5, extracted with ethyl acetate (400 mL×3). The combined organic phase was dried over Na 2 SO 4 , filtrated and concentrated to give B (45.94 g, ˜100%).
Synthesis of 6-[bis(tert-butoxycarbonyl)amino]-5-[(1S)-1-(2,6-dichloro-3-fluoro-phenyl)ethoxy]pyridazine-3-carboxylic acid (C)
Step 1: To a solution of A5 (41.8 g, 200 mmol) in 1,2-dichloroethane (800 mL) was added Boc-L-Pro (26.9 g, 125 mmol) followed by EDCI (31.1 g, 163 mmol) and DMAP (4.12 g, 33.8 mmol) at 0° C. The resulting mixture was stirred at r.t. overnight and then water (350 mL) was added and separated, the water phase was extracted with DCM (150 mL×3), dried over MgSO 4 , concentrated and purified by column chromatography to (PE:EA=30:1) to give C1 (13.72 g, yield: 65.6%).
Step 2: The procedure from C1 to C was similar to that of B1 to B (9.46 g, yield: 26.4% from C1).
Example 1
Synthesis of {5-[(1R)-1-(2,6-dichloro-3-fluorophenyl)ethoxy]-6-aminopyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide
Step 1: To a solution of 1a (16.0 g, 114 mmol) in DMF (500 mL) was added NaH (5.5 g, 137 mmol). The suspension was stirred at 0° C. for 0.5 h and added CH 3 I (17.8 g, 126 mmol) dropwise at 0° C. The resulting mixture was allowed to warm to r.t. for 1 h and evaporated. The residue was added sat. NaHCO 3 (50 mL) and water (50 mL). The suspension was extracted with DCM (300 mL) twice. The combined extract was washed water, dried over MgSO 4 and concentrated. The residue was retreated with PE:EA=10:1 to provide 1b (11.05 g, 63.0%).
Step 2: Reductive iron powder (39.0 g, 69.6 mmol) and 2N HCl (20 mL) were added to a stirred solution of 1b (15.4 g, 100 mmol) in ethanol (300 mL) at 0° C. The resulting mixture was heated under reflux for 2 h and filtrated. The brown solid was washed with ethanol for several times. The combined ethanol phase was evaporated and the residue was dissolved in ethyl acetate (400 mL) and washed with 1.5N Na 2 CO 3 aq. (400 mL). The bi-phase mixture was separated and the water phase was re-extracted with ethyl acetate (250 mL×3). The combined organic phase was dried over MgSO 4 , filtered and evaporated to give 1c (10.0 g, 80.6%).
Step 11: The mixture of B (20.00 g, 36.6 mmol), HATU (28.00 g, 73.7 mmol) and DIEA (14 g, 108.5 mmol) in DMF (200 mL) was stirred at room temperature for 0.5 h, then was added 1c (10 g, 81.9 mmol). The resulting mixture was stirred at room temperature for 0.5 h and evaporated. The residue was purified by column chromatography (EA:MeOH=5:1) to provide 1d (18.0 g, 75.4%).
Step 12: 1d (18.0 g, 27.6 mmol) was dissolved in a mixture of DCM (150 mL) and TFA (50 mL), stirred at r.t. for 2 hours and evaporated. The residue was adjusted by sat. Na 2 CO 3 to pH=8 and extracted with DCM (200 mL×5). The combined organic phase was dried over MgSO 4 and concentrated. The residue was triturated with methanol and filtered, then the solid was dissolved in DCM and a solution of HCl in Et 2 O was added, the mixture was stirred at r.t. overnight, then concentrated and dried over oil pump to afford 1 (13.5 g, 84.1% from 1d). 1H-NMR (300 MHz, DMSO-d 6 ): δ=1.82 (d, 3H), 3.41 (s, 3H), 6.24 (q, 1H), 6.38 (d, 1H), 7.04 (s, 1H), 7.42-7.66 (m, 3H), 8.17 (s, 1H). LC-MS [M+H] + : 452.0.
Example 2
Synthesis of {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide
The procedure from A to 2 was similar to that in Example 1 (70 mg, 42% from A). 1H-NMR (300 MHz, CDCl 3 ): δ=1.89 (d, 3H), 3.57 (s, 3H), 5.40 (s, 2H), 6.21-6.27 (m, 1H), 6.59 (d, 1H), 7.06-7.12 (m, 1H), 7.26-7.37 (m, 3H), 8.28 (d, 1H), 9.40 (s, 1H). LC-MS [M+H] + : 451.9.
Example 3
Synthesis of {5-[(1S)-1-(2,6-dichloro-3-fluorophenyl)ethoxy]-6-aminopyridazin-3-yl}-N-(1-methyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide
The procedure from C to 3 was similar to that in Example 1 to give 3 (1.29 g, yield: 71.3% from 7c). 1H-NMR (300 MHz, DMSO-d6): δ=1.86 (d, 3H), 3.42 (s, 3H), 6.27 (q, 1H), 6.41 (d, 1H), 7.06 (s, 1H), 7.52 (t, 1H), 7.61-7.70 (m, 2H), 8.23 (d, 1H), 10.47 (s, 1H). LC-MS [M+H] + : 452.1.
Example 4
Synthesis of {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(1-methyl-6-oxo(3-piperidyl)carboxamide
Step 1: To a solution of 1b in methanol was added 10% Pd/C. The mixture was hydrogenated under H2 atmosphere overnight. Pd/C was filtered off and the filtrate was evaporated to provide crude 4a which was used for next step without purification.
Step 2: The procedure from 4a to 4 was similar to that in Example 1 (131 mg, 21% from A). 1H-NMR (300 MHz, CDCl 3 ): δ=1.88 (d, 3H), 1.92-2.08 (m, 2H), 2.47-2.54 (m, 2H), 2.92 (d, 3H), 3.20-3.27 (m, 1H), 3.59-3.65 (m, 1H), 4.39-4.42 (m, 1H), 5.37 (s, 2H), 6.18-6.24 (m, 1H), 7.06-7.11 (m, 1H), 7.31-7.36 (m, 2H), 7.95 (d, 1H). LC-MS [M+H] + : 457.1.
Example 5
Synthesis of {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide
Step 1: The procedure from 1a to 5a was similar to that of 1b to 1c which provided 2a which was used for next step without purification.
Step 2: The procedure from 2a to 5 was similar to that in Example 1 (6.8 mg, 4.2% from 5a). 1H-NMR (300 MHz, DMSO-d 6 ): δ=1.82 (d, 3H), 6.14-6.21 (m, 1H), 6.32 (d, 1H), 6.89 (s, 2H), 6.99 (s, 1H), 7.47 (t, 1H), 7.56-7.61 (m, 1H), 7.76-7.80 (m, 1H), 7.93 (s, 1H), 10.40 (s, 1H), 11.41 (brs, 1H). LC-MS [M+H] + : 437.9.
Example 6
Synthesis of {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-[1-(2-methoxyethyl)-6-oxo-1,6-dihydro-pyridin-3-yl]carboxamide
The synthesis was similar to that of Example 1 (157 mg, 56% from B). 1H-NMR (300 MHz, CDCl 3 ): δ=1.89 (d, 3H), 3.32 (s, 3H), 3.69 (t, 2H), 4.10-4.15 (m, 2H), 5.38 (s, 2H), 6.23-6.27 (m, 1H), 6.58 (d, 1H), 7.07-7.12 (m, 1H), 7.32-7.44 (m, 3H), 8.13 (d, 1H), 9.39 (s, 1H). LC-MS [M+H] + : 496.0.
Example 7
Synthesis of {6-amino-5-[(2,6-dichloro-3-fluorophenyl)ethoxy]pyridazin-3-yl}-N-(1-ethyl-6-oxo-1,6-dihydro-pyridin-3-yl)carboxamide
Step 1: Sodium hydride (0.63 g of a 60% dispersion in mineral oil, 15.8 mmol) is added to a solution of compound 1a (2 g, 14.4 mmol) in DMF (20 mL) at room temperature and stirred for 30 min. Ethyl iodide (2.2 g, 14.4 mmol) is added to the reaction mixture and stirred for 16 hours at room temperature. The reaction mixture is diluted with ethyl acetate, washed with water, dried over sodium sulfate and concentrated under vacuo to give compound 7a (2 g, 60%).
Step 2: A mixture of compound 7a (5 g, 29.7 mmol), Fe (6.7 g, 119 mmol) in AcOH (5 mL), water (50 mL) and MeOH (50 mL) was heated to reflux for 30 min. The solvent was removed in vacuo and the residue was purified by column chromatography to give compound 7b (2.5 g, 60%).
Step 3: To a solution of compound 7b (1 g, 7.25 mmol) in DMF (30 ml) was added HATU (4.13 g, 10.87 mmol) and compound B (20 mg, 163 mmol), DIEA (3.8 mL, 21.74 mmol), and the mixture was stirred at room temperature overnight. The reaction mixture was treated with water and extracted with EA. The organic layer was washed with brine, dried over MgSO 4 and concentrated under reduce pressure, the crude product was purified by flash chromatography (DCM:MeOH=10:1) to afford compound 7c (3.2 g, 66%).
Step 4: To the solution of compound 7c (2 g, 3 mmol) in DCM (5 mL) was added TFA (3 mL). The mixture was stirred at room temperature for 4 h and evaporated. The residue was purified by column chromatography (DCM:MeOH=20:1) to provide 7 (700 mg, 50%). 1H-NMR (300 MHz, DMSO-d6): δ=10.04 (s, 1H), 8.23-8.24 (d, 1H), 7.69-7.73 (dd, 1H), 7.56-7.61 (m, 1H), 7.44-7.50 (t, 1H), 6.97 (s, 1H), 6.92 (s, 2H), 6.33-6.37 (d, 1H), 6.15-6.18 (q, 1H), 3.85-3.92 (q, 2H), 1.80-1.82 (d, 3H), 1.17-1.22 (t, 3H), LC-MS [M+H] + : 467.0.
Example 8
Biological Data
Met, ALK Biochemical Assays
Kinase Assays. Assays were performed as described in Fabian et al. (2005) Nature Biotechnology , vol. 23, p. 329 and in Karaman et al. (2008) Nature Biotechnology , vol. 26, p. 127.
For most assays, kinase-tagged T7 phage strains were grown in parallel in 24-well blocks in an E. coli host derived from the BL21 strain. E. coli were grown to log-phase and infected with T7 phage from a frozen stock (multiplicity of infection ˜0.1) and incubated with shaking at 32° C. until lysis (˜90 minutes). The lysates were centrifuged (6,000×g) and filtered (0.2 mm) to remove cell debris. The remaining kinases were produced in HEK-293 cells and subsequently tagged with DNA for qPCR detection. Streptavidin-coated magnetic beads were treated with biotinylated small molecule ligands for 30 minutes at room temperature to generate affinity resins for kinase assays. The liganded beads were blocked with excess biotin and washed with blocking buffer (SeaBlock (Pierce), 1% BSA, 0.05% Tween 20, 1 mM DTT) to remove unbound ligand and to reduce non-specific phage binding. Binding reactions were assembled by combining kinases, liganded affinity beads, and test compounds in 1× binding buffer (20% SeaBlock, 0.17×PBS, 0.05% Tween 20, 6 mM DTT). Test compounds were prepared as 40× stocks in 100% DMSO and directly diluted into the assay. All reactions were performed in polypropylene 384-well plates in a final volume of 0.04 ml. The assay plates were incubated at room temperature with shaking for 1 hour and the affinity beads were washed with wash buffer (1×PBS, 0.05% Tween 20). The beads were then re-suspended in elution buffer (1×PBS, 0.05% Tween 20, 0.5 mM non-biotinylated affinity ligand) and incubated at room temperature with shaking for 30 minutes. The kinase concentration in the eluates was measured by qPCR.
Most examples in this invention with R 6 being unsaturated heterocycle are selective c-Met inhibitors. Specifically, the R-enantiomer (e.g. Example 1) or racemic mixture (e.g. Examples 2, 5, 6, and 7) provided IC 50 values of <5 nM in this c-Met assay, while the corresponding IC 50 's for ALK were higher (>10 nM).
In contrast, the S-enantiomer (Example 3) did not show any significant inhibition at up to 50 nM in this c-Met assay.
Furthermore, the example with R 6 being a saturated heterocycle (Example 4) had IC 50 's of >100 nM in both of the c-Met and ALK assays, while an example (shown below) with R 6 being an aromatic ring was potent against both c-Met and ALK (IC 50 <5 nM).
Therefore, the R-enantiomer of compound with R 6 being unsaturated heterocycle (e.g. Example 1) has the surprising biological property of being a potent and selective (compared to, at least, ALK) c-Met inhibitor.
c-Met Receptor Phosphorylation Assay
A549 cells are used in this assay. Cells are seeded at a density of 40,000 cells/well in the growth media (RPMI+10% FBS) into 24-well plates and cultured overnight at 37° C. for attachment. Cells are exposed to the starvation media (RPMI+1% BSA). Dilutions of the test compounds are added to the plates and incubated at 37° C. for 1 hour. Cells are then cool down to room temperature for 15 min followed by stimulation with 40 ng/ml HGF for 15 minutes. Cells are washed once with ice-cold PBS and then lysed with 110 ul/well lysis buffer (Cell Signaling #9803+0.2% protease inhibitor, Sigma P1860) for 1 hour at 4° C. Cell lysates are transferred to microcentrifuge tubes and are spun at 10000 rpm for 10 min at 4° C. and phosphorylated HGFR is quantitated by Human Phospho-HGF R/c-Met ELISA kit (R&D, DYC2480) according to the manufacture's instructions.
In Vivo Anti-Tumor Efficacy of Compound 1 of EXAMPLE 1 Against U-87MG Tumor Xenograft Model
(a) Selection of Cell Lines Based on Cellular Phosphorylation Status of c-Met
HeLa, NIH-3T3, HEK293T, U87MG, PC3 and Caki were obtained from ATCC and were cultured in 10 cm plates with full growth medium. Actively proliferating cells were washed with 1×PBS once, and then lysed in the lysis buffer, pro-sonicated, and cleared by centrifugation for 10 minutes at 10,000 rpm. Total protein was measured using a BCA protein assay kit. Equal amounts of protein lysate for each cell line were loaded for western blotting.
(b) Animal:
Balb/c nude mice (6 weeks old, male) were purchased from Shanghai Slac Laboratory Animal Co. Ltd (Shanghai, China). All mice were maintained in a pathogen-free facility for ˜2 weeks before implantation. They were housed in plastic cages (4˜6 mice/cage) containing corn cob and maintained in a pathogen-free facility (20˜25° C., 30˜70% humidity) with a 12-h light:dark cycle.
(c) Xenograft Human Tumor Model:
U-87 MG xenograft model was established by implanting athymic Balb/c nude mice s.c in the right flank with U-87 MG cells, 3.6×10 6 /mouse (120 ul). Tumors were allowed to reach 120˜380 mm 3 in size.
Group and Dosage:
Group
n
Dosage
Treatment
Vehicle Control
8
Formulation Vehicle
ig, BID × 11 days
EXAMPLE 1
8
25 mg/kg
ig, BID × 11 days
EXAMPLE 1
8
50 mg/kg
ig, BID × 11 days
Note:
All treatments are given through oral gavage (10 ml/kg). For multi-dosing a day, the second dose was given 7 hours after the first one.
(d) Observation Index
Tumor volumes were measured twice a week with caliper. Tumor volumes were calculated by the formula <Tumor volume=length×width 2 /2>.
Percentage of tumor growth inhibition (GI) after initiation of treatment was calculated by the formula:
GI=100×{1−[(tumor volume final −tumor volume initial for the compound-treated group)/(tumor volume final −tumor volume initial for the vehicle-treated group)]}
Relative tumor volume is defined as the ratio of the volume at a given time and the volume at the start of treatment. The relative tumor volume (RTV) was calculated by the formula:
RTV=100×TV T /TV 0
TV 0 : tumor volume initial
TV T : tumor volume at T time
The relative tumor growth rate (T/C %) was calculated by the formula:
T/C %=100 ×T RTV /C RTV
T RTV : The relative tumor volume of treatment
C RTV : The relative tumor volume of control
Body weight of each mouse was weighed twice a week along with the tumor size measurement. The Percentage of weight loss was calculated by the formula:
Percentage of Weight Loss=100%×(Body Weight initial −Body Weight initial )/Body Weight initial
The tumor weight was measured by the end of experiment. The tumor inhibitory rate (IR) was calculated by the formula:
IR=( W C −W T )/ W C ×100%.
(e) Results
The treatment started 24 days post tumour implantation while the average tumor volume reached 230.52±8.04 mm 3 (Mean±SE). After 11 days of consecutive treatment, EXAMPLE 1 at 25 and 50 mg/kg ig BID showed significant tumor growth inhibition (GI), with GI rates of 65.95% (P<0.01) and 88.71% (P<0.01) respectively. The results are summarized in Table 8.1 and FIG. 2 .
TABLE 8.1
The effects of EXAMPLE 1 on the tumor volume
(mean ± S.E in mm 3 ) and GI (%)
Days Post
Implantation
d24
d28
d31
d35
Vehicle
231.4 ± 25.1
588.7 ± 53.0
971.9 ± 94.8
1483.0 ± 158.6
EXAMPLE 1,
230.4 ± 23.0
365.7 ± 29.3**
453.7 ± 19.7**
627.7 ± 33.9**
25, BID
GI
62.14%
77.04%
65.95%
EXAMPLE 1,
230.2 ± 24.5
305.9 ± 22.0**
337.4 ± 27.8**
371.5 ± 34.4**
50, BID
GI
78.82%
85.52%
88.71%
Note:
*donates P values <0.05,
**donates P values <0.01 compared with vehicle control, respectively.
While we have described a number of embodiments of this invention, it is apparent that our basic examples may be altered to provide other embodiments that utilize the compounds and methods of this invention. Therefore, it will be appreciated that the scope of this invention is to be defined by the appended claims rather than by the specific embodiments that have been represented by way of example.
The contents of all references (including literature references, issued patents, published patent applications, and co-pending patent applications) cited throughout this application are hereby expressly incorporated herein in their entireties by reference. Unless otherwise defined, all technical and scientific terms used herein are accorded the meaning commonly known to one with ordinary skill in the art. | The new pyridazine derivatives have unexpected drug properties as inhibitors of protein kinases especially against c-Met and are useful in treating disorders related to abnormal protein kinase activities such as cancer. | 2 |
BACKGROUND OF THE INVENTION
The application is directed to a fluid dispensing system and in particular to one which includes a pipette assembly adapted for use with disposable pipette tips.
Various types of chemical tests can be performed by automated test equipment, an example of testing of considerable interest being the assay of biological substances for human health care. Automated test equipment allows large numbers of test samples to be processed rapidly. Such equipment is employed in health care institutions including hospitals and laboratories. Biological fluids, such as whole blood, plasma or serum are tested to find evidence of disease, to monitor therapeutic drug levels, etc.
In the automated test instrument a sample of the test fluid is typically provided in a sample cup and all of the process steps including pipetting of the sample onto an assay test element, incubation and readout of the signal obtained are carried out automatically. All the process steps can be carried out while the assay test element is carried by a conveyor within a temperature controlled chamber. Further, in such instruments disposable pipette tips are typically used for the delivery of one fluid only and then discarded so as to avoid contamination which could lead to errors in the assay result.
It is necessary in many instances, when dispensing the sample fluid and/or test reagent(s) to the assay element, that the orifice of the pipette tip be located at a predetermined, precisely controlled location above the assay element to prevent spilling or splashing of the fluid and to ensure the transfer of a precise amount of fluid. This requirement can be better understood from the following discussion of the typical manner in which a fluid dispensing system operates in a typical automated analytical instrument. The fluid dispensing system which includes a pipette is used to transfer sample fluid and/or test reagents from storage cups or wells within the instrument to the assay test element. The pipette includes a hollow tube or stem typically of metal, which is adapted to cooperate with a disposable pipette tip, which is typically made of a polymeric material. The disposable pipette tips are provided in a storage tray within the instrument. Initially, the pipette is advanced downwardly to secure a disposable tip by frictional contact. Thereafter, a predetermined amount of fluid is aspirated into the pipette tip and the tip is then moved automatically to a dispense position above an assay test element where a predetermined volume of the fluid is dispensed to the assay element. Upon completion of the dispense step the tip is discarded and a clean disposable tip is used for the next dispense step.
A problem can arise in the use of such a fluid dispense system due to the fact that each disposable tip is positioned on the metal stem of the pipette by a frictional fit. Since the polymeric materials from which disposable tips are typically made are flexible, there may be some variation from tip to tip as to the distance of the tip orifice from the metal stem of the pipette. Since, as mentioned previously, it may be necessary to locate the pipette tip orifice at a predetermined, precisely controlled position above the assay element during the dispense steps, any variation in the positioning of the disposable tip on the pipette stem can result in an error in the desired positioning of the pipette tip which can lead to an error in the assay result.
Accordingly, it would be desirable to provide, in an analytical instrument which utilizes disposable tips in conjunction with a pipette for delivering fluids to an assay test element, the capability of accurately establishing the relative positions of the tip orifice and the holder on which the tip is carried.
SUMMARY OF THE INVENTION
These and other objects and advantages are provided in accordance with the invention by providing a fluid dispensing system which includes a pipette assembly and a disposable pipette tip. It is an object of the invention to provide a system wherein disposable pipette tips can be repetitively removed and replaced whereby the orifice of each tip attached to the pipette assembly is located at substantially the same distance from the stem of the pipette assembly on which the tip is carried. Where the pipette assembly is incorporated in an automated analytical instrument, the pipette can be positioned accurately in the dispense position by a microprocessor controlled transport assembly, the latter having a vertical drive for raising and lowering the pipette assembly. After the fluid is dispensed to the assay element, the pipette assembly is prepared for reuse by removal of the used tip and replacing it with a new one. The used tip can be removed by moving the pipette into a tip extractor which envelops a lip formed around the upper end of the tip and raising the pipette assembly to cause the pipette tip to be removed and caught by a collection receptable. A replacement tip is provided on the pipette stem by positioning the pipette assembly above a new tip located on a pipette tip holder and lowering the pipette assembly such that the stem engages a proximal end of the tip.
In accordance with the invention the fluid dispense system comprises a pipette assembly having a pipette tip holder which includes a crown and a stem extending from the crown, and a disposable pipette tip. The pipette tip has a chamber for receiving the stem of the tip holder. A snap-action device located along an interface between the holder stem and the tip crown retains the holder stem in the tip chamber. The tip stem has a passage extending along a central axis of the tip from a distal port of the tip to communicate with the tip chamber at a distal end of the tip chamber. The tip crown is constructed with a ledge at the distal end of the tip chamber, the ledge being located at a predetermined distance from the distal port of the tip. The ledge encircles a proximal end of the stem passage. The holder stem has a passage extending along a central axis of the holder stem to a distal port of the holder stem to communicate with the tip passage upon insertion of the holder stem into the tip chamber. A surface of the distal part of the holder stem is configured to mate with the ledge so as to position the holder distal part at the predetermined distance from the tip orifice.
In accordance with further features of the invention, the ledge in the pipette tip chamber is advantageously constructed of a resilient material, preferable polymeric, to form a fluid seal with the distal part of the holder. The vertical drive preferably comprises a stepper motor for accurate positioning of the pipette. The vertical drive is connected to the pipette by a spring-loaded lost-motion connection which allows relative motion between the pipette and the vertical drive upon a contacting of the holder with a replacement tip on the tray. Inner and outer rings may also be provided along an interface between the tip cavity and the holder stem to provide a further fluid seal.
BRIEF DESCRIPTION OF THE DRAWING
For a better understanding of the invention as well as other objects and further features thereof, reference is made to the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a stylized view, partially diagrammatic, of an analytical instrument utilizing assay test modules and a carousel for moving the modules among various work stations;
FIG. 2 is a stylized view, partially diagrammatic of a pipette transport for moving the pipette between a supply of pipette tips and reagent reservoirs and compartments of an assay test module;
FIG. 3 is a longitudinal sectional view of a pipette tip employed in the system of FIG. 2 and incorporating features of the invention;
FIG. 4 is an end view of the pipette tip, taken along the line 4--4 in FIG. 3;
FIG. 5 is a side view of a stem of a pipette tip holder to be inserted into the tip of FIG. 3;
FIG. 6 is a side view of a pipette of FIG. 2, the view being partially sectioned adjacent a longitudinal central axis of the pipette;
FIG. 7 is a side view of the pipette with the tip pressed against a tray which holds replacement tips (the tray being shown in FIG. 2), the view of FIG. 7 showing compression of a lost-motion connection between a tip holder and a vertical drive (the drive being shown in FIG. 2); and
FIG. 8 is an exploded view of the pipette showing various components thereof, except for the pipette tip which has been deleted to simplify the drawing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, there is shown an analytical instrument 20 which provides automatically a sequence of process steps to accomplish an assay of a test sample. A plurality of assay modules 22 are employed within the instrument 20 to increase the throughput rate, one process step being carried out with one module concurrently with the performance of other process steps with other modules. The modules 22 are illustrated with respect to a preferred embodiment thereof which includes one or more chambers in the housing. Such chambers may be configured as wells, or reservoirs, for the storage and/or mixing of fluids which are used in the assay procedure or the chambers may culminate in an opening to permit fluids to be provided to a reaction zone within the module. The chambers are formed integrally within the housing of the module. The analytical instrument 20 includes a turntable or carousel 24 which is rotated about an axle 26 by a motor 28. By way of example, the motor 28 may be mechanically coupled to the carousel 24 by a gear 30 or by a belt drive (not shown). The carousel 24 carries the modules 22 from one work station to another work station, two such work stations 32 and 34 being shown, by way of example, in FIG. 1. The carousel 24 rotates within a temperature controlled chamber 36 having a heater 38 for maintaining a desired temperature at the various work stations so as to allow for a process step of incubation.
Work station 32 is a pipetting station whereat sample fluid and any other required fluid test reagent(s) are delivered to the assay modules 22. By way of example, there are shown two pipettes 40 and 42. The pipettes, 40 and 42, are positioned and operated by a pipette mechanism 44 mechanically connected to the pipettes 40 and 42, as indicated by dashed lines.
During the assay procedure, as a result of the reaction(s) and interaction(s) between the sample fluid and the test reagent(s) which take place, a detectable change is effected corresponding to the presence of an analyte or component of interest in the sample fluid. The detectable change may be a color change which may be read spectrophotometrically such as with a densitometer or, in an assay method based on fluorescent-labeled biologically active species or one which involves the generation of a fluorescent species as a result of a reaction between test reagents, a fluorescent output signal can be generated and read spectrofluorometrically. Such detectable changes may be read from above or below the assay module. At work station 34 there is shown by way of example a fluorometer 46 for irradiating the reaction zone within the assay module and for measuring the fluorescence emitted from the fluorescent species present therein.
The carousel 24 may be arranged so as to accomodate varying numbers of assay modules 22. Each position, or berth 54 for holding an assay module is provided in this embodiment with a small aperture 56 to allow the irradiating illumination to reach the reaction zone in the assay module and to permit the fluorescent emissions to be collected and measured. Also shown is an injector 58 for inserting a module 22 in an empty berth 54, the injector 58 having an arm 60 for gripping a module 22 during the insertion operation. The injector 58 also serves to extract a module from a berth 54 by use of the arm 60 upon completion of a test procedure. Operation of the motor 28, the pipette mechanism 44, the fluorometer 46 and the injector 58 are synchronized by means of a microprocessor 62.
FIG. 2 provides detail in the construction of the pipette mechanism 44 of FIG. 1. To facilitate description of the invention, the pipette mechanism 44 will be described hereinafter as having a pipette transport 64 operative with only one of the pipettes, namely, the pipette 40. The transport 64 provides for relative movement, in two dimensions, between the pipette 40 and a set of reservoirs 66. The reservoirs 66 are located at a distance from a module 22 on the carousel 24, the reservoirs 66 serving to store reagents useful in carrying out assay tests by the analytical instrument 20. The reservoirs 66 are located on a movable tray or table 68 which also holds a set of tips 70 which are to be affixed to a stem 72 of the pipette 40. With reference to an X-Y-Z coordinate axis system, the pipette 40 is translatable in the X direction along a box beam 74 of the transport 64, and the table 68 is translatable in the Y direction by riding along a rail 76 of the transport 64. A vertical drive 78 is located within the beam 74 and serves to raise and to lower the pipette 40 in the Z direction.
A horizontal drive 80 is located within the box beam 74, and drives the pipette in the X direction. The vertical drive 78 and the horizontal drive 80 are of conventional design, and are indicated in simplified fashion in FIG. 2. Briefly, the vertical drive 78 may be described as comprising a wheel 82 slidably mounted to a spline shaft 84 which, alternatively, may have a square cross section. The shaft 84 is rotated by a motor 86. The horizontal drive 80 includes a base 88 which slides in the X direction along the beam 74 in response to rotation of a motor 90. The motor 90 drives a belt 92 through a pulley 94, the belt 92 being connected to the base 88 for translating the base 88 upon rotation of the pulley 94 by the motor 90. A fixture 96 upstanding from the base 88 slides the wheel 82 along the shaft 84 upon movement of the base 88 so that the wheel 82 stays in fixed position relative to the base 88. The pipette 40 passes through the base 88 so as to be translated in the X direction by the base 88. The wheel 82 is mechanically connected to the pipette 40, as by gear teeth on the wheel 82, or by means of a belt drive (not shown). The mechanical connection of the wheel 82 to the pipette 40 provides for a translation of the pipette 40 in the Z direction upon rotation of the wheel 82 by the motor 86. A belt drive 98 may be employed, similarly, for driving the table 68 in the Y direction in response to rotation of a motor 100 affixed to the rail 76.
As noted above in the description of the system of FIG. 1, the motor 28 is under control of the microprocessor 62. Similarly, motors 100, 90, and 86 are also under control of the microprocessor 62. Connections of the motors 28, 100, 90, and 86 are indicated in FIG. 2 by terminals A, B. C, and D, respectively. Thereby, movement of the pipette 40 can be synchronized with a positioning of the module 22 by the carousel 24 to a location directly beneath the beam 74. In order to provide access to the module 22 by the pipette 44, a slot 102 is provided in a top wall 104 of the temperature controlled chamber 36. The slot 102 is parallel to the beam 74. The location of the slot 102 relative to the beam 74 permits the stem 72 of the pipette 40 to be lowered through the slot 102 selectively above a desired compartment of a plurality of compartments 106 of a module 22. The length of the slot 102 is commensurate with the length of the module 22 to permit displacement of the stem 72 in the X direction for alignment with a selected one of the compartments 106. The slot 102 is relatively narrow, and has a width large enough to clear the stem 72 and the tip 70 mounted on the distal end of the stem 72. With respect to the overall dimension of the temperature controlled chamber 36, the area occupied by the slot 102 is sufficiently small to preclude any significant amount of air flow between the interior and the exterior of the chamber 36. Thereby, the slot 102 has no more than a negligible effect in the control of the chamber temperature, which temperature is controlled by the heater 38 (FIG. 1).
Fluid reagent is drawn into the pipette tip 70 and expelled from the tip 70 by vacuum pressure delivered to the pipette 40 by a suction unit which is of well-known form and is located within the pipette 40. The suction unit comprises a linear actuator 108 driven by a stepping motor (not shown) for driving a piston 110 via a rod 112. The piston 110 connects via a conduit 114 which passes through the stem 72 and into the tip 70. The microprocessor 62 commands the actuator 108 to apply vacuum for inducting fluid, and for releasing vacuum and applying positive pressure, if necessary, to expel the fluid reagent. Induction of fluid is done from a selected one of the reservoirs 66. Expelling of the fluid reagent is accomplished only when the tip 70 is in the position for dispensing the fluid to the selected one of the compartments 106 in the designated module 22. It is noted also that fluid reagent can be withdrawn also at one of the compartments 106 of the module 22 to be dispensed in another of the compartments 106. In this respect, a reservoir for storage of fluid reagent can be located directly within the module 22 or remote from the module 22, as at the table 68.
The locations of the various reservoirs 66 of the table 68 are stored in a memory of the microprocessor 62. This enables the microprocessor 62 to move the table 68 to a specific address in the Y direction, and to move the pipette 40 to a specific address in the X direction, the X and the Y components of the address fully identifying the requisite one of the reservoirs 66. In similar fashion, the microprocessor 62 stores locations of the available tips 70 held by the table 68 so that successive ones of the tips 70 can be selected for affixation to the stem 72.
The transport 64 is operative in the process of affixing a tip 70 to the stem 72 of a pipette 40, and in the detachment of the tip 70 from the stem 72. The procedure begins by a lifting of the pipette 40 so that the tip 70 clears the slot 102. The pipette 40 is then free to move along the beam 74 to an extractor 116. The extractor 116 has a semicircular channel 118 cut out in the edge of a horizontal portion of the extractor 116, the channel 118 having a diameter large enough to permit clearance of the stem 72 by the channel 118, but small enough to permit engagement of the channel 118 with the proximal end of the tip 70. Under commands of the microprocessor 62, the pipette 40 is brought towards the extractor 116 with the tip 70 being below the channel 118. The stem 72 enters the channel 118 after which the pipette 40 is raised to engage the tip 70 with the extractor 116. The tip 70 remains stationary as the stem 72 lifts out of the tip 70. Thereupon, the tip 70 falls into a bin 120 for collection of used tips 70. It is advisable to employ the extractor 116 at the beginning of operation of the test system 20 to ensure that the stem 72 is free for affixation of a new tip 70.
After ensuring that the stem 72 is free for reception of a tip 70, the pipette 40 is brought, by displacement in the X direction, to a location above the table 68, whereupon the table 68 is translated in the Y direction to bring the stem 72 above and in registration with a selected tip 70 held by the table 68. The pipette 40 then advances downward, along a central longitudinal axis of the pipette 40, to make contact with the interior surface of the tip 70. Thereupon, the pipette 40 is raised, and the tip 70 is retained on the distal end of the stem 72 by a feature of the invention described in the following.
In accordance with the invention, and with reference to FIGS. 2-8, the pipette 40 includes a novel pipette assembly 122 comprising the tip 70 and a tip holder 124. The tip 70 is formed as a hollow body comprising a crown 126 and a stem 128 which extends downwardly from the crown 126 in the normal vertical attitude of the pipette 40. The holder 124 is also formed as a hollow body and comprises a crown 130 and the aforementioned stem 72 which extends downwardly from the crown 130 in the normal vertical attitude of the pipette 40. Included within the tip crown 126 is a chamber 132 for receiving the holder stem 72. The chamber 132 forms a part of a passage 134 which extends from a proximal end 136 of the tip 70 to a distal port 138 at the far end of the tip stem 128. The tip passage 134 includes a relatively narrow bore 140 opening at the distal port 138, the opposite end of the bore 140 widening into a bowl 142 which communicates with the tip chamber 132. The tip bowl 142 has sufficient volume for storage of fluid drawn in through the tip bore 140 which fluid is to be expelled later via the tip bore 140.
The holder 124 is also formed of a hollow body and includes a chamber 144 located in the holder crown 130, the holder 124 including a passage 146 which extends from the chamber 144 through the holder stem 72 to a distal port 148 at the end of the stem 72. Upon connection of the tip 72 with the holder 124, as depicted in FIGS. 2, 6 and 7, the holder passage 146 and the tip passage 134 together constitute the conduit 114 previously disclosed in FIG. 2. A set of fins 150 extend radially outward from the tip crown 126 for supporting the tip 70 in an aperture 152 of the table 68 (FIGS. 2 and 7).
In accordance with a feature of the invention, the tip 70 is retained upon the holder stem 72 by a snap-lock retainer 154 (FIG. 3) formed along an interface between a sidewall 156 of the tip 70 and a sidewall 158 of the holder 124. The sidewall 156 encloses the tip chamber 132, and the sidewall 158 encloses the holder passage 146 (FIG. 5). One portion of the retainer 154 is formed as an assembly of ridges 160 formed of the inner surface of the tip sidewall 156 and extending inwardly towards a central longitudinal axis 162 of the tip 70. By way of example, three ridges 160 are provided, the ridges 160 being disposed symmetrically about the axis 162. The cross section of the tip sidewall 156 is circular. An inner edge of each ridge 160 is formed as a chord of the circular cross section of the Q tip sidewall 156. The holder stem 72 has a generally circular cylindrical shape about a longitudinal central axis 164 of the holder 124. A second part of the retainer 154 is formed as a protuberance 166 which extends from the outer surface of the holder sidewall 158 with circular symmetry about the holder axis 164.
In the sectional view of the tip 70 of FIG. 3, there is superposed an outline in phantom view of the holder stem 72 to portray an interrelationship among surface features of the holder stem 72 and features of the inner surface of the tip sidewall 156. The tip sidewall 156 at the tip crown 126 is tapered with the cross section of the tip chamber 132 increasing in size with progression from the distal end of the chamber 132 towards the proximal end 136 of the tip 70. This facilitates manufacture of the tip 70 by a process of molding the tip 70 from a polymeric material. Preferably, the polymeric material should be relatively soft and resilient to permit elastic deformation of the tip 70 during insertion of the holder stem 72 into the tip chamber 132. Such elastic deformation is important for securing the snap-action of the retainer 154 and for construction of fluid seals as will be described hereinafter. With respect to the longitudinal sectional view of FIG. 3, a longitudinal ray of the sidewall 156 of the truncated conic surface of the tip chamber 132 is inclined relative to the tip axis 162. Similar inclination of a ray of the surface of the tip sidewall 156 is present in the extension of the sidewall 156 to the tip bowl 142 and to the tip bore 140 to provide taper of the tip stem 128 to facilitate manufacture by molding. The entire tip 70 is molded as an integral unit.
In the construction of the retainer 154, the protuberance 166 has a leading surface 168 and a trailing surface 170 which are inclined relative to the holder axis 164. This permits engagement of the protuberance 166 with the tip ridges 160, and distention of the ridges 160 away from the tip axis 162 during insertion of the holder stem 72 into the tip chamber 132 and during a retraction of the holder stem 72 from the tip chamber 132. Upon insertion of the holder stem 72 into the tip chamber 132, the tip axis 162 and the holder axis 164 coincide. As can be seen with reference to FIGS. 3 and 4, the minimum distance of each ridge 160 from the axis 162 is less than the maximum distance of the protuberance 166 from the axis Q 164. This produces a snap-action as each of the ridges 160 slide up the leading surface 168 and then begin to slide down the trailing surface 170 of the protuberance 166.
In the tip 70, at the distal end of the chamber 132, there is formed a ledge 172 in the tip sidewall 156, the ledge 172 extending in a plane transverse to the axis 162. At the inner edge of the ledge 172, there is formed a lip 174 which extends toward the proximal end 136 of the tip 70. The lip 174 engages with a surface 176 of a nose 178 of the holder stem 72. The nose surface 176 extends transversely away from the distal port 148 of the holder 124, and then extends further in an inclined fashion relative to the axis 164 as a skirt 180 of the nose 178. In a preferred embodiment of the invention, the inclination of a ray of the skirt 180 relative to the axis 164 is approximately 45 degrees. Upon insertion of the holder tip 72 into the tip chamber 132, the nose 178 advances to the ledge 172 with the skirt 180 abutting the lip 174 of the ledge 172. At the retainer 154, the inclination of the trailing surface 170 coacts with the ridges 160 to develop a force having a longitudinal component along the axis 162. The force of the retainer 154 urges the holder stem 72 towards the distal end of the tip 70, thereby driving the skirt 180 against the lip 174 with slight deformation of the lip 174. The deformation of the lip 174 conforms the lip 174 to the surface of the skirt 180 and provides a seal 182 which blocks all flow of air from the tip bowl 142 into the tip chamber 132.
The force along the axis 162 developed by the retainer 154 is provided by the resilience of the plastic material of the tip sidewall 156 which enables the tip sidewall 156 and the assembly of ridges 160 to act as a spring for securing the holder stem 72 within the tip chamber 132. During use of the extractor 116 (FIG. 2) for removal of a used tip 70 from the holder stem 72, the tip sidewall 156 and the assembly of ridges 160 readily deform to clear the protuberance 166, the force exerted by the extractor 116 upon the proximal end 136 of the tip 70 exceeding the snap-action force of the retainer 154 to allow extraction of the stem 72.
In a preferred embodiment of the invention, a second seal 184 is located along the interface between the holder sidewall 158 and the tip sidewall 156 in the chamber 132. The holder stem 72 is provided with an outwardly extending ring 186 which forms a part of the nose 178. An inwardly extending ring 188 is located on the inner surface of the tip sidewall 156 in the chamber 132, and is disposed with circular symmetry about the axis 162. The inwardly extending ring 188 is arranged between the first-mentioned seal 182 and the retainer 154. The; 15 outwardly extending ring 186 is tapered for increasing diameter with progression away from the distal port 148. The taper allows for engagement of the outwardly extending ring 188 with the inwardly extending ring 186 to form the seal 184 upon insertion of the holder stem 72 within the chamber 132. The ring 186 of the holder 124 extends for a greater distance along the holder axis 164 than the corresponding extent of the ring 188 of the tip 70 along the tip axis 162 to allow for sliding of the nose 178 past the tip ring 188. The resilience of the plastic material of the tip sidewall 156, which material is also employed in the construction of the ring 188, allows for elastic deformation of the ring 188 as is slides along the tapered surface of the ring 186 on the nose 178.
A feature of the invention is the establishment of a predetermined length to the pipette assembly 122 including the holder 124 in conjunction with any one of a number of replacement tips 70. Thus, when any previously used tip 70 is replaced with a new tip 70, the total length of the pipette assembly 122 has the desired predetermined length, which length is measured from the tip distal port 138 to a reference point in the holder 124, such as the distal end of the nose 178 or the distal edge of the crown 130. This predetermined length is maintained accurately among all of the tips 70 by the abutment of the skirt 180 of the nose 178 against the lip 174 of the ledge 172. The retainer 154, by urging the holder stem 72 against the ledge 172 ensures accurate mating of the skirt 180 with the lip 174 to maintain the desired predetermined length of the pipette assembly 122.
In the construction of the ridges 160, and in the construction of the inwardly extending ring 188 of the tip 70, the forward edges (the edges closest to the tip distal port 138) of the ridges 160 and the ring 188 are provided with a taper which facilitates the molding operation in the manufacture of the tip 70. The taper facilitates removal of the tip 70 from the part of the mold located within the tip 70 by allowing the ridges 160 and the ring 188 to slide over corresponding depressions in the mold. In the manufacturing process, testing of a completed tip 70 is provided by use of a circular pin-shaped gauge which is inserted into the tip 70 to contact the lip 174 to test the circumference thereof. Other circular gauges of differing diameters are employed similarly to check the circumferences of the tip ring 188 and the assembly of the ridges 166. A correct measure of circumference indicates proper performance of each of the seals 182 and 184 as well as of the snap-action of the ridges 160. Also, a correct circumference of the lip 174 indicates proper seating of the holder nose 178 against the tip lip 174 to ensure a correct distance between the holder distal port 148 and the tip distal port 138.
By way of example in the construction of a preferred embodiment of the tip 70, the following dimensions are employed. With respect to the construction of the tip stem 128, a longitudinal ray of the tip bore 140 is inclined at an an angle of 2 degrees with respect to the tip axis 162. The same angle of inclination is employed for longitudinal rays in the sidewall 156 of the tip bowl 142 and in a forward portion of the sidewall of the tip chamber 132. The forward portion of the sidewall of the tip chamber 132 extends approximately one-half of the axial length of the chamber 132. The sidewall 156 of the remaining half of the chamber 132 is tapered to a greater extent such that a ray of the sidewall is inclined at an angle of approximately 4 degrees. At the assembly of the ridges 166, the minimum diameter of a circular tangent to the inwardly extending edges of the ridges 160 is 0.270 inches with a tolerance of 0.002 inches. The angle of inclination of a ray of the sidewall 156 at the distal end of the tip bowl 142 is approximately 45 degrees. The inner diameter of the tip ring 188 of the second seal 184 is in the range of 0.243 inches to 0.246 inches. The diameter of the lip 174 of the ledge 172 is 0.187 inches with a . tolerance of 0.002 inches. The extent of the lip 174 along the tip axis 162 is 0.005 inches.
With respect to the tip holder 124, the ring 186 of the nose 178 has a maximum diameter of 0.248 inches and a minimum diameter of 0.238 inches both with a tolerance of 0.002 inches. The ring 186 of the nose 178 is tapered such that a longitudinal ray of the surface of the ring is inclined relative to the holder axis 164 at an angle of 3 degrees. In the construction of the protuberance 166 of the holder stem 72, the maximum diameter is 0.286 inches with a tolerance of 0.002 inches, and the minimum diameter at the distal and proximal ends of the protuberance 166 is 0.20 inches with a tolerance of 0.002 inches. The leading and the trailing surfaces 168 and 170 of the protuberance 166 are tapered such that a ray of the surfaces is inclined at an angle of 15 degrees relative to the holder axis 164.
In a preferred embodiment the pipette tip has three notches spaced about 120° apart cut into the proximal end 136 of the tip 70. One such notch 151 is shown in FIG. 3 for purposes of illustration. The notches 151 are about 0.1 inch deep, about 0.1 inch across at the top and preferably form an included angle of about 25° with relation to axis 162. As illustrated in FIG. 4 the notches 151 are arranged such that the ridges 160 are not formed directly below them. The notches 151 allow the protruberance 166 to be extended outwardly farther from axis 164 (FIG. 5). The leading surface 168 of the protruberance 166 can be at a larger angle, for example, 30°, relative to axis 164 and the trailing surface 170 can remain the same, e.g., 15°. By including the notches 151 and providing the leading surface at the larger angle the force by which the pipette tip is retained can be advantageously increased.
The tip holder 124 is constructed of a metal, such as stainless steel, and is provided with a smooth surface to facilitate sliding into the tip chamber 132. The length of the pipette assembly 122 is selected in accordance with dimensions of the analytical instrument employed in the system 20 (FIGS. 1 and 2), including dimensions of the carousel 24, the module 22, and the chamber 36. By way of example in the selection of length, in a preferred embodiment of the invention, the length of the tip 70, as measured from the distal port 138 to the proximal edge of the lip 174, is in the range of 0.750 inch to 0.754 inch. In the holder stem 72, the distance from the distal port 148 to the center of the protuberance 166 (the outwardly extending peak) is 0.470 inches. With respect to the ridges 60, the maximum width of a ridge 160, as measured in a plane transverse to the tip axis 162, is approximately 0.015 inches. The interior diameter of the tip chamber 132 at the ledge 172 is 0.250 inch.
In accordance with a further feature of the invention, and as shown in FIGS. 2, 6, 7, and 8, the pipette 40 further comprises a spring-loaded lost-motion connection 190 which permits use of a stepping motor, the motor 86, for operating the vertical drive 78. As is well known, a stepping motor advances stepwise. Therefore, by use of a stepping motor in the vertical drive 78, the pipette 40 moves upward and downward in a sequence of incremental steps. The sequence of incremental steps is advantageous for control by the microprocessor 62 in that accurate control of the position of the pipette 40 can be attained by the microprocessor by the designation of a specific number of steps for advancement or retraction of the pipette 40. FIG. 6 shows the situation in which the pipette 40 can be advanced or retracted in the vertical direction freely. FIG. 7 shows the situation in which downward advancement of the pipette 40 is constrained by the table 68 which supplies the replacement tips 70 for the pipette 40. During the replacement of a pipette tip 70, upon the insertion of the holder stem 72 into the tip 70 to bring the holder nose 178 into abutment with the tip lip 174 (FIG. 3), the fins 150 are being pressed against the table 68 (FIG. 7). The pipette assembly 122 is restrained by the table 68 from further downward advancement even though the motor 86 may still be activated electrically for further advancement.
In view of the fact that, generally, the distance which the pipette 40 must travel in the vertical direction to reach the table 68 is a non-integral number of steps of the stepwise travel, provision must be made to absorb the additional movement of at least one fractional step. The lost-motion connection 190 provides this function so that even if the number of steps directed by the microprocessor 62 exceed the amount required to seat the nose 178 against the lip 174, the lost-motion connection 190 allows the pipette 40 to remain stationary while the vertical drive 78 continues to advance downwardly. The spring 192 in the connection 190 maintains downward force against the holder 124 during the additional advancement of the vertical drive 78, the force exerted by the spring 192 being sufficient to seat the nose 178 of the holder 124 against the lip 174 of the tip 70.
In addition to the spring 192, the lost-motion connection 190 further comprises a support body 194 having a crown 196 and a stem 198 extending downward from the crown 196, a slide 200 comprising a base 202 extending transversely of an axis of the pipette 40 and a collar 204 extending from the base 202 parallel to the pipette axis, and a nut 206 which is knurled to permit tightening by hand. The slide 200 slides along the stem 198, and includes a set screw 208 which mounts within the collar 204 and extends into a slot 210 in the stem 198 to allow translation of the slide 200 along the stem 198 while preventing rotation of the slide 200 about the stem 198. If desired, two "O" rings 212 may be positioned on opposite sides of the set screw 208 for encircling the stem 198 to maintain lubrication between the stem 198 and the slide 200. Apertures 214 in the base 202 allow connection of the slide 200 to an outer housing 216 of the vertical drive 78. Securing of the base 202 to the housing 216 may be accomplished by screws (not shown) passing through the apertures 214 into the housing 216.
The linear actuator 108, previously described with reference to FIG. 2, is located above the crown 196 and is enclosed within a cap 218 which is secured by threads to the crown 196. The motor of the actuator 108 operates a positioning element 220 by linear translation of the element 220 along the pipette axis. Also included within the pipette 40 is a piston assembly 222 which is supported within the chamber 144 of the holder 124, and extends upwardly through a central bore 224 of the support body 194 to connect with the positioning element 220. The piston assembly 222 is of well-known construction and is available commercially, the piston assembly 222 having the piston rod 112 which drives the piston 110, previously described with reference to FIG. 2. (The piston 110 is not shown in FIG. 8.) The piston 110 has the form of an insert of inert material, such as polytetrafluoroethylene (Teflon), within a nylon cylinder 226. The cylinder 226 is dimensioned to nest within the holder chamber 144 and serves as a liner between the holder 124 and the piston 110. The piston 110 is spring-loaded by a coil spring 228 disposed within a cylindrical shell 230 of the assembly 222 The positioning element 220 drives the piston rod 112 to advance the piston 110 in a downward direction towards the holder stem 72, and the spring 228 exerts a retractive force for retracting the piston away from the holder stem 72.
In operation, an electrical cable 232 connects the actuator 108 with the microprocessor 62, the cable passing through an aperture in the cap 218. The base 202, being fixed to the bottom of the housing 216 moves up and down with the vertical drive 78. In the event that the pipette 40 is free to move up and down, then the movement of the pipette 40 follows the movement of the slide 200 exactly. In the event that, during a downward motion of the vertical drive 78, the pipette 40 meets resistance of the table 68, then the slide 200 continues to advance further in the downward direction, and slides along the stem 198 of the support body 194. This sliding motion of the slide 200 constitutes a lost-motion connection of the slide 200 to the stem 198, and allows the vertical drive 78 to move stepwise further in the downward direction in response to the designated step count of the microprocessor 62. During the lost motion, the spring 192 is compressed so as to maintain a desired force of the holder 124 upon the tip 70 as the tip 70 is held by its fins 150 in the aperture 152 of the table 68.
With respect to an assembly of the pipette 40, and with reference particularly to FIG. 8, the piston assembly 222 is inserted through the bore 224 of the support body 194 to be connected to the positioning element 220 of the actuator 108. The electrical cable 232 for the actuator 108 is pulled through the aperture in the cap 218, and the actuator 108 is placed within the cap 218, the latter being secured to the crown 196. The slide 200 is provided with the optional oil rings 212, and then is slid onto the stem 198 of the support body 194. The slide 200 is then oriented to place the set screw 208 in registration with a slot 210, whereupon the set screw 208 is rotated to advance the screw to the slot 210. The spring 192 is slid onto the stem 198 beneath the slide base 202 and is secured in its position on the stem 198 by the nut 206, the latter having an internal thread for mating with an external thread on the bottom end of the stem 198. The bottom portion of the piston assembly 222 is then placed in the chamber 144 of the tip holder 124, whereupon the holder 124 is secured to the bottom end of the stem 198 by external threads on the holder 124 which mate with internal threads on the body stem 198. A flat 234 on the holder crown 130 facilitates the gripping of the crown with a wrench for tightening the holder 124 into the stem 198.
Thereby, the system of the invention permits the pipette to transport fluid from a reservoir to a module compartment, and allows for the replacement of pipette tips between successive dispensing of the fluid. In addition, the pipette holder can engage with a replacement tip by a snap action by use of a vertical drive employing a stepping motor, this being accomplished by the use of a spring-loaded lost-motion connection.
Although the invention has been described in detail with respect to various preferred embodiments those skilled in the art will recognize that the invention is not limited thereto but rather that variations and modifications may be made which are within the spirit of the invention and the scope of the appended claims. | There is described a fluid dispensing system which includes a pipette assembly adapted for use with disposable pipette tips. To ensure a precise location of a disposable pipette tip on the distal end of the stem of the pipette assembly which holds the pipette tip, a proximal chamber of the pipette tip envelops the distal end of the stem and includes a ledge which encircles an annular region of the stem to form an abutment for the stem and establish a precise distance between the distal end of the stem and the pipette tip orifice. In a preferred embodiment the fluid dispensing system is incorporated in an automated analytical instrument. | 1 |
CROSS REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This application is a non-provisional patent application which claims priority to European Patent Application No. 02078119.1, filed Jul. 30, 2002. The European Application No. 02078119.1 is hereby incorporated by reference as thought fully set forth herein.
BACKGROUND OF INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to a paneling system for ceilings of a building in which panels are suspended by hook-shaped flanges, on opposite sides of each panel, from flat arms of L- or Z-shaped panel carriers or support rails. This invention particularly relates to ceiling panels with hook-shaped flanges, one flange of each panel extending over the flange of the neighboring panel atop the horizontal arm of a panel carrier.
[0004] 2. Description of Known Art
[0005] Such paneling systems are described in DE 1 934 185, FR 1 203 394, and DE 84 37 592 U. For example, DE 1 934 185 describes: a plurality of conventional, horizontal spaced apart, parallel, panel carriers ( 1 ), each having a horizontal arm with an upstanding free end ( 2 ), so that the arm forms an upwardly-open U-shaped channel; and a plurality of adjacent, horizontally-extending, ceiling panels ( 3 ), each panel having a hook-shaped flange ( 4 , 5 ) on each horizontally opposite side, forming a downwardly-open U-shaped channel above the bottom of the panel. One hook-shaped flange ( 5 ) of each panel ( 3 ) has a horizontally narrow, inwardly-extending top portion ( 7 ) and, at its free end, an inwardly- and downwardly-extending rim or edge ( 8 ), and the other hook-shaped flange ( 4 ) has a horizontally longer, outwardly-extending top portion ( 6 ) and, at its free end, a downwardly- and inwardly-extending rim ( 9 , 10 ). The narrow flange ( 5 ) is provided under the longer flange ( 4 ) when adjacent panels ( 3 ) are installed with their flanges overlying the arm of a carrier, between the adjacent panels, and overlying the upstanding free end ( 2 ) of that carrier's arms.
SUMMARY OF INVENTION
[0006] In accordance with this invention, a ceiling paneling system, is provided with panels having improved hook-shaped flanges on opposite sides of the panels and panel carriers with improved arms adapted to hold the panels' flanges, so as to enable easy installation and removal of individual panels. The paneling system comprises:
[0007] a plurality of adjacent, longitudinally-extending panels: each panel having a pair of hook-like flanges on longitudinally-opposite sides; each hook-like flange forming a downwardly-open U-shaped channel above the bottom of the panel; a first hook-like flange of each panel having an inwardly-extending first top portion and, at its free end, a downwardly-extending first rim; a second hook-like flange of each panel having an outwardly-extending second top portion and, at its free end, a downwardly-extending second rim; the second top portion being of substantially the same length, but slightly longer, than the first top portion; and the first rim being longitudinally spaced away from an adjacent side of the panel; and
[0008] a plurality of longitudinally spaced apart, parallel panel carriers, each carrier having a longitudinally-extending arm with an upstanding free end forming an upwardly-open U-shaped channel; both the first top portion of a first flange on one longitudinal side of a first panel and the second top portion of a first flange on one longitudinal side of a first panel and the second top portion of a second flange on the opposite longitudinal side of an adjacent second panel being atop the arm of the carrier to attach the first and second panels to the carrier; the second top portion being atop the first top portion.
[0009] Preferably, the first rim on the first flange of each panel comprises a downwardly-extending locking member with a downwardly and outwardly angled surface facing the adjacent side of the panel. It is also preferred that an arm of each carrier comprises an upwardly-extending locking lug that is longitudinally spaced away from the upstanding free end of the arm; the rims of the first and second panel, attached to the carrier, being on longitudinally opposite sides of the locking lug and preferably contact the upper surface of the arm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Further aspects of the invention will be apparent from the detailed description below of a particular embodiment and the drawings thereof, in which:
[0011] [0011]FIG. 1 is a vertical cross-section of a ceiling panel of a paneling system according to the invention;
[0012] [0012]FIG. 2 is a vertical cross-section of a panel carrier of a paneling system according to the invention;
[0013] [0013]FIG. 3 is a vertical cross-section of an assembled paneling system of the invention; and
[0014] [0014]FIGS. 4. 1 - 4 . 4 are schematic representations of how the paneling system of FIG. 3 can be assembled.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] [0015]FIG. 1 shows a conventional, longitudinally-extending, preferably rectangular ceiling panel 1 for an interior ceiling of a building. A plurality of such panels 1 can be lain side-by-side to cover a ceiling with the paneling system of this invention. The panel 1 is a metal skin sandwich panel with the top metal skin layer 3 , a bottom metal skin layer 5 and a core layer 7 extending between the top and bottom skins. The bottom skin 5 is visible when the panel 1 is mounted in a ceiling. The core 7 is preferably a honeycomb material but can be any other core material or even several stacked layers of different core materials. The panel 1 can be an acoustic panel, where the bottom skin 5 is perforated. The panel 1 is preferably rectangular and has a front side (not shown), a back side (not shown), a left side 9 and a right side 11 .
[0016] Longitudinally opposite sides 9 , 11 of the panel 1 are adapted for attaching the panel to one of the panel carriers (shown in FIG. 2) of the paneling system of this invention. In this regard, left and right mounting profiles 13 , 15 are provided on the panel, preferably by adhesively attaching them respectively to the left and right sides of the core 7 . In this regard, the left mounting profile 13 includes a left profile connector 21 , with a hollow rectangular cross-section, on the left side 9 of the core 7 , and the right mounting 15 includes a right profile connector 22 , with a hollow rectangular cross-section, on the right side 11 of the core. In order to facilitate the attachment of the profile connectors 21 , 22 to the panel sides 9 , 11 , portions of the core 7 are removed from these sides to make room for the profile connectors which then take the place of the removed core portions. The mounting profiles 13 , 15 , particularly their profile connectors 21 , 22 , preferably have a lateral length (not shown) and the height that are the same as the panel 1 . It is also preferred that the bottom skin 5 extends further longitudinally than does the top skin 3 on both sides 9 , 11 , so that the bottom skin 5 can be adhesively attached to, and cover, the bottom and upstanding sides of the mounting profiles 13 , 15 . In this way, the bottom of the panel 1 , that is visible when the panel is mounted, is always covered with the bottom skin 5 , and the core 7 does not show. It is also preferred that the top of the left and right profile connectors 21 , 22 is also at least partially covered by the top skin 3 and that the top of the core 7 is completely covered by the top skin.
[0017] As seen from FIGS. 1 and 3, the left mounting profile 13 also includes a first or left, hook-like flange 23 forming a downwardly-open U-shaped channel above a longitudinally-extending support member 25 of the left profile 13 . The support member 25 connectors the left profile connector 21 with the left flange 23 . In this regard, the left profile connector 21 preferably includes a left wall 21 A, a right wall 21 B, a top wall 21 C and a bottom wall 21 D, and the support member 25 is preferably integral with the bottom wall 21 D.
[0018] As also seen in FIGS. 1 and 3, the left flange 23 has; an upstanding left side wall 27 , the left side of which is preferably covered by the bottom skin 5 ; and a left top wall 29 that is atop the upstanding left wall and extends to the right, horizontally and inwardly (i.e., towards the adjacent panel side 9 ), away from the left side wall 27 . Preferably, the left top wall 29 also extends to the left, horizontally and outwardly (i.e., away from the adjacent panel side 9 ), away from the left side wall 27 and over the width of the left side wall and an upstanding left end of the bottom skin 5 . A small downwardly-extending left outer rim 31 on the left end of the left top wall 29 holds securely the left end of the bottom skin 5 against the left side wall. At the right end of the left top wall 29 is a small downwardly-extending left inner rim 33 for locking the panel to a carrier. The left inner rim 33 has an inner surface 33 A, facing the adjacent side 9 of the panel, and an outer surface 33 B. The inner surface 33 A is preferably slanted downwardly and leftwardly (i.e., outwardly of the core 7 ). The left inner rim 33 is longitudinally spaced away from the adjacent left wall 21 A of the left profile connector 21 on the left side 9 of the panel to form a horizontal gap 34 in the left mounting profile 13 over the support member 25 .
[0019] As further seen from FIG. 1, the right mounting profile 15 also includes a second or right, hook-like flange 37 forming a downwardly-open U-shaped channel. The right, hook-like flange 37 is connected to the right side of the right profile connector 22 . In this regard, the right profile connector 22 preferably includes a left wall 22 A, a right wall 22 B which is preferably covered by the bottom skin 5 , a top wall 22 C which is integral with the right flange 37 , and a bottom wall 22 D.
[0020] As still further seen in FIG. 1, the right flange 37 has a right top wall 41 that extends to the right, horizontally and outwardly (i.e., away from the adjacent panel side 11 ), away from the top wall 22 C of the right profile connector 22 , and a depending left rim 43 that is adjacent the right wall 22 B of the right profile connector 22 and that holds securely the right end of the bottom skin 5 against the right wall 22 B. At the right end of the right top wall 41 is a small downwardly-extending right rim 45 for locking the panel to a panel carrier. Preferably, the right top wall 41 is not covered by the top skin 3 .
[0021] In accordance with this invention, the right top wall 41 of the right flange 37 extends to the right, horizontally and outwardly, away from the top wall 22 C of the right profile connector 22 by a distance that is the substantially the same, but slightly greater, than the distance that the left top wall 29 of the left flange 23 extends to the right, horizontally and inwardly, away from the left side wall 27 . Thereby, the right top wall 41 can completely cover left top wall 29 when the right top wall lies directly atop the left to wall when the flanges 23 , 37 are used to mount a pair of panels 1 on a carrier.
[0022] Also in accordance with this invention, the right rim 45 of the right flange 37 extends downwardly from its right top wall 41 by a distance that is substantially the same, but slightly greater, than the distance that the left inner rim 33 of the left flange 23 extends downwardly from the right side of its left top wall 29 . Thereby, when the right top wall 41 lies directly atop the left top wall 29 , the bottom of the right rim 45 will be substantially horizontal with the bottom of the left inner rim 33 .
[0023] The mounting profiles 13 , 15 are preferably made as extrusions that are mounted on the left and right sides 9 , 11 of the panel 1 , adjacent its core 7 . However, the mounting profiles 13 , 15 could also be integrally formed with the bottom skin 5 of the panel or with the core 7 .
[0024] [0024]FIGS. 2 and 3 show a preferred panel carrier 47 of the paneling system of this invention. A plurality of such carriers 47 , in parallel and spaced apart relationship, can be used to support a plurality of the panels 1 of FIG. 1 to cover a ceiling with the paneling system of this invention. Depending on the type of ceiling or wall construction to be used with the panel 1 , the carrier 47 can be an elongated extrusion or a hook-like member.
[0025] As shown in FIGS. 2 and 3, the carrier 47 preferably has a conventional, generally L- or Z-shaped configuration, with; a horizontally-extending top flange 49 , to be connected to a ceiling or panel suspension system; a vertically-extending intermediate member 51 , the top of which is connected to the left end of the top flange; and a horizontally-extending bottom flange 53 , connected to the bottom of the intermediate member. The bottom flange 53 preferably extends horizontally and leftwardly away from the top flange 49 to a free left side 53 A. The top surface 53 C of the bottom flange 53 , on which a pair of panels 1 can be mounted, has: a vertically-extending locking lug 57 , between the carrier lug and the intermediate member 51 . The carrier lug 55 has: a gentle left ramp 55 A extending downwardly and leftwardly towards the free left side 53 A of the bottom flange 53 ; a sharper, vertically downward or angled-back right wall 55 B; and a top wall 55 C, between them. The left ramp 55 A facilitates the installation of a panel 1 on the carrier 47 , even when the adjacent panel 1 is already in place as will be explained below. The height of the top wall 55 C of the carrier lug, above the top surface 53 C of the bottom flange 53 , is at least equal to the distance that the left inner rim 33 extends below the left top wall 29 of the left flange 23 , and the locking lug 57 preferably has a height above the top surface of the bottom flange that is at least equal to the distance that the right rim 45 extends below the right top wall 41 of the right flange 37 . Hence, the locking lug 57 is preferably higher than the carrier lug 55 , and this difference in height should be at least equal to the difference in the height of the right rim 45 and the left inner rim 33 .
[0026] Between the carrier lug 55 and the locking lug 57 , there is a first or left, upwardly-open U-shaped carrier channel 59 , adapted to receive the left inner rim 33 of the left flange 23 when a panel 1 is mounted on the panel carrier 47 . Between the carrier locking rim 57 and the upstanding intermediate member 51 is a second or right, upwardly-open U-shaped carrier channel 61 , adapted to receive the right rim 45 of the second flange 37 when a panel 1 is mounted on the panel carrier 47 .
[0027] [0027]FIG. 3 shows a carrier with a pair of adjacent ceiling panels of FIG. 1, mounted on the panel carrier of FIG. 2. The panels are the same, but for clarity, like parts of one panel have the same reference numerals as the panel of FIG. 1 while the other panel has reference numerals greater by “100” than those of the panel of FIG. 1.
[0028] As shown in FIG. 3, the left top wall 29 of the left flange 23 of the left mounting profile 13 of one of the panels 1 is mounted on the carrier lug 55 of the bottom flange 53 of the panel carrier 47 . This was done by tilting the panel upwardly to the right and moving its left side 9 , so as to: i) insert the free end 53 A of the bottom flange 53 of the carrier 47 through the vertical gap 34 in the left mounting profile 13 of the panel, between the left inner rim 33 and the left profile connector 21 ; and ii) then hook the left flange 23 over the carrier lug 55 , so that the left inner rim 33 passes over the carrier lug 55 and past its right wall 55 B. As a result, the bottom of the left inner rim rests on the top surface 53 C of the bottom flange 53 in the left carrier channel 59 .
[0029] On top of the left top wall 29 of the left flange 23 in FIG. 3 is the right top wall 141 of the right flange 137 of the right mounting profile 115 of the other panel 101 . The bottom surface of its right top wall 141 rests on the top surface of the left top wall 29 of the left flange 23 of the panel 1 . The left outer rim 31 of the left flange 23 of the panel 1 abuts the depending left rim 143 of the right flange 137 of the adjacent panel 101 . The bottom of the right rim 145 of the right flange 137 rests on the top surface 53 C of the bottom flange 53 of the carrier 47 in the second carrier channel 61 .
[0030] [0030]FIG. 3 clearly shows that the height of the left top wall 29 (i.e., the height of the upstanding left side wall 27 ) of the left flange 23 , above the support member 25 , is substantially more than the height of the carrier lug 55 to assure maneuvering height when installing the left side 9 of the panel 1 , before the right side 111 of the other panel 101 , on the bottom flange 53 of the carrier 47 . Also, the gap 34 in the left mounting profile 13 of the panel 1 is sufficiently wide horizontally, so that the left side 9 of the panel can be moved around the flange 53 of the carrier 47 to insert the flange's free end 53 A between the left top wall 29 and the support member 25 of the left mounting profile. Further, the slopes of the left ramp 55 A of the carrier lug 55 and the inner surface 33 A of the left inner rim 33 preferably allow the left inner rim 33 to ride easily upward along the left ramp 55 A when installing the left flange 23 of a panel 1 on the carrier 47 . In addition, the locking lug 57 of the carrier 47 , which provides a wall between both the left and right, carrier channels 59 and 61 , is preferably a bit higher than the carrier lug 55 . In this regard, the excess height of the locking lug 57 is preferably a little less or equal to the thickness of the right top wall 141 of the right flange 137 , thus ensuring that the right top wall contacts the whole horizontal length of the left top wall 29 when the right and left flanges are atop one another on the carrier's bottom flange 53 .
[0031] [0031]FIGS. 4. 1 - 4 . 4 show a methods of mounting and dismounting a plurality of identical ceiling panels 1 , 101 , 201 , etc. of FIG. 1 and on a plurality of parallel identical carriers 47 , 147 , etc. of FIGS. 2 and 3, mounted on a ceiling.
[0032] Step 1. As shown in FIG. 4. 1 , a first panel 1 is mounted on parallel adjacent, first and second carriers 47 , 147 . the first panel is first slightly tilted with its right side 11 extending upward, so that the first panel can then be placed between the two carriers. The bottom flange 53 of the first carrier 47 is then inserted through the vertical gap 34 in the left mounting profile 13 of the first panel. Then, the left flange 23 of the left mounting profile 13 of the first panel is hooked around the free end 53 A of the bottom flange of the first carrier, so that its left inner rim 33 is over the carrier lug 55 while the right side 11 of the panel is above the bottom flange 153 of the second carrier 147 . While hooking the first panel 1 over the carrier's free end 53 A, the left inner rim 33 rides upwardly and leftwardly along the left ramp 55 A of the carrier lug 55 to a position where the left inner rim 33 can subsequently descend into the left carrier channel 59 on the bottom flange 53 when the right side 11 of the first panel is moved downwardly until the first panel is horizontal.
[0033] Step 2. As shown in FIG. 4. 2 , the right side 11 of the panel 1 is subsequently lowered, and the right rim 45 of the right flange 37 rests in the right carrier channel 161 on the bottom flange 153 of the second carrier 147 .
[0034] Step 3. As shown in FIG. 4. 3 , a second panel 101 is subsequently mounted on the second carrier 147 and on a third carrier 247 by first lifting slightly the right flange 37 of the first panel from the bottom flange 153 of the second carrier 147 as shown in FIG. 4. 3 . Then, the second panel 101 is slightly tilted with its right side 111 extending upward, so that the second panel can then be inserted between the two carriers 147 , 247 . The left flange 123 of the second panel 101 is then hooked around the second carrier's free end 153 A as described above in Step 1. In so hooking the left flange 123 , its left inner rim 133 and its left top wall 129 pass between the carrier lug 155 of the second carrier 147 and the right mounting profile 15 of the first panel 1 .
[0035] Step 4. As shown in FIG. 4. 4 , the right side 111 of the second panel 101 is subsequently lowered, so that the right rim 145 of its right flange 137 rests in the right carrier channel 261 of the bottom flange 253 of the third carrier 247 and the left inner rim 133 of its left flange 123 rests in the left carrier channel 159 of the bottom flange 153 of the second carrier 147 . Then, the right side 11 of the first panel 1 is lowered, so that the right top wall 41 of its right flange 37 rests atop the left top wall 129 of the left flange 123 of the second panel 101 and the right rim 45 of its right flange 37 rests in the right carrier channel 161 of the bottom flange 153 of the second carrier 147 .
[0036] Of course, these mounting steps can be repeated for more panels and panel carriers. These steps can also be reversed for easily dismounting any panels from the carriers, to which they are attached.
[0037] This invention is, of course, not limited to the above-described embodiments which may be modified without departing from the scope of the invention or sacrificing all of its advantages. In this regard, the terms in the foregoing description and the following claims, such as “right,” “left,” “front,” “back,” “vertically,” “horizontally,” “longitudinally,” “upper,” “lower,” “top,” and “bottom,” have been used only as relative terms to describe the relationships of the various elements of the panel and carrier of the ceiling paneling system of this invention.
[0038] For example, the left and right mounting profiles 13 , 15 of panel 1 are preferably each made as one piece, but can also be made as separate pieces with separate profiles connectors 19 , 21 , elongated supporting member 25 and hook-like flanges 23 , 37 , which are subsequently attached. Moreover, the paneling system of this invention is also applicable to the walls of buildings and is not limited to their ceilings. | A paneling system for ceilings of a building structure in which the panels are suspended by hook shaped flanges, on opposite sides of each panel from flat arms of L- or Z-shaped panel carriers or support rails. One flange of each panel extends over the flange of a neighboring panel atop the horizontal arm of a panel carrier. | 4 |
This application is related priority to German Application DE 198 46 499.1, filed Oct. 9, 1998, which disclosure is incorporated herein by reference.
FIELD OF THE INVENTION
Pantothenic acid is a vitamin of commercial importance which is used in cosmetics, medicine, human nutrition and animal nutrition.
BACKGROUND OF THE INVENTION
Pantothenic acid can be prepared by chemical synthesis, or biotechnologically by the fermentation of suitable microorganisms in suitable nutrient solutions. In the chemical synthesis, DL-pantolactone is an important compound. It is prepared in a multi-stage process from formaldehyde, isobutyraldehyde and cyanide. In further process steps, the racemic mixture is separated, D-pantolactone is subjected to a condensation reaction with β-alanine, and D-pantothenic acid is obtained.
An advantage of the fermentative preparation by microorganisms is the direct formation of the desired stereoisomeric D-form.
Various types of bacteria, such as, for example, Escherichia coli, Arthrobacter ureafaciens, Corynebacterium erythrogenes, Brevibacterium ammoniagenes , and also yeasts, such as, for example, Debaromyces castellii , can produce D-pantothenic acid in a nutrient solution which comprises glucose, DL-pantoic acid and β-alanine, as shown in EPA 0 493 060. EPA 0 493 060 furthermore shows that in the case of Escherichia coli , the formation of D-pantothenic acid is improved by amplification of pantothenic acid biosynthesis genes contained on the plasmids pFV3 and pFV5, in a nutrient solution comprising glucose, DL-pantoic acid and β-alanine.
EPA 0 590 857 and U.S. Pat. No. 5,518,906 describe mutants derived from the Escherichia constrain IFO3547, such as FV5714, FV525, FV814, FV521, FV221, FV6051 and FV5069, which carry resistances to various antimetabolites, such as salicylic acid, α-ketobutyric acid, β-hydroxyaspartic acid, O-methylthreonine and α-ketoisovaleric acid and produce pantoic acid in a nutrient solution comprising glucose, and D-pantothenic acid in a nutrient solution comprising glucose and β-alanine. It is furthermore shown in EPA 0 590 857 and U.S. Pat. No. 5,518,906 that after amplification of the pantothenic acid biosynthesis genes contained on the plasmid pFV31 in the abovementioned strains, the production of D-pantoic acid in a nutrient solution comprising glucose and the production of D-pantothenic acid in a nutrient solution comprising glucose and β-alanine is improved.
In addition, WO 97/10340 shows that in strains of Escherichia coli which form pantothenic acid, pantothenic acid production can be increased further by increasing the activity of the enzyme acetohydroxy acid synthase II, an enzyme of valine biosynthesis.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved process for the preparation of pantothenic acid.
The vitamin pantothenic acid is a product of commercial importance which is used in cosmetics, medicine, human nutrition and animal nutrition. There is therefore a general interest in providing improved processes for the preparation of pantothenic acid. When D-pantothenic acid or pantothenic acid or pantothenate are mentioned in the present application, they are intended to include not only the free acid but also the salts of D-pantothenic acid, such as, for example, the calcium, sodium, ammonium or potassium salt.
The invention provides a process for the preparation and improvement of pantothenic acid-producing microorganisms by amplification, in particular over-expression, of nucleotide sequences which code for ketopantoate reductase, in particular sequences of the panE gene, individually or in combination with one another, and optionally, in addition, sequences of the ilvC gene.
The term “amplification” in this connection is intended to mean an increase in the intracellular activity of one or more enzymes which are coded by the corresponding DNA by increasing the number of copies of the gene(s), using a potent promoter or a gene which codes for a corresponding enzyme having a high specific activity, and optionally combining these measures.
In particular, it has been found that over-expression of the panE gene together with the genes panB, panC and panD, further improves the formation of pantothenic acid. To achieve the over-expression, the number of copies of the corresponding genes can be increased by means of plasmid vectors, such as, for example, pBR322 (Sutcliffe, COLD SPRING HARBOR SYMPOSIA ON QUANTITATIVE BIOLOGY 1979, 43: 77-90) or pUC19 (Viera, Gene 1982 19:259-268), or the promoter and regulation region upstream of the structural gene can be mutated. A known example of this is the lac-UV5 mutation of the lac promoter (Winnacker: Gene und Klone, Eine Einf{umlaut over (u)}hrung in die Gentechnologie [From Genes to Clones, Introduction to Gene Technology (Verlag Chemie, Weinheim, Germany, 1990). Expression cassettes which are incorporated upstream of the structural gene act in the same way. This method has been used, for example, by LaVallie et al. (BIO/TECHNOLOGY 11, 187-193 (1993) and in PCT/US97/13359. Alternatively, over-expression of the genes in question can be achieved by changing the composition of the media and the culture procedure. An example of this is the universally known regulation of the expression of the lac operon by glucose and lactose. The present inventors moreover have found that over-expression of the panE gene has an advantageous effect in strains which have resistance mutations to metabolites and antimetabolites, such as, for example, resistance to L-valine. It has furthermore been found that over-expression of the panE gene has an advantageous effect in strains which have defect mutations in genes of metabolic routes, such as, for example, the avtA or ilvE gene, which convert precursors of pantothenic acid or reduce the formation of pantothenic acid.
The microorganisms to which the present invention relates can synthesize pantothenic acid from glucose, sucrose, lactose, fructose, maltose, molasses, starch, cellulose or from glycerol and ethanol. These are fungi, yeasts or, in particular, Gram-positive bacteria, for example, of the genus Corynebacterium, or Gram-negative bacteria, such as, for example, those of the Enterobacteriaceae. Of the family of the Enterobacteriaceae, the genus Escherichia with the species Escherichia coli may be mentioned in particular. Within the species Escherichia coli there may be mentioned the so-called K-12 strains, such as, for example, the strains MG1655 or W3110 (Neidhard et al.: Escherichia coli and Salmonella. Cellular and Molecular Biology (ASM Press, Washington D.C.)) or the Escherichia coli wild type strain IF03547 (Institute of Fermentation, Osaka, Japan) and mutants derived from these. Of the genus Corynebacterium, the species Corynebacterium glutamicum , which is known among specialists for its ability to form amino acids, is of particular interest. This species includes wild type strains, such as, for example, Corynebacterium glutamicum ATCC13032 , Brevibacterium flavum ATCC14067 , Corynebacterium melassecola ATCC17965 and others.
To isolate the ilvC gene and the panE gene, a mutant of, for example, Escherichia coli which carries a mutation in the ilvC gene and panE gene, is first prepared.
The nucleotide sequence of the ilvC gene of Escherichia coli is known (Wek and Hatfield, Journal of Biological Chemistry 261, 2441-2450 (1986)). Methods for isolation of chromosomal DNA are also known (Sambrook et al.: Molecular Cloning, A Laboratory Manual (Cold Spring Harbor Laboratory Press, 1989). By choosing suitable primers, the ilvC gene can be amplified with the aid of the polymerase chain reaction (Innis et al., PCR protocols. A guide to methods and applications, 1990, Academic Press). It is then introduced into a plasmid vector. Possible plasmid vectors are those which can replicate in the corresponding microorganisms. For Escherichia coli , for example, the vectors pSC101 (Vocke and Bastia, Proceedings of the National Academy of Science U.S.A. 80 (21), 6557-6561 (1983)) or pKK223-3 (Brosius and Holy, Proceedings of the National Academy of Science USA 81, 6929 (1984)), for Corynebacterium glutamicum , for example, the vector pJC1 (Cremer et al., Mol. Gen. Genet. 220:478-480 (1990)) or pEKEx2 (Eikmanns et al., Gene 102:93-98 (1991)) or pZ8-1 (European Patent Specification 0 375 889) and for Saccharomyces cerevisiae , for example, the vector pBB116 (Berse, Gene 25: 109-117 (1983)) or pDG1 (Buxton et al., Gene 37: 207-214 (1985)) are possible for the present invention. Methods for incorporation of DNA fragments into plasmid vectors are described by Sambrook et al.: Molecular Cloning, A Laboratory Manual (Cold Spring Harbor Laboratory Press, 1989). Methods for transformation and electroporation are described by Tauch et al. (FEMS Microbiology Letters 123:343-347 (1994)). A example of such a transformed strain is the Escherichia coli strain MG1655/pFE32. Plasmid pFE32 contains the ilvC gene of MG1655 which has been incorporated into the vector pBR322. Another example of such a transformed strain is the Corynebacterium glutamicum strain ATCC13032/pFE91. Plasmid pFE91 contains the ilvC gene of ATCC13032 which has been incorporated into the vector pECm3. Plasmid pECm3 is a derivative of plasmid pECm2 (Tauch, 1994, FEMS Microbiological Letters, 123:343-348), the kanamycin resistance gene of which has been removed by a BglII and BamHI restriction with subsequent re-ligation
For incorporation of a mutation into the ilvC gene which eliminates its function, for example, a deletion or insertion can be used. To generate a deletion, an internal part of the nucleotide sequence of the structural gene can be removed with the aid of suitable restriction enzymes and subsequent linking of the ends formed. The ilvC gene mutated in this manner has no function. A second gene which codes for a resistance to an antibiotic can be incorporated into the ilvC gene in the same manner. The ilvC gene mutated in this manner also has no function. The ilvC gene mutated in this manner can then be introduced into a microorganism to replace the wild type gene in the chromosome thereof. Methods of how to carry out this gene exchange are known in the literature. For Escherichia coli , the method described by Hamilton et al. (Journal of Bacteriology 171, 4617-4622 (1989)), which is based on temperature-sensitive replication mutants of the plasmid pSC101, can be employed. pMAK705 is an example of such a plasmid. For Corynebacterium glutamicum , the method of gene exchange described by Schwarzer and P{umlaut over (u)}hler (BIO/TECHNOLOGY 9, 84-87 (1991)), in which non-replicative plasmid vectors are used, can be used. For Saccharomyces cerevisiae a method of controlled gene exchange is described by Roca et al. (Nucleic Acid Research 20(17), 4671-4672 (1992)).
A mutated ilvC gene can be prepared, for example, from a wild type ilvC gene as follows. Plasmid pFE32 comprised of pBR322, is incorporated into the BamHI restriction cleavage site of the ilvC wild type gene. The aacC1 gene, which codes for resistance to the antibiotic gentamycin, was incorporated into the KpnI cleavage site of the ilvC gene of pFE32 (Schweizer, BioTechniques 15 (5), 831-834 (1993)). The plasmid pFE33 obtained in this manner contains the ilvC::aacC1 allele, which can no longer form functional ilvC gene product. The ilvC::aacC1 allele was removed from the plasmid pFE33 and introduced into the SphI cleavage site of the plasmid pMAK705, as a result of which the plasmid pDB1 was formed. Plasmid pDB1 is a plasmid vector which is capable of allele exchange and comprises on the one hand pMAK705 and on the other hand the ilvC::aacC1 allele. Plasmid pDB1 was used in the method described by Hamilton et al. to exchange the wild type ilvC gene present in MG1655 for the ilvC::aacC1 allele. The strain formed in this manner is designated FE4.
To isolate a mutant of FE4 which carries a mutation in the panE gene, the strain FE4 was subjected to a transposon mutagenesis with the transposon Tn5. Transposon Tn5 is described by Auerswaid (COLD SPRING HARBOR SYMPOSIA ON QUANTITATIVE BIOLOGY 45, 107-113 (1981)). The method of transposon mutagenesis is described, for example, in the handbook by Miller, A: Short Course in Bacterial Genetics, A Laboratory Manual and Handbook for Escherichia coli and Related Bacteria (Cold Spring Harbor Laboratory Press, 1992). The method is furthermore described by Simon (Gene 80, 161-169 (1998)) and also in the handbook by Hagemann: Gentechnologische Arbeitsmethoden [Working Methods of Genetic Engineering] (Gustav Fischer Verlag, 1990) and in numerous other publications accessible to the public. Mutants can also be produced after mutagenesis with ultraviolet light or after treatment with a mutation-inducing chemical, such as, for example, N-methyl-N′-nitro-N-nitrosoguanidine. Among the mutants obtained in this manner, after testing the growth substance requirements, in particular the pantothenic acid requirement, those mutants which carry a mutation in a gene of pantothenic acid biosynthesis can be isolated. Those mutants in need of pantothenic acid which can utilize not ketopantoate but pantoate as a growth substance and are therefore mutated in the panE gene which codes for ketopantoate reductase (EC 1.1.1169) are of particular interest. An example of this is the strain FE5 obtained in this manner, which, in addition to the ilvC::aacC1 mutation, carries a panE::Tn5 mutation.
Microorganisms which carry a defect mutation in the ilvC and panE gene, such as, for example, the Escherichia coli strain FE5, can be used as cloning hosts for isolation of the ilvC gene and of the particularly interesting panE gene, or of nucleotide sequences which code for proteins with ketopantoate reductase activity.
A gene library of the microorganisms of interest was created in this context. The construction of gene libraries is described in generally known textbooks and handbooks. The textbook by Winnacker: Gene und Klone, Eine Einf{umlaut over (u)}hrung in die Gentechnologie [From Genes to Clones, Introduction to Gene Technology] (Verlag Chemie, Weinheim, Germany, 1990) or the handbook by Sambrook et al.: Molecular Cloning, A Laboratory Manual (Cold Spring Harbor Laboratory Press, 1989) may be mentioned, for example. A known gene library is that of the E. coli K-12 strain W3110 described by Kohara et al. (Cell 50, 495-508 (1987)). It has since become possible to acquire gene libraries of various microorganisms commercially, such as, for example, a gene library of Saccharomyces pombe strain Sp63 from Stratagene (Heidelberg, Germany) in the plasmid lambda FIX II (Elgin, Strategies 4: 6-7(1991)), a gene library of the Escherichia coli strain W1485 from CLONTECH (Heidelberg, Germany) in the plasmid pGAD10 (Kitts, CLONTECH (Heidelberg, Germany) Vectors On Disc version 1.3, 1994), the nucleotide sequence of which is accessible under the GenBank accession number U13188. The gene library prepared in the manner described above can then be introduced by transformation into the host FE5 described above. By way of example, the pGAD10 gene library of W1485 was thus introduced into the strain FE5 by transformation, and the resulting transformants were investigated for their ability to grow on a pantothenic acid-free nutrient medium. The insertions contained in the plasmid DNA of the resulting pantothenic acid-prototrophic transformants can be investigated by determination of the nucleotide sequence. Methods for determination of nucleotide sequences can be found, for example, in Sanger et al. (Proceedings of the National Academy of Science USA 74:5463-5467 (1977)). Nucleotide sequences can be assigned to genes by means of homology investigations. One possibility for this homology search is comparison with nucleotide sequences of the EMBL and GenBank databanks, which can be carried out by means of the BLAST E-mail Service (Altschul, Journal of Molecular Biology 215, 403-410 (1990)). An example of such a transformant is the Escherichia coli strain FE5/pFEbank16 which carries the panE gene of the E. coli strain MG1655.
The panE gene isolated and identified in the manner described can then be expressed in a desired microorganism. For this purpose, it is amplified by plasmid vectors. These in turn can be equipped with signal structures, which ensure efficient transcription and translation. An overview of expression vectors is to be found, for example, in the textbook by Winnacker: Gene und Klone, Eine Einf{umlaut over (u)}hrung in die Gentechnologie [From Genes to Clones, Introduction to Gene Technology] (Verlag Chemie, Weinheim, Germany, 1990) or in Sambrook et al.: Molecular Cloning, A Laboratory Manual (Cold Spring Harbor Laboratory Press, 1989). Expression signals, such as, for example, the tac promoter, can furthermore be incorporated into the chromosome upstream of the panE gene. Such methods are described in WO 98/04715. The panE gene to be expressed can be removed from the cloned chromosomal DNA fragment, or it can be amplified in turn with the aid of the polymerase chain reaction. The amount of ketopantoate reductase present in the microorganism in question can be determined with the aid of the method described by Shimizu et al. (Journal of Biological Chemistry 263: 12077-12084 (1988)). A example of such a strain is the Escherichia coli strain MG1655/pFE65. Plasmid pFE65, comprising the vector pKK223-3, has been incorporated into the EcoRI restriction cleavage site of the panE gene of Escherichia coli MG1655.
According to the invention, it has proved advantageous to amplify, in particular to over-express, one or more genes of pantothenic acid biosynthesis in addition to the panE gene, which codes for ketopantoate reductase. These include the genes which code for the enzymes ketopantoate hydroxymethyltransferase (EC 4.1.2.12), aspartate 1-decarboxylase (EC 4.1.1.11) and pantothenate synthetase (EC 6.3.2.1). In Escherichia coli , these genes are designated panB, panD and panC (Miller, A Short Course in Bacterial Genetics, A Laboratory Manual and Handbook for Escherichia coli and Related Bacteria (Cold Spring Harbor Laboratory Press, 1992)). For this, the genes can be incorporated into various compatible plasmid vectors. Examples of these are described by Bartolome et al. (Gene 102, 75-78 (1991). Gene expression can furthermore be increased by changing the chromosomal signal structures lying upstream. The genes in question can, moreover, be placed under the control of a common promoter, in an arrangement in succession, and incorporated into a plasmid vector and introduced into a suitable microorganism. An example of this is Escherichia coli strain MG1655/pFE80. The plasmid pFE80 comprises the plasmid pKK223-3, which contains the genes panB, panD, panC and panE in the stated sequence. The tac promoter is contained in pFE80 as an expression signal upstream of the panB gene.
It has also proved advantageous to over-express the panE gene and the expression unit consisting of the genes panB, panD, panC and panE in host strains which contain chromosomal mutations.
It is possible to use mutations, individually or together, which produce resistances to metabolism products, such as, for example, L-valine or α-ketoisovaleric acid, or to analogues of metabolism products, such as, for example, β-hydroxyaspartic acid or O-methylthreonine. Such mutants occur spontaneously or can be produced by mutagenesis with ultraviolet light or treatment with a mutation-inducing chemical, such as, for example, N-methyl-N′-nitro-N-nitrosoguanidine, and can then be selected on agar plates containing the appropriate substance. Processes for inducing mutation and for selection are generally known and can be found, inter alia, in Miller (A Short Course in
Bacterial Genetics, A Laboratory Manual and Handbook for Escherichia coli and Related Bacteria (Cold Spring Harbor Laboratory Press, 1992)) or in the handbook “Manual of Methods for General Bacteriology” of the American Society for Bacteriology (Washington D.C., USA). An example of such a mutant is Escherichia coli strain FE6, which has been isolated as a spontaneously occurring, L-valine-resistant mutant of the strain MG1655.
Adverse or troublesome chromosomally coded metabolism reactions can furthermore be eliminated in a controlled manner. For this, insertions or deletions are introduced into the corresponding genes and the mutated genes or alleles formed in this manner are incorporated into the chromosome of the host. The methods which have been described above for mutation of the ilvC gene can be employed. An example of such a mutant is the Escherichia coli strain FE7, which carries an avtA::aadB mutation in the chromosome. This is the strain MG1655, in which the aadB gene from plasmid pHP45 Ω, which imparts resistance to streptomycin, has been introduced into the avtA gene (Prentki and Krisch, Gene 29, 303-313 (1984)). The panE gene can then be over-expressed in the host strains prepared in this manner, either alone or in combination with other genes. Examples of these are the strains FE6/pFE80 and FE7/pFE80.
The microorganisms prepared according to the invention can be cultured continuously or discontinuously in the batch process or in the fed batch (feed process) or repeated fed batch process (repetitive feed process) for the purpose of pantothenic acid production. A summary of known culture methods is described in the textbook by Chmiel (Bioprozesstechnik 1. Einf{umlaut over (u)}hrung in die Bioverfahrenstechnik [Bioprocess Technology 1. Introduction to Bioprocess Technology (Gustav Fischer Verlag, Stuttgart, 1991)) or in the textbook by Storhas (Bioreaktoren und periphere Einrichtungen [Bioreactors and Peripheral Equipment] (Vieweg Verlag, Braunschweig/Wiesbaden, 1994)). The culture medium to be used must meet the requirements of the particular microorganisms. Descriptions of culture media for various microorganisms are contained in the handbook “Manual of Methods for General Bacteriology” of the American Society for Bacteriology (Washington D.C., USA, 1981). Sugars and carbohydrates, such as, for example, glucose, sucrose, lactose, fructose, maltose, molasses, starch and cellulose, oils and fats, such as, for example, soya oil, sunflower oil, groundnut oil and coconut fat, fatty acids, such as e.g. palmitic acid, stearic acid and linoleic acid, alcohols, such as, for example, glycerol and ethanol, and organic acids, such as, for example, acetic acid, can be used as the source of carbon. These substances can be used individually or as a mixture. Organic nitrogen-containing compounds, such as peptones, yeast extract, meat extract, malt extract, corn steep liquor, soya bean flour and urea, or inorganic compounds, such as ammonium sulphate, ammonium chloride, ammonium phosphate, ammonium carbonate and ammonium nitrate, can be used as the source of nitrogen. The sources of nitrogen can be used individually or as a mixture. Phosphoric acid, potassium dihydrogen phosphate or dipotassium hydrogen phosphate or the corresponding sodium-containing salts can be used as the source of phosphorus. The culture medium must furthermore comprise salts of metals, such as, for example, magnesium sulfate or iron sulfate, which are necessary for growth. Finally, essential growth substances, such as amino acids and vitamins, can be employed in addition to the abovementioned substances. Precursors of pantothenic acid, such as β-alanine or ketopantoic acid and salts thereof, can also be added to the culture medium. The starting substances mentioned can be added to the culture in the form of a single batch, or can be added during the cultivation in a suitable manner.
Basic compounds, such as sodium hydroxide, potassium hydroxide and ammonia, or acid compounds, such as phosphoric acid and sulfuric acid, can be used to control the pH of the culture. Antifoams, such as, for example, fatty acid polyglycol esters or silicone oils, can be employed to control the development of foam. Suitable substances having a selective action, for example, antibiotics, can be added to the medium to maintain the stability of plasmids. To maintain aerobic conditions, oxygen or oxygen-containing gas mixtures, such as, for example, air, are introduced into the culture. The temperature of the culture is usually 20° C. to 50° C., and preferably 25° C. to 45° C. Culturing is continued until a maximum of pantothenic acid has formed. This target is usually reached within 10 hours to 160 hours.
The concentration of pantothenic acid formed can be determined by known processes (Velisek; Chromatographic Science 60, 515-560 (1992)).
The following microorganisms were deposited at the Deutsche Sammlung f{umlaut over (u)}r Mikrorganismen und Zellkulturen (DSMZ=German Collection of Microorganisms and Cell Cultures, Braunschweig, Germany) on Aug. 18, 1998 in accordance with the Budapest Treaty:
Escherichia coli K12 strain FE5 as DSM12378
Escherichia coli K12 strain MG1655/pFE32 as DSM12413
Escherichia coli K12 strain MG1655/pFE65 as DSM12382
Escherichia coli K12 strain MG1655/pFE80 as DSM12414
Escherichia coli K12 strain FE6 as DSM12379
Escherichia coli K12 strain FE7 as DSM12380
The process according to the invention provides the person skilled in the art with a new tool for improving the formation of pantothenic acid by microorganisms in a controlled manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 : Map of the plasmid pDB1
FIG. 2 : Map of the plasmid pGAD10
FIG. 3 : Map of the plasmid pFEbank 16
FIG. 4 : Map of the plasmid pFE32
FIG. 5 : Map of the plasmid pFE65
FIG. 6 : Map of the plasmid pFE80
FIG. 7 : Map of the plasmid pFE91
FIG. 8 : Map of the plasmid pJDCEX2.
FIG. 9 : Map of the plasmid pJD-YHR063c including SEQ ID NO: 17 and SEQ ID: 18 adjacent to the YHR063c open reading frame.
The base pair numbers stated are approx. values obtained in the context of reproducibility.
The abbreviations used in the figures have the following meaning:
rrnBT1T2: transcription terminator of the rmB gene
Ptac: tac promoter
P AHD1: promoter of the ADH1 gene from Saccharomyces cerevisiae
T ADH1: terminator of the ADH1 gene from Saccharomyces cerevisiae
repts: thermosensitive replication origin
ilvC: coding region of the ilvC gene
ilvO’: 5′ region of the ilvC gene
‘ilvC: 3′ region of the ilvC gene
panB: coding region of the panB gene
panC: coding region of the panC gene
panD: coding region of the panD gene
panE: coding region of the panE gene
Amp: resistance gene for ampicillin
tet’: 5′ region of the tet gene
‘tet: 3′ region of the tet gene
Cm: resistance gene for chloramphenicol
Gm: resistance gene for gentamicin
GaI4: regulator for galactose-inducible genes from Saccharomyces cerevisiae
bps: base pairs
LEU2: beta-isopropyl malate dehydrogenase gene of Saccharomyces cerevisiae
2 μ: sequences of the endogenous 2 μ plasmid of Saccharomyces cerevisiae
Ap R : beta-lactamase gene
P-CUP1: promoter of the Saccharomyces cerevisiae CUP1 gene (metallothionein)
T-CYC1: terminator of the CYC1 gene (cytochrome C) of Saccharomyces cerevisiae
ORF: open reading frame
SD: Shine-Dalgarno sequence
EcoRI: cleavage site of the restriction enzyme EcoRI
EcoRV: cleavage site of the restriction enzyme EcoRV
HincII: cleavage site of the restriction enzyme HincII
HindIII: cleavage site of the restriction enzyme HindIII
KpnI: cleavage site of the restriction enzyme KpnI
SalI: cleavage site of the restriction enzyme SalI
SmaI: cleavage site of the restriction enzyme SmaI
SphI: cleavage site of the restriction enzyme SphI
PvulI: cleavage site of the restriction enzyme PvuII
NotI: cleavage site of the restriction enzyme NotI from Norcardia otitidis-cavarium
SpeI: cleavage site of the restriction enzyme SpeI from sphaerotilus
spec.
XbaI: cleavage site of the restriction enzyme Xbal from Xanthomonas
badrii
PstI: cleavage site of the restriction enzyme Pstl from Providencia stuartii
DETAILED DESCRIPTION OF THE INVENTION
The present invention is explained in more detail in the following examples.
EXAMPLE 1
Preparation of an ilvC::aacC1 panE::Tn5 Mutant of Escherichia coli K12 Strain MG 1655
1. Preparation of the ilvC::aacC1 mutant
PCR primers were synthesized using the nucleotide sequence for the ilvC gene in E. coli K12 MG1655, (EMBL-GenBank: Accession No. M87049), (MWG Biotech (Ebersberg, Germany)). A DNA fragment approximately 1500 bp in size could be amplified with these primers by the standard PCR method of Innis et al. (PCR protocols. A guide to methods and applications, 1990, Academic Press). The chromosomal E. coli K12 MG1655 DNA employed for the PCR was isolated by means of the NucleoSpin C+T Kit (Macherey-Nagel (D{umlaut over (u)}ren, Germany), Product Description NucleoSpin C+T, Cat. no. 740952). The size was determined by separation by gel electrophoresis (30 minutes, 10V/cm) in a 0.8% agarose gel.
PCR primers for the ilvC gene from E. coli:
iIvCl 5′- AGAAGCACAACATCACGAGG -3′
(SEQ ID NO:1)
iIvC2 5′- CTCCAGGAGAAGGCTTGAGT -3′
(SEQ ID NO:2)
The PCR product of the ilvC gene was transformed into the plasmid pCR®2.1 and into the E. coli strain TOP10F′ (Invitrogen (Leek, The Netherlands), Product Description Original TA Cloning® Kit, Cat. no. KNM2030-01).
Successful cloning was demonstrated by cleavage of the DNA of the plasmid pCR®2.1 ilvC with the restriction enzymes Eagl (Pharmacia Biotech (Freiburg, Germany), Product Description Eagl, Code no. 27-0885-01), EcoRI (Pharmacia Biotech (Freiburg, Germany), Product Description EcoRI, Code no. 27-0884-03) and KpnI (Pharmacia Biotech (Freiburg, Germany), Product Description KpnI, Code no. 27-0908-01). For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit (QIAGEN (Hilden, Germany), Cat. no. 27106) and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm).
To isolate the ilvC gene from the plasmid pCR®2.1ilvC, the plasmid DNA isolated was cleaved with the enzymes HindIII (Pharmacia Biotech (Freiburg, Germany), Product Description HindIII, Code no. 27-0860-01) and XbaI (Pharmacia Biotech (Freiburg, Germany), Product Description XbaI, Code no. 27-0948-01), the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 1.5 kbp ilvC fragment was isolated with the aid of the GLASSMAX™ Kit (GIBCO BRL (Eggenstein, Germany), Product Description GLASSMAX™ Spin Cartridges, Cat. no.15590-052). The ilvC fragment isolated was ligated with the plasmid pMAK705, also cleaved with HindIII and XbaI (Hamilton et al., Journal of Bacteriology 1989,171: 4617-4622), by means of T4 DNA ligase (Pharmacia Biotech (Freiburg, Germany), Product Description T4 DNA Ligase, Code no.27-0870-03), and the E. coli strain DH5αmcr (Grant, Proceedings of the National Academy of Science 1990, 87: 4645-4649) was electroporated with the ligation batch (Tauch, FEMS Microbiology Letters 1994, 123: 343-347). Selection for plasmid-carrying cells was made by plating out the electroporation batch on LB agar (Lennox, Virology 1955,1: 190), to which 25 μg/ml chloramphenicol (Sigma (Deisenhofen, Germany) Code no. C 0378) had been added, and incubation at 30° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzymes HindIII, XbaI and KpnI in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE30.
To isolate the ilvC gene from the plasmid pFE30, the plasmid DNA isolated was cleaved with the enzyme BamHI (Pharmacia Biotech (Freiburg, Germany), Product Description BamHI, Code no. 27-0868-03), the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 1.5 kbp ilvC fragment was isolated with the aid of the GLASSMAX™ Kit. The ilvC fragment isolated was ligated with the plasmid pBR322, also cleaved with BamHI (Sutcliffe, COLD SPRING HARBOR SYMPOSIA ON QUANTITATIVE BIOLOGY 1979, 43: 77-90), by means of T4 DNA Ligase and the E. coli strain DH5αmcr was electroporated with the ligation batch. Selection for plasmid-carrying cells was made by plating out the electroporation batch on LB agar, to which 100 μg/ml ampicillin (Sigma (Deisenhofen, Germany) Code no. A 9518) had been added, and incubation at 37° C. for 24 hours. The colonies obtained were inoculated in parallel on to LB+ampicillin agar and LB+(5 μg/ml)tetracycline (Sigma (Deisenhofen, Germany), Code no. T3383). DNA from tetracycline-sensitive colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of a BamHI and KpnI cleavage and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm). The plasmid constructed was called pFE32.
An aacC1 gene was cloned into the KpnI cleavage site of the plasmid pFE32 and the resulting plasmid was called pFE33. For this, the aacC1 gene was isolated from an agarose gel (30 minutes, 10V/cm) in which a KpnI restriction batch of the plasmid pMS255 (Becker, Gene 1995, 162: 37-39) was separated. Ligation was carried out with T4 DNA ligase. After electroporation of the ligation batch into the strain DH5αmcr, the transformants were selected on PA agar (Sambrook, Molecular cloning, 2 nd edn, Cold Spring Harbor, 1989), to which 10 μg/ml gentamycin (Sigma (Deisenhofen, Germany), Code no. G3632) was added. DNA from gentamycin-resistant colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of a BamHI and KpnI cleavage and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm).
The ilvC::aacC1 fragment was cleaved from plasmid pFE33 by means of SphI (Pharmacia Biotech (Freiburg, Germany), Product Description SphI, Code no. 27-0951-01) restriction, separated in 0.8% agarose gel (30 minutes, 10V/cm) and isolated with the GLASSMAX™ Kit. The fragment was ligated with the plasmid pMAK705, which was cleaved with SphI, by means of T4 DNA ligase, the ligation batch was electroporated into the strain DH5αmcr and transformants were selected by incubation on PA+gentamycin agar for 24 hours at 30° C. DNA from gentamycin -resistant colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of an SphI and EcoRI cleavage in 0.8% agarose gel (30 minutes, 10V/cm). The plasmid constructed was called pDB1.
The chromosomal ilvC gene in the strain E. coli K12 MG1655 was exchanged for the interrupted ilvC::aacC1 fragment with the aid of the plasmid pDB1. A modified method according to Hamilton et al. was used for the gene exchange. Plasmid pDB1 was electroporated into the E. coli K12 MG1655 strain, and the transformants were then incubated on LB-chloramphenicol agar at 42° C. for 24 hours for selection for cointegrates. For individualization, the resulting colonies were in turn smeared on to the same medium and incubated at 42° C. for 24 hours. For disintegration of the plasmid, individual colonies were incubated in 5 ml LB liquid medium at 42° C. for 24 hours, and a dilution series of the liquid medium was then plated out on LB-chloramphenicol agar. This dilution series was incubated at 30° C. for 24 hours. For curing of the plasmid, individual colonies obtained from the dilution series were cultured in 3 successive individual colony smears on LB agar at 42° C. for in each case 24 hours. To check the phenotype, the resulting individual colonies were inoculated in parallel on to agar plates with the following media: Medium E (Vogel, Journal of Biological Chemistry 1956, 218: 97-106)+glucose (0.4%), medium E+glucose (0.4%) (Sigma (Deisenhofen, Germany), Code no. G8270)+50 μg/ml isoleucine (Sigma (Deisenhofen, Germany), Code no.17268), medium E+glucose (0.4%)+50 μg ketoisovalerate (ICN (Eschwege, Germany), Code no. 151395), medium E+glucose (0.4%)+50 μg/ml isoleucine+50 μg ketoisovalerate, PA medium+gentamycin and LB medium+chloramphenicol. These media were incubated at 37° C. for 48 hours. Of 150 individual colonies tested, there was one of which the phenotype displayed the exchange of the chromosomal ilvC gene for the ilvC::aacC1 fragment. This strain was called FE4.
2. Preparation of the ilvC::aacC1 panE::Tn5 double mutant
The strain FE4 was cultured in 5 ml LB liquid medium+10 mM MgSO 4 +0.2% maltose (Sigma (Deisenhofen, Germany), Code no. M5885) (LBMgMaI) at 37° C., to an optical density of 0.5. The optical density was measured with a Pharmacia (Freiburg, Germany) Novaspec II photometer at a wavelength of 660 nm. 2 ml of the bacteria solution were centrifuged for 5 min at 3000rpm (Beckmann Model J2-21 Centrifuge, Rotor JA-17). After the pellet had been taken up in 0.5 ml LBMgMaI liquid medium, 30 μl λ::Tn5(Simon, Gene 1989, 80(1):161-169) lysate, approx. 10 8 bacteriophages, were added to the suspension. This lysate was isolated from the strain E. coli K12 C600 (Appleyard, Genetics 1954, 39:440-452) by the method of Hagemann (Gentechnologische.Arbeitsmethoden [Genetic Engineering.Working Methods], Gustav Fischer Verlag,1990: 14-18).The suspension with the λ::Tn5 lysate was incubated at 30° C. for 45 minutes. After centrifugation at 3000 rpm for 5 minutes, the pellet was taken up in 10 ml PA+10 mM pyrophosphate and incubated at 37° C. for 3 hours. The bacteria solution was plated out as a dilution series on medium E agar+glucose (0.4%)+25 μg/ml kanamycin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate+50 μg/ml pantothenate and incubated at 37° C. for 48 hours. Individual colonies were inoculated in parallel on medium E agar+glucose (0.4%)+25 μg/ml kanamycin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate+50 μg/ml pantothenate and on medium E agar+glucose (0.4%)+25 μg/ml kanamycin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate and incubated at 37° C. for 48 hours. Among 14000 individual colonies inoculated, it was possible to identify one, called FE5, colony which grew on medium E agar+glucose (0.4%)+25 μg/ml kanamycin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate+50 μg/ml pantothenate but not on medium E agar+glucose (0.4%)+25 μg/ml kanamycin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate.
3. Characterization of the strains FE4 and FE5
Together with the E. coli strains SJ2 (Jakowski, Genetic Stock Center, Yale University),which carries a mutation in the panB gene, MW6 (Williams, Genetic Stock Center, Yale University), which carries a mutation in the panC gene, and DV9 (Vallari, Journal of Bacteriology 1985, 164:136-142), which carries a mutation in the panD gene, and a wild type, the strains FE4 and FE5 were smeared on to various supplemented base media (medium E agar+glucose (0.4%)+50 μg/ml isoleucine+50 μg/ml ketoisovalerate; and in the case of SJ2, DV9 and MW6 additionally 50 μg/ml thiamine) and were incubated at 37° C. for 48 hours. Pantothenate (calcium salt), ketopantoate (sodium salt), β-alanine (Sigma (Deisenhofen, Germany), Code no. A7752) and pantoate (potassium salt) were used as additional supplements. Ketopantoate was prepared from ketopantolactone by treatment with equimolar amounts of NaOH at 60° C. and subsequent evaporation. Ketopantolactone was synthesized by the method of Ojima et al. (Organic Synthesis 63, 18 (1985)). Pantoate was prepared from pantoyllacton (Sigma (Deisenhofen, Germany), Code no. P2625) by the method of Primerano and Burns (Journal of Bacteriology 1983, 153:259-269). The result of the growth test (table 1) showed that the strain FE4 grew on all the base media with various supplements. The strain FE5 grew only on media which were supplemented with either pantothenate or pantoate, but not on base media to which ketopantoate was added.
TABLE 1
Supplements in the base medium
β-Alanine
Ketopantoate
Pantoate
Pantothenate
Strain
none
[50 μg/ml]
[50 μg/ml]
[50 μg/ml]
[50 μg/ml]
MG1655
+
+
+
+
+
SJ2
−
−
+
+
+
MW6
−
−
−
−
+
DV9
−
+
−
−
+
FE4
+
+
+
+
+
FE5
−
−
−
+
+
+ = growth
− = no growth
EXAMPLE 2
Isolation of the panE gene from Escherichia coli K12 Strain W1485
The E. coli K12 W1485 MATCHMAKER Genomic Library (CLONTECH (Heidelberg, Germany), Cat. no. XL4001AB) was electroporated into the strain FE5. The E. coli K 12 MATCHMAKER Genomic Library contains the chromosomal DNA of E. coli K12 W1485 as inserts on average 1.0 kbp in size in the plasmid pGAD10, the size of the individual inserts here varying from 0.5-3.0 kbp (CLONTECH (Heidelberg, Germany)). The transformants were selected by plating out on medium E agar+glucose (0.4%)+100 μg/ml ampicillin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate. The plasmid DNA was isolated from 20 resulting colonies with the aid of the QIAprep Spin Plasmid Kit. By an EcoRI cleavage of the plasmid DNA and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm), it was shown that the plasmids were 20 pGAD10 vectors with inserts of different sizes. Sequencing (IIT Biotech (Bielefeld, Germany)) of the inserts showed, by homology comparisons with the BLAST program (Altschul, Journal of Molecular Biology 1990, 215: 403-410), that in 7 cases the inserts contained a complete ilvC gene and in 13 cases an open reading frame, which was described as “similar to Salmonella typhimurium apbA” (EMBL-GenBank: Accession No. U82664). This open reading frame was called panE.
EXAMPLE 3
Over-expression of the ilvC gene of E. coli in E. coli K12 Strain MG1655
For over-expression of the ilvC gene, plasmid pFE32 (see example 1) was used. In plasmid pFE32, the coding region of the ilvC gene is under the control of the tet promoter coded by plasmid pBR322. Plasmid pFE32 was electroporated into the strain E. coli K12 MG1655 and transformants were selected on LB agar, after subsequent incubation at 37° C. for 24 hours, to which 100 μg/ml ampicillin was added. The resulting strain was called MG 1655/pFE32.
EXAMPLE 4
Over-expression of the panE gene of E. coli in E. coli K12 Strain MG1655
Starting from the nucleotide sequence for the panE gene in E. coli K12 MG1655, PCR primers were synthesized (MWG Biotech (Ebersberg, Germany)). A DNA fragment approximately 1000 bp in size could be amplified from chromosomal E. coli K12 MG1655 DNA with these primers by the standard PCR method. The chromosomal E. coli K12 MG1655 DNA employed for the PCR was isolated by means of the NucleoSpin C+T Kit. The size was determined by separation by gel electrophoresis (30 minutes, 10V/cm) in a 0.8% agarose gel.
PCR primers for the panE gene from E. coli:
panEl 5′- AGGAGGACAATGAAAATTAC -3′
(SEQ ID NO:3)
panE2 5′- TCAGTCTCTTCACTACCAGG -3′
(SEQ ID NO:4)
The PCR product of the pan E gene was transformed into the plasmid pCR®2.1 and into E. coli strain TOP10F′ (Invitrogen (Leek, The Netherlands), Product Description Original TA Cloning® Kit, Cat. no. KNM2030-01). Successful cloning was demonstrated by cleavage of the DNA of the plasmid pCR®2.1 panE with the restriction enzymes EcoRI and HincII (Pharmacia Biotech (Freiburg, Germany), Product Description HincII, Code no. 27-0858-01). For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm).
To isolate the panE gene from the plasmid pCR®2.1 panE the plasmid DNA isolated was cleaved with the enzyme EcoRI, the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 1.0 kbp panE fragment was isolated with the aid of the GLASSMAX™ Kit. The panE fragment isolated was ligated with the plasmid pKK223-3, also cleaved with EcoRI, by means of T4 DNA ligase and the E. coli strain DH5αmcr was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation at 37° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzymes EcoRI and HincII in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE65.
In plasmid pFE65, the coding region of the panE gene is under the control of the tac promoter coded by plasmid pKK223-3. Plasmid pFE65 was electroporated into the strain E. coli K12 MG1655 and transformants were selected on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation for 24 hours at 37° C. The resulting strain was called E. coli K12 MG1655/pFE65.
EXAMPLE 5
Over-expression of the panE gene of E. coli Together With panB, panC and panD of E. coli in E. coli K12 Strain MG1655.
Starting from the nucleotide sequence for the panB gene, panC gene and panD gene in E. coli K12 MG1655, (EMBL-GenBank: Accession No. L17086), PCR primers were synthesized (MWG Biotech (Ebersberg, Germany)). From chromosomal E. coli K12 MG1655 DNA, a DNA fragment approximately 800 bp in size could be amplified with the panB primers, and a DNA fragment approximately 400 bp in size could be amplified with the panD primers, using the standard PCR method. A DNA fragment approx. 850 bp in size could be amplified from chromosomal E. coli K12 MG1655 DNA with the panC primers by means of a modified standard PCR method. Taq polymerase was replaced by Pfu polymerase and the buffer conditions in the PCR batch were modified accordingly (STRATAGENE (Heidelberg, Germany), Product Description Pfu Polymerase, Code no. 600135). The chromosomal E. coli K12 MG1655 DNA employed for the PCR was isolated by means of the NucleoSpin C+T Kit The size of all the amplified products was determined by separation by gel electrophoresis (30 minutes, 10V/cm) in a 0.8% agarose gel.
PCR primers for the panB gene from E. coli:
panB1 5′- AGGATACGTTATGAAACCGA -3′
(SEQ ID NO:5)
panB2 5′- ACAACGTGACTCCTTAATGG -3′
(SEQ ID NO:6)
PCR primers for the panC gene from E. coli:
panCl 5′- AGGAGTCACGTTGTGTTAAT -3′
(SEQ ID NO:7)
panC2 5′- AAGTATTACGCCAGCTCGAC -3′
(SEQ ID NO:8)
PCR primers for the panD gene from E. coli:
panD1 5′- AGGTAGAAGTTATGATTCGC -3′
(SEQ ID NO:9)
panD2 5′- TAACAATCAAGCAACCTGTA -3′
(SEQ ID NO:10)
The PCR product of the panB gene was transformed into the plasmid pCR®82.1 and into the E. coli strain TOP10F′ (Invitrogen (Leek, The Netherlands). Successful cloning of the panB PCR product was demonstrated by cleavage of the DNA of the plasmid pCR®2.1 panB with the restriction enzymes EcoRI, EcoRV (Pharmacia Biotech (Freiburg, Germany), Product Description EcoRV, Code no. 27-0934-01) and PvuII (Pharmacia Biotech (Freiburg, Germany), Product Description PvuII, Code no. 27-0960-01). For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm). The PCR product of the panD gene was transformed into the plasmid pCR®2.1 and into the E. coli strain TOP10F′ (Invitrogen (Leek, The Netherlands). Successful cloning of the panD PCR product was demonstrated by cleavage of the DNA of the plasmid pCR®2.1 panD with the restriction enzymes EcoRI, EcoRV and HincII. For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm). The PCR product of the panC gene was electroporated into the plasmid pUC19 (Viera, Gene 1982 19:259-268) and into the E. coli strain DH5αmcr. Successful cloning of the panC PCR product was demonstrated by cleavage of the DNA of the plasmid pUC19panC with the restriction enzymes EcoRI, HindIII and SalI (Pharmacia Biotech (Freiburg, Germany), Product Description SalI, Code no. 27-0882-01). For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm). The plasmid constructed was called pFE60.
To isolate the panB gene from the plasmid pCR®2.1panB the plasmid DNA isolated was cleaved with the enzyme EcoRI, the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 800 bp panB fragment was isolated with the aid of the GLASSMAX™ Kit. The panB fragment isolated was ligated with the plasmid pKK223-3, also cleaved with EcoRI, by means of T4 DNA ligase and the E. coli strain DH5αmcr was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on LB agar, to which 100 μ/ml ampicillin was added, and subsequent incubation at 37° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the restriction enzymes EcoRI, EcoRV and PvuII in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE40. In plasmid pFE40, the coding region of the panB gene is under the control of the tac promoter coded by plasmid pKK223-3.
To isolate the panD gene from the plasmid pCR®2.1panD the plasmid DNA isolated was cleaved with the enzyme EcoRI, the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 400 bp panD fragment was isolated with the aid of the GLASSMAX™ Kit. The panD fragment isolated was ligated with the plasmid pKK223-3, also cleaved with EcoRI, by means of T4 DNA ligase and the E. coli strain DH5αmcr was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation at 37° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzymes EcoRI, EcoRV and HincII in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE50. In plasmid pFE50, the coding region of the panD gene is under the control of the tac promoter coded by plasmid pKK223-3.
The panC gene was isolated from the plasmid pFE60 by means of a HindIII-SmaI (Pharmacia Biotech (Freiburg, Germany), Product Description SmaI, Code no. 27-0942-01) cleavage, for which the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 850 bp panC fragment was isolated with the aid of the GLASSMAX™ Kit. The panC fragment isolated was ligated with the plasmid pFE50, also cleaved with HindIII and SmaI, by means of T4 DNA ligase and the E. coli strain DH5αmcr was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on LB agar, to which 100μg/ml ampicillin was added, and subsequent incubation at 37° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzymes EcoRI, EcoRV, Smal, HindIII and HincII in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE52. In plasmid pFE52, the coding regions of the panD gene and of the panC gene are under the control of the tac promoter coded by plasmid pKK223-3 and form an operon.
The panB gene was cloned into the EcoRI cleavage site of plasmid pFE52 following the tac promoter, and the resulting plasmid was called pFE70. For this, the panB gene was isolated from an agarose gel (30 minutes, 10V/cm) in which an EcoRI restriction batch of the plasmid pFE40 was separated. Ligation was carried out with T4 DNA ligase. After electroporation of the ligation batch into the strain SJ2, the transformants were selected on mediumE agar, to which 0.4% glucose, 100 μg/ml thiamine and 100 μg/ml ampicillin were added. DNA from ampicillin-resistan colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of an EcoRI, EcoRV, Smal, HindIII and HincII cleavage and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm). In plasmid pFE70, the coding regions of the panB gene, panD gene and of the panC gene are under the control of the tac promoter coded by plasmid pKK223-3 and form an operon.
The panE gene was isolated from the plasmid pFE65 by means of a HindIII-SphI (Pharmacia Biotech (Freiburg, Germany), Product Description SphI, Code no. 27-0951 -01) cleavage, for which the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the panE fragment was isolated with the aid of the GLASSMAX™ Kit. The panE fragment isolated was ligated with the plasmid pFE70, also cleaved with HindIII and partly with SphI, by means of T4 DNA ligase and the strain FE5 was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on mediaE agar+glucose (0.4%)+50 μg/ml isoleucine+50 μg/ml ketoisovalerate, to which 100 μg/ml ampicillin was added, and subsequent incubation at 37° C. for 48 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzymes EcoRI, EcoRV, SphI, HindIII and HincII in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10V/cm), and was called pFE80. In plasmid pFE80, the coding regions of the panB gene, panD gene, panC gene and of the panE gene are under the control of the tac promoter coded by plasmid pKK223-3 and form an operon.
Plasmid pFE80 was electroporated into the strain E. coli K12 MG 1655 and transformants were selected on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation for 24 hours at 37° C. The resulting strain was called MG1655/pFE80.
EXAMPLE 6
Over-expression of the panE gene of E. coli Together with panB, panC and panD of E. coli in a Valine-resistant Mutant of E. coli K12 MG1655.
The E. coli K12 strain MG1655 was smeared on to mediumE agar, to which 0.4% glucose and 100 μg/ml valine (Sigma (Deisenhofen, Germany),V0258) were added. After incubation at 37° C. for 48 hours, a colony could be isolated. This strain was called FE6. Plasmid pFE80 was electroporated into the strain FE6 and transformants were selected on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation for 24 hours at 37° C. The resulting strain was called FE6/pFE80.
EXAMPLE 7
Over-expression of the panE gene of E. coli Together With panB, panC and panD of E. coli in an avtA::aadB Mutant of E. coli K12 MG1655.
Starting from the nucleotide sequence for the avtA gene (EMBL-GenBank: Accession No. Y00490) in E. coli K12 MG1655, PCR primers were synthesized (MWG Biotech (Ebersberg, Deutschland)). A DNA fragment approx. 1.6 kbp in size could be amplified from chromosomal E. coli K12 MG1655 DNA with these primers by the standard PCR method. The size was determined by separation by gel electrophoresis (30 minutes, 10V/cm) in a 0.8% agarose gel.
PCR primers for the avtA gene from E. coli:
avtAl 5′- TGCTCTCTCTCAACGCCGAA -3′
(SEQ ID NO:11)
avtA2 5′- GAAGCCGCCAACCAGGATAA -3′
(SEQ ID NO:12)
The PCR product of the avtA gene was transformed into the plasmid pCR®2.1 and into the E. coli strain TOP10F′ (Invitrogen (Leek, The Netherlands)). Successful cloning was demonstrated by cleavage of the DNA of the plasmid pCR®2.1 avtA with the restriction enzymes EcoRI and SmaI. For this, the plasmid DNA was isolated by means of the QIAprep Spin Plasmid Kit and, after cleavage, separated in a 0.8% agarose gel (30 minutes, 10V/cm). An aadB gene was cloned into the SmaI cleavage site of plasmid pCR®2.1 actA and the resulting plasmid was called pFE23. For this, the aadB gene was isolated from an agarose gel (30 minutes, 10V/cm) in which an SmaI restriction batch of the plasmid pHP45Ω (EMBL-GenBank: Accession No. K02163) was separated. Ligation was carried out with T4 DNA ligase. After electroporation of the ligation batch into the strain DH5αmcr, the transformants were selected on PA agar, to which 20 μg/ml streptomycin (Sigma (Deisenhofen, Germany), Code no. S6501 ) was added. DNA from streptomycin-resistant colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of an EcoRI and SphI cleavage and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm).
The avtA::aadB fragment was cleaved out of the plasmid pFE23 by means of EcoRI restriction, separated in 0.8% agarose gel (30 minutes, 10V/cm) and isolated with the GLASSMAX™ Kit. The fragment was ligated with the plasmid pMAK705, which was partly cleaved with EcoRI, by means of T4 DNA ligase, the ligation batch was electroporated into the strain DH5αmcr and transformants were selected by incubation on LB agar+20 μg/ml streptomycin+25 μg/ml chloramphenicol for 24 hours at 30° C. DNA from streptomycin- and chloramphenicol-resistant colonies was isolated with the QIAprep Spin Plasmid Kit and successful cloning was verified by means of an SphI and EcoRI cleavage in 0.8% agarose gel (30 minutes, 10V/cm). The plasmid constructed was called pFE24.
The chromosomal avtA gene in the strain E. coli K12 MG1655 was exchanged for the avtA::aadB allele with the aid of the plasmid pFE24. A modified method according to Hamilton et al. was used for the gene exchange. Plasmid pFE24 was electroporated into the E. coli K12 MG1655 strain, and the transformants were then incubated on LB-chloramphenicol agar at 42° C. for 24 hours for selection for cointegrates. For individualization, the resulting colonies were in turn smeared on the same medium and incubated at 42° C. for 24 hours. For disintegration of the plasmid, individual colonies were incubated in 5 ml LB liquid medium at 42° C. for 24 hours, and a dilution series of the liquid medium was then plated out on LB-chloramphenicol agar. This dilution series was incubated at 30° C. for 24 hours. For curing of the plasmid, individual colonies obtained from the dilution series were cultured in 3 successive individual colony smears on LB agar at 42° C. for in each case 24 hours.
To check the phenotype, the resulting individual colonies were inoculated in parallel on agar plates with LB medium+20 μg/ml streptomycin and LB medium+25 μg/ml chloramphenicol. These media were incubated at 37° C. for 48 hours. Of 250 individual colonies tested, there was one of which the phenotype displayed the exchange of the chromosomal avtA gene for the avtA::aadB fragment. This strain was called FE7.
Plasmid pFE80 was electroporated into the strain FE7 and transformants were selected on LB agar, to which 100 μg/ml ampicillin was added, and subsequent incubation for 24 hours at 37 2° C. The resulting strain was called FE7/pFE80.
EXAMPLE 8
Determination of the Ketopantoate Reductase Activity in Various Strains of Escherichia coli K12.
The specific ketopantoate reductase activity was determined by the method described by Shimizu et al. (Journal of Biological Chemistry 263:12077-12084 (1988)). For this, cell extracts of the individual strains were obtained by means of a Hybaid RiboLyser (Heidelberg, Germany) and the RiboLyser Kit Blue. The ketopantoate reductase activity of the extracts was determined with the aid of the NADPH consumption on addition of ketopantoate. The specific ketopantoate reductase activity determined was 6.5 mU/mg for the strain E. coli K12 MG1655, and 22.0 mU/mg for the strain E. coli K12 MG1655/pFE65. In the case of strain FE5, no activity was measurable.
EXAMPLE 9
Formation of Pantothenate by Various Strains of Escherichia coli K12
The formation of pantothenate by the strains MG1655, MG1655/pFE32, MG 1655/pFE65, MG 1655/pFE80, FE6/pFE80 and FE7/pFE80 was investigated in a batch culture. The culture medium used was the medium E described by Vogel (Journal of Biological Chemistry 1956, 218:97-106) with glucose (0.4%) as the source of carbon. The composition of the medium used is shown in Table 2.
TABLE 2
Compound
Concentration
MnSO 4 *7H 2 O
0.2
g/l
Citric acid monohydrate
2.0
g/l
K 2 HPO 4
10.0
g/l
NaNH 4 HPO 4 *H 2 O
3.5
g/l
250 ml conical flasks were filled with 25 ml of the stated nutrient medium and the batch was inoculated. After an incubation time of 48 hours at 37° C., the optical density and the pantothenate concentration were determined. For determination of the cell density, the optical density with a Novaspec II Photometer photometer from Pharmacia (Freiburg, Germany) at a measurement wavelength of 580 nm was employed. The pantothenate content was determined in the sterile-filtered culture supernatant. The pantothenate (as the calcium salt) was determined with the aid of the strain Lactobacillus plantarum ATCC® 8014 as described in the handbook “DIFCO MANUAL” from DIFCO (Michigan, USA;, 10 th Edition, 1100-1102 (1984)). The result is summarized in Table 3.
TABLE 3
Concentration
Cell density
Productivity
Strain
[μg/ml]
[OD 580 ]
[μg/ml/OD 580 ]
MG1655
0.51
2.8
0.18
MG1655/pFE32
1.7
2.8
0.60
MG1655/pFE65
4.6
2.9
1.6
MG1655/pFE80
14.0
2.9
4.8
FE6/pFE80
35.7
3.2
11.2
FE7/pFE80
41.7
3.0
13.9
EXAMPLE 10
Formation of pantothenate by Various strains of Escherichia coli K12 in the Presence of ketopantoate
The formation of pantothenate by the strains MG1655, MG1655/pFE32, MG1655/pFE65 with added ketopantoate was investigated in a batch culture. For this, the medium described in example 8 was supplemented with 50 μg/ml ketopantoate. The other conditions of the experiment are as described in example 8. The result is shown in Table 4.
TABLE 4
Concentration
Cell density
Productivity
Strain
[μg/ml]
[OD 580 ]
[μg/ml/OD 580 ]
MG1655
6.2
2.9
2.1
MG1655/pFE32
9.0
2.9
3.1
MG1655/pFE65
12.6
2.9
4.3
EXAMPLE 11
Isolation of the ilvC gene of Corynebacterium glutamicum ATCC13032
Chromosomal DNA from C. glutamicum ATCC 13032 was isolated as described by Tauch et al. (Plasmid, 33:168-179,1995) and partly cleaved with the restriction enzyme Sau3A (Pharmacia Biotech (Freiburg, Germany), Product Description Sau3A, Code no. 27-0913-02). DNA fragments in a size range of 7-9 kb were isolated with the aid of the “Nucleotrap Extraction Kit for Nucleic Acids” (Macherey und Nagel, D{umlaut over (u)}ren, Germany; Cat. No. 740584) and ligated into the dephosphorylated BamHI cleavage site of the vector pUC19 (Viera et al., 1982, Gene, 19:259-268; MBI Fermentas, Lithuania). The ligation was carried out as described by Sambrook et al. (1989, Molecular Cloning: A laboratory Manual, Cold Spring Harbor), the DNA mixture being incubated overnight with T4 ligase (Pharmacia Biotech, Freiburg, Germany). This ligation mixture was then electroporated into the E. coli strain DH5aMCR (Grant, 1990, Proceedings of the National Academy of Sciences U.S.A., 87:4645-4649; Tauch, 1994, FEMS Microbiological Letters, 123:343-348) and plated out on LB agar (Lennox, 1955, Virology, 1:190)+100 mg/ml ampicillin. After incubation for 24 h at 37° C., the C. glutamicum gene library could be obtained from the transformants by re-isolation of the plasmid DNA by the “alkaline lysis method” of Birnboim and Doly (1997, Nucleic Acids Research, 7:1513-1523).
Competent cells of the E. coli strain FE5, which carries mutations in the panE and ilvC gene, were electroporated with this gene library. After the regeneration phase (Tauch et.al., 1994, FEMS Microbiological Letters, 123:343-347), the electroporation batch was washed twice with medium E (Vogel and Bonner, 1956, Journal of Biological Chemistry, 218:97-106). The transformants were selected by plating out on medium E agar+glucose (0.4%)+100 μg/ml ampicillin+50 μg/ml isoleucine+50 μg/ml ketoisovalerate. The plasmid DNA was isolated from 4 resulting colonies with the aid of the QIAprep Spin Plasmid Kit. By an XbaI cleavage of the plasmid DNA and subsequent separation in 0.8% agarose gel (30 minutes, 10V/cm), it was shown that the plasmids were pUC19 vectors with inserts approximately 6.5 kbp in size. Sequencing of the inserts with subsequent homology comparisons with the aid of the BLAST program (Altschul, Journal of Molecular Biology 1990, 215:403-410) showed that in all cases the inserts contained a complete ilvC gene from C. glutamicum (EMBL-GenBank: Accession No. L09232). One of these plasmids was called pFE90.
EXAMPLE 12
Expression of the ilvC Gene of Corynebacterium glutamicum ATCC13032 in Corynebacterium glutamicum ATCC13032
The plasmid pECm3 was used for expression of the ilvC gene from C. glutamicum in C. glutamicum ATCC13032. Plasmid pECm3 is a derivative of plasmid pECm2 (Tauch, 1994, FEMS Microbiological Letters, 123:343-348), the kanamycin resistance gene of which has been removed by a BgIII (Pharmacia Biotech (Freiburg, Germany), Product Description BgIII, code no. 27-0946-02)and BamHI restriction with subsequent re-ligation. The plasmids pECm2 and pECm3 are capable of replication both in E. coli and in C. glutamicum . To isolate the ilvC gene from the plasmid pFE90 (example 11), the plasmid DNA isolated was cleaved with the enzyme Xbal (Pharmacia Biotech (Freiburg, Germany), Product Description XbaI, Code no. 27-0948-01), the cleavage batch was separated in 0.8% agarose gel (30 minutes, 10V/cm) and the 6.5 kbp ilvC fragment was isolated with the aid of the GLASSMAX™ Kit. The ilvC fragment isolated was ligated with the plasmid pECm3, also cleaved with Xbal, by means of T4 DNA ligase and E. coli strain FE5 was electroporated with the ligation batch. Selection for plasmid-carrying cells was carried out by plating out the electroporation batch on LB agar, to which 50 μg/ml chloramphenicol was added, and subsequent incubation at 37° C. for 24 hours. The required plasmid could be identified, after isolation of the DNA and checking of the cleavage, with the enzyme Xba in one clone by subsequent gel electrophoresis in 0.8% agarose gel (30 minutes, 10 V/cm), and was called pFE91.
Plasmid pFE91 was electroporated into the strain C. glutamicum ATCC13032 and transformants were selected on LB agar, to which 75 μg/ml chloramphenicol was added, and subsequent incubation for 48 hours at 302° C. The resulting strain was designated C. glutamicum ATCC13032/pFE91.
EXAMPLE 13
Formation of Pantothenate by Corynebacterium glutamicum ATCC13032
The formation of pantothenate by the C. glutamicum strain ATCC13032/pFE91 was investigated in medium CGXII (Keilhauer et al., 1993, Journal of Bacteriology, 175:5595-5603) with 10 mg/ml chloramphenicol (referred to as “ C. glutamicum test medium” in the following). This medium is shown in Table 5. In each case 50 ml of freshly prepared C. glutamicum test medium were inoculated with a 16 hours old culture ( C. glutamicum test medium 302° C., 150 rpm) with an OD 580 of 0.1. After incubation at 30° C. and 150rpm for 48 hours, the cells were removed by centrifugation at 5000×g for 10 minutes, the supernatant was sterile-filtered and the pantothenate concentration was determined. The cell density was determined as described in example 9.
The pantothenate (as the calcium salt) was determined with the aid of the strain Lactobacillus plantarum ATCC® 8014 as described in the handbook “DIFCO MANUAL” from DIFCO (Michigan, USA;,10 th Edition, 1100-1102 (1984)). The result is shown in Table 6.
TABLE 5
Substance
Amount per liter
Comments
(NH 4 ) 2 SO 2
20
g
Urea
5
g
KH 2 PO 4
1
g
K 2 HPO 4
1
g
MgSO 4 *7H 2 O
0.25
g
MOPS
42
g
CaCl 2
10
mg
FeSO 4 *7H 2 O
10
mg
MnSO 4 *H 2 O
10
mg
ZnSO 4 *7H 2 O
1
mg
CuSO 4
0.2
mg
NiCl 2 *6H 2 O
0.02
mg
Biotin
0.5
mg
Glucose
40
g
autoclave separately
Protocatechuic acid
0.03
mg
sterile-filter
TABLE 6
Concentration
Cell density
Productivity
Strain
[μg/ml]
[OD 580 ]
[μg/ml/OD 580 ]
ATCC13032
0.2
20
0.010
ATCC13032/pFE91
0.3
20
0.015
EXAMPLE 14:
Expression of the panE Gene of Saccharomyces cerevisiae
1. Amplification of the reading frame YHRO63c:
Starting from the nucleotide sequence of the Saccharomyces cerevisiae reading frame YHR063c (Accession No. U00061 of the National Center for Biotechnology, Bethesda, Md., USA) the following PCR primers were synthesized (MWG-Biotech, Ebersberg, Germany). The start and end of the reading frame are identified by a dot (.):
oJD539 (5′ EcoRI-NotI START): 5′- GCG CGA ATT CAG ATC CGC GGC CGC AAA GAG GAG AAA TTA ACT.ATG ACT GCA CCA CAC AGA AG-3′ (SEQ ID NO: 13)
oJD540 (3′ SpeI-PstI STOP): 5′- CGC GAC TAG TCT GCA G.TC AGT CCT TTC TCC AGT CAC-3′(SEQ ID NO: 14)
Genomic DNA of the S. cerevisiae strain JD242, which was isolated by the method of C. Guthrie and G. R. Fink (Guide to yeast genetics and molecular biology, Methods in Enzymology, Vol. 194, Academic Press, San Diego, Calif., 1991), was used as the template. This strain is a haploid segregant of the diploid strain SC288C. (Winston et al., Yeast 11, 53 et seq. (1995)), the genome of which has been sequenced (Goffeau et al., Science 274, pp. 546, (1996)).
The tetrad analysis was carried out by the method of C. Guthrie and G. R. Fink (Guide to yeast genetics and molecular biology, Methods in Enzymology, Vol. 194, Academic Press, San Diego, Calif., 1991). The strain JD242 is auxotrophic for leucine (leu2Al allele) and uracil (ura3-52 allele). A DNA fragment about 1.2 kb in size could be amplified using the “High Fidelity Expand Polymerase” Kit from Roche (Mannheim) by 28 PCR cycles under the conditions described by the manufacturer. The size was determined by separation by electrophoresis in a 0.8% agarose gel.
2. Construction of pJD-YHR063c:
For expression of the YHR063c reading frame in S. cerevisiae , the product amplified by PCR was incorporated into the E. coli - S. cerevisiae shuttle vector pJDCEX2 (FIG. 8 and Dohmen et al., 1995, Journal of Biological Chemistry 270, 18099-18109).
The PCR product was first restricted with EcoRI and Spel (AGS, Heidelberg, Germany). It was then mixed with pJDCEX2-DNA, which had been treated with EcoRI and XbaI (AGS, Heidelberg, Germany), and ligated with T4 DNA ligase (Roche, Mannheim, Germany). The ligation batch was transformed into the E. coli strain XL1 -Blue (Bullock et al., 1987, Biotechniques 5, 376). Transformants were obtained by selection on LB agar comprising 150 μg/ml ampicillin (Sigma (Deisenhofen, Germany). Plasmid DNA from the ampicillin-resistant clones was prepared by alkaline lysis (Sambrook et al.: Molecular Cloning, A Laboratory Manual, Cold Spring Harbor Laboratory Press, 1989). The plasmid DNA isolated was then investigated by restriction with NotI and PstI and subsequent separation in 0.8% agarose gel. The plasmid with the desired structure was given the name pJD-YHR063c (FIG. 9 ). The sequence of the PCR product cloned in pJD-YHR063c was verified by sequencing with the oligonucleotides oJD105 and oJD106.
oJD105 (T-CYC1): 5′-GAAGTCATCGAAATAG-3′ (SEQ ID NO: 15)
oJD106 (P-CUP1): 5′-TCGTTTCTGCTTTTTC-3′ (SEQ ID NO: 16)
3. Construction of pKK-YHR063c:
The plasmid pKK223-3 (Brosius and Holy, Proceedings of the National Academy of Science USA 81, 6929 (1984) was used for expression of the YHR063c reading frame E. coli . For this, the plasmid pJD-YHR063c was first restricted with EcoRI and PstI (AGS, Heidelberg, Germany). After electrophoretic separation in a 0.8% agarose gel, the YHR063c fragment about 1.2 kb in size was cut out of this and the DNA was isolated with the QuaexII Gel Extraction Kit (Qiagen, Hilden, Germany). It was then ligated into the plasmid pKK223-3, which had been opened with EcoRI and Pstl, with T4 DNA ligase (Roche, Mannheim, Germany). The ligation batch was transformed into the E. coli strain XL1-Blue (Stratagene, LaJolla, Calif., USA). Tranformants were obtained by selection on LB meduim comprising 150 μg/ml ampicillin (Sigma Deisenhofen, Germany). Plasmid DNA from the ampicillin-resistant clones was prepared by alkaline lysis (Sambrook et al.: Molecular Cloning, A Laboratory Manual, Cold Spring Harbor Laboratory Press, 1989). Successful cloning was checked by restriction with EcoRI and PstI and subsequent separation in 0.8% agarose gel. The plasmid with the desired structure was given the name pKK-YHR063c.
EXAMPLE 15:
Complementation of the E. coli mutant FE5
To analyse the panE function of the YHR063c reading frame from S. cerevisiae , it was investigated whether expression of this reading frame can complement the need for pantothenic acid of the E, coli strain FE5 (example 1). This strain is mutated in the gene loci panE and ilvC. For this, the strain FE5 was first transformed with plasmid pKK-YHR063c.
The growth of the strain FE5/pKK-YRH063c on M9 minimal agar (Sambrook et al.: Molecular Cloning, A Laboratory Manual, Cold Spring Harbor Laboratory Press, 1989), which had been supplemented with 50 μg/ml ketoisovalerate (Kiv) and 50 μg/ml isoleucine (Ile), was then investigated as a function of the addition of pantothenate (50 μg/ml). The strain FE5/pKK223-3 served as a negative control and the strain FE4/pFE65 (example 4) as a positive control. Table 7 shows the result of the experiment: The S. cerevisiae reading frame YHR063c contained in plasmid pKK-YHR063c complements panE-ilvC double mutation of the E. coli strain FE5. The reading frame YRH063c has the function of a panE gene.
TABLE 7
M9 + Kiv + Ile
M9 + Kiv + Ile
Strain
with pantothenate
without pantothenate
FE5/pFE65
growth
growth
FE5/pKK223-3
growth
no growth
FE5/pKK-YHR063c
growth
growth
EXAMPLE 16
Determination of the ketopantoate reductase Activity in Various Strains of Saccharomyces cerevisiae
The S. cerevisiae strain JD242 (see example 14) was transformed with the plasmids pJDCEX2 and pJD-YHR063c by the method of Dohmen et al. (Dohmen et al., Yeast 7, 691(1991)). Selection for transformants was carried out on leucine-free minimal medium with 1.8% agar (see Tables 8 a,b ).
The nutrient medium used was a pantothenic acid-free variant of the Yeast Nitrogen Base-Minimal medium (YNB) described in the Difco manual (Michigan, USA;, 10 th edition, 1100-1102 (1084)). It additionally comprised glucose (2%), uracil (40 μg/ml), CuSO 4 (150 μM) for induction of the P cup1 promoter of pJDCEX2 and pJD-YHR-063c, -Leu Drop-Out Supplement from CLONTECH (Heidelberg, Germany, Cat. no. 8605-1) (650 μg/ml) and the supplements ketopantoate (100 μg/ml) and β-alanine (100 μg/ml). The composition of the medium used is shown in Table 8 a and b.
TABLE 8a
Compound
Amount per liter
(NH 4 ) 2 SO 2
5
g
KH 2 PO 4
1
g
MgSO 4 *7H 2 O
0.5
g
NaCl
0.1
g
CaCl 2
0.1
g
H 3 BO 3
500
μg
CuSO 4
40
μg
KI
100
μg
FeCl 3 *6H 2 O
200
μg
MnSO 4 *H 2 O
400
μg
Na 2 MoO 4 *2H 2 O
400
μg
ZnSO 4 *7H 2 O
200
μg
Biotin
2
μg
Folic acid
2
μg
Inositol
2
mg
Niacin
400
μg
p-Aminobenzoic acid
200
μg
Pyridoxine hydrochloride
400
μg
Riboflavin
200
μg
Thiamine hydrochloride
400
μg
TABLE 8b
Additives
Amount per liter
Glucose
20
g
Uracil
40
mg
CuSO 4
24
mg
-Leu DO Supplement
650
mg
Ketopantoate
100
mg
β-Alanine
100
mg
250 ml conical flasks were filled with 50 ml of the stated nutrient medium, and the batch was inoculated with an individual colony from an agar plate with the aid of an inoculating loop (see Tables 8 a,b ) and incubated at 30° C. and 175 rpm for 72 hours. With this preculture, 50 ml of the same nutrient medium in a 250 ml conical flask were inoculated with the preculture such that the optical density (580 nm) was 0.5. After an incubation time of 24 hours at 30° C. and 175 rpm, the optical density was measured with a Novaspec II photometer from Pharmacia (Freiburg, Germany) at a measurement wavelength of 580 nm. It was 4.0 for both cultures. The specific ketopantoate reductase activity of the S. cerevisiae strains JD242/pJDCEX2 and JD242/pJD-YHR063c was determined by the method described by Shimizu et al. (Journal of Biological Chemistry 263:12077-12084 (1988)).
For this, cell extracts of the individual strains were obtained by means of a Hybaid RiboLyser (Heidelberg, Germany) and the RiboLyser Kit Red. The ketopantoate reductase activity of the extracts was determined with the aid of the NADPH consumption on addition of ketopantoate. The protein content was determined by the method of Bradfort (Bradfort, Analytical Biochemistry 72, 248ff.(1976)). A specific ketopantoate reductase activity of 3 mU/mg protein was determined for the control strain JD242/pJDCEX2 and a specific activity of 386 mU/mg protein was determined for the strain JD242/pJD-YHR063c.
EXAMPLE 17
Formation of Pantothenate by Various Strains of Saccharomyces cerevisiae
The formation of pantothenate by the strains S. cerevisiae JD242/pJDDCEX2 and JD242/pJD-YHR063c was investigated in a batch culture.
250 ml conical flasks were filled with 50 ml of the nutrient medium stated in Tables 8 a,b , and the batch was inoculated with an individual colony from an agar plate with the aid of an inoculating loop (see Table 8 a,b ) and incubated at 30° C. and 175rpm for 72 hours. With this preculture, 50 ml of the same nutrient medium in a 250 ml conical flask were inoculated with the preculture such that the optical density (580 nm) was 0.5. After an incubation time of 24 hours at 30° C. and 175rpm, the optical density (580 nm) and the pantothenate concentration were determined. For determination of the cell density, the optical density was measured with a Novaspec II photometer from Pharmacia (Freiburg, Germany) at a measurement wavelength of 580 nm. The pantothenate content was determined in the sterile-filtered culture supernatant.
The pantothenate (as the calcium salt) was determined with the aid of the strain Lactobacillus plantarum ATCC® 8014 as described in the handbook “DIFCO MANUAL” from DIFCO (Michigan, USA;, 10 th Edition, 1100-1102 (1984)). The result is summarized in Table 9.
TABLE 9
Concentration
Cell density
Productivity
S. cerevisiae strain
[μg/ml]
[OD 580 ]
[μg/ml/OD 580 ]
JD242/pJDCEX2
0.93
4.0
0.023
JD242/pJD-
1.12
4.1
0.027
YHR063c
References and patents cited herein are hereby incorporated by reference.
18
1
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
1
agaagcacaa catcacgagg 20
2
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
2
ctccaggaga aggcttgagt 20
3
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
3
aggaggacaa tgaaaattac 20
4
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
4
tcagtctctt cactaccagg 20
5
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
5
aggatacgtt atgaaaccga 20
6
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
6
acaacgtgac tccttaatgg 20
7
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
7
aggagtcacg ttgtgttaat 20
8
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
8
aagtattacg ccagctcgac 20
9
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
9
aggtagaagt tatgattcgc 20
10
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
10
taacaatcaa gcaacctgta 20
11
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
11
tgctctctct caacgccgaa 20
12
20
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
12
gaagccgcca accaggataa 20
13
62
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
13
gcgcgaattc agatccgcgg ccgcaaagag gagaaattaa ctatgactgc accacacaga 60
ag 62
14
36
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
14
cgcgactagt ctgcagtcag tcctttctcc agtcac 36
15
16
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
15
gaagtcatcg aaatag 16
16
17
DNA
Artificial Sequence
Description of Artificial SequencePCR primer
16
tcgtttctgt ctttttc 17
17
41
DNA
Artificial Sequence
Description of Artificial SequencePortion of
plasmid pJD-YHR063c
17
gaattcagat ccgcggccgc aaagaggaga aattaactat g 41
18
12
DNA
Artificial Sequence
Description of Artificial SequencePortion of
plasmid pJD-YHR063c
18
ctgcagacta ga 12 | The invention relates to a process for the preparation and improvement of D-pantothenic acid-producing microorganisms by amplification of nucleotide sequences which code for ketopantoate reductase, in particular the panE gene, individually or in combination with one another, and optionally additionally of the ilvC gene, the microorganisms containing these nucleotide sequences, and a process for the preparation of D-pantothenic acid comprising fermentation of these microorganisms, concentration of pantothenic acid in the medium or in the cells of the microorganisms, and isolation of the D-pantothenic acid. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a mass spectrometer, particularly to miniaturization and weight reduction of the mass spectrometer.
2. Description of the Related Art
In a mass spectrometer, a molecule or an atom as an analytical target is ionized, and the ions are transported in vacuum to be subjected to mass separation by utilizing an electric field and a magnetic field. The separated ions are detected by a detector. When a degree of vacuum in a vacuum vessel of a mass spectrometer is low, the ion collides with a residual gas molecule in the vacuum vessel at a number of times, and loses its charge due to exchange of charges or changes its traveling direction due to collision, whereby the number of ions reaching the detector is decreased to hardly perform correct mass spectrometry. Therefore, the degree of vacuum is set to be about 10 −3 Pa or less in a spatial area of a vacuum chamber in which a mass separator such as a Q-mass filter and a detector such as a channeltron or a photomultiplier are disposed. For example, when a TOF (Time Of Flight) type mass spectrometer in which an ion reflector (reflector) and an MCP (multichannel plate) detector are combined is used under low vacuum, an adverse effect such as an interference between the ion and the residual gas molecule emerges for the same reason, and therefore the spatial area of the vacuum chamber in which the mass separator and the detector are disposed is set to be a high degree of vacuum.
Generally, in a mass spectrometer, a sample or an ionized sample is introduced to a vacuum side from an atmosphere, and the space in which a detector is disposed is maintained under high vacuum. Therefore, plural orifices are disposed between an ion source and the detector, and the space is evacuated in a differential pumping manner by a vacuum pump (for example, see Japanese Patent Application Laid-Open No. 2005-259483).
Recently, social concern with safety and security has been increasing in mainly security and food fields. Conventionally, a large-size mass spectrometer installed in an analytical laboratory has been used to sense a trace harmful substance. However, there is a need to rapidly measure the trace harmful substance on site, and miniaturization and weight reduction of the mass spectrometer have been attempted.
In order to miniaturize the mass spectrometer, it is necessary to miniaturize components constituting the mass spectrometer. A vacuum pump that is a component having a high structural ratio with respect to a size has been also miniaturized. Generally, with the miniaturization of the vacuum pump, a pumping rate is decreased to degrade the degree of vacuum of a vacuum vessel. When the degree of vacuum is degraded, as described above, the number of ions reaching the detector is decreased to hardly perform the mass spectrometry correctly. Therefore, a diameter of a fine hole of the orifice has been further reduced to decrease a flow rate in the vacuum vessel, thereby achieving the high degree of vacuum in the vacuum vessel.
Frequently a voltage is applied to the orifice so that the orifice extracts, accelerates, and focuses the ion beam, and the orifice is fixed to the vacuum vessel having a ground potential through an electric insulator such as alumina. An axis deviation of the orifice may be generated up to about 100 μm with respect to a correct center axis due to accumulation of machining tolerances such as deviations of a diameter of a hole in which the insulator of a vacuum chamber is attached, a diameter of the insulator, a diameter of a hole in which the insulator of the orifice is fitted, and a center axis of the fine hole of the orifice. Interference is generated between the ion beam and the orifice due to the axis deviation when the ion beam passes through the plural orifices, and the amount of ions reaching the detector is reduced to degrade apparatus performance such as the apparatus sensitivity and the resolution degradation.
By decreasing the mechanical tolerance of each component, the axis deviation amount can be decreased but the apparatus becomes expensive. It is necessary to adjust the axis deviation amount up to several tens of micrometers. Therefore, it is necessary to finely adjust the axis. When the component is exchanged for the purpose of orifice maintenance, the axis deviation amount after the re-assembly may be different from the axis deviation amount before the maintenance, and the amount of ion reaching the detector may vary. Therefore, the apparatus performances such as the apparatus sensitivity and resolution are changed and not stabilized. A sample gas adheres to a surface of the orifice to form an insulating film on the surface of the orifice, which results in a problem such that a drift of the ion beam is generated due to accumulation of charge. In order to prevent such a problem, sometimes the orifice is heated to a high temperature by a heater. In such a case, the orifice is thermally expanded. The temperature of the orifice changes depending on the time elapsed after the start-up of the apparatus, and a thermal expansion amount also changes, which results in a problem such that the axis deviation amount changes transiently.
An object of the present invention is to provide means for solving the problems of the related art. Examples of the problems include sensitivity degradation and resolution degradation of a mass spectrometer, which are caused by an axis deviation of a component, particularly at least one orifice, located between an ion source and a detector, to decrease the number of ions reaching the detector, and a variation in performances caused by exchange of components such as the orifice.
SUMMARY OF THE INVENTION
For example, the invention has the following configuration in order to solve the problems above.
A mass spectrometer includes: an ion source; a detector that detects an ion; an orifice and a mass separator that are disposed between the ion source and the detector; and an axis adjusting mechanism that adjusts axis positions of the orifice and/or the mass separator such that an opening of the orifice and/or an incident port of the mass separator is disposed on a line connecting the ion source and an incident port of the detector.
According to the invention, the center axis of the component located between the ion source and the detector, particularly the center axis of the orifice and an ion beam traveling axis connecting a beam outgoing axis of the ion source and an incident port axis of the detector can substantially be aligned with each other to minimize the axis deviation amount, so that the number of ions reaching the detector can be maximized. Therefore, the vacuum pump can be miniaturized, and the compact, light-weight, high-sensitivity, high-resolution mass spectrometer can be implemented.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an entire configuration of a mass spectrometer according to an embodiment of the invention;
FIGS. 2A and 2B illustrate relationships between an axis deviation amount and a passing beam current amount;
FIG. 3 illustrates an entire configuration of a mass spectrometer according to an embodiment of the invention in which APCI (Atmospheric Pressure Chemical Ionization) is used;
FIG. 4 illustrates a relationship between an output current value of a detector and an elapsed time;
FIG. 5 illustrates a relationship between a mass-to-charge ratio m/z and ion strength (relative value);
FIG. 6 illustrates an axis position adjusting mechanism of a first orifice;
FIG. 7 illustrates an axis position adjusting method;
FIG. 8 illustrates an entire configuration of a TOF (Time Of Flight) mass spectrometer according to an embodiment of the invention;
FIG. 9 illustrates an axis position adjusting mechanism of a first orifice;
FIGS. 10A to 10D illustrate an axis position adjusting mechanism of a first orifice; and
FIG. 11 illustrates a change in signal amount by axis position adjustment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An exemplary embodiment of the invention will be described below with reference to the drawings.
FIG. 1 is a sectional view illustrating a conceptual configuration of a mass spectrometer according to an embodiment of the invention.
For example, electron ionization (EI), chemical ionization (CI), electron spray ionization (ESI), nano-electron spray ionization, atmospheric pressure chemical ionization (APCI), fast atom bombardment ionization (FAB), electric field ionization (FI), electric field desorption ionization (FD), matrix-assisted laser desorption ionization (MALDI), desorption electrospray ionization (DESI), desorption electrospray ionization (DART), or barrier discharge ionization is used for ionization of an ion source 1 .
An ion beam 2 is extracted from the ion source 1 by an extraction electric field that is applied between a first orifice 3 and an ion source electrode (not illustrated). Air containing the ion beam 2 flows through a fine hole of the first orifice 3 in a first differential pumping chamber 4 connected to a rough vacuum pump 5 .
Similarly, the air flows through a fine hole of a second orifice 6 in a second differential pumping chamber 7 connected to a second pumping port (low pumping speed side) of a main vacuum pump 18 . An octopole 8 is disposed in the second differential pumping chamber 7 . In the octopole 8 , eight multipole rod electrodes are disposed in an axially symmetric manner in parallel with one another, a potential having an identical phase is provided to the rod electrodes that are opposite to each other, and a potential having a constant phase difference is provided to the adjacent rod electrode. In the octopole 8 , an octopole high-frequency electric field is generated to form a potential that becomes convex on the axis, which allows the ion to be focused near the axis.
Potentials of tens volts are provided to the first orifice 3 and the second orifice 6 in order to extract the ion beam, and the ion is accelerated by a potential difference between the first orifice 3 and the second orifice 6 .
The air containing the ion beam 2 flows through a fine hole of a third orifice 9 in an analytical chamber 10 . The analytical chamber 10 is evacuated by connection with a first pumping port (high pumping speed side) of the main vacuum pump 18 . A background of the main vacuum pump 18 is evacuated by the rough vacuum pump 5 .
The analytical chamber 10 includes a quadrupole mass separator 11 and a detector 20 . The quadrupole mass separator 11 includes a front electrode 12 , a quadrupole rod 13 , a blade electrode 14 , a front wire 15 , a rear wire 16 , and a rear electrode 17 . In the quadrupole rod 13 , an identical AC voltage (identical amplitude and phase) is provided to the electrodes that are opposite each other, and an AC voltage whose phase is inverted is applied to the adjacent electrode. Generally the AC voltage ranges from several hundred volts to 5 kV and the frequency ranges from 500 kHz to 2 MHz. In a radial direction of the quadrupole rod 13 , a concave potential is formed in an axis center portion to focus the ion around the axis by the applied AC voltage. In an axial direction of the quadrupole rod 13 , an inclined DC potential is formed on a beam axis by mainly the front electrode 12 and the rear electrode 17 . The ion is trapped in the quadrupole mass separator 11 by the concave potential and the inclined DC potential. Accumulation and emission of the ion are sequentially performed by mainly changing the voltages at the front electrode 12 and the rear electrode 17 .
A mass spectrometry sequence will be described below.
MS analysis and MS n analysis can be cited as an example of the mass spectrometry sequence. In the MS analysis, an amplitude of an AC voltage is changed to trap the ion, the ion is selectively ejected in an ion beam traveling axial direction, the ion is detected by the detector 20 , and a molecular structure and a molecular formula of the sample are fixed from a relationship between a mass-to-charge ratio m/z and a detected ion current strength (relative value).
In the MS n analysis, a specific ion (precursor ion) is caused to selectively remain in the quadrupole mass separator 11 , collision induced dissociation (CID) of the precursor ion is generated to create a fragment ion, and mass scanning and mass separation of the fragment ion are performed to finely investigate the molecular structure of the sample. The MS n analysis will be described in detail below. A filtered noise field (FNF) having frequencies except a specific frequency is provided to the blade electrode 14 to eject ions except the specific precursor ion to the outside of the quadrupole mass separator 11 , thereby selecting the specific precursor ion. The AC voltage having a resonant frequency of the precursor ion is applied to the precursor ion remaining in the quadrupole mass separator 11 . At this point, a gas (such as helium, nitrogen gas, or argon) for collision induced dissociation is caused to flow in the quadrupole mass separator 11 to collide with the precursor ion, and the precursor ion is dissociated to create a product ion. The ion scanning and the mass separation of the created product ion are performed by changing the amplitude of the AC voltage amplitude applied to the quadrupole rod 13 and the blade electrode 14 . At this point, only the product ion overcoming a potential barrier caused by a DC voltage applied to the front wire 15 is incident to the detector 20 by the extraction electric field of the rear wire 16 . A variation in ion energy flowing in the ion detector is reduced by the front wire 15 and the rear wire 16 , so that resolution can be improved.
Magnetic field (sector type) mass spectrometry, time of flight mass separation (TOFMS), ion trap mass spectrometry (ITMS), Fourier transform ion cyclotron resonance mass spectrometry (FT-ICRMS) in which the mass separation is performed by utilizing ion rotation motion generated by the magnetic field, or orbitrap mass spectrometry in which the ion rotation motion generated by the electric field is utilized can be used as a mass separation method except the quadrupole mass separator in which the quadrupole rod is used.
The detector will be described below.
In FIG. 1 , the detector 20 exhibits a secondary electron photomultiplier provided with a conversion dynode 21 . The ion is caused to collide with the conversion dynode 21 by the electric field that is generated by the voltage of several kilovolts applied to the conversion dynode 21 , and the generated secondary electron 28 is amplified to a degree of the sixth power of ten by a multi-stage dynode 22 . The amplified secondary electron 28 is taken out to the atmosphere using a current introduction terminal 25 , further amplified by an amplifier circuit 26 , and captured in a micro ammeter 27 to perform monitoring. For example, a Farady cup in which the ion is received by a cup-shaped electrode to measure an amount of generated secondary electron, a channeltron in which the electrode is not independently formed but constitutes a high-resistance pipe, a micro channeltron including channeltrons having diameters range from 10 to 20 micrometers and arrayed in plate, or a photomultiplier in which light is converted into a photoelectron by a photoelectric surface to amplify the generated secondary electron can be used as the ion detector.
The mass spectrometer includes an axis adjusting mechanism 30 on the ion traveling axis connecting a center axis of an ion beam outgoing port of the ion source 1 and a center axis of an incident port of the detector 20 such that center axes of the fine holes of the first orifice 3 , the second orifice 6 , and the third orifice 9 are aligned with one another. Therefore, in the mass spectrometer, the axis position adjustment can be performed at a micrometer level. The components, such as the octopole 8 and the quadrupole mass separator 11 , which are disposed between the ion source 1 and the detector 20 can be adjusted by an axis adjusting mechanism (not illustrated). For the octopole 8 and the quadrupole mass separator 11 , plural axis adjusting mechanisms 30 may be provided near the incident port and the outgoing port so as not to deviate (incline) the axis.
FIGS. 2A and 2B illustrate positional relationships between a fine hole 35 of the second orifice and an ion beam 36 passing through the fine hole of the first orifice when the small and large axis deviations are generated between the first orifice and the second orifice (left side), and intensity distributions 38 of the ion beam passing through the first orifice on the second orifice surface and states of an ion beam 37 passing through the second orifice (right side). Because a diameter of the first orifice is larger than a diameter of the second orifice, the ion beam 36 incident to a surface of the second orifice through the first orifice does not interfere with the fine hole 35 of the second orifice in case of small axis deviation. On the other hand, part of the ion beam passing through the first orifice does not pass through the fine hole 35 of the second orifice in case of large axis deviation, and the ion beam current reaching the detector is decreased to generate troubles such as sensitivity degradation of an apparatus and resolution degradation.
Therefore, the axes (positions) of the first orifice and the second orifice are adjusted to align the center axes by means of the axis adjusting mechanism 30 such that the ion beam passing through the first orifice can pass through the second orifice. Although the relationship between the first orifice and the second orifice is adjusted in the embodiment, the axis position adjustment may be performed in the components disposed between the ion source and the detector.
The invention will be described below referring to embodiments applied to specific apparatuses.
First Embodiment
FIG. 3 illustrates an entire configuration of an apparatus in which APCI (Atmospheric Pressure Chemical Ionization) is used as the ion source in the apparatus of FIG. 1 . In FIG. 1 , the octopole 8 and the quadrupole mass separator 11 are illustrated in the perspective views. On the other hand, in FIG. 3 , the octopole 8 and the quadrupole mass separator 11 are illustrated in a plan view. Hereinafter, the overlapping description is omitted.
Air 45 is taken in the ion source 1 by a suction pump 40 . At this point, TCP (trichlorophenol) that is of a standard sample 41 is heated and vaporized by a heater 42 . After a vaporized gas amount becomes constant while the standard sample 41 is maintained at a constant temperature, a flow rate of the air 45 is set through a filter 44 by a mass flow controller 43 . The heater 42 is wound around pipe 46 located on a downstream side such that adhesion of a vaporized component of TCP to the pipe 46 is suppressed as much as possible. A voltage of several kilovolts is applied to a discharge needle 50 through a power cable 51 and a holder 52 , which are connected to a power supply (not illustrated). A voltage lower than the voltage applied to the discharge needle 50 is applied to a counter electrode 53 that located several millimeters from a leading end of the discharge needle 50 (for positive ion). A corona discharge 55 is generated in the air by the potential difference. A voltage of several tens of volts is applied to the first orifice 3 . The ion beam is extracted toward the detector 20 by the differential voltage. As illustrated in FIG. 3 , contrary to the ion beam extraction direction, the air 48 containing the TCP sample gas flows from the counter electrode 53 to the discharge needle 50 . The reason that the flow of the sample gas is set to the opposite direction to the ion beam extraction direction is that a reaction area where the desired ion reacts with radical and other ions is reduced to the minimum. The sample gas flows in the corona discharge area to generate the radical and other ions, which are the electrically neutral, in addition to the desired ion. The radical and other ions block the desired ionization to lower the desired ion current. Therefore, the flow of the sample gas is set to the opposite direction to the ion beam extraction direction in order to minimize the reaction area where the desired ion reacts with the radical and other ions.
The whole of ion source is heated to a high temperature by a heater (not illustrated). The first orifice 3 includes an elongated pipe in the center portion thereof. The elongated pipe has an inner diameter of about 100 micrometers and a length of 10 millimeters. The first differential pumping chamber 4 located on the downstream side of the first orifice 3 is connected to a diaphragm pump (not illustrated) having a pumping speed of several tens of liters per minute, and the degree of vacuum of the first differential pumping chamber 4 becomes about 1000 pascals. Because the air containing the sample gas is adiabatically expanded when flowing in the first orifice 3 , the temperature of the air containing the sample gas is lowered to generate clustering of the ion. When the clustering of the ion is generated, the mass spectrometry cannot correctly be performed. The sample gas adheres to the surface of the first orifice 3 to form an insulating film, and the charge is accumulated on the insulating film to generate a drift of the ion beam. Therefore, the first orifice 3 is heated to several hundreds of degrees Celsius by a heater (not illustrated) in order to prevent the drift from generating.
Similarly the second orifice 6 is heated by a heater (not illustrated). The first orifice 3 is fixed to a vacuum chamber 58 with an insulator 47 and a vacuum O-ring 59 interposed therebetween. The O-ring 59 is used to retain the vacuum. The ion is accelerated to enter the octopole 8 by the potential difference between the first orifice 3 and the second orifice 6 . A hole having a diameter of several hundreds of micrometers is made in the second orifice 6 . The second differential pumping chamber 7 located on the downstream side of the second orifice 6 is connected to a split-flow turbo molecular pump (not illustrated) having a pumping speed of several liters per second through a second pumping port. The air containing the sample gas flowing in the second differential pumping chamber 7 is restricted by a flow rate narrowing-down effect of the second orifice 6 , and the degree of vacuum of the second differential pumping chamber 7 becomes several pascals. The octopole 8 is disposed in the second differential pumping chamber 7 . The octopole 8 performs the above-described operation, and causes the ion beam to be focused and to pass through the fine hole of the third orifice 9 , so that the ion beam is incident to the analytical chamber 10 . The third orifice 9 has the hole diameter of about 1 millimeter. The pumping port of the analytical chamber 10 located on the downstream side of the third orifice 9 is connected to a split-flow turbo molecular pump (not illustrated) having a pumping speed of several tens of liters per second through a first pumping port. The analytical chamber 10 becomes the degree of vacuum of the minus third power of ten. The operation of the quadrupole mass separator 11 disposed in the analytical chamber 10 is described above. The scanned and separated ion having the mass-to-charge ratio m/z is incident to the detector 20 .
The output of the detector 20 is obtained as follows.
FIG. 4 illustrates a temporal change of the total ion current value that is the output of the detector 20 when the quadrupole mass separation is not performed. FIG. 4 shows that the total ion current value has a variation of about plus or minus several percent. Although the total ion current value has the above-described variation when the apparatus runs normally, the total ion current value of the detector is largely decreased, when the amount of sample gas that is source material flowing in the ion source is decreased due to the adhesion of the sample on a cold spot on a pipe, or when an ion beam passage rate is decreased due to clogging of the orifice.
FIG. 5 illustrates a relationship between the mass-to-charge ratio m/z and the ion strength (relative value) when the quadrupole mass separation is performed at a time T 1 of FIG. 4 . Because TCP is used as the standard sample, a peak is observed at the mass-to-charge ratio m/z of 195.
A specific configuration of the axis adjusting mechanism 30 will be described below.
FIG. 6 illustrates the axis adjusting mechanism between the first orifice and the second orifice as an example of the axis adjusting mechanism. A adjustment screw mounting plate 60 is fixed to the vacuum chamber 58 . Screw holes are made in the first orifice 3 , and adjustment screws 61 are threaded in the screw holes. An elastic member such as a spring 62 is fixed to a position opposite the adjustment screws 61 . The position of the first orifice 3 can be adjusted by a balance between a spring repulsive force 63 of the spring 62 and a pressing force 64 of the adjustment screw 61 . A trapezoidal disc spring as the spring 62 is used to generate the large repulsive force in the narrow area. The identical mechanism is provided in a direction orthogonal to the adjustment direction, and the identical adjustment can be performed. The adjustment can be performed in the two directions orthogonal to each other by the method. Alternatively, the position of the fine hole may be adjusted not two-dimensionally but three-dimensionally including a trolling angle by additionally providing an inclination mechanism (not illustrated). FOMBLIN having a sufficiently low saturated vapor pressure is applied to the O-ring 59 such that friction between the first orifice 3 and the vacuum chamber 58 is reduced to improve slippage and such that apparatus performance is not adversely affected. The first orifice 3 can be fixed using a fixing screw 66 after the axis adjustment. A distance of movement and adjustment of the first orifice 3 is several hundreds of micrometers. Similarly the second orifice 6 is fixed to the vacuum chamber 58 with the insulator 47 interposed therebetween. The ion beam 2 is extracted onto the detector side by the potential difference between the first orifice 3 and the second orifice 6 . When a fine screw having a screw pitch of 0.5 mm is used as the adjustment screw, because the screw travels by 0.5 mm per rotation of 360°, the movement and adjustment of about 10 μm can be performed by 7°. For the finer adjustment, a piezoelectric element, a servo motor and a ball screw, and a precisely direct acting stage may be used as a driving structure, to allow the adjustment to be performed at a nanometer level at the minimum. FIG. 6 illustrates the axis position adjusting mechanism between the first orifice and the second orifice. Similarly the axis position adjusting mechanism (not illustrated) may be provided among the first orifice 3 , the quadrupole mass separator 11 , and the detector 20 to perform the axis adjustment.
Sometimes the vaporized gas of the lubricant agent is generated when the lubricant agent is used in the O-ring. In such cases, possibly the ionization of the sample is blocked to decrease the necessary ion current value. Also, a noise component is increased to possibly degrade an S/N ratio. On the other hand, when the lubricant agent is not used, the friction between the first orifice 3 and the O-ring 59 is increased to twist the O-ring 59 , which sometimes causes a leak of the vacuum chamber.
Therefore, as illustrated in FIG. 9 , a mechanism that moves the first orifice 3 in the direction identical to that of the beam axis is provided to separate the first orifice 3 and the O-ring 59 , and the first orifice 3 is moved in the direction orthogonal to the axial direction. A dovetail groove (a sidewall of a groove in which the O-ring is accommodated is inclined) is provided in order that the generation of the twist of the O-ring 59 and the generation of the leak are prevented to lessen the motion of the O-ring 59 as much as possible.
At this point, the first orifice 3 is moved as illustrated in FIGS. 10A to 10D . The first orifice 3 is moved from a state ( FIG. 10A ) in the beam axis direction to the upstream side (the side of the ion source 1 ) by a screw 67 ( FIG. 10B ). The first orifice 3 is moved in the direction orthogonal to the beam axis by the adjustment screw 61 ( FIG. 10C ). The first orifice 3 is moved in the beam axis direction to the downstream side (the side of the detector 20 ) by the screw 67 and fixed by the fixing screw 66 ( FIG. 10D ).
The mechanism is used in each orifice and each mass separator to adjust the axis position.
An axis adjusting method will be described below.
FIG. 7 illustrates a method for adjusting the axis deviation. The first orifice 3 is moved along an axis 1 - 1 ′. The right side in the upper stage of FIG. 7 illustrates a transition of the beam current value when the first orifice 3 passes through the fine hole of the second orifice 6 . In FIG. 7 , the first orifice 3 is moved in the direction of a→e. The output signal of the detector becomes the maximum at the position c. Then the adjustment is performed in the direction of 2 - 2 ′ illustrated in the lower stage of FIG. 7 . First the first orifice is located in the position c. When the first orifice is moved in the direction of c→a*→b*, the detected current value is decreased. Therefore, the first orifice is returned and moved in the direction of b*→c*→d*. The right side in the lower stage of FIG. 7 illustrates the change of the detected signal. The detected signals are connected by an approximate curved line to determine the first orifice position in which the detected signal is maximized, and the first orifice is adjusted to the position and fixed. Then the axis deviation adjusting work is ended. In the embodiment, the axis adjustment is less frequently performed. However, actually it is necessary to repeatedly perform the adjustment plural times. In the embodiment, the adjustment is manually performed. Alternatively, the adjustment may automatically be performed such that the current value of the detector becomes the maximum, when a combination of a motor (stepping motor) and a ball screw is used to drive the orifice, or when a combination of the piezoelectric element and precision stage is used to drive the orifice.
Because sizes of maintenance components such as the orifice vary within mechanical tolerances, it is necessary to perform the axis adjustment after the maintenance. Because the orifice is heated by the heater as described above, the center axis position of the fine hole changes in the transient state. Therefore, the adjustment is efficiently performed after the apparatus is thermally stabilized in the running state. Whether the apparatus is thermally stabilized can be determined based on whether the signal of the detector 20 in the ion beam detecting state is substantially kept constant (the variation falls within a predetermined range). It is necessary that the axis position adjustment is performed when the apparatus runs normally. The stability of the apparatus is confirmed by the variation in total ion current value that is a kind of the detector output and the mass-to-charge ratio m/z in which the peak of the ion intensity (relative value) is observed as illustrated in FIGS. 4 and 5 . The variation in total ion current value and the mass-to-charge ratio m/z are monitored in performing the axis adjustment. When an abnormality is generated, if a warning is issued to an operator to stop the axis adjustment and the repair or maintenance of the apparatus is performed, operability, performance, and reliability of the apparatus are improved.
FIG. 11 illustrates an example of test result. In FIG. 11 , a horizontal axis indicates a movement distance in the direction orthogonal to the beam axis, and a vertical axis indicates the total ion current value (TCP signal intensity). The change of maximum/minimum=about two times is generated by the axis adjustment, and the maximum performance can be exerted by the current correction using the axis adjustment mechanism.
Thus, the axis adjusting mechanism is used to effectively reduce the mechanical tolerance.
Second Embodiment
FIG. 8 illustrates a TOF (Time Of Flight) mass spectrometer provided with the axis adjusting mechanism. The ion is accelerated in the orthogonal direction by an acceleration electric field of several hundreds of volts to several kilovolts applied to a push-out electrode 71 and an acceleration pull-out electrode 72 , the ion deflects through the ion reflector 73 which is called a reflector reaches the detector, and the ion reaches the detector such as a multi channel plate 74 . The variation in initial energy of the ion is corrected to equalize a total flight time of the ions having the identical mass-to-charge ratio m/z using the reflector, so that mass resolution can be enhanced.
The miniaturization of the mass spectrometer can also be implemented by utilizing the axis adjusting mechanism 30 in each orifice.
Description of Reference Numerals
1 ion source
3 ion beam
3 first orifice
4 first differential pumping chamber
5 rough vacuum pump
6 second orifice
7 second differential pumping chamber
8 octopole
9 third orifice
10 analytical chamber
11 quadrupole mass separator
12 front electrode
13 quadrupole rod
14 blade electrode
15 front wire
16 rear wire
17 rear electrode
18 main vacuum pump
20 , 23 detection unit
21 conversion dynode
22 dynode
25 current introduction terminal
26 amplifier circuit
27 micro ammeter
28 secondary electron
30 axis adjusting mechanism
33 adjustment direction
35 fine hole
36 ion beam that already passing through first orifice
37 ion beam that already passing through second orifice
38 intensity distribution
40 suction pump
41 standard sample
42 heater
43 mass flow controller
44 filter
45 air
46 pipe
47 insulator
48 air containing sample gas
50 discharge needle
51 power cable
52 holder
53 counter electrode
55 corona discharge
58 vacuum chamber
59 O-ring
60 adjustment screw mounting plate
61 adjustment screw
62 spring
63 spring repulsive force
64 screw pressing force
65 first fine hole
66 fixing screw
67 screw
71 push-out electrode
72 pull-out electrode
73 ion reflector (reflector)
74 multi channel plate
75 vacuum pump | An object of the present invention is to provide means for solving troubles. Examples of the troubles include sensitivity degradation and resolution degradation of a mass spectrometer, which are caused by an axis deviation of a component, particularly at least one orifice located between an ion source and a detector, to decrease the number of ions reaching the detector, and a variation in performance caused by exchange of components such as the orifice.
For example, the invention has the following configuration in order to solve the troubles. A mass spectrometer includes: an ion source; a detector that detects an ion; an orifice and a mass separator that are disposed between the ion source and the detector; and an axis adjusting mechanism that adjusts axis positions of the orifice and/or the mass separator such that an opening of the orifice and/or an incident port of the mass separator is disposed on a line connecting the ion source and an incident port of the detector. | 7 |
BACKGROUND OF THE INVENTION
Ion retardation, using "snake-cage polyelectrolytes", is discussed in an article in Industrial and Engineering Chemistry, Vol. 49, No. 11, November 1957 (pp 1812-1819), titled "Preparation and Use of Snake-Cage Polyelectrolytes" by Melvin J. Hatch, John A. Dillon, and Hugh B. Smith. It is disclosed there that a "snake-cage resin" is a cross-linked polymer system containing physically trapped linear polymer. For example, acrylic acid, when polymerized in situ within the reticules of a cross-linked copolymer of styrene and divinylbenzene (DVB), forms a "caged snake" of polyacrylic acid. Ordinarily polyacrylic acid is soluble in alkaline aqueous solutions, but, when entrapped within the styrene DVB copolymer bead, does not dissolve out of its "cage". The article discloses, e.g., the use of Dowex 1 ion exchange resin with entrapped polyacrylic acid as a resin which is more selective for NaCl than for NaOH.
Preparation of the Dowex 1 ion exchange resin is reported in the literature as comprising the polymerization of styrene containing divinylbenzene (DVB) as a crosslinker. The amount of crosslinking is about 8%±0.5%. The cross-linked styrene-DVB copolymer is chloromethylated in a Friedel-Crafts condensation employing, e.g., as catalyst, anhydrous AlCl 3 , ZnCl 2 , or SnCl 2 . The chloromethyl groups (--CH 2 Cl) attached to phenyl rings along the polymer structure are quaternized by reaction with a tertiary alkyl amine, trimethylamine, thus forming ion-exchange groups along the polymer chain which may be illustrated by the following empirical structure: ##STR1## The resin particles are substantially spherical, generally have a standard mesh size (wet) of 20-50, and have a density (wet with 43% moisture content) of about 44 lb./ft. 3 . Ordinarily the total exchange capacity (Cl - form) is about 3.5 meq./mg. (dry basis) and about 1.33 meq./ml. (wet basis).
U.S. Pat. No. 3,041,292 by Melvin J. Hatch also discloses ion exchange resins having entrapped polyacrylic acid. U.S. Pat. Nos. 3,078,140; 3,205,184; and 3,332,890, which are all continuation-in-parts of U.S. Pat. No. 3,041,292, also contain information relevant to the present invention. Canadian Pat. No. 575,049 also contains relevant information. U.S. Pat. No. 2,606,098 (alkali metal hydroxide method) and U.S. Pat. No. 3,228,275 (countercurrent working procedure) are somewhat related to the present subject matter.
Of the ion retardation resin systems disclosed in the above references which may be useful in desalting caustic, it is the type exemplified by commercially-available Dowex 1 ion exchange resin (with polyacrylic acid entrapped therein) which is of pertinence in the present invention. The various Dowex ion exchange resins are registered tradenames of The Dow Chemical Company.
Dowex 1 ion exchange resin is a strongly basic anion exchanger formed by co-polymerizing styrene with divinylbenzene (DVB) as a crosslinker and featuring, as nuclear substituents on the polymer chain, trimethyl benzyl ammonium quaternary salts. The resin is commercially available in the Cl - or OH - form, but for the present invention, the Cl - form is preferable.
In preparing the pertinent polyacrylic acid snake-cage resins, the ion exchange resin is filled with monomeric acrylic acid, then the acrylic acid is polymerized in situ in the exchange resin. The polymerization may be initiated or catalyzed by the use of a free radical catalyst, a redox catalyst, and/or by increasing the temperature to overcome the inhibitors normally used in stored acrylic acid.
Whereas the art suggests the use of various amounts of acrylic acid polymer to be used with a given amount of quaternary ammonium groups, the teachings suggest that a stoichiometric balance between the carboxylic groups and the quaternary ammonium groups is preferred in order that there be no substantial excess of either one when the resin is to be employed in desalting caustic.
SUMMARY OF THE INVENTION
We have now found, unexpectedly, that when a Dowex 1 type of ion exchange resin (containing entrapped polyacrylic acid) is used for desalting caustic, that the desalting efficiency is enhanced by employing a resin which has no quaternary ammonium groups which are not complexed with carboxyl groups of a polyacrylic acid and which have an excess of carboxylic groups in the range of about 0.4 to about 1.0 meq./ml. of resin, especially about 0.5 to about 0.75 meq./ml. of resin.
DETAILED DESCRIPTION OF THE INVENTION
The attached drawings (Graphs I-VIII) depict curves of data obtained as shown in the Examples.
The "snake-cage" resins of the present invention, also known as "ion-retardation resins", which involve polymerization of acrylic acid inside Dowex 1 type of ion exchange resin beads are prepared according to published methods taught, e.g., in U.S. Pat. No. 3,041,292. Such resins are characterized as a bead form of polystyrene containing about 8% crosslinking with divinyl benzene and having nuclear substituted quaternary trialkyl ammonium groups, wherein said quaternary ammonium groups are neutralized by carboxylic acid groups which are pendant on chains of polyacrylic acid entrapped within the resin beads. The principal distinguishing feature of the resins used in the present invention is that the amount of polyacrylic acid incorporated into the resin, by the in-situ polymerization of acrylic acid, is controlled so as to provide enough carboxylic groups to complex with all the quaternary ammonium groups of the ion exchange resin and to have a large excess of carboxylic groups.
We would not wish the present invention to be prejudiced by the following postulated explanation, but it is believed that when the polyacrylic acid is formed in the ion exchange resin, the pendant carboxylic groups do not all align themselves in such a way that each one is able to "reach" one of the quaternary ammonium groups and thereby react or neutralize the quaternary ammonium groups; thus an excess is needed so as to assure complete neutralization of the quaternary ammonium groups. This leaves some of the --COOH groups in the unreacted state, but as long as these excess carboxylic groups are controlled within a critical range of concentration, then unexpected beneficial improvements are attained.
When essentially all of the quaternary ammonium groups are neutralized or complexed with --COOH groups on the non-leachable acrylic acid polymer, the expression ΔC + =0 meq./ml. capacity is used. The expression ΔC - =X meq./ml. capacity, where X is a positive integer, is used to indicate the amount of --COOH groups which are not complexed or reacted with a quaternary ammonium group. Effectively, the value of ΔC - is the stoichiometric excess of COOH groups over the quaternary amine groups. In the present invention it is critical that ΔC + =0 and that ΔC - =X, where X is about 0.4 to about 1.0 meq./ml., preferably about 0.5 to about 0.75 meq./ml. Any ΔC + value of less than about 0.005 is considered to be essentially zero as a practical matter.
The criticality of the above ΔC values in achieving the unexpected benefits of the present invention is evidenced by the data in the examples shown in this disclosure. Where ΔC + capacity is greater than zero, a salt-free NaOH is not attained, even if ΔC - capacity is within the critical range. Where ΔC + =0, but ΔC - is below about 0.4 meq./ml. the NaCl wash-out rate is slow; above about 1.0 meq./ml., the separation capacity is decreased as shown by an earlier rise of the NaCl concentration.
As stated previously, the present invention involves the use of the particularly described ion exchange resin in a process for desalting caustic, e.g., the separation of NaCl from aqueous solutions of NaOH. Of particular interest are cell effluents from electrolytic chlorine-caustic diaphragm cells where catholyte withdrawn from the cell, as cell effluent, contains NaOH product contaminated by NaCl. It is usually necessary for commercial and technical reasons to reduce the NaCl to as low a level as is feasibly possible. The present invention affords a method for producing aqueous NaOH having very low salt levels, so low in fact that when the NaOH is concentrated to high concentrations of 50-70%, no precipitation of NaCl is encountered.
One of the benefits of the present invention is that with the high ΔC - capacity, assuring that ΔC + =0, a rapid Cl - wash-out (a sharp trailing Cl - gradient) is obtained which yields a high NaCl concentration in the effluent; this allows the use of less water per ton of NaOH produced.
It will be appreciated and understood by practitioners of the relevant arts, having read this disclosure, that the ion exchange resins of the present invention are highly effective in absorbing chloride and chlorate ions from aqueous alkali metal hydroxide solutions, thereby permitting the recovery of a purified alkali metal hydroxide solution. The absorbed anion impurities can thereafter be washed from the composite resin bodies so as to regenerate the same, and the process can be repeated in alternating absorption and regeneration cycles.
In standard practice, the ion exchange resin is placed in a vessel, usually an elongated vertically-disposed vessel, equipped with at least one flow means at, or near, the top and also at, or near, the bottom. The aqueous stream to be treated may be fed through the resin bed from the bottom or from the top, but is preferably fed from the bottom. Also, the wash liquid employed to regenerate the resin by washing out the absorbed material may be fed through the resin from the bottom or from the top. Thus, the wash cycle may be co-flow or counter-flow to the absorption cycle. We prefer, in the practice of the present invention to employ counter-flow cycles by feeding the NaCl-containing NaOH solution from the bottom until NaCl begins to show up in the effluent stream leaving the top, then flowing the wash liquid through the resin from the top and taking the eluted NaCl out the bottom. By using the counter-flow alternate cycles, a better separation is attained which economizes on the amount of water involved and which deals more efficiently with the "tailings" or "hold-up" in the resin bed which remains after each cycle.
Whereas the present invention provides a means, e.g., for substantially removing NaCl from NaOH solutions, by passing the solution through a single stage of NaCl removal, further improvement in the NaCl separation may be desired and is possible by passing the NaOH solution through a second stage, such as through a second resin bed, to even further reduce the NaCl content. With two stages of resin treatment a NaCl-containing NaOH solution, e.g., a chlorine cell effluent, is effectively purified to a chloride level of less than 10 ppm. The technique is useful, in general, for desalting of caustic solutions.
The temperature employed for the desalting of caustic may be from about 0° C. to about 100° C., and is preferably about 30° C. to about 60° C. At temperatures much above about 60° C., the effective life of the resin may be decreased because of degradation of the quaternary groups. At temperatures below about 30° C., the rate is relatively slow and therefore not usually economical. Most preferably, the temperature is in the range of about 45° C. to about 55° C.
EXAMPLES I-VIII
A number of "snake-cake" resins are prepared by the published method of polymerizing acrylic acid insitu in Dowex 1 ion exchange beads, using various amounts of acrylic acid. Then the resins are washed well with water to remove any leachable monomeric, dimeric or oligomeric acrylic acid. The exchange capacities are determined essentially by the method described in page 1819 of Hatch, et al article in Vol. 49, No. 11 of Industrial and Engineering Chemistry identified supra.
For these examples, the NaCl-containing NaOH solution is the cell effluent (catholyte flow) from an electrolytic diaphragm chlor-alkali cell. The cell effluent is passed through the following identified resins and the absorbed NaCl values are then eluted with a water wash cycle.
The resins, shown in the attached graphs of the same Roman Numerals, are measured as follows:
______________________________________Capacity in Meq./ml. (wet basis) Within Scope ofResin No. ΔC.sup.+ ΔC.sup.- Present Invention______________________________________I 0 1.60 noII 0 1.034 yesIII 0 0.75 yesIV 0 0.44 yesV 0 0.55 yesVI 0.17 0.45 noVII 0.013 0.334 noVIII 0.075 0.03 no______________________________________
A water jacketed column of 116 cc capacity is filed with the wet resin sample. Water is circulated in the jacket from a controlled bath to maintain the column at 60° C. A continuous flow of, alternately, cell effluent and water is maintained at 3.3 cc/minute. The cell effluent is 3.15 N NaOH and 2.76 N NaCl. After 16.17 minutes of cell effluent flow, a water flow of 18.72 minutes is then followed with cell effluent and then water again in alternate cycles. Monitoring the column effluent in small increments for alkalinity, chloride, and density give the representative curves as shown in the attached graphs, the graphs being numbered to coincide with the Resin No. shown above.
In Graphs I-VIII, the normality (N) of the effluent flows from the resin are plotted. In Graphs II, III, IV, and V, which represent examples within the scope of the presently claimed invention, the separation of NaOH and NaCl is seen to be better than in comparative Graphs I, VI, VII, and VIII. In Graph I the "breakthrough" of the NaCl is seen to occur significantly sooner than in Graphs II, III, IV, and V. In Graphs VI, VII, and VIII it is seen that the level of NaCl concentration throughout the NaOH collection is significantly higher than in Graphs II, III, IV, and V.
EXAMPLE IX
Counterflow-Operation
Cell effluent (8.77% NaOH, 14.9% NaCl) is passed upwardly through a bed of ion retardation resin contained in an elongated vertically-disposed vessel at 60° C. The resin capacity is: ΔC + =0.002 (essentially nil) and ΔC - =0.51 meq./ml. The amount of cell effluent passed through is considered as "one volume". The caustic effluent taken out overhead (0.9 volume) contains 10.47% NaOH and 0.088% NaCl. Then 1.25 volumes of deionized recycle water (0.3% NaOH, 0.028% NaCl) is passed downwardly through the resin bed at 60° C. to wash the NaCl from the resin and 1.35 volumes of a saline effluent (0.43% NaOH, 12.9% NaCl) is removed from the bottom. The amount of NaOH in the saline effluent is about 5.7% of the NaOH which was in the cell effluent. If desired, the NaOH in the saline effluent may be substantially recovered by further ion exchange treatment or sent to some other process or treatment.
The NaCl content in the caustic effluent may be further reduced by giving the caustic effluent a second treatment with the same or similar resin as was used in the first treatment described above.
EXAMPLE X
Co-flow Operation
One volume of a cell effluent (8.0% NaOH, 16.0% NaCl, 106 ppm ClO 3 - , 1650 ppm SO 4 = ) is passed downwardly at 50° C. through a bed of resin similar to the resin of Example IX above. The caustic effluent from the bottom of the resin bed is 0.9 volume and contains 9.8% NaOH, 0.5% NaCl, 20 ppm ClO 3 - and 2200 ppm SO 4 = . Then 2.8 volumes of softened river water (61 ppm SO 4 = , 1 ppm Ca ++ ) is passed downwardly through the resin bed to wash the NaCl from the resin. The saline effluent (2.9 volumes) from the bottom of the resin bed contains 0.1% NaOH, 6.5% NaCl, 43 ppm ClO 3 - and 25 ppm SO 4 = . The amount of NaOH in the saline effluent is about 4% of the amount in the cell effluent feed. Note in this Example, as compared with Example IX, that the amount of water needed to achieve good wash-out of the resin is much greater.
The foregoing Examples are to illustrate particular embodiments of the present invention, but the invention is not limited to those particular embodiments. | Ion retardation resins particularly useful for desalting caustic solutions are prepared by employing ion exchange resins consisting essentially of a mixture of a reticular, insoluble, cross-linked styrene/divinylbenzene copolymer with an entrapped non-leachable polymer of acrylic acid contained therein and where the amount of carboxylic acid groups on the polyacrylic acid are in substantial excess over the amount needed to react with all the quaternary ammonium groups which are nuclear substituted on the styrene copolymer chains. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Taiwan Patent Application No. 103106710, filed on Feb. 27, 2014 in Taiwan Intellectual Property Office, the contents of which are hereby incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a microwave power amplification apparatus and method thereof by using, particularly, period-one nonlinear dynamics of semiconductor lasers.
[0004] 2. Description of the Related Art
[0005] Communication networks are generally classified into wireless networks and wireline networks. In the wireless networks, microwaves are used as carriers to deliver data through air to provide communication between mobile electronic devices. In the wireline networks based on optical technologies, optical waves function as carriers to deliver data through optical fibers to provide communication between immobilized electronic devices. These two networks depend on completely different communication approaches and cover completely different communication scopes. Due to the rapid advances of broadband wireless technologies and also due to the various developments of online applications, the capacity demand for data transmission in the wireless networks increases considerably. If the wireless networks are required to manage both the front-end data transmission between users and wireless base stations and the back-end data transmission between the wireless base stations and central offices, currently developed broadband wireless technologies are not capable of meeting the vast capacity demand for data transmission when the wireless networks are simultaneously accessed by a variety of different users or devices.
[0006] Since each channel of the wireline networks based on optical technologies provides data transmission capacity of the order of a few Gbits/s to tens of Gbits/s, the optical communication networks are highly suitable to work as backbones for huge back-end data transmission for various network applications. Therefore, radio-over-fiber (RoF) networks which integrate the wireless networks (responsible for the front-end data transmission) and the optical wireline networks (responsible for the back-end data transmission) have become very attractive for the next generation of communication technology and system.
[0007] To ensure the communication quality in the RoF networks, the power of the microwaves needs to be high enough. Three approaches are commonly adopted to increase the microwave power. In the first approach, electronic microwave amplifiers are used after photo-detection at base stations. However, to fulfill the demand of considerably increasing data transmission in the future, significantly more data bandwidth is necessary. This therefore requires continuous upgrade or replacement of the electronic microwave amplifiers with higher bandwidth capability, suggesting an enhancement of operation cost. In the second approach, optical power amplifiers are used before photo-detection to increase the power of the input optical signals upon photodetectors. However, too much of the input optical power would damage the photodetectors. In the third approach, the optical modulation depth of the input optical signals is increased, which in turn increases the microwave power after photo-detection under the same received optical power. This can be achieved by increasing the microwave power when directly or externally modulating semiconductor lasers. However, nonlinear effects, such as harmonic or intermodulation distortion, are generally induced, which affect the quality of the received signals. In addition, under the same received optical power at the photodetectors, the optical modulation depth can be increased by reducing the power difference between the optical modulation sidebands and the optical carrier, which is commonly quantified by the sideband-to-carrier ratio (SCR). Currently, the optical filtering scheme is applied to achieve a better SCR value by suppressing the power of the optical carrier while maintaining that of the optical modulation sidebands. This, however, considerably reduces the overall power of the optical signal and therefore requires extra optical power amplifiers to compensate for the power loss.
SUMMARY OF THE INVENTION
[0008] According to the problems and challenges encountered in prior arts, the purpose of the present invention is to provide an apparatus for microwave power amplification in the RoF networks through optical modulation depth improvement by applying period-one nonlinear dynamics of semiconductor lasers. The microwave power amplification apparatus of the present invention includes a semiconductor laser as the key component, which can be reconfigured for different communication networks with different requirements or different applications adopting different microwave frequencies.
[0009] Another purpose of the present invention is to provide a method for microwave power amplification in the RoF networks through optical modulation depth improvement by applying period-one nonlinear dynamics of semiconductor lasers. In this manner, similar and even improved microwave quality and bit-error ratio (BER) are obtained, which shall enhance the signal detection sensitivity of communication networks, the transmission distance of optical fibers, and the network transmission efficiency.
[0010] According to the aforementioned purposes, the present invention provides a microwave power amplification apparatus to amplify power of microwaves in the RoF networks. The microwave power amplification apparatus includes a microwave power amplification module. While the optical input of the microwave power amplification module is an optical signal carrying a power-to-be-amplified microwave signal and has at least one modulation sideband, the optical output of the microwave power amplification module is an optical signal carrying a power-amplified microwave signal. The microwave power amplification module includes a microwave-power amplification laser, which converts the optical input into the optical output using period-one nonlinear dynamics of the microwave-power amplification laser, wherein the optical input falls within the domain for microwave power amplification using the period-one nonlinear dynamics of the microwave-power amplification laser.
[0011] Preferably, the microwave power amplification apparatus further includes a microwave-modulated optical signal generation module to generate the optical input. The microwave-modulated optical signal generation module includes a laser to generate a continuous-wave optical signal, an optical polarization controller to adjust the polarization of the continuous-wave optical signal, a microwave signal generator to generate the power-to-be-amplified microwave signal, and an external modulator to superimpose the power-to-be-amplified microwave signal on the continuous-wave optical signal to generate the optical input.
[0012] Preferably, the microwave-modulated optical signal generation module further includes a data signal generator to generate a data signal to be transmitted, which can be an analog signal or a digital signal, and an electrical signal mixer to mix power-to-be-amplified microwave signal with the data signal to generate a power-to-be-amplified microwave signal carrying the data signal.
[0013] Preferably, the microwave power amplification module further includes an optical power adjuster and an optical polarization controller. The optical power adjuster includes an active optical device or a passive optical device to adjust the optical power of the optical input, and the optical polarization controller adjusts the polarization of the optical input.
[0014] Preferably, the active optical device is an optical power amplifier and the passive optical device is an optical power attenuator.
[0015] Preferably, the microwave power amplification module may include an optical path controller, connected to the microwave-power amplification laser, to unidirectionally direct the optical input toward the microwave-power amplification laser, and to unidirectionally direct the optical output toward an output port of the microwave power amplification apparatus.
[0016] Preferably, the optical path controller is an optical circulator and the microwave-power amplification laser is a semiconductor laser.
[0017] According to the aforementioned purposes, the present invention further provides a microwave power amplification method to amplify power of microwaves in the RoF networks. The microwave power amplification method includes the following steps:
[0000] (1) using a microwave-modulated optical signal generation module to generate an optical input, wherein the optical input is an optical signal carrying a power-to-be-amplified microwave signal and the optical input has at least one modulation sideband, and
(2) using a microwave-power amplification laser to convert the optical input into an optical output using period-one nonlinear dynamics of the microwave-power amplification laser, wherein the optical output is an optical signal carrying a power-amplified microwave signal and the optical input falls within the domain for microwave power amplification using the period-one nonlinear dynamics of the microwave-power amplification laser.
[0018] Furthermore, the step of using the microwave-modulated optical signal generation module to generate the optical input further includes the following steps:
[0000] (1) using a laser to generate a continuous-wave optical signal,
(2) using an optical polarization controller to adjust the polarization of the continuous-wave optical signal,
(3) using a microwave signal generator to generate the power-to-be-amplified microwave signal,
(4) using a data signal generator to generate a data signal to be transmitted, and the data signal being either an analog signal or a digital signal,
(5) using an electrical signal mixer to mix the power-to-be-amplified microwave signal with the data signal to generate a power-to-be-amplified microwave signal carrying the data signal, and
(6) using an external modulator to superimpose the power-to-be-amplified microwave signal on the continuous-wave optical signal to generate the optical input.
[0019] Furthermore, two more steps are also included between the step of using the microwave-modulated optical signal generation module to generate the optical input and the step of using the microwave-power amplification laser to convert the optical input into the optical output:
[0000] (1) using an optical power adjuster to adjust the optical power of the optical input, and
(2) using an optical polarization controller to adjust the polarization of the optical input.
[0020] Furthermore, in the step of using the microwave-power amplification laser to convert the optical input into the optical output, an optical path controller is also used to unidirectionally direct the optical input toward the microwave-power amplification laser, and to unidirectionally direct the optical output toward an output port.
[0021] As mentioned above, the microwave power amplification apparatus and method based upon the present invention possess one or more of the following characteristics and advantages:
[0000] (1) While maintaining the power of the optical carrier, the microwave power amplification apparatus and method of the present invention are able to increase the power of the optical modulation sidebands, which therefore reduces the power difference between the optical carrier and the optical modulation sidebands. Since the power level of the optical output is similarly maintained or even enhanced compared with that of the optical input, no extra optical power amplifier is necessary for power loss compensation.
(2) The microwave power amplification apparatus can be reconfigured for different communication networks with different requirements or different applications adopting different microwave frequencies. In addition, the apparatus is insensitive to the ambiance temperature and can self-adapt to the adjustment of the operating conditions of the communication networks, leading to a considerably stable operation of the apparatus. Therefore, the microwave power amplification apparatus of the present invention has the advantages of simple structure, stable operation, and low installation and maintenance cost.
(3) By using the period-one nonlinear dynamics of semiconductor lasers, the microwave power amplification method of the present invention provides an approach to amplify microwave power through the improvement of the optical modulation depth in the RoF networks or even other applications. In this manner, similar and even improved microwave quality and bit-error ratio (BER) are obtained, which shall enhance the signal detection sensitivity of communication networks, the transmission distance of optical fibers, and the network transmission efficiency.
[0022] The aforementioned purposes, characteristics, and advantages of the present invention are more fully described with preferred embodiments and drawings as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The device structure, operating principle, and advantageous characteristics of the present invention are described with more details hereinafter with reference to the accompanying drawings that show various embodiments of the present invention as follows.
[0024] FIG. 1 is a schematic representation of a microwave power amplification apparatus according to a preferred embodiment of the present invention;
[0025] FIG. 2 is a first flow diagram showing a microwave power amplification method according a preferred embodiment of the present invention;
[0026] FIG. 3 is a second flow diagram showing the microwave power amplification method according to the preferred embodiment of the present invention;
[0027] FIG. 4 shows a dynamical mapping of the microwave-power amplification laser subject to continuous-wave optical injection in terms of the injection level and the detuning frequency according to the preferred embodiment of the present invention;
[0028] FIG. 5 shows an optical spectrum of the period-one nonlinear dynamics of the microwave-power amplification laser subject to continuous-wave optical injection according to the preferred embodiment of the present invention
[0029] FIG. 6 shows an optical spectrum of the optical input carrying a power-to-be-amplified microwave signal according to the preferred embodiment of the present invention;
[0030] FIG. 7 shows an optical spectrum of the optical output carrying a power-amplified microwave signal according to the preferred embodiment of the present invention;
[0031] FIG. 8 shows microwave spectra of the optical input and the optical output, respectively, according to the preferred embodiment of the present invention;
[0032] FIG. 9 shows microwave power and microwave gain in terms of the input sideband-to-carrier ratio (SCR) after microwave power amplification according to the preferred embodiment of the present invention;
[0033] FIG. 10 shows microwave gain and output sideband-to-carrier ratio (SCR) in terms of the microwave frequency after microwave power amplification according to the preferred embodiment of the present invention;
[0034] FIG. 11 shows spectra of the input data signal and the output data signal, respectively, according to the preferred embodiment of the present invention;
[0035] FIG. 12 shows bit-error ratios (BERs) of the input data signal and output data signal, respectively, in terms of the received optical power according to the preferred embodiment of the present invention; and
[0036] FIG. 13 shows eye diagrams of the input data signal and the output data signal, respectively, according to the preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] To illustrate the device structure, operating principle, and advantageous characteristics of the present invention, a preferred embodiment and the corresponding drawings are provided with more details. The purpose of the drawings being used is for illustration, and they are not necessarily the real proportion and precise allocation of the embodiments of the present invention. Therefore, they should not be used to limit the privilege coverage of the practical embodiments of the present invention.
[0038] Referring to FIG. 1 , FIG. 1 is a schematic representation of a microwave power amplification apparatus according to a preferred embodiment of the present invention. In FIG. 1 , a microwave power amplification apparatus 1 includes a microwave power amplification module 20 . The optical input of the microwave power amplification module 20 is an optical signal carrying a power-to-be amplified microwave signal and has at least one modulation sideband. The microwave power amplification module 20 includes a microwave-power amplification laser 203 , which converts the optical input into an optical output carrying a power-amplified microwave signal using the period-one nonlinear dynamics. The optical input falls within the domain for microwave power amplification using the period-one nonlinear dynamics of the microwave-power amplification laser 203 .
[0039] Moreover, the microwave power amplification apparatus 1 further includes a microwave-modulated optical signal generation module 10 to generate the optical input. The microwave-modulated optical signal generation module 10 includes a laser 101 to generate a continuous-wave optical signal, an optical polarization controller 102 to adjust the polarization of the continuous-wave optical signal, a microwave signal generator 103 to generate the power-to-be-amplified microwave signal, and an external modulator 106 to superimpose the power-to-be-amplified microwave signal on the continuous-wave optical signal to generate the optical input.
[0040] Moreover, the microwave-modulated optical signal generation module 10 further includes a data signal generator 104 to generate a data signal to be transmitted, which can be an analog signal or a digital signal, and an electrical signal mixer 105 to mix the power-to-be-amplified microwave signal with the data signal to generate a power-to-be-amplified microwave signal carrying the data signal.
[0041] Moreover, the microwave-modulated optical signal generation module 10 further includes a DC power supply 107 to supply a constant bias voltage to the external modulator 106 .
[0042] Moreover, the microwave power amplification module 20 further includes an optical power adjuster 201 and an optical polarization controller 202 . The optical power adjuster 201 includes an active optical device or a passive optical device to adjust the optical power of the optical input, and the optical polarization controller 202 adjusts the polarization of the optical input.
[0043] Moreover, the active optical device is an optical power amplifier and the passive optical device is an optical power attenuator.
[0044] Moreover, the microwave power amplification module 20 further includes an optical path controller 204 , connected to the microwave-power amplification laser 203 , to unidirectionally direct the optical input toward the microwave-power amplification laser 203 , and to unidirectionally direct the optical output toward an output port of the microwave power amplification apparatus 1 .
[0045] Moreover, the optical path controller 204 is an optical circulator and the microwave-power amplification laser 203 is a semiconductor laser.
[0046] To detect and analyze the optical input and the optical output of the microwave power amplification apparatus 1 , the following devices are used:
[0000] (1) an optical spectrum analyzer 301 to analyze spectral features of the optical input or the optical output,
(2) a photodetector 302 to retrieve the power-to-be-amplified microwave signal from the optical input or to retrieve the power-amplified microwave signal from the optical output,
(3) a microwave spectrum analyzer 303 to analyze spectral features of the power-to-be amplified microwave signal retrieved from the optical input or the power-amplified microwave signal retrieved from the optical output,
(4) a microwave signal generator 304 to generate a microwave signal of the same frequency as the power-to-be-amplified microwave signal generated by the microwave signal generator 103 ,
(5) an electrical signal mixer 305 to mix the power-to-be amplified microwave signal retrieved from the optical input or the power-amplified microwave signal retrieved from the optical output with the microwave signal generated by the microwave signal generator 304 in order to down-convert the input data signal or the output data signal,
(6) a low-pass filter 306 to filter out unnecessary high-frequency components of the input data signal or the output data signal, and
(7) an error tester 307 to compare the output data signal with the input data signal in order to calculate the bit-error ratio.
For RoF networks, the aforementioned photodetector 302 can be installed within a wireless base station to retrieve data-encoded microwave signals carried by the optical input through fiber transmission.
[0047] Referring to FIG. 2 , FIG. 2 is a first flow diagram showing a microwave power amplification method according a preferred embodiment of the present invention. The microwave power amplification method of the present invention includes the following steps:
[0000] (S 10 ): Using a microwave-modulated optical signal generation module 10 to generate an optical input carrying a power-to-be-amplified microwave signal;
(S 20 ) Using an optical power adjuster 201 to adjust the power of the optical input;
(S 21 ): Using an optical polarization controller 202 to adjust the polarization of the optical input;
(S 22 ): Using a microwave-power amplification laser 203 to convert the optical input into an optical output carrying a power-amplified microwave signal through period-one nonlinear dynamics; and
(S 23 ): Using an optical path controller 204 to unidirectionally direct the optical input toward the microwave-power amplification laser 203 , and unidirectionally direct the optical output toward an output port of the microwave power amplification apparatus 1 .
[0048] Referring to FIG. 3 , FIG. 3 is a second flow diagram showing the microwave power amplification method according to the preferred embodiment of the present invention. The step of S 10 further comprises the following steps:
[0000] (S 11 ): Using a laser 101 to generate a continuous-wave optical signal;
(S 12 ): Using an optical polarization controller 102 to adjust the polarization of the continuous-wave optical signal;
(S 13 ): Using a microwave signal generator 103 to generate the power-to-be-amplified microwave signal;
(S 14 ): Using a data signal generator 104 to generate a data signal to be transmitted, and the data signal being an analog signal or a digital signal;
(S 15 ): Using an electrical signal mixer 105 to mix the power-to-be-amplified microwave signal with the data signal to generate a power-to-be-amplified microwave signal carrying the data signal; and
(S 16 ): Using an external modulator 106 to superimpose the power-to-be-amplified microwave signal carrying the data signal on the continuous-wave optical signal to generate the optical input.
[0049] Based on the above description, the microwave power amplification apparatus of the present invention includes a microwave-power amplification laser, which is a semiconductor laser. Without any external perturbation, the typical output of the microwave-power amplification laser is a continuous wave of one single frequency. Under proper conditions of the injection level and frequency and without any microwave modulation, injecting the continuous-wave optical signal generated by the laser 101 in FIG. 1 into the microwave-power amplification laser induces period-one nonlinear dynamics showing completely different physical behaviors and characteristics.
[0050] In the following explanations, the injection level, ξ i , indicates the strength of the optical injection and the detuning frequency, f i , indicates the frequency of the optical injection relative to the free-running frequency of the microwave-power amplification laser. Referring to FIGS. 4 and 5 , FIG. 4 shows a dynamical mapping of the microwave-power amplification laser subject to continuous-wave optical injection in terms of the injection level and the detuning frequency according to the preferred embodiment of the present invention, and FIG. 5 shows an optical spectrum of the period-one nonlinear dynamics of the microwave-power amplification laser subject to continuous-wave optical injection according to the preferred embodiment of the present invention. FIG. 4 presents the region of the period-one nonlinear dynamics of the microwave-power amplification laser under different injection levels and detuning frequencies. When applying the microwave power amplification apparatus and method of the present invention, the injection level and detuning frequency of the optical input sent into the microwave power amplification module are chosen within the region of the period-one nonlinear dynamics in FIG. 4 where microwave power amplification can be achieved. In practical applications, the choice of the injection level and the detuning frequency can be determined based on the requirement of microwave power amplification. Under ξ i =1.1 and f i =21 GHz, FIG. 5 presents the optical spectrum of the microwave-power amplification laser subject to continuous-wave optical injection at the period-one nonlinear dynamics. In addition to the regeneration at f i =21 GHz, two oscillation sidebands emerge, which are equally separated from the regeneration by f 0 =35 GHz. Generally speaking, because of the red shift of laser cavity resonance, the power of the lower-frequency oscillation sideband is very close to that of the regeneration. In FIG. 5 of the present embodiment, the lower-frequency oscillation sideband is only 2 dB weaker than the regeneration. The microwave power amplification apparatus and method of the present invention take advantage of this characteristic to achieve microwave power amplification.
[0051] By adjusting ξ i or f i of the continuous-wave optical injection mentioned above, the frequency difference f 0 between adjacent frequency components and the power of each frequency component can be varied, resulting in different characteristics of the period-one nonlinear dynamics of the microwave power amplification laser. The injection level can be adjusted through the optical power adjuster, which may include an active optical device (typically an optical power amplifier) and a passive optical device (typically an optical power attenuator). However, if the injection level is high enough, only an optical power attenuator is required for the optical power adjustment. To effectively generate the period-one nonlinear dynamics, the polarization of the optical injection should align with that of the microwave-power amplification laser, which can be achieved through the optical polarization controller. In addition, to direct the optical injection and to minimize unnecessary back reflection, an optical circulator is adopted to unidirectionally direct the optical injection toward the microwave-power amplification laser and to unidirectionally direct the output of the microwave-power amplification laser toward an optical coupler (not shown). The optical coupler splits the output of the microwave-power amplification laser into two beams and sends these beams into the optical spectrum analyzer and the photodetector, respectively, for analysis.
[0052] Referring to FIG. 6 , FIG. 6 shows an optical spectrum of the optical input carrying a power-to-be-amplified microwave signal according to the preferred embodiment of the present invention. By externally modulating the continuous-wave optical signal generated by the laser 101 in FIG. 1 at a microwave frequency of f m =35 GHz, two modulation sidebands with equal optical power appear, as shown in FIG. 6 , which are equally separated from the continuous-wave optical signal by f m =35 GHz. The sideband-to-carrier ratio (SCR) of this optical input carrying a power-to-be-amplified microwave signal is 35 dB, corresponding to an optical modulation depth of about 3.6%. Referring to FIG. 7 , FIG. 7 shows an optical spectrum of the optical output carrying a power-amplified microwave signal according to the preferred embodiment of the present invention. When the optical input carrying a power-to-be-amplified microwave signal is injected into the microwave-power amplification laser under the same ξ i =1.1 and f i =21 GHz, the power of the lower-frequency modulation sideband of the optical input is so considerably increased that SCR=−2 dB, as shown in FIG. 7 , which results from the period-one nonlinear dynamics. Referring to FIG. 8 , FIG. 8 shows microwave spectra of the optical input and the optical output, respectively, according to the preferred embodiment of the present invention. As shown in FIG. 8 , the substantial enhancement of the optical modulation depth significantly amplifies the microwave power by 27 dB. In addition, the linewidth and phase noise of the microwave signal are similarly kept after microwave power amplification, which therefore greatly improves the signal-to-noise ratio and which in turn significantly enhances the detection sensitivity and the transmission distance.
[0053] By adjusting ξ i and f i , the frequency difference f 0 between adjacent frequency components and the power of each frequency component in FIG. 5 can be varied, resulting in different characteristics of the period-one nonlinear dynamics of the microwave power amplification laser. Therefore, this feature can be utilized to adjust the microwave gain of a microwave signal, or to achieve the same microwave gain for microwave signals of different frequencies. More discussion on this feature will be provided below.
[0054] Referring to FIG. 9 , FIG. 9 shows microwave power and microwave gain in terms of the input sideband-to-carrier ratio (SCR) after microwave power amplification according to the preferred embodiment of the present invention. Under the same ξ i =1.1, f i =21 GHz, and f m =35 GHz, the characteristics of the period-one nonlinear dynamics in the microwave-power amplification laser are the same. Accordingly, as shown in FIG. 9 , the same output microwave power is obtained for different values of input SCR, leading to a reducing microwave gain as the input microwave power increases.
[0055] Referring to FIG. 10 , FIG. 10 shows microwave gain and output sideband-to-carrier ratio (SCR) in terms of the microwave frequency after microwave power amplification according to the preferred embodiment of the present invention. Different characteristics of the period-one nonlinear dynamics can result in different f 0 but a same output SCR value, which can be used to obtain a same microwave gain for input microwave signals of different frequencies. As shown in FIG. 10 , a set of different characteristics of the period-one nonlinear dynamics is so obtained for f m ranging from 25 to 35 GHz that the output SCR of these microwave signals is around −0.8 dB, leading to the same microwave gain of 29 dB. It can be observed in FIG. 10 that the output SCR is also around −0.8 dB for f m =35 to 63 GHz, suggesting that the same microwave gain of 29 dB can also be achieved for these microwave signals.
[0056] Referring to FIG. 11 , FIG. 12 , and FIG. 13 , FIG. 11 shows spectra of the input data signal and the output data signal, respectively, according to the preferred embodiment of the present invention, FIG. 12 shows bit-error ratios (BERs) of the input data signal and output data signal, respectively, in terms of the received optical power according to the preferred embodiment of the present invention, and FIG. 13 shows eye diagrams of the input data signal and the output data signal, respectively, according to the preferred embodiment of the present invention. To investigate whether the aforementioned microwave power amplification leads to the performance improvement of the communication networks, analyzing the quality of the data signal carried by the microwave signal before and after microwave power amplification is conducted. First, as shown in FIG. 11 , while the power of the microwave signal is enhanced by 10 dB, that of the data signal (at a bit rate of 1.25 Gb/s) carried by the microwave signal (at f m =35 GHz) is similarly increased by about 7 dB. Since the frequency range of the power-amplified data signal is on the order of GHz, the microwave power amplification apparatus and method of the present invention can be applied to the RoF networks with a data rate of at least several Gb/s. Second, as shown in FIG. 12 , the bit-error ratio (BER) analysis of the data signal shows that, after microwave power amplification, not only a similar BER behavior is obtained as a function of the received optical power but also a lower received optical power (about 4 dB lower) is necessary to achieve a typically required BER of 10 −9 . This indicates that the data detection sensitivity is enhanced, and that the transmission distance and efficiency are also similar improved. The result of FIG. 13 suggests that, in the above embodiment, the adequate power difference between the binary data for high bit rates ensures correct retrieval of the data signal to be transmitted.
[0057] Refer to FIG. 5 to FIG. 13 . At the period-one nonlinear dynamics, FIG. 5 shows that the power of the lower-frequency oscillation sideband is close to that of the regeneration, which is only 2 dB weaker in the present embodiment. The microwave power amplification apparatus and method of the present invention take advantage of this characteristic to achieve microwave power amplification. The optical input carrying the power-to-be-amplified microwave signal shown in FIG. 6 is a typical optical double-sideband modulation signal, and FIG. 7 to FIG. 13 demonstrate the results and analyses of the optical double-sideband modulation signal after microwave power amplification using the period-one nonlinear dynamics. Since similar processes and results of the aforementioned microwave power amplification are observed for an optical input that is an optical single-sideband modulation signal, no matter whether it exhibits a lower- or higher-frequency modulation sideband, they will not be repeated.
[0058] It should be understood that the present invention is not limited to the details thereof. Various equivalent variations and modifications may still occur to those skilled in this art in view of the teachings of the present invention. Thus, all such variations and equivalent modifications are also embraced within the scope of the present invention as defined in the appended claims. | Period-one nonlinear dynamics of semiconductor lasers are utilized to provide an apparatus for photonic microwave power amplification in radio-over-fiber links through optical modulation depth improvement. The microwave power amplification apparatus includes a microwave-modulated optical signal generation module and a microwave power amplification module. The amplification capability of the present microwave power amplification apparatus covers a broad microwave range, from less than 25 GHz to more than 60 GHz, and a wide gain range, from less than 10 dB to more than 30 dB. The microwave phase quality is mainly preserved while the microwave power is largely amplified, improving the signal-to-noise ratio up to at least 25 dB. The bit-error ratio at 1.25 Gb/s is better than 10 −9 and a sensitivity improvement of up to at least 15 dB is feasible. | 7 |
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 11/306,273, filed Dec. 21, 2005, which claims the benefit of U.S. provisional patent application Ser. No. 60/639,669, filed Dec. 28, 2004, both of which are hereby incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates to valves used in fluid handling systems including fluid transport tankers and, more particularly, to a valve having a modular lining system that protects the metallic valve components from adverse effects of contact with corrosive fluids, wherein the lining is easily cleaned and easily replaced when damaged.
BACKGROUND OF THE INVENTION
[0003] Fluid handling systems are often used in handling corrosive materials or products that must be maintained in a high state of purity. One type of fluid handling system includes bulk fluid transport tankers. Fluid tankers and associated piping and valve components are typically made of stainless steel or other corrosion resistant metallic material. Some tanks are passivated at predetermined time intervals to maintain a protective coat on the tank interior to help increase corrosion resistance. However, tankers are often used to carry acids and corrosive chemicals that will attack virtually any type of metal over a period of time. Examples of such fluids include hydrochloric acid, hydrofluoric acid, ferric chloride, and bleach, to name a few. Transport of these chemicals requires that the tank surfaces and associated components are protected from adverse effects of contact with the cargo by a lining material. Typical tank lining materials are natural rubber, chlorobutyl, or hypalon. The associated piping and valves have also been lined.
[0004] Efforts have been made to develop a lined valve to use with such applications. These prior art lined valves typically have a lining permanently affixed (i.e. bonded, molded) to the interior of the valve. This creates a problem if the lining of the permanently lined valve is damaged, as the entire valve will need to be replaced.
[0005] Another problem is that the tank and tank valves must be cleaned periodically, especially when the tank will be used to transport a different chemical. The new chemical may react with the previously transported chemical which may not have been completely removed from the tank or valve components. The prior art permanently lined valves are difficult to clean within the confines of the valve.
[0006] The lining material typically used in prior art valves are relatively soft and somewhat flexible. The valves are typically designed so that the various lining pieces seal against each other. This can lead to cold flow and eventual leaking of the valve.
[0007] Another limitation of prior art valves involves the flow blocking device (butterfly disc, diaphragm, rotary plug, or ball), which is also typically coated with a permanently affixed lining material. If the lining on the flow blocking device is damaged, the entire valve needs to be replaced. Also, the permanent coating increases the thickness of the flow blocking device thereby reducing the volume of fluid flow.
[0008] Accordingly, there is need for providing an improved lined valve over current known valves that overcomes one or more of these problems.
SUMMARY OF THE INVENTION
[0009] The present invention overcomes at least one disadvantage of the prior art by providing a valve comprising a valve body comprising a tubular first body portion having a first end and a second end, and a tubular second body portion affixed to and intersecting the first body portion, the second body portion having a first end distal from the first body portion; a tubular first lining removably positioned in the first body portion; a tubular second lining removably positioned in the second body portion, the second lining sealingly engaging an aperture in the first lining; and an actuator removably attached to the first end of the first body portion or the first end of the second body portion, the actuator comprising means for selectively stopping and allowing fluid flow through the valve.
[0010] The present invention further overcomes at least one disadvantage of the prior art by providing a method of assembling lining into a valve body comprising a cylindrical first body portion having a first end and a second end, and a cylindrical second body portion intersecting the first body portion, the second body portion having a first end distal from the first body portion, the method comprising the steps of slidably inserting a non-metallic first lining into the outlet end of the first body portion such that the first lining extends from the outlet end to the actuator attachment end of the first body portion; slidably inserting a non-metallic second lining into the inlet end of the second body portion such that the second lining sealingly engages an aperture in the first lining and such that the second lining extends from the sealed engagement with the first lining to the inlet end of the second body portion; slidably inserting a non-metallic piston of an actuator into the first lining or the second lining; and attaching the actuator to the end of the corresponding body portion.
[0011] These and other advantages will be apparent upon a review of the drawings and detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] This invention will now be described in further detail with reference to the accompanying drawings, in which:
[0013] FIG. 1 is an elevational side view of an end portion of a tanker trailer of a type usable with the valve of the present invention;
[0014] FIG. 2 is an elevational end view of an end portion of the tanker trailer of FIG. 1 ;
[0015] FIG. 3 is a cross-sectional view of an embodiment of the valve of the present invention in a valve open condition;
[0016] FIG. 4 is a cross-sectional view of the valve of FIG. 3 shown in a valve closed condition;
[0017] FIG. 5 is an elevational end view of the valve of FIG. 3 ; and
[0018] FIG. 6 is a cross-sectional exploded view showing the modular lining components and the valve body and how the modular lining components are removed from the valve body and how they are inserted into the valve body.
DETAILED DESCRIPTION OF THE INVENTION
[0019] This invention will now be described in detail with reference to various embodiments thereof. Referring now to FIG. 1 , an end portion of a tanker trailer 110 is shown. Tanker trailer 110 typically has a stainless steel cargo tank 112 which may be used for transporting fluids including acids, solvents or other chemicals. When hauling these types of materials, the interior 114 of tank 112 is typically lined to protect the tank from adverse effects of contact with the cargo. Typically these tank interiors 114 are lined with natural rubber, chlorobutyl, or hypalon. Piping 116 is shown attached to tank 112 for loading/unloading the cargo. The piping 116 is also preferably lined. Associated with the piping 116 , valve 118 is shown in a typical position where the valve of the present invention may be utilized.
[0020] The lined valve assembly 10 of the present invention is shown in FIG. 3 in a valve open condition, in FIG. 4 in a valve closed position, and in FIG. 5 in an outlet end view. The valve assembly 10 comprises a metallic valve body 20 comprising a cylindrical first body portion 30 having an outlet end 32 and an actuator attachment end 34 , and a cylindrical second body portion 40 fixably attached and intersecting the first body portion 30 in a generally perpendicular position, the second body portion having an inlet end 42 distal from first body portion 30 . Although shown herein as a ninety degree elbow, it is contemplated that other valve configurations could be used with the present invention. The valve assembly 10 further comprises a cylindrical first non-metallic lining 50 removably positioned in the first body portion 30 and extending from the outlet end 32 to the actuator attachment end 34 of the first body portion 30 . A cylindrical second non-metallic lining 60 is removably positioned in the second body portion 40 . A seal 80 on a leading end 62 of the second lining 60 sealingly engages an aperture 52 in the first lining 50 . The second lining 60 extends from the engagement with the first lining 50 to the inlet end 42 of the second body portion 40 . The valve assembly 10 further comprises a means 70 for selectively preventing and allowing fluid flow between the outlet 32 and the inlet 42 of the valve 10 . Means 70 is shown herein as an actuator assembly 70 removably attached to the actuator attachment end 34 of the first body portion 30 . Actuator assembly 70 comprises a reciprocal plug 72 shown herein as a cylindrical, non-metallic piston 72 sealingly moveable within the first lining 50 of the first body portion 30 for selectively preventing and allowing fluid flow between the outlet 32 and the inlet 42 of the valve 10 . In the valve open condition, the reciprocal plug 72 is completely removed from the fluid passageway allowing maximized fluid flow through the valve 10 . The actuator assembly 70 further comprises a main spring 74 , which keeps the valve assembly 10 in a closed position. When the actuator 70 is hydraulically activated, the main spring 74 is compressed and the piston 72 is retracted, opening the valve assembly 10 . An indicator rod 76 extends from the end of the actuator assembly 70 signaling that the valve assembly 10 is in a valve open condition. Although shown herein as a hydraulically actuated valve, the invention is not intended to be limited as such, and it is contemplated that actuation could be accomplished by any standard means such as manual or pneumatic actuation.
[0021] The linings 50 , 60 form a modular replaceable interlocking lining system. The linings 50 , 60 are formed of rigid lining materials formed to removably slide into the valve body, and do not need to be molded or bonded to the valve body, as best shown in FIG. 6 . The valve 10 is assembled by slidably inserting the first lining 50 into the outlet end 32 of the first body portion 30 such that the first lining 50 extends from the outlet end 32 to the actuator attachment end 34 of the first body portion 30 . Lining 50 is oriented such that aperture 52 is aligned with the second body portion. Lining 50 includes a lining flange 54 that registers against a corresponding recess 38 in the outlet attachment flange 32 of the first body portion 30 and acts to axially locate the lining 50 in the first valve body portion 30 . It is noted that the lining flange 54 extends slightly beyond the outlet end 32 to ensure a proper seal with the lining of the adjacent piping (not shown). The lining flange 54 can also be used to aid in the removal of the lining 50 when the lining 50 is configured as a snug fit with the first body portion 30 .
[0022] The next step is to slidably insert the second lining 60 into the inlet end 42 of the second body portion 40 such that the seal 80 on the leading end 62 of the second lining 60 sealingly engages the aperture 52 in the first lining 50 such that the second lining 60 extends from the sealed engagement with the first lining 50 to the inlet end 42 of the second body portion 40 . Lining 60 includes a lining flange 64 , which registers against a corresponding recess 48 in the inlet attachment flange 42 of the second body portion 40 and acts to axially locate the lining 60 in the second valve body portion 40 . It is noted that the lining flange 64 extends slightly beyond the inlet end 42 to ensure a proper seal with the lining of the adjacent piping (not shown). As with the first lining 50 , the lining flange 64 can also be used to aid in the removal of the lining 60 when the lining 60 is configured as a snug fit with the second body portion 40 .
[0023] The next step involves slidably inserting the piston 72 of the actuator assembly 70 into the first lining 50 and attaching the actuator 70 to the actuator attachment end 34 of the first body portion 30 . The piston 72 sealingly engages the interior of the first lining 50 utilizing a seal 82 on the leading end of the piston 72 and a seal 84 on a trailing end of the piston. Secondary seals 86 can be utilized as desired. It is noted that piston 72 may utilize a stepped configuration is association with a stepped interior of the first lining 50 .
[0024] The plug or piston 72 may be made of the same material as the linings 50 , 60 . It is also contemplated that the piston 72 may be made of a different lining material or of a metallic material that is covered with a lining material.
[0025] When the valve 10 needs to be cleaned, or if one or more of the linings is worn or damaged, or if the installed linings are unsuitable for a fluid to be used in the tank 112 , the valve assembly 10 can be easily disassembled and the components cleaned or replaced as needed. To disassemble the valve assembly 10 , the steps are generally the reverse of the assembly (although the order of the removal of the actuator assembly 70 and the second lining 60 can be reversed). The second lining 60 needs to be removed prior to removal of the first lining 50 as the second lining helps lock the first lining 50 in position by preventing axial movement of the lining 50 in the first body portion 30 .
[0026] Unlike existing valves, the modular nature of the linings of the valve of the present invention allows more rigid materials to be used. Since more rigid lining materials can be used, this valve incorporates seals between the lining components, as discussed above, to eliminate cold flow problems. Examples of suitable lining materials include, but are not intended to be limited to, UHMW Polyethylene, Teflon® (PTFE), PVC and the like. Accordingly, the present invention allows a wider range of materials to be selected with less restriction in comparison to prior art lined valves.
[0027] Although the present invention has been described above in detail, the same is by way of illustration and example only and is not to be taken as a limitation on the present invention. | A modular lining system for a valve body for use in fluid handling systems including fluid transport tankers, and a method for lining a valve body using the modular lining system. The lining system is slidably inserted into the valve body to protect the valve body from corrosive or other damaging materials. The liners are placed such that they are easily removable for cleaning or replacing when damaged. An actuator comprising a piston is actuated within one of the liners to selectively allow and stop fluid flow. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention concerns a jack-hammer, and particularly its structure and the assembly of the various parts thereof.
2. Description of the Prior Art
Basically, a jack-hammer includes a cylindrical body housing having a reciprocating piston therein which is reciprocally moved by the action of compressed air distributed by an oscillating pellet.
Usually, this cylindrical body is made of forged steel and machined so as to obtain:
a guiding hole for guiding the tool or working pick;
a seat located inside the cylinder to limit the forward stroke of the piston;
compressed air distributing channels, one of them leading to the front of the cylinder and the other to the rear of the said cylinder; and
a housing for the compressed air distribution unit, controlled, for example, by a check valve which is itself controlled by a lever pivotally mounted on the jack-hammer handle.
One of the disadvantages of the above systems is that the machining of such a cylindrical body housing is often complex and this can cause the cost of the jack-hammer to be high.
Furthermore, the access to the various components in the cylindrical body housing is accomplished with difficulty which complicates the maintenance of the jack-hammer in corroding conditions (such as for example, public work sites, mines and the like).
Finally, the cost of the jack-hammer is also increased when equipped with a muffler or noise abatement system as well as with a handle shock absorbing system.
The purpose of this invention is to overcome these disadvantages, and to build a light and economical jack-hammer, and still improve its reliability and efficiency, and greatly facilitate its maintenance. All of these results are achieved by the present invention which provides a new structure adapted to a silent jack-hammer and which provides a shock absorber equiped handle.
SUMMARY OF THE INVENTION
A jack-hammer modified according to this invention is of a type similar to those which are controlled by the reciprocating movement of a piston moving inside a cylinder through the action of a compressed air distributor and is characterized by:
a cylindrical tube which is the body of the device;
a counterbored sleeve, including a central, axial hole; this counterbored sleeve is at least partially fitted lengthwise inside the tube at one end along the axis of the cylindrical tube;
a distributor unit comprising two parts mounted on the opposite end of the tube and closes off the rear end of the tube;
detachable mounts to assemble and lock together the tube, the two distributor parts, a catch or pin and a moulded part fitted around the tube to channel the compressed air flow system;
a casing made of a shock absorbing material and protecting most of the operating areas of the tube, but constructed of a material which is strong enough to form the handle of the machine; and
a piston moving between a stop piece formed by the rear end of the guiding sleeve of the pick or tool and the front wall of a part of the detachable air distribution system.
According to another characteristic, the compressed air distributor system is obtained through casting or molding of a material such as aluminum or aluminum alloy, or even a synthetic material such as rigid elastomer or rubber. This casting is made on a cylindrical die equipped with at least two side inserts to provide:
a relief channel connecting the distributor to the front part of the cylinder by the first insert of the die; and
an air muffler and exhaust chamber communicating with holes provided on the side wall of the cylinder tube by the second insert of the die.
According to another characteristic, the cast part forming the compressed distributor system includes at one end, a recess located in an internal wall which forms the inlet chamber for the compressed air coming from an air distributor feeder.
According to another characteristic, the distributor block is fastened inside the tube by a cotter pin introduced in holes in the tube walls of each distributor part, the casting and the shock absorbing casing. This cotter pin is locked by the resilient casing itself.
According to another characteristic, the casing provides above the cylindrical tube, a hollow handle equipped with a lever which is pivotally connected at one end of the handle. The other end of the lever acts against the back end of a sliding rod contained in the handle. The sliding rod controls, through its front end, a truncated cone block or similar piece, which is equipped with a spring mechanism and held in such a position that it shuts off the distributor chamber air inlet. Thus, when the sliding rod is pushed, it pushes the block against the spring mechanism so as to tilt it and force its base away from the inlet hole. The air is thus fed into the distributor unit and which causes the oscillating pellet in the distributor unit to vibrate.
According to another characteristic, the counterbored sleeve is press fitted to the inside of the front end of the tube, with the distributor block being locked thereto by a simple cotter pin. Thus, by pulling the pin, it is possible to disassemble, from the back of the jack-hammer, that is, near the handle, all of the moving components including the distributor and the piston.
This construction is clearly aimed at limiting to simple, quick and inexpensive operations, the machining of metal or even rubber parts (such as drilling or boring of simple elements). Moreover, the die used for the construction of the compressed air system is a simple mechanical mold producing a part which does not require any further boring on the outside diameter of the tube.
It is thus possible to obtain an economical jack-hammer, wherein maintenance is made easier by the accessibility of the distributor components through the cavity in the handle, without altering the design of the tool. Finally, the jack-hammer thus obtained is equipped with an exhaust muffler and a handle shock absorbing system.
Among its main advantages, and besides the simplified machining and molding procedures, the following features should be noted:
lightness of the device which can operate in any position;
reliability and easy replacement of the distributor, compressed air feeding control unit (the normal check valve being replaced by a swiveling block); and
safety lock of the air through the casing, the elasticity of which allows for the quick removal of the cotter pin.
BRIEF DESCRIPTION OF THE DRAWINGS
The attached drawings, given as a non-exclusive example, permits a better understanding of the invention.
FIG. 1 shows a longitudinal cross sectional view of a jack-hammer according to the invention.
FIGS. 2 through 6 show sectional views taken along lines 2--2, 3--3, 4--4, 5--5 and 6--6 respectively of FIG. 1.
FIG. 7 is an exploded view of the main components of the device.
FIG. 8 shows the detail of the structure of the distributor block.
FIG. 9 is a partial detailed sectional view of the compressed air inlet control system.
FIGS. 10 and 11 are, respectively, a longitudinal cross sectional view and a cross sectional view taken along line 11--11 of FIG. 10 in which the air channels are obtained by casting of parts made of aluminum or similar material about the tube and covering the cast part by a noise-insulating casing as a first alternate embodiment of the invention.
FIGS. 12 and 13 represent another version in which the exhaust muffler chamber is encapsulated by a moulding of noise insulating material which is fastened to the shock absorbing casing of a second alternate embodiment.
FIGS. 14 and 15 show a longitudinal cross sectional view and a cross sectional view along line 15--15 of FIG. 14 of a third alternate embodiment of the invention.
FIGS. 16 and 17 show a sectional view and longitudinal cross section view of a fourth alternate embodiment of the invention in which the air channel walls are noise insulated.
FIGS. 18 and 19 illustrate a longitudinal cross sectional view and a sectional view along line 19--19 of FIG. 18 which shows a fifth alternate embodiment which includes a secondary tube within the shock absorbing casing.
FIG. 20 shows a perspective view of the handle and the opening providing access to the air distributor unit through the cavity in the handle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The drawings illustrate a percussion device of the hand jack-hammer type 11. This device includes:
a body consisting of a tube 1;
a compressed air distribution unit 2 with an inlet port 3; the distribution unit 2 includes two parts 4 and 5 between which a pellet 6 oscillates as best shown in FIG. 8. The distribution unit 2 is located inside and at the rear part or rightward portion of the tube 1 as viewed in FIG. 1;
a sleeve press is fitted on the front part of the tube which sleeve 7 includes a hexagonal bore 8 which constitutes the axial guide for a pick or tool (not shown);
a piston 9 reciprocates between the rear end of the sleeve and the front cross-wall of the distributor, the piston 9 moving within the cylinder 10 defined by the side wall of the tube 1;
a hollow handle 12 is made in one piece from a casing 13 which is cast to the side walls of the device;
a compressed air inlet control lever 14;
a cotter pin 15 which locks the distribution unit 2 to the rear part of the tube 1; and
at least one cast part 16 on the outside of the rear part of the tube 1, the part 16 constituting for example, the cavity forming the air inlet chamber 17, the relief channel 18 connecting the front of the cylinder to the distribution unit 2 and finally, an exhaust chamber 19 allowing for a silent operation of the device 11.
The assembled device 11 is shown in FIG. 1. FIGS. 2 through 6 however, respectively illustrate various cross sectional views of the device 11, along lines 2--2 through 6--6, perpendicular to the longitudinal axis of the device 11. These sections show, as discussed below, the simple construction and assembly of the device.
The basic components of the device 11 are shown in the exploded view of FIG. 7. The distributor unit 2, as well as the tube 1 and the cast part 16, have their side walls drilled with holes 20, 21 and 37, respectively for the installation of the lock-pin or cotter pin 15 therethrough. Other holes such as 22, 23 and 24 provide the compressed air supply holes. The sleeve 7 has a counterbore and is machined so that its cylindrical rear portion 8a can be press-fitted in the front end of the tube 1. As stated previously, the rear part of the tube 1 receives the distribution unit 2. The part 16 is cast on a cylindrical die similar in shape to the tube 1, and is equipped with side metal inserts used to form the cavities 17, 18 and 19 in a pattern well known in the art. After the items 1, 2, 7 and 16 have been positioned and locked with one another (they are then aligned as shown in FIGS. 1 through 6), the casing 13 has a rear portion which is drilled through from side to side to form a cavity 25 as best shown in FIGS. 1 and 2 to thus form a shock absorbing handle 12. The cavity 25 communicates with the inside of tube 1 through a hole 26 drilled in the casing 12.
FIG. 8 shows the structure of the distribution unit 2, including:
two parts 4 and 5 assembled one inside the other;
one oscillating pellet 6; and
holes are provided to lock the two parts together, on the one hand, and the holes also distribute the air into the inlet 28, then to the relief channel 29, and to the percussion channel 30.
The stroke of the pellet 6 is defined by the respective positions of the seats 31 and 32 when the parts are locked together against the counterbore 33.
The inlet air control to the device 11 is illustrated in FIGS. 1 and 9. The lever 14 is pivotally connected to the handle. The lever 14 controls, through its free end 14a, the movement of the sliding rod 34. One end of the rod 34 pushes against the side face of a truncated cone block 35. The base of the cone block 35 shuts off the air inlet (the deactivated position is shown in FIG. 1). When the lever 14 is pushed, the rod 34 pushes against the block 35 and causes the block to swivel so that the opposite face comes in contact against the wall of the port 3. The peripheral sealing flange of the large base 36 moves away from the inlet hole (FIG. 9) which induces the feeding of compressed air to the inlet chamber 17 and then to the distributor unit 2.
The assembly of the jack-hammer is accomplished following these steps and referring to FIGS. 1 through 8:
inserting the piston 9 in the tube 1;
press-fitting the sleeve 7 into the tube 1, the sleeve having an axial bore which defines a small diameter for guiding the power from the piston 9 to the pick or tool;
assembling the two parts of the distributor unit 2 together which is then mounted on the rear end of the tube 1;
positioning the cotter-pin 15 into the holes 20 and 21 which locks the parts 4 and 5 in the tube 1. The external machined portion of the cotter-pin 15 is received in the bored, centered hole 37 in the cast part 16;
casting in situ, the resilient material casing 13 to the side walls of the device. The casing 13 therefore covers most of the metal elements and provides, in the rear, a hollow portion 12 which forms the handle and allows for the disassembly and maintenance (or replacement) of the working components, particularly the distributor unit 2 and the piston 9 as shown in FIGS. 1 and 20; and
drilling holes 38 in the casing 13. The casing 13 is made of 85 shores hardness rubber, or similar elastomer. The holes 38 are in alignment with the pin 15 positioning holes. The holes 38 have a slightly smaller diameter than that of the cotter-pin 15 so that the pin is axially locked but the elasticity of the rubber allows for the removal of the pin to permit the disassembly of the unit.
The device is now ready to operate, the compressed air distribution sequence being defined as follows and referring to FIGS. 1 and 4 through 9:
(a) percussion stroke: the air enters past the block 35, through hole 27 (FIG. 9), into the inlet chamber 17, and circulates through the radial holes 40 in the tube 1, hole 41 the in the distributor and into an annular pressure chamber 42 (FIG. 8). The pellet 6 is pushed against the rear seat 32 of the distributor, and the compressed air flows as shown by arrow 30 against the back of the piston.
(b) relief stroke: the pellet 6 oscillates and the chamber 42 communicates with the holes 22 in the distributor and holes 23 and 24 in the tube and with the relief channel 18. In this position, the pellet 6 rests against its seat 31 and the compressed air is sent to the front of the cylinder 10, following the arrow 29.
(c) exhaust: the air let into the cylinder 10 is exhausted as quickly as possible. For this purpose, the exhaust holes 44 are drilled in the tube 1 to let the cylinder 10 communicate with the exhaust chamber and the muffler 19. The air circulates in this chamber so as to regulate the air flow and thus eliminates the pressure "peaks" resulting from the alternating movement of the piston 9. Finally, vents 45, 46 are provided in the casing 13 and in the casting 16 respectively (which is press-fitted around the cylinder tube) to let the air exhaust outside.
From the foregoing, it is apparent that the compressed air jack-hammer is simple in construction. One of the main advantages of the present invention is to combine the "percussion" function, the shock absorbing function of the handle and the "muffling" function in an economical construction. Actually, the machining operations are simple and easy (for example, boring, lathing or drilling).
The base part consists of a tube on which it is possible to adapt a part which is molded or cast in a mold and whose cost is lower than the one required for prior art devices of the same type.
Finally, the disassembly (therefore the maintenance) of the unit is easy. The only operation required is to unlock the distribution unit 2 (by removing the pin 15 which is then forced between the holes 38 of the casing 13), and push on the piston 9 to retrieve, at the back of the device, all of the working parts which are recovered through the cavity 25.
The present invention permits modifications of a few details in the design, say for example, to obtain additional capacity for the cylinder lubricant. Furthermore, the illustrations given as examples in FIGS. 10 through 19 show, in particular, several arrangements (which are not exhaustive) of the compressed air circulating cavities.
According to the construction described in FIGS. 1 through 7, the casting 16 defines, through its fitting on tube 1, the inlet chamber 17, the relief channel 18 and the exhaust chamber 19. FIGS. 10 and 11 show a simpler construction as a first alternate embodiment. This part 56 can be made from an aluminum alloy casting defining the side inlet chamber 50 and the relief channel 51. After molding of a rubber casing 13, a portion of the part 56 remains exposed. On the edges and at 53 of the casing 54, assembly or fastening elements are provided for the installation of a piece 55 made of a noise insulating material such as an elastomer or a rubber. An exhaust chamber 57 is thus formed whose dimensions are limited inside by the external wall of the casting 56 and outside by the internal face of the fastened piece 55. This chamber communicates, through various holes drilled in its walls, both with the cylinder and the outside of the device, the casing 54 being, as previously described, both noise insulating and shock absorbing.
In the second alternate embodiment illustrated by FIGS. 12 and 13, the casing is actually made of at least three pieces, which are fastened together, namely:
the casing 60 is molding on tube 1 after positioning of inserts to provide the inlet 61 and spaces which are open to inlet and exhaust holes for the air circulating inside the cylinder;
a casting 62 which is fastened by its sides on the casing 60 to form a relief channel 63 between its internal wall and the external wall of tube 1; and
another casting 64, fastened in the same fashion as the previous one and designed to form the exhaust chamber 65.
According to the third alternate embodiment illustrated by FIGS. 14 and 15, the tube is equipped with two hollow inserts 71 and 72 to form the chamber 73 and the channel 73 upon moulding of the casing 75. A part rigidly mounted with each of the external shells of the mould provides a space around the tube. This space is then sealed by a piece 76 to form the chamber 77.
According to FIGS. 16 and 17, showing a fourth alternate embodiment, it is possible to line the internal and external walls of the channel 80 and of the exhaust chamber 81 with a noise insulating and shock absorbing material, directly moulded in one piece with the casing and the handle 82. The moulding is then covered by a sleeve 84 which is pressfitted on the embossments 83 and radially positioned by such brackets as 85. The sleeve 84 can be made of aluminum, elastomer or rubber material.
It should be noted that in the alternate embodiments presented in FIGS. 12 through 17, the only machining operations required are the drilling of the tube, and/or the inserts and/or the moulded materials whose edges offer appropriate shapes for the clipping or fastening of detachable castings.
In a fifth alternate embodiment shown in FIGS. 18 and 19, the device's construction is very similar to the one illustrated on FIGS. 14 and 15. The only difference is that the relief channel 90 is insulated by moulding the casing 91 on a tube equipped, besides the side insert 92, with a tubular element 93 which includes elbows on each end and positioned so as to be roughly parallel to the axis of the tube 1. After moulding, the secondary tube 93 is covered by the casing 91, and its end elbows, which are roughly radial, communicate with the holes drilled in the distributor on the one hand, and in the front part of the cylinder on the other hand. The exhaust chamber 94 is enclosed by a prefilled piece 95 which is fastened onto the casing.
Having described my invention, it will become apparent to those skilled in the art it is possible to vary the distribution means, the shock absorbing material, the structure of the air passageways, the air inlet mechanism, and other portions of the invention without departing from the scope or spirit of the invention as defined in the following claims. | A reciprocating piston jack-hammer is provided with an easily detachable air distribution mechanism, a resilient casing for muffling the noise by the emitted air, and a shock absorbing housing. A cylindrical tube houses the reciprocating piston and has molded thereabout a housing with air channels between the housing and the tube. The handle of the jack-hammer has a cavity and a mechanism which controls the supply of compressed air to the distribution system. The distribution system employs two parts, one disposed in the other, with an oscillating pellet between the two parts, which oscillating pellet serves to distribute the incoming compressed air either to drive the piston or to direct the air to a piston relief channel, thereby returning the piston to the upper position. Upon return of the piston to its upper position, the air is exhausted from the cylinder below the piston out to a muffling exhaust chamber, out to the atmosphere. The cavity communicates with the tube so as to permit the accessibility of the air distributor unit through the handle. | 8 |
This is a division of copending application Ser. No. 412,656, filed Nov. 5, 1973, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the processing of yarns, and more particularly pertains to the drawing of a plurality of yarns about draw rolls in adjacent, untwisted relation. The provided process has particular application to the processing of yarn ends, each of which has a different color, which ends are to be subsequently twisted into a single yarn having uniform color properties throughout its length.
In the processing of yarns, the prior art has employed various expedients for purposes of facilitating the drawing of yarn from feed rolls. Thus, in Aelion et al. U.S. Pat. No. 3,337,930 the use of a straight pin between series of draw rolls to prevent slippage and assist in the drawing of the yarns from a supply source is shown. Although helpful in positioning the yarns on the draw rolls, such pins do not control the yarn relative dispositions on the draw rolls so as to prevent cabling thereof.
Also, combing or use of pins has been employed for controlling the order of yarn ends in the draw zone. However, combing or the use of a series of yarn-spacing pins has in the past caused "lace-up" and other operating problems. In addition, the separation of the yarn ends by spacer pins allows heat loss to more readily occur in the interval between the draw rolls and yarn sources, thereby rendering the yarn drawing operation less efficient.
In accordance with one embodiment of the invention, a plurality of yarns of different colors, which are to be combined subsequently into a single yarn, are drawn over a set of draw rolls and maintained in an adjacent contiguous relationship while running on the rolls. A means for effecting the desired yarn relationship comprises a roller having an annularly relieved concave outer periphery. The guide is placed at an angle of approximately 45° relative to the plane of the yarns in the draw zone defined by the yarns between the feed rolls and draw rolls. The concave guide surface of the roller displaces the yarns a small interval of less than one inch from their original plane and urges them into contiguous relationship.
Accordingly, it is an object of this invention to provide a method of simultaneously drawing a plurality of yarns over a set of draw rolls and maintaining the yarns in the same relative position by having the yarns engage a concave guide surface set at an angle to the plane of the yarns moving onto the draw rolls.
It is another object of the invention to provide a novel guide having a concave surface adapted to engage a plurality of yarns in the course of moving from feed rolls onto draw rolls whereby the relative order of the yarns is maintained and cabling of the yarns is avoided.
The above and other objects of this invention will become apparent from the following description when read in the light of the accompanying drawing in which:
FIG. 1 is a side view illustrating in a somewhat schematic manner apparatus whereby a plurality of yarns are engaged by a concave guide surface in the course of passing from feed rolls to draw rolls in accordance with the provided invention;
FIG. 2 is an end view of the apparatus illustrated in FIG. 1;
FIG. 3 is a fragmentary top plan view of the apparatus of FIGS. 1 and 2, partly broken away, illustrating the angular disposition of the concave roller of this invention to the plane of the yarns passing between the feed and draw rolls;
FIG. 4 is a sectional view illustrating a guide roller of this invention in elevation and depicting the relative disposition of the yarns relative to the roller as viewed along the normal yarn paths leading from the feed rolls; and
FIG. 5 is a view similar to FIG. 4 illustrating the roller-yarn relationship at the points of roller-yarn contact.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 of the drawing, three yarn source rolls 10, 12 and 14 which may have wound thereon yarns R, W and B of three different colors are disposed above feed rolls 16U and 16L. After engaging guides 15, the yarns are wound about the feed rolls prior to passing to the draw rolls 18U and 18L. The latter rolls are driven at a desired increased rate of speed relative to the speed of the feed rolls so as to effect the desired stretching of the yarns R, W and B wound thereabout.
In accordance with this invention, the yarns R, W and B are maintained in desired untwisted, side-by-side relationship on the draw rolls by engaging a concave guide surface such as roller 20 having an annularly relieved concave outer periphery as is most clearly seen from FIGS. 4 and 5. The roller 20 may be rotatably mounted on pin 22.
Roller 20 is preferably formed of ceramic or other wear-resistant material or composition. The roller 20, upon engaging the yarns R, W and B slightly displaces the same from the vertical plane defined by the normal straight-line yarn passage from the feed rolls to the draw rolls toward the axes of said rolls as is clearly seen from FIG. 2. The linear displacement of the engaged yarn, between the normal plane illustrated in dotted lines in FIG. 2 and the true yarn location illustrated in full lines is preferably less than one inch in the vicinity of roller engagement.
The yarns upon engaging the periphery of roller 20, are gathered into an adjacent relationship illustrated in FIG. 5 from the spaced relationship illustrated in FIG. 4. It will be noted from FIG. 5 that the curvature of the guide surface is such that the yarns are in substantially horizontal alignment thereon at the points of contact, in which alignment they proceed to the underlying draw rolls. As a result of contacting roller 20, the yarns R, W and B are guided about the peripheries of draw rolls 18U and 18L without twisting or cabling. The relative yarn dispositions illustrated in FIGS. 1 and 3 are schematic with the actual yarn relationships being more clearly shown in FIGS. 4 and 5.
It is seen from the figures of the drawing that roller 20 comprises a cylinder which has been annularly relieved about its periphery. Thus, a section taken through the longitudinal axis thereof defines a planar figure having opposed curved edges coincident with the roller outer periphery. Such curves comprising the concavity of the roller define a surface whereby yarns engaging the same are urged toward the longitudinal midpoint of the roller comprising the deepest point of the curve. (See FIG. 5)
The maintaining of the same relative dispositions between yarns R, W and B is of particular importance where such yarns are of different colors and are to be subsequently employed in the formation of a heather product as by entangling such yarns into a single yarn having complete color uniformity. Also, the yarns, by being maintained in the same adjacent relationship across the draw rolls, are, of course, easier to string up.
The guide roller 20, by way of example, may have the concavity of its outer periphery disposed in a plane traversing the roller longitudinal axis formed along a one and one-half inch radius. The guide roller 20 controls the relative order of the yarns, controls placement of such yarns on the draw roll and maintains the yarns in a relatively tight yarn bundle (see FIG. 5) so as to minimize heat loss which is undesired in the course of passing the yarns from the yarn sources to the draw rolls. Accordingly, the steps above described are beneficial even when processing yarns of the same color since a more efficient operation is assured.
The foregoing process steps may be employed, for example, as preliminary steps in the formation of a heather product made from yarns of a thermoplastic material such as polypropylene. The assurance of uniform color in the yarns employed in such product, in turn, assures the absence of color streaks. | A plurality of yarns are drawn from supply sources onto feed rolls and over a set of draw rolls in adjacent relationship. The yarns are urged into a desired contiguous relationship on the draw rolls by a concave guide surface in the course of passing from the yarn feed rolls to the draw rolls. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to photon detection in general, and more particularly to amplifiers for single photon readout of semiconductor photodetectors in pixellated imaging arrays.
2. Description of the Related Art
Optical sensors transform incident radiant signals in the X-ray (λ<0.001 μm), ultraviolet (λ=0.001-0.4 μm), visible (λ=0.4-0.8 μm), near infrared (IR) (λ=0.8-2 μm), shortwave IR (λ=2.0-2.5 μm), mid IR (λ=2.5-5 μm), and long IR (λ=5-20 μm) bands into electrical signals that are used for data collection, processing, storage and display such as real-time video. Available conventional photodetectors such as photodiodes and photoconductors are inexpensive, exhibit bandwidths that support current video frame rates, are sensitive to wavelengths well into the long IR band, and exhibit a high degree of uniformity from pixel to pixel when used in an imaging array. However, these photodetectors have no gain, i.e. each incident photon generates, at most, a single electron; these imaging systems thus work very well only in moderate to bright light conditions. They provide electrical signals at low light levels that are too small to be read-out by conventional readout circuits.
In conditions of low ambient light, the standard photodetector is often replaced with an avalanche photodiode that provides gain such that conventional readout circuits, such as charge coupled devices, i.e. CCDs, can read out the data at video frame rates with a high signal-to-noise ratio (SNR). The fabrication of avalanche photodiodes is much more difficult and expensive than standard photodetectors because they must exhibit very high controlled gain and very low noise. Furthermore, currently available avalanche photodiodes exhibit relatively poor uniformity, are constrained to shorter wavelengths than standard photodetectors (0.7 μm), and have limited sensitivity due to their relatively low quantum efficiency. Imaging intensified systems use an array of avalanche photodiodes or microchannel plates to drive respective display elements such as CCDs or phosphors, and have even lower wavelength capabilities (approximately 0.6 μm max) due to the limitations of the photodiode.
Chamberlain et al. “A Novel Wide Dynamic Range Silicon photodetector and Linear Imaging Array” IEEE Transactions on Electron Devices, Vol. ED-31, No. 2, February 1984, pp. 175-182 describes a gate modulation technique for single photon readout of standard photodetectors. Chamberlain provides a high gain current mirror that includes a load FET whose gate is connected to its drain to ensure subthreshold operation and to eliminate threshold voltage (V T ) non-uniformity. The pixel-to-pixel V T non-uniformity associated with standard silicon CMOS fabrication processes would otherwise substantially degrade the performance of the imaging array. The signal from the photodetector is injected into the load FET thereby producing a signal voltage at the gate of a gain FET. This signal modulates the gain FET's gate voltage, thereby storing integrated charge in a storage capacitor that is read out and reset via a pair of FET switches.
Although Chamberlain's particular gain modulation technique provides a large dynamic range and is useful for detecting signals across a broad spectral range, the current mirror's bandwidth severely restricts the imaging array's bandwidth. Specifically, the dominant RC time constant is the parallel combination of the photodetector's capacitance and the resistance of the load FET. In subthreshold operation, the FET's transconductance is very low and, hence, its load resistance is very large, at >10 14 ohms; the minimum resulting RC time constant is on the order of seconds. Thus, Chamberlain's gate modulation technique is only practically useful for imaging daylight scenes or static low-light-level scenes such as stars. Furthermore, to achieve large current gain, the load FET is typically quite small. As a result, the load FET exhibits substantial 1/f noise, which under low light conditions seriously degrades the performance of the imaging array.
Kozlowski et al. “SWIR staring FPA Performance at Room Temperature,” SPIE Vol. 2746, pp. 93-100, April 1996 describes a phenomenon called “night glow” in the short wavelength infrared (SWIR) band that enables detection on very dark nights where photon flux is on the order of one hundred photons per imaging frame. Kozlowski details InGaAs and HgCdTe detector arrays for use with two different readout circuits. Both use current mirrors similar to Chamberlain, but one also buffers the detector node to maintain constant detector bias. Unlike SWIR band and longer wavelength detector arrays, near IR and visible detectors are not sensitive to changes in detector bias, and thus buffering to maintain constant bias is irrelevant. More importantly, the buffering enhances the circuit bandwidth such that the bandwidth is significantly enhanced; yet the bandwidth is still insufficient for displaying video at very high frame rates. The negative feedback amplifier A 1 , in U.S. Pat. No. 5,929,434, reduces the input impedance of the high-gain circuit and thereby enhances its bandwidth. In the case where the buffer amplifier is approximated to have infinite voltage gain and finite transconductance, the dominant pole is given by: τ B - L = C f g m Q1
where C f is the effective feedback capacitance of the buffer amplifier from its output to its input. Assuming a cascoded amplifier configuration, the gate-source capacitance of Q 1 is dominant and C f is set by the gate-to-source capacitance of the subthreshold FET Q 1 . This is approximately given by the parasitic metal overlap capacitance. Assuming a minimum width transistor in 0.25 μm CMOS technology, for example, the minimum C f will be about 0.1 fF. Though this facilitates single photon sensing at video frame rates, additional boost is needed to support imaging at high frame rates well above 30 to 60 Hz.
Merrill finally teaches in U.S. Pat. No. 6,069,376 a pixel amplifier (FIG. 6) with speed switch suitable for still camera applications. This apparatus provides high-bandwidth signal integration with downstream gain, but its sensitivity is limited by the generation of reset noise at the storage element. Furthermore, a method is not provided for maximizing the signal's dynamic range at the input to the amplifier.
SUMMARY OF THE INVENTION
The invention is a photodetector readout circuit, with extremely high sensitivity, capable of single-photon detection. A photodetector (preferably a photodiode) integrates a small-signal photocharge on the detector capacitance in response to incident photons, producing a photodetector output signal. A buffer amplifier is arranged to receive the photodetector output signal and to produce a buffered photodetector output signal. A coupling capacitor, has a first terminal connected to the buffered output signal and a second terminal connected to a signal input of a signal amplifier. The coupling capacitor shifts signal level at the input to the signal amplifier by an offset voltage. An electronic offset reset switch, connected to the coupling capacitor, allows resetting of the offset voltage, preferably during a simultaneous reset of the photodiode. When sampling of the photodiode signal begins, the offset across the coupling capacitor is also clamped. This effects correlated double sampling of the photogenerated signal, and facilitates elimination of correlated noise generated by resetting (discharging) photodetector capacitance. An adjustment voltage is also preferably summed with signal at the input of the signal amplifier, to set the operating point of the signal amplifier above threshold and thereby improve transimpedance, dynamic range, and linearity.
These and other features and advantages of the invention will be apparent to those skilled in the art from the following detailed description of preferred embodiments, taken together with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a generalized pixel amplifier in accordance with the invention;
FIG. 2 is a schematic diagram for one embodiment of an ultra-low noise, high gain, high-bandwidth pixel amplifier suitable for single-photon readout of various photodetectors having detector capacitance of the order of 5 to 25 fF;
FIG. 3 is a schematic diagram for an alternate embodiment of an ultra-low noise, high gain, high-bandwidth pixel amplifier for single-photon readout of various photodetectors having detector capacitance of the order of 25 to 125 fF;
FIG. 4 is a schematic diagram for another alternate embodiment of an ultra-low noise, high gain, high-bandwidth pixel amplifier for single-photon readout of various photodetectors having large capacitance range;
FIG. 5 is a schematic diagram for another alternate embodiment of an ultra-low noise, high gain, high-bandwidth pixel amplifier, suitable for single-photon readout of various photodetectors having detector capacitance in the range from around 25 up to several hundred femtofarads; and
FIG. 6 is a schematic diagram for yet another embodiment of an ultra-low noise, high gain, high-bandwidth pixel amplifier, suitable for single-photon readout of various photodetectors having detector capacitance in the range from about 5 up to several hundred femtofarads.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a high bandwidth, ultra low-noise pixel amplifier that is capable of single photon readout of photodetectors in extremely low-light conditions, i.e. photon flux levels approaching zero photons per sampling period. This circuit can be used to effectively count incident photons on individual photodetectors, in an imaging array as the front-end to a conventional video system or in high frame-rate wavefront sensors. One of the primary benefits of the approach is that the circuit can use off-the-shelf photodetectors such as photodiodes or photoconductors that have gain <1 rather than, for example, avalanche multiplication within the photodiode. Such known photodetectors with gain <1 are cheaper, more uniform, easier to fabricate, more reliable, less susceptible to excess noise mechanisms within the detector, and support a much broader range of the electromagnetic spectrum than avalanche photodiodes.
The generalized circuit in accordance with the invention is shown in FIG. 1 . Before photodetection begins, the circuit is initialized by closing switches S 1 and S 2 . In this initial state, any Cpd (which represents the capacitance of photodiode PD 1 ) is discharged (reset). Any offset voltage is amplified by amplifier Al, which is most suitably a unity gain buffer amplifier such as a source follower amplifier. Given sufficient reset time, the voltage across capacitor Cclamp will (VoAl−Vadjust) where VoAl is the voltage at output of Al in the presence of no signal input.
At some time both switches S 1 and S 2 are closed, setting the circuit in a sampling mode. Any photoelectric charge from PD 1 will be integrated across Cpd. The voltage across Cpd provides an input the the buffer amplifier A 1 , and the amplified signal is coupled capacitively, through series capacitance Cclamp, to the input of a signal amplifier A 2 (suitably an inverting amplifier, as discussed below). The voltage across Cclamp has been effectively clamped by the opening of switch s 2 . Thus, the voltage at the input of A 2 will be (signal plus VoA 1 ) minus (VoA 1 −Vadjust) or, more simply, signal +Vadjust. Vadjust is preferably set to fix the operating point of the signal amplifier, A 2 , in a range which is above threshold and chosen to yield large transimpedance, gain and dynamic range.
A specific embodiment is shown in FIG. 2 wherein a source follower amplifier converts the photocharge stored on the capacitance of photodetector diode PD 3 to a significant voltage at a signal bandwidth limited by either the photodiode or the specific source follower design. Though the photodetector can also be a photoconductor of relatively high impedance, the generation rate for all carriers must be sufficiently low to not saturate the storage capacitance for the applicable integration time. When Φ rst is high, Q 20 sets the bias voltage across the photodetector diode PD 3 . The signal developed during the integration time across PD 3 's capacitance at node 10 is amplified and buffered by source follower FET Q 21 , which is current biased by Q 22 . The voltage V bias (at the gate of Q 22 ) is preferably set to bias Q 22 in the subthreshold region to minimize its luminance, which would otherwise increase noise and compromise the available dynamic range at long integration times.
Since the transimpedance established by the combined capacitance of the detector and amplifier transistor Q 21 does not facilitate reading noise levels below about 10 e− at typical video rates, the invention preferably uses a level shifting stage in conjunction with a compact inverting amplifier stage. The inverting amplifier consisting of FETS Q 24 and Q 25 boosts the low-noise signal with voltage gain of several tens to several hundreds depending on the process used and the configuration of the inverter amplifier.
The output of the source follower FET Q 21 is capacitively coupled by series capacitor C clamp initially, under control of a reset signal Φ CDS applied to the gate of Q 23 at the start of integration. After integration of the signal for the prescribed integration time, the integrated signal is sampled through the clamp capacitor to the gate of amplifier FET Q 24 . The clamping and sampling facilitated in this manner effects correlated double sampling of the photogenerated signal. This signal, which is essentially free of circuit-induced noise, subsequently drives the compact amplifier comprised of amplifier FET Q 24 and bias FET Q 25 . The signal driving the amplifier FET Q 24 is the difference between the photosignal plus offset voltage, minus the offset voltage initially stored on C clamp at the start of integration. The correlated noise generated by resetting the detector capacitance is thereby eliminated. By minimizing the capacitances of PD 3 and the gate of FET Q 21 , the basic transimpedance can be maximized to first order to minimize the required size of the capacitor C clamp . To facilitate sub-electron read noise, C clamp must, at a minimum, be at least 1 fF for operation at room temperature of 295K.
The clamping circuit comprised of C clamp and bias transistor Q 23 , also effects a compact method for setting the minimum signal level at a quiescent operating point compatible with exercising the full dynamic range of the compact amplifier comprised of transistors Q 24 and Q 25 . The clamping circuit thus facilitates both correlated double sampling and dynamic range management.
Since the combined total capacitance of the photodetector and the gate of FET Q 21 will practically be, at a minimum, >5 fF, the maximum photoconversion gain defined at the input to the compact amplifier is thus 32 μV/e−. Because the minimum read noise referred to the output needs to be on the order of 250 μV to 1 mV in practical video cameras, the ability to detect quanta requires that the compact amplifier provide a minimum voltage gain of from 10 to 30. This is facilitated in a compact manner via a CMOS inverter amplifier having minimum load transistor gate length in most submicron CMOS process technologies.
For some applications, on the other hand, the typical sense capacitance for useful detectors will often be as much as 100 fF. In this case, the compact amplifier needs to supply voltage amplification of up to 600. This is accomplished in the alternative embodiment of FIG. 3 by adding a cascode transistor Q 28 to the inverter stage to boost the voltage gain. Once again the load FET has minimum gate length, e.g., typically from 0.25 to 0.32 μm for 0.25 μm CMOS technology, to uniformly minimize the amplifier's gain to a useful value.
The output of the low-noise pixel amplifier is read from the pixel by enabling Φ access to supply the signal to the bus via the CMOS transmission switch comprising transistors Q 26 and Q 27 . In many cases, the switch can be simplified to a transistor of one or the other polarity since the inverter amplifier does not swing from rail to rail. Furthermore, compression and extinction of high-level signals is effected by appropriately choosing a switch transistor of one appropriate polarity.
The pixel amplifier's output signal is then subsequently band-limited for the specific application via both the parasitic bus capacitance C L and by optionally adding capacitance external to the pixel, if necessary, to reduce the compact amplifier's wide-band thermal noise. This preferred amplifier, which is compatible with integration into pixels having pixel pitch smaller than 10 μm, is thus capable of detecting quanta with many types of detectors spanning a broad range in capacitance and spectral response.
The signal applied to transistor Q 22 to supply bias current to the amplifier transistor Q 21 can alternately be a duty-cycled clock, Φ snap , to facilitate the enabling and disabling of signal passthrough. This feature can be used to facilitate synchronous integration of the image across a two-dimensional imaging array. By thus applying a synchronous Φ rst clock to the array to provide uniform reset time and appropriately applying a synchronous Φ snap clock across the imaging sensor to first store the reset voltage across Cclamp and then sample the photovoltage onto the gate capacitance of all transistors Q 24 in the mosaic, snapshot image formation is facilitated.
FIG. 4 shows the schematic circuit for a second alternate embodiment wherein a broader range in capacitance is supported with the same basic design. In this case the switched bias, V select , is alternately applied to the configuration transistor Q 29 to facilitate either the basic or cascoded configuration for the compact amplifier. Detection of single quanta can hence be effected for a broad range of detector capacitance from 5 fF to over 125 fF, depending on the specific amplifier design.
FIG. 5 shows a third alternate embodiment that is extensible to pixel pitch significantly less than 10 μm using 0.25 μm CMOS process technology. For this embodiment the compact amplifier is distributed amongst the pixel and an external support circuit; the amplifier FET and dual-purpose (pixel access and cascode) FET Q 32 are located in the pixel while the current source supplying this amplifier's bias current is located, for example, in the circuitry that supports each column or row of pixels in an imaging array. Because more semiconductor area is available at the end of the column or row, the current source is readily adjustable via various means and the circuitry at each pixel can fit into an even smaller area.
Low-noise level shifting also enables the use of a differential amplifier in place of the inverter as in FIG. 6 . The alternative differential amplifier consists of tail transistor Q 40 , amplifier transistors Q 41 and Q 42 , and load resistors R 1 and R 2 . Depending on the necessary gain, those skilled in the art can also appreciate that the load resistors can alternately be transistors.
This fourth alternate embodiment can be operated in at least two modes to produce either a noninverted or inverted video signal. In either mode the offset voltage stored on C clamp is sampled onto both the inverting and noninverting inputs of the differential amplifier by enabling both Φ sample — 1 and Φ sample — 2 . When the photosignal plus offset is read at the end of the integration time, either Φ sample — 1 or Φ sample — 2 , is enabled to effect inverted or noninverted readout, respectively.
The alternate embodiment of FIG. 6 is also capable of snapshot image formation by synchronously applying the various clocking operations across the imaging array including Φ rst , Φ CDS , Φ sample — 1 , and Φ sample — 2 . Only the process of reading out the integrated signal by separately enabling the various Φ access clocks occurs at different times across the imaging array.
Applying negative feedback in the appropriate manner can externally set the closed-loop gain of the differential amplifier.
The ultra-low noise amplifiers of this invention provide a total transimpedance that can be expressed as: Z T , Amp = t int C det + C input · A v
where t int is the integration time, C det is the detector capacitance, C input is the combined capacitance of the source follower transistor and any other capacitances at this node, both stray and intentional, and A V , is the gain of the compact amplifier. The compact amplifier's gain thus mitigates the deleterious reductions in transimpedance resulting from either short integration time or large capacitance.
While several illustrative embodiments of the invention have been shown and described, numerous variations and alternate embodiments will occur to those skilled in the art. Such variations and alternate embodiments are contemplated, and can be made without departing from the spirit and scope of the invention as defined in the appended claims. | An ultra-low noise, high gain interface pixel amplifier is provided with capability for single-photon readout of known photodetectors at high electrical bandwidths for diverse spectral bandpass from the x-ray to long IR bands. The detector charge modulates a source follower whose output is double sampled to remove correlated noise by a compact stage that also provides optimum level shift for subsequent amplification of the full signal excursion. The level-shifted signal finally drives a compact amplifier that generates a robust end-to-end transimpedance. Single-photon readout of photodetectors at high electrical bandwidths in small pixel areas is thereby facilitated. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation of application ser. No. 11/143,129, filed on Jun. 3, 2005, and now U.S. Pat. No. 7,270,350.
BACKGROUND OF THE INVENTION
The present invention is directed to a coupler for connecting a male-end of one hose, tube, connector, faucet, and the like, to a female end of another hose, tube, connector, and the like. Examples of prior-art quick-connecting hose couplers are disclosed in Applicant's previous U.S. Pat. Nos. 5,503,437; 5,788,289; and 6,786,516, and copending application Ser. No. 10/728,428 filed Dec. 8, 2003, and Ser. No. 10/746,508 filed Dec. 29, 2003. It has, however, been learned that these quick-connecting couplers are difficult to use by the elderly or persons suffering from disabilities that affect their ability to grip and connect the couplers between mating ends of hoses and/or faucets, and the like. The present invention provides a quick-connecting coupler that allows ease of use by anyone, including the elderly, the infirm, and those suffering from disabilities.
SUMMARY OF THE INVENTION
It is, therefore, the primary objective of the present invention to provide a quick-connecting coupler for hoses, faucets, and the like, which is more easily used during connection and disconnection, whereby elderly, the infirm, and those suffering from disabilities may use it without difficulty.
It is also the primary objective of the present invention to provide such a coupler that utilizes a handle by which the quick-connecting coupler may be gripped and held, for ease of use and which is used for actually mounting the female end of the coupler to a male end inserted in the female end of the coupler.
Toward these and other ends, the quick-connecting coupler of the invention has a first male end for connecting to a first female end of a hose, connector, tube, and the like, and a second female end for receiving a second male end of another hose, connector, faucet, and the like. Each of the first male end and second female end of the quick-connecting coupler of the invention is conventional in the sense that the second female end of the quick-connecting coupler is provided with an opening for receiving the second male end of another hose, or the like, and has a washer for sealing the connection. However, the second female end of the invention is different from the prior art in that it is provided with a pair of spaced-apart through-slots or openings for receiving therethrough the pair of forks or leg-sections of a mounting element. Each of the pair of forks or leg-sections is provided with at least one interior-facing linear thread or rib for engaging with the male threads of a mating male end. The second female end of the coupler of the invention has a pair diametrically-opposed cutouts through which portions of the linear threads or ribs are exposed, whereby these exposed portions of the threads or ribs may mate with corresponding portions of the threads of the mating male end positioned in the second female end of the coupler. The exposed portions of the linear threads engage with the male threads of the mating male end positioned in the female end of the coupler, whereby the second female end of the coupler is mounted onto the mating male end positioned therein and sealed thereto via a washer. The linear ribs of the pair of forks or leg sections of the mounting element may be provided at a slope or pitch matching that of the male threads, or, alternatively, may have no slope or pitch. Each fork or leg section may also be provided with a plurality of linear threads or ribs for engaging with the threads of the mating male end. As the forks are slid in the through-slots of the coupler at the female end thereof, the sloping threads, through wedging or camming action, force the male end against the sealing washer in the female end of the coupler, to sealingly lock the male end therein.
BRIEF DESCRIPTION OF THE DRAWING
The invention will be more readily understood with reference to the accompanying drawings, wherein:
FIG. 1 is an isometric assembly view showing the first embodiment of the quick-connecting coupler of the invention;
FIG. 2 is a front elevational view thereof;
FIG. 3 is a side elevational view thereof;
FIG. 4 is a top view thereof;
FIG. 5 is an isometric view of the coupling yoke with forked section for sliding in the coupler of FIG. 1 and used for engaging with the threads of an inserted male end;
FIG. 6 is a side view of one of the fork-elements of the coupling yoke of FIG. 5 ;
FIG. 7 is a top view of the coupling yoke of FIG. 5 ;
FIG. 8 is a front view of the coupling yoke of FIG. 5 ;
FIG. 9 is an isometric view showing the operating or engaged position of the coupling yoke of FIG. 5 in the coupler of FIG. 1 for locking a threaded male of a mating part in the female end of the coupler;
FIG. 10 is an isometric view showing the disengaged position of the coupling yoke of FIG. 5 in the coupler of FIG. 1 after a threaded male of a mating part in the female end of the coupler has been released and removed from the female end of the coupler;
FIG. 11 is an isometric view of a modification of the coupler of FIG. 1 ;
FIG. 12 is an isometric view similar to FIG. 9 and showing the operating or engaged position of a modified coupling yoke for use in the coupler of FIG. 11 for locking a threaded male of a mating part in the female end of the coupler;
FIG. 13 is a vertical cross-section view of the coupler of FIG. 11 thereof;
FIG. 14 is a longitudinal cross-sectional view of anther embodiment of the invention where only a female end is provided which, in combination with the coupling yoke of FIG. 5 , is used as a nut for securing a threaded bolt, screw, and the like; and
FIG. 15 is a side elevation view of the embodiment of FIG. 14 shown in combination with the yoke of FIG. 5 , where the combination of the female end of FIG. 14 and the yoke serves as a nut for a bolt, screw, and the like.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, and to FIGS. 1-10 , there is shown in the preferred embodiment the quick-connecting coupler for coupling hoses, connectors, and the like, together or to a faucet, and the like, and is indicated generally by reference numeral 10 . The coupler 10 has a circular cross-section, main body portion or housing 12 consisting of a first, threaded male end 14 for connecting to a female end of a hose, connector, and the like, and a second, female end 16 for receiving therein a mating, threaded male end of another hose, connector, faucet, or the like. The second female end 16 is of larger diameter than the male end 14 , with both ends 14 and 16 defining a hollow interior for the flow of fluid therethrough. The female end 16 is provided with a seat 16 ′ ( FIG. 13 ) for a sealing washer, o-ring, or other equivalent sealing element, 20 for providing a seal for the connection between the female end 16 and a mating male end inserted therein, in the conventional manner.
The female end 16 has no interior threads itself that can mate with the threads of a male end inserted therein. Instead, in accordance with the invention, a separate and slidable mounting element or part 22 ( FIGS. 5-8 ) is used for providing interior threads that mate with the threads of the male end inserted in the female end 16 . The mounting element 22 consists of a yoke 24 having a handle section 26 , and a forked section 28 defining a pair of spaced-apart fork elements or leg-sections 30 , 32 . Each fork element 30 , 32 has a free or cantilevered end 30 ′, 32 ′, and an interior surface 30 ″, 32 ″ ( FIG. 7 ), on which is provided or formed at least one toothed bar or linear thread 34 , 36 , respectively. In the preferred embodiment, preferably a plurality of parallel toothed bars or linear threads 34 , 36 , are provided, respectively, on each interior surface 30 ″, 32 ″, which plurality of threads 34 , 36 are spaced apart the requisite distance from each other for matching the pitch of the male threads of a male end to be inserted into the female end 16 . The threads 34 , 36 extend along the respective interior surfaces 30 ″, 32 ″ for at least most of the length of the respective fork element 30 , 32 . Each of the toothed bars linear threads 34 , 36 , in the preferred embodiment, extends at a downwardly-extending slope or angle in the direction from the respective free ends 30 ′, 32 ′ toward the handle section 26 in order to expedite the connection of the coupler 10 to a mating male end inserted into the female end 16 . The degree of slope or pitch of each of the toothed ribs or linear threads 34 , 36 preferably matches that of the threads of a male end to be inserted into the female end 16 , although it may differ.
Referring to FIGS. 1-5 , the housing 12 of the coupler 10 is provided with a pair of oppositely-disposed slots or channels 40 , 42 in which, or through which, are received and slide the fork elements 30 , 32 . The slots or channels 40 , 42 are located on diametrically-opposed portions thereof at the female end 16 . With the fork elements 30 , 32 inserted for sliding movement in the channels 40 , 42 , respectively, portions of the linear threads 34 , 36 are exposed to the interior of the female end-portion via oppositely-disposed, interior cutout portions 40 ′, 42 ′ (best seen in FIG. 13 ) formed in the interior of the housing 12 , as can be seen in FIGS. 1 and 5 . These interior cutout portions are formed by arcuately cutting diametrically-opposed sections of inner circular wall 38 of the female end, which are arcuately extended enough of a distance such that the toothed ribs or linear threads 34 , 36 project interiorly and radially inwardly into the interior of the female end, whereby the interiorly and radially inwardly projecting exposed portions of the linear threads 34 , 36 may be described as defining chords of a circle, which circle that of the interior circular wall 38 . These exposed portions of the linear threads project into the interior volume of the female end 16 by which they may engage with the threads of an inserted male end of a connecting hose, connector, faucet, or the like. In the preferred embodiment, the height of the channels 40 , 42 , as viewed in the vertical direction when viewing FIGS. 1 and 9 , is greater that the height of the two forks 50 , 52 , also taken in the vertical direction when viewing FIGS. 1 and 8 , so that there is provided a gap or space for vertically positioning the forks 50 , 52 in the channels, as is clearly shown in FIG. 9 , in order to vertically maneuver the forks so that the toothed ribs or threads 34 , 36 may be aligned with and come into threaded engagement with the juxtapositioned portion of the threads of the male end inserted in the female end 16 and exposed thereat via the cutout portions 40 ′, 42 ′. Depending upon how the male end is inserted in the female end 16 , the exposed portion of the threads of the male end will be of different vertical location or elevation relative to the height of the channels 40 , 42 . This ensures that one may engage the linear threads with a portion of the threads of the male end inserted in the female end 16 , so that the below-described camming effect for effecting sealing may occur, without any relative rotation of the coupler needed relative to the inserted male end. However, this gap need not provided, in the case of which relative rotation between the coupler 10 and the inserted male end may, in some circumstances, be required for effecting the seal, as described hereinbelow.
In the preferred embodiment, since the slope and pitch of the threads 34 , 36 are approximately the same as that of the threads of a male end to be inserted into the female end-portion 16 , one need not rotate the coupler 10 to attach and seal the female end to an inserted male end, but one need only push the fork section 28 of the mounting element 22 through the through-slots 40 , 42 , by which the pitched or downwardly sloping linear threads 34 , 36 engage with the threads of the male end inserted in the female end-portion 16 , and whereupon further sliding of the fork section in the through-slots 40 , 42 causes the sloping linear threads to cam or wedge the male end inserted into the female end-portion against the sealing washer 20 , without any need of causing relative rotation between the male end inserted in the female end-portion 16 and the female end 16 itself.
As explained above, the linear threads 34 , 36 preferably have a slope approximately equal to the slope and pitch of the threads of the male end to be inserted into the female end 16 , whereby any relative rotation between the male end inserted in the female end-portion 16 and the female end 16 is not needed in order to connect the male end in the female end 16 . However, it is within scope and purview of the invention to provide linear threads 34 , 36 that have a slope that is different from that of the threads of the male end to be inserted into the female end 16 . Thus, the slope of the linear threads 34 , 36 may be steeper that that of the threads of the male end to be inserted into the female end-portion 16 , whereby greater force would be required to seal a male end in the female end 16 against the washer 20 . Alternatively, the slope of the linear threads 34 , 36 may be shallower than that of the threads of the male end to be inserted into the female end 16 , whereby less force would be required to seal a male end in the female end-portion against the washer 20 , in which case longer linear threads 34 , 36 may required along with the concomitant lengthening of the mounting element 22 . It is also possible to provide non-sloping or horizontal linear threads 34 , 36 , whereby relative rotation between the female end 16 and the male end inserted therein may be required for forcing and retaining the inserted male end against the washer 20 . In this instance, by rotating the female end-portion via the handle-section 26 , the exposed portions of the linear threads mate with the threads of the inserted male end, drawing the inserted male end inwardly into the interior hollow volume of the female end-portion, until the end of the inserted, mating male end seats against the sealing washer 20 , whereby a sealed connection is achieved. It is, also, noted that in all variations of the slope of the linear threads 34 , 36 , one may, if desired, also rotate the female end-portion 16 relative to the inserted male end in order to achieve in an even tighter seal against the washer 20 , if necessary.
The main body portion housing 12 is also provided with a pair of diametrically-opposite, tangential flanges or arms 50 , 52 located at the entrance to the through-slots 40 , 42 , respectively. Each flange 50 , 52 has a first end 50 ′, 52 ′, adjacent a respective entrance to the channels 40 , 42 and a cantilevered, or free, end 50 ″, 52 ″, with each flange defining an interior-facing inner surface 54 , 56 , respectively, in which is formed a guide slot or groove. The surface wall of each channel 40 , 42 , respectively, is also formed with a groove or slot 53 , 55 ( FIG. 2 ) matching, and in alignment with, the grooves in the interior-facing grooves of the flanges 50 , 52 , whereby one elongated guide slot or groove 54 ′ or 56 ′ is provided. Each guide groove or slot 54 ′, 56 ′ slidingly receives therein a guide pin or post 58 , 60 , respectively, projecting outwardly or exteriorly from a respective free or cantilevered end 30 ′, 32 ′, of a fork element 30 , 32 . The guide pins retain the fork elements 30 , 32 in the slots 54 ′, 56 ′, with the closed ends of the slots 54 ′, 56 ′ serving as a stop for the guide pins for preventing the forked section 28 from exiting from the channels 40 , 42 , whereby the mounting element 22 , with the yoke 24 , handle section 26 , and a forked section 28 thereof, remain attached to the female end 16 of the housing 12 ( FIGS. 9 and 10 ). Moreover, as can be seen in FIG. 10 , when the coupler 10 of the invention is not being used, the mounting element 22 may be slid in a direction away from the coupler 10 , until the guide pins 58 , 60 abut against the closed ends of the slots in the flanges 54 , 56 , thereby acting as stops thereagainst. In this limit position, the guide pins 58 , 60 also serve as hinges or pivot pins, by which the mounting element 22 may be pivoted or rotated 90 degrees, until it is at a right angle with respect to the longitudinal axis of the coupler 10 , whereby easier storage of the device is made possible. When the mounting element 22 is needed to be used again, one simply rotates or pivots it in the opposite direction whereby its length is substantially co-extensive with the longitudinal axis of the coupler 10 , in the manner described above during the use of the coupler 10 . The coupler 10 is, also, preferably provided with a T-shaped drain vent or drain channel 70 having a base channel section 70 ′ through which water pressure is relieved during initial disconnection of the mating parts, so as prevent unwanted spraying or water jets when disconnecting the inserted male end from the female end 16 . This vent or drain may be located anywhere, but, as shown in, is preferably near or adjacent the sealing washer 20 . By locating this vent at the sealing washer, when the coupler 10 is in use, the “piston-effect” similar to that disclosed in applicant's U.S. Pat. No. 5,788,289, is not created, whereby the sealing washer 20 is not urged or forced in the opposite direction to the flow of water, against the juxtapositioned end of the inserted male end. However, if such a piston-effect were desired, then the base channel section 70 ′ may be eliminated.
When using the coupler 10 in order to connect a pair of hoses, connectors, and the like, together, or to a faucet or other water accessory, one first inserts the male end into the female end 16 of the coupler 10 , until it is seated against the sealing washer 28 . Then, the mounting element 22 is moved toward the coupler 10 so that the fork elements 30 , 32 slide in the channels 40 , 42 as guided by the guide pins 58 , 60 . As the forks slide, the sloping linear threads 34 , 36 thereof, through camming or wedge action, cooperate with the threads of the male element inserted in the female end-portion 16 , translating and forcing the male element against the sealing washer 28 with enough force so as to provide a water-tight seal. If additional tightening is desired or necessary, one may rotate the mounting element 22 via its handle, in order to rotate it and the attached coupler 10 relative to the inserted threaded male end.
Referring now to FIGS. 11-13 , there is shown a modification of the coupler of the invention and indicated generally by reference numeral 80 . The coupler 80 is substantially the same as the coupler 10 except that the housing 82 thereof is not provided with the flanges 50 , 52 of the coupler 10 , nor do the forks 84 , 86 of the mounting element 88 thereof, which serves the same function as that of the mounting element 22 of the coupler 10 , have the guide pins or stops 58 , 60 of the mounting element 22 of the coupler 10 . Therefore, the mounting element 88 with its fork elements 84 , 86 is completely removable and separable from the coupler 80 during non-use and storage.
While it has been described that the preferred embodiment utilizes downwardly sloping linear threads 34 , 36 on the interior surfaces of the forks, they may made to extend horizontally without slope, whereupon, in order to connect the coupler to a male end, one may have to rotate the coupler relative to the inserted male end via the mounting element 22 . It is also within the scope and purview of the invention to provide sloping linear threads 34 , 36 that slope upwardly in a sense opposite to that shown in the drawings for the couplers 10 and 80 . In this case, rotation of the coupler relative to the inserted male end via the mounting element 22 would be a requirement and would proceed by means of the cross-threading of the threads of the male end with the linear threads of the mounting element 22 . In addition, even the case of the preferred embodiment, where the linear threads are downwardly-sloping and preferably at the same angle and pitch as the threads of the inserted male end, if, for some reason, the male end inserted into the female end of the coupler 10 is not properly aligned therein, the linear threads of the mounting element 22 will still secure and causing the sealing between the male end and the female end of the coupler by the cross-threading of the two parts, in which case relative rotation between the female end 16 and the male end inserted therein would be a requirement in order to effect the seal therebetween. Therefore, no matter what degree or sense of slope of the linear threads 34 , 36 is provided, if cross-threading thereof with the outer threads of the male end inserted in the female end 16 were to occur, the seal may still be achieved by such relative rotation. Such relative rotation is achieved by gripping the handle section 26 of the mounting element 22 and turning.
While the preferred embodiment has been disclosed as being directed to a threaded male end to be inserted in the female end 16 , the coupler 10 or 80 may also be used for receiving in its female end a grooved or flared male end, as described in applicant's U.S. Pat. No. 6,786,516. In this instance, there would only be required one linear thread 34 , 36 . Moreover, this one linear thread would be downwardly sloping, in the manner described above and shown in FIGS. 5-9 .
It is also noted that under some limited circumstances, only one fork 30 or 32 need be provided. In this case, the other of the forks 30 or 32 could be dispensed with altogether, and the linear threads on the one remaining fork would engage with the threads of the inserted male end. In this case, the female end 16 would be made extra long with a longer cutout portion 40 ′ or 42 ′ being provided to expose a greater length of exposed linear thread or threads 34 or 36 . In this case, only one channel 40 or 42 , therefore, would need to be provided. Alternatively, both forks may be provided, but only one of them would be provided with the linear thread or threads.
The couplers 10 and 80 may be used, not only in liquid environment, but may also be used in fluid environments in general, such as pressurized gases, and the like. It is also possible to replace the male end 14 with a female end for thereby coupling together two male parts.
Referring now to FIGS. 14 and 15 , there is shown another embodiment 100 of the coupler of the invention in which it is used as a “quick” nut for use with a threaded bolt, rod, screw, and the like, for serving as a temporary or semi-permanent nut. In this embodiment, only a female or receiving portion 116 is provided, and no male end. In this embodiment, the coupler 100 acts or serves as a nut for use with a threaded bolt, rod, screw, and the like. The female portion 116 , since it not used in a fluid environment, does not have a sealing washer, but simply provides a passageway or hollow through-volume through which may pass the shaft 120 of a threaded bolt or screw 118 . The female portion 116 is provided with a pair of channels 140 , 142 similar to the channels 40 , 42 of the embodiments of FIGS. 1-13 , as well as oppositely-disposed, interior cutout portions (not shown) the same as the oppositely-disposed, interior cutout portions 40 ′, 42 ′ of the embodiments of FIGS. 1-13 . The channels 140 , 142 receive therethrough the forks of the mounting element 122 that is essentially identical to the mounting element 22 of the embodiments of FIGS. 1-13 , and, therefore, consists of a yoke 124 having a handle section 126 , and a forked section 128 defining a pair of spaced-apart fork elements or leg-sections. In use, the shaft 120 of a bolt or screw 118 is inserted through the opening of the coupler 100 until the desired portion of the shaft is located within the hollow interior of the coupler's female portion 116 . Then, the forks of the forked section 128 of the mounting element 122 are slid through the respective channels 140 , 142 of the coupler 100 , whereupon the linear threads in the interior surfaces of the forks engage with the threads of the shaft 120 , to thereby lock the coupler 100 to the shaft 120 . The number, size, slope and pitch of the linear threads of the forks of the forked section 128 are identical to that described above with respect to the other embodiments, and operate in the same manner as described above for securing the coupler 100 to the bolt or screw 118 .
An example of use of the coupler 100 as a nut for a bolt, rod, or screw, is as a quick-adjusting nut for use on miter frame clamps. These clamps utilize long lengths of threaded rod. Depending on the size of the work piece, the coupler 100 serving as a “quick” nut is adjustable to fit without requiring turning. The coupler 100 also works on a bench wood worker's vise and any vise or clamp that uses threads. The adjustment of these devices would be made with the “quick” nut of FIGS. 14 and 15 without requiring turning, or, if turning of the coupler 100 serving as a “quick” nut is required, may be achieved via the handle 126 . In addition, a C-clamp could be made by using the “quick” nut of FIGS. 14 and 15 , where the C-clamp is made up of a long piece of threaded bolt. The bolt is slid back and forth to the desired opening, and then the forks of the forked element 128 is slid in to tighten. The “quick” nut of FIGS. 14 and 15 would, also, work with a long piece of an all-threaded rod. Instead of conventionally screwing a nut onto 8 ″ or 10 ″ all-thread rod, with the coupler 100 , one simply pushes on the female portion 116 to the desired placement, and then installs the forks of the forked element 128 for a tight fit.
It is also noted, as described above with regard to the other embodiments, that under some limited circumstances, only one fork need be provided. In this case, the other of the forks could be dispensed with altogether, and the linear threads on the one remaining fork would engage with the threads of the threaded shaft of the bolt, rod, or screw. In this case, the female or receiving portion would be made extra long with a longer cutout portion being provided to expose a greater length of exposed linear thread or threads. In this case, only one channel 140 or 142 , therefore, would need to be provided. Alternatively, both forks may be provided, but only one of them would be provided with the linear thread or threads.
While specific embodiments of the invention have been shown and described, it is to be understood that numerous changes and modifications may be made therein without departing from the scope and spirit of the invention as set forth in the appended claims. | A quick-connecting coupler for connecting hoses, connectors together or to a faucet or other water accessories that allows ease of use by anyone, including the elderly, the infirm, and those suffering from disabilities. The quick-connecting coupler has a first male-end and a second female end. The second female end is provided with of spaced-apart through-slots or opening for receiving therethrough a pair of forks or leg-sections of a yoke. Each of the pair of forks or leg-sections is provided with at least one interior-facing linear thread or rib for engaging with the male threads of the mating male end of another hose, or the like. The second female end of the coupler of the invention has a pair diametrically opposed cutouts through which portions of the linear threads or ribs are exposed, whereby these exposed portions of the threads or ribs may mate with corresponding portions of the male threads of the mating male end positioned in the second female end of the coupler for coupling the mating male end in the female end of the coupler. | 5 |
BACKGROUND
[0001] Hydrocarbon-producing wells often are stimulated by hydraulic fracturing operations, wherein a fracturing fluid may be introduced into a portion of a subterranean formation penetrated by a well bore at a hydraulic pressure sufficient to create or enhance at least one fracture therein. Stimulating or treating the well in such ways increases hydrocarbon production from the well.
[0002] In some wells, it may be desirable to individually and selectively create multiple fractures along a well bore at a distance apart from each other. The multiple fractures should have adequate conductivity, so that the greatest possible quantity of hydrocarbons in an oil and gas reservoir can be drained/produced into the well bore. When stimulating a reservoir from a well bore, especially those well bores that are highly deviated or horizontal, it may be difficult to control the creation of multi-zone fractures along the well bore without cementing a casing or liner to the well bore and mechanically isolating the subterranean formation being fractured from previously-fractured formations, or formations that have not yet been fractured.
[0003] To avoid explosive perforating steps and other undesirable actions associated with fracturing, certain tools may be placed in the well bore to place fracturing fluids under high pressure and direct the fluids into the formation. In some tools, high pressure fluids may be “jetted” into the formation. For example, a tool having jet forming nozzles, also called a “hydrojetting” or “hydrajetting” tool, may be placed in the well bore near the formation. Hydrojetting may also be referred to as a process of controlling high pressure fluid jets with surgical accuracy. The jet forming nozzles create a high pressure fluid flow path directed at the formation of interest. In another tool, which may be called a casing window, a stimulation sleeve, or a stimulation valve, a section of casing includes holes or apertures pre-formed in the casing. The casing window may also include an actuatable window assembly for selectively exposing the casing holes to a high pressure fluid inside the casing. The casing holes may include jet forming nozzles to provide a fluid jet into the formation, causing tunnels and fractures therein.
SUMMARY OF THE INVENTION
[0004] An embodiment of a well bore servicing apparatus includes a housing having a through bore and at least one high pressure fluid aperture in the housing, the fluid aperture being in fluid communication with the through bore to provide a high pressure fluid stream to the well bore, and a removable member coupled to the housing and disposed adjacent the fluid jet forming aperture and isolating the fluid jet forming aperture from an exterior of the housing. In other embodiments, the removable member is a degradable sleeve removed by degradation. Still other embodiments include a jet forming nozzle in the high pressure fluid aperture.
[0005] An embodiment of a method of servicing a well bore includes applying a removable member to an exterior of a well bore servicing tool, wherein the removable member covers at least one high pressure fluid aperture disposed in the tool, lowering the tool into a well bore, exposing the tool to a well bore material, wherein the removable cover prevents the well bore material from entering the fluid aperture, removing the removable member to expose a fluid flow path adjacent an outlet of the high pressure fluid aperture, and flowing a well bore servicing fluid through the fluid aperture outlet and flow path. In other embodiments, removing the removable member includes degrading a protective sleeve. In yet other embodiments, flowing the well bore servicing fluid further expands the fluid flow path adjacent the tool, into the surrounding formation, or both.
[0006] Another embodiment of a method of servicing a well bore includes disposing a fluid jetting tool in the well bore, the fluid jetting tool having a fluid jetting aperture and a removable member adjacent the fluid jetting aperture, cementing the fluid jetting tool into the well bore, wherein the removable member prevents cement from entering the fluid jetting aperture, and removing the removable member to expose a fluid flow path adjacent an outlet of the fluid jetting aperture. Other embodiments include pumping a well bore servicing fluid into the fluid jetting tool and through the fluid jetting aperture, and perforating the cement to further expand to the fluid flow path. Still other embodiments include continuing to pump the servicing fluid into a formation adjacent the perforated cement to fracture the formation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more detailed description of the embodiments, reference will now be made to the following accompanying drawings:
[0008] FIG. 1 is a schematic, partial cross-section view of a fluid stimulation tool in an operating environment;
[0009] FIG. 2 is a cross-section view of a hydrojetting tool assembly;
[0010] FIG. 3 is a cross-section view of a fluid pressurizing well completion assembly;
[0011] FIG. 4A is a partial cross-section view of a hydrojetting casing window assembly;
[0012] FIG. 4B is a partial cross-section view of the casing window assembly of FIG. 4A in a shifted position;
[0013] FIG. 5 is a partial cross-section view of a well completing assembly including embodiments of FIGS. 4A and 4B ;
[0014] FIG. 6A is a partial cross-section view of an exemplary fluid jetting window assembly in an open position;
[0015] FIG. 6B is a partial cross-section view of an embodiment of the assembly of FIG. 6A in a closed position;
[0016] FIG. 6C is a partial cross-section view of an embodiment of the assembly of FIG. 6B showing removal of a removable member;
[0017] FIG. 6D is a partial cross-section view of an embodiment of the assembly of FIG. 6C showing fracturing;
[0018] FIG. 6E is a partial cross-section view of an embodiment of the assembly of FIG. 6D moved to a closed position; and
[0019] FIG. 7 is a partial cross-section view of an alternative embodiment of the fluid jetting window assembly of FIG. 6A .
DETAILED DESCRIPTION
[0020] In the drawings and description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. The present invention is susceptible to embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. Unless otherwise specified, any use of any form of the terms “connect”, “engage”, “couple”, “attach”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Reference to up or down will be made for purposes of description with “up”, “upper”, “upwardly” or “upstream” meaning toward the surface of the well and with “down”, “lower”, “downwardly” or “downstream” meaning toward the terminal end of the well, regardless of the well bore orientation. The various characteristics mentioned above, as well as other features and characteristics described in more detail below, will be readily apparent to those skilled in the art upon reading the following detailed description of the embodiments, and by referring to the accompanying drawings.
[0021] Disclosed herein are several embodiments of fracturing or stimulation tools wherein pressurized fluid is directed or jetted through fluid apertures into an earth formation to create and extend fractures in the earth formation, or otherwise extend a flow path from the tool to the formation. Also disclosed are several embodiments of a removable member disposed over the fluid apertures, particularly jet forming nozzles, for example, to isolate the fluid apertures from an exterior environment of the tool. The exterior environment of the tool may include cement or other viscous, aperture-plugging materials that negatively effect the pressurizing or jetting nature of the apertures. As disclosed herein, exemplary embodiments of the removable member include a degradable sleeve wrapped around a portion of the tool housing having the fluid apertures. A degradable sleeve can comprise a variety of materials, as disclosed below. Also disclosed herein are operations of a fluid pressurizing or jetting tool including the removable member disposed over the fluid apertures to isolate such apertures from materials that may encumber or obstruct the fluid apertures. As disclosed, the operations of the fluid pressurizing or jetting tools may include a complete well servicing or treatment process to adequately fracture the earth formation.
[0022] FIG. 1 schematically depicts an exemplary operating environment for a fluid pressurizing or hydrojetting tool 100 for fracturing an earth formation F. As disclosed below, there are many embodiments of the fluid pressurizing or hydrojetting tool 100 , but for reference purposes, the schematic tool 100 will be called the “fluid stimulation tool 100 .” As depicted, a drilling rig 110 is positioned on the earth's surface 105 and extends over and around a well bore 120 that penetrates a subterranean formation F for the purpose of recovering hydrocarbons. The well bore 120 may drilled into the subterranean formation F using conventional (or future) drilling techniques and may extend substantially vertically away from the surface 105 or may deviate at any angle from the surface 105 . In some instances, all or portions of the well bore 120 may be vertical, deviated, horizontal, and/or curved.
[0023] At least the upper portion of the well bore 120 may be lined with casing 125 that is cemented 127 into position against the formation F in a conventional manner. Alternatively, the operating environment for the fluid stimulation tool 100 includes an uncased well bore 120 . The drilling rig 110 includes a derrick 112 with a rig floor 114 through which a work string 118 , such as a cable, wireline, F-line, Z-line, jointed pipe, coiled tubing, or casing or liner string (should the well bore 120 be uncased), for example, extends downwardly from the drilling rig 110 into the well bore 120 . The work string 118 suspends a representative downhole fluid stimulation tool 100 to a predetermined depth within the well bore 120 to perform a specific operation, such as perforating the casing 125 , expanding a fluid path therethrough, or fracturing the formation F. The drilling rig 110 is conventional and therefore includes a motor driven winch and other associated equipment for extending the work string 118 into the well bore 120 to position the fluid stimulation tool 100 at the desired depth.
[0024] While the exemplary operating environment depicted in FIG. 1 refers to a stationary drilling rig 110 for lowering and setting the fluid stimulation tool 100 within a land-based well bore 120 , one of ordinary skill in the art will readily appreciate that mobile workover rigs, well servicing units, such as slick lines and e-lines, and the like, could also be used to lower the tool 100 into the well bore 120 . It should be understood that the fluid stimulation tool 100 may also be used in other operational environments, such as within an offshore well bore or a deviated or horizontal well bore.
[0025] The fluid stimulation tool 100 may take a variety of different forms. In an embodiment, the tool 100 comprises a hydrojetting tool assembly 150 , which in certain embodiments may comprise a tubular hydrojetting tool 140 and a tubular, ball-activated, flow control device 160 , as shown in FIG. 2 . The tubular hydrojetting tool 140 generally includes an axial fluid flow passageway 180 extending therethrough and communicating with at least one angularly spaced lateral port 142 disposed through the sides of the tubular hydrojetting tubular hydrojetting tool 140 . In certain embodiments, the axial fluid flow passageway 180 communicates with as many angularly spaced lateral ports 142 as may be feasible, (e.g., a plurality of ports). A fluid jet forming nozzle 170 generally is connected within each of the lateral ports 142 . As used herein, the term “fluid jet forming nozzle” refers to any fixture that may be coupled to an aperture so as to allow the communication of a fluid therethrough such that the fluid velocity exiting the jet is higher than the fluid velocity at the entrance of the jet. In certain embodiments, the fluid jet forming nozzles 170 may be disposed in a single plane that may be positioned at a predetermined orientation with respect to the longitudinal axis of the tubular hydrojetting tool 140 . Such orientation of the plane of the fluid jet forming nozzles 170 may coincide with the orientation of the plane of maximum principal stress in the formation to be fractured relative to the longitudinal axis of the well bore penetrating the formation.
[0026] The tubular, ball-activated, flow control device 160 generally includes a longitudinal flow passageway 162 extending therethrough, and may be threadedly connected to the end of the tubular hydrojetting tool 140 opposite from the work string 118 . The longitudinal flow passageway 162 may comprise a relatively small diameter longitudinal bore 164 through an exterior end portion of the tubular, ball-activated, flow control device 160 and a larger diameter counter bore 166 through the forward portion of the tubular, ball-activated, flow control device 160 , which may form an annular seating surface 168 in the tubular, ball-activated, flow control device 160 for receiving a ball 172 . Before ball 172 is seated on the annular seating surface 168 in the tubular, ball-activated, flow control device 160 , fluid may freely flow through the tubular hydrojetting tool 140 and the tubular, ball-activated, flow control device 160 . After ball 172 is seated on the annular seating surface 168 in the tubular, ball-activated, flow control device 160 as illustrated in FIG. 2 , flow through the tubular, ball-activated, flow control device 160 may be terminated, which may cause fluid pumped into the work string 118 and into the tubular hydrojetting tool 140 to exit the tubular hydrojetting tool 140 by way of the fluid jet forming nozzles 170 thereof. When an operator desires to reverse-circulate fluids through the tubular, ball-activated, flow control device 160 , the tubular hydrojetting tool 140 and the work string 118 , the fluid pressure exerted within the work string 118 may be reduced, whereby higher pressure fluid surrounding the tubular hydrojetting tool 140 and tubular, ball-activated, flow control device 160 may flow freely through the tubular, ball-activated, flow control device 160 , causing the ball 172 to disengage from annular seating surface 168 , and through the fluid jet forming nozzles 170 into and through the work string 118 .
[0027] The hydrojetting tool assembly 150 , schematically represented at 100 in FIG. 1 , may be moved to different locations in the well bore 120 by using work string 118 . Work string 118 also carries the fluid to be jetted through jet forming nozzles 170 . During use, the hydrojetting tool assembly 150 may be exposed to a variety of hindrances or nozzle plugging materials. Therefore, it is desirable to maintain unhindered jet forming nozzles 170 such that successful fluid jets are created each time the tool assembly 150 is used.
[0028] Referring now to FIG. 3 , in another embodiment, the schematic fluid jetting tool 100 comprises an exemplary well completion assembly 200 . The well completion assembly 200 is disposed in the well bore 120 coupled to the surface 105 and extending down through the subterranean formation F. The completion assembly 200 includes a conduit 208 extending through at least a portion of the well bore 120 . The conduit 208 may or may not be cemented to the subterranean formation F. In some embodiments, the conduit 208 is a portion of a casing string coupled to the surface 105 by an upper casing string, represented schematically by work string 118 in FIG. 1 . Cement is flowed through an annulus 222 to attach the casing string to the well bore 120 . In some embodiments, the conduit 208 may be a liner that is coupled to a previous casing string. When uncemented, the conduit 208 may contain one or more permeable liners, or it may be a solid liner. As used herein, the term “permeable liner” includes, but is not limited to, screens, slots and preperforations. Those of ordinary skill in the art, with the benefit of this disclosure, will recognize whether the conduit 208 should be cemented or uncemented and whether conduit 208 should contain one or more permeable liners.
[0029] The conduit 208 includes one or more pressurized fluid apertures 210 . Fluid apertures 210 may be any size, for example, 0.75 inches in diameter. In some embodiments, the fluid apertures 210 are jet forming nozzles, wherein the diameter of the jet forming nozzles are reduced, for example, to 0.25 inches. The inclusion of jet forming nozzles 210 in the well completion assembly 200 adapts the assembly 200 for use in hydrojetting. In some embodiments, the fluid jet forming nozzles 210 may be longitudinally spaced along the conduit 208 such that when the conduit 208 is inserted into the well bore 120 , the fluid jet forming nozzles 210 will be adjacent to a local area of interest e.g., zones 212 in the subterranean formation F. As used herein, the term “zone” simply refers to a portion of the formation and does not imply a particular geological strata or composition. Conduit 208 may have any number of fluid jet forming nozzles, configured in a variety of combinations along and around the conduit 208 .
[0030] Once the well bore 120 has been drilled and, if deemed necessary, cased, a fluid 214 may be pumped into the conduit 208 and through the fluid jet forming nozzles 210 to form fluid jets 216 . In one embodiment, the fluid 214 is pumped through the fluid jet forming nozzles 210 at a velocity sufficient for the fluid jets 216 to form perforation tunnels 218 . In one embodiment, after the perforation tunnels 218 are formed, the fluid 214 is pumped into the conduit 208 and through the fluid jet forming nozzles 210 at a pressure sufficient to form cracks or fractures 220 along the perforation tunnels 218 .
[0031] The composition of fluid 214 may be changed to enhance properties desirous for a given function, i.e., the composition of fluid 214 used during fracturing may be different than that used during perforating. In certain embodiments, an acidizing fluid may be injected into the formation F through the conduit 208 after the perforation tunnels 218 have been created, and shortly before (or during) the initiation of the cracks or fractures 220 . The acidizing fluid may etch the formation F along the cracks or fractures 220 , thereby widening them. In certain embodiments, the acidizing fluid may dissolve fines, which further may facilitate flow into the cracks or fractures 220 . In another embodiment, a proppant may be included in the fluid 214 being flowed into the cracks or fractures 220 , which proppant may prevent subsequent closure of the cracks or fractures 220 . The proppant may be fine or coarse. In yet another embodiment, the fluid 214 includes other erosive substances, such as sand, to form a slurry. Complete well treatment processes including a variety of fluids and fluid particulates may be understood with reference to Halliburton Energy Service's SURGIFRAC® and COBRAMAX®. The fluid component embodiments described above may be used in various combinations with each other and with the other embodiments disclosed herein.
[0032] Referring now to FIGS. 4A and 4B , an exemplary casing window assembly 300 is shown as adapted for use in the well completion assembly 200 . As used herein, the term “casing window” refers to a section of casing configured to enable selective access to one or more specified zones of an adjacent subterranean formation. A casing window has a window that may be selectively opened and closed by an operator, for example, movable sleeve member 304 . The casing window assembly 300 can have numerous configurations and can employ a variety of mechanisms to selectively access one or more specified zones of an adjacent subterranean formation.
[0033] The casing window 300 includes a substantially cylindrical outer casing 302 that receives a movable sleeve member 304 . The outer casing 302 includes one or more apertures 306 to allow the communication of a fluid from the interior of the outer casing 302 into an adjacent subterranean formation. The apertures 306 are configured such that fluid jet forming nozzles 308 may be coupled thereto. In some embodiments, the fluid jet forming nozzles 308 may be threadably inserted into the apertures 306 . The fluid jet forming nozzles 308 may be isolated from the annulus 310 (formed between the outer casing 302 and the movable sleeve member 304 ) by coupling seats or pressure barriers 312 to the outer casing 302 .
[0034] The movable sleeve member 304 includes one or more apertures 314 configured such that, as shown in FIG. 4A , the apertures 314 may be selectively misaligned with the apertures 306 so as to prevent the communication of a fluid from the interior of the movable sleeve member 304 into an adjacent subterranean formation. The movable sleeve member 304 may be shifted axially, rotatably, or by a combination thereof such that, as shown in FIG. 4B , the apertures 314 selectively align with the apertures 306 so as to allow the communication of a fluid from the interior of the movable sleeve member 304 into an adjacent subterranean formation. The movable sleeve member 304 may be shifted via the use of a shifting tool, a hydraulic activated mechanism, or a ball drop mechanism.
[0035] Referring now to FIG. 5 , an exemplary well completion assembly 400 includes open casing window 402 and closed casing window 404 formed in a conduit 406 . Alternatively, the well completion assembly 400 may be selectively configured such that the casing window 404 is open and the casing window 402 is closed, such that the casing windows 402 and 404 are both open, or such the that casing windows 402 and 404 are both closed.
[0036] A fluid 408 may be pumped down the conduit 406 and communicated through the fluid jet forming nozzles 410 of the open casing window 402 against the surface of the well bore 120 in the zone 414 of the subterranean formation F. The fluid 408 would not be communicated through the fluid jet forming nozzles 418 of the closed casing window 404 , thereby isolating the zone 420 of the subterranean formation F from any well completion operations being conducted through the open casing window 402 involving the zone 414 . The fluid 408 may include any of the embodiments disclosed elsewhere herein.
[0037] In one embodiment, the fluid 408 is pumped through the fluid jet forming nozzles 410 at a velocity sufficient for fluid jets 422 to form perforation tunnels 424 . In one embodiment, after the perforation tunnels 424 are formed, the fluid 408 is pumped into the conduit 406 and through the fluid jet forming nozzles 410 at a pressure sufficient to form cracks or fractures 426 along the perforation tunnels 424 .
[0038] The embodiments disclosed above including hydrojetting are especially useful in deviated or horizontal well bores. In deviated or horizontal well bores, fractures induced in the formation tend to extend longitudinally, or parallel, relative to the well bore. Such fractures limit production. Hydrojetting causes fractures to extend radially outward, transverse, or perpendicular relative to the well bore. Such transverse fractures increase the area of the fractured zone, thereby increasing production of hydrocarbons from the formation. Including more hydrojetting apertures along the tool also increases the length of the fractured zone.
[0039] The embodiments described above are illustrative of various fluid jetting tools and conveyances to which embodiments described below may be applied. Other conveyances for fluid jetting apertures or nozzles are contemplated by the present disclosure as indicated below and elsewhere herein.
[0040] Referring now to FIG. 6A , a partial cross-section view of a fluid jetting window assembly 500 is shown, wherein the lower half of the assembly 500 is shown in cross-section for viewing certain internal components of the assembly 500 . The fluid jetting window assembly 500 includes an outer housing 502 having a flow bore 512 and apertures 504 , which will be described as jet forming apertures 504 but may also be pressurizing apertures or ports for directing fracturing fluids from the tool into the formation. The outer housing 502 may be coupled to casing string portions 506 , 508 to form a casing string cementable within a well bore as previously shown and described herein. As noted previously, the well bore may be vertical, horizontal, or various angles in between, and thus it is to be understood that the horizontal depiction of assembly 500 in FIGS. 6A-E and 7 may apply to any such well bore orientation. The outer housing 502 retains a movable window sleeve 510 , the window sleeve 510 being reciprocally disposed within the flowbore 512 of the outer housing 502 . The window sleeve 510 includes apertures 514 for communicating with a fluid flowing through the flow bore 512 . A removable member 516 is disposed over a portion of the outer surface of the outer housing 502 having the jet forming apertures 504 .
[0041] In the embodiment shown in FIG. 6A , the removable member 516 is a sleeve disposed around the outer housing 502 and over the jet forming apertures 504 . Retaining rings 518 are positioned above and below the removable sleeve 516 to couple the sleeve 516 to the outer housing 502 and retain the sleeve 516 in place over the jet forming apertures 504 (sleeve 516 and rings 518 being shown in cross-section). In some embodiments, the retaining rings 518 protect the removable sleeve 516 as the assembly 500 moves through the well bore 120 . The removable sleeve 516 is configured to cover the jet forming apertures 504 and isolate them from materials, fluid, and other obstructions that may be applied to the exterior of the outer housing 502 in the well bore environment. For the sake of clarity, the embodiments of FIGS. 6A through 7 are described with the removable member 516 being a sleeve, and the jetting tool assembly 500 being a jetting window conveyed as part of a casing string. Further, the casing string and assembly 500 are cemented in the well bore with cement 520 as one example of a plugging material that may obstruct the fluid jet forming apertures. However, as is recognized throughout the present disclosure, other combinations of fluid pressurizing or jetting tools (e.g., tools such as those shown in FIGS. 1 to 5 ), removable members, and obstructions are contemplated as part of the present disclosure.
[0042] In some embodiments, the sleeve 516 is removable by degradation. The degradable sleeve 516 may comprise a variety of materials. For example, the degradable sleeve may comprise water-soluble materials such that the sleeve degrades as it absorbs water. In an embodiment, the degradable sleeve 516 comprises a biodegradable material such as polylactic acid (PLA). In some embodiments, the degradable sleeve 516 comprises metals that degrade when exposed to an acid, also known as “acidizing.” Other embodiments for degradable sleeve 516 are also disclosed herein.
[0043] For example, the sleeve 516 comprises consumable materials that bum away and/or lose structural integrity when exposed to heat. Such consumable components may be formed of any consumable material that is suitable for service in a downhole environment and that provides adequate strength to enable proper operation of the degradable sleeve 516 . In embodiments, the consumable materials comprise thermally degradable materials such as magnesium metal, a thermoplastic material, composite material, a phenolic material or combinations thereof.
[0044] In an embodiment, the degradable materials comprise a thermoplastic material. Herein a thermoplastic material is a material that is plastic or deformable, melts to a liquid when heated and freezes to a brittle, glassy state when cooled sufficiently. Thermoplastic materials are known to one of ordinary skill in the art and include for example and without limitation polyalphaolefins, polyaryletherketones, polybutenes, nylons or polyamides, polycarbonates, thermoplastic polyesters such as those comprising polybutylene terephthalate and polyethylene terephthalate; polyphenylene sulphide; polyvinyl chloride; styrenic copolymers such as acrylonitrile butadiene styrene, styrene acrylonitrile and acrylonitrile styrene acrylate; polypropylene; thermoplastic elastomers; aromatic polyamides; cellulosics; ethylene vinyl acetate; fluoroplastics; polyacetals; polyethylenes such as high-density polyethylene, low-density polyethylene and linear low-density polyethylene; polymethylpentene; polyphenylene oxide, polystyrene such as general purpose polystyrene and high impact polystyrene; or combinations thereof.
[0045] In an embodiment, the degradable materials comprise a phenolic resin. Herein a phenolic resin refers to a category of thermosetting resins obtained by the reaction of phenols with simple aldehydes such as for example formaldehyde. The component comprising a phenolic resin may have the ability to withstand high temperature, along with mechanical load with minimal deformation or creep thus provides the rigidity necessary to maintain structural integrity and dimensional stability even under downhole conditions. In some embodiments, the phenolic resin is a single stage resin. Such phenolic resins are produced using an alkaline catalyst under reaction conditions having an excess of aldehyde to phenol and are commonly referred to as resoles. In some embodiments, the phenolic resin is a two stage resin. Such phenolic resins are produced using an acid catalyst under reaction conditions having a substochiometric amount of aldehyde to phenol and are commonly referred to as novalacs. Examples of phenolic resins suitable for use in this disclosure include without limitation MILEX and DUREZ 23570 black phenolic which are phenolic resins commercially available from Mitsui Company and Durez Corporation respectively.
[0046] In an embodiment, the degradable material comprises a composite material. Herein a composite material refers to engineered materials made from two or more constituent materials with significantly different physical or chemical properties and which remain separate and distinct within the finished structure. Composite materials are well known to one of ordinary skill in the art and may include for example and without limitation a reinforcement material such as fiberglass, quartz, kevlar, Dyneema or carbon fiber combined with a matrix resin such as polyester, vinyl ester, epoxy, polyimides, polyamides, thermoplastics, phenolics, or combinations thereof. In an embodiment, the composite is a fiber reinforced polymer.
[0047] The degradable sleeve 516 is used for description purposes herein, but the removable member is not to be limited by same. In some embodiments, the removable member is removable by other means. For example, in some embodiments, the removable member is a sleeve movable by actuation or shifting, as with the movable sleeve member 304 . In other embodiments, the removable member may be removed by breakage.
[0048] Referring now to FIGS. 6A through 6E , the fluid jetting window assembly 500 is illustrated in operation, wherein the embodiment shown includes a degradable sleeve 516 . Referring first to FIG. 6A , a closed position of the fluid jetting window assembly 500 is shown, wherein the window sleeve 510 is positioned such that the apertures 514 communicating with the fluid in the flowbore 512 are misaligned with the jet forming apertures 504 . The degradable sleeve 516 is disposed about the outer housing 502 adjacent the jet forming apertures 504 , and retained by retaining rings 518 . The window assembly 500 , in this “run-in” position, may be coupled to casing string portions 506 , 508 and conveyed together into a well bore, such as well bore 120 . Cement 520 may then be applied to the outer portions of the window assembly 500 and casing string portions 506 , 508 to attach them to the well bore (not shown). The sleeve 516 prevents cement from entering the jet forming apertures 504 and plugging them or otherwise obstructing the apertures.
[0049] In some embodiments of the cemented, closed position shown in FIG. 6A , the degradable sleeve 516 begins to degrade immediately or soon after the assembly 500 is cemented into position. For example, if the degradable sleeve 516 is a PLA sleeve, water from the environment exterior of the housing 502 will contact the PLA sleeve and begin to degrade it. Water may come from screens in the back side of the casing, for example, or from the cement slurry. The degradable sleeve 516 may experience varying degrees of degradation, from little to entire sleeve consumption, for example, while the assembly 500 is closed. Alternatively, the sleeve 516 may have begun to degrade from exposure to other fluids or materials present in the well bore during other operations involving the jetting window assembly 500 .
[0050] Referring now to FIG. 6B , fluid jetting window assembly 500 is shown in the open position. The window sleeve 510 has been selectively actuated, mechanically, hydraulically, or by other means for actuating movable sleeves, to a position where the window apertures 514 are aligned with the jet forming apertures 504 . The alignment of the window apertures 514 and the jet forming apertures 504 provides a fluid jet flow path 530 between the interior flow bore 512 and the exterior of the outer housing 502 . At this time, in embodiments including a biodegradable sleeve 516 , the sleeve 516 is in varying stages of degradation. In alternative embodiments, the sleeve 516 is moved, broken, or otherwise removed from covering the jet forming apertures 504 just before or after the assembly is opened as just described. It may be desirable to degrade or remove the sleeve 516 before the assembly 500 is opened such that the apertures 504 are uncovered, or partially uncovered, while pressure integrity is maintained within the assembly 500 .
[0051] In some embodiments wherein a degradable sleeve is present, while the assembly 500 is in the open position, a fluid is communicated from the flow bore 512 , through the jet flow path 530 , and to the degradable sleeve 516 to begin or assist in the degradation process. In embodiments where the sleeve is made of PLA or other biodegradable materials, it may take, for example, a day to several days for substantial degradation of the sleeve to occur while only exposed to the well bore environment. In one embodiment, an acid may be “spotted” through the jet flow path 530 to assist with degradation of the sleeve 516 . This provides a more selective degradation of the degradable sleeve 516 . Spotting acid at this point and location may also focus the process of extending the jet flow path from the jet forming apertures 504 radially outward from the housing 502 at least to a distance equal to the width W of the sleeve 516 . In a further embodiment wherein the sleeve 516 is made of metal, such as aluminum, or another more robust material, an acid may be flowed into the jet flow path 530 to melt or otherwise degrade the sleeve while the assembly 500 is in the open position.
[0052] In additional embodiments wherein the sleeve 516 is degradable, the degradation of the sleeve 516 may create an acid, such as lactic acid, or other erosive material which then begins to degrade the cement. Degradation of the cement beyond the sleeve 516 assists in further extending the jet flow path generally in the area 522 of the cement formation 520 (which is created from a cement slurry applied in the usual manner).
[0053] In still further embodiments, the jet forming apertures 504 may be filled with a degradable substance or removable member. In one embodiment, the apertures 504 are filled with a plug made of the same material as the degradable sleeve 516 , such as PLA. A PLA plug may simply be a portion of PLA in the shape of a plug that is adapted to be inserted into an aperture 504 . In another embodiment, the apertures 504 are filled with a gel that can be degraded as disclosed herein, or may be pushed out of the apertures 504 with fluid pressure. It yet another embodiment, the apertures 504 can be filled with removable members, for example, rupture disks that are selectively ruptured for removal. In the embodiments just described, the aperture-fillers may be used in conjunction with the sleeve 516 , or, alternatively, in place of the sleeve. If the sleeve 516 is not present, the aperture-fillers just described may be removed consistent with those embodiments disclosed herein. In such an embodiment, certain benefits may be achieved, such as the presence of less PLA material; however, certain features are compromised, such as the cavity created by a sleeve beyond the outer tool surface to increase jetting, and the increased acidization provided by a sleeve.
[0054] Referring now to FIG. 6C , degradation of the sleeve 516 has weakened the sleeve 516 and, in some embodiments, the adjacent cement or other surrounding degradable materials. A fluid, such as a perforating or fracturing fluid, is pumped through the flow bore 512 and into the first jet flow path 530 formed by the aligned window apertures 504 and jet forming apertures 504 . The fluid jet from the jet forming apertures 504 creates a perforation 524 , or second jet flow path, extending from the jet forming apertures 504 , through the degraded sleeve 516 (or possibly a completely eliminated sleeve depending on the degree of degradation), and into the cement formation 520 .
[0055] Despite the high pressure in flow bore 512 , the perforation 524 or other extension of the jet fluid flow path beyond the jet forming apertures 504 is significantly hindered without the sleeve 516 . As used herein, high pressure, for example, is generally greater than about 3,500 p.s.i., alternatively greater than about 10,000 p.s.i., and alternatively greater than about 15,000 p.s.i. If sleeve 516 is not present, the cement 520 abuts the outer housing 502 and is flush with the jet forming apertures 504 , thereby obstructing them and resisting fluid flow. Cement may also enter the jet forming apertures 504 and plug them, thereby further increasing resistance to fluid flow therethrough. Under these circumstances, the area of the cement, or other viscous material applied to the outer housing 502 , to which the high pressure fluid in the flow bore 512 is applied is very small, i.e., the size of the jet forming aperture, which is intended to be small to provide the fluid jetting function. If, for example, the jet forming aperture has a diameter of 0.25 inches, the area of the aperture is 0.049 inches squared. Even at 5,000 p.s.i. in flow bore 512 , the force applied to the cement 520 is approximately 250 pounds. A force of this size is typically not efficient to crack or perforate the cement 520 .
[0056] Removal of the sleeve 516 , however, increases the force applied to the cement 520 by creating distance between the jet forming apertures 504 and the cement 520 and widening the area upon which the high pressure jet is applied. For example, as shown in FIGS. 6A and 6B , the area of applied pressure may be increased, in one dimension, from the diameter of the aperture 504 to the length L of the sleeve 516 . Furthermore, the distance between the apertures 504 and the cement 520 also allows the high pressure fluid to flow along an extended fluid jet flow path. For example, as also shown in FIGS. 6A and 6B , the distance W may be used to extend the high pressure fluid jet flow path.
[0057] Referring next to FIG. 6D , the fluid in flow bore 512 continues to be pumped at a high pressure such that the fluid continues to flow along the first jet fluid flow path 530 at apertures 514 , 504 , along the second jet fluid flow path extending from the jet forming apertures 504 and along the perforations 524 , and further extends the jet fluid flow path at the fractures 526 . The fractures 526 increase production of hydrocarbons from the formation F. In one embodiment, hydrocarbons may be produced through the assembly 500 by pumping fluids in the flow bore 512 in the opposite direction, thereby drawing hydrocarbons from the formation F along the jet fluid flow path at the fracture 526 , the perforations 524 , and finally in through the aligned apertures 514 , 504 . In another embodiment, as shown in FIG. 6E , the jetting window assembly 500 maybe closed. The window sleeve 510 is moved or actuated back to its original closed position, thereby misaligning the apertures 514 and the jet forming apertures 504 and preventing fluid flow therebetween.
[0058] Referring to FIG. 7 , an alternative embodiment of the jetting window assembly is shown. Jetting window assembly 600 includes a larger degradable sleeve 616 (which may also be any of the various sleeves or removable members disclosed herein) bounded by larger retaining and protection rings 618 . In this embodiment, the area of isolation about the jet forming apertures 604 is increased, as partially shown by the dimensional length L 2 . As previously disclosed, increasing the length to L 2 increases the available area for fluid jetting onto the cement formation (not shown), and thereby increasing the perforating and fracturing forces on the cement. Furthermore, the length L 2 , as opposed to the length L of FIGS. 6A and 6B , for example, provides more flow space for creating longitudinal fractures. A sleeve with length L may be used for creating transverse fractures.
[0059] The various embodiment described herein provide a system for isolating apertures in a high pressure fluid stimulation tool from the exterior of the tool and preventing the apertures from becoming plugged or otherwise obstructed. In some embodiments, the apertures include jet forming nozzles that are susceptible to plugging when the tool in which the jet forming nozzles are placed is cemented onto a well bore. In addition to cementing, other downhole operations or conditions may also introduce plugging materials or hindrances at the nozzles in a jetting tool. A plugged or hindered jetting nozzle then cannot perform its fluid jetting function properly. Thus, maintaining unplugged and unobstructed high pressure fluid apertures and/or jet forming nozzles in high precision fluid stimulation tools is very beneficial. In addition, while some embodiments disclosed herein include acidizing a degradable sleeve, the embodiments of the system disclosed herein avoid the difficult and expensive step of attempting to acidize cement or other obstruction present inside the relatively small fluid apertures and/or jet forming nozzles.
[0060] While specific embodiments have been shown and described, modifications can be made by one skilled in the art without departing from the spirit or teaching of this invention. The embodiments as described are exemplary only and are not limiting. Many variations and modifications are possible and are within the scope of the invention. Accordingly, the scope of protection is not limited to the embodiments described, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. | An embodiment of a well bore servicing apparatus includes a housing having a through bore and at least one high pressure fluid aperture in the housing, the fluid aperture being in fluid communication with the through bore to provide a high pressure fluid stream to the well bore, and a removable member coupled to the housing and disposed adjacent the fluid jet forming aperture and isolating the fluid jet forming aperture from an exterior of the housing. An embodiment of a method of servicing a well bore includes applying a removable member to an exterior of a well bore servicing tool, wherein the removable member covers at least one high pressure fluid aperture disposed in the tool, lowering the tool into a well bore, exposing the tool to a well bore material, wherein the removable cover prevents the well bore material from entering the fluid aperture, removing the removable member to expose a fluid flow path adjacent an outlet of the high pressure fluid aperture, and flowing a well bore servicing fluid through the fluid aperture outlet and flow path. | 4 |
This is a continuation of application Ser. No. 07/447,862, filed Dec. 8, 1989, now abandoned.
FIELD OF THE INVENTION
This invention relates to pads for concrete railway ties. More particularly, it relates to improvements in the shape of such pads with the object of attenuating the dynamic loads generated by train wheel surface anomalies and the resulting stresses to which vehicle components (wheels, bearings etc.) and track components (concrete railway ties, rails) are exposed.
BACKGROUND TO THE INVENTION
Under the action of good wheels and a level track or bridge system, the distribution of train wheel loads on the concrete ties, according to the conventional wisdom, depends on:
(a) the tie spacing;
(b) the ballast stiffness or the stiffness of the tie-girder bearing pads in the case of open deck bridges; and
(c) the size of the rail. Changing the size of the tie and the characteristics of rail-tie pad has not generally been thought to have a significant effect on the distribution of train wheel load on concrete ties. This invention concerns improvements to the pads in ways not previously perceived as being available.
In practice, track and bridge ties are subjected to moving axle loads. Because of the vehicle speed, wheel imperfections and random differences of levels and other differences in the field, the dynamic load transmitted to the concrete tie is much higher than the static load. This increase over the static load manifested itself in 1980 along the North-East rail corridor (between Washington D.C. and Boston) where concrete track ties were found to have developed hairline cracks only a few months after their installation. It should be noted that concrete ties normally are thought to have a projected life expectancy of 50 years. Similar experiences of tie failure have been reported by the Canadian, European and Japanese railways.
To accommodate this increase of dynamic loads over the static load and the resulting risk of damage, the code committees in various countries use the so called "Impact Factor", (I.F.), in concrete tie design to accommodate for the dynamic component of the railway track loading. In North America, an Impact Factor of 60% (excess design load over 100% static load capacity) was initially recommended by the Association of American Railroads (AAR). The disappointing performance of concrete ties designed with the 60% increase factor led to a recommendation by the AAR for an "Impact Factor" (I.F.) of 150% which is presently used today. Yet concrete ties designed with the 150% Impact Factor have suffered the same fate as their predecessors. Presently, a new proposal has been tabled by some members of the AAR asking for an increase of the Impact Factor to 200%.
To understand the nature of distribution and attenuation of dynamic (especially impact) loading, attention must be paid to the effects of rail-to-tie pad stiffness and tie-to-girder pad stiffnesses.
It has been found that the dynamic over-loading of concrete ties is not influenced by the train speed, provided that the train wheels are smooth and have no surface irregularities, such as "shells" or flats. When these are present on the wheel running surface, the response of the concrete tie to the wheel loading has been observed to be dependent on the train speed and the impact load is dependent on the unsprung mass of the train-wheel set. At low speeds (0-40 mph), (0-64 km/h), there can be a complete unloading of the ties followed by impact. At high speeds (above 50 mph {80 km/h}), particularly in the case of lighter passenger trains, the wheels can become temporarily airborne for a very small time interval, and then impact on the rail a number of times on landing. This creates very high dynamic loads not only on the supporting tie, but also on other track and vehicle components.
To protect concrete ties and to reduce the probability of rail or wheel fractures or shelling due to the impact resulting from the wheel defects on the various trains, the EVA (Ethyl Vinyl Acetate) pad, a solid and very stiff (stiffness=10800 kips/in) pad, was developed by Pandrol Limited in Britain. This pad has been used extensively between rails and concrete ties. Research findings have shown, however, that solid pads and other equivalently stiff pads transmit enough impact energy to cause cracking of concrete ties. Solid, stiff pad designs commercially available do not afford the degree of protection for ties that would be desired by the railways. As indicated previously, in some cases, the concrete ties have developed cracks less than six months after being put into service.
Attempts in the past to improve the performance of the tie-pads have included the selection of certain surface profiles, such as linear grooves, perforations, surface patterns in the form of directly opposed studs and shallow dimples.
Prior patents that have addressed these issues are as follows:
U.S. Pat. No. 2,656,116--Protzeller assigned to Arthur Wm. Nelson (perforations)
U.S. Pat. No. 4,254,908--Matsubara assigned to Tokai Rubber Industries Ltd. (offset grooves)
U.K. 2,161,524--Brister et al, issued to Pandrol Limited (opposed studs)
U.S. Pat. No. 4,648,554--McQueen, issued to Acme Plastics Inc. (offset dimples)
The effect of such profile variants has been to provide pads that substantially absorb applied loads by undergoing compression. Design control over the response of such pads under compression is, however, limited.
Ideally, a railway tie pad should be capable of both absorbing the equivalent static load of a heavy, slow-moving freight train, and the dynamic, high frequency, shock loading created by higher speed trains. Such dual characteristics are not easily found in a single pad design.
This invention achieves an improvement in the design for the rail-tie pads by controlling the stiffness of the pad under such variable conditions. This is done by modifying its shape in order to improve the attenuation of impact loading. Tie pads made in accordance with the invention rely on the creation of shear stress within the pad and/or novel surface profiles to provide a means for creating a multi-stage response function that is suitable for sustaining both light and heavy loads and, at the same time, attenuating high frequency dynamic stresses.
These and further features of the invention will be apparent from the description which now follows.
SUMMARY OF THE INVENTION
According to the invention tie-pads are provided with studded upper and lower surfaces laid over a central core wherein respective studs on opposed sides of the pad are substantially off-set from vertical alignment with each other so as to permit the formation of bending and shear stress in the core of the pad and compressive stresses in the studs when the pad is subjected to loading.
By a further feature of the invention, the studs provided on the pad surfaces are of differing lengths so that, upon progressive loading of the pad, studs of differing lengths are progressively exposed to loading.
In a further aspect of the invention a tie-pad is provided having on at least one side of the pad a mixed field of two classes of studs consisting of: (1) a first class of primary studs of greater height off the pad core and (2) a second class of secondary studs of a lesser height off the pad wherein the primary studs are substantially offset from vertical alignment with the corresponding primary studs on the opposite side of the pad core, and the secondary studs are substantially vertically aligned with the corresponding primary studs on the opposite side of the pad core whereby when the pad is progressively loaded, the primary class of studs absorb loading first, followed by the secondary class of studs.
These and further features of the invention will be apparent from the descriptions of the preferred embodiments which now follow.
SUMMARY OF THE FIGURES
FIG. 1 is an example of a prior art pad with linear grooves;
FIG. 2 is an example of a prior art pad with opposed studs;
FIG. 3 is an example of a prior art pad with dimples;
FIG. 4 is an example of a pad according to the invention with offset studs;
FIG. 5 is a pad according to the invention with slightly overlapping opposed studs;
FIG. 6 is a pad with studs of primary and secondary heights on opposed sides of the pad;
FIG. 7 is a pad in which the primary and secondary studs are of differing diameters;
FIG. 8 is an alternate arrangement for studs of differing diameters; and
FIG. 9 is a cross-sectional view of studs showing filleting in the corners.
FIG. 10 is a cross-section of a rail mounted on a pad that is adapted to resist the canting of the rail.
Where face and sectional views are provided of the same pad, the face view is designated by "a" and the sectional view by "b".
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a known configuration of pad 1 with linear groves 2. The grooves 2 are spaced so that the core 3 of the pad 1 is generally subject to compression on loading. In such pads, strain is typically a linear function of stress.
FIG. 2 shows another known pad 1 configuration in which pad 1 is provided with a series of studs 5 mounted on opposed sides of the pad 1 in substantial vertical alignment with each other.
FIG. 3 shows a further known pad configuration in which the pad 1 is provided with shallow dimples 4 on opposed sides of the pad 1. The dimples 4 are distributed in such a manner that the core 3 of the pad is substantially in a state of compression when loaded.
FIG. 4 shows a pad 1 according to one aspect of the invention whereby the pad 1, of generally planar proportions, has studs 5 formed on opposed sides in an off-set manner. Thus a specific stud 6 on the upper side 7a is not directly over a stud on the lower side 7b. The most proximate stud 8 on the lower side 7b is off-set from alignment with the upper stud 6.
FIG. 4 shows a case where the off-set is total. That is, there is no vertical overlap between the upper 6 and lower studs 8. This results in shear and bending stress developing within the core 3 in the stress region 9 between the two studs. With the selection of suitable materials for the body or core 3 of the pad, the stress region 9 will deform elastically under load. Such deformation will exhibit a differing level of stiffness than would arise from the compression of the studs 6, 8.
The core should be made of a resilient material, capable of bearing a degree of tension resiliently, as well as being resiliently resistant to compression. Further control over the level of stiffness arising from deformation of the off-set region 9 may be provided by including a fibre matrix 10 within the core of the pad which is adapted to enhance its ability to resist, resiliently, tensile stress.
The degree of offset shown in FIG. 4 has been exaggerated for clarity. To provide a high bearing surface for a rail, the degree of offset should be minimal.
FIG. 5 shows a pad with upper and lower studs 11 and 12 in which the off-set is less than total. Also, studs of optional circular form are shown. In this case, a small degree of overlap occurs in the overlap region 13 that lies between the edges of the upper and lower studs 11 and 12. This overlapping allows an array of studs of higher density to be formed, increasing the bearing surface area of the pad. The studs are optionally laid-out so that the overlap occurs along diagonals. By providing a small degree of overlap, a mixed condition of compression and shear stress can be created within the pad core 3. This provides a means to reduce the rate of onset of deformation under load that will arise from bending around the overlap region 13.
The preferred maximum degree of overlap, where overlap is provided, that is believed suitable in this application is between 0 and about 20% of the surface area of the studs. Where a single larger upper stud is opposed by several lower studs of smaller diameter, the total overlapped area for the upper, larger stud may be as much as 50%. However, a significantly greater degree of overlap will produce a pad in which compressive resistance to loading predominates, and in which the benefits of creating a bending stress will be significantly reduced.
The pad of FIG. 5 is capable of absorbing shock loads to a superior degree by reason of the reduced stiffness of such a pad, achieved by providing the studs' material with more space to deform into, as compared to a pad of the types of FIGS. 1 to 3. The improved performance of the studs resulting from the extra space for the material to deform-into arises from the fact that rubber like materials has poisson ratio close to 0.5 and thus does not under go a volumetric change under load. The bearing surface of the pad of FIGS. 4 & 5 is, however, reduced. Under light loads the surface area may suffice. To protect this pad from excessive distortion under heavy loads, and to allow the pad to accommodate heavy loads, a further optional feature may be provided.
FIG. 6 shows a pad 1 in which an additional shorter stud 14 is placed in the gap below an upper stud 11. This stud 14 is shorter than the adjacent full-height stud 12. The result is that on loading of the pad, the shorter stud limits the degree of deformation that will occur in the off-set regions 9, or overlapping regions 13 in FIG. 5a,b, as the case may be. This shorter stud 14 serves to prevent the over-stressing of such regions beyond the elastic limit of the material in the core 3.
It is not necessary in this configuration that all studs of the greater height be offset from the corresponding full-height studs on the opposing side. A mixed field of studs of greater and lesser heights will provide a progressive resistance to loading, whether or not bending stresses are created. It is preferable, however, that the creation of some bending stresses be present.
FIG. 7 shows a pad in which a first set of higher, primary upper studs 15a, constituting a field of studs, are interspersed on the same upper side 7a of the pad with a second set of shorter, secondary studs 16 of a lesser diameter, constituting a second field of studs. A similar but offset pattern of studs is provided on the lower side 7b of the pad 1. Thus the field of wider, upper primary studs 15a are opposed on the side opposite by a field of secondary studs 17 of shorter height than the primary lower studs 15b on the lower side 7b. These secondary studs 16,17 are all of a height suitable to reduce the risk of excessive deformation of the core 1, while permitting bending strain to arise within the core 1. At the same time this lower secondary stud 17 is surrounded by larger diameter primary studs 15b which induce bending strain when the pad is initially, or lightly, loaded.
The use of alternate studs of differing diameters as well as heights allows for a higher density of studs to be formed, increasing the bearing surface, while still providing a means to influence stiffness. Once again, the offset between primary upper and lower studs allows the pad to absorb loads partially through bending, while the secondary studs limit the degree of deformation under bending stress, thus protecting the pad from excessive distortion and improving the pads capacity to handle heavy loads.
An even higher density array of studs of mixed diameters and heights is shown in FIG. 8. In this example, the wider, upper studs 19 are laid-out in staggered rows 20. Each upper stud 19 is opposed on the lower side by a secondary stud 21 of a diameter that is less than that of the upper stud 19.
Surrounding each secondary stud 21 on the lower side is an encircling array of primary lower studs 22 that are offset from the upper studs 19, and are of a smaller diameter than such upper studs 19. Thus, the lower primary studs 22 are not opposed by a secondary stud on the upper side. And the bearing area of primary studs 22 on the lower side exceeds that of the secondary studs 21 on the lower side.
In all of the foregoing drawings the studs, whether of a round or rectilinear cross-section, have been shown as having vertical walls and sharp corners and edges. These are not essential characteristics. The corners 23 of the studs 24 at the base of the stud walls 26 may be filleted 27 for ease of manufacture, and to reduce stress concentration and subsequent crack formation. This is shown in FIG. 9.
Studs have been shown which are round and square in cross-section. These shapes are not critical to the functioning of the invention. Studs according to the invention may be rectilinear in cross-section, e.g. hexagonal, or have continuous curvature e.g. elliptical. While studs may have both positive and negative curvature in the shape of their outer walls in cross-section (a circle being defined as having positive curvature) it is believed that studs of positive curvature are to be preferred as providing greater freedom for the walls of the studs to bulge or expand on compression.
Further, while the studs shown are all depicted as being substantially free-standing from each other, the effects of creating bending stresses will still be obtained even if the studs are linked by bridging elements. Such bridging elements should not, however, be so extensive as to eliminate the creation of bending stresses, which are a preferred characteristic of the invention.
In selecting a configuration for a stud pattern, it is desirable to present a high surface area on the stud ends facing the directions of applied forces, i.e. up and down; while providing sufficient space between the studs to allow for expansion of the stud walls through bulging under load. It is further thought that near-vertical walls are preferable as providing improved expansion freedom for the walls on compression, although such a feature is not essential.
The optimum material for producing the pads according to the invention will be known to those engaged in the art. Essentially, pads should be made of polymeric material with high elasticity and low damping characteristics, such as hard cured rubber, and modern synthetic equivalents.
FIG. 6 shows one further pad variant adapted for use on corners and curves on a railway track. The pad 1 in FIG. 6 is provided with a partially elevated outer support region 28 which is intended, by reason of the absence of studs, to have a greater stiffness than the studded region of the pad. This outer support region 28 should also be of slightly less height than the adjacent primary studs 11. The object is to provide support for the outer edge of the rail bottom when a rail 29 is slightly canted by a sideways force. This effect is shown in FIG. 10. Once the adjacent primary studs 11 are partially compressed, the rail 29 will bear on the relatively incompressible outer support region 28 of the pad 1 and resist further canting of the rail 29.
In this configuration, the outer support region 28 is made of the same material as the studs 11, thereby having the same intrinsic compressibility. This allows for the pad to be molded with a single material for each element. The variation in stiffness between the studded region and the outer support region 28 arises only from the differences in their geometric configuration. Because reduced stiffness for the studded region arises due to the freedom of the studs to bridge and for bending strain to develop (due to the offset arrangement of studs) the studs and outer support region may be made of a more incompressible material. This provides flexibility in design to ensure that the outer support region 28 is sufficiently stiff to serve its function.
This arrangement represents an improvement that may be used in conjunction with offset studs to improve a pad of such configuration. But this arrangement will also serve usefully whether or not the studs are offset. The ability to utilize material of the same compressibility for the central region of the pad as well as the outer support region 28 arises so long as the overall compressibility of the central region is reduced by geometrically interrupting the pad surfaces in this region to provide fields of more highly compressible studs. Such studs need not be offset, but may be opposed, in whole or in part.
SUMMARY
The effect of the invention is to provide a railway tie-pad which has increased capacity to absorb dynamic or shock loading. Further features include the capacity to provide multiple spring action adapted to accommodate heavy static (or rolling) loads, and capable of improved dissipation of dynamic (or impact) loads when the pad is less heavily loaded.
The theory behind pads made according to the invention is that it is desirable to provide a pad of reduced compressivity, lower modulus of elasticity and low damping characteristics in order to attenuate impact loads. At the same time, provision may be made to ensure that the pad is not liable to excessive deformation under higher rolling loads.
Since resistance to compression increases with loading, impact loads are not accommodated as satisfactorily when a tie is heavily loaded as when a tie is lightly loaded. Such loss of impact resistance is, in existing pads, presently approximately a linear, or at least a continuous, function of loading. This invention provides means to varying the schedule of resistance exhibited by a pad under progressive loading, thereby providing greater control over the capacity of such a pad to dissipate impact loads.
When pads according to the invention are subject to light loads, e.g. passenger trains, such pads are relatively compressive and effective. Under such conditions, pads according to one aspect of the invention have lower stiffness and a higher capacity to absorb shock stresses.
Under heavier rolling loads, e.g. fright trains, the pad of the invention, in a further version, deforms past its low stiffness condition and become stiffer. In such a condition, the pad is still able to at least partially dissipate impact shocks to an improved extent. This is because for the shock loading to be imparted onto the rail, there has to be a prior partial or complete unloading of the rail. When unloaded the pad immediately springs back to its highly elastic (low stiffness) state in readiness to receive the impact (shock). At the same time these pads can sustain the heavier rolling load. After the heavy rolling load has passed, these pads are able to resume their low stiffness state, and thus are able once again to show improved dissipation of impact loads.
The foregoing has constituted a description of exemplary embodiments of the invention. These are examples only. The full scope and character of the invention is further described and defined in its broadest and more specific applications in the claims which now follow. | A railway tie pad is provided with studs that are either offset from opposed positions from each other, on opposite sides of the pad; or are of differing heights. Pads with these features are capable of being more efficient in isolating ties and rails from shock loading, and in accommodating varying loads with differing cushioning characteristics. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY
[0001] The present application is related to and claims priority under 35 U.S.C. §119(a) to an Indian patent provisional application filed in the Indian Intellectual Property Office on Oct. 22, 2014 and assigned Serial No. 5275/CHE/2014 and an Indian patent complete application filed in the Indian Intellectual Property Office on Sep. 30, 2015 and assigned Serial No. 5275/CHE/2014, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The embodiments herein relate to wireless communication networks and, more particularly, to transmitting and receiving protocol data unit between a User Equipment (UE) and Base Station (BS) in the wireless communication networks.
BACKGROUND
[0003] To meet the demand for wireless data traffic having increased since deployment of 4G (4th-Generation) communication systems, efforts have been made to develop an improved 5G (5th-Generation) or pre-5G Communication system. Therefore, the 5G or pre-5G communication system is also called a ‘Beyond 4G Network’ or a ‘Post LTE System’.
[0004] The 5G communication system is considered to be implemented in higher frequency (mmWave) bands, e.g., 60 GHz bands, so as to accomplish higher data rates. To decrease propagation loss of the radio waves and increase the transmission distance, the beamforming, massive multiple-input multiple-output (MIMO), Full Dimensional MIMO (FD-MIMO) array antenna, an analog beam forming, large scale antenna techniques are discussed in 5G communication systems.
[0005] In addition, in 5G communication systems, development for system network improvement is under way based on advanced small cells, cloud Radio Access Networks (RANs), ultra-dense networks, device-to-device (D2D) communication, wireless backhaul, moving network, cooperative communication, Coordinated Multi-Points (CoMP), reception-end interference cancellation and the like.
[0006] In the 5G system, Hybrid FSK and QAM Modulation (FQAM) and sliding window superposition coding (SWSC) as an advanced coding modulation (ACM), and filter bank multi carrier (FBMC), non-orthogonal multiple access (NOMA), and sparse code multiple access (SCMA) as an advanced access technology have been developed.
[0007] In existing communication networks, comprising user equipment (UE), enhanced node B (eNB), serving gateway (S-GW) and packet data node gateway (PDN-GW), the incoming data via any of several protocols, such as IP, TCP and so on, are converted to blocks of data that can be transported by the Physical layer, by intermediate layers, namely PDCP (Packet Data Convergence Protocol), RLC (Radio Link Control) and MAC (Medium Access Control). These layers provide several functions such as multiplexing, parsing, unpacking, reassembly functions among others.
[0008] Any data received by an LTE network is converted to transport blocks by the various layers present in the LTE network in order for the data to be transported by the physical layers. Data transported between various levels come in different sized blocks. Each transport layer communicates the size of each block transported to the next layer and the penultimate layer. The MAC layer generates the MAC Protocol Data Unit (PDU) carrying one or more data blocks for MAC Service Data Units). The MAC layer adds a MAC subheader for each of the MAC SDU in MAC PDU. The size of MAC SDU is indicated in length field of MAC subheader wherein the length field is either 7 bits or 15 bits. Format bit field in the MAC subheader indicates whether length field is 7 bit or 15 bits. The maximum size of MAC SDU that can be indicated using the current MAC subheader is 32767 octets or bytes.
[0009] However, the 15-bit field indicating the size of each transport block is insufficient to indicate the size of any data greater than 32767 octets. For emerging communication technologies such as aggregation of large number of carriers or usage of carriers of larger bandwidth to support high data rate, the size of the length field is insufficient to indicate size of the data blocks being transported from any transmitter to a receiver and vice versa. Since the current communication technologies are already deployed with this limitation a backward compatible solution is needed to support larger MAC SDU sizes. Two MAC subheaders can be defined wherein one MAC subheader has a shorter length field and another MAC subheader has longer length field. Network indicates in signaling whether to use first header or second subheader. The disadvantage of this method is that once the network indicates to use header with large length field then irrespective of size of MAC SDU this subheader needs to be used. This leads to unnecessary overhead in each MAC PDU for shorter size MAC SDU.
SUMMARY
[0010] To address the above-discussed deficiencies, it is a primary object of the embodiments herein is to transmit and receive Protocol Data Unit (PDU) between a transmitting node and a receiving node in a communication network.
[0011] In view of the foregoing, a first embodiment herein provides a method for data transmission in a communication network. Initially, a length of MAC SDU to be transmitted is determined by a transmitting node of said communication network. The transmitting node further decides whether said length of MAC SDU is less than a threshold. If the length of MAC SDU is less than the threshold, then the transmitting node encodes the length of MAC SDU in a first MAC subheader format. If the length of said MAC SDU is not less than the threshold, then the transmitting node determines whether a large MAC SDU is configured or not. The transmitting node encodes the length of MAC SDU in a second MAC subheader format, if said large MAC SDU is configured and if said length of MAC SDU is not less than said threshold. The transmitting node encodes the length of MAC SDU in a third MAC subheader format, if said large MAC SDU is not configured and if said length of MAC SDU is not less than said threshold. Further, the MAC SDU is transmitted with the MAC subheader, to a receiving node of said communication network, by said transmitting node.
[0012] In a second embodiment, a system for data transmission in a communication network is provided. A transmitting node in the system determines a length of MAC SDU to be transmitted, and then determines whether said length of MAC SDU is less than a threshold. If the length of MAC SDU is lesser than said threshold, then the transmitting node encodes the length of MAC SDU in a first MAC subheader format. If the length of MAC SDU is not less than the threshold, then the transmitting node determines whether a large MAC SDU is configured. If said large MAC SDU is configured and if said length of MAC SDU is not less than said threshold, the transmitting node encodes the length of MAC SDU in a second MAC subheader format. If said large MAC SDU is not configured and if said length of MAC SDU is not less than said threshold, then the transmitting node encodes the length of MAC SDU in a third MAC subheader format. Further, the MAC transmitting node transmits the MAC SDU with said MAC subheader, to a receiving node of said communication network.
[0013] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
[0014] Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well, as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized, or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that, in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0016] FIG. 1 illustrates a block diagram of an example communication network according to this disclosure;
[0017] FIG. 2 is a flow diagram that depicts steps involved in an example process of transmitting protocol data unit by the transmitting node to the receiving node in the communication network according to this disclosure;
[0018] FIGS. 3A and 3B illustrate flow diagrams that depict example transmitter side operations and receiver side operations, respectively, according to this disclosure; and
[0019] FIGS. 4A-4H illustrate different example frame formats of MAC sub-header, used for transmitting and receiving protocol data unit in the communication network, according to this disclosure.
DETAILED DESCRIPTION
[0020] FIGS. 1 through 4H , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged communication system. The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein are practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein
[0021] The embodiments herein disclose a mechanism for transmitting and receiving protocol data unit between a transmitting node and a receiving node in a communication network. Referring now to the drawings, and mote particularly to FIGS. 1 through 4H , where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0022] FIG. 1 illustrates a block diagram of an example communication network according to this disclosure. The communication network (network) 100 comprises of at least one transmitting node 101 a and at least one receiving node 101 b. In an embodiment, the transmitting node 101 a is a User Equipment (UE) and the receiving node is a Base Station (BS). In another embodiment, the transmitting node 101 a is a BS and the receiving node is a UE. In the network 100 , the UE 101 a establishes connection (also referred as Radio Resource Control (RRC) connection) with the BS 101 b and performs communication with BS 101 b over the established connection. In the uplink direction, the UE 101 a transmits to the BS 101 b. In the downlink direction, the BS 101 b transmits to the UE 101 a. One or more data radio bearers are established between the UE 101 a and BS 101 b for data communication. In the network 100 the UE 101 is a mobile phone, smart phone, smart watch, tablet and the like. The network architecture, as well, as the number of components of the network, as depicted in FIG. 1 is for illustration purpose only, and does not impose any restriction in terms of the structure, and number of components, or any related parameters.
[0023] The UE 101 a is configured to receive data transfer requirement, from the network 100 . In an embodiment, the transmitting node 101 a receives a signaling parameter in radio resource control (RRC) signaling message indicating whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The network 100 can, during a Radio resource Control (RRC) signaling for connection setup or data radio bearer establishment, identify data transfer requirements, and signal the same, to the transmitting node 101 a.
[0024] The transmitting node 101 a, is configured to select a MAC subheader format to indicate the size of a MAC SDU or MAC control element from a plurality of MAC subheader formats, each MAC subheader format having a different size of length field, wherein the determination of MAC subheader format for said MAC SDU is done based on size of said MAC SDU or MAC control element and a signaling parameter in radio resource control (RRC) signaling message indicating whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported, or not. Further, the transmitting node 101 a encodes the length of MAC SDU in the selected subheader format, and transmits MAC PDU carrying the said MAC SDU or MAC control element with MAC subheader to the to the receiving node 101 b.
[0025] The receiving node 101 b is configured to receive the MAC PDU from the transmitting node 101 a, determine the MAC subheader format used, and then determine size of MAC SDU or MAC Control Element (MAC CE), according to the subheader format being used by the transmitting node 101 a.
[0026] FIG. 2 is a flow diagram that depicts steps involved in an example process of transmitting protocol data unit by the transmitting node to the receiving node in the communication network according to this disclosure. The transmitting node 101 a transmits one or more MAC SDU(s) to the receiving node 101 b. Each MAC SDU is of different size. The amount of data to be transmitted in each MAC SDU is determined based on various scheduling algorithms in communication network and can be done by any standard procedure. For the purpose of explaining the concept, it is assumed that the MAC SDU or MAC control element is already generated in transmitting node 101 a and needs to be transmitted to receiving node 101 b. The transmitting nods 101 a indicates the size (such as an amount of data in unit of bytes or bits) of MAC SDU or MAC control dement in a MAC subheader, wherein, the MAC subheader and the corresponding MAC SDU or MAC control element are transmitted in a MAC PDU. One or more MAC SDUs or MAC control elements is transmitted in a MAC PDU wherein a MAC subheader is included for each of one or more MAC SDUs or MAC control elements.
[0027] The transmitting node 101 a first selects (at step 202 ) a MAC subheader format to indicate the size of a MAC SDU or MAC CE from a plurality of MAC subheader formats, each MAC subheader format having a different size of length field, wherein the determination of MAC subheader format for said MAC SDU is done based on size of said MAC SDU and a signaling parameter in radio resource control (RRC) signaling message indicating whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value ‘one’ indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and value ‘zero’ indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. In another embodiment, presence of signaling parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported, and absence of signaling parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported.
[0028] In order to select a MAC subheader format to indicate the size of MAC SDU or MAC control element from a plurality of MAC subheader formats, the transmitting node 101 a first determines whether the size of MAC SDU or MAC control element to be transmitted to receiving node 101 b is lesser than a threshold. The threshold is pre-defined in the system or configured by the network 100 . The network 100 configures the threshold during connection setup between the transmitting node 101 a and receiving node 101 b. If the size of the MAC SDU or MAC control element to be transmitted to the receiving node 101 b is lesser than the threshold, then the transmitting node 101 a selects a first MAC subheader format. If the size of MAC SDU or MAC control element to be transmitted to receiving node 101 b is not less than (such as greater than or equal to) the threshold, then the transmitting node 101 b determines whether large MAC SDU (or extension of length field in MAC subheader) is configured/supported for transmitting one or more MAC SDU(s) or MAC control elements not.
[0029] The transmitting node 101 a determines whether the large MAC SDU is configured for transmitting one or more MAC SDU(s) or MAC control element or not, based on value of the signaling parameter transmitted by network 100 in RRC signaling. If transmitting node 101 a determines that the large MAC SDU (or extension of length field in MAC subheader) is configured/supported than transmitting node 101 a selects a second MAC subheader format. If the large MAC SDU (or extension of length field in MAC subheader) is not configured/supported than transmitting node 101 a selects a third MAC subheader format. The size of length field in first MAC subheader format is less than length field in third MAC subheader format. The size of length field in third MAC subheader format is less than length field in second MAC subheader format.
[0030] The transmitting node 101 a then encodes (at step 204 ) the size of the MAC SDU or MAC control element in the selected MAC subheader format. Encoding size of MAC SDU or MAC control element in selected MAC subheader format comprises encoding size of said MAC SDU or MAC control element in one or more length fields in selected MAC subheader format, encoding one or more fields in selected MAC subheader which distinguishes the selected MAC subheader format from other MAC subheader formats. Other information such as logical channel identifier of logical channel associated with said MAC SDU or MAC control element is also encoded in selected MAC subheader format. The transmitting node 101 a then transmits (at step 206 ) the MAC PDU carrying the said MAC SDU or MAC control element with MAC subheader to the receiver.
[0031] Various embodiments of the proposed invention that can be adopted by the transmitting and receiving nodes 101 to transmit and receive the protocol data unit are explained below:
[0032] In a first embodiment, the transmitting node 101 a and the receiving node 101 b transmit and receive the Protocol Data Unit (PDU) as follows: in this embodiment (as depicted in FIGS. 3A and 3B ), if large MAC SDUs (or extension of length field in MAC subheader) needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. In various embodiments, the signaling parameter is indicated for each data radio bearer independently in RRC signaling message, or is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value ‘one’ indicates that large MAC SDU for extension of length field in MAC subheader) is configured/supported, and value ‘zero’ indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. In another embodiment, presence of the signaling parameter in the RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported, and the absence of the signaling parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported.
[0033] At the transmitting end (as depicted in FIG. 3A ), the transmitting node 101 a first checks (at step 302 ) the size of MAC SDU or MAC CE. If (at step 304 ) the size of MAC SDU or MAC CE is less than a threshold (such as 128 bytes), then the size of MAC SDU or MAC CE is indicated using a first MAC subheader format. The first MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and 7 bits length field. The Format Bit (F) is set (at step 306 ) to zero, and size of MAC SDU or MAC CE is indicated in 7 bits length field of MAC subheader format. The logical channel identifier for logical channel associated with MAC SDU or MAC CE is indicated using 5 bit logical channel identifier field.
[0034] If the size of the MAC SDU or MAC CE is not less than (such as greater than or equal to) the threshold (for example, 128 bytes), then the transmitting node 101 a determines (at step 308 ) whether large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not, that is determined based on the presence/absence or value of signaling parameter.
[0035] If (at step 310 ) the large MAC SDU (or extension of length field in MAC subheader) is not configured/supported, then a third MAC subheader format is selected and used to indicate the size of MAC SDU or MAC CE. The third MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and 15 bits length field. The Format Bit (F) is set (at step 312 ) to one, and size of the MAC SDU is indicated in 15 bits length field of MAC subheader format. The logical channel identifier for logical channel associated with MAC SDU or MAC CE is indicated using 5 bit logical channel identifier field. If large MAC SDU (or extension of length field in MAC subheader) is configured, then the size of MAC SDU or MAC CE is indicated using a second MAC subheader format. The second MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and X bits length field. In one embodiment size of length field in second MAC subheader format is 16 bits. The Format Bit (F) is set (at step 314 ) to one, and size of MAC SDU is indicated in ‘X’ bits length field, wherein the value of ‘X’ is pre-defined, or value of ‘X’ is signaled by network. The logical channel identifier for logical channel associated with MAC SDU is indicated using 5 bit logical channel identifier field.
[0036] In one embodiment, value of X is ‘ 15 +N’ wherein the value of ‘N’ is pre-defined or value of ‘N’ is signaled by network. In one embodiment, absolute value of ‘N’ is signaled. In another embodiment, various values of ‘N’ are indexed and index is signaled by network.
[0037] At the receiving end (as depicted in FIG. 3B ), the receiving node 101 b receives MAC PDU transmitted by the transmitting node 101 a. The receiving node 101 b (at step 316 ) checks the value of the format bit (F). If (at step 318 ) the value of F is equal to 0 in MAC subheader of received MAC PDU, then the receiving node identifies that MAC subheader is of first MAC subheader format wherein the length field in the MAC sub header is of 7 bits length, and reads (at step 320 ) 7 bits of length field in MAC sub header to determine length of MAC SDU. If value of F is 1, then the receiving node 101 b determines (at step 322 ) if large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not, based on at least one of a presence/absence or value of the signaling parameter. If (at step 324 ) large MAC SDU is configured/supported, then the receiving node 101 b identifies that MAC subheader is of second mac header format wherein the length field in the MAC sub header is of X bits length and reads (at step 326 ) ‘X’ bit length field in MAC sub-header to determine size of MAC SDU. If large MAC SDU (or extension of length field in MAC subheader) is not configured/supported, then the receiving nods 101 b identifies that MAC subheader is of third mac header format wherein the length field in the MAC sub header is of 15 bits length and reads (at step 328 ) ‘15’ bit length field in MAC sub-header to determine size of MAC SDU or MAC CE.
[0038] The various MAC subheader formats, criteria to select and encoding of fields in each of these formats by transmitter node in this embodiment are summarized in Table 1A.
[0000]
Size of MAC SDU or
Signaling
MAC CE to be
MAC Subheader Format
Parameter
transmitted
Fields
0
<128 bytes
R1 (1 bit), R2(1 bit), E(1 bit),
Note: Absence of this
LCID(5 bit), F (1 bit) set to 0,
parameter is also
Length (7 bit)
treated as ‘0’
0
>=128 bytes
R1 (1 bit), R2(1 bit), E(1 bit),
LCID(5 bit), F (1 bit) set to 1,
Length (15 bit)
1
>=128 bytes
R1 (1 bit), R2(1 bit), E(1 bit),
LCID(5 bit), F (1 bit) set to 1,
Length (X bits)
[0039] The criteria to determine the MAC subheader format and determine size of MAC SDU by receiver node is summarized in Table 1B.
[0000]
Signaling
Parameter
Format bit Value
MAC SDU size determination
0
0
Decode/parse the MAC
Note: Absence of this
subheader according to MAC
parameter is also
subheader format with R1 (1
treated as ‘0’
bit), R2 (1 bit), E (1 bit) , LCID
(5 bit), F (1 bit), Length (7 bit).
Length indicates size of MAC
SDU.
0
1
Decode/parse the MAC
subheader according to MAC
subheader format with R1 (1
bits), R2 (1 bit), E (1 bit), LCID
(5 bit), F (1 bit), Length (15
bits). Length indicate size of
MAC SDU.
1
1
Decode/parse the MAC
subbeader according to MAC
subheader format with R1 (1
bit), R2 (1 bit), E (1 bit), LCID
(5 bit), F (1 bit), Length (X bits).
Length indicates size of MAC
SDU.
[0040] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, if large MAC SDUs (or extension of length field in MAC subheader) needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported.
[0041] At the transmitting end, the transmitting node 101 a first determines if Large MAC SDU (or extension of length field in MAC subheader) (is configured/supported or not. Accordingly, the transmitting node sets values of Format Bit and the length field in MAC subheader as mentioned below:
[0042] If large MAC SDU (or extension of length field in MAC subheader) is not configured/supported and size of MAC SDU or MAC CE is lesser than 128 bytes, then the size of MAC SDU or MAC CE is indicated using a MAC subheader format wherein the MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and 7 bits length field. The Format Bit (F) is set to zero, and size of MAC SDU is indicated in 7 bits length field of MAC subheader format. The logical channel identifier for logical channel associated with MAC SDU or MAC CE is indicated using 5 bit logical channel identifier field. If large MAC SDU (or extension of length field in MAC subheader) is not configured/supported and size of MAC SDU or MAC CE is greater than equal to 128 bytes then the size of MAC SDU or MAC CE is indicated using a MAC subheader format wherein the MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and 15 bits length field. The Format Bit (F) is set to one, and size of MAC SDU is indicated in 15 bits length field of MAC subheader format. The logical channel identifier for logical channel associated with MAC SDU is indicated using 5 bit logical channel identifier field.
[0043] If large MAC SDU (or extension of length field in MAC subheader) is supported/configured and size of MAC SDU or MAC CE is lesser than 128 bytes, then the size of MAC SDU or MAC CE is indicated using a MAC subheader format wherein the MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and 7 bits length field. The Format Bit (F) is set to zero, and size of MAC SDU is indicated in 7 bits length, field of MAC subheader format. The logical channel identifier for logical channel associated with MAC SDU is indicated using 5 bit logical channel identifier field. The value of ‘X’ is pre-defined or value of ‘X’ is signaled by network. In one embodiment, absolute value of ‘X’ is signaled. In another embodiment, various values of ‘X’ is indexed and index is signaled by network. In one embodiment X equals to 8. In one embodiment X bit length field is added in MAC subheader using two length fields L and EL (as shown in FIG. 4H ) wherein some most significant bits of length is set in EL field and remaining bits in L field. The format bit is set to zero. In one embodiment EL is one bit and L is 7 bits.
[0044] If large MAC SDU (or extension of length field in MAC subheader) is supported/configured and size of MAC SDU or MAC CE is greater than equal to 2(×) bytes then the size of MAC SDU is indicated using a MAC subheader format wherein the MAC subheader format comprises of two reserved field of size one bit each, one extension bit field, 5 bit logical channel identifier field, one bit format bit field and Y bits length field wherein the value of ‘Y’ is pre-defined or value of ‘Y’ is signaled by network. In one embodiment, absolute value of ‘Y’ is signaled. In another embodiment, various values of ‘Y’ are indexed and index is signaled by network. The Format Bit (F) is set to one, and size of MAC SDU is indicated in Y bits length field of MAC subheader format. In one embodiment Y equals to 16. The logical channel identifier for logical channel associated with MAC SDU is indicated using 5 bit logical channel identifier field. In one embodiment Y bit length field is added in MAC subheader using two length fields L and EL (as shown in FIG. 4H ) wherein some most significant bits of length is set in EL field and remaining bits in L field. The format bit is set to one. In one embodiment EL is one bit and L is 15 bits.
[0045] In one embodiment, multiple sets of two length fields (X, Y) are there. Network signals which set is indicated by format field in MAC sub-header. At the receiving end, the receiving node 101 b receives the MAC PDU transmitted by the transmitting node 101 a, and checks if large MAC SDU (or extension, of length field in MAC subheader) has been configured or not. If large MAC SDU (or extension of length field in MAC subheader) is not configured, then if Format bit F equal to zero in Mac sub-header of received MAC PDU, then the receiving node identifies that MAC subheader is of first MAC subheader format wherein the length field in the MAC sub header is of 7 bits length and reads ‘7’ bit length field in MAC sub-header to determine size of MAC SDU, and if Format bit F equal to one in Mac sub-header of received MAC PDU, then the receiving node identifies that MAC subheader is of second MAC subheader format wherein the length field in the MAC sub header is of 15 bits length and reads 15 hit length field in MAC sub-header to determine size of MAC SDU. If large MAC SDU (or extension of length field in MAC subheader) has been configured, then if Format bit F equal to zero in Mac sub-header of received MAC PDU, then the receiving node identifies that MAC subheader is of third MAC subheader format wherein the length field in the MAC sub header is of X bits length and reads X bit length field in MAC sub-header to determine size of MAC SDU The value of ‘X’ is pre-defined or is signaled by the network 100 . In one embodiment X is 8. In one embodiment receiver node reads the X bits of length using two length fields BL and L. Most significant bits are in EL and remaining bits in L field. If large MAC SDU (or extension of length field in MAC subheader) has been configured, then if Format bit F equal to one in Mac sub-header of received MAC PDU, then the receiving node identifies that MAC subheader is of fourth MAC subheader format wherein the length field in the MAC sub header is of Y bits length and reads Y bit length field in MAC sub-header to determine size of MAC SDU. The value of ‘Y’ is pre-defined or is signaled by the network 100 . In one embodiment Y is 16. In one embodiment receiver node reads the Y bit of length using two length fields EL and L. Most significant bits are in EL and remaining bits in L field.
[0046] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, a new MAC sub-header format (as depicted in FIG. 4A ) is proposed. The new MAC sub-header is defined such that Logical Channel ID (LCID) location is same in the new as well as in legacy MAC sub-header. In this embodiment of the proposed invention, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length field extension m MAC subheader is not indicated in signaling by the network 100 , then legacy MAC sub-header (such as MAC subheader formats with 7 and 15 bit length fields) is used. If large MAC SDU or length field extension in MAC subheader is indicated in signaling by network 100 , then this new MAC sub-header is used. In this embodiment, using the two bit format field of new MAC subheader, up to four different sizes of length field can be indicated. In one embodiment some bits are reserved for future extension. In one embodiment the sizes indicated by format field are fixed. In another embodiment the sizes indicated by format field are configurable.
[0047] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method a new MAC sub-header format (as depicted in FIG. 4B ) is proposed. The new MAC sub-header is defined such that LCID location is same in new and legacy MAC sub-header. The size of length field can be fixed or configured by network. In this embodiment of the proposed invention, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU is not configured/supported. If large MAC SDU or length field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. If large MAC SDU or length field extension in MAC subheader is indicated in signaling by network then this new MAC sub-header is used.
[0048] In another embodiment the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, a new MAC sub-header format (as depicted in FIG. 4C ). If the length of MAC SDU or MAC CE is longer than length than is indicated using legacy MAC sub-header, then the transmitting node 101 a transmits two MAC sub headers in MAC PDU for a single MAC SDU or MAC CE, wherein the new sub-header follows the legacy sub-header. The most significant bits (or least significant bits) of length are carried in legacy sub-header and least significant bits (or most significant bits) are carried in this new sub-header. The LCID in the legacy sub-header is the LCID of logical channel associated with DRB whereas LCID in new sub-header is a reserved LCID which is reserved specifically for this new sub header. The number of extended length bits in this new MAC sub-header is predefined, or is configured as the time of DRB establishment by network. In another embodiment, a format bit is included in this new MAC sub-header to indicate various sizes of extension bits. In another embodiment multiple MAC sub-headers with extension bits are added.
[0049] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (or extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. If large MAC SDU or length field extension in MAC subheader is indicated then both F and R 1 (or R 2 ) bits in the legacy MAC sub-header are used to indicate the size of length field in the MAC sub-header (as depicted in FIG. 4D ). In this method, the size of length field in MAC subheader is determined as follows:
[0050] If F==0 then, it indicates 7 bits length field else
[0051] If F==&& R 1 (or R 2 )==0 then it indicates 15 bits length field else
[0052] If F==1 && R 1 (or R 2 )==1 then it indicates ‘X’ bits length field, wherein ‘X’ is pre-defined or ‘X’=15+‘N’ wherein ‘N’ is pre-defined. In one embodiment ‘N’ is signaled by network.
[0053] The transmitting node 101 a determines the size of MAC SDU and if size is lesser than 128 bytes then it sets F equals zero in MAC subheader and encodes the size of MAC SDU in 7 bit length field. If size of MAC SDU is greater than or equal to 128 bytes but lesser than 32768 then it sets F equals to one, R 1 (or R 2 ) equals to zero and encodes the size of MAC SDU in 15 bits length field. If size of MAC SDU is greater than or equal to 32768 bytes then it sets F equals to one, R 1 (or R 2 ) equals to one and encode the size of MAC SDU in X bits length field. X is 16 bits in one implementation.
[0054] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length, field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. If large MAC SDU or length field extension in MAC subheader is indicated then in this embodiment both F and R 1 , R 2 bits in the legacy MAC sub-header are used to indicate the size of length field in the MAC sub-header (as depicted in FIG. 4D ). In this method, the size of length field in MAC subheader is determined as follows:
[0055] If F==0 then it indicates 7 bits length field
[0056] If F==1 && R 1 R 2 ==00 then it indicates 15 bits length field
[0057] If F==1 && R 1 R 2 ==01 then it Indicates ‘X’ bits length field
[0058] If F==1 && R 1 R 2 ==10 then it indicates ‘Y’ bits length field
[0059] If F==1 && R 1 R 2 ==11 then it indicates ‘Z’ bits length field
[0060] ‘X’, ‘Y’ and ‘Z’ are pre-defined
[0061] The transmitting node 101 a determines the size of MAC SDU and accordingly encodes the size of length field, F, R 1 R 2 bits in the MAC subheader.
[0062] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. If large MAC SDU or length field extension in MAC subheader is indicated in signaling by network then, two MAC sub headers for same LCID for one MAC SDU is sent (as depicted in FIG. 4E ). The length of MAC SDU is combined length in both sub headers, wherein, L 1 : MSBs of length; L 2 : LSBs of length and L 1 and L 2 indicated in first and second sub-header respectively or vice versa. Alternately the length L of MAC SDU equals=value of length field in first sub-header+value of length field in second sub-header. The network 100 configures this method during DRB establishment or connection establishment.
[0063] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this method, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU (or extension of length field in MAC subheader) is configured and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. In this embodiment, a new MAC sub-header is defined (as depicted in FIG. 4F ). The new MAC sub-header is defined such that LCID location is same in new and legacy MAC sub-header. In this method, If large MAC SDU or length field extension in MAC subheader is not configured in signaling by network then legacy MAC sub-header is used wherein F=1 indicates 15 bit length field and F=0 indicates 7 bit length field. If large MAC SDU or length field extension in MAC subheader is indicated/configured in signaling by network then this new MAC sub-header ( FIG. 4F ) is used wherein F=0 indicates 7 bit length field and F=1 indicates 16 bit length. The 15 LSBs of 16 bit length field is encoded in L field following the F field. The MSB of 16 bit length field is encoded in EL field of MAC subheader. EL field is present in first or second bit of MAC sub-header. The transmitting node 101 a determines the size of MAC SDU and if MAC SDU size is lesser than equal to 128 bytes, then F bit in MAC subheader is set to zero and size of MAC SDU is encoded in 7 bit length field. If size of MAC SDU is greater than or equal to 128 bytes and large MAC SDU or length field extension in MAC subheader is configured/supported Indication is received in signaling from network then F is set to one and size of MAC SDU is encoded in L and EL field of MAC subheader.
[0064] Alternately, If large MAC SDU or length field extension in MAC subheader is indicated in signaling by network 100 , then this new MAC sub-header ( FIG. 4H ) is used wherein F=0 indicates 8 bit length field and F=1 indicates 16 bit length. If F equals to one, then 15 LSBs of 16 bit length field is encoded in L field following the F field. The MSB of 16 hit length field is encoded in EL field of MAC subheader. EL field is present in first or second bit of MAC sub-header. If F equals to zero, then 7 LSBs of 8 bit length field is encoded in L field following the F field. The MSB of 8 bit length field is encoded in EL field of MAC subheader. EL field is present in first or second bit of MAC sub-header.
[0065] If large MAC SDU or length field extension in MAC subheader (such as extended Length) is not configured by higher layer and the size of the MAC SDU or variable-sized MAC control element is less than 128 byte, F field is set to 0. If large MAC SDU or length field extension in MAC subheader (such as extended Length ) is configured by higher layer and the size of the MAC SDU or variable-sized MAC control element is less than 256 byte, F field is set to 0. Otherwise it is set to one.
[0066] If large MAC SDU or length field extension in MAC subheader (such as extended Length) is configured by higher layers, the L field is extended with the EL field of the corresponding MAC subheader. The EL-field is added as the most significant bit for the Length field.
[0067] The Extended Length (EL) field is used for L field extension bit, if configured by higher layers. If extended L field is not configured, by higher layers, the EL field is set to “0”.
[0068] In another embodiment, the transmitting and receiving nodes 101 transmit and receive the protocol data unit as follows: In this embodiment, if large MAC SDUs needs to be supported, then the network 100 , during the DRB creation or connection setup, signals the same to nodes 101 . A signaling parameter in radio resource control (RRC) signaling message transmitted by network 100 indicates whether the large MAC SDU (extension of length field in MAC subheader) is configured/supported or not. The RRC signaling message is an RRCConnectionReconfiguration message. The said signaling parameter is indicated for each data radio bearer independently in RRC signaling message or it is applicable to all data radio bearers. The signaling parameter is a one bit value, wherein value one indicates that large MAC SDU for extension of length field in MAC subheader) is configured/supported and value zero indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. Alternately, if signaling parameter is present in RRC signaling then it indicates that large MAC SDU (or extension of length field in MAC subheader) is configured/supported and absence of this parameter in RRC signaling indicates that large MAC SDU (or extension of length field in MAC subheader) is not configured/supported. If large MAC SDU or length field extension in MAC subheader is not indicated in signaling by network then legacy MAC sub-header is used. Otherwise, in this embodiment, a new MAC sub-header is defined (as depicted in FIG. 4G ). The new MAC sub-header is defined such that LCID location is same in new and legacy MAC sub-header. If the size of the MAC SDU or variable-sized MAC control element is larger than 32768 bytes, the value of the F 2 field is set to 1; otherwise it is set to 0. If the F 2 field is set to 0, then F field above is used to indicates the size of the Length field between 7 bits and 15 bits, and if F 2 field is set to 1, F field does not exist; In this MAC sub-header, F 2 equals one indicates that 16 bit length field follows the LCID field in MAC sub-header.
[0069] The various actions in method 300 can be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in FIG. 3 may be omitted.
[0070] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the network elements. The network elements shown in FIG. 1 include blocks which can he at least one of a hardware device, or a combination of hardware device and software module.
[0071] The embodiments disclosed herein specify a mechanism for synchronizing communication between transmitting and receiving nodes in a communication network. The mechanism allows synchronized encryption and decryption of data, providing a system thereof. Therefore, it is understood that the scope of protection is extended to such a system and by extension, to a computer readable means having a message therein, said computer readable means containing a program code for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The method is implemented in a preferred embodiment using the system together with a software program written in, for ex. Very high speed integrated circuit Hardware Description Language (VHDL), another programming language, or implemented by one or more VHDL or several software modules being executed, on at least one hardware-device. The hardware device can be any kind of device which can be programmed including, for ex. any kind of a computer like a server or a personal computer, or the like, or any combination thereof, for ex. one processor and two FPGAs. The device may also include means which could be for ex. hardware means like an ASIC or a combination of hardware and software means, an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein. Thus, the means are at least one hardware means or at least one hardware-cum-software means. The method embodiments described herein could be implemented in pure hardware or partly in hardware and partly in software. Alternatively, the embodiment may be implemented on different hardware devices, for ex. using a plurality of CPUs.
[0072] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims. | The present disclosure relates to a pre-5 th -Generation (5G) or 5G communication system to be provided for supporting higher data rates Beyond 4 th -Generation (4G) communication system such as Long Term Evolution (LTE). A method and system for managing data transmission in a communication network is provided. During Data Resource Bearer (DRB) creation, network signals to a transmitting node, the data transfer requirement. The network uses a signaling parameter to indicate a large data transfer requirement. Based on the data transfer requirement information collected from the network, the transmitting node determines the type of data format that needs to be used for the data transmission. If the network signals large data transfer requirement, then the transmitting node selects a Subheader format in which the length field of the data format suits the large data transfer requirement. Further, data communication is initiated using the selected Subheader format. | 7 |
REFERENCE TO RELATED APPLICATION
This application claims priority to Provisional U.S. Patent Application No. 60/765,012, file on Feb. 3, 2006, the entire content of which are incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates generally to actuators and corresponding methods and systems for controlling such actuators, and in particular, to actuators providing independent lift and timing control with minimum energy consumption.
BACKGROUND OF THE INVENTION
Variable valve actuation (VVA) systems are used to actively control the timing and lift of engine valves to achieve improvements in engine performance, fuel economy, emissions, and other characteristics. Depending on the means of the control or the actuator, VVA systems are classified as mechanical, electrohydraulic, and electromechanical (sometimes called electromagnetic). Depending on the extent of the control, they are classified as variable valve-lift and timing, variable valve-timing, and variable valve-lift. They are also classified as cam-based or indirect acting and camless or direct acting. In the case of a cam-based system, the traditional engine cam system is kept and modified somewhat to indirectly adjust valve timing and/or lift. In a camless system, the traditional engine cam system is completely replaced with electrohydraulic or electromechanical actuators that directly drive individual engine valves. All current production automotive variable valve systems are cam-based, although camless systems will offer broader controllability, such as individual valve control and cylinder or valve deactivation, and thus better fuel economy.
The most prevailing design of an electromechanical VVA (or EMVVA) actuator includes an armature moving longitudinally between first and second electromagnets, a rod connected with the armature and an engine valve, and a pair of actuation springs attached to the rod and urging or centering the moving mass to a zero spring force or neutral position when the armature is not latched on either of the electromagnets. The engine valve is kept to closed and open positions when the armature is latched to the first and second electromagnets, respectively. For a simple, full-lift valve actuation, this spring-mass pendulum system is energy efficient, with the springs storing and releasing potential energy and the moving mass accumulating and releasing kinetic energy.
The prevailing EMVVA design does have several problems or potential problems. One of them is its power-off state. When engine power is off, the net spring force of the two actuation springs keeps the engine valve half open and the armature at the middle point between the two electromagnets. In certain vehicle regulations, it is required to keep engine valves closed at power-off. Also, to initialize an EMVVA actuator at the start of power-on, great effort and a large amount electrical current are spent to pull the armature from the middle point to either of the two electromagnets because of the nonlinear nature of the electromagnetic force. Therefore, it is desirable to keep the engine valve at the closed position and the armature near the first electromagnet.
With its fixed placement of the electromagnets and the actuation springs and nonlinear magnetic forces, prevailing EMVVA actuators also have trouble actuating an engine valve with a short stroke or lift, which is generally desirable and in some cases necessary for low load and idle engine operations. Some prevailing EMVVA actuators may perform short-lift actuation, but at great expense of electrical energy sustaining a large electromagnetic force through a substantial air gap to counter the spring centering force. This additional electrical energy further stretches the limit of a vehicle electrical system, especially during low load and idle operations when the vehicle alternator or electrical generator is the least efficient.
Disclosed in U.S. Pat. No. 5,996,539, assigned to FEV Motorentechnik GmbH & Co KG, is an EMVVA actuator including an adjusting device to vary the valve strokes. The adjusting device supports and controls the displacement of a base of the opener spring, thus controlling the pre-stress of the two actuation springs and the neutral position of the armature. At the least and most pre-stressed states of the actuation springs, the engine valve operates at partial and normal strokes, respectively. The design has the potential to resolve the valve stroke variability issue associated with most EMVVA designs. However, it fails to provide a solution to meet the need to keep the engine valve closed at power-off , and it also entails an additional hydraulically-operated-and-controlled locking mechanism, which incurs added complexity and reliability concern, to stabilize the adjusting device for partial stoke operations.
SUMMARY OF THE INVENTION
Briefly stated, in one aspect of the invention, one preferred embodiment of an electromechanical actuator comprises a housing, first and second electromagnets rigidly disposed in the housing and separated from each other by an armature chamber, an armature disposed in the armature chamber and movable between the first and second electromagnets, an armature rod rigidly connected with the armature and operably connected with a load, at least one first actuation spring biasing the armature in a first direction, at least one second actuation spring biasing the armature in a second direction, and one fluid-operated spring controller capable of controlling the position of the first-direction end of the at least one second actuation spring.
In operation, the actuation springs drive the armature and the load through pendulum motions between the first and second electromagnets, which in turn latch, over desired periods of time, and release the armature. The spring controller allows the actuation springs at their least compressed state and the engine valve closed when power is off or when the control fluid pressure is below a certain level or threshold. The spring controller may also be adjusted, with a low or moderate control fluid pressure, to allow the engine valve to operate with a partial lift.
In another embodiment, the spring controller allows the engine valve to operate with a small lift when the control fluid pressure is below a certain level or threshold. In still another embodiment, the spring controller includes a damping mechanism, without too much more complexity, to stabilize its operation.
The present invention provides significant advantages over the prevailing EMVVA actuators and their control. For example, it can effectively close the engine valve at power-off to meet certain vehicle regulations. The closed engine valve is also a good start-up point for the next power-on procedure or initialization. The invention also provides means to efficiently and effectively operate engine valves with a small lift. The present invention thus provides, with one mechanism, at least three significant functions: a closed engine valve at power-off, easy start-up, and partial or variable stroke. The present invention also provides partial stroke operation stability without too much more complexity.
The present invention, together with further objects and advantages, will be best understood by reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of one preferred embodiment of the electromechanical actuator, at its zero-lift state;
FIG. 2 is a schematic illustration of the embodiment of FIG. 1 at the end of the start-up process, when the second actuation spring is greatly compressed.
FIG. 3 is a schematic illustration of the embodiment of FIG. 1 when the actuation springs are substantially equally compressed, the net spring force is zero, the armature is at the middle point between the electromagnets, and the engine valve is half open.
FIG. 4 is a schematic illustration of the embodiment of FIG. 1 with the spring controller experiencing a small displacement when the fluid supply pressure is adjusted to a low or moderate value.
FIG. 5A is a schematic illustration of another preferred embodiment including an intentional, substantial gap between the spring-controller cylinder and the spring-controller piston outer dimension to pressurize both spring-controller first and second chambers.
FIG. 5B is a schematic illustration of yet another preferred embodiment including at least one spring-controller orifice that is to equalize steady-state pressures in the spring-controller first and second chambers and provide damping effect to reduce oscillation the spring controller may experience.
FIG. 5C is a schematic illustration of another preferred embodiment including a housing extension.
FIG. 6 is a schematic illustration of another preferred embodiment with the second actuation spring and the spring controller relocated to the first-direction end of the actuator.
FIG. 7 is a schematic illustration of another preferred embodiment, in which the steady-state or power-off armature first air gap and the engine valve opening are equal to a small value, instead of zero, when the spring-controller first surface is up against the spring-controller cylinder first surface.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 , a preferred embodiment of the invention provides an engine valve control actuator 100 . The actuator 100 includes a housing 32 . Rigidly disposed within the housing 32 , along the longitudinal axis 102 and from a first to a second direction (from the top to the bottom in the drawing), are a first electromagnet 34 , an armature chamber 46 , a second electromagnet 36 , and a spring-controller cylinder 68 . The first and second electromagnets 34 and 36 further include their electrical windings and lamination stacks. An armature 38 is disposed inside the armature chamber 46 and between the first and second electromagnets 34 and 36 and is rigidly connected to an armature rod 40 . The armature rod 40 is slideably disposed through the first and second electromagnets 34 and 36 , the housing 32 , and a spring controller 70 . The spring controller 70 is slideably disposed within the spring-controller cylinder 68 and through the second-direction end of the housing 32 . The armature rod 40 is operably connected, at its second-direction end, with the stem 24 of an engine valve 20 , which is guided by an engine valve guide 52 rigidly disposed in the cylinder head 50 . The engine valve 20 includes an engine valve head 22 with first and second surfaces 28 and 30 exposed to gaseous pressure forces. The engine valve head 22 moves relative to a valve seat 26 , defining an engine valve opening Xev and controlling air exchange for an engine cylinder in an internal combustion engine (not shown in FIG. 1 ). The peak value of a cyclic valve opening is called the stroke or lift.
The actuator 100 further includes first and second actuation springs 42 and 44 , concentrically wrapped around the engine valve stem 24 and the armature rod 40 , respectively. The first actuation spring 42 is supported by a first spring retainer 54 and the cylinder head 50 at its first- and second-direction ends, respectively. The second actuation spring 44 is supported by a third spring retainer 58 and a second spring retainer 56 at its first- and second-direction ends, respectively. The first and second spring retainers 54 and 56 are fixed on the engine valve stem 24 and the armature rod 40 , respectively, whereas the third spring retainer 58 is fixed on and thus moves with the second-direction end of the spring controller 70 .
The first and second actuation springs are preferably substantially identical or symmetric in major geometrical, physical parameters, such as stiffness and preload to have an efficient pendulum system. They may be purposely designed to be somewhat asymmetric to achieve asymmetric needs for engine valve opening and closing, which, for example, experience dissimilar frictional forces and need different seating or slow-down strategies. For simplicity, the spring symmetry is assumed in many parts of the specification of this application, which does not however exclude the applicability of the embodiments and teachings of this invention to situations where asymmetric springs are more desirable.
The spring retainers 54 and 56 are illustrated to be of the shape generally used in current production engines. They do not have to be that way. In fact, when possible and practical, they may be combined into a single mechanical piece.
The spring controller 70 partitions the spring-controller cylinder 68 into spring-controller first and second chambers 72 and 74 . The first chamber 72 is fed with a working fluid through a spring-controller port 60 and from a fluid supply at a pressure Psp. The fluid supply Psp is switched on and off by a spring-controller on-off valve 62 . The second chamber is generally not pressurized and is exposed to either atmosphere or a fluid return line to the tank of the working fluid (not shown). Therefore there is negligible force on a spring-controller second surface 78 . The fluid pressure force on a spring-controller first surface 76 balances the spring force on the third spring retainer 58 from the second actuation spring 44 , resulting in the longitudinal position of the spring controller 70 and thus that of the third spring retainer 58 , which in turn controls the neutral position of the armature and the engine valve. A neutral position is defined as a steady-state position only under spring forces, without electromagnetic forces and contact forces at electromagnets and the engine valve seat and generally ignoring gravitational and frictional forces. At a neutral state or position, the two spring forces are equal in magnitude and opposite in direction, and the net spring force is thus equal to zero. The position or travel of the armature and engine valve assembly is also limited in the first direction when the engine valve head 22 comes in contact with the engine valve seat 26 and in the second direction when the armature 38 comes in contact with the second electromagnet 36 . The position or travel of the spring controller 70 is limited by spring-controller cylinder first and second surfaces 92 and 94 in the first and second directions, respectively.
The spring controller 70 can be alternatively designed without the flange feature that gives off, or is characterized in the form of, the spring-controller second surface 78 shown in FIGS. 1-7 . The elimination of the flange feature may facilitate the assembly process in certain situations. Without the flange feature, the travel of the spring controller 70 may be limited by some other lock-up mechanisms. For example, a mechanical block, not shown in FIGS. 1-7 , may be placed at a predetermined longitudinal position to limit the range of the travel of the third spring retainer 58 and thus that of the spring controller 70 in the second direction.
Power-Off State
At power-off, the spring-controller on-off valve 62 is at its default or open position, and the fluid supply pressure Psp is generally at the atmosphere pressure or zero gage pressure. The spring controller 70 is thus at its farthest position in the first direction, with its first surface 76 butting against the spring-controller cylinder first surface 92 , and the actuation springs 42 and 44 are at their least compressed states. The actuator 100 is so geometrically and physically designed such that the engine valve 20 is fully closed with a finite seating or contact force, if desired, and the armature 38 is substantially approximate, depending on the lash, to the first electromagnet 34 . The armature and engine valve assembly are not exactly in the neutral position if the seating force is not zero.
Because of thermal expansion, wear and elasticity in an engine valve mechanism, the longitudinal dimension stack-up is not exact, and lash adjustment has to be considered. When the armature 38 is latched to the first electromagnet 34 , they may not necessarily be in real physical or metal-to-metal contact. For simplicity of discussion and illustration, the clearance between the armature 38 and the electromagnet 34 and its variation, when they are latched, are to be ignored or de-emphasized. But that does not exclude the general applicability of the embodiments and teachings of this invention to situations with substantial lash.
Symbolically in FIG. 1 , the variable Xsp is defined the spring controller displacement, which is a distance between the spring-controller first surface 76 and the spring-controller cylinder first surface 92 . The variable Xev is defined as the engine valve opening, a longitudinal distance between the engine valve head 22 and the engine valve seat 26 . The variables Xar 1 and Xar 2 are defined as armature first and second air gaps, respectively, for the distance between the armature 38 and the first electromagnet 34 and that between the armature 38 and the second electromagnet 36 . Ignoring the engine valve lash and at power-off, one generally has
Xsp=0,
Xev=0,
Xar 1 =0, and
Xar 2 =Xspmax−Xar 1 =Xspmax,
where Xspmax is the maximum spring-controller displacement.
The actuator 100 falls into the power-off state soon after the engine power is turned off, either intentionally or by accident, keeping the engine valve closed as required in some vehicle regulations. From this power-off state, it is also easy to initialize the actuator 100 at the engine start-up, without spending too much energy (see the following discussion).
Start-Up
At the power-off state as shown in FIG. 1 , the armature first air gap Xar 1 is substantially equal to zero. The actuator 100 can be initialized by energizing only the first electromagnet 34 to a holding level of force, thus latching the armature 38 to the first electromagnet 34 , mostly by force and not by physical contact. The holding level of force is much smaller than the force otherwise needed to attract the armature 34 if it is in the middle of the armature chamber 46 .
Also at the start-up, the fluid supply builds up its pressure Psp, and the pressure force starts pushing the spring controller 70 in the second direction until it is against and limited by the spring-controller cylinder second surface 94 , with Xsp=Xspmax. However, this pressure build-up and the subsequent spring controller displacement are much slower than the action to energize the first electromagnet 34 and latch the armature 38 , and the armature-and-engine valve assembly stay securely latched as shown in FIG. 2 . FIG. 2 illustrates the state of the embodiment at the end of the start-up process, when the second actuation spring 44 is greatly compressed, the spring controller 70 is secured by the working fluid at the farthest position in the second direction, and the engine valve 20 is fully closed.
Full Lift Operation
For the normal, full or maximum lift operation, the spring controller 70 remains in the position as shown in FIG. 2 , and the actuator 100 operates otherwise like a prevailing EMVVA actuator. The two actuation springs 42 and 44 alternatively store and release potential energy, and the armature-and-engine valve assembly travels like a pendulum, with the armature 38 being latched at the two electromagnets 34 and 36 for fully closed and open positions, respectively. Between the two end positions is a neutral position as shown in FIG. 3 , where the actuation springs 42 and 44 are substantially equally compressed, the net spring force is zero, the armature 38 is at the middle point between the electromagnets 34 and 36 with Xar 1 =Xar 2 =0.5 Xspmax, and the engine valve 20 is half open with Xev=0.5 Xspmax.
Small Lift Operation
The actuator 100 is also able to operate at a small lift. The spring controller 70 illustrated in FIG. 4 experiences a small displacement Xspsmall when the fluid supply pressure Psp is adjusted or controlled to a low or moderate value. The resulting neutral positions (shown in FIG. 4 ) for the armature and the engine valve are not far away from the fully closed positions, with Xar 1 =0.5 Xspsmall and Xev=0.5 Xspsmall. The armature 38 and the engine valve 20 are held in these neutral positions by the force balance between the two actuation springs 42 and 44 while the position of the third spring retainer 58 results from the balance between the fluid force on the spring-controller first surface 76 and the spring force from the second actuation spring 44 . Therefore, the small engine valve opening Xev=0.5 Xspsmall is achieved and maintained without the usage of electrical power or energy. It is however conceivable to use a smaller electromagnetic force from the first electromagnet 34 to perform a closed-loop position control if better opening accuracy is desired, with the correctional electromagnetic force increasing with the engine valve opening overshoot beyond the target value to pull the armature 38 and thus the engine valve 20 in the first direction to reduce the deviation. One can purposely bias the open-loop engine valve opening data points more into the overshoot (vs. undershoot) range to deal with the inability of the first electromagnet 34 to push the armature 38 in the second direction because of the nature of the electromagnetic force and the ineffectiveness of the second electromagnet 36 to pull the armature in the second direction because of the large second air gap Xar 2 during the small lift operation.
It is also possible to use a lock-up mechanism, such as a fluid actuated lock pin (not shown in FIG. 1 ) to accurately pin-down the spring controller 70 to the small displacement Xspsmall. To close the engine valve 20 , the first electromagnet 34 is energized to pull the armature 38 in the first direction and hold it once the engine valve is closed, all against the net spring force. To open the engine valve 20 afterwards, the first electromagnet 34 is de-energized for the armature 38 and the engine valve 20 to return, under the net spring force, to the neutral positions as shown in FIG. 4 .
This small lift operation operates differently from that with the full lift, and the engine valve opens and closes under the net spring force and the electromagnetic force, respectively, instead of under generally symmetric, pendulum dynamics. The armature 38 is latched at the closed position and balanced at the open position by the first electromagnet 34 and the actuation springs 42 and 44 , respectively, instead of by the first and second electromagnets 34 and 36 , respectively. In fact, the second electromagnet 36 may not be involved at all. This asymmetric operation is, in theory, not energy efficient, but it is, in absolute terms, still efficient because of its much reduced lift. In addition, the balance at the engine valve open position, a neutral position, is achieved by the actuation springs 42 and 44 , without consuming electrical energy. With a prevailing EMVVA actuator, a substantial amount of electrical energy has to be consumed to counter a large spring return force at this position, which is not a neutral position in a prevailing design.
During the operation, the second actuation spring 44 does change its level of compression and offers a varying force to the spring controller 70 , which makes it necessary to incorporate design considerations to damp out oscillatory displacement for the spring controller 70 .
It is generally preferred for all VVA actuators 100 in an engine to use a single fluid supply. When the system changes its supply pressure Psp from a high pressure to a lower pressure for a small lift operation or vice versa, timing of the system pressure change may not be ideal for individual actuators 100 . The system control may purposely closes off an individual spring-controller on-off valve 62 by energizing its solenoid to momentarily isolate its associated spring controller 70 . Otherwise, the spring-controller on-off valve 62 may be eliminated from the system to simplify.
The spring controller 70 and its associated fluid actuation design illustrated in FIGS. 1 to 4 are only one of many possible combinations of piston-cylinder designs and fluid supply systems. FIGS. 5A , 5 B, and 5 C illustrate a few other embodiments, with graphic details only around the spring controller 70 and its fluid supply subsystem to emphasize their variations. The embodiment in FIG. 5A features an intentional, substantial gap or clearance between the spring-controller cylinder 68 and the spring-controller piston, or flange, outer dimension 90 to pressurize both spring-controller first and second chambers 72 and 74 . The gap may function as a damping orifice, or flow restriction, between the two pressurized chambers 72 and 74 to counter the oscillatory force from the second actuation spring. This substantial gap eliminates one pair of tightly sliding surfaces and reduces manufacturing cost. This embodiment offers, as a design option, a reduced effective pressure area, which is equal to the differential area between the first and second surfaces 76 and 78 . The embodiment in FIG. 5A also features no spring-controller on-off valve 62 (used in the embodiment illustrated in FIG. 1 ), which reduces some control flexibility while simplifying the overall structure of the actuator or system.
The embodiment in FIG. 5B features at least one spring-controller orifice 88 , a flow restriction, that is to equalize steady-state pressures in the spring-controller first and second chambers 72 and 74 and provide damping effect to reduce oscillation the spring controller 70 may experience. This embodiment also offers, as a design option, a reduced effective pressure area, which is equal to the differential area between the first and second surfaces 76 and 78 . This embodiment features a spring-controller pressure control valve 64 , which is able to provide individualized pressure control for the actuator. If needed, the feedback control can be incorporated based on the position information of the spring controller 70 . Physically, the spring-controller pressure control valve 64 can be any of many possible proportional pressure control valve, such as a variable force solenoid (VFS) valve which delivers an output pressure either proportional or inversely proportional to the input current. Functionally, a VFS valve can also be replaced by a pulse width modulation (PWM) valve combined with a proper position or pressure feedback control (not shown here).
The embodiment in FIG. 5C features another variation in the spring control mechanism. In this embodiment, the spring controller bore 80 slides over a housing extension 86 , instead of the armature rod 40 . The housing extension 86 does not have to be an inseparable part of the housing 32 and can be a separate part but rigidly assembled or connected to the housing 32 . This design can greatly reduce the potential for the working fluid to leak into the armature chamber 46 (see FIG. 1 ) through the clearance around the armature rod 40 . It also provides more solid bearing or support to the traveling armature rod 40 . The embodiment also features a spring-controller 3 -way valve 66 that selectively feed the spring-controller first chamber 72 with the working fluid either from a high-pressure fluid supply Ph or a low-pressure fluid supply Pl. Ideally, the high-pressure Ph is set to push the spring controller 70 all the way against the spring-controller cylinder second surface 94 while the low-pressure Pl is set to drive the spring controller 70 to the small displacement Xspsmall designed for idle and low load engine operations. Although the fluid power symbol for the 3-way valve 66 indicates the Ph connection to be its default position, it is also feasible to have the Pl connection to be the default position. Alternatively, one may choose, for the valve 66 , actuation means other than a combination of one return spring and one solenoid.
The design variations of the spring controller mechanisms and the fluid supply schemes illustrated in FIGS. 5A , 5 B, and 5 C can be recombined among themselves and with other possible variations.
FIG. 6 demonstrates a variation of the embodiment illustrated in FIG. 1 . In this case the second actuation spring 44 and the associated spring controller 70 b are relocated to the first-direction end of the actuator 100 b. The spring-controller first chamber 72 b is pressurized, and it can be supplied, through the spring controller port 60 b, by several possible fluid sources like those for the embodiments in FIGS. 1-5C . The spring-controller second chamber 74 b is generally not pressurized and is fluid communication (details not shown in FIG. 6 ) either with the atmosphere or a return line to the tank of the working fluid. Basic schemes utilized for the spring controller in the embodiments in FIGS. 5A , 5 B, and 5 C can also be incorporated in this embodiment.
When the spring-controller first surface 76 b is in contact with the spring-controller cylinder first surface 92 b (as shown in FIG. 6 ), the steady-state net spring force secures the armature 38 substantially approximate to the first electromagnet 34 and the engine valve 20 at its closed position, with the required contact force. This is an ideal situation for power-off or default position and actuator initialization. When the spring-controller second surface 78 b is in contact with the spring-controller cylinder second surface 94 b (not shown in FIG. 6 ), the steady-state net spring force moves the neutral position of the engine valve 20 to be in the substantially middle point, if so desired, between the closed and full open positions.
Refer now to FIG. 7 , which is a drawing of yet another preferred embodiment of the invention. When the spring-controller first surface 76 is up against the spring-controller cylinder first surface 92 , the steady-state or power-off armature first air gap Xar 1 and the engine valve opening Xev are not equal to zero, and, instead, Xar 1 =Xev=Xevsmall, where Xevsmall is small valve opening. This embodiment is useful in applications where engine valves are not required to be closed at power-off, and at the same time, the accuracy of the small valve opening Xevsmall is stringent, which can be greatly helped by the position accuracy of the spring controller 70 c guaranteed by a solid stop against the cylinder first surface 92 . The actuator 100 c also features other design variations. The armature rod 40 c does not extend beyond the armature 38 in the first direction, which may reduce the design complexity and weight. The rod 40 c also slides inside an added sleeve 84 to provide proper mechanical support and specific material match.
In all the above descriptions, the first and second actuation springs 42 and 44 are each identified or illustrated, for convenience, as a single spring. When needed for strength, durability or packaging, however each or any one of the first and second actuation springs 42 and 44 may include a combination of two or more springs. In the case of mechanical compression springs, they can be nested concentrically, for example. The spring subsystem may also include a single mechanical spring (not shown) that can take both tension and compression. The spring subsystem may also include a combination of pneumatic and mechanical springs, or even two pneumatic springs.
Also in some illustrations and descriptions, the fluid medium may be assumed or implied to be hydraulic or in liquid form. In most cases, the same concepts can be applied, with proper scaling, to pneumatic actuators and systems. As such, the term “fluid” as used herein is meant to include both liquids and gases. Also, in many illustrations and descriptions so far, the application of the actuator 100 or 100 b or 100 c is defaulted to be in engine valve control, and it is not limited so. The actuator 100 or 100 b or 100 c can be applied to other situations where a fast and/or energy efficient control of the motion is needed.
Although the present invention has been described with reference to the preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. As such, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting and that it is the appended claims, including all equivalents thereof, which are intended to define the scope of this invention. | Actuators, and corresponding methods and systems for controlling such actuators, provide independent lift and timing control with minimum energy consumption. In an exemplary embodiment, an electromechanical actuator comprises a housing, first and second electromagnets rigidly disposed in the housing and separated from each other by an armature chamber, an armature disposed in the armature chamber and movable between the first and second electromagnets, an armature rod rigidly connected with the armature and operably connected with a load, at least one first actuation spring biasing the armature in a first direction, at least one second actuation spring biasing the armature in a second direction, and one fluid-operated spring controller capable of controlling the position of the first-direction end of the at least one second actuation spring. The spring controller allows the actuation springs at their least compressed state and the engine valve closed when engine power is off. The spring controller may also be adjusted, with a low or moderate control fluid pressure, to allow the engine valve to operate with a partial lift. | 5 |
RELATED APPLICATION
[0001] This application is a continuation-in-part application of U.S. patent application Ser. No. 13/103,154 filed May 9, 2011.
FIELD OF THE INVENTION
[0002] The invention relates to an auxiliary system for providing positive steering to marine crafts using jet propulsion systems, typically personal jet driven watercrafts such as jet boats and jet skis.
BACKGROUND OF THE INVENTION
[0003] By way of background, there are two types of jet propulsion systems currently in use. The first type most commonly used is found on personal watercrafts usually referred to as Jet Skis. This type uses a directional nozzle. The nozzle turns from side to side directing water from the jet to change the direction of the watercraft.
[0004] The second type is commonly used on Jet Boats and incorporates a movable hood or cover over the directional nozzle to force the water from the jet below the boat to add reverse thrust and allows the boat to back up. For forward thrust, it is pulled up above the jet nozzle.
[0005] In both types, the steering of the watercraft relies completely on the direction and force of the water being expelled from the directional nozzle. This steering method is extremely unreliable as it responds slowly and fails totally if power is reduced or turned off. As a result, there have been many deadly accidents as a result of such watercraft not being able to quickly and positively respond to a need for directional change at any speed, even if engine power is cut off.
[0006] In this specification, reference to a directional nozzle drive assembly or system generically includes both of the above types of systems, that is, a directional nozzle by itself or a combination directional nozzle with the reverse thrust hood or cover.
[0007] The present invention addresses this steering deficiency currently found in existing watercrafts powered by jet propulsion systems by incorporating an auxiliary keel system to dramatically enhance the steering performance of such watercrafts. In normal operation, the keel steering enhances the watercraft's maneuverability with immediate and controlled response.
[0008] In operating conditions where the operator reduces the jet power or stalls the engine, the keel steering takes over and the watercraft will steer accurately. Consequently, the present invention makes the operation of jet propelled watercrafts more enjoyable and, more importantly, much safer.
SUMMARY OF THE INVENTION
[0009] The present invention is an auxiliary rudder system configured for use with a jet propelled watercraft having a directional nozzle drive assembly at the stern of the watercraft, or configured for use with a jet propelled watercraft having a directional nozzle drive assembly at the stern of the watercraft and a movable hood that rotates over a directional nozzle to downwardly direct and force water from the directional nozzle below the watercraft for providing reverse thrust. In either case, the invention attaches to the directional nozzle drive assembly at the stern of the watercraft.
[0010] The embodiments of the present invention described herein provide for the versatility of operating as a rudder assisted steering in power or reduced power mode, that is, slow or idle speeds, or the invention can be set to provide rudder assistance to the steering at all speeds. In either case, the rudders are capable of being deflected up if they contact a submerged object while the boat is moving or anchored.
[0011] To provide this multi-functional operation, the invention uses a dual purpose thrust operated actuator, wherein the actuator may be set in an up mode, a lower mode and the modes may be selectable, or in a fixed non-selectable mode pre-set for up or down mode only. While in the up mode, the actuator uses the force of the jet pump to raise the rudders out of the water at speed, and with the use of one or more articulating or bias means, for example, spring(s) or cable(s) configured to contact with one of the rudders or be attached to one of the rudders, to deploy the rudders down at slow or idle speed to provide needed steering assistance to the operator. The actuator is set to capture water being expelled by the jet pump and as the thrust increases the rudders lift out of the water gradually decreasing their influence to the boat handling, up to the final position where they have no influence at speed meeting the individual needs or desires of the boat operator. The articulating or bias means may further incorporate means for adjusting the tension of any spring(s) or cable(s). Such tensioning devices are known in the art and are easily provided to adapt to the articulating or bias method chosen, whether the preferred spring or alternative cable or any other suitable method.
[0012] With the actuator set in the down mode, the invention uses the force of the jet pump water to hold the rudder in the water. As the boat increases speed the pump also increases thrust. The rudders are held down as the water flows on top of the actuator, which is essentially close to or approximately located on a plane more or less aligned with the bottom of the nozzle opening. The thrust of the water exiting the nozzle opening maintain the actuator down, thereby also keeping the rudders in the down position for enhanced steering. The back-up springs or other equivalent articulating or bias means are utilized in the event of power loss or reduced pump thrust due to clogging of the jet with weeds and other possible obstructions to the jet pump. However, in normal operation, the articulating or bias means do not function due to the downward force of the jet pump. This will greatly reduce spring fatigue and increase the reliability of the auxiliary rudder system.
[0013] In the down mode, the rudders will provide enhanced steering response, feedback to the operator through the helm, better control for handling rough water conditions. Further, the boat will maintain high speed turns while reducing speed. This is something jet steering will not do by itself. Conventional jets will immediately lose their turning ability if the engine power is reduced dramatically while making a turn. Further, the boat would perform better at towing tubes and skiers.
[0014] The spaced-apart rudders are typically configured to be mounted to the outside of an original equipment manufacturer directional nozzle housing. When nozzle reverse hoods are installed on the existing nozzle assembly, then the rudder system may be configured to be installed such that the rudders are either on the outside the nozzle/reverse hood assembly or the rudders can be configured to be installed between the nozzle and the reverse hood, depending on the practicality of the overall design of the nozzle/reverse hood assembly. For purposes of illustration only, the rudders will be depicted in the below described drawings on the outside.
[0015] The down mode will also provide assistance to the operator while making turns at high speed by reducing the force needed to turn the helm. This is due to external side forces being placed on the rudders as the boat turns at speed.
[0016] In the present invention a side force stabilizer is placed between the spaced-apart rudders. The stabilizer is attached to the existing nozzle housing below its exit opening. It serves as means for transferring the force to the steering helm and to prevent the rudders from bending due to the side forces.
[0017] Conventional jet steering becomes quite difficult at speed due to internal side forces from the high pressure water jet striking the inner wall of the steering nozzle as it tries to re-direct the water jet to turn the boat. With the rudders deployed at speed, external forces build up on the rudders as they are pushed through the water sideways. These forces counteract the internal forces and reduce the physical strength required to turn the helm. The end result is a power steering effect.
[0018] The present invention may also incorporate one or more anti-oscillation veins placed on the actuator as necessary to eliminate oscillation of the steering unit as it rides in or on the high pressure jet of water exiting the jet pump nozzle. These veins may be added to the top, bottom or both sides of the actuator as needed to obtain the required results, although the preferred location is on the bottom surface. This added stabilization is important especially when the steering unit is set to ride on top of the jet stream as the parts can build up a violent harmonic vibration caused by thousands of swirling pulsations in the exiting jet of water. Generally, the fins serve as anti-oscillation veins but when the fins are up, the veins assist the fins and provide an anti-oscillation functional feature. This vibration has been reported to cause serious issues with the operation of the boat and is suspected of causing damage to adjacent parts of the pump as well.
[0019] Another embodiment includes a variation for the stops where it is built in to the side force stabilizer and the actuator so that they meet at points for the fins to rest against when the set is in the down mode. The actuator itself would be configured to interact with the stabilizer and serve as a stop in lieu of using a boss as described above. On example of a configuration is providing the actuator with an extended portion at each end or at the edge near the fins and the side force equalizer could have points (although such points are necessary) going up at the end to make contact with the actuator and act as a set of stops for the fins to come to rest on when in use in the down function.
[0020] In another embodiment, a set of variable effect rudders, using a fixed position side force stabilizer and several graduating mounting holes on the fins that allow the consumer to vary the amount of steering assistance they receive. From full assistance with the fins all the way down, they will get both high speed and slow speed assistance. With the fins part way down they get less assistance in high speed and with the fins all the way up, they only get low speed assistance. This system can use a number of positioning holes so they can fine tune the results they desire, without having to modify the system. In this variant of the invention, the auxiliary rudder system comprises a pair of spaced-apart fins, the fins being configured to be attached at one end to a proximal end of the nozzle drive system so that the fins are oriented along sides of the nozzle drive system. The fins extend in length from the proximal end of the nozzle drive system a predetermined distance beyond a jet water flow outlet of the nozzle drive assembly. A side force stabilizer member is configured to be fixed to an underside of the directional nozzle of the nozzle drive system. The stabilizer member is oriented transversely such that respective ends of the stabilizer member are attached to the inside surface of the fins. The fins are selectively attachable to the stabilizer member ends such that the fins are positioned in an “up” position, a “down” position and one or more intermediate positions relative to the stabilizer member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In the accompanying drawings:
[0022] FIG. 1 is a cross-sectional conceptual view of the present invention with the hood lifted out of the way and the actuator member in position 2 , that is, the lower positioning aperture being utilized on the bent portion of the actuator member to allow exiting water to flow over the actuator member upper surface;
[0023] FIG. 2 is a representational cross-sectional view of FIG. 1 with the hood of the nozzle drive system lowered;
[0024] FIG. 3 is a is a cross-sectional conceptual view of the present invention with the hood lifted out of the way and the actuator member in position 1 , that is, the upper positioning aperture being utilized on the bent portion of the actuator member to allow exiting water to flow partially under the actuator member;
[0025] FIG. 4 is a perspective rear view of the present invention with the hood down over the outlet and the fins in a down position;
[0026] FIG. 5 is a is a perspective rear view of the present invention with the hood up over the outlet and the fins in a down position;
[0027] FIG. 6 is a perspective view of the present invention looking toward the outlet with the hood up and the fins down;
[0028] FIG. 7 is a perspective view of the present invention looking toward the outlet with the hood up and the fins up;
[0029] FIG. 8 is a view similar to that of FIG. 6 except with the actuator being pre-set and fixed to the sides of the fins;
[0030] FIG. 9 is a view similar to that of FIG. 7 except with the actuator being pre-set and fixed to the sides of the fins;
[0031] FIG. 10 is a view similar to that of FIG. 3 except with the actuator being pre-set and fixed to the sides of the fins;
[0032] FIG. 11 is a view similar to that of FIG. 2 except with the actuator being pre-set and fixed to the sides of the fins;
[0033] FIG. 12 is a perspective view of the present invention looking toward the outlet with the hood up and the fins down with an added feature of the anti-oscillating veins, in this case, a single vein added to the actuator;
[0034] FIG. 13 is a depiction similar to FIG. 12 except the depiction of multiple veins, in this case, two veins added to the actuator;
[0035] FIG. 14 is a depiction similar to FIG. 12 except the depiction of multiple veins, in this case, three veins added to the actuator;
[0036] FIG. 15 is a depiction of another embodiment of the invention wherein the actuator is configured to contact with stabilizer to stop the travel of the fins;
[0037] FIG. 16 is a depiction of the embodiment of FIG. 15 with the actuator separated from contacting the stabilizer;
[0038] FIG. 17A is a conceptual depiction of another variant of the present invention where the fins are attached directly to the ends of the stabilizer member, in this case, the fins are positioned in the “DOWN” position;
[0039] FIG. 17B is a conceptual depiction of the invention of FIG. 17B where the fins are attached directly to the ends of the stabilizer member, in this case, the fins are positioned in one of the one or more “INTERMEDIATE” positions; and
[0040] FIG. 17C is a conceptual depiction of the invention of FIG. 17A where the fins are attached directly to the ends of the stabilizer member, in this case, the fins are positioned in the “UP” position.
DETAILED DESCRIPTION OF THE INVENTION
[0041] Referring now to the drawings, FIGS. 1-11 conceptually disclose the present invention, which is an auxiliary rudder system configured for use with a jet propelled watercraft having a directional nozzle drive system 12 . The directional nozzle itself is depicted as 12 a and its outlet is depicted as 12 b . The rudder system is depicted generally as 10 .
[0042] The auxiliary rudder system 10 comprises a pair of spaced-apart fins 14 . The fins 14 are configured to be pivotally attached at one end to a proximal end of said nozzle drive system 12 so that said fins 14 pivot up or down along sides of said nozzle drive system 12 . The fins 14 extend in length from said proximal end of said nozzle drive system 12 a predetermined distance beyond a jet water flow outlet 12 b of the directional nozzle 12 a of the drive assembly 12 . The length beyond the outlet plane is sufficient to include the dual thrust actuator 16 between the fins 14 and to also subject the actuator surfaces 16 a , 16 b to thrust forces from the water flow exiting the nozzle outlet 12 b.
[0043] The invention further includes a thrust operated actuator 16 . Each end of the actuator is removably attached or optionally permanently fixed to an inside surface of the fins 14 . The actuator 16 further has respective top and bottom surfaces 16 a , 16 b , and is dimensioned and configured to be subjected to a thrust force caused by a flow of water exiting the outlet 12 b of the directional nozzle.
[0044] In one embodiment when the permanent fixed installation of the actuator 16 is not desired, the actuator 16 may further comprise opposing bent portions 16 c at each end of the actuator 16 . Each of the bent portions 16 c are in contact with a respective inside surface of the fins 14 . The bent portions 16 c are attached to the inside surfaces of the fins 16 . They can be attached with or without a pivoting feature, for example, if the actuator 16 is intended to be oriented to stay in a down position at speed or if the actuator 16 is intended to be oriented so as to lift the fins 14 at speed as water flows partially under the bottom surface of the actuator 16 . Of course, the bent portions 16 c can pivotally attached to the fins 14 to provide for dual purpose operating characteristics, as further described below. The bent portions 16 c shown in the drawings are depicted to be vertically oriented in an upward direction however it is understood that they may be vertically oriented in the downward direction as well.
[0045] The bent portions 16 c further have means 24 for pivoting and positioning the actuator orientation such that the top surface 16 a of the actuator 16 is constantly subjected to a thrust force of water exiting the nozzle outlet 12 b to keep the fins 14 in a down position at any speed or for pivoting and positioning the actuator orientation such that a bottom surface 16 b of the actuator 16 is at least partially subjected to the thrust force of water exiting the nozzle outlet 12 b to lift the fins 14 in an up position at an operating speed. This can be done in a number of ways. The pivoting feature can be a rotatable rivoted or fastened pivot point 24 a in which the actuator bent portions 16 c are pivoted attached to the fins 14 . Then two apertures 24 b can be provided on the fins 14 and an additional aperture 24 c can be provided on the bent portions 16 c through which a removable pin or fastener 24 d may be inserted and passed through one of the two apertures on the fins 14 . Each aperture represents a position 1 for allowing for partial flow of exiting water to pass under the actuator 16 and position 2 to for allowing the water flow above the top surface of the actuator 16 . Other means not depicted may include two slots on each fin where the fins can be partially disassembled (spread out) and the ends of the actuator may be placed in corresponding slots to provide for the up or down performance characteristics described above.
[0046] A side force stabilizer member 18 is configured to be fixed to an underside of a directional nozzle 12 a of the nozzle drive system 12 . The stabilizer member 18 is oriented transversely such that respective ends of the member 18 are located juxtaposed the inside surface of the fins 14 when the fins 14 are in a down position.
[0047] The invention further includes fin rotation stop means 20 for limiting a rotation downwardly of the fins 14 . This can be done in a number of ways such as providing various ridges or protrusion from the inside surface of at least one of the fins 14 or by having a portion of the side force stabilizer member configured to extend below the fins 14 to that as the fins are lowered, the bottom edge of the fins come in contact with the stabilizer member 18 extended end. This example is not shown in the drawings. A preferred embodiment is to include the former example, that is, a boss member 20 attached to an inside surface of one of the fins 14 and located so as to contact the side force stabilizer member 18 when the fins 14 are rotated downwardly.
[0048] The invention further comprises bias means 22 a for holding the fins 14 in the down position. The bias means 22 a are configured and tensioned to allow the fins 14 to lift in an up position when an object is struck by the fins 14 . In a preferred example of such bias means, at least one spring 22 a is provided that has an extended end 22 b which is in contact with a top edge 14 c of one of the fins 14 .
[0049] The inventive rudder system components can be made from a variety of materials, including stainless steel, aluminum, bronze/brass materials, polymeric composite materials or many other suitable materials sufficient for the environment in which such watercrafts are used.
[0050] The present invention may also incorporate one or more anti-oscillation veins 16 d placed on the actuator as necessary to eliminate oscillation of the steering unit as it rides in or on the high pressure jet of water exiting the jet pump nozzle. FIGS. 12-14 depict the veins 16 d under the actuator 16 . These veins 16 d may be added to the top, bottom or both sides of the actuator as needed to obtain the required results, although the preferred location is on the bottom surface. This added stabilization is important especially when the steering unit is set to ride on top of the jet stream as the parts can build up a violent harmonic vibration caused by thousands of swirling pulsations in the exiting jet of water. This vibration has been reported to cause serious issues with the operation of the boat and is suspected of causing damage to adjacent parts of the pump as well.
[0051] Another embodiment depicted in FIGS. 15-16 includes a variation for the stops 20 discussed above. In this embodiment, stop 16 e is provided. That is, the actuator 16 is configured so that the actuator 16 directly interacts with stabilizer 18 by coming in contact with the stabilizer 18 . The actuator itself would be configured to interact with the stabilizer and serve as a stop in lieu of using a boss as described above. One example of a configuration is providing the actuator with an extended portion at each end or at the edge near the fins and the side force equalizer could have points (although such points are necessary) going up at the end to make contact with the actuator 16 and act as a set of stops 16 e for the fins to come to rest on when in use in the down function.
[0052] In another embodiment depicted in FIGS. 17A-17C , a set of variable effect rudders 14 , using a fixed position side force stabilizer 18 and several graduating mounting holes 14 d on the fins 14 that allow the consumer to vary the amount of steering assistance they receive. In this variant of the invention, the auxiliary rudder system comprises a pair of spaced-apart fins 14 , the fins 14 being configured to be attached at one end to a proximal end of the nozzle drive system so that the fins are oriented along sides of the nozzle drive system 12 . The fins 14 extend in length from the proximal end of the nozzle drive system 12 a predetermined distance beyond a jet water flow outlet of the nozzle drive assembly 12 . A side force stabilizer member 18 is configured to be fixed to an underside of the directional nozzle 12 a of the nozzle drive system 12 . The stabilizer member 18 is oriented transversely such that respective ends of the stabilizer member 18 are attached to the inside surface of the fins 14 . The fins 14 are selectively attachable to the stabilizer member 18 ends such that the fins 14 are positioned in an “up” position, a “down” position and one or more intermediate positions relative to the stabilizer member using positioning holes 14 d for selectively fastening the fins 14 to the stabilizer member 18 so that the fins 14 are in a desired orientation in relation to the directional nozzle outlet.
[0053] It should be understood that the preceding is merely a detailed description of one or more embodiments of this invention and that numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit and scope of the invention. The preceding description, therefore, is not meant to limit the scope of the invention. Rather, the scope of the invention is to be determined only by the appended claims and their equivalents. | A rudder system that uses a dual purpose thrust operated actuator. The actuator is selectively positioned for use in an up or constant down mode. While in the up mode, the actuator uses the force of the jet pump to raise the rudders out of the water at speed, and with the actuator set in the down mode, the invention uses the force of the jet pump water to hold the rudder in the water. In an alternative embodiment, the invention includes anti-oscillating veins attached to the thrust operated actuator. In another alternative embodiment, the travel of the actuator is limited by configuring it to come into contact with a rudder stabilizer bar. Another embodiment includes providing adjustable fin positions relative to the side force stabilizer. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a guide arrangement and more specifically to a guide railing for guiding moving containers. In the beverage-producing industry, transport belts which transport for example containers or else beverage crates or boxes and the like are used at many locations. In order to ensure lateral guidance at these transport belts, guide belts or guide railings are provided, along which the respective containers are transported. Depending on the respective containers, different rails are used, for example metal profiles, plastic profiles, profiles with rolling bodies and the like. These various railings are configured differently in each case.
A large number of different railing guides are known from the prior art. U.S. Pat. No. 3,325,131 describes a device for mounting railings. In this case, a railing with a semicircular cross-section is pushed into a guide device. DE 101 18 566 A1 discloses a holding device for a lateral guide of a continuous conveyor. In this case, a lateral guide which is composed of a plurality of rectilinear wall sections is held by the holding device.
DE 296 10 201 U1 describes a railing for a container conveyor. In this case, a holding clamp is provided which holds the railing. U.S. Pat. No. 6,105,757 discloses a guide system. This comprises a holding clamp in which a guide railing with rectilinear side faces is held.
DE 91 05 736 U1 describes a wear profile for guide railings in container conveying devices. Here too, a clamp is provided which clamps a guide element, wherein this guide element itself forms the actual guide device of the railing. DE 27 13 223 likewise discloses a railing guide. In this case, the actual railing is introduced into a guide clamp.
DE 24 39 804 A1 describes a guide railing for container conveyors. In this case, a guide element is carried centrally by a holding arm.
SUMMARY OF THE INVENTION
The objection of the present invention is to provide a guide arrangement which can be used in a versatile manner, that is to say for different types of container. The intention is for it to be possible to use the same basic elements in each case and to adapt only individual components of the guide arrangement. Furthermore, it should be preferably also be possible to hold a number of guide elements using one holder.
A guide arrangement according to the invention for guiding moving containers comprises at least one guide element and in particular a lateral guide element which extends in a predefined extension direction at least in some sections along the transport path of the containers, and at least one holding device which holds the guide element at a predetermined position relative to the transport path. According to the invention, the holding device has a clamp element which clamps the guide element, wherein the clamp element bears against the guide element in a direction perpendicular to the extension direction, and the guide element has in its cross-section two holding sections and a wall section which is formed between these holding sections and in one piece with these holding sections, and wherein the holding sections are curved at least by 90° and an outer circumference of the holding sections is in contact with the clamp element at least in some sections, and the guide element has a recess which is formed by the wall section and the holding sections and in which a further guide device can be received.
The transport path of the containers is understood to mean the path along which the containers are conveyed. A clamp element is understood to mean an element which contacts another element from two sides and preferably from two opposite sides and thus preferably clamps it. The direction perpendicular to the extension direction is preferably a direction which is perpendicular not only to the extension direction but also to the plane of a transport belt. Bearing in this perpendicular direction is understood to mean in particular that the clamp element bears against the guide element from above and below and thus in the direction pointing from top to bottom.
The cross-section of the guide element is understood to mean a cross-section in a cross-sectional plane which is perpendicular to the extension direction. The holding sections serve in this case to hold a further guide device, and the wall section located therebetween preferably runs in a rectilinear manner. The curvature by at least 90° may in this case be a curvature in the shape of a circle or a arc of a circle, but a different, for example elliptical, curvature by 90° would also be possible, or even a curvature composed of a plurality of rectilinear sections which are angled relative to one another.
These holding sections of the guide element are in contact with the clamp element in some sections, that is to say the holding of the guide element relative to the clamp element takes place at least also via a holding between the clamp element and said holding sections. In particular a further guide device, such as a plastic body for example, can be introduced into said recess which is formed by the wall section and the holding sections.
In a further advantageous embodiment, at least one holding section is symmetrical in relation to a plane parallel to the wall section. Preferably, both holding sections are formed symmetrically in relation to the plane parallel to the wall section. By virtue of this symmetrical shape of the curvature, the guide element can be introduced into the clamp element both in such a way that the recess projects outwards, that is to say in the direction of the containers to be conveyed, and in such a way that the recess projects inwards, that is to say away from the containers. In this way, the wall section itself on the one hand can be used as a guide body and on the other hand in the reverse position can form a guide device inserted in the recess.
Such a procedure is not possible for example in the case of some of the devices known in the prior art, since the guide element in those cases can be inserted into the clamp element only in one direction. Preferably, the holding sections have a curvature of more than 100°, preferably more than 120°, preferably more than 140° and particularly preferably in a range of 160°-180°, but preferably the curvature is also no greater than 180°. In one particularly preferred embodiment, the two holding sections have a semicircular profile and are connected to one another by a wall section running in a rectilinear manner.
In a further advantageous embodiment, the clamp element has a C-shaped profile. In one preferred embodiment, the guide element also has a C-shaped profile but, as mentioned, the wall section of the guide element is preferably rectilinear.
In a further advantageous embodiment, the clamp element clamps the guide element by means of two fixing sections located opposite one another, wherein these fixing sections are curved by a smaller angle than the holding sections of the guide element. By means of this curvature this curvature, which is smaller and at most of equal size, it is achieved that that the guide element can be comfortably received in the holding sections. More specifically, the guide element can be pushed into the clamp element both in its longitudinal direction and also from the front after slightly loosening the clamp element beforehand. Preferably, an outer profile of the guide element is adapted to an inner profile of the clamp element. This means that both the holding sections of the guide element and the fixing sections have a corresponding contour, for example both have a cross-section in the shape of a segment of a circle.
In a further preferred embodiment, a width of the outer circumference of the guide element is larger than a width of the inner circumference of the clamp element. This means that the guide element always protrudes beyond the holding device and the clamp element regardless of its arrangement in the clamp element. This prevents containers from butting directly against the clamp element during transport.
Preferably, a further guide device is arranged in the recess of the guide element. With particular preference, this is a guide device which is made from plastic. In this case, this guide device is configured in such a way that it protrudes outwards relative to the guide element, that is to say in the direction of the containers. In this way, the containers will in this case not butt against the guide element during transport, but rather only against the guide device.
In a further advantageous embodiment, the further guide device comprises a plurality of rotatable bodies. As mentioned above, the guide arrangement according to the invention is intended to be suitable, when equipped accordingly, for a large number of different containers. If, as in this case, the guide device comprises a plurality of rotatable bodies, for example in the form of plastic rollers, it is particularly preferably suitable for example for so-called disposable shrink packs. Instead of plastic rollers, plastic balls may also be provided as rotatable bodies. If, as mentioned above, the guide device is a plastic profile, it is suitable for example for disposable and reusable boxes. Use of the guide element alone, for example by turning the guide element around relative to the clamp element, may be suitable for containers in the form of bottle crates.
In a further advantageous embodiment, the holding device comprises a carrier, on which the clamp element is releasably arranged in a fixed position. This may be for example a rod-shaped carrier, on which the clamp element is arranged via engagement means.
The present invention also relates to a holding device for holding a guide element for guiding moving containers. In this case, the holding device comprises a clamp element for holding the guide element and a carrier on which this clamp element is arranged. According to the invention, the clamp element comprises a first clamp part and a second clamp part which cooperates with this first clamp part in order to hold the guide element, and also at least one connection element, by means of which the two clamp parts can be releasably connected to one another, wherein the clamp parts have a receiving region for receiving an end section of the carrier in such a way that the end section of the carrier can be received between the clamp parts and clamped between the clamp parts in a non-rotatable manner.
The holding device is understood to mean a device which holds the guide element at a predetermined position relative to a transport belt for example. As mentioned above, the clamp parts serve to clamp the guide element, wherein they clamp the guide element preferably from above and below. Screws, nuts and the like may be provided for example as the connection element for connecting the two clamp parts.
Preferably, two such connection elements are provided and the end section of the carrier is arranged between these two connection elements in the assembled state.
By virtue of the releasable arrangement, it is possible quickly to replace or to turn around the guide element. Also by virtue of this measure, a larger strip width on different guide arrangements can be produced using simple means.
Preferably, the carrier is a rod-shaped body. In a further advantageous embodiment, the carrier has a first engagement means which cooperates with a second engagement means of at least one clamp part. In this case, it is possible that the carrier has a protrusion which engages in a matching groove of the clamp part. Conversely, however, the carrier may also have a groove, in which there engages a protrusion or a circumferential collar of the clamp part or parts.
In a further advantageous embodiment, an engagement body with a non-circular cross-section is provided on an end section of the carrier. By virtue of this non-circular cross-section, it is possible to fix or lock a certain rotary position of the carrier relative to the clamp parts. In this case, preferably this engagement body is spaced apart from the other regions of the carrier by a circumferential groove.
In a further preferred embodiment, at least one clamp part and preferably just one clamp part has an opening, through which a section of the carrier can pass. In this case it is possible that this opening is adapted in such a way that only the engagement body can pass through it, but not a main body of the carrier. In a further advantageous embodiment, the two clamp parts are configured in such a way that in the assembled state they form an opening, in which the carrier is held. Preferably, this opening in the clamp part is a closed opening. Preferably, the carrier can pass through this opening only in a certain rotary position.
In a further advantageous embodiment, at least one clamp part has a recess, the geometric shape of which is adapted to a cross-section of an end section of the carrier. More specifically, this recess is adapted to an end section of the engagement body. During assembly, the engagement body can be latched into this recess and then the two clamp elements can be screwed to one another.
The present invention also relates to a guide arrangement of the type described above comprising at least one holding device of the type described above. In the holder according to the invention, it is possible in one preferred embodiment that the bolt or carrier latches into the two holding devices as a result of rotation and in this way the guide device or the railing is clamped and thus easy mounting is possible. By virtue of the design according to the invention, it is possible to provide a standardised main carrier which is preferably produced from stainless steel. This main carrier or this profile can be used both for an outer railing and for a central railing. By contrast, in the prior art, different profiles are used as the main carrier, depending on whether an outer railing or a central railing is desired. The main carrier and guide elements also differ in the prior art according to the outer area and central area, which makes production more expensive.
As mentioned above, the shape of the guide element is such that a wide range of guide possibilities is available for rapid exchange, such as rollers, plastic guide rails or even the guide element alone.
BRIEF SUMMARY OF THE DRAWINGS
Further advantages and embodiments will emerge from the appended drawings:
In the drawings:
FIGS. 1 a - 1 d show different embodiments of a guide element, in some cases with a guide device;
FIG. 2 a shows a side view of a guide arrangement with an inserted guide element;
FIG. 2 b shows a view of a guide arrangement with the guide element inserted the other way round;
FIGS. 3 a - 3 c show a guide arrangement with a horizontal holder;
FIGS. 4 a - 4 c show a guide arrangement with a double holder;
FIGS. 5 a - 5 c show a guide arrangement with a vertical holder;
FIG. 6 a shows a holding device with a vertical carrier and a single clamp element;
FIG. 6 b shows a holding device with a vertical carrier and a double clamp element;
FIG. 6 c shows a holding device with a horizontal carrier and a clamp element;
FIG. 7 shows one possible structure for a railing;
FIG. 8 shows a side view of a holding device with two clamp elements;
FIG. 9 shows an enlarged view of a guide arrangement with an inserted guide element; and
FIG. 10 shows an enlarged view of a further guide arrangement with an inserted guide element.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 a - 1 c show a guide element 4 in different embodiments. FIG. 1 a shows the guide element without an insert. This guide element has a first holding section 9 a and a second holding section 9 b located opposite the first, wherein a wall section 8 is provided between these two holding sections 9 a , 9 b . Here, this wall section runs in one plane and extends in an extension direction E of the guide element. By virtue of this wall section 8 and the two holding sections 9 a and 9 b , a recess 18 is formed, into which further guide devices can be inserted.
This guide element can be used alone, for example for transporting bottle crates.
FIG. 1 b shows the guide element of FIG. 1 a , wherein here a guide device 12 in the form of a plastic profile 12 is inserted in the recess 18 . This plastic profile 12 protrudes from the guide element 4 and/or from the holding sections 9 a and 9 b in the direction R. Furthermore, the guide device 12 is configured in such a way that it engages at least partially behind the two holding sections 9 a and 9 b.
As can be seen in particular from FIGS. 1 a and 1 b , the two holding sections 9 a and 9 b have a curvature, wherein here there is a substantially circular curvature which has an angle of approximately 180°. The guide element shown in FIG. 1 b is particularly suitable as a transport railing for disposable and reusable boxes.
FIG. 1 c shows a guide element, wherein here the guide device 12 comprises a plurality of plastic rollers 14 . This outer circumference of the plastic rollers also protrudes from the guide element 4 in the direction R. This embodiment is particularly suitable for transporting disposable shrink packs.
FIG. 1 d shows a further embodiment of a guide element 4 a . Here too, a C-shaped profile of the guide element is provided, and also a guide device comprising a plurality of plastic balls 15 . This guide element is also particularly suitable for disposable shrink packs. It can be seen that the different guide devices, which are configured in particular in the form of plastic inserts, can in each case be used on the same guide element 4 .
FIG. 2 a shows a side view of a guide arrangement according to the invention. Said guide arrangement comprises a carrier 20 , onto which two clamp parts 7 a and 7 b are screwed by means of a screw 22 . These clamp parts 7 a and 7 b in turn form a clamp element 6 ; more specifically, this clamp element is formed of two clamp sections 6 a and 6 b . The guide element 4 is arranged within these clamp sections 6 a and 6 b . It can be seen that the outer width Y of the holding section 9 b or 9 a is larger than the inner width X of the clamp element 6 .
In this way, the guide element always protrudes from the holding element 6 in the direction R. In this way, a plastic profile inserted in the guide element 4 in FIG. 2 a also always protrudes from the holding element 6 and in this way it is possible to prevent transported piece goods from butting directly against the clamp element 6 during transport.
In the embodiment shown in FIG. 2 a , the two holding sections 9 a and 9 b are curved by 180° as mentioned above. The holding sections 6 a and 6 b also have a curvature, but here the angle of curvature is less than 180°, but preferably also greater than 90°. Such an angle of curvature means that the guide element 4 is held on the one hand and on the other hand also protrudes from the holding element 6 in the direction R.
FIG. 2 b shows a further arrangement of the guide element. It can be seen here that merely the guide element 4 has been rotated through 180° in the plane of the figure. In this way, the guide element 4 or the wall section 8 thereof can be used directly as a railing for piece goods. By comparing the diagrams shown in FIGS. 2 a and 2 b , it is possible to see that a wide range of guide railings can be formed using a small number of components. In the embodiment shown in FIG. 2 b , the recess 18 does not play any role since it is turned inwards.
FIGS. 3 a - 3 c show different embodiments of a holding arrangement. In each case a carrier 20 is provided, on which the holding sections 6 a and 6 b and also the guide element with its holding sections 9 a and 9 b are arranged. In the embodiment shown in FIG. 3 a , the guide element is turned in a manner similar to that in FIG. 2 a , so that the wall section 8 points outwards. In the embodiment shown in FIG. 3 b , a guide device 12 comprising rolling bodies is inserted. In the embodiment shown in FIG. 3 c , a guide device 12 without rollers is inserted, wherein this guide device 12 has protrusions 14 which are adapted to the inner cross-section of the holding sections 9 a and 9 b , and by means of which this guide device 12 is held.
Furthermore, in this embodiment, a gap 16 is provided between the guide device and the wall section 8 , wherein this guide section brings about a certain spring capability of the guide device 12 relative to the guide element 4 .
FIGS. 4 a - 4 c show a corresponding embodiment for a double holder. Here, the carrier 20 is arranged vertically and two holding sections 9 a and 9 b pointing in different directions with the respective guide elements 4 are arranged on the carrier. This arrangement is suitable in particular for transport paths on which piece goods are conveyed on both sides of the railing. Once again, in a manner corresponding to the embodiment shown in FIGS. 3 a - 3 c , different arrangements of the guide element and different guide devices are conceivable.
FIGS. 5 a - 5 c show a further embodiment with a vertically arranged carrier 20 but just one one-sided guide element.
As can be seen from FIGS. 3 a - 5 c , in each case a standardised main carrier is used, which is preferably produced from stainless steel. This profile can be used both for an outer railing and for a central railing. By contrast, in the prior art, different profiles are presently used as the main carrier.
By virtue of the arrangement according to the invention and the shape of the carrier device, a wide range of guide possibilities is thus available for rapid exchange, such as rollers or plastic guide rails or even, as shown above, the guide element alone.
For constructing a guide arrangement, a number of the components shown in FIGS. 3 a - 5 c can also be combined with one another, for example a double holder with a single holder and a holder with a horizontal carrier. In this way, modular railings can be constructed on the whole.
FIG. 6 a shows the assembly of a holder with a vertically oriented carrier 20 . Provided on this carrier 20 is a protrusion 26 which has a non-circular cross-section and in this case in particular a rectangular cross-section. This protrusion or bolt can be pushed into an opening 38 of the clamp part 7 a . In this case, it can preferably be pushed in only in one particular rotary position. A recess 34 is also provided, along which the main body of the carrier 20 can be guided.
The second clamp part 7 b has a recess 32 , the surface area of which is adapted to an end face of the protrusion 26 . During assembly, firstly the carrier in FIG. 6 a is rotated through 90°, so that it can be passed through the accordingly matched opening 38 . After it has been passed through, the carrier is once again rotated through 90°, so that the protrusion 26 engages in the recess 32 . In this state, the two clamp elements 7 a and 7 b are screwed to one another using the screws 22 and the nuts 36 and in this way a stable holding of the carrier relative to the clamp elements 7 a and 7 b is brought about. A collar 29 prevents the carrier 20 from being able to pass back out of the opening 38 and thus the clamp part 7 a in this rotary position.
FIG. 6 b shows a further arrangement, wherein here a double holding element is provided. In a manner similar to the embodiment shown in FIG. 6 a , the carrier here is also firstly rotated through 90° in order then ultimately, after passing through the opening (not shown here), to latch with its end face in the recess 32 . The two clamp elements 7 a and 7 b can then again be screwed to one another using screws 22 and nuts 36 .
FIG. 6 c shows a holding arrangement, wherein here the carrier 20 is arranged horizontally. In this embodiment, the carrier is inserted into a recess 28 in such a way that a collar 25 engages in a groove 23 formed between the protrusion 26 of the carrier and the main body 20 a of the carrier. The second holding element 7 a is then placed on and the two holding elements are screwed to one another using the screws 22 and the nuts 36 . Here too, a stable hold of the carrier relative to the holding elements 7 a and 7 b is possible.
It can be seen that in all the embodiments a standardised carrier 10 having a standardised protrusion 26 can be used, which overall reduces the production costs for the railing.
FIG. 7 shows a diagram to illustrate a modular construction for a railing. Here, two guide elements 4 a having a larger width B and two further guide elements 4 b having a smaller width b are provided. Accordingly, the clamp elements 6 also have different widths for receiving these guide elements 4 a , 4 b . Via the two central guide elements 4 b having the smaller widths b and the clamp elements 6 arranged at the edge sides thereof, the two outer guide elements 4 a having the large widths B are connected to one another. At the same time, it can be seen that the distance between the two outer guide elements can be achieved by displacing the two inner guide elements 4 b having the small width b towards one another.
Reference 40 denotes the central holder shown in FIG. 8 , on which the two guide elements 4 b having the small width b are arranged. This central holder 40 has an upper clamp section 6 a and a lower clamp section 6 b . Arranged between these two clamp sections 6 a , 6 b is a central web which fulfils the function of the two clamp sections 6 a , 6 b . The two guide elements 4 are arranged between the individual holding elements, wherein in this embodiment a displacement of these two guide elements 4 b towards one another in a direction perpendicular to the plane of the figure is possible.
FIG. 9 shows an enlarged view of the guide element also shown in FIG. 3 b with the inserted guide device 12 . It can be seen that the guide device 12 has two engagement means 11 which respectively engage in the recesses formed by the holding sections 9 a , 9 b . The contour of these engagement means 11 is advantageously designed for the stability of the inserted guide device 12 . More specifically, the engagement means 11 have two obliquely running side sections 11 a and 11 b and an end section 11 c which runs horizontally in FIG. 9 .
By virtue of the end section 11 c and the corresponding end section on the lower engagement means 11 , the guide device completely fills the guide element 4 in the vertical direction and in this way the stability is increased.
Recesses or free areas 17 are formed between the two side sections 11 a and 11 b on the one hand and the guide element 4 on the other hand. These free areas 17 serve the purpose that the guide device 12 can be better introduced into the shaped or curved guide element 4 .
FIG. 10 shows a further embodiment of a guide element 4 with a guide device 12 . Here too, the engagement means 11 have the side sections 11 a and 11 b and also the end section 11 c , and here too the free areas 17 are formed between the guide device 12 and the guide element 4 . The gap 16 between the guide device 12 and the guide element 4 can also clearly be seen in FIG. 10 .
All of the features disclosed in the application documents are claimed as essential to the invention in so far as they are novel individually or in combination with respect to the prior art. | A guide arrangement for guiding moving containers, includes at least one guide element which extends in a predefined extension direction at least in some sections along the transport path of the containers, and at least one holding device which holds the guide element at a predetermined position relative to the transport path. The holding device has a clamp element which clamps the guide element, wherein the clamp element bears against the guide element in a direction perpendicular to the extension direction, and the guide element has in its cross-section two holding sections and a wall section which is formed between these holding sections and in one piece with these holding sections, wherein these holding sections are curved at least by 90° and an outer circumference of the holding sections is in contact with the clamp element at least in some sections, and the guide element has a recess which is formed by the wall section and the hold sections and by which a further guide device can be held. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of devices used generally to store and retrieve video programming and, more particularly, to a stand-alone personal video recorder that can be integrated into a television set thereby allowing local control and enhanced video viewing.
BACKGROUND OF THE INVENTION
[0002] With the widespread availability of cable television and the increase in channel capacity, television viewers today have a virtually endless number of programming choices. Not only is there a vast array of programs and movies from which to choose, but programming is offered twenty four hours per day on the majority of television channels.
[0003] Although the television viewers today benefit from the increased programming choices, there remain many drawbacks and inconveniences associated with real time viewing of television programs. For example, a viewer may desire to view a particular program only to be precluded from doing so because the program is aired at an inconvenient time for the viewer. Even when the viewer is able to watch a program as it is being broadcast, it may be difficult for the user to focus his or her attention on the program due to telephone calls and other typical interruptions.
[0004] With the widespread availability of video cassette recorders (VCRs), the ability to record television programs for viewing at a later time has become essentially universal. Not only can VCR users record television programs for subsequent viewing, but they have more control over their viewing of the prerecorded material. Once a program is recorded, a VCR user can view the program when he or she wishes. Moreover, the user can control the viewing experience by utilizing VCR operator controls such as REWIND, FAST FORWARD and PAUSE. If the viewer is interrupted, he can simply stop the program and come back at a later time to finish watching it.
[0005] However, the use of VCRs is limited in that the conventional VCR can only record one program stream at a time. If there are two programs being broadcast simultaneous on separate channels, the VCR user can only record one of the programs. With the ever-increasing number of channels available to today's television viewers, it frequently occurs that a viewer would like to record multiple programs being broadcast at the same time, especially as many channels concentrate their popular programming during prime time viewing hours.
[0006] Furthermore, if a viewer is using the VCR to view a prerecorded program, the viewer cannot simultaneously record another program being broadcast real time. If a viewer is watching a television program as it is being broadcast real time, and she is interrupted by a five-minute telephone call, she may choose to record the remainder of the program. But when the telephone call ends, she does not have the option of simply watching the program from the point at which the program was when the telephone call came. This is because if the program is still being broadcast in real time, the viewer would have to rewind the videotape to the point at which she was interrupted, but she could not then use the VCR to record the remainder of the program being broadcast in real time.
[0007] Thus, there exists the need for a device that allows for recording of multiple programs being broadcast simultaneously. There further exists the need for a device that allows the user to record one or more programs being broadcast live while at the same time allowing the viewer to watch a prerecorded program. The device should further allow the viewer to effectively suspend live broadcasting in order to deal with an interruption and then resume the broadcast from the point of interruption, even as the program continues to be broadcast live.
[0008] There are available on the market today services to which viewers can subscribe that allow for greater control of their viewing experiences. For instance, TIVO is a subscription service that offers its subscribers various programming and recording options that overcome many of the VCR's limitations. In order to take advantage of the TIVO service, subscribers must connect an external digital recorder to their television set. The recorder can be programmed through the service to digitally record particular television shows at particular times and can record multiple shows being broadcast at the same time. The use of the digital recorder in conjunction with the TIVO service allows for video time shifting by temporarily storing digital recorded matter so that live broadcasting can be temporarily “paused” for a short period of time.
[0009] Although services such as TIVO overcome many of the limitations of VCR viewing, there remains the need for a device that allows viewers to have complete local control over their television viewing without having to subscribe to expensive services. There further exists the need for a device that will allow users to control their viewing experience without having to purchase and use recording devices that operate external to and independently of their television set. There also is a need for a device that, through local storage of prerecorded commercial material, can forward targeted commercial advertising to particular viewers during particular television broadcasts.
SUMMARY OF THE INVENTION
[0010] The present invention is directed toward a stand-alone personal video recorder that can be integrated directly into a television set, as well as other Original Equipment Manufacturer (“OEM”) devices. The personal video recorder (“PVR”) of this invention utilizes MPEG-2 standard encoding and decoding devices coupled with a hard disk drive for storage. The PVR is compatible with the common video broadcast formats, namely NTSC (National Television Standards Committee), and PAL (Phase Alternating Line system). The small size and the low power consumption of the PVR of this invention allows for an easy and efficient incorporation into various OEM devices, including television sets, IRD recorders, digital VCRs, as well as state-of-the-art home entertainment centers. Integrated Receiver/Decoder or in other words a PVR integrated in a Settop box.
[0011] Regardless of the OEM device in which the PVR is integrated, the PVR can be operated by a remote control thereby further enhancing the viewing experience.
[0012] In its elemental form, the PVR of the present invention comprises a printed circuit board and a hard disk drive for storage of any digitally recorded programming. The circuit board includes an analog decoder that receives analog video streams and converts the streams into digital CCIR 656 form. The circuit board also includes a digital encoder that accepts a real time digital video stream, compresses it and encodes into an MPEG-2 stream. Video streams encoded in the MPEG-2 standard can then be stored on the hard disk drive. The circuit board further includes a decoder that can take stored MPEG-2 streams and decode them back to analog and digital video format.
[0013] The PVR's compression and storage of audio and video signals allows for a highly interactive television and video viewing experience. When the PVR is integrated into an OEM device, such as a television, the user of the device will be able to digitally record television programs, without the need for videotape. Moreover, the user will be able to enjoy various simultaneous recording and playback options as well as various “trick play” modes. Without having to rely on a service provider, viewers can use the integrated PVR to have complete local control over their individual viewing experiences.
[0014] It is an aspect of this invention to provide a device that allows for television and video viewers to have complete local control of their individual viewing experiences.
[0015] Is another aspect of this invention to provide a stand-alone PVR that can be fully integrated into a television set or other OEMs, such as a digital VCR, an IRD (Integrated Receiver/Decoder), or a state-of-the art home entertainment center.
[0016] It is an aspect of the invention to allow users to record broadcast program while simultaneously watching another live or prerecorded program.
[0017] It is another aspect of this invention to allow users to “pause” a live broadcast during a viewing interruption and resume watching the broadcast from the point of interruption.
[0018] It is an aspect of the invention to allow a user, after having paused a live broadcast, to continue recording and then review the recorded programming in either normal speed or fast-forwarded speed to “catch up” to the live program.
[0019] It is a further aspect of the invention to allow viewers to enjoy various “trick play” modes such as INSTANT REPLAY, PAUSE, FAST FORWARD, REWIND, of prerecorded programming while at the same time recording one or more live broadcasts.
[0020] It is an aspect of the PVR to allow viewers to instantly access any portion of prerecorded video, rather than having to rewind or fast forward sequentially through recorded video.
[0021] It is another aspect of the PVR of this invention to provide high quality video recording and storage without the image degradation associated with conventional VCR recording and tapes.
[0022] It is an aspect of the invention to provide highly reliable storage of recorded video.
[0023] It is a further aspect to provide a PVR that allows local storage of particular commercial programming so it can be targeted to the specific PVR user.
[0024] It is an aspect of the invention to provide a PVR that can be controlled with the same remote control device that controls the television set or OEM in which the PVR is integrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a block diagram of the PVR and its interfacing with a conventional television set.
[0026] [0026]FIG. 2 is a block diagram illustrating the individual components of the printed circuit board of the PVR.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Fundamentally, the PVR of this invention receives an incoming video stream, compresses the stream into a digital format, stores it on a hard disk drive in its compressed form, and upon user demand, converts the stream back into a decompressed form for display to the viewer. Because the PVR operates within the television set or other OEM device, the user has complete control of the viewing experience without any requirement for subscription to a remotely operated service.
[0028] As illustrated in FIG. 1, the architecture of the PVR 10 of this invention fundamentally comprises a hard disk drive 15 and a printed circuit board (PCB) 20 which houses the individual video encoding, compression and decoding components of the PVR 10 . In the preferred embodiment of the invention, the PCB 20 is coupled to a conventional hard disk drive 15 using a conventional hard disk drive interface 25 . The preferred embodiment of the PVR 10 of this invention can accommodate either an Integrated Drive Electronics (IDE) interface or an Ultra DMA standard interface. The support of both these interfaces assures connectivity to most industry standard hard disk drives. There generally are six main interfaces between the PVR 10 and the OEM device in which the PVR 10 is integrated. For purposes of illustration, the OEM shown in FIG. 1 is a conventional television 30 . A video input interface 32 and an audio input interface 33 are used to feed a live video program and a live audio stream respectively from-the television 30 to the PVR 10 . A video output interface 34 and an audio output interface 35 are used to feed video and audio signals respectively to the television 30 for viewing by the user. The operations of the PVR 10 are controlled by signals sent and from the television or other OEM through a operations control interface 36 . The preferred embodiment of the PVR 10 of this invention utilizes an 12C interface for the operations control interface 36 . An 12C interface is an industry standard by bi-directional 2-wire interface. Additionally, the PVR 10 can utilize an RS232 standard interface to control the operations of the PVR 10 . These interfaces are common means of controlling circuits within modern television sets and each is well known to those ordinarily skilled in the art. The operations of the PVR 10 can be controlled by the user through a remote control device 40 .
[0029] The stand-alone PVR 10 of this invention can be powered through +5 or +12 volt power control interface 38 to the television 30 or other OEM device and a common ground. Due to the small size and low power consumption of the PVR 10 , it can easily be integrated into a television set or other OEM devices. While no mechanical or electrical modifications are normally required to integrate PVR 10 into television 30 or other OEM devices; in some cases, a particular OEM manufacturer may want to customize the functions or control of PVR 10 . This can be accomplished by modifying the on-board operating software residing in flash memory 39 .
[0030] As explained further below, the hard disk drive 15 is used to store compressed video and audio data, device configuration data, and other non-volatile information such as electronic programming data. The video and audio data is stored on the hard disk drive 15 in MPEG-2 compression standard, while other data is stored as is. The amount of data that can be stored on the hard disk drive 15 is dependent on the disk size used and the compression ratio of the data. In “high video quality” mode (close to DVD quality) close to 2 gigabytes of storage is required for every hour of recorded video, while in “low quality mode” (close to VHS tape) close to 600 megabytes of storage is needed for every hour of recorded video. Accordingly, an eight-gigabyte hard disk drive can store four or more hours of good quality video. A larger disk drive can of course store more.
[0031] The PVR 10 of this invention utilizes MPEG-2 encoding/decoding architecture to enhance the traditional television viewing experience. MPEG-2, developed by the Moving Pictures Expert Group, is a standard for digital video and audio compression and decompression. By decompressing and encoding a video stream, the PVR can minimize necessary storage space and bandwidth requirements, thereby enhancing the overall system efficiency while reducing the overall system cost.
[0032] Referring now to FIG. 2, a description of the individual components of the PCB 20 is given. Because many available video signals are available in analog form only, the PVR 10 includes on the PCB 20 an analog decoder 50 that can decode standard analog signals and convert them into digital form. Analog digital signals typically are streamed in any one of the major international television standards such as NTSC (National Television Standards Committee), PAL (Phase Alternating Line system) Composite or S-Video forms. Devices used to decode analog signals and convert them into digital form are common in the industry and familiar to those skilled in the art. The preferred embodiment of this invention utilizes for the analog decoder 50 a PHILLIPS SAA7114 video decoder, which can decode an NTSC, PAL standards, in Composite or S-Video format signal into a digital video stream in the digital form 50 ′. The audio input is analog. Analog to Digital Converter 33 ′ is used to convert the analog audio input to a digital format. Analog to Digital Converter 33 ′ is a standard well known in the art device.
[0033] If the video program to be recorded is received in digital format 32 ′, such as the DVB-SPI standard that is a common output of digital tuners, it need not be converted by the analog decoder 50 . Because a DVB-SPI signal is already encoded in MPEG-2 format, it bypasses the KFIR II Processor 55 , and is fed directly into the Sti5512 decoder 65 . This provides improves picture quality by eliminating the need to first go through an analog to digital conversion stage. These are described in the next paragraph.
[0034] The digital video stream, and the digitized audio stream, are fed to an MPEG-2 encoder 55 . MPEG-2 encoding is a well known process by which a video and audio stream are compressed into a standardized format. The PVR 10 utilizes a local SDRAM storage device 60 , external to the MPEG-2 encoder 55 , to temporarily store intermediate video frames during the encoding process. The MPEG-2 compression allows for local storage of a significant amount of video and audio data on the hard disk drive 15 of the PVR 10 .
[0035] MPEG-2 encoding devices are well known in the art, and a variety of processors can be used for the MPEG-2 encoding. The inventors have utilized a KFIR II Processor for the MPEG-2 encoder 55 of the preferred embodiment of this invention. Once a program stream has been decoded into MPEG-2 standard, the compressed digital stream is stored on the hard disk drive 15 for later viewing on demand.
[0036] To display previously stored video and audio streams that have been stored on the hard disk drive 15 , the streams must first be decoded from the MPEG-2 compressed format. The PVR 10 utilizes a video processor 65 to decode the compressed stream either back to analog video format (NTSC or PAL) or into CCIR 656 digital format depending on whether the OEM user display is in analog or digital form. There are available various video processors capable of decoding MPEG-2 streams that can be used in the PVR 10 . The preferred embodiment of the PVR 10 of this invention utilizes the ST MICROELECTRONICS STi5512 Omega video processor for MPEG-2 decoding.
[0037] Overall control of the preferred embodiment of the PVR is performed also by the video processor 65 . The STi5512 Omega Video processor is capable of controlling the operations of the PVR 10 , although other similar processors can be used. The STi5512, as well as other members of the STi55XX family, contains an embedded DSP (Digital Signal Processor). This DSP, rated at 60 MIPS, is capable of performing general purpose computing operations. The “PVR Control” program running on this DSP is responsible for initializing the PVR hardware after power-up or reset and loading the correct configuration into the Encoder and the Decoder section of the PVR. In addition, the “PVR Control” program accepts control commands from RS-232 and 12C ports and reconfiguring the PVR components according to the command. A flash memory 39 is connected with the video processor 65 . The video processor 65 must be capable of controlling the power-up of the PVR 10 , the system configuration initialization and setup. The video processor 65 also controls the hard disk drive 15 , the MPEG-2 encoder 55 , the MPEG-2 decoding function, as well as the graphics of the onscreen display for user control.
[0038] As illustrated in FIG. 2, the PVR 10 accepts a live broadcast video through the video input interface 32 . If the live video stream is already in digital form, the stream is fed directly to the MPEG-2 encoder 55 for compression and encoding. If the live video stream is in analog form, it is first fed to the analog video decoder 50 where it is converted into digital CCIR 656 format before being fed to the MPEG-2 encoder 55 for compression and encoding. The digital audio stream associated with the live video stream is received through the audio input interface 33 and is fed to the MPEG-2 encoder. Once the input video and audio streams are compressed and encoded into MPEG-2 format, they are processed by the video processor Sti5512 65 and stored on the hard disk drive 15 for later retrieval upon command by the user. The clock, horizontal and vertical synchs derived in the Video Decoder 50 are directly driving video processor Sti5512 65 . In this manner, this synchronization prevents video artifacts from being created inside television 30 . The compressed data is packaged into fixed-length blocks and are written on the hard-disk drive 15 one block at the time. The size of the block is optimized for disk-drive performance. The sequence of the blocks on the hard disk drive is unique to assure content protection. In other words, a PC or other standard computer can't read the information stored by the PVR on the disk drive. It can only be read by another PVR. Upon a retrieval command by the user, a compressed video program, and its associated audio stream, can be retrieved from storage on the hard disk drive 15 for viewing. The compressed video and audio streams are fed to the video processor 65 for MPEG-2 decoding. After the MPEG-2 decoding process is complete, a video output stream is fed to the television 30 through the video output interface 34 . The associated decompressed audio stream is likewise fed to the television 30 through the audio output interface 35 .
[0039] The PVR user's ability to access and control the viewing of video and audio streams stored in MPEG-2 format allows for a highly enhanced and interactive viewing experience. A program stored on the PVR 10 can be accessed precisely and quickly because a user can direct the PVR 10 to retrieve a particular program without having to filter through other material stored on the hard disk drive 15 . Conventional VCR recording is done sequentially, thereby often requiring the user to fast forward and rewind through recorded material to access a particular prerecorded program. With the PVR 10 , accessing a particular program is more akin to choosing a particular song on a compact disk—the user simply selects the program to be viewed, and he or she has virtually immediate access to the program. Additionally, the hard disk drive 15 of the PVR 10 allows for local storage of the recorded and compressed video. In conjunction with-the ability to record a live broadcast while viewing prerecorded material, viewers can effectively “pause” a live broadcast while attending to interruptions that occur during the live broadcast of the program. For instance, a viewer who wishes to watch his favorite weekly sitcom can command the PVR 10 to record the live broadcast. The PVR 10 then records the program and stores the compressed video stream on the hard disk drive 10 . If the telephone rings during the live broadcast and the viewer is interrupted for five minutes of the live broadcast, the live broadcast continues to be stored and recorded on the hard disk drive 15 . When the viewer returns from his interruption, he can command the PVR 15 to display the recorded program from the point of the interruption while continuing to record the live broadcast. Because the PVR 10 is capable of displaying recorded material to the viewer while simultaneously recording the live broadcast, the viewer can simply continue watching the recorded program essentially with a five-minute delay from the live broadcast. After pausing a program, pressing a FAST FORWARD button will automatically fast forward the pre-recorded program until the PVR ‘catches up’ with real time broadcast. Then the display switches to show real time programming content.
[0040] As a further example, a user can rewind a program to a specified point of interest, for example to view again a touchdown in a football game.
[0041] The PVR's ability to compress and store prerecorded video streams allows for prerecorded advertising material, i.e., commercials, to be stored and incorporated into television programs based on the particular user of the PVR. In other words, commercials can be selectively stored on a particular viewer's PVR to cause those commercials to be targeted to particular consumers. Control of the recording process and playback can be accomplished via coded signals embedded in the VBI (Vertical Blank Interval). When the TV is not in use (for example at night time), upon commands issued in the VBI, several prerecorded commercials can be downloaded into the hard drive 15 from a special TV channel dedicated for this purpose. At a later time, when TV is in use, and during a commercial time slot, other commands issued in the VBI can direct a specific pre-recorded message to play.
[0042] Although a preferred embodiment of the invention has been described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the scope or spirit of the following claims. | A stand-alone personal video recorder that can be integrated directly into a television set, as well as other Original Equipment Manufacturer (“OEM”) devices. The personal video recorder (“PVR”) of this invention utilizes MPEG-2 standard encoding and decoding devices coupled with a hard disk drive for storage. The PVR is compatible with the common video broadcast formats, namely NTSC (National Television Standards Committee), PAL (Phase Alternating Line system) or S-Video forms. The small size and the low power consumption of the PVR of this invention allows for an easy and efficient incorporation into various OEM devices, including television sets, IRD recorders, digital VCRs, as well as state-of-the-art home entertainment centers. | 7 |
FIELD OF THE INVENTION
This invention relates to an envelope handling device, such as a mailing machine, including a moistener system. More particularly, this invention is directed to a moistener system having a first water well at a first elevation and a second water well at a second elevation both of which are fed from a single water supply.
BACKGROUND OF THE INVENTION
Mailing machines are well known in the art. Generally, mailing machines are readily available from manufacturers such as Pitney Bowes Inc. of Stamford, Conn. Mailing machines often include a variety of different modules or sub-systems that automate the processes of producing mailpieces where each module performs a different task on the mailpiece. The typical mailing machine includes the following modules: singulator (separating the mailpieces one at a time from a stack of mailpieces), scale, moistener (wetting and sealing the gummed flap of an envelope or tape), printer (applying evidence of postage), meter (accounting for postage used) and stacker (stacking finished mailpieces). However, the exact configuration of each mailing machine is particular to the needs of the user. Customarily, the mailing machine also includes a transport apparatus that feeds the mailpieces in a path of travel through the successive modules of the mailing machine.
In some mailing machines it is desirable to print postal indicia on both envelopes and tapes. The tapes being used when the package or envelope to be mailed is oversized or too large to be fed through the mailing machine. Thus, the postal indicia is printed on a tape and then the tape is adhered to the oversized item. As a result, the moistener module is required to wet both envelope flaps and tapes.
Generally, all moistener modules include an applicator assembly for applying water to the envelope flap or the tape, as the case may be. A wide variety of applicator assemblies are known such as those employing moistening belts, pads, brushes and the like as described in the following U.S. Pat. Nos.: 3,905,325; 4,038,941; 4,450,037; 4,643,123; 5,209,806; 5,354,407, 5,525,185; 5,569,327 and 5,674,348. Typically, the applicator assembly is operatively coupled to a local water supply or well from which the applicator assembly draws water usually through some form of wicking or capillary action. In turn, the well is supplied by a remotely located water reservoir that the operator may replenish as needed. In this manner, the applicator assembly remains properly saturated as water is transferred to the envelope.
Although such prior art systems work generally well, they suffer from certain complications when it is desirable to employ a dual applicator assembly system having a first well and applicator for moistening envelopes and a second well and applicator spaced apart from the first well and applicator for moistening tapes. Thus, it is necessary to keep two wells supplied with water. This dual applicator assembly is further complicated when it is desirable to supply the two wells from a single reservoir. Still another complication occurs when the two wells are required to be maintained at different elevations as may be required by the differences between moistening envelopes and tapes and/or the changes in elevation dictated by a feed deck that is inclined from horizontal to assist in aligning the top edge of the envelopes along a registration wall as they are fed through the mailing machine.
Those skilled in the art will recognized that an active system for maintaining the two wells from a single reservoir may be employed through appropriate use of pumps, water level detection sensors, shutoff valves (i.e. solenoid operated) and the like. Although such an active system may be simple to implement, it suffers from certain drawbacks. As examples, the use of these devices increases the cost, space requirements and power requirements of the overall moistener module.
On the other hand, those skilled in the art will recognized that a passive system for maintaining the two wells may be employed through appropriate use of separate reservoirs for feeding each of the two wells, respectively. Although such a passive system may also be simple to implement, it too suffers from certain drawbacks. As examples, the use of two separate reservoirs increases the cost and space requirements of the overall moistener module as well as doubling the amount of operator intervention required. The operator must now check and maintain two reservoirs.
Therefore, there is a need for a moistener module that utilizes a passive system for supplying two wells at different elevations from a single reservoir. In this way, the drawbacks associated with the systems described above may be overcome in a cost effective manner without increasing the amount of operator intervention required.
SUMMARY OF THE INVENTION
The present invention provides a cost effective moistener module for passively supplying two water wells with water where the two water wells are at different elevations.
In conventional fashion, this invention may be incorporated into a variety of envelope handling devices requiring a moistener module, such as: a postage meter, a mailing machine, an inserter or other general purpose envelope handling device.
In accordance with the present invention, there is provided an envelope handling device including a moistener module where the moistener module includes a reservoir assembly, a first well tank and a second well tank. The reservoir assembly includes a reservoir tank for holding a supply of reservoir water having a predetermined height; a first well tank for holding a supply of first well water, the first well tank directly coupled to the reservoir tank via a first well tank hose so that the reservoir water is capable of flowing through the first well tank hose to the first well tank and raising the first well water to the predetermined height; and a second well tank for holding a supply of second well water at a different height from the predetermined height, the second well tank coupled to the reservoir tank via a second well tank hose and a trap, the trap establishes a pressure differential between the predetermined height and a level of water within the trap; and wherein the reservoir water is capable of flowing through the second well tank hose and the trap to the second well tank and raising the second well water to the different height as air is captured within the trap to balance the pressure differential.
Therefore, it is now apparent that the present invention substantially overcomes the disadvantages associated with the prior art. Additional advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
FIG. 1 is a simplified schematic of an elevational cross sectional view of a moistener module in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a simplified view a moistener module 10 is shown. For the sake of clarity, only those aspects of the moistener module 10 that are necessary for an understanding of the present invention are shown.
The moistener module 10 includes a reservoir assembly 20, a tape well assembly 80 and an envelope well assembly 100. Additionally, the moistener module 10 includes an applicator assembly (not shown) operatively coupled to both the tape well assembly 80 and the envelope well assembly 100, respectively, for applying water to the tapes and envelopes as the case may be. As used in this application, the term water is intended to include any fluid, such as E-Z Seals® available from Pitney Bowes Inc. of Stamford, Conn., used to wet and soften a gummed (glued) flap of an envelope or gummed surface of a tape.
The reservoir assembly 20 includes a water bottle 30 and a tank 40 where the water bottle 30 is adapted to be removable from the tank 40 and the tank 40 is vertically repositionable by any conventional means (not shown) such as by a slotted bracket (not shown) mounted to a frame (not shown). The water bottle 30 includes a cap 32, a bottom neck portion 34 and a spring loaded rubber stopper 36 fixably mounted to the bottom neck portion 34. An operator (not shown) may supply the bottle 30 with water 38 by removing the cap 32. The tank 40 includes a shelf 42 on which the bottle 30 rests and a plunger 44 that engages the rubber stopper 36 so that the supply water 38 may flow into the tank 40 and create a supply of reservoir water 46. As is known in the art, the height H r of the reservoir water 46 within the tank 40 remains constant because the supply water 38 flows into the tank 40 as the stopper 36 is exposed to air and stops flowing into the tank 40 as the height H r of the reservoir water 46 covers the stopper 36.
The tank 40 further includes a tape well outlet 52 operatively coupled with the tape well assembly 80 via a tape hose 82, an envelope well outlet 54 and a trap 56. The envelope well outlet 54 is operatively coupled to the trap 56 via an intermediate hose 102 while the trap 56 is in turn operatively coupled to the envelope well assembly 100 via a secondary reservoir hose 104. The tape well assembly 80 includes a tape well tank 84 having an inlet 86 connected with the tape hose 82. The tape well tank 84 is fixably mounted to any suitable structure (not shown) by conventional means (not shown) and holds a supply of tape well water 88. Those skilled in the art will recognize that the height of the tape well water 88 is equal to the height H r of the reservoir water 46 because they are directly coupled together. Thus, the height of the tape well water 88 within the tape well tank 84 may be raised or lowered by vertically repositioning the tank 40 eventhough the position of the reservoir water 46 relative to the tank 40 remains constant as described above.
The envelope well assembly 100 includes a secondary reservoir tank 120 vertically repositionable by any conventional means (not shown) such as by a slotted bracket (not shown) mounted to a frame (not shown) and an envelope well tank 140 fixably mounted to any suitable structure (not shown) by conventional means (not shown). The secondary reservoir tank 120 includes a secondary reservoir tank inlet 124 connected to the intermediate hose 104 and a secondary reservoir tank outlet 126 connected to an envelope hose 106. Thus, the envelope hose 106 connects the secondary reservoir tank 120 with the envelope well tank 140 via an envelope well tank inlet 144. The secondary reservoir tank 120 holds a supply of water 122 while the envelope well tank 140 also holds a supply of water 142.
The trap 56 includes a trap inlet 58 operatively coupled with the envelope well outlet 54 via the intermediate hose 102 and a trap outlet 60 operatively coupled with the secondary reservoir tank 120 via the intermediate hose 104. Due to the geometric configuration of the trap 56, a generally inverted V-shaped member, air is captured in the trap 56 and the intermediate hose 104. The height H 1 of the water in the trap 56 rises up to a notch 59 within the trap 56 before falling down into the intermediate hose 104 and establishing a height H 2 within the intermediate hose 104. Additionally, the secondary reservoir water 122 achieves a height H sr that is duplicated in the envelope well tank 140 by the envelope well water 142 because they are directly coupled together via the envelope hose 106.
With the structure of the moistener module 10 described as above, an overview of the functional and operational characteristics will now be described. Generally, the air captured with the trap 56 creates an air lock that allows the establishment of the height H sr of the secondary reservoir water at a different elevation form the height H r of the reservoir water. Additionally, the difference in hydrostatic pressure between the height H r of the reservoir water 46 and the height H 1 of the water in the trap 56 is equal to the difference in hydrostatic pressure between the height H sr of the secondary reservoir water 122 and the height H 2 of the water in the intermediate hose 104. This is due to the overall moistener module 10 reaching equilibrium and is described in more detail below.
At initial installation, water must be added to the moistener module 10 because the moistener module 10 is shipped dry. To accomplish this, the operator removes the bottle 30 from the moistener module 10 and fills it with water before replacing it. Once placed inside the tank 40, bottle water 38 begins flowing into the tank 40. As described above, reservoir water 46 flows out of the tank 40 via the tape well outlet 52 and the envelope well outlet 54. Since no air is trapped in the tape hose 82, the height or level of the tape well water 88 will reach the height H r of the reservoir water 46. Thus, as the well water 88 is consumed through use, it is automatically replenished from the reservoir water 46 which is in turn replenished from the bottle water 38.
On the other hand, the envelope well assembly 100 operates differently. At initial installation, reservoir water 46 flows out the envelope well outlet 54, through the intermediate hose 102, around the trap 56 and into the secondary reservoir hose 104. At this point, the secondary reservoir water 122 and the envelope well tank 140 fill via the envelope tank hose 106. Since no air is trapped in the envelope tank hose 106, the height or level of the envelope well water 142 will reach the height H sr of the secondary reservoir water 122. In contrast, air will remain in the secondary reservoir hose 104 since the secondary reservoir tank inlet 124 has a horizontal orientation. Thus, the secondary reservoir water 122 will not cover the inlet 124 until the secondary reservoir water 122 rises to a height above the inlet 124. Once this occurs, air becomes trapped in the secondary reservoir hose 104 and compressed within the secondary reservoir hose 104 so as to offset the difference in hydrostatic pressure created by the difference in hydrostatic pressure between the height H r of the reservoir water 46 and the height H 1 of the water in the trap 56. That is, the difference in hydrostatic pressure between the height H r of the reservoir water 46 and the height H 2 of the water in the trap 56 is equal to the difference in hydrostatic pressure between the height H sr of the secondary reservoir water and the height H 2 of the water in the intermediate hose 104. Thus, an air lock is formed that still maintains the capability to allow reservoir water 46 to pass over the notch 59 in the trap 56. Because as envelope well water 142 is consumed, it is replenished by the secondary reservoir water 122 which is in turn replenished from the secondary reservoir hose 104 which results in a decrease in pressure that allows reservoir water 46 to fall over the notch 59 until the pressure again reaches equilibrium.
Those skilled in the art will appreciate that the placement of the various components of the moistener module 10 is dictated by functional constraints and operational considerations of convenience and accessibility. For example, the adjustable components such as the reservoir tank 40 and the secondary reservoir tank 120 must be accessible by the operator. On the other hand, the tape well tank 84 and the envelope well tank 140 are likely required to be located deep within the apparatus of the envelope handling device so as to perform their required tasks of supplying their respective applicators with water. As a result, the tape well tank 84 and the envelope well tank 140 are fixably mounted within an envelope handling device (not shown) according to the nominal dimensions associated with the requirements for the height H sr of the envelope well water 142 and the height H r of the tape well water 88. Additionally, the tank 40 and the secondary reservoir tank 120 are also mounted within the middle of their respective adjustable ranges according to the nominal dimensions associated with the envelope handling device.
However, due to manufacturing tolerances and differences in sites (for example, a non-level platform for the envelope handling device) where the envelope handling device is installed, some adjustments to the moistener module 10 are likely necessary to optimize the performance of the moistener module 10. Therefore, to raise or lower the level of the tape well water 88, the reservoir tank 40 may be vertically repositioned accordingly. For example, raising the reservoir tank 40 by a fixed amount also raises the level of the tape well water 88 by the fixed amount because the height of the tape well water 88 must remain equal to the height H r of the reservoir water 46. Importantly, raising the reservoir tank 40 has no effect on the height H sr of the secondary reservoir water 122 and in turn the envelope well water 142. This is because the difference in hydrostatic pressure between the height H r of the reservoir water 46 and the height H 1 of the water in the trap 56 is established by fixed geometry and thus remains constant as the reservoir tank 40 is repositioned. Thus, the air within the trap 56 and the intermediate hose 104 does not realize any pressure change that would trigger a flow of reservoir water 46 over the notch 59. Instead, the air merely shifts position slightly to accommodate the new shape of the secondary reservoir hose 104.
To raise or lower the level of the envelope well water 142, a different approach is used. In this case, vertically repositioning the secondary reservoir tank 120 in an appropriate manner causes the envelope well water 142 to raise or lower accordingly, as the case may be. Here again, the air within the trap 56 and the intermediate hose 104 does not realize any pressure change and again the air merely shifts position slightly to accommodate the new shape of the secondary reservoir hose 104. Since the air within the trap 56 and the intermediate hose 104 does not realize any pressure change, the reservoir water 46 remains unaffected by any repositioning of the secondary reservoir tank 120. Thus, raising or lowering the secondary reservoir tank 120 has no effect on the height H r of the reservoir water 46 and in turn the tape well water 88.
It should now be apparent to those skilled in the art that the present invention substantially addresses those drawbacks and problems discussed above in the Background. The reservoir water 46 operates as a single source for supply both the tape well water 88 and the envelope well water 142 while they remain independently vertically adjustable.
Importantly, a few details of the preferred embodiment have been found through empirical testing to improve the overall performance of the present invention. One detail is the shape of the trap 56. Generally, it has revealed that it is better to have the upstream side (inlet side) of the notch 59 have a smaller opening than downstream side (outlet side). In this manner, the flow of reservoir water 46 over the notch 59 may be controlled. For example, if reservoir water 46 flows too quickly over the notch 59 into a small opening, then there is a risk that the force of the reservoir water 46 through the intermediate hose 104 will drive all or most of the air out of the system. Thus, a suitable air lock may not form. Therefore, it is preferable to restrict the flow of reservoir water 46 over the notch. On the other hand, if the flow is reduced to a trickle, then the system will be slow to reach equilibrium at initial installation and slow to response to changes. Preferably, the ratio of the cross sectional area on the upstream side of the notch 59 to the cross sectional area on the downstream side of the notch 59 should be in the range of about 0.25 to 0.75.
As another detail, the amount of horizontal slack in the secondary reservoir hose 104 is important to the operation of the moistener module 10. A large horizontal span of slack in the secondary reservoir hose 104 helps the secondary reservoir hose 104 assume a new shape or configuration in response to repositioning of the reservoir tank 40 and/or the secondary reservoir tank 120 with little change in the elevation of the height of the water within the secondary reservoir hose 104. In this manner, it is easier to keep the tape well water 88 and the envelope well water 142 isolated. Preferably, the ratio of horizontal span of the secondary reservoir hose 104 to the vertical span of the secondary reservoir hose 104 should be greater than about 2.0.
Many features of the preferred embodiment represent design choices selected to best exploit the inventive concept as implemented in a mailing machine. However, those skilled in the art will recognize that various modifications can be made without departing from the spirit of the present invention. For example, the secondary reservoir tank 120 is provided merely so that it may be located more conveniently than the envelope well tank 140 to make adjustments easier. Those skilled in the art will recognize that the secondary reservoir tank 120 may serve directly as the envelope well tank 140. Thus, those skilled in the art will readily be able to adapt the inventive concepts of the present invention to suit their own particular applications.
Therefore, the inventive concept in its broader aspects is not limited to the specific details of the preferred embodiments but is defined by the appended claims and their equivalents. | An envelope handling device including a moistener module where the moistener module includes a reservoir assembly, a first well tank and a second well tank. The reservoir assembly includes a reservoir tank for holding a supply of reservoir water having a predetermined height; a first well tank for holding a supply of first well water, the first well tank directly coupled to the reservoir tank via a first well tank hose so that the reservoir water is capable of flowing through the first well tank hose to the first well tank and raising the first well water to the predetermined height; and a second well tank for holding a supply of second well water at a different height from the predetermined height, the second well tank coupled to the reservoir tank via a second well tank hose and a trap, the trap establishes a pressure differential between the predetermined height and a level of water within the trap; and wherein the reservoir water is capable of flowing through the second well tank hose and the trap to the second well tank and raising the second well water to the different height as air is captured within the trap to balance the pressure differential. | 1 |
BACKGROUND
[0001] Many types of gowns used in medical procedures by patients, visitors, and medical personnel exist. Both disposable and reusable gowns are utilized. It is important that they can easily be put on and secured by the user. Securing the gown so that it does not fall off is critical. Various means are used such as ties, buttons, hooks and loops, and snaps. All require additional action by the user or another person.
SUMMARY
[0002] Elastic strips are included on the gown to allow placement over the head of the user with no action needed to ensure the gown will not fall off the user.
BRIEF DESCRIPTION OF DRAWINGS
[0003] FIG. 1 depicts the back of a patient wearing a gown.
[0004] FIG. 2 depicts a partial view of a section of FIG. 1 .
[0005] FIG. 3 depicts a front view of one embodiment of the gown.
DETAILED DESCRIPTION
[0006] The described embodiment shown on the figures is a gown ( 1 ) with one or more elastic strips ( 2 ). Typically the gown has an opening from its top area which is intended to lay on the user's shoulders to its bottom area. One end of each elastic/stretchable strip ( 2 ) is secured to one side ( 3 ) of the opening in the back of the gown ( 1 ) with the second end of the strip ( 2 ) attached to the other side ( 4 ) of the opening in the gown ( 1 ). At least one elastic strip is typically located on the upper portion of the gown near the top area of the gown as shown on FIG. 1 . As shown on FIG. 1 , the gown extends from the shoulder to at least the thigh area of the user. The flexible strip(s) are positioned to be in the neck/shoulder area of the user to prevent the gown from falling off the user and also allows for the gown to stretch and adjust to the movements and requirements of users of different sizes. The material of the gown can be varied as warranted by the intended use and the intended user. Thus the gown can be disposable or reusable.
[0007] The gown can include sleeves and openings for the user's hands as shown on FIG. 1 . The separate openings for the thumb ( 7 ) and other fingers ( 8 ) provide an additional means to secure the gown to the user. This is especially important when the user is for example a surgeon.
[0008] Numerous embodiments are envisioned by this invention. The number, dimensions and locations of the elastic strips can be changed as warranted for an intended user of the gown.
[0009] An additional means to further secure the gown may be included as warranted. FIGS. 1 and 3 show one such means. FIGS. 1 and 3 show a strap ( 5 ) secured to the front ( 6 ) which is long enough to surround the gown and tied in the back. One or more loops as used for belts on pants can be located on the gown as desired to hold the strap in place. The length of the strap and means to secure it to the gown can be varied as desired to allow closure in the front, side or rear of the gown.
[0010] In other embodiments, the location and number of openings in the gown are varied. And in other embodiments, the strap is replaced by other means to further secure the gown. These include the use of hook and loop, pressure sensitive adhesive strips, or snaps attached to each side of the opening in the gown and located as warranted.
[0011] All of these embodiments can be incorporated into disposable or reusable gowns. I also include gown used in other applications besides medical such as food preparation, chemical testing and industrial clean rooms.
[0012] The above is a detailed description of particular embodiments of the invention. It is recognized that departures from the disclosed embodiments may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. Those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed herein and still obtain a like or similar result without departing from the spirit and scope of the invention. All of the embodiments disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. | A body covering gown which is secured on the user by one or more stretchable strips which extend across an opening in the gown. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to dark box apparatuses for fluoroscopy, fluoroscopy systems, and fluoroscopy methods.
This application is based on Japanese Patent Applications No. 2004-257240, the contents of which are incorporated herein by reference.
2. Description of Related Art
As a technique for non-invasively examining the interior of a specimen, some known confocal microscopes or multiphoton-excitation microscopes employ a fluoroscopy method for illuminating a specimen with excitation light, such as a laser beam, to examine fluorescence generated by the specimen.
However, since fluorescence generated by a specimen is very weak, it is difficult to acquire a clear fluorescence image due to external noise if fluoroscopy is performed in the presence of extraneous light. For this reason, if fluoroscopy is to be performed in a darkroom, a specimen is first positioned with respect to the microscope apparatus under external light, and then the specimen is illuminated with excitation light with all extraneous light blocked to detect fluorescence emitted from the specimen.
Though in a totally different technical field, a so-called dark-place observation device for examining the influence of particular wavelengths of light upon plants in a place dark enough to prevent the plants from being affected by light is also known (e.g., see Japanese Unexamined Patent Application Publication No. 2002-369624).
For examination with these known dark-place observation devices, plants are first positioned in a dark box completely protected from extraneous light to prevent the plants from experiencing biological effects, such as gene expression, due to extraneous light, and then an infrared light source emitting infrared light with wavelengths that do not affect the plants and an infrared CCD camera are placed in the dark box to observe an image from the infrared CCD camera on a monitor outside the dark box.
If fluoroscopy is to be performed in a darkroom such that a specimen is first positioned with respect to the microscope apparatus under extraneous light and then the specimen is illuminated with excitation light with all extraneous light blocked to detect fluorescence emitted from the specimen, unsuccessful positioning of the specimen, such as a shift of the specimen from the desired examination position, may occur. In this case, the positional relationship between the microscope apparatus and the specimen needs to be re-adjusted. Thus, the positional relationship between the microscope and the specimen may need to be adjusted by feeling with the hands in a darkroom where extraneous light is blocked. This may cause the objective lens of the microscope apparatus to interfere with the specimen, possibly damaging the objective lens or the specimen. In addition, repeating the procedure of introducing extraneous light for positioning and then blocking the extraneous light again for examination is time-consuming and annoying.
BRIEF SUMMARY OF THE INVENTION
The present invention has been conceived in light of these circumstances, and it is an object of the present invention to provide a dark box apparatus for fluoroscopy, a fluoroscopy system, and a fluoroscopy method for eliminating noise in a fluorescence image acquired during fluoroscopy to present a clear fluorescence image and for checking the relative positional relationship between the fluoroscopy unit and the specimen even while fluoroscopy is in progress.
In order to achieve the above-described objects, the present invention provides the following solutions.
According to a first aspect of the present invention, a dark box apparatus for fluoroscopy includes: a dark-box main body enclosing a specimen and a fluoroscopy unit for illuminating the specimen with excitation light with a first spectral band and for detecting fluorescence with a second spectral band generated by the specimen; an illumination light source disposed in the dark-box main body to emit light with a third spectral band different from the first spectral band and the second spectral band; and an observation window disposed on the dark-box main body, the observation window being capable of transmitting light with a fourth spectral band which includes at least part of the third spectral band and does not include the first spectral band and the second spectral band.
According to this aspect, when fluoroscopy is to be performed by placing the specimen and the fluoroscopy unit in the dark-box main body and radiating excitation light with the first spectral band to detect fluorescence with the second spectral band emitted from the specimen, the illumination light source is operated in the dark-box main body to emit visible light with the third spectral band. Since the observation window provided in the dark-box main body can transmit light with the fourth spectral band including at least part of the third spectral band, part of light with the third spectral band reflected at the specimen and the fluoroscopy unit passes through the observation window and is observed by an external observer.
In other words, the observer can easily recognize the state of the specimen, the positional relationship between the specimen and the fluoroscopy unit, etc. in the dark-box main body with the aid of light with the third spectral band coming through the observation window. On the other hand, since the third spectral band differs from the first spectral band, even if light with the third spectral band is emitted in the dark-box main body, the fluorescent material of the specimen is not excited with the emitted visible light with the third spectral band. Furthermore, since the third spectral band differs from the second spectral band, light with the third spectral band emitted in the dark-box main body is not detected by the fluoroscopy unit, and hence noise in the acquired fluorescence image does not increase.
Since the observation window transmits light with the fourth spectral band, light with the fourth spectral band may enter the dark-box main body from outside the dark-box main body. However, since the fourth spectral band does not include the first spectral band and the second spectral band, the fluorescent material is not excited by light entering the dark-box main body or noise in the fluorescence image does not increase, just like in the above-described case. On the other hand, the observation window transmits at least part of other light with the third spectral band from outside the dark-box main body. This transmitted light can be used as illumination light along with the light from the illumination light source.
In the above-described aspect, it is preferable that the illumination light source be disposed at a location such that the illumination light source is not directly visible from outside through the observation window.
In this manner, the observer observing from outside the dark-box main body through the observation window does not look directly at the illumination light source. This prevents light of the illumination light source from dazzling the observer. More specifically, the illumination light source may be provided out of the field of view of the observation window or alternatively, a baffle plate etc. may be provided to prevent light from the illumination light source from directly reaching the observation window.
According to a second aspect of the present invention, a dark box apparatus for fluoroscopy includes: a dark-box main body for blocking entry of extraneous light by enclosing a specimen and a fluoroscopy unit for illuminating the specimen with excitation light with a first spectral band and for detecting fluorescence with a second spectral band generated by the specimen; an illumination light source disposed in the dark-box main body to emit light with a third spectral band different from the first spectral band and the second spectral band; a photography unit disposed in the dark-box main body to photograph the specimen illuminated by the illumination light source and the fluoroscopy unit; and an image display unit disposed outside the dark-box main body to display an image acquired by the photography unit.
According to this aspect, when the specimen and the fluoroscopy unit are placed in the dark-box main body and excitation light with the first spectral band is radiated to perform fluoroscopy for detecting fluorescence with the second spectral band emitted from the specimen, the illumination light source is operated in the dark-box main body to radiate light with the third spectral band. Light with the third spectral band is radiated onto the specimen and the fluoroscopy unit and is photographed by the photography unit provided in the dark-box main body. An acquired image is displayed on the image display unit outside the dark-box main body. The observer can easily recognize the state of the specimen, the positional relationship between the specimen and the fluoroscopy unit, etc. by observing on the image display unit the specimen and the fluoroscopy unit illuminated with light with the third spectral band.
On the other hand, since the third spectral band differs from the first spectral band, even if light with the third spectral band is emitted in the dark-box main body, the fluorescent material of the specimen is not excited with the emitted light with the third spectral band. Furthermore, since the third spectral band differs from the second spectral band, light with the third spectral band emitted in the dark-box main body is not detected by the fluoroscopy unit, and hence noise in the acquired fluorescence image does not increase.
In the above-described aspect, it is preferable that the illumination light source be disposed at a location such that light emitted from the illumination light source is not directly incident upon the photography unit.
In this manner, an image acquired by the photography unit can be free of noise, such as flare, due to light from the illumination light source. Therefore, light from the illumination light source does not interfere with the observation. More specifically, the illumination light source may be provided out of the field of view of the photography unit or alternatively, a baffle plate etc. may be provided to prevent light from the illumination light source from being directly incident upon the photography unit.
In the above-described aspect, a camera including the photography unit and the image display unit may be provided on a wall surface of the dark-box main body such that the photography unit faces inward and the image display unit faces outward.
In this manner, an image which would appear if the interior of the dark box were observed through the observation window can be displayed on the image display unit.
In the above-described aspect, a bellows member may be provided between the wall surface of the dark-box main body and the camera such that the bellows member supports the camera so that the camera is movable relative to the wall surface.
In this manner, the image display range on the image display unit can easily be adjusted by moving the camera with respect to the wall surface through deformation of the bellows member.
In the above-described aspect, the illumination light source may include a wavelength-switching mechanism for switching a spectral band of emitted light.
When examination is to be performed using the fluoroscopy unit with the wavelength of the excitation light switched, the wavelength-switching mechanism is operated to switch the spectral band of light to be emitted by the illumination light source, thereby allowing the wavelength of the excitation light to be selected more flexibly.
According to a third aspect of the present invention, a fluoroscopy system includes: a fluoroscopy unit for illuminating a specimen with excitation light with a first spectral band and for detecting fluorescence with a second spectral band generated by the specimen; and one of the above-described dark box apparatuses for fluoroscopy, wherein the dark-box main body includes: a door for opening and closing the dark-box main body; an open/closed sensor for detecting an open/closed state of the door; and an excitation-light control section for stopping emission of excitation light from the fluoroscopy unit when the open/closed sensor detects that the door is opened.
According to this aspect, the specimen and the fluoroscopy unit are placed in the dark-box main body, the door is closed, excitation light with the first spectral band is radiated onto the specimen in the fluoroscopy unit, and fluorescence with the second spectral band emitted from the specimen is detected to perform fluoroscopy. If the door is opened for some reason during fluoroscopy, the open/closed sensor detects an open state of the door and emission of excitation light in the fluoroscopy unit is stopped by the operation of the excitation light control section. As a result, the excitation light is prevented from leaking from the dark box.
Furthermore, when the open/closed sensor detects a closed state of the door, excitation light is emitted by the operation of the excitation light control section. As a result, fluoroscopy is performed while light serving as noise from outside the dark box is blocked. This provides a clear fluorescence image with less noise.
According to a fourth aspect of the present invention, a fluoroscopy system includes: a fluoroscopy unit for illuminating a specimen with excitation light with a first spectral band and for detecting fluorescence with a second spectral band generated by the specimen; and one of the above-described dark box apparatuses for fluoroscopy, wherein the dark-box main body includes: a door for opening and closing the dark-box main body; an open/closed sensor for detecting an open/closed state of the door; and an operation control section for decreasing an operation speed of the fluoroscopy unit when the open/closed sensor detests that the door is closed.
According to this aspect, the door of the dark-box main body is opened, the specimen is positioned with respect to the fluoroscopy unit, preparations are made for rough alignment of the focal position of the fluoroscopy unit, and then the door is closed to arrange the specimen and the fluoroscopy unit in the dark-box main body. In this state, fluoroscopy is performed by radiating excitation light with the first spectral band onto the specimen in the fluoroscopy unit while the positional relationship between the specimen and the fluoroscopy unit is finely adjusted under light with the third spectral band from the illumination light source to detect fluorescence with the second spectral band emitted from the specimen. In this case, according to the present invention, the operation of the operation control section causes the fluoroscopy unit to operate at a lower operation speed while the open/closed sensor detects a closed state of the door compared to when the open/closed sensor detects an open state of the door. As a result, it is possible to reduce the risk of the fluoroscopy unit mistakenly interfering with the specimen in the dark-box main body because only limited information is obtained through the observation window or the image display unit. Therefore, damage to the fluoroscopy unit and the specimen can be avoided.
According to a fifth aspect of the present invention, a fluoroscopy method for emitting excitation light with a first spectral band from a fluoroscopy unit onto a specimen and for examining fluorescence with a second spectral band emitted from the specimen, the method includes steps of: enclosing the specimen and the fluoroscopy unit with a dark box; emitting light with a third spectral band different from the first spectral band and the second spectral band in the dark box; and manipulating the specimen or the fluoroscopy unit from outside the dark box while observing light with the third spectral band outside the dark box through an observation window, disposed in the dark box, capable of transmitting light with a fourth spectral band which includes at least part of the third spectral band and does not include the first spectral band and the second spectral band or through a photography unit disposed in the dark box.
According to this aspect, the fluoroscopy unit and the specimen are irradiated with light with the third spectral band to carry out examination through the observation window or the photography unit. Therefore, the positional relationship between the fluoroscopy unit and the specimen can easily be recognized in the dark box for reliable operation without disturbing fluoroscopy with the fluoroscopy unit. Therefore, blind operation is eliminated, and hence an annoying repeated procedure of turning ON and OFF the illuminating light in the darkroom can be avoided.
According to the present invention, since the fluoroscopy unit and the specimen are irradiated with light with the third spectral band different from the first and second spectral bands for examination through the observation window or the photography unit, the positional relationship between the fluoroscopy unit and the specimen can easily be recognized in the dark box for reliable operation without disturbing fluoroscopy with the fluoroscopy unit. Therefore, blind operation is eliminated, and hence an annoying repeated procedure of turning ON and OFF the illuminating light in the darkroom can be avoided.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a dark box apparatus for fluoroscopy according to a first embodiment of the present invention.
FIG. 2 is a diagram depicting a spectral band of fluorescence in response to light from an illumination light source of the dark box apparatus for fluoroscopy shown in FIG. 1 and the transmittance characteristic of an observation window.
FIG. 3 is a longitudinal sectional view of a dark box apparatus for fluoroscopy according to a second embodiment of the present invention.
FIG. 4 is a longitudinal sectional view of a modification of the dark box apparatus for fluoroscopy shown in FIG. 3 .
FIG. 5 is a longitudinal sectional view of a fluoroscopy system according to a third embodiment of the present invention.
FIG. 6 is a longitudinal sectional view of a modification of the fluoroscopy system shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
A dark box apparatus for fluoroscopy 1 according to a first embodiment of the present invention will now be described with reference to FIGS. 1 and 2 .
Referring to FIG. 1 , the dark box apparatus for fluoroscopy 1 according to this embodiment includes a dark-box main body 2 ; an illumination light source 3 arranged in the dark-box main body 2 ; and an observation window 4 arranged in a wall surface 2 a of the dark-box main body 2 .
The above-described dark-box main body 2 is a box member composed of a material blocking light of all wavelengths, and is large enough to completely contain an examination head 6 of a fluoroscopy unit 5 , to be described below; a raising-and-lowering mechanism 7 for raising and lowering the examination head 6 ; a specimen A; and a stage 8 holding the specimen A for moving the specimen A two-dimensionally in the horizontal direction or tilting the specimen A.
As shown in FIG. 1 , the fluoroscopy unit 5 includes an optical unit 9 ; the examination head 6 ; and an optical fiber 10 for connecting the optical unit 9 and the examination head 6 .
The optical unit 9 includes an excitation light source 11 emitting excitation light L 1 with a first spectral band B 1 (e.g., a wavelength of 545 nm), such as a laser beam; a collimating lens 12 for converting the emitted excitation light L 1 into collimated light; a coupling lens 13 for focusing the excitation light L 1 converted into collimated light onto an end surface 10 a of the optical fiber 10 ; a dichroic mirror 14 for separating fluorescence L 2 with a second spectral band B 2 (e.g., a wavelength of 550 nm) from return light returning through the optical fiber 10 ; a focusing lens 15 for focusing the separated fluorescence L 2 ; and a photodetector 16 for detecting the focused fluorescence L 2 . The photodetector 16 is realized by, for example, a photomultiplier tube (PMT).
The examination head 6 includes a casing 17 which includes a collimating lens 18 for converting the excitation light L 1 from the excitation light source 11 into collimated light; an optical-scanning section 19 performing two-dimensional scanning of the collimated light transmitted from the collimating lens 18 ; a pupil-projection lens 20 for forming an intermediate image by focusing the scanned excitation light L 1 ; and an imaging lens 21 for converting the excitation light L 1 of the intermediate image into collimated light. The casing 17 further includes an objective lens 22 for focusing the excitation light L 1 from the imaging lens 21 to re-form an image at a predetermined focal position.
The optical-scanning section 19 is realized by, for example, so-called proximity galvano mirrors, which are two galvano mirrors 19 a and 19 b arranged so as to oppose each other and which are rockable about mutually orthogonal axes.
The raising-and-lowering mechanism 7 supporting the examination head 6 such that the examination head 6 can be raised and lowered includes a raising-and-lowering slider 25 which can be raised and lowered by a driving device (not shown) in a support stand 24 extending vertically from a base 23 . The driving device can be operated from outside the dark-box main body 2 through remote operation.
The above-described illumination light source 3 is realized by, for example, an argon laser light source emitting visible light L 3 with a third spectral band B 3 in the vicinity of, for example, 458 nm.
As shown in FIG. 1 , the observation window 4 is provided on a tilted surface in the front of the dark-box main body 2 , namely, on the tilted surface constituting part of the wall surface 2 a of the dark-box main body 2 . Through the observation window 4 , the examination head 6 of the fluoroscopy unit 5 , which is arranged on the other side of the wall surface 2 a of the dark-box main body 2 , and the specimen A are in the field of view.
Referring to FIG. 2 , the observation window 4 blocks the excitation light L 1 with the first spectral band B 1 emitted from the excitation light source 11 of the fluoroscopy unit 5 and the fluorescence L 2 with the second spectral band B 2 emitted from the specimen A, while transmitting the visible light L 3 with the third spectral band B 3 emitted from the illumination light source 3 . In short, the observation window 4 is characterized by transmitting light with wavelengths shorter than 480 nm and blocking light with wavelengths of 480 nm and longer.
In this embodiment, the dark-box main body 2 further includes a baffle plate 26 arranged between the observation window 4 and the illumination light source 3 . The baffle plate 26 is arranged to block the illumination light source 3 from the observation window 4 , thus preventing the illumination light source 3 from being viewed directly through the observation window 4 .
A fluoroscopy method using the dark box apparatus for fluoroscopy 1 according to this embodiment, with the above-described structure, will now be described.
In order to perform fluoroscopy of the specimen A using the dark box apparatus for fluoroscopy 1 according to this embodiment, first the excitation light source 11 of the fluoroscopy unit 5 is turned OFF, the specimen A is immobilized on the stage 8 outside the dark-box main body 2 , and the raising-and-lowering mechanism 7 is operated to roughly position the objective lens 22 of the examination head 6 with respect to the specimen A. In this state, the specimen A, the examination head 6 , the stage 8 , and the raising-and-lowering mechanism 7 are placed in the dark-box main body 2 . The dark-box main body 2 may be constructed so as to enclose the specimen A, the examination head 6 , etc. Alternatively, the dark-box main body 2 may have a door, as described in another embodiment later, so that the examination head 6 and other members are enclosed by closing this door.
Next, the illumination light source 3 is operated to emit the visible light L 3 with the third spectral band B 3 in the dark-box main body 2 . The visible light L 3 with the third spectral band B 3 is radiated onto the objective lens 22 of the examination head 6 in the dark-box main body 2 and the specimen A opposed to the objective lens 22 . Part of the visible light L 3 with the third spectral band B 3 reflected at the objective lens 22 and the specimen A goes out of the dark-box main body 2 through the observation window 4 .
Therefore, outside the dark-box main body 2 , the observer can observe the visible light L 3 with the third spectral band B 3 transmitted through the observation window 4 to clearly learn the positional relationship between the objective lens 22 and the specimen A, as well as the state of the specimen A in the dark-box main body 2 .
Based on this positional relationship between the objective lens 22 and the specimen A observed through the observation window 4 , the observer operates the raising-and-lowering mechanism 7 and the stage 8 through remote operation from outside the dark-box main body 2 to adjust the positional relationship.
Next, the fluoroscopy unit 5 is operated to emit the excitation light L 1 with the first spectral band B 1 from the excitation light source 11 . The excitation light L 1 is guided into the examination head 6 in the dark-box main body 2 via the optical fiber 10 . The excitation light L 1 guided into the examination head 6 is converted into collimated light by the collimating lens 18 , is two-dimensionally scanned by the optical-scanning section 19 , and is re-focused onto the specimen A through the pupil-projection lens 20 , the imaging lens 21 , and the objective lens 22 .
When the specimen A is irradiated with the excitation light L 1 , fluorescent material in the specimen A or a fluorescent agent that has been pre-administered to the specimen A is excited to emit the fluorescence L 2 with the second spectral band B 2 . The emitted fluorescence L 2 enters an end surface 10 b of the optical fiber 10 through the objective lens 22 , the imaging lens 21 , the pupil-projection lens 20 , the optical-scanning section 19 , and the collimating lens 18 .
Since the end surface 10 b of the optical fiber 10 is arranged to have a conjugate positional relationship with the focal position of the objective lens 22 , only the fluorescence L 2 generated near the focal position of the objective lens 22 , from among the fluorescence L 2 returning from the specimen A, enters the end surface 10 b of optical fiber 10 and is returned to the optical unit 9 . The fluorescence L 2 returned to the optical unit 9 is converted into collimated light by the coupling lens 13 , separated from the light path by the dichroic mirror 14 , focused by the focusing lens 15 , and finally detected by the photodetector 16 .
The excitation light L 1 is two-dimensionally scanned at the focal position of the objective lens 22 through the operation of the optical-scanning section 19 . In this manner, a clear two-dimensional fluorescence image can be acquired by detecting the fluorescence L 2 from each position of the specimen A with the photodetector 16 .
According to the dark box apparatus for fluoroscopy 1 of this embodiment, the third spectral band B 3 of the visible light L 3 from the illumination light source 3 differs from the first spectral band B 1 of the excitation light L 1 and the second spectral band B 2 of the fluorescence L 2 . Therefore, even if the visible light L 3 is emitted from the illumination light source 3 onto the specimen A during fluoroscopy, the fluorescent material in the specimen A is not excited. Furthermore, even if the visible light L 3 with the third spectral band B 3 reflected at the specimen A enters the detection light path of the fluorescence L 2 through the objective lens 22 , the visible light L 3 cannot be deflected by the dichroic mirror 14 . Thus, the visible light L 3 does not enter the photodetector 16 , and is not therefore detected as noise by the photodetector 16 .
In short, the visible light L 3 with the third spectral band B 3 from the illumination light source 3 does not interfere with fluoroscopy, and hence can continue to be emitted during fluoroscopy, as well as at a preliminary stage of fluoroscopy. Since the observation window 4 can transmit the visible light L 3 with the third spectral band B 3 , the visible light L 3 with the third spectral band B 3 is likely to enter the dark-box main body 2 through the observation window 4 from outside the dark-box main body 2 . However, since the visible light L 3 with the third spectral band B 3 does not interfere with fluoroscopy as described above, the visible light L 3 does not adversely affect fluoroscopy even if it enters the dark-box main body 2 through the observation window 4 .
During fluoroscopy, the observer may wish to adjust the positional relationship between the specimen A and the fluoroscopy unit 5 while checking on the monitor (not shown) a fluorescence image acquired with the photodetector 16 . For this purpose, the observer can perform adjustment work while clearly seeing, through the observation window 4 , the specimen A and the examination head 6 which are brightly illuminated with the visible light L 3 with the third spectral band B 3 emitted from the illumination light source 3 .
Consequently, unlike with the known method, blind adjustment in a darkroom is not required according to this embodiment, and hence an annoying repeated procedure of turning ON and OFF the illuminating light in the darkroom can be avoided.
In the dark box apparatus for fluoroscopy 1 according to this embodiment, the baffle plate 26 provided in the dark-box main body 2 prevents the visible light L 3 emitted from the illumination light source 3 from directly reaching the observation window 4 . Therefore, the observer is prevented from looking directly at the illumination light source 3 . Because of this, the observer is not too dazzled to see the interior of the dark-box main body 2 , which would occur if the observer looked directly at the illumination light source 3 .
Furthermore, according to this embodiment, the optical unit 9 including the excitation light source 11 is arranged outside the dark-box main body 2 . For this reason, the temperature in the dark-box main body 2 is prevented from rising due to heat emission of the excitation light source 11 . This is advantageous in preventing the specimen A from becoming dry and maintaining stable examination conditions.
Although this embodiment has been described by way of the third spectral band B 3 , which is shorter than the first spectral band B 1 of the excitation light L 1 and the second spectral band of the fluorescence L 2 , alternatively, a spectral band B 3 ′ that is longer than the first spectral band B 1 and the second spectral band B 2 may be adopted, as shown in FIG. 2 . In this case, it is sufficient to set the transmittance characteristic of the observation window 4 to cover a spectral band including the spectral band B 3 ′.
In addition, the illumination light source 3 may be provided with a filter-switching unit 27 for switching the spectral band B 3 of the visible light L 3 to be emitted.
When examination is to be performed using the fluoroscopy unit 5 with the wavelength of the excitation light L 1 switched, the filter-switching unit 27 is operated to switch the spectral band B 3 of the visible light L 3 to be emitted by the illumination light source 3 , thereby allowing the wavelength of the excitation light L 1 to be selected more flexibly.
A dark box apparatus for fluoroscopy 30 according to a second embodiment of the present invention will now be described with reference to FIG. 3 .
The same components in this embodiment as those used in the dark box apparatus 1 according to the first embodiment shown in FIG. 1 are denoted by the same reference numerals, and thus will not be described.
Referring to FIG. 3 , the dark box apparatus for fluoroscopy 30 according to this embodiment includes a dark-box main body 31 in place of the dark-box main body 2 of the dark box apparatus for fluoroscopy 1 according to the first embodiment. The dark-box main body 31 is not provided with the observation window 4 in the dark-box main body 2 to completely block extraneous light. Instead, a camera (photography unit) 32 is provided in the dark-box main body 31 and a monitor 33 is provided outside the dark-box main body 31 .
The camera 32 has a field of view large enough to allow both the objective lens 22 of the fluoroscopy unit 5 and the specimen A to be photographed simultaneously in the dark-box main body 31 . Furthermore, the camera 32 is arranged opposite to the illumination light source 3 on the other side of the baffle plate 26 and is prevented from directly photographing the illumination light source 3 . The camera 32 may be realized by a CMOS camera or a CCD camera. A CMOS camera has low power consumption, and is advantageous in terms of energy efficiency.
In the dark box apparatus for fluoroscopy 30 according to this embodiment, with the above-described structure, the interior of the dark-box main body 31 can be observed using the camera 32 and the monitor 33 , even during fluoroscopy, with the aid of the illumination light source 3 emitting light L 3 (not limited to visible light in this case) having the third spectral band B 3 , which does not interfere with fluoroscopy. This allows the observer to finely adjust the positional relationship between the fluoroscopy unit 5 and the specimen A during fluoroscopy, in the same manner as in the first embodiment.
With the dark box apparatus for fluoroscopy 30 according to this embodiment, the dark-box main body 31 may be provided with a plurality of cameras 32 . This allows images from the plurality of cameras 32 to be observed by switching the screen on the single monitor 33 . In this manner, the specimen A can be examined from a plurality of angles. This is advantageous in adjusting the positional relationship between the fluoroscopy unit 5 and the specimen A more accurately and easily.
Furthermore, in a case where the specimen A is a living organism, various items of information, such as vital information and temperature information, from several sensors (not shown in the figure) attached to the specimen A and the dark-box main body 31 may be simultaneously displayed on the monitor 33 .
As shown in FIG. 4 , a dark box apparatus for fluoroscopy 30 ′ where the camera 32 is integrated with the monitor 33 by means of a wall surface 31 a ′ of a dark-box main body 31 ′ or the camera 32 is provided with the monitor 33 in some way may also be employed. In this case, the camera 32 is mounted so as to face the interior of the dark-box main body 31 ′, whereas the monitor 33 is mounted so as to face the exterior of the dark-box main body 31 ′, namely, opposite to the camera 32 . In this manner, the observer of the monitor 33 can see into the dark-box main body 31 ′ as if he or she were looking into the dark-box main body 2 through the observation window 4 of the dark box apparatus for fluoroscopy 1 according to the first embodiment. Therefore, the observer can perform adjustment of the examination head 6 and the stage 8 through remote operation while intuitively recognizing the movement direction and the amount of movement of the examination head 6 and the stage 8 on the monitor 33 .
In addition, as shown in FIG. 4 , the camera 32 provided or integrated with the monitor 33 may be secured on the wall surface 31 a ′ of the dark-box main body 31 ′ with bellows 34 . The position of the camera 32 can be adjusted through deformation of the bellows 34 , and a region to be examined can be adjusted within the deformation range of the bellows 34 .
A fluoroscopy system 40 according to a third embodiment of the present invention will now be described with reference to FIG. 5 .
The same components in this embodiment as those used in the dark box apparatuses 1 and 30 according to the first and second embodiments are denoted by the same reference numerals, and thus will not be described.
Referring to FIG. 5 , a fluoroscopy system 40 according to this embodiment includes the above-described fluoroscopy unit 5 and a dark box apparatus for fluoroscopy 41 . As shown in FIG. 5 , the dark box apparatus for fluoroscopy 41 is provided on a dark-box main body 42 such that a door 43 can be opened and closed with a hinge 44 . The dark-box main body 42 is provided with an open/closed sensor 46 that can detect a detection member 45 on the door 43 when the door 43 is closed.
Furthermore, an excitation-light control unit 47 is connected to the open/closed sensor 46 . When the door 43 is opened, the open state of the door 43 is detected by the excitation-light control unit 47 and the open/closed sensor 46 . Since the detection member 45 goes out of the detection range of the open/closed sensor 46 at this time, the excitation light source 11 is turned OFF and stops the excitation light L 1 from being emitted.
In the fluoroscopy system 40 according to this embodiment, with the above-described structure, when the door 43 is closed, the detection member 45 is detected by the open/closed sensor 46 and a signal indicating a closed state is sent to the excitation-light control unit 47 . As a result, the excitation-light control unit 47 allows the excitation light source 11 to emit the excitation light L 1 . In the same manner as with the dark box apparatus for fluoroscopy 1 according to the first embodiment, the positional relationship between the fluoroscopy unit 5 and the specimen A is adjusted through the observation window 4 with the aid of the illumination light source 3 while fluoroscopy of the specimen A is in progress.
In this state, for the fluoroscopy system 40 according to this embodiment, when the door 43 of the dark-box main body 42 is opened for some reason, the open/closed sensor 46 is actuated to detect that the door 43 is in an open state. As a result, the excitation-light control unit 47 stops the excitation light source 11 from emitting the excitation light L 1 . In this manner, the excitation light L 1 is prevented from leaking out of the dark-box main body 42 . Consequently, fluoroscopy with the door 43 opened, which would cause extraneous light with various spectral bands to enter the dark-box main body 42 , is prevented. Therefore, photographing a fluorescence image with a high degree of noise is avoided.
In this embodiment, the excitation light source 11 is prevented from emitting the excitation light L 1 depending on the open/closed state of the door 43 . Alternatively, a shutter (not shown in the figure) may be provided in front of the excitation light source 11 and the excitation light L 1 may be turned ON/OFF according to open/close state of the shutter. Furthermore, when the door 43 is opened, the excitation light L 1 may be blocked and the illumination light source 3 may be turned OFF. As a result of the illumination light source 3 being turned OFF while the dark-box main body 42 is observed through the observation window 4 , the observer is informed of an open state of door 43 earlier.
Furthermore, a timer that is operatively associated with the operation of the open/closed sensor 46 may be provided to record information about the period of time for which the door 43 is open or to display such information on the monitor.
In this embodiment, the excitation light source 11 is disabled when the door 43 is open. Instead of or in addition to this, an operation control unit 48 connected to the open/closed sensor 46 may be provided, as shown in FIG. 6 . The operation control unit 48 is connected to, for example, the raising-and-lowering mechanism 7 of the examination head 6 or to the driving device of the stage 8 , so that when the open/closed sensor 46 detects the closed state of the door 43 , the operation speed in a closed state, such as the speed of the raising-and-lowering mechanism 7 in the dark-box main body 42 , is preferably set to lower than the speed in an open state.
Although the interior of the dark-box main body 42 can be observed through the observation window 4 , the amount of information acquired from the observation window 4 is restricted, and therefore, by setting the operation speed such as the speed of the raising-and-lowering mechanism 7 to a lower value while the door 43 is closed, the risk of damage to the specimen A and to the objective lens 22 due to interference between the specimen A and the objective lens 22 can be reduced. | Noise in a fluorescence image acquired during fluoroscopy is eliminated to present a clear fluorescence image, and the relative positional relationship between the fluoroscopy unit and the specimen can be recognized even while fluoroscopy is in progress. A dark box apparatus for fluoroscopy includes: a dark-box main body enclosing a specimen and a fluoroscopy unit for illuminating the specimen with excitation light with a first spectral band and for detecting fluorescence with a second spectral band generated by the specimen; an illumination light source disposed in the dark-box main body to emit light with a third spectral band different from the first spectral band and the second spectral band; and an observation window disposed in the dark-box main body, the observation window being capable of transmitting light with a fourth spectral band which includes at least part of the third spectral band and does not include the first spectral band and the second spectral band. | 6 |
BACKGROUND OF INVENTION
[0001] Disc drill bits are one type of drill bit used in earth drilling applications, particularly in petroleum or mining operations. In such operations, the cost of drilling is significantly affected by the rate the disc drill bit penetrates the various types of subterranean formations. That rate is referred to as rate of penetration (“ROP”), and is typically measured in feet or inches per hour. As a result, there is a continual effort to optimize the design of disc drill bits to more rapidly drill specific formations and reduce these drilling costs.
[0002] Disc drill bits are characterized by having disc-shaped cutter heads rotatably mounted on journals of a bit body. Each disc has an arrangement of cutting elements attached to the outer profile of the disc. Disc drill bits can have three discs, two discs, or even one disc. An example of a three disc drill bit 101 , shown in FIG. 1A , is disclosed in U.S. Pat. No. 5,064,007 issued to Kaalstad (“the '007 Patent”), and. incorporated herein by reference in its entirety. Disc drill bit 101 includes a bit body 103 and three discs 105 rotatably mounted on journals (not shown) of bit body 103 . Discs 105 are positioned to drill a generally circular borehole 151 in the earth formation being penetrated. Inserts 107 are arranged on the outside radius of discs 105 such that inserts 107 are the main elements cutting borehole 151 . Furthermore, disc drill bit 101 includes a threaded pin member 109 to connect with a threaded box member 111 . This connection enables disc drill bit 101 to be threadably attached to a drill string 113 .
[0003] In this patent, inserts 107 on discs 105 are conically shaped and used to primarily generate failures by crushing the earth formation to cut out wellbore 151 . During drilling, a force (referred to as weight on bit (“WOB”)) is applied to disc drill bit 101 to push it into the earth formation. The WOB is translated through inserts 107 to generate compressive failures in the earth formation. In addition, as drill string 113 is rotated in one direction, as indicated by arrow 131 , bit body 103 rotates in the same direction 133 as drill string 113 , which causes discs 105 to rotate in an opposite direction 135 .
[0004] Referring now to FIG. 1B , another type of disc drill bit, as disclosed in U.S. Pat. No. 5,147,000 also issued to Kaalstad (“the '000 Patent”) incorporated herein by reference in its entirety, is shown. The '000 Patent discloses a similar three disc drill bit to that of the '007 Patent, but instead shows another arrangement of the inserts on the discs of the disc drill bit. In FIG. 1B , inserts 123 are disposed on the face of discs 125 , instead of on the outside radius. The primary function of inserts 123 is to cut out the borehole by generating compressive failures from WOB. After inserts 123 generate the primary compressive failures, they then perform a secondary function of excavating the compressively failed earth. The conical shape and location of inserts 123 on disc drill bit 121 are effective for generating compressive failures, but are inadequate in shape and location to excavate the earth formation also. When used to excavate the earth formation from the compressive failures, inserts 123 wear and delaminate very quickly.
[0005] Although disc bits have been used successfully in the prior art, further improvements in the drilling performance may be obtained by improved cutting configurations.
SUMMARY OF THE INVENTION
[0006] In one aspect, the present invention relates to a drill bit. The drill bit includes a bit body and a journal depending from the bit body. The drill bit further includes a disc rotatably mounted on the journal and PDC cutting elements disposed on the disc.
[0007] In another aspect, the present invention relates to a cutting structure to be used with a disc drill bit. The cutting structure includes a shearing portion arranged in a shearing configuration, wherein the shearing portion comprises PDC. The cutting structure further includes a compressive portion arranged in a compressive configuration. The shearing portion and the compressive portion of the cutting structure are formed into a single body.
[0008] In another aspect, the present invention relates to a method of designing a drill bit, wherein the drill bit includes a bit body, a journal depending from the bit body, a disc rotatably mounted to the bit body, first radial row of cutting elements, and second radial of row cutting elements. The method includes identifying a relative velocity of the drill bit, and determining a compressive configuration of the first radial row of cutting elements based on the relative velocity. The method further includes determining a shearing configuration of the second radial row cutting elements based on the relative velocity of the drill bit. Then, the first radial row cutting elements are arranged on the disc of the drill bit based on the compressive configuration, and the second radial row cutting elements are arranged on the disc of the drill bit based on the shearing configuration.
[0009] Other aspects and advantages of the invention will be apparent from the following description and the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
[0010] FIG. 1A shows an isometric view of a prior art three disc drill bit.
[0011] FIG. 1B shows a bottom view of a prior art three disc drill bit.
[0012] FIG. 2A shows an isometric view of a disc drill bit in accordance with an embodiment of the present invention.
[0013] FIG. 2B shows an isometric view of the bottom of the disc drill bit of FIG. 2A .
[0014] FIG. 3A shows a schematic view of a prior art disc drill bit.
[0015] FIG. 3B shows a schematic view of a prior art disc drill bit.
[0016] FIG. 4 shows an isometric view of a prior art PDC bit.
[0017] FIG. 5 shows a bottom view of a disc drill bit in accordance with an embodiment of the present invention.
[0018] FIG. 6 shows a bottom view of the disc drill bit of FIG. 5 .
[0019] FIG. 7 shows an isometric view of a cutting structure in accordance with an embodiment of the present invention.
[0020] FIG. 8A shows a bottom view of a disc drill bit in accordance with an embodiment of the present invention.
[0021] FIG. 8B shows a bottom view of the disc drill bit of FIG. 8A .
[0022] FIG. 9A shows an isometric view of a disc drill bit in accordance with an embodiment of the present invention.
[0023] FIG. 9B shows an isometric view of the disc drill bit of FIG. 9A .
[0024] FIG. 9C shows an isometric view of the disc drill bit of FIGS. 9A and 9B .
[0025] FIG. 10A shows an isometric view of a disc drill bit in accordance with an embodiment of the present invention.
[0026] FIG. 10B shows an isometric view of the disc drill bit of FIG. 10A .
DETAILED DESCRIPTION
[0027] As used herein, “compressive configuration” refers to a cutting element that primarily generates failures by crushing the earth formation when drilling.
[0028] As used herein, “shearing configuration,” refers to a cutting element that primarily generates failures by shearing the earth formation when drilling.
[0029] In one or more embodiments, the present invention relates to a disc drill bit having at least one disc and at least one cutting element disposed on the disc to be oriented in a either a compressive configuration or a shearing configuration. More particularly, the cutting element oriented in either configuration can be made of polycrystalline diamond compact (“PDC”). The compact is a polycrystalline mass of diamonds that are bonded together to form an integral, tough, high-strength mass. An example of a PDC cutter for drilling earth formation is disclosed in U.S. Pat. No. 5,505,273, and is incorporated herein by reference in its entirety.
[0030] Referring now to FIG. 2A , a disc drill bit 201 in accordance with an embodiment of the present invention is shown. Disc drill bit 201 includes a bit body 203 having one or more journals (not shown), on which one or more discs 205 are rotatably mounted. Referring now to FIG. 2B , an enlarged view of disc drill bit 201 is shown. Disposed on at least one of discs 205 of disc drill bit 201 are a first radial row 207 of cutting elements and a second radial row 209 of cutting elements. First radial row 207 of cutting elements are located closer to an axis of rotation 202 of disc drill bit 201 than second radial row 209 of cutting elements. Thus, extending radially out from axis of rotation 202 , first radial row 207 of cutting elements come before second radial row 207 of cutting elements. First radial row 207 of cutting elements and second radial row 209 of cutting elements act together to drill a borehole with a radius at which second radial row 209 of cutting elements extend from the axis of rotation of the disc drill bit. First radial row 207 of cutting elements penetrate into the earth formation to form the bottom of the borehole, and second radial row 209 of cutting elements shear away the earth formation to form the full diameter of the borehole. In this particular embodiment, each cutting element of second radial row 209 is configured into a single cutting structure 211 with a corresponding cutting element of first radial row 207 . FIG. 7 shows a similar cutting structure to that of cutting structure 211 . Cutting elements of first radial row 207 are arranged about the outside radius of discs 205 such that cutting elements of first radial row 207 are in a compressive configuration. Also, cutting elements of second radial row 209 are disposed on the face of discs 205 such that cutting elements of second radial row 209 are in a shearing configuration.
[0031] In some embodiments, cutting elements of the first radial row are oriented in the compressive configuration may be comprised of tungsten carbide, PDC, or other superhard materials, and may be diamond coated. Cutting elements of the first radial row are designed to compress and penetrate the earth formation, and may be of conical or chisel shape. The second radial row cutting elements have PDC as the cutting faces, which contact the earth formation to cut out the borehole. Also, cutting elements of the second radial row are oriented to shear across the earth formation.
[0032] Because the cutting elements of the first radial row on the discs of the disc drill bit are in a compressive configuration, the cutting elements primarily generate failures by crushing the earth formation when drilling. Additionally, because the cutting elements of the first radial row are more suited to compressively load the earth formation, significant shearing of the earth formation by the cutting elements of the first radial row should be avoided. Too much shearing may prematurely wear and delaminate the cutting elements of the first radial row. To arrange the cutting elements of the first radial row in a compressive configuration, the cutting elements should be oriented on the disc drill bit to have little or no relative velocity at the point of contact with respect to borehole. If the cutting elements of the first radial row have no relative velocity with the point of contact of the borehole, the cutting elements will generate compression upon the earth formation with minimal shearing occurring across the borehole.
[0033] Referring now to FIG. 8A , a relative velocity 855 of cutting elements of first radial row 207 and the components making up relative velocity 855 with respect to the borehole, is shown. Relative velocity 855 at the point of contact of cutting elements of first radial row 207 is made from two corresponding velocities. The first contributing velocity is bit body velocity 851 , the velocity of the cutting element of first radial row 207 from the rotation of the bit body. Bit body velocity 851 is the product of rotational speed of the bit body, ω bit , and distance of the cutting element of the first radial row from the axis of rotation of the bit body, R bit . The second contributing velocity is disc velocity 853 , the velocity of the cutting element of first radial row 207 from the rotation of the discs. Disc velocity 853 is the product of rotational speed of the of the disc, ω disc , and distance of the cutting element of the first radial row from the axis of rotation of the disc, R disc . Relative velocity 855 , V first radial row , is the sum of bit body velocity 851 and disc velocity 853 , and is shown below:
V firstradialrow =(ω bit ×R bit )+(ω disc ×R disc ) [Eq. 1]
[0034] When the bit body is in one direction of rotation, the disc is put into an opposite direction of rotation. If such values are inserted into the formula then, either the value ω disc or the value ω bit would be negative. As cutting elements of first radial row 207 on the disc then passes through a contact point 871 with the borehole, the two corresponding velocity components, bit body velocity 851 and disc velocity 853 , can be of equal magnitude and cancel out one another, resulting in a relative velocity of zero for V first radial row . With little or no relative velocity then, the cutting elements of first radial row 207 located at contact point 871 would therefore generate almost entirely compressive loading upon the earth formation with minimal shearing occurring across the borehole. Thus, the cutting elements of the first radial row should be designed to contact and compress the borehole most at contact point 871 . When the cutting elements of the first radial row can no longer maintain little or no relative velocity, they should disengage with the earth formation to minimize shearing action. With the determination of the direction of the relative velocity, the compressive configuration can be optimized to improve the compressive action of the cutting elements of the first radial row.
[0035] In contrast to cutting elements of first radial row 207 , cutting elements of second radial row 209 are oriented to use the relative velocity to improve their shearing cutting efficiency. Referring still to FIG. 8A , a relative velocity 855 of cutting elements of second radial row 209 is made up of the same two corresponding velocities, bit body velocity 851 and disc velocity 853 , as discussed above. Because cutting elements of first radial row 207 and cutting elements of second radial row 209 are located closely together, relative velocity 855 of cutting elements of first radial row 207 and cutting elements of second radial row 209 at points 871 and 873 are similar. Cutting efficiency of cutting elements of second radial row 209 improves if the shear cutting action occurs in the direction of relative velocity 855 . Contact point 873 shows relative velocity 855 of cutting elements of second radial row 209 . When cutting elements of second radial row 209 are oriented to shear in the direction of relative velocity 855 , as shown, the shearing cutting efficiency is improved. With the determination of the direction of the relative velocity, the shearing configuration can be optimized to improve the shearing action of the cutting elements of the second radial row.
[0036] Referring now to FIG. 8B , another view of the embodiment of the present invention of FIG. 8A is shown. FIG. 8B depicts two zones 891 , 893 of the cutting action from the disc drill bit. Compressive zone 891 is the zone which allows first radial row 207 of cutting elements to most effectively generate compressive failures. Contact point 871 , which minimizes relative velocity of first radial row 207 of cutting elements, is located in the compressive zone 891 . Shearing zone 893 is the zone which allows second radial row 209 of cutting elements to most efficiently generate shearing failures. Contact point 873 , which has a high relative velocity for shearing of second radial row 209 of cutting elements, is located in shearing zone 893 .
[0037] In one or more embodiments of the present invention, the discs in the disc drill bit may be positively or negatively offset from the bit body. Referring now to FIGS. 3A & 3B , examples of negative and positive offset in a prior art disc drill bit 301 are shown. Disc drill bit 301 includes a bit body 303 having a journal (not shown), on which a disc 305 is rotatably mounted. Inserts 307 are arranged on the outside radius of disc 305 . Disc drill bit 301 further includes a center axis 311 of rotation of bit body 303 offset from an axis 313 of rotation of disc 305 . Bit body 303 rotates in one direction, as indicated in the figures, causing disc 305 to rotate in an opposite direction when cutting a borehole 331 . Referring specifically to FIG. 3A , axis 313 of rotation of disc 305 is offset laterally backwards in relation to the clockwise rotation of bit body 303 , showing disc drill bit 301 as negatively offset. Referring specifically to FIG. 3B , axis 313 of rotation of disc 305 is offset laterally forwards in relation to the clockwise rotation of bit body 303 , showing disc drill bit 301 as positively offset.
[0038] The positive and negative offset of the discs ensures that only an appropriate portion of the PDC cutting elements and inserts are cutting the borehole at any given time. If -the entire surface of the disc was effectively drilling the borehole, the discs and drill would be prone to stalling in rotation. The offset arrangement of the discs assures that only a selected portion of the disc is cutting. Also, offsets force the discs to shear while penetrating the earth formation. The present invention is particularly well adapted to be used with negative offset.
[0039] Referring now to FIG. 5 , another disc drill bit 501 in accordance with an embodiment of the present invention is shown. Disc drill bit 501 includes a bit body 503 having one or more journals (not shown), on which one or more discs 505 are rotatably mounted. Disposed on at least one of discs 505 of disc drill bit 501 are first radial row 507 of cutting elements and second radial row 509 of cutting elements. In this embodiment, cutting elements of second radial row 509 are not configured into individual cutting structures with cutting elements of first radial row 507 and are instead maintained as separate bodies. Cutting elements of first radial row 507 are arranged about the outside radius of discs 505 in a compressive configuration. Cutting elements of second radial row 509 are disposed on the face of disc 505 in a shearing configuration. As shown in FIG. 5 , first radial row 507 of cutting elements form a row arranged radially outboard (away from the center of the disc) of the radial position of a row formed by second radial row 509 of cutting elements.
[0040] Disc drill bit 501 further includes a webbing 511 disposed on discs 505 . Webbing 511 is arranged on the outside radius of discs 505 and is adjacent to first radial row cutting 507 of cutting elements. Optionally, webbing 511 can be an integral part of discs 505 , as shown in FIG. 5 , wherein webbing 511 is manufactured into discs 505 . However, webbing 511 can also be an overlay that is placed on discs 505 after they have been manufactured. Furthermore, discs 505 could be manufactured, webbing 511 then placed on discs 505 adjacent to first radial row 507 of cutting elements, and webbing 511 then brazed onto discs 505 if necessary.
[0041] When drilling earth formations, webbing 511 can provide structural support for first radial row 507 of cutting elements to help prevent overloading. The compressive forces distributed on the cutting elements of first radial row 507 could be translated to webbing 511 for support. The height of webbing 511 can be adjusted such that the depth of cut of the cutting elements of first radial row 507 is limited. Having a low webbing height would allow the cutting elements of first radial row 507 to take a deeper cut when drilling into the earth formation, as compared to the depth of cut a high webbing height would allow. The adjustable webbing height further prevents overloading of the first radial row 509 of cutting elements.
[0042] Furthermore, FIG. 5 shows PDC cutting elements 551 located on the bottom of bit body 503 of disc drill bit 501 . Referring now to FIG. 6 , an enlarged view of the arrangement of PDC cutting elements 551 is shown. As discs 505 of disc drill bit 501 cut out a borehole in the earth formation, a bottom uncut portion may form at the bottom of the borehole that is not covered by the cutting surface of discs 505 . Bottom uncut portion 171 is shown in FIG. 1 . As disc drill bit 501 drills into the earth formation, PDC cutting elements 551 may be used to cut out the bottom of the borehole. FIG. 6 also shows a nozzle 553 , which is located on the bottom of bit body 503 . Nozzle 553 provides circulation of drilling fluid under pressure to disc drill bit 501 to flush out drilled earth and cuttings in the borehole and cool the discs during drilling.
[0043] Embodiments of the present invention do not have to include the features of the webbing arranged on the discs and the single cutting structure formed from the first and second radial row cutting elements. Embodiments are shown with the webbing alone, and embodiments are shown with the single cutting structure alone. However, other embodiments can be created to incorporate both the webbing and the single cutting structure or exclude both the webbing and the single cutting structure. Those having ordinary skill in the art will appreciate that the present invention is not limited to embodiments which incorporate the webbing and the single cutting structure.
[0044] Further, those having ordinary skill in the art will appreciate that the present invention is not limited to embodiments which incorporate only two rows of cutting elements. Other embodiments may be designed which have more than two rows of cutting elements. Referring now to FIG. 9A , another disc drill bit 901 in accordance with an embodiment of the present invention is shown. Disc drill bit 901 includes a bit body 903 having one or more journals (not shown), on which one or more discs 905 are rotatably mounted. Disposed on at least one of discs 905 of disc drill bit 901 are first radial row 907 of cutting elements, second radial row 909 of cutting elements, and third radial row 911 of cutting elements. Cutting elements of first radial row 907 are located closest to the axis of rotation of disc drill bit 901 , followed by the cutting elements of second radial row 909 , and then the cutting elements of third radial row 911 . The cutting elements of first radial row 907 , second radial row 909 , and third radial row 911 act together to drill a borehole with a radius at which the cutting elements of third radial row 911 extend from the axis of rotation of the disc drill bit. Cutting elements of first radial row 907 penetrate into the earth formation to form the bottom of the borehole, the cutting elements of second radial row 909 shear the earth formation to form the sides of the borehole, and the cutting elements of third radial row 911 ream and polish the earth formation to form the full diameter of the borehole. Cutting elements of third radial row 911 enlarge the borehole to a radius at which the third radial row 911 of cutting elements extend from the axis of rotation of disc drill bit 901 .
[0045] Referring still to FIG. 9A , first radial row 907 of cutting elements are arranged about the outside radius of discs 905 such that its cutting elements are in a compressive configuration. Second radial row 909 of cutting elements are disposed on the face of discs 905 such that its cutting elements are in a shearing configuration. The third radial row 911 of cutting elements are also disposed on the face of discs 905 of disc drill bit 901 , but second radial row 909 of cutting elements are radially outboard (away from the center of the disc) of the radial position of third radial row 911 of cutting elements.
[0046] In some embodiments, the cutting elements of the first radial row are oriented in the compressive configuration and may be comprise tungsten carbide, PDC, or other superhard materials, and may be diamond coated. The cutting elements of the first radial row cutting elements are designed to compress and penetrate the earth formation, and may be of conical or chisel shape. Preferably, the cutting elements of the second radial row have PDC as the cutting faces, which contact the earth formation to cut out the borehole. The cutting elements of the second radial row are oriented to shear across the earth formation. Similarly, the cutting elements of the third radial row have cutting faces which are comprised of PDC. The cutting elements of the third radial row shear across the earth formation to enlarge the borehole to full diameter.
[0047] In one or more embodiments of the present invention, to assist in the shearing action, the cutting elements of the second and third radial rows may be oriented with a negative or positive rake angle. Referring now to FIG. 4 , an example of negative rake angle is shown in a prior art PDC cutter 401 . PDC cutter 401 has a PDC cutter disc 403 rearwardly tilted in relation to the earth formation being drilled. A specific angle “A” refers to the negative rake angle the PDC cutter is oriented. Preferably, a rake angle from about 5 to 30 degrees of rake angle orientation is used. Similarly, a positive rake angle would refer to the PDC cutter disc forwardly tilted in relation to the earth formation being drilled. An effective rake angle would prevent delamination of the PDC cutting element. FIGS. 9B and 9C show an embodiment incorporating the use of one rake angle orientation, and FIGS. 10A and 10B show another embodiment incorporating the use of two rake angle orientations.
[0048] In FIG. 9B , the cutting elements of second radial row 909 and third radial row 911 are oriented with a positive rake angle to allow the sides of the cutting elements to perform the cutting action. As shown in FIG. 9C , when the cutting elements are moving in the direction 951 , the sides (cylindrical edge) of the cutting elements shear across the borehole to generate failures in the earth formation. Therefore, the sides of the cutting elements are loaded with the predominant cutting forces. The shearing sides of the cutting elements are shown in zones 991 and 993 .
[0049] In FIG. 10A , the cutting elements of third radial row 1011 are oriented with a positive rake angle to allow the sides of the cutting elements to perform the shearing cutting action. However, the cutting elements of second radial row 1009 are oriented in a negative rake angle to instead the faces of the cutting elements to perform the shearing cutting action. Thus, with a negative rake angle, the faces of the cutting elements are loaded with the predominant cutting forces. Referring now to FIG. 10B , another view of the embodiment in FIG. 10A is shown. When the cutting elements are moving in the direction 1051 to maximize shearing, the cutting elements in zone 1093 are oriented in a positive rake angle to allow the sides of the cutting elements to shear across the borehole to generate failures in the earth formation, while the cutting elements in zone 1091 are oriented in a negative rake angle to allow the faces of the cutting elements to shear across the borehole. Both rake angle orientations can be used for the cutting elements of embodiments of the present invention. The rake angle orientation may be varied from disc to disc of the disc drill bit, or from radial row to radial row, or even from cutting element to cutting element. The rake angle orientation is not intended to be a limitation of the present invention.
[0050] Those having ordinary skill in the art will appreciate that other embodiments of the present invention may be designed with arrangements other than three discs rotatably mounted on the bit body. Other embodiments may be designed to incorporate only two discs, or even one disc. Also, embodiments may be designed to incorporate more than three discs. The number of discs on the disc drill bit is not intended to be a limitation of the present invention.
[0051] As seen in roller cone drill bits, two cone drill bits can provide a higher ROP than three cone drill bits for medium to hard earth formation drilling. This concept can also be applied to disc drill bits. Compared with three disc drill bits, two disc drill bits can provide a higher indent force. The “indent force” is the force distributed through each cutting element upon the earth formation. Because two disc drill bits can have a fewer amount of total cutting elements disposed on the discs than three disc drill bits, with the same WOB, two disc drill bits can then provide a higher indent force. With a higher indent force, two disc drill bits can then provide a higher ROP. Two disc drill bits can also allow larger cutting elements to be used on the discs, and provide more flexibility in the placement of the nozzles. Further, the discs on two disc drill bits can be offset a larger distance than the discs of three disc drill bits. In the event a two disc drill bit is designed, an angle from about 165 to 180 degrees is preferred to separate the discs on the disc drill bit.
[0052] Additionally, those having ordinary skill in the art that other embodiments of the present invention may be designed which incorporates discs of different sizes to be disposed on the disc drill bit. Embodiments may be designed to incorporate discs to be rotatably mounted to the disc drill bit, in which the discs vary in size or thickness in relation to each other. The size of the discs is not intended to be a limitation of the present invention.
[0053] Referring now to FIG. 7 , a cutting structure 701 in accordance with another embodiment of the present invention is shown. Cutting structure 701 includes a compressive portion 705 and a shearing portion 703 formed into a single body. Shearing portion 703 of cutting structure 701 is comprised of PDC. Cutting structure 701 may be placed on a disc of a disc drill bit by being brazed onto the disc, or cutting structure 701 may be integrally formed into the discs when manufactured. Cutting structure 701 is then disposed on the disc such that shearing portion 703 is arranged in a shearing configuration to generate failures by shearing the earth formation when drilling and compressive portion 705 is arranged in a compressive configuration to generate failures by crushing the earth formation when drilling.
[0054] In the embodiments shown, compressive portion 705 of cutting structure 701 may be comprised of tungsten carbide, PDC, or other superhard materials, and may be diamond coated. Compressive portion 705 , which may be of a conical or chisel shape, is designed to compress and penetrate the earth formation. Shearing portion 703 of cutting structure 701 has PDC as the cutting face which contacts the earth formation to cut out the borehole. Shearing portion 703 is designed to shear across the earth formation.
[0055] While the invention has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. | The invention provides an improved drill bit and a method for designing thereof. The drill bit includes a bit body, a journal depending from the bit body, and a disc rotatably mounted on the journal. The disc of the drill bit has PDC cutting elements disposed on it. Also provided is an improved cutting structure for the discs of the drill bit. The cutting structure includes a portion that is comprised from PDC. | 4 |
FIELD OF THE INVENTION
[0001] The present invention relates to rigging systems including those for theaters, studios, concert halls, arenas, television studios, casino showrooms and cruise ships, and more particularly, to a counterweight arbor guide shoe assembly having a curvilinear rail contacting surface and elongated slots for operably engaging the guide shoe assembly and the counterweight arbor in a plurality of operable positions.
BACKGROUND OF THE INVENTION
[0002] Counterweight systems are often employed for balancing battens and loaded battens in a stage environment. In principal, the counterweight is set to generally match the combined load of the batten and any attached load, such as scenery, lighting or sound equipment. The counterweights are releasably connected to the counterweight arbors or carriages. The conventional counterweight arbor has a top and a bottom between which the weights are selectively disposed. The counterweight arbor (carriage) is slidably translated along vertically extending rails. The slidable interconnection of the counterweight arbor and the rails is accommodated by a multi component structure specifically sized for the specific spacing of the rails in a respective counterweight arbor.
[0003] However, the need exists for a counterweight arbor guide shoe assembly that can be utilized for a variety of rail spacings, without requiring separate construction of the guide shoes. The need further exists for a counterweight arbor guide shoe assembly that can be adjusted to accommodate tolerances derived from manufacture of the rail, the arbor or installation of the counterweight system.
SUMMARY OF THE INVENTION
[0004] The present invention provides a counterweight arbor guide shoe assembly for slidably interconnecting a counterweight arbor and a guide rail. The present guide shoe assembly can be disposed to accommodate guide rail systems having differing spacing between the guide rails. That is, the present guide shoe assembly can be utilized in rail systems having six, eight or tern inch centers, as well as intermediate spacings.
[0005] In a first configuration, the guide shoe assembly includes a guide shoe having a curvilinear rail bearing surface and a curvilinear arbor mounting slot. In one construction, the counterweight arbor includes a pair of mounting apertures or pins disposed along an inclined line. The corresponding mounting slots in the guide shoe assembly are selected to allow the guide shoe assembly to be mounted relative to the counterweight arbor at a plurality of orientations. Preferably, the guide shoe assembly can be operably connected to the counterweight arbor at and between 90° orientations.
[0006] In a further configuration, the guide shoe assembly is constructed of a pair of identical interlocking guide plates, wherein the guide plate includes a pair of arbor mounting slots and a curvilinear rail contacting surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] [0007]FIG. 1 is a perspective view of a counterweight arbor assembly employing the present guide shoe assembly.
[0008] [0008]FIG. 2 is a perspective view of a guide shoe assembly.
[0009] [0009]FIG. 3 is a partial cutaway of perspective view of a guide shoe assembly showing structural features.
[0010] [0010]FIG. 4 is a top plan view of a guide shoe assembly.
[0011] [0011]FIG. 5 is a top plan view of a guide plate.
[0012] [0012]FIG. 6 is a side elevational view of the inside surface of a guide plate.
[0013] [0013]FIG. 7 is a perspective view of the inside surface of a guide plate.
[0014] [0014]FIG. 8 is a side elevational view of the outside surface of a guide plate.
[0015] [0015]FIG. 9 is a cross sectional view taken along lines 9 - 9 of FIG. 8.
[0016] [0016]FIG. 10 is a cross sectional view taken along lines 10 - 10 of FIG. 8.
[0017] [0017]FIG. 11 is a perspective view of the outside surface of a guide plate.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] Referring to FIG. 1, the guide shoe assembly 10 of the present invention is employed in a counterweighted rigging system, such as a stage or theater rigging. However, the invention is independent of the specific location or application of the rigging system. The rigging system usually includes a plurality of variable counterweights for balancing loads attached to corresponding battens, wherein the battens are to be raised and lowered relative to a stage.
[0019] The counterweight system includes a plurality of counterweight arbors 20 that are raised and lowered along corresponding vertical rails or flanges 30 . The counterweight arbor usually includes or are connected to an arbor guide for guiding the counterweight arbor relative to the rails. The counterweight arbor 20 includes an arbor top 22 and an arbor bottom 24 . Preferably, each of the arbor top 22 and the arbor bottom 24 include a pair of mounting apertures 25 for operable alignment with the guide shoe assembly 10 . In previous systems, the arbor top 22 and arbor bottom 24 included a single mounting hole to engage fastener for coupling to the guide shoe. In some systems, two vertically aligned mounting holes. While such mounting holes can be accommodated in the present invention, one configuration employs the mounting holes 25 of the arbor top 22 and the arbor bottom 24 disposed along a line inclined 45° from vertical.
[0020] Typically, the rails 30 are spaced at predetermined intervals along a wall 32 or frame to which the counterweight system is attached. Typical spacings of the rails 30 are 6, 8 or 10 inch centers. However, within a system spacing of a given distance, installation and manufacturing tolerances result in variances along the length of the rails 30 . Although the term rail 30 is used the description, it encompasses flanges along which the counterweight arbor 20 is to be guided.
[0021] The rail 30 can be any of a variety of configurations and typically includes the projecting flange for engaging the arbor guide assembly. Thus, the rail 30 may have a variety of cross sectional profiles including L, T, U, I, H, C and still employ the present invention.
[0022] The guide shoe assembly 10 operably interconnects the counterweight arbor 20 and a rail 30 . Preferably, the guide shoe assembly 10 engages a pair of consecutive spaced apart rails 30 and the counterweight arbor 20 .
[0023] The guide shoe assembly 10 includes a rail contacting surface 40 and an arbor mounting slot 50 . The guide shoe assembly 10 defines a major axis 12 extending along a longer dimension of the assembly and a transverse minor axis 14 extending along a lesser coplanar dimension. As shown in FIG. 2, the major axis 12 and the minor axis 14 intersect at a central point of the guide shoe assembly 10 .
[0024] Although the guide shoe assembly 10 is shown as having a generally obround periphery, it is understood the rail contacting surface 40 can be a circular arc, a portion of an ellipse, hyperbola or other curvilinear segment.
[0025] The rail contacting surface 40 defines that portion of the guide shoe assembly 10 that engages the rails 30 to retain and guide the counterweight arbor 20 relative to the rails. The rail contacting surface 40 preferably defines channel that can contact three sides of the rail 30 such as the front, the exposed edge and the back. The rail contacting surface 40 can have any of a variety of cross sections such as C, U or even V shaped. It is desired the channel have a sufficient depth (that the legs of the cross sectional profile have a sufficient length) to accommodate tolerances and variations within a given rail system spacing.
[0026] The rail contacting surface 40 defines a rail capture distance, or span 41 that is the distance between any two points that are diametrically opposed across the center of the guide shoe assembly. As the rail contacting surface 40 is curvilinear, the rail capture distance 41 depends upon the orientation of the guide shoe assembly 10 relative to the counterweight arbor 20 and the rail 30 .
[0027] The rail contacting surface 40 is selected such that as the guide shoe assembly 10 is rotated relative to the counterweight arbor 20 (and the rails 30 ), the horizontal distance between the extremes of the rail contacting surfaces is varied. That is, as the guide shoe assembly 10 is rotated relative to the counterweight arbor and the rails, the rail capture distance varies. Thus, as the guide shoe assembly 10 is disposed with the major axis horizontal, the rail contacting surface 40 spans the greatest rail capture distance. In contrast, as the guide shoe assembly 10 is disposed to locate the minor axis horizontal, the rail contacting surface 40 defines a minimum rail capture distance. Preferably, the spanned distance of the rail contacting surfaces 40 continuously varies from the maximum distance along the major axis to a minimum distance along the minor axis. However, it is understood the spanned distance can vary incrementally rather than continuously, wherein the increments are selected to operably engage any of a variety of rail spacings. That is, preferably, the rail contacting surface 40 is curvilinear or sufficiently multi-faceted to permit a plurality of operable orientations of the guide shoe assembly relative to the rails.
[0028] As shown, the present rail contacting surface 40 defines a generally obround profile. That is, the rail contacting surface 40 has a curvilinear section 42 and a straight section 44 . In one configuration, the section of the rail contacting surface 40 extending between the maximum rail capture distance and the minimum rail capture distance is curvilinear, or sufficiently faceted to allow a discrete stepwise function that accommodates the anticipated tolerances in the rail system. In the configuration of FIGS. 1 - 3 , as the guide shoe assembly 10 is disposed with the major axis being horizontal, the portion of the rail contacting surface 40 which contacts the rails 30 is curvilinear. In contrast, as the guide shoe assembly 10 is disposed with the minor axis being horizontal, the portion of the rail contacting surface 40 engaging the rails 30 is substantially straight, wherein the intermediate orientations of the guide shoe assembly expose a curvilinear (or incrementally faceted) rail contacting surface to the rails.
[0029] However, it is understood these are predominately design choices and so long as the arbor guide assembly has rail contacting surfaces 40 which can be operably located at the desired spacing by rotation of the guide shoe assembly 10 relative to the arbor top plate 22 or arbor bottom plate 24 , the rail contacting surface can be thus selected.
[0030] Referring to FIGS. 2, 3, 6 and 7 , the guide shoe assembly 10 includes a pair of arbor mounting slots 50 . The arbor mounting slots 50 are selected to allow the guide shoe assembly 10 to rotate relative to the counterweight arbor 20 and the rails 30 . It is this rotation that allows varying the rail capture distance presented by the guide shoe assembly 10 .
[0031] Preferably the arbor mounting slots 50 are arcuate and define an approximately 90° arc, thus allowing the guide shoe assembly 10 to rotate between presenting the maximum rail capture distance to the minimum rail capture distance. However, it is understood the rotation of the guide shoe assembly 10 can be accomplished with a pivot point and a single slot, or other equivalent structures.
[0032] In a preferred configuration, the guide shoe assembly 10 is formed of a pair of identical interlocking guide plates 60 . Although the guide shoe assembly 10 is shown as a pair of interlocking guide plates 60 , it is understood the guide shoe assembly can be formed of a single piece of material. In alternative configurations, the guide plates can be uniquely formed. The benefit of identical guide plates 60 is reduction in inventory requirements and manufacturing considerations.
[0033] The guide plate 60 includes the arbor mounting slot 50 and a part of the rail contacting surface 40 . Referring to FIGS. 1 - 4 , the guide plate 60 defines one leg of a U shaped rail contacting channel and a portion of the closed end of the rail contacting channel. The fully defined channel cross section is formed upon the engagement of two guide plates 60 .
[0034] Operable engagement of a pair of guide plates 60 is provided by interlocking tabs and recesses. In one configuration, the guide plate 60 includes a spaced apart tab 62 and slot 63 for receiving a corresponding guide plate 60 in an interlocking manner. Preferably, the guide plate 60 includes a pair of tabs 62 and a pair of spaced apart slots 63 . The tabs 62 and slots 63 are symmetrically located on the guide plate 60 to allow two identical guide plates 60 to interlock.
[0035] It is understood that any of a variety of interlocking mechanisms can be employed, such as snap fits and friction fits. Further, the guide plates 60 may be temporarily retained by manual retention prior to operable engagement with the counterweight arbor 20 .
[0036] Although the guide shoe assembly 10 is shown as formed of identical interlocking guide plates 60 , it is understood that one of the guide plates can include or define the rail contacting surface, such as the channel and the remaining plate serve as forming the shoulder upon operable engagement with the first plate. Thus, the guide's plates can be unique.
[0037] Any of a variety of interconnecting mechanisms can be used to interconnect the guide shoe assembly 10 and the arbor top 22 , and the arbor bottom 24 . The interconnecting mechanisms include, but are not limited to screws, threads, bolts, rods, or pins. For purposes of simplicity and description, the configuration employing a bolt for is disclosed.
[0038] In contrast to prior systems, which employ a single bolt for interconnecting the arbor top plate 22 and the guide shoe assembly 10 , and the arbor bottom plate 24 and the guide shoe assembly, the present arbor top plate 22 and arbor bottom plate 24 includes a pair of mounting apertures located along an inclined line. Preferably, the mounting apertures lie upon a line 45° from vertical and horizontal. The arbor mounting slots 50 are selected to operably align with the corresponding mounting apertures in the arbor top plate 22 and the arbor bottom plate 24 .
[0039] Installation and Operation
[0040] To operably interconnect to the counterweight arbor 20 and the rail 30 , a pair of guide plates 60 is interlocked by engaging the corresponding tabs 62 and slots 63 . The guide shoe assembly 10 is then rotated to be dispose the rail contacting channel 40 between opposing rails 30 . The guide shoe assembly 10 is then rotated in the opposite direction to contact or abut the rail contacting surface 40 with the corresponding portion of the rail 30 . The guide shoe assembly 10 can be disposed with the major axis 12 being horizontal or vertical, or any orientation therebetween (assuming the rail contacting surface is continuous—it is understood if the rail contacting surface is multi-faceted, there will be discrete orientations intermediate the horizontal and vertical disposition of the major axis).
[0041] Upon the guide shoe assembly 10 being rotated to operably dispose a portion of the rails 30 within the rail contacting channel and contact the rail contacting surface, mounting bolts are passed through the arbor mounting slots 50 in the guide plates 60 and into the corresponding offset apertures in the arbor top plate 22 , or arbor bottom plate 24 , and tightened to thus locate the guide shoe assembly 10 relative to the counterweight arbor 20 and rail 30 .
[0042] While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | An arbor guide shoe assembly for slidably interconnecting an arbor top plate or bottom plate with a pair of spaced rails. The guide shoe assembly has a rail contacting channel which defines a plurality of operable rail capturing distances, and an elongate slot for orienting the guide shoe assembly with a plurality of orientations with respect to the counterweight arbor. | 4 |
FIELD OF THE INVENTION
The present invention relates to a process for producing a pitch (which is an improved raw material for producing carbon fibers having a high modulus of elasticity), using a petroleum heavy residual oil.
BACKGROUND OF THE INVENTION
In pitches which are used as a raw material for producing carbon fibers having excellent strength and excellent modulus of elasticity, optical anisotropy is observed by a polarizing microscope. It has been believed that such pitches contain a mesophase. Further, these pitches used as a raw material for carbon fibers need not possess only optical anisotropy but must also be capable of being stably spun.
Accordingly, in order to produce carbon fibers having excellent strength and excellent modulus of elasticity, it is not always possible to use any material as the raw material for making pitches. Materials having specified properties are required. However, in many published patents, for example, U.S. Pat. Nos. 3,976,729 and 4,206,788, the raw material is not specifically described or disclosed in the patent specifications and it appears as if pitches used as a raw material for carbon fibers can be produced by carrying out thermal modification of a wide variety of raw materials.
However, when the detailed descriptions and examples in such patents are examined in detail, it becomes apparent that desired pitches can only be produced by using the specified raw materials described in the examples of such patents. For example, U.S. Pat. No. 4,115,527 discloses that substances such as chrysene or tarry materials by-produced during the high temperature cracking of petroleum crude oil are suitable for producing the pitch, i.e., a carbon precursor, but conventional petroleum asphalts and coal tar pitches are not suitable.
U.S. Pat. No. 3,974,264 discloses that an aromatic base carbonaceous pitch having a carbon content of about 92 to 96% by weight and a hydrogen content of about 4 to 8% by weight is generally suitable for preparation of a mesophase pitch. It has been described that elements excepting carbon and hydrogen, such as oxygen, sulfur and nitrogen, should not be present in an amount of more than about 4% by weight, because they are not suitable. Further, it has been described that the precursor pitch used in Example 1 of the same patent publication has properties comprising a density of 1.23 g/cc, a softening point of 120° C., a quinoline insoluble content of 0.83% by weight, a carbon content of 93.0%, a hydrogen content of 5.6%, a sulfur content of 1.1% and an ash content of 0.044%. Even if the density of 1.23 g/cc in these properties is maintained, petroleum fractions having such a high density are hardly known in conventional petroleum fractions. U.S. Pat. Nos. 3,976,729, 4,026,788 and 4,005,183 also describe examples wherein the pitch is produced using a specified raw material.
The properties of heavy petroleum oils actually depend essentially upon the properties of crude oils from which they were produced and the process for producing the heavy oil. However, it is rare for heavy oils to have the suitable properties described in the above examples, and such oils are often not available. Accordingly, in order to produce carbon fibers having excellent strength and excellent modulus of elasticity industrially in a stabilized state using petroleum heavy oils, it is necessary to develop a process for producing a pitch wherein the properties of the finally resulting pitch are stabilized even if the properties of the raw materials used for making the pitch vary.
SUMMARY OF THE INVENTION
The present invention relates to a process for producing an improved pitch which is used for producing carbon fibers having a high modulus of elasticity. The pitch is produced industrially in a stabilized state using not only a specified raw material but also an easily available petroleum heavy residual oil.
The pitch used for producing carbon fibers having a high modulus of elasticity is produced by a process which comprises subjecting a petroleum heavy residual oil to hydrogenation treatment in the presence of a catalyst, removing a low boiling point fraction by reduced pressure distillation, subjecting the resulting reduced pressure distillation residual oil to solvent extraction treatment with using an organic solvent, and carrying out thermal modification of the resulting extraction component.
DETAILED DESCRIPTION OF THE INVENTION
There are a large number of different petroleum heavy residual oils and the properties of them vary over a fairly wide range depending upon the different crude oils from which they are produced or the process for producing them from crude oils. The hydrogenation treatment by which the above-described difference is reduced is carried out in the presence of a catalyst at a temperature of 370° to 450° C., preferably 380° to 410° C., a pressure of 70 to 210 Kgf/cm 2 , preferably 100 to 170 Kgf/cm 2 , a liquid space velocity of 0.4 to 2.0 Hr -1 , preferably 0.4 to 1.0 Hr -1 , and a ratio of hydrogen/oil of 700 to 1,700 Nm 3 /Kl, preferably 800 to 1,500 Nm 3 /Kl. By such a process components contained in the petroleum heavy residual oil, such as sulfur, nitrogen, oxygen and slight amounts of metals, etc., are removed. Further, at the same time, the amount of aromatic components having a comparatively high molecular weight such as asphaltenes is reduced by the hydrogenation treatment.
Petroleum heavy residual oils to be subjected to such hydrogenation treatment have a boiling point of 300° C. or more and are prepared with a conventional distillation apparatus used in the petroleum industry. The conditions of the hydrogenation treatment are suitably controlled within the above-described ranges according to properties of the petroleum heavy residual oil.
The petroleum heavy residual oil is first subjected to hydrogen treatment and then processed by a reduced pressure distillation apparatus to remove a low boiling point fraction. The low boiling point fraction to be removed in this case means a fraction having a boiling point of about 450° C. or less and, preferably, 500° C. or less when distilling by means of a reduced pressure distillation apparatus conventionally used in the petroleum industry.
The resulting reduced pressure distillation residual oil is then subjected to solvent extraction treatment using an organic solvent, and the component extracted with the solvent is taken out.
This solvent extraction treatment is carried out in order to reduce the amount of the asphaltene in the reduced pressure distillation residual oil, by which the asphaltene is nearly completely removed in addition to the effect of removing the asphaltene by the abovedescribed hydrogenation treatment.
The asphaltene is one component in case of analyzing by solvent fractionation. More specifically, it is the component which is insoluble in n-heptane and soluble in benzene when carrying out solvent fractionation.
The solvent extraction treatment is carried out using saturated hydrocarbon compounds as a solvent which have 3 to 7 carbon atoms. These compounds may be one or more of propane, butane, pentane, hexane and heptane. When the treatment is carried out the ratio of solvent to oil is 3:1 to 15:1, the temperature is 50° to 230° C. and the pressure is 5 to 50 Kgf/cm 2 . Thereby, the extraction component is obtained. The condition of solvent extraction treatment is suitably controlled with consideration to the properties of the reduced pressure distillation residual oil and properties of the extraction component.
As described above, since sulfur, nitrogen, oxygen, metals and asphaltene, etc., are removed from the petroleum heavy residual oil by carrying out hydrogenation treatment, reduced pressure distillation and solvent treatment, the difference in the properties is finally eliminated resulting in a product having uniform properties, even if the initial properties of the petroleum heavy residual oil are fairly different from others. The sulfur content, vanadium content, nickel content, and asphaltene content in the extraction component which are removed from the petroleum heavy residual oil are 2.5 wt% or less, 15 ppm or less, 7 ppm or less, and 0.05 wt% or less, respectively. Further, the properties of the oils become suitable for the following thermal modification.
The above-described extraction component is then subjected to thermal modification under a condition comprising a temperature of 390° to 430° C. to obtain a pitch used as a raw material for carbon fibers. It is necessary that the time for thermal modification is controlled within a range such that infusible materials which obstruct spinning are not formed when carrying out melt spinning of the above-described pitch used as a raw material for carbon fibers.
As described above, properties of the petroleum heavy residual oils may be fairly different from each other. Therefore, it is generally difficult to directly produce a pitch used as a raw material for carbon fibers having a high strength and a high modulus of elasticity from every petroleum heavy residual oil. However, some oils may be used for directly producing the pitch used as a raw material for carbon fibers having a high strength and a high modulus of elasticity.
The present invention is characterized by the fact that the pitch used as a raw material for the carbon fibers having a high modulus of elasticity can be produced industrially and stably using various kinds of petroleum heavy residual oils including the petroleum heavy residual oils which cannot be used for producing the pitch by the conventional process, by carrying out a series of processings comprising hydrogenation→reduced pressure distillation→solvent extraction→thermal modification.
The pitch thus produced by the invention is utilized to produce the carbon fiber. The carbon fiber can be produced by the conventional processes, for example, the process as described in U.S. Pat. No. 3,767,741 which comprises spinning the pitch as a raw material, infusiblizing and carbonizing.
In the following, the present invention is illustrated in greater detail by examples. However, the invention is not limited to these examples.
EXAMPLE 1
After a heavy residual oil having a boiling point of 350° C. or more prepared by distillation of Middle East crude oil (A) was subjected to hydrogenation treatment under a condition comprising a temperature of 390° C., a pressure of 160 Kgf/cm 2 , a liquid space velocity of 0.5 Hr -1 and a ratio of hydrogen/oil of 1,000 Nm 3 /Kl, a fraction having a boiling point of 500° C. or less was removed by reduced pressure distillation. The resulting reduced pressure residual oil was subjected to solvent extraction treatment with heptane as a solvent under a condition comprising a ratio of solvent to oil of 10:1, a temperature of 180° C. and a pressure of 40 Kgf/cm 2 . The resulting extraction component was subjected to thermal modification at a temperature of 410° C. for 10 hours to obtain a pitch used as a raw material for carbon fibers.
Properties of the heavy residual oil from Middle East crude oil (A) used as a raw material, those of the solvent extraction component and those of the pitch used as a raw material for carbon fibers are shown in Table 1.
Further, carbon fibers which were obtained by melt spinning of the above-described pitch used as a raw material for carbon fibers at 360° C., infusiblizing at 260° C. in the air and carbonizing at 1,000° C. had a tensile strength of 11 tons/cm 2 and a modulus of elasticity of 1,000 tons/cm 2 .
When the fibers prepared by carbonizing at 1,000° C. were additionally graphitized at 1,800° C., they had a tensile strength of 15 tons/cm 2 and a modulus of elasticity of 2,100 tons/cm 2 .
EXAMPLE 2
After a heavy residual oil having a boiling point of more than 350° C. prepared by distillation of Middle East crude oil (B) was subjected to hydrogenation treatment under a condition comprising a temperature of 390° C., a pressure of 160 Kgf/cm 2 , a liquid space velocity of 0.5 Hr -1 and a ratio of hydrogen/oil of 1,000 Nm 3 /Kl, a fraction having a boiling point of 500° C. or less was removed by reduced pressure distillation. The resulting reduced pressure residual oil was subjected to solvent extraction treatment with heptane as a solvent under a condition comprising a ratio of solvent to oil of 10:1, a temperature of 180° C. and a pressure of 40 Kgf/cm 2 . The resulting extraction component was subjected to thermal modification at a temperature of 400° C. for 15 hours to obtain a pitch used as a raw material for carbon fibers.
Properties of the heavy residual oil from Middle East crude oil (B) used as a raw material, those of the solvent extraction component and those of the pitch used as a raw material for carbon fibers are shown in Table 1.
Further, carbon fibers which were obtained by melt spinning of the above-described pitch used as a raw material for carbon fibers at 370° C., infusiblizing at 260° C. in the air and carbonizing at 1,000° C. had a tensile strength of 10 tons/cm 2 and a modulus of elasticity of 1,000 tons/cm 2 .
COMPARATIVE EXAMPLE 1
A heavy residual oil having a boiling point of 350° C. or more prepared by distillation of Middle East crude oil (A) was subjected to reduced pressure distillation to remove a fraction having a boiling point of 500° C. or less.
The resulting reduced pressure distillation residual oil was subjected to thermal modification at a temperature of 410° C. for 10 hours.
Properties of the heavy residual oil from Middle East crude oil (A) used as a raw material and those of the pitch in this case are shown in Table 1.
When fibers were produced by melt spinning of the above-described pitch at 350° C., infusiblizing at 260° C. in the air and graphitizing at 1,000° C., they had a tensile strength of 5.5 tons/cm 2 and a modulus of elasticity of 350 tons/cm 2 .
TABLE 1______________________________________ Compar- ative Example Example Example 1 2 1______________________________________Properties of raw materialSpecific gravity @ 15/4° C. 0.955 0.960 0.955Kinetic viscosity cSt @ 50° C. 230 550 230Residual carbon content wt % 8.5 11 8.5S wt % 3.0 4.3 3.0N ppm 1,950 2,200 1,950V ppm 29 60 29Ni ppm 8 15 8Asphaltene content wt % 2.0 3.2 2.0Properties of component aftersolvent extraction treatmentby process of the presentinventionSpecific gravity @ 15/4° C. 0.940 0.951Kinetic viscosity cSt @ 100° C. 26.1 30.5Residual carbon content wt % 6.1 7.6S wt % 1.2 2.2N ppm 300 310V ppm 5 10Ni ppm 3 5Asphaltene content wt % 0.03 0.04Properties of pitchSpecific gravity @ 25/25° C. 1.30 1.32 1.32Softening point °C. 330 320 335Quinoline insoluble content 19.8 18.5 23.1wt %______________________________________
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A process for producing a pitch which is used as a raw material for producing carbon fibers is disclosed. The process comprises subjecting a petroleum heavy residual oil to hydrogenation treatment in the presence of catalysts, removing a low boiling point fraction of the oil by reduced pressure distillation, subjecting the resulting reduced pressure distillation residual oil to solvent extraction treatment, and carrying out thermal modification of the resulting extraction component.
By utilizing the process for producing the pitch it is possible to use a wide variety of different types of oils in order to produce carbon fibers. The carbon fibers produced from the pitch produced according to the disclosed process have desirable characteristics. | 3 |
This is a continuation of application Ser. No. 07/637,841 filed Jan. 7, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ignition timing control apparatus for an internal combustion engine used for, for instance, an outboard machine.
2. Discussion of Background
In a conventional ignition timing control apparatus, a crank angle was detected on the basis of a signal from a crank angle sensor which produces every 1°, for instance, a signal, and the ignition of engine was performed at the optimum angle on the basis of the detected crank angle.
In the conventional ignition timing control apparatus, however, when the crank angle sensor became abnormal because of disconnection of wire, a short circuit or the like, information of the crank angle was not provided and ignition control became impossible, resulting in an engine stop. If such problem occurs in an outboard machine with the ignition timing control apparatus in a ship on the sea, there is a danger that the ship can not return to a harbor.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an ignition timing control apparatus capable of performing an ignition control for the engine even when a crank angle sensor becomes faulty.
The foregoing and other objects of the present invention have been attained by providing an ignition timing control apparatus for an internal combustion engine which comprises, an ignition signal coil for producing a first pulse signal in synchronism with the revolution of the engine and in correspondence to a predetermined crank angle position, a crank angle sensor for producing a second pulse signal in synchronism with the revolution of the crank, the second pulse signal having a greater frequency than said first pulse signal, and a microcomputer for performing an ignition control of the engine by detecting the crank angle on the basis of said first and second pulse signals, said microcomputer being adapted to perform an ignition control by another means when an abnormal state of the crank angle sensor is detected from said second pulse signal.
BRIEF DESCRIPTION OF DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a block diagram which is common to first and second embodiments of the ignition timing control apparatus according to the present invention;
FIG. 2 is a waveform diagram of signals showing the operation of the first and second embodiments of the present invention;
FIGS. 3a and 3b are flow charts showing the operation of the first embodiment of the present invention; and
FIG. 4 is a flow chart showing the operation of the second embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, wherein the same reference numerals designate the same or corresponding parts throughout several views, and more particularly to FIG. 1 thereof there is shown a block diagram which is used commonly for explanation of first and second embodiments.
In FIG. 1, the ignition timing control apparatus according to the first and second embodiments of the present invention comprises a crank angle sensor 1, an ignition signal coil 2 for the first cylinder, an ignition signal coil 3 for the second cylinder, a microcomputer 4 connected to the crank angle sensor 1 and the ignition signal coils 2, 3, and ignition coils 5, 6 connected to the microcomputer 4. The microcomputer 4 includes a CPU 4a, an ROM 4b, an RAM 4c, a sensor abnormality counter 4d and an ignition counter 4e.
In the next, the operation of the first embodiment will be described with reference to FIG. 2 and 3 wherein FIG. 2 is a waveform diagram of signals showing the operation of the first embodiment and FIG. 3 is a flow chart showing the operation of the first embodiment of the present invention.
The main program (not shown) stored in the microcomputer 4 governs the retrieval of ignition timing from a map and control for injectors. Since the main program is usually operated with a relatively long period (for instance, 10 ms), an ignition timing control which is usually operated with a relatively short period is conducted so as to interrupt the main program. Namely, the ignition reference signal interruption loop as in FIG. 3a is executed in the main program as soon as the pulse signal of the ignition signal coil 2 or 3 is produced.
At Step 10 in FIG. 3a, determination is made as to whether or not the value of the sensor abnormality counter 4c is equal to or higher than a predetermined value n. When the determination is negative, the sequential step goes to Step 11. When the determination is affirmative, the treatment of Step 14 is taken.
At Step 11, a figure "1" is added to the value of the sensor abnormality counter 4d.
At Step 12, the target count value corresponding to the optimum ignition timing in the main program is read so that a target value for the ignition counter 4e is set.
At Step 13, counting of the ignition counter 4e is initiated. Then, other treatments (such as control of over-revolution and so on) are executed, and then, the operation of the main program is again taken.
On the other hand, the ignition counter 4e counts the number of pulses of the pulse signal from the crank angle sensor 1. When a counted value reaches a target value, the operation is transferred to an ignition treatment loop as shown in FIG. 3b in which the engine is ignited (Step 20) and the sensor abnormality counter 4d is cleared (Step 21). Then, the operation is returned to the main program.
During the operation of the engine, if an abnormal state occurs in the crank angle sensor 1, it does not generate any pulse signal. Then, the count value of the ignition counter 4e does not reach the target value and the transfer to the ignition treatment loop is prohibited, whereby the sensor abnormality counter 4d is not cleared. Accordingly, the value of the sensor abnormality counter is accumulated each time when the ignition reference signal interruption loop is actuated by the generation of the pulse signal from the ignition signal coil 2 or 3. When the value accumulated in the sensor abnormality counter reaches the predetermined value n, the operation of Step 14 is taken.
At step 14, an ignition treatment at an abnormal time is executed. Namely, the ignition of the engine is controlled by forecasting time. For instance, when the ignition control of the engine is to be conducted at a predetermined crank angle θ by measuring a period T through the pulse signals of the ignition signal coils 2, 3 for the first and second cylinders, a formula T·θ/360° is obtainable from the pulse signals of the ignition signal coils 2, 3 and the ignition control is conducted after the lapse of time of T·θ/360°. In this case, when θ=10°, the ignition control is conducted after the lapse of time of T/36. Then, other treatments are executed and the operation is returned to the main routine. During the ignition control, a misfiring state temporarily takes place in the course from the ordinary ignition treatment to the ignition treatment at an abnormal time. However, such misfiring state is in a very short time and there is no problem in the operation of the engine.
The operation of the second embodiment of the present invention will be described with reference to FIGS. 2 and 4.
FIG. 4 is a flow chart showing the operation of the second embodiment of the present invention.
In the ignition timing control apparatus of the second embodiment of the present invention, the pulse signals of the crank angle sensor 1 are counted by the ignition counter 4e and ignition timing is determined on the basis of the counted pulse signals as in the same manner as first embodiment.
At Step 30, the microcomputer 4 checks a value of the ignition counter every predetermined time and judges whether or not the value detected at the last time is equal to the value detected at this time. When the values detected are equal, Step 33 is taken. When the values are different, the sequential step goes to Step 31.
At Step 31, the sensor abnormality detecting counter 4d is cleared. At Step 32, the ordinary ignition treatment is conducted in the same manner as the first embodiment. Then, sequential step is returned to Step 30.
When the values detected are different, a figure "1" is added to the sensor abnormality detecting counter at Step 33.
At Step 34, determination is made as to whether or not the value of the sensor abnormality detecting counter 4d is a predetermined value or higher. When the determination affirmative, the ignition treatment at abnormal time is conducted at Step 35. Otherwise, the ordinary ignition treatment is conducted at Step 32.
At Step 35, the ignition treatment at an abnormal time is conducted in the same manner as the first embodiment. Thereafter, the sequential step is returned to Step 30.
In the first and second embodiments of the present invention, when the abnormality of the crank angle sensor 1 is detected, the ignition treatment without using the crank angle sensor 1 is conducted separate from the ordinary ignition treatment, and accordingly, engine stop due to the abnormality of the crank angle sensor 1 can be prevented. Therefore, when the ignition timing control apparatus of the present invention is used for an outboard engine, a ship provided with the outboard engine can return to a harbor even when the crank angle sensor becomes an abnormal state, whereby the safeness can be remarkably improved.
In the above-mentioned embodiments, the reason why the ignition treatment at an abnormal time is conducted only when the value of the sensor abnormality detecting counter is a predetermined value (for instance, the value corresponding two revolutions) or higher is to assure that temporary abnormal state in signal such as a mere contact failure in the crank angle sensor 1 is not deemed as an abnormal state.
The predetermined time as used in the second embodiment is a constant time of 5 m sec or a random non-constant time. Further, the same effect can be attained by the repetition of a combination of two or more kinds of constant time having different time widths.
In the above-mentioned embodiments, the ignition control at an abnormal time is conducted by forecasting time. However, the same effect can be obtained by igniting the engine when the pulse signals of the ignition signal coil 2 or 3 reach a predetermined level.
In the above-mentioned embodiments, the ignition timing control apparatus is applied to a two-cylinder engine. However, the present invention is applicable to another type of multi-cylinder engine.
Thus, in accordance with the present invention, the engine can be continuously operated at at least lowest level without causing engine stop even when the crank angle sensor becomes abnormal. Accordingly, reliability of the engine is improved and the safeness of the engine can be assured.
Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. | An ignition timing control device for an internal combustion engine includes an ignition signal coil for producing a first pulse signal in synchronism with the revolution of the engine and in correspondence to a predetermined crank angle position, a crank angle sensor for producing a second pulse signal in synchronism with the revolution of the crank, the second pulse signal having a greater frequency than said first pulse signal, and a microcomputer for performing an ignition control of the engine by detecting the crank angle on the basis of the first and second pulse signals. The microcomputer is adapted to perform an ignition control by another means when an abnormal state of the crank angle sensor is detected from the second pulse signal. | 5 |
BACKGROUND
The invention relates to a device for mixing two paste-like compounds for a dental-molding compound and a catalyst for the acceleration of polymerization. The device has a housing, which has a mixing area with at least two inlet openings for the two paste-like compounds and an outlet opening for the mixed paste-like compound. The device also has a mixing element that is arranged so that it can be especially propelled in the mixing area and is pivotable in the housing along its longitudinal axis. The housing also has a coupling section that is situated in front of the mixing area with two coupling openings for connecting with two dispensing openings of a device for dispensing the two paste-like compounds. A first and a second duct connect to the coupling openings, extending through the coupling section to the inlet opening for the mixing area. The two ducts are formed so that the time needed for the entry of the paste-like compound into the coupling opening of the coupling section, until the entry into the inlet opening of the mixing area of the housing, is greater for the first duct than for the second duct.
The device is attached to the two outlet supports of a delivery device, wherein the compounds to be mixed are inserted into the mixing device by applying pressure to the compounds. After these compounds are mixed in the mixing device, they are dispensed from this device as one compound.
In numerous technical application areas it is necessary to apply two separately stored paste-like compounds in a mixed form. Here either a dynamic or a static flow mixer is used such as a mixer with a moveable or stationary mixing element, which mixes the compounds with each other while flowing through the mixing housing.
A dynamic mixer is known from U.S. Pat. No. 5,249,862. This known device has a mixer housing that is essentially tube-shaped with a pivotable mixer element arranged in it. The mixer element has a number of radially protruding rib-like mixer arms that rotate around the flow of compounds, and thus mixes the two paste-like compounds with each other when the mixer element is driven. The paste-like compounds reach the mixer element via a radial front wall at the back end of the mixer housing. Thus, the front wall has two inlet supports, which are attached to the outlet supports of the device for yielding the paste-like compounds.
However, regardless of whether a static or dynamic mixer is used, the above devices encounter problems because of the uneven flow of the different mixing components and thus the uneven amounts of the components in the mixing region.
It is already known that the problem can be constructively dealt with by having the base component or components within the mixer that tend to overdose flow a longer way to the mixer element than the other component or catalyzing components. This flow is between the reserve receptacle and the mixer. A first example for such a concept is described in DE-U-298 18 499, according to which the duct of the one component runs in the form of an arch around the longitudinal axis of the pivotable mixer element between the inlet of a dynamic mixer to the actual mixer area. An example for solving the problem in the case of a static mixer is given in U.S. Pat. No. 6,135,631, whereby this mixer was already on the market before the application date of the subject of DE-U-298 18 499, and was freely distributed and disbursed to third parties. Also for these known static mixers, the base component that tended to overdose was redirected in an arch-like form in the mixer, and the flow of compounds was divided in two, to reach the stationary mixing element next to the compound flow of the other component or other catalyzing component. In so doing, the introduction of the non-advancing (catalyzing) component flows as directly as possible, i.e. without any detours that would increase the flow resistance. Further examples for such mixers which delay the advancement of faster flowing compounds serving as dead volume are known from U.S. Pat. No. 5,487,606, and EP-A 0664 153.
In the case of the known mixers, a recontamination can occur after the deploying process ends, such as when the application device is shut off. This can occur because the base component flows into the container of the catalyzing component due to the varying pressure in the reserve receptacles of the paste-like compounds. If these components mix with each other and polymerize or harden in the deploying duct of one of the reserve receptacles of the paste-like compounds, the entire reserve receptacle and its content are unusable.
The present invention provides an additional device for mixing two paste-like compounds, whose mixing ratio is constant from the beginning of the dispensing of the mixed compounds, and also prevents a recontamination of these two compounds.
SUMMARY OF THE INVENTION
Thus, this device includes two ducts which are formed so that at least the first duct has a first segment that extends from the coupling opening in an axial direction of the mixer element, and a redirecting section that is connected to this. There is also a second segment leading to the associated inlet opening, whereby the axes of the first and second segments lie on a common level with the longitudinal axis of the mixer element.
Moreover, in addition to this, the two ducts are formed so that at least the first duct has a segment that extends from the coupling opening in the form of an arch around the axis of the mixing element. A second segment is provided which is placed in axial direction of the mixing element to the first segment, and leads to the associated inlet opening. There is a redirection segment that connects the first and the second segment. The redirection segment is arranged further away from the coupling opening, and serves as the inlet opening.
Basically, the temporary initial excess of the prescribed dosage or overdosage of one of the two components or compounds is compensated for by a corresponding form of the duct through which this compound flows until it arrives at the mixer element. This compensation occurs so that the paths, and thus also the retention periods vary the time the paste-like compounds need from the entry into the coupling openings of the coupling section of the mixer housing, to the entry into the inlet openings of the tube-shaped section of the mixer housing. It can be determined, from a study of the overdose amount and, if need be, of the flow speeds of both of the components to be mixed, how to form one of the two or both ducts by changes, such as via cross sectional changes, or form and size changes, as well as changes in length of the duct or ducts, so that both components simultaneously arrive in the inlet openings of the tube-shaped section of the mixer housing.
Beyond that, the invention also overcomes this problem by providing a second duct that has an extension section that lengthens the path between the coupling's opening and the associated inlet opening. This lengthening or extension section in certain areas, can be in the form of an arch around the longitudinal axis of the mixer element. In addition, the lengthening section has a first segment extending from the coupling opening in an axial direction of the mixer element, and a redirection section connected to this section, and a second segment that leads to the associated inlet opening, whereby the axes of the first and the second segments lie at a common level with the longitudinal axis of the mixer element. The lengthening section can extend, for example, 90° or 45° around the longitudinal axis of the mixer element in the form of the second duct that runs in an arch shape around the longitudinal axis of the mixer element. The occurrence of recontamination could also be avoided, even with an arch-shaped redirection of only approximately 5°. The entry of the (catalyzing) component in the mixer area is delayed by redirecting the paste-like compound in the second duct. To prevent an underdosage of the (catalyzing) component in the initial phase, the path of in the first duct can be lengthened, or by increasing the corresponding time which the paste-like (basis) compound requires from its entry in the coupling opening of the coupling section to its entry in the inlet opening of the mixer area of the housing. The redirecting in the second duct at the same time, increases the flow resistance in the second duct to prevent a recontamination by the base compound flowing into the second duct from the first duct, which would otherwise occur at the end of the deploying process, for example, when the application device is shut off. Thus, a mixing and hardening (polymerization) of the two components consequently cannot occur in the area upstream from the coupling opening, which is the device that dispenses the two paste-like compounds.
To compensate for the overdosage of one flow of compounds, the (first) duct assigned to this compound is designed to have a longer flow than the other (second) duct. This lengthening is achieved by extending the pertinent duct initially from the inlet opening of the coupling section of the mixer housing in the axial direction of the mixer element, or is formed as an arch around the axis of the mixer element. This duct is then a redirected preferably 180° and extends subsequently in the axial direction of the mixer element, or in the form of an arch around the axis of the mixer element, so that it ends, after being redirected 90° to 180° in the inlet opening of the mixer area. This form of the duct saves space while still providing a tolerable flow resistance. At the same time, as a result of these designs of the duct, the inlet opening of the mixer area is situated close to the coupling opening. When the coupling openings are arranged at 180° to each other, the inlet openings lie far from each other so that this recontamination is prevented. Moreover, the increased flow resistance in the other or second duct can be compensated for by this duct design where the duct includes a lengthening section to avoid any recontamination.
The duct formed in accordance with the invention can also be divided into two or several duct segments respectively that are basically parallel or, in particular, with regard to their path, formed the same. In other words, the coupling section of the housing of the mixer in accordance with the invention has ducts of various lengths that lead to the entry openings of the tube-shaped housing section. Alternatively, the two ducts can also have a varying sized dead volume, which is designed in accordance with fluid mechanics so that the compound only continues to flow in the direction of the inlet opening assigned to the pertinent duct, only after filling the pertinent dead volume. Instead of furnishing both ducts with dead volume, it is also possible to form only one of the two ducts with a dead volume.
In practice, mixers that are attached to two outlet supports of an application device are arranged at intervals to each other, to function properly. The mixer housing has thus in its coupling section, two coupling openings, which are axially staggered to the mixer element, and arranged diametrically opposite to each other. The inlet openings of the tube-shaped section of the mixer housing for the known mixers also lie, as a rule, diametrically opposite one another. Thus, for the known mixer designs, short ducts result between the coupling openings and the inlet openings assigned to them. The redirecting of at least one (or base) compound along segments of the first duct occurs so that ducts of varying lengths can be formed with such a mixing concept, whereby the axis of the first duct lies at a common level with the axis of the mixer element, or is in the shape of an arch around the longitudinal axis.
The arrangement of the segments of the first duct are formed so that the longitudinal axes of the segments together with the longitudinal axis of the mixer element span a joint radial level, and has the advantage of providing a space-saving form of the longer first duct. The segments of the first duct are preferably formed linearly. Alternatively, it is also possible that the ducts can be formed curvilinear or curved. However, in this case the curved longitudinal axis are arranged in turn in a joint radial level together with the (linear) longitudinal axis of the mixer element.
In the case described above, in which the segments of the first duct are formed linearly, it is furthermore advantageous if they run parallel to each other. The redirecting section is formed U-shaped in this case, for example, extending over 180°.
If the segments of the first duct extend in the form of an arch around the longitudinal axis of the mixer element, for example, they are formed over each other in an axial direction, wherein the redirection section is formed C-shaped, or it extends over 180°. In so doing, the compound flows at first in the first segment in the shape of an arch away from the coupling opening, and after redirecting, led back toward the inlet opening, which preferably lies near to the coupling opening. This design of the first duct is particularly space saving.
The inlet openings of the two ducts into the mixing area can lead axially or radially into the mixer element. An additional redirection section can still be connected to the second segment whichever form of the alignment of the inlet openings is used. This additional redirection section extends by 90° when the two segments of the first duct are aligned parallel, if the inlet openings discharge radially into the mixing area. This redirection extends over a total of 180° if the inlet openings discharge axially into the mixing area.
In another embodiment, the mixer element has at least one redirection element for support of the transport of the paste-like compounds in axial direction. These compounds arrive through the inlet openings into the tube-shaped section of the housing. At this point, the redirection element has a redirection surface that extends around the axis and runs inclined to the radial level of the axis. In this embodiment, compounds are fed radially in the essentially tube-shaped section of the mixer housing. Thus, the tube-shaped section of the housing has two radial inlet openings that are disposed diametrically opposite one another. The flows of paste-like compounds, which are inserted by applying pressure into the mixer, encounter at least one redirection element that extends around the axis of the mixer element within the tube-shaped section of the housing. This redirection element rotates with the revolving mixer element, and has a redirection surface that runs diagonally to the radial level of the axis. In other words, at least one redirection element has an essentially saw-tooth-shaped wedge that bends around the axis of the mixer element. This redirection element functions like a conveying screw for a spiral pump, and ensures that the upcoming paste-like material is directly transported in the axial direction from the inlet openings toward the outlet opening. Thus, recontamination continues to be prevented since the redirection element supports the axial feeding of the paste-like compounds arriving through the inlet openings in the tube-shaped section of the mixer housing.
The redirection element can have a wedge form. Alternative to this wedge form, the redirection element can be formed as a ridge that runs in the shape of a helix around the axis. In this embodiment, the redirection element thus has the form of a screw thread. These circumferential ridges are known from spiral pumps and conveying screws.
Two redirecting elements are advantageously arranged on the axis at the level of the radial inlet openings of the mixer area of the housing. The redirecting elements are diametrically arranged opposite to each other. These redirecting elements or every redirecting element extends preferably across an angular range of 180° to 90°.
The housing has an insertion aligned transversely to the axis on its back end, from which two inlet supports protrude. These inlet supports connect the mixer to the two outlet supports of a squeezing device. The insertion is in a conically widened section of the housing that is connected to the mixer area. It has two ducts that extend from the inlet supports. These two ducts run under, bending radially in a concentric cylindrical intake recess on the inner side of the insertion, by which the axis of the mixer element is taken in with at least the one redirecting element. Thus, the cylindrical intake recess of the insertion forms a subarea of the mixer area. The two inlet supports of the insertion form the couplings openings, and are connected to the outlet supports of the delivery or squeezing device. Thus, it is possible that the outlet supports are connected to the inlet supports.
However, unlike the previous embodiments, the two ducts extend then to the mixer element. Thus, the duct which extends from that inlet support, through which the compound material flows with the overdosage, at the beginning of the operation of the delivery device, is divided into two or more partial ducts that preferably at first, extend in the circumferential direction around the cylindrical intake recess, in two or more of these inlet openings, assigned respectively to these partial ducts.
The form of the mixer is such that several ducts extend from one or both coupling openings. The ducts end in several inlet openings, which discharge particularly uniformly in the section of the mixer housing with the mixer element. In addition to the improved fluidic performance of the paste-like compounds, it has the advantage that the materials admitted into the mixing area can be better and more homogeneously mixed. The spatially distributed insertion of each of the two compounds or at least of one of the two compounds, contributes to this because this distributed insertion of both compounds or at least of one of the two compounds in the mixer area has the advantage that a sort of premixing takes place through the portioning of the compounds flow into several inlet openings.
The individual partial ducts can be of the same or different length. They can be formed in the shape of a collective duct departing from the related coupling opening. Several diverging ducts branch off from the collective duct and they end in the inlet openings.
This concept of the spatially distributed feeding of the flows of compounds in the mixing area is applicable independent of whether the inlet openings are now arranged radially or axially. In other words, the normal lines of the opening cross sections of the inlet openings can be arranged both in the direction of the longitudinal extension of the mixer element, and also radially.
Also, the concept described above of the constructive design of the mixer, provides that both of the compounds arrive at the same time in the mixer area despite a possible occurrence of excessive flow rate of one of the two compounds, especially at the start of the material delivery. This result can likewise be achieved independent of whether the normal lines of the inlet openings run radially or parallel to the mixer element, or in another angle to it.
The invention has the benefit that several mixer arms are in the tube-shaped housing section between the radial inlet openings and the axial outlet opening. These arms protrude like a type of radial ribbing from the axis, and reach close to the inner surface of the tube-shaped housing section. These mixer arms are arranged within several radial levels from the shaft, and lead to a redirecting of the compounds flows that extend axially through the housing. Thus the desired mixing occurs through this. The mixing effect is further strengthened if these mixing arms, which due to their radial alignment, prevent the direct flow between the inlet openings and the outlet opening, and extend to a larger angular range, for example 90°. This can be achieved if adjacent mixer arms are connected to each other by a circumferential segment. In this way, therefore, mixer arms result that are formed like a type of quarter circles, whereby it can also be favorable if these quarter circles in their middle sections, as viewed in the circumferential direction, are more distant from the inner surface of the tube-shaped section of the housing in relation to their ends. It is practical if, from a first radial level to a second radial level, offset in the circumferential direction, two adjacent radial running mixer arms are respectively connected to each other in the way described above.
In addition to the rigid mixer arms, it is also advantageous for the thorough mixing process if the mixer element has additional flexible wiper elements, which sweep along at the inner wall of the tube-shaped housing due to their flexibility, or at least on the basis of their flexibly formed free end, are spaced from the axis. Alternatively, the wiper elements can also be formed rigidly and be tangentially distant from the axis of the mixer element. Two arranged rigid wiper elements are then arranged diametrically opposite to two different radial levels of the mixer element. Finally, it is also possible to provide for flexible and rigid wiper elements jointly at the mixer element.
In a further advantageous embodiment of the invention, the mixer arms of the adjacent first radial levels, which are in the axial direction to the inlet openings of the tube-shaped section of the housing, are shorter than the mixer arms in the remaining second radial levels. Thus, the distance between the radial outlying ends of the mixer arms to the tube-shaped housing section within the first radial levels is greater than within the second radial levels. This leads to a larger mixer area in the area of the tube-shaped housing section, which connects to the inlet openings. This larger mixing area has the advantage that dosage tolerances conditioned by the squeezing or delivery device are better compensated. The material component moving ahead has a longer retention period in the mixing area through the additional arrangement of the tangentially distant wiper elements within this enlarged mixing area. Through this, more time is available for mixing the slower material component with the material component moving ahead.
A larger mixing area in the area described before is however advantageously achieved when the axis of the mixer element is smaller in diameter than the remaining area, and the mixer arms extend radially, precisely as far as all other mixer arms, namely directly to the inner side of the tube-shaped housing section.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings which disclose the embodiments of the present invention. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention.
In the drawings, wherein similar reference characters denote similar elements throughout the several views:
FIG. 1 is a side cross sectional view of a delivery device for mixed components;
FIG. 2 is a cross sectional view of a dynamic mixer wherein the dynamic mixer is used as a delivery device for the embodiment shown in FIG. 1 ;
FIG. 3 is a cross-sectional view of the mixer shown in FIG. 2 taken along the line III—III;
FIG. 4 is a cross-sectional view of the mixer shown in FIG. 2 taken along the line IV—IV;
FIG. 5 is a cross sectional view of the mixer shown in FIG. 2 taken along the line V—V;
FIG. 6 is a cross-sectional view of the mixer shown in FIG. 2 taken along the line VI—VI;
FIG. 7 is a cross sectional view similar to the view shown in FIG. 6 , showing an alternative form of the mixer element;
FIG. 8 is a longitudinal sectional view through the dynamic mixer shown of FIG. 2 being used with the delivery device shown in FIG. 1 ; and
FIG. 9 is a view of the back wall of a dynamic mixer according to a third embodiment, wherein the mixer is being used with the delivery device shown in FIG. 1 .
DETAILED DESCRIPTION
Referring in detail to the drawings, FIG. 1 shows a delivery device 10 that is displayed in a side view for two paste-like components that are to be mixed with one another. Device 10 comprises a squeezing part 12 , and a mixer part 14 , whereby squeezing part 12 has two pressure tanks 16 , and 18 for receiving tubular bags 20 , and 22 containing the two paste-like compounds. At the forward frontal ends 24 , and 26 of pressure tanks 16 , and 18 , these dispensing openings have outlet supports 28 , and 30 . By applying pressure to the back end of tubular bag 20 , and 22 its contents are delivered through outlet supports 28 and 30 . The pressure impact of tubular bag 20 , and 22 occurs via pressure pistons 32 , and 34 , which are driven by a motor not shown.
A dynamic mixer 36 is attached to outlet supports 28 , and 30 . Dynamic mixer 36 is shown in FIGS. 2-7 . Dynamic mixer 36 has a motor that drives mixer element 38 . Mixer element 38 can be coupled with a driving bar 40 that is rotatably driven by a motor that is also not shown. It is possible in the same way to attach a mixer 36 ′ or 36 ″ shown in the FIGS. 8 or 9 to outlet supports 28 , and 30 of device 10 .
Dynamic mixer 36 is shown in greater detail in FIG. 2 . FIG. 2 shows a longitudinal cut through mixer 36 . Mixer 36 has a housing 42 that comprises an essentially cylindrical or tube-shaped section 44 , which defines a mixer area 45 , in which mixer element 38 is arranged. Moreover, housing 42 has a conically widened coupling section 46 connected to tube-shaped section 44 . Conically widened coupling section 46 is turned toward squeezing part 12 at a back end. Mixer 36 also has a tapered forward end 50 opposite this back end 48 . Tapered forward end 50 is formed as outlet supports and defines outlet opening 52 for the material mix, while at back end 48 of housing 42 , two inlet supports 54 , 56 are arranged that form coupling openings 55 and 57 and can be attached to outlet supports 28 , and 30 of squeezing part 12 . Between two inlet supports 54 , and 56 is an opening 58 , in which one end 60 of mixer element 38 is pivoted. Driving bar 40 can be coupled with mixer element 38 through this opening.
Inlet supports 54 , 56 and opening 58 are formed by an insertion 62 that is inserted at back end 48 of housing 42 in its conical coupling section 46 . Departing from inlet supports 54 , and 56 , two ducts 64 , and 66 extend through insertion 62 . These two ducts 64 , and 66 meet through a redirection in radial openings 68 , and 70 . These inlet openings 68 , and 70 are radially arranged with regard to section 44 of housing 42 . The two paste-like components are delivered into dynamic mixer 36 through ducts 64 , and 66 . There the paste-like components meet in the radial direction of mixer element 38 .
FIGS. 2 and 3 show that insertion 62 has an intake recess that is central and essentially cylindrical. This intake recess is arranged concentric to opening 58 and inserted in mixer element 38 . Inlet openings 68 , and 70 are inserted in cylindrical wall 71 of intake recess 69 . Furthermore, ducts 64 , and 66 are also formed in this area. These ducts 64 , 66 are formed as grooves open above, or notches, which together with the essentially conically widened coupling section 46 form a duct closed on all sides.
FIG. 2 , shows first duct 64 is divided into several diversely running sections. Thus, first duct 64 has a first segment 59 that connects to coupling opening 55 . First segment 59 extends in an axial direction of mixer element 38 . At the end of this first segment 59 is a U-arch-shaped redirecting section 63 , which gives way to a second linear section 65 . From this, it goes through a further redirecting section 67 , which is essentially a 90° arch, before ending in inlet opening 68 . Two segments 59 and 65 extend parallel to each other, whereby their two parallel longitudinal axes run in a joint radial level to longitudinal axis 72 . The special essentially S-shaped form of first duct 64 is formed by an interaction between housing 42 and a protruding wall element 73 of insertion 62 .
Duct 64 extends first in the direction of outlet opening 52 and afterwards is redirected in order then to run back toward the back end of mixer 36 . This design is a direct route instead of the second duct 66 departing from its coupling opening 57 and flowing directly radially into inlet opening 70 . Thus, duct 64 can be given a longer length than duct 66 . Thus, in other words, a dead volume results due to the additionally created duct volume, which first has to be filled so that the flowing compound can flow further into the inlet opening 68 . Thus overdosages of the compound flowing through this duct can be corrected.
Mixer element 38 has a pivoted axis 72 , from which four rib shaped mixer arms 74 , and 75 , respectively, essentially radially protrude in a multitude of radial levels. The exact arrangement of these mixer arms 74 , and 75 results from the sectional view according to FIGS. 4 to 6 . A limiting lateral edge of mixer arms 74 , and 75 , which lies in the circumferential direction, runs essentially tangentially to the peripheral surface of axis 72 . Furthermore as viewed from the flow direction, first mixer arms 74 are shorter than second mixer arms 75 arranged turned toward outlet opening 52 . Thus, the radial distance out from mixer arms 74 to inner surface 76 of tube-shaped section 44 is thus greater than in the case of mixer arm 75 . Thus, viewed from the flow direction of the compound, a mixing area section within housing 42 follows inlet openings 68 , and 70 . This mixing area section is larger than the mixing area section, in which longer mixer arms 75 are arranged. Between adjacent radial levels of mixer arms 74 , moreover, tangentially protruding wiper elements 77 are arranged, which contribute to an improvement of the mixing. The larger first section of the mixer area with regard to volume, moreover, assures that, as needed, the one leading compound also has a longer retention period in the mixer area, so that enough time remains for the other slower flowing compound to mix homogeneously with the compound first mentioned.
FIG. 2 shows a variation of the mixer which is indicated with dashed lines. With this variation, axis 72 is thinner in the area of the first radial level than within the remaining radial levels. Mixer arms 74 , and 75 have all the same extension, namely, directly contiguous to housing section 44 .
FIG. 4 shows four mixer arms 74 that are disposed on each radial level. Mixer arms 75 , reach according to FIG. 3 to a region contiguous to inner surface 76 of housing section 44 . The total area between inlet openings 68 , and 70 and the end of mixer element 38 , extends to tapered end 50 of housing 42 . In addition, mixer element 38 has mixer arms 78 formed like a quadrant. These mixer arms 78 are formed by connecting two adjacent mixer arms 74 in a radial level. In this embodiment, the radially outlying limiting edge of mixer arm 78 is formed in the shape of circular arc, while it runs with the alternative according to FIG. 7 secantially. FIG. 7 shows mixer arm 78 ′ which therefore has in a middle circumferential section a larger distance to inner surface 76 of housing section 44 .
As shown in FIG. 7 , mixer arms 74 , 78 , and 78 ′ assure a redirecting and thus turbulence of the axially flowing paste-like compounds due to their radial extension close to housing section 44 with the rotation of mixer element 38 , mixer element 38 has three redirecting elements 80 in the area of the radial inlet openings 68 , and 70 that are arranged uniformly offset by 120° to each other and are formed like a type of conveying screw. Redirecting elements 80 are formed as sawtooth-shaped wedges that extend to approximately 60° around axis 72 of mixer element 38 . As shown in FIG. 2 , redirecting elements 80 have a redirecting surface 82 that rises in the circumferential direction. Redirecting surface 82 points toward outlet opening 52 of dynamic mixer 36 and runs angled to a level radial to axis 72 . These redirecting elements 80 run therefore sectionally in the form of a helix and assure an axial movement component of the paste-like compound flows along longitudinal axis 72 . Thus, redirecting elements 80 support the delivery of the paste-like compound, which enters from inlet openings 68 , and 70 into housing section 44 . This supporting and thus strengthening discharging of the paste-like compound in the axial direction reduces the danger of contamination of the two paste-like compounds, which is the undesired mixing or recontamination of the two paste-like compounds through inlet opening 68 , and 70 in ducts 64 , and 66 possibly further in outlet supports 28 , and 30 . If there is a contamination and thus a polymerization in these areas, the residual material that may still be in tubular bags 20 , and 22 can no longer be delivered due to stoppage of outlet supports 28 , and 30 . Diverging from the illustration in FIG. 2 redirecting elements 80 can be formed in so that at least its back end in the movement direction extends along sufficiently far in mixer area 45 in the direction of outlet opening 52 of dynamic mixer 36 so that this extends to both inlet openings 68 , and 70 . The flow of compounds delivered through inlet openings 68 , and 70 for improving the mixing and reducing a recontamination can be cut off for a short time or at least reduced.
In addition to redirecting elements 80 , mixer element 38 has two wiper ribs 86 that lie diametrically opposite each other. These ribs are spaced radially from axis 72 of mixer element 38 and run parallel to axis 72 . Wiper ribs 86 move with little clearance within along cylindrical wall 71 of insertion 62 while mixer element 38 is rotating. These wiper ribs contribute to an overall homogeneous thorough mixing of the two compound flows. FIG. 2 shows two wiper ribs 77 that connect two mixer arms 74 that lie diametrically opposite each other within the first radial level of mixer arms 74 . This radial level connects to inlet openings 68 , and 70 , with the end of mixer element 38 arranged in opening 58 of insertion 62 .
FIG. 6 shows a further characteristic of dynamic mixer 36 wherein mixer arms 74 are rigid, essentially radially protruding ribs, which lead to a turbulence of the compound flows due to the rotation around axis 72 . In addition to rigid mixer arms 74 , and 75 and wiper elements 77 , dynamic mixer 36 can have further mixer arms 86 formed like thin flexible ribs, which wipe from within along inner side 76 of housing section 44 . These additional flexible mixer arms 86 assure a turbulence of the compound flow. One of flexible mixer arms 86 per level exists in several consecutive radial levels of mixer element 38 , whereby these mixer arms 86 are arranged around a constant angular range offset from one radial level to another radial level. The same is true for mixer arms 78 or 78 ′, which connect two adjacent mixer arms 74 , and 75 with each other and likewise are arranged in this case displaced offset from each other by 90° from radial level to radial level. These mixer arms 86 and mixer arms 78 or 78 ′ are therefore arranged uniformly distributed along a helix around axis 72 . Both mixer arm types are excellent for a homogeneous mixing of the paste-like compounds in dynamic mixer 36 , which also can be characterized as a flow path mixer.
Dynamic mixer 36 ′ shown in FIG. 8 essentially corresponds to mixer 36 shown in FIG. 2 . The form of first duct 64 with a first segment 59 that connects to coupling opening 55 and extends in an axial direction of mixer element 38 , with a U-shaped redirecting section 63 and with a second linear segment 65 corresponds approximately to the design of first duct 64 according to the embodiment according to FIG. 2 . For this, a wall element 73 is formed in insert 62 that runs essentially parallel to longitudinal axis 72 of mixer 36 ′.
Thus a second duct 66 ′ of dynamic mixer 36 ′ is also furnished with a first segment 88 that is connected to coupling opening 57 . Segment 88 extends in the axial direction of mixing element 38 . At the end of this first segment 88 , is a U-arch-shaped redirecting section 89 that leads to a second linear segment 90 and from this, leads through an additional redirecting section 91 that is essentially a 90° arch and ends in inlet opening 70 . Redirecting section 89 , second linear segment 90 and additional redirecting section 91 together form a lengthening section lengthening the way from coupling opening 57 to inlet opening 70 . Two segments 88 and 90 extend parallel to each other, whereby their two parallel longitudinal axes run in a common radial level to longitudinal axis 72 . The special form of second duct 66 ′, which is essentially S-shaped, is achieved in interaction between housing 42 and a protruding wall element 92 of insertion 62 .
Duct 66 ′ is given a greater length and the flow resistance is increased because duct 66 ′ first extends in the direction of outlet opening 52 and afterwards is redirected, so that it then runs back in the direction of back end 48 of mixer 36 ′. Consequently, there is a reduction in the danger of contamination of the two paste-like compounds, which results from undesired mixing or recontamination of the two paste-like compounds through inlet openings 68 , and 70 in ducts 64 , and 66 ″ and may be further contaminated in the outlet supports. If there is a recontamination in these areas and thus a polymerization of the compounds, the residual material that may still be in the tubular bags can no longer be delivered, as mentioned above, due to the stoppage of the outlet supports.
The greater length of duct 66 ′ is however compensated by the design of duct 64 described above, so that the compounds arrive through ducts 64 and 66 ″ simultaneously via inlet openings 68 or 70 in mixer area 45 .
A further embodiment of a dynamic mixer 36 ″ is shown in FIG. 9 , as seen from its back end 48 . Tube-shaped section 44 of housing 42 and mixer element 38 included in it corresponds essentially to the form described in FIGS. 1-8 . The form of the ducts, which extend from coupling openings 55 and 57 to inlet openings 68 , and 70 , diverge in this embodiment.
For example, first duct, which extends between coupling opening 55 and inlet opening 68 is divided into two partial ducts 64 ′, and 64 ″, which extend in opposite directions in the form of an arch around longitudinal axis 72 . Both partial ducts 64 ′, and 64 ″ have a first segment that connects to coupling opening 55 . First segment extends about 45° around longitudinal axis 72 . At the end of this first segment is a U-arch-shaped redirecting section, which leads to a second arch-shaped segment that extends essentially in the axial direction underneath the first segment. The two segments of partial ducts 64 ′, and 64 ″ can then lead to a common inlet opening 68 or into two inlet openings separate from each other. The redirection between the first and second segments occurs at about 180°, so that the partial compound flows in partial ducts 64 ′, and 64 ″. These ducts 64 ′ and 64 ″ are at first directed in the form of an arch away from the coupling opening 55 and after the redirecting in a offset level are led back to inlet opening 68 or inlet openings, which are arranged in the vicinity of coupling opening 55 .
With this design partial ducts 64 ′, and 64 ″ are given a greater length, so that additional duct volume results. The additional duct volume must first be filled so that the compound can flow into inlet opening 68 . Both compounds enter therefore approximately at the same time in mixer area 45 .
Second duct 66 ″, which extends from coupling opening 57 to inlet opening 70 , also runs in the shape of an arch along longitudinal axis 72 . In the embodiment shown in FIG. 9 , the flowing compound is redirected in second duct 66 ″ by about 5° around longitudinal axis 72 . It is however also possible, to achieve other, in particular larger, redirections around longitudinal axis 72 . It is also still possible to also form second duct 66 ″ with two partial ducts that extend in the opposite direction in the form of an arch around longitudinal axis 72 .
The length of second duct 66 ″ is insignificantly greater as a result of the redirecting in second duct 66 ″, while the flow resistance in second duct 66 ″ however clearly increases. The danger of a recontamination is considerably reduced through this design.
Inlet openings 68 , and 70 of the two compounds advantageously lie nearly diametrically opposite one another in the embodiment shown in FIG. 9 . The path that a compound must cover before a recontamination can occur, exits from one inlet opening into the inlet opening of the other compound, which lies essentially opposite it, is consequently chosen to be as large as possible. The danger of recontamination is thus further reduced.
The designs of the first and second ducts shown in the examples can of course be combined with each other in any way desired. It is therefore possible to provide an arch-shaped redirecting of the first duct and an axial redirecting of the second duct. In the same way, an arch-shaped redirecting of the second duct can also be achieved with an axial redirecting of the first duct.
Accordingly, while at least one embodiment of the present invention has been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims. | A device for mixing two paste like compounds, such as a dental molding compound using a catalyst for the acceleration of polymerization. The housing has a mixing area with at least two inlet openings for the compounds and an outlet opening for the mixed compound. The device also has a mixing element that is disposed in the mixing area and propelled around a longitudinal axis. The housing has a coupling section that is situated in front of the mixing area with two coupling openings for connecting with two dispensing openings of a device for dispensing the two paste like compounds. The first and second ducts connect to the couplings via the coupling openings extending through the coupling section into the inlet openings for the mixing area. The two ducts are formed so that the first duct requires a greater time of entry of the compound into the mixing area than the time required for the second compound flowing through the second duct. | 1 |
This is a division of application Ser. No. 08/835,482 filed Apr. 8, 1997.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improvement in the treatment of Parkinson's disease and related disorders. More specifically, the present invention introduces novel formulations of the combination carbidopa and levodopa, the current mainstay of therapy.
2. Background and Prior Art
Parkinson's disease is associated with the depletion of dopamine from cells in the corpus striatum. Since dopamine does not cross the blood brain barrier and cannot therefore be used to treat Parkinson's disease, its immediate precursor, levodopa, is used instead because it penetrates the brain where it is decarboxylated to dopamine. But levodopa is also decarboxylated to dopamine in peripheral tissues and consequently only a small portion of administered levodopa is transported unchanged to the brain. This reaction can be blocked by carbidopa which inhibits decarboxylation of peripheral levodopa but cannot itself cross the blood brain barrier and has no effect on the metabolism of levodopa in the brain.
The combination of carbidopa and levodopa is considered to be the most effective treatment for symptoms of Parkinson's disease (The Medical Letter, 35:31-34, 1993). Nevertheless, certain limitations become apparent within two to five years of initiating combination therapy. As the disease progresses, the benefit from each dose becomes shorter (“the wearing off effect”) and some patients fluctuate unpredictably between mobility and immobility (“the on-off effect”). “On” periods are usually associated with high plasma levodopa concentrations and often include abnormal involuntary movements, i.e., dyskinesias. “Off” periods have been correlated with low plasma levodopa and bradykinetic episodes.
In an effort to reduce the occurrences of “wearing off” and “on-off” phenomena, a controlled release oral dosage combination was introduced with claims of slow and simultaneous release of carbidopa and levodopa from the formulation (U.S. Pat. No. 4,900,755 issued Feb. 13, 1990). Data from clinical trials cited in the patent indicate that effective anti-Parkinson effects were achieved with fewer daily doses of the controlled release form as compared with the conventional combination.
Nevertheless, there remains a significant flaw in the therapeutic application of controlled release carbidopa-levodopa; that is, the considerable delay in onset of action. Mean time to peak concentration in healthy elderly subjects was found to be two hours for controlled release carbidopa-levodopa and only 0.5 hours for the conventional form (Physicians Desk Ref., 47 th Ed., p. 976, 1993). A controlled release dosage form that could also provide rapid onset of action, at least equivalent to that of conventional carbidopa-levodopa would have an obvious clinical advantage over current therapy.
The strategy proposed in the present invention is to formulate oral dosage forms containing both immediate release carbidopa-levodopa and controlled release carbidopa-levodopa. Ingestion would provide rapid onset anti-Parkinson activity via the immediate release component followed by sustained therapeutic activity from the controlled release component.
SUMMARY OF THE INVENTION
It is the purpose and principal object of this invention to provide an improved method for the treatment of Parkinson's disease by using novel formulations of the combination carbidopa-levodopa which a) are effective in preventing the symptoms of Parkinson's disease and yet which b) act rapidly, avoiding significant onset delay common to the standard controlled release therapy.
DETAILED DESCRIPTION
The novel oral dosage formulations of the present invention each contain immediate release and controlled release components of the anti-Parkinson agents carbidopa (5-200 mg) and levodopa (25-600 mg). The conventional immediate release combination of carbidopa-levodopa reaches peak plasma concentrations in 30 minutes, whereas the onset of the controlled release component is two hours followed by prolonged release over a four- to six-hour period.
The usual daily therapeutic dose of levodopa, when administered with carbidopa, is 300 to 750 mg and the dose of carbidopa approximately 75 mg per day but the latter is apparently devoid of adverse effects even at doses of 400 mg per day (J. E. Ahlskog, Hosp. Form., 27:146, 1992). Although the optimum daily dosage of carbidopa-levodopa must ultimately be determined by titrating each patient, a preferred range for twice daily maintenance therapy may include immediate release of 10-25 mg carbidopa and 50-200 mg levodopa and sustained release of 25-75 mg carbidopa and 100-400 mg levodopa.
Specific examples of these formulations are cited below. The amount and excipients listed can be changed through methods known to those skilled in the preparation of immediate and sustained release dosage forms. Some of these methods are available in Remington's Pharmaceutical Sciences, 17 th Ed., 1985, a standard reference in the field.
EXAMPLE 1
A two compartment tablet consisting of a core layer of sustained release carbidopa-levodopa overcoated with a layer of immediate release carbidopa-levodopa. The core ingredients are blended separately (as are the outer layer ingredients), compressed to produce core tablets and then overcoated with the compressed outer layer blend using a suitable coating press.
Ingredient
Mg per Tablet
Outer Layer (Immediate Release)
Carbidopa
25.0
Levodopa
100.0
Microcrystalline Cellulose
224.0
Croscarmellose Sodium
15.0
Silicon Dioxide
3.0
Magnesium Stearate
3.0
Core Layer (Sustained Release)
Carbidopa
50.0
Levodopa
200.0
Methocel E4M Premium CR
80.0
Microcrystalline Cellulose
61.0
Croscarmellose Sodium
15.0
Silicon Dioxide
2.0
Magnesium Stearate
2.0
EXAMPLE 2
A bilayer or multilayer tablet consisting of one layer of sustained release carbidopa-levodopa either adjacent to a layer of immediate release carbidopa-levodopa or separated by an additional excipient layer. The ingredients from each layer are blended separately, then compressed to produce a layered tablet using a suitable layered press.
Ingredient
Mg per Tablet
Layer 1 (Immediate Release)
Carbidopa
12.5
Levodopa
50.0
Microcrystalline Cellulose
123.5
Silicon Dioxide
2.0
Magnesium Stearate
10.0
Layer 2 (Sustained Release)
Carbidopa
37.5
Levodopa
150.0
Methocel E4M Premium CR
80.0
Microcrystalline Cellulose
53.5
Silicon Dioxide
2.0
Magnesium Stearate
2.0
EXAMPLE 3
An oral dosage form, such as a capsule or compressed tablet, containing immediate and sustained release carbidopa-levodopa pellets prepared by the following methods:
1. Dissolve Povidone in isopropyl alcohol (10% w/w)
2. Disperse micronized carbidopa and levodopa in Povidone solution
3. Layer the slurry from step 2 onto sugar spheres to form core pellets using a fluid-bed with a Wurster air suspension coating column
4. Dissolve ethyl cellulose and polyethylene glycol 4000 in methylene chloride and methanol (4:1) mixture (5% w/w)
5. Coat pellets from step 3 with polymer solution from step 4 in a fluid-bed with a Wurster air suspension coating column.
Appropriate amounts of uncoated core pellets containing immediate release carbidopa-levodopa (step 3) and polymer coated pellets containing sustained release carbidopa-levodopa (step 5) are included in an oral dosage form to provide the desired ratio of immediate and sustained release carbidopa-levodopa.
Ingredient
Mg per Tablet
Uncoated Core Pellets
(Immediate Release)
Carbidopa
12.5
Levodopa
50.0
Povidone (K-30)
17.5
Sugar Spheres (35-40 Mesh)
20.0
Coated Pellets
(Sustained Release)
Core Pellet
94.0
Ethyl Cellulose
4.5
Polyethylene Glycol 4000
1.5 | An oral anti-Parkinson drug delivery system consisting of carbidopa and levodopa in immediate and sustained release compartments provides a significant clinical advantage over currently available carbidopa-levodopa preparations. | 0 |
RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/875,453, filed Jun. 24, 2004 and titled “Flash Memory,” which is a divisional of U.S. patent application Ser. No. 10/159,885 filed May 29, 2002, now U.S. Pat. No. 6,795,348 issued Sep. 21, 2004 and titled “Method and Apparatus for Erasing Flash Memory,” both of which are commonly assigned and incorporated by reference in their entirety herein.
TECHNICAL FIELD
[0002] The present invention relates in general to a method and apparatus for erasing of a non-volatile memory device and in particular to a method and apparatus for an erase operation of a memory array of a nonvolatile memory device that can reduce the number of trapped holes in the tunnel oxide of flash memory cells.
BACKGROUND
[0003] FIG. 1 illustrates a cross sectional view of a conventional flash memory cell 100 . Memory cell 100 includes a substrate 102 , a source 104 , a control gate 108 , a floating gate 106 electrically isolated by an insulating layer of silicon dioxide (SiO 2 ) 110 , and a drain 112 . Memory cell 100 is thus basically an n-channel transistor with the addition of a floating gate. Electrical access to floating gate 106 takes place only through a capacitor network of surrounding SiO 2 layers and source 104 , drain 112 , channel 105 , and control gate 108 . Any charge present on the floating gate 106 is retained due to the inherent Si—SiO 2 energy barrier height, leading to the non-volatile nature of the memory cell.
[0004] Programming a flash memory cell means that charge (i.e., electrons) is added to the floating gate 106 . A high drain to source bias voltage is applied, along with a high control gate voltage. The gate voltage inverts the channel, while the drain bias accelerates electrons towards the drain. In the process of crossing the channel, some electrons will experience a collision with the silicon lattice and become redirected towards the Si—SiO 2 interface. With the aid of the field produced by the gate voltage some of these electrons will travel across the oxide and become added to the floating gate. After programming is completed the electrons added to the floating gate increase the cell's threshold voltage. Programming is a selective operation, performed on each individual cell.
[0005] Reading a flash memory cell takes place as follows. For cells that have been programmed, the turn-on voltage V t of cells is increased by the increased charge on the floating gate. By applying a control gate voltage and monitoring the drain current, differences between cells with charge and cells without charge on their floating gates can be determined. A sense amplifier compares cell drain current with that of a reference cell (typically a flash cell which is programmed to the reference level during manufacturing test). An erased cell has more cell current than the reference cell and therefore is a logical “1,” while a programmed cell draws less current than the reference cell and is a logical “0.”
[0006] Erasing a flash cell means that electrons (charge) are removed from the floating gate 106 . Erasing flash memory is performed by applying electrical voltages to many cells at once so that the cells are erased in a “flash.” A typical erase operation in a flash memory may be performed by applying a positive voltage to the source 104 , a negative or a ground voltage to the control gate 108 , and holding substrate 102 of the memory cells at ground. The drain 112 is allowed to float. Under these conditions, a high electric field (8-10 MV/cm) is present between the floating gate and the source. The source junction experiences a gated-diode condition during erase and electrons that manage to tunnel through the first few angstroms of the SiO 2 are then swept into the source. After the erase has been completed, electrons have been removed from the floating gate, reducing the cell threshold voltage Vt. While programming is selective to each individual cell, erase is not, with many cells being erased simultaneously.
[0007] Stress Induced leakage current (SILC) in a flash memory occurs when there is tunneling from the floating gate through the insulating oxide surrounding it at abnormally low voltages. This can result from holes that become trapped in the tunnel oxide of the flash memory cells after the memory cell has been cycled through read, write and erase operations a number of times, i.e., “stressed,” and can severely degrade the performance of the memory. SILC presents a major challenge to designers and manufacturers of flash memory devices and will present even greater challenges as device size continues to be reduced and the insulating oxide surrounding the floating gate is made thinner.
[0008] Various solutions have been proposed to address the problem of SILC. For example, a triple well channel erase flash memory has been proposed in which a memory cell is fabricated inside a P-well that is, in turn, inside an N-well. Unfortunately, a triple well construction increases process complexity and memory area. Thus there is a need for a flash memory cell method and apparatus that reduces SILC as the device is cycled.
[0009] For the reasons stated above and for additional reasons stated hereinafter, which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for an improved method and apparatus for erasing flash memory. The above-mentioned problems of traditional flash memories and other problems are addressed by the present invention, at least in part, and will be understood by reading and studying the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram of a prior art flash memory cell.
[0011] FIG. 2 shows a simplified schematic of a flash memory of an embodiment of the present invention.
[0012] FIG. 3 is a graph showing an example of a sequence of pulses for a conventional source erase operation of a flash memory.
[0013] FIG. 4 is a graph showing the stress induced leakage current (SILC) from simulated application of successive erase-program cycles on an array of a flash memory cells.
[0014] FIG. 5 is a graph showing a prior art example of a sequence of pulses for an erase operation of a flash memory built inside a triple well showing an extra step of a channel erase.
[0015] FIG. 6 is a graph showing an example of a sequence of pulses for an erase operation of a flash memory to neutralize trapped holes, according to the present invention.
[0016] FIG. 7A is a graph showing an example of a sequence of pulses for an erase operation of a flash memory to neutralize trapped holes that does not require a higher negative voltage source, according to the present invention.
[0017] FIG. 7B is a graph showing an additional example of a sequence of pulses for an erase operation of a flash memory, according to the present invention.
[0018] FIG. 7C is a graph showing an additional example of a sequence of pulses for an erase operation of a flash memory
[0019] FIG. 8 is a simplified schematic of a flash memory with P channel wordline drivers.
[0020] FIG. 9 is a side cut view of a P channel transistor showing components relevant to parasitic capacitances.
[0021] Although, various embodiments have been illustrated using particular electronic components it will be understood by those of ordinary skill in the art that other circuit elements could be used to implement the invention and that the present invention is not limited to the arrangement of circuit elements disclosed. Moreover, it will also be understood in the art that the present invention could be applied to a erasing memory in devices other than flash memory circuits. Therefore, the present invention is not limited to a method and apparatus for erasing flash memory.
DETAILED DESCRIPTION
[0022] FIG. 1 shows a conventional floating gate memory cell 100 including an n+ type source 104 , a p type channel 105 , an n+ type drain 112 , and a p type substrate 102 . A floating gate 106 is sandwiched between an insulating dielectric layer 110 and thin tunnel oxide 114 over channel 105 . Floating gate 106 is the memory storage element in a flash memory and is electrically insulated from other elements of the memory cell. Control gate 108 is located on top of the insulating dielectric 110 and is positioned over floating gate 106 .
[0023] FIG. 2 shows a simplified schematic of a flash memory 200 of the present invention. Flash memory 200 includes a control circuit 202 for controlling the operations of the memory such as reading, writing and erasing, column decoder 204 , sense amplifiers/bitline drivers 206 , column multiplexer 218 , wordlines 212 , memory array 210 , bitlines 208 , and row decoder 214 with wordline drivers 216 .
[0024] An example of the sequence of voltage pulses for a conventional flash memory erase operation is illustrated in FIG. 3 . As can be seen, the source-drain voltage is increased to about 5 to 6 V while at the same time the gate-substrate voltage is decreased to about −10 V. This potential difference is held for about 10 ms and then abruptly discharged to zero. The combination of voltage values induces an electric field across tunnel oxide 114 between floating gate 106 and source 104 , resulting in tunneling that drives electrons off floating gate 106 and effectively erases the memory cell. At the same time, however, the reverse bias on the junction between body 102 and source 104 injects holes into tunnel oxide 114 and some of these holes become trapped in tunnel oxide 114 . Some of the trapped holes remain unneutralized at the end of an erase operation and/or after subsequent programming. The holes trapped in tunnel oxide 114 may effectively reduce the barrier for low-field electron injection from floating gate 106 into tunnel oxide 114 , thus causing SILC and SILC-related charge loss or gain for the flash cell.
[0025] An example of SILC in an array of 4096 flash memory cells having polysilicon 1 gates, connected in parallel is shown in FIG. 4 . Curve 201 shows the tunnel I-V characteristics (IP 1 vs. VP 1 ) for a fresh, unstressed array in a voltage sweep (V-sweep) of the polysilicon 1 gate of the flash memory cells of the array at negative voltage with the substrate and source at ground. As curve 201 demonstrates, leakage current does not begin in a fresh, unstressed array until there is a gate-substrate potential of −10V. Curve 202 shows the result of stressing, i.e., application of successive erase-program cycles on an array of floating gate cells. In this example, stressing is simulated by a constant voltage stress in which the gate-substrate is held at −10V and the source-substrate is held at 6 V, a high reverse junction bias, for 200 seconds. Curve 202 shows that onset of leakage current will occur at an abnormally low voltage of about −7V, after stressing the array. Curves 203 , 204 and 205 show successive V-sweeps where the stress voltage has been removed, the gate voltage successively swept to further negative values, and the substrate and source are held at ground. Curves 203 , 204 and 205 demonstrate that the SILC is suppressed and the onset of tunneling is advantageously shifted to a higher negative gate-substrate voltage after the array has been subjected to gate V-sweeps at zero voltage across the source-substrate junction. In each successive V-sweep curve, the onset of tunneling is pushed back to a higher voltage, and thus, SILC is more effectively suppressed.
[0026] Based on the results above, a qualitative model can be designed for the creation and suppression of SILC. SILC is created and/or enhanced when the gated source diode is subjected to high reverse bias and there is low tunneling current across the gate oxide. These conditions are favorable for hole generation and injection into the gate oxide. On the other hand, SILC may be suppressed when the gated source diode is subjected to a high electron tunneling current across the gate oxide at zero or low reverse current bias for the source junction.
[0027] Various approaches may be suggested based on the above model. One possible way to neutralize holes trapped in the tunnel oxide during an erase pulse is to apply a condition of uniform tunneling at high negative gate and low or zero positive source voltage at the end of the erase pulse. This Prior Art approach is illustrated in FIG. 5 . As can be seen, two positive 6 V pulses of about 3 ms are applied to the source (Vs) over a 10 ms erase period. A positive 6 V pulse is also applied to the substrate (Vsub) concurrent with the second positive source pulse. The gate-substrate voltage (VG) is held at negative 10V for the entire 10 ms period. Application of a positive voltage pulse on the substrate allows the erase operation to be done in a single step channel erase. However, this also requires the added complexity of building the memory array inside a triple well.
[0028] A channel erase condition may also be realized by applying an additional voltage pulse of higher negative value to the gate (wordlines) while the source is biased at the same potential as the substrate (ground), after the regular erase pulse. This procedure is illustrated in FIG. 6 . As can be seen, a positive pulse of about 5V is applied between source and substrate for a period of about 10 ms. At the same time, the gate substrate voltage is taken to negative 10V. At the end of the 10 ms period when the source-substrate voltage is reduced to zero, the voltage between the gate and substrate is increased to negative 15 volts and held at that potential for an additional 5 ms. While this approach can be implemented on a flash memory without a triple well surrounding the array, it has the disadvantage of requiring extra erase time and the supply of a higher negative voltage.
[0029] A more convenient approach, illustrated in FIG. 7A , is to discharge the source toward the substrate potential (or other area of common voltage) at the end of the regular erase pulse, while the negative voltage to the control gate (wordlines) is maintained. As can be seen, a positive pulse of about 5V is applied between source and substrate for about 10 ms. At the same time, the gate-substrate voltage is brought to negative 10 V and held for the 10 ms period. At the end of the 10 ms period, the source-substrate potential is discharged rapidly, in a fraction of a millisecond, but the discharge of negative gate-substrate voltage is delayed for a time in the range of 1-100 ms. During this interval the negative voltage is allowed to float and any regulation of the voltage supplied by the negative pump is disabled. The excess negative wordline voltage thus created will be called “negative gate bootstrap” in the following paragraphs. In this case, the rapidly falling source-substrate voltage will couple to the floating gates and onto the control gates (wordlines), in effect, pushing them more negative below the voltage supplied by the negative pump. Thus, the desired condition of relatively high negative voltage for the wordlines and floating gates along with zero voltage source to substrate bias will be realized on a transient basis without the need for generating a higher negative voltage, or for adding extra time to the erase operation.
[0030] FIG. 7A depicts the expected behavior for the gate voltage VGSub if the forced discharge of the source VSSub takes place in a time of a fraction of 1 millisecond or faster. The amount of the excess negative gate voltage and its gradual decrease on the waveform for VGSub after the discharge of the source (VSSub) and before the active discharge of the gate represent the capacitive coupling of the VSSub transient and the subsequent natural decay for the voltage on the control gate (wordline) when left floating. The rate of decay depends on the aggregate leakage of the gates, which in turn is determined by the structure and layout of the transistors in the periphery of the memory array which drive the cell control gates, or wordlines. Note that any leakage of the control gates through tunnel oxide as represented in FIG. 4 , would not affect the rate of VGSub decay in FIG. 7A since it would not contribute leakage to the control gate.
[0031] To the extent that the relevant wordline drivers in the periphery are devised to have low parasitic capacitance compared to the capacitance between the source and the control gate (wordline) of the memory cells on each row, and low leakage, the excess negative voltage VGSub can be larger and hold for a longer time without substantial decay. In the limit of negligible parasitic capacitance and fast discharging of VSSub, the maximum amplitude of excess negative gate voltage would be equal in absolute value to the amplitude of the source voltage. On the other hand, if the leakage of the wordline drivers were ideally zero, the excess negative voltage on the gate would be assumed to hold indefinitely with no decay as long as it is not forcefully discharged to ground potential by external circuitry.
[0032] Thus, if the design of the memory circuit fulfills the three conditions described above, i.e.,
1. fast—shorter than 1 ms—discharging for VSSub, 2. low parasitic capacitance for wordline drivers—in the order of 1-10 fF or below, and 3. low drain leakage for the same wordline drivers—in the order of pA,
then each erase pulse represented by the waveforms in FIG. 7A can be regarded as a succession of two erase mechanisms: source erase and channel erase, and the relative duration for each mechanism can be adjusted by the designer to fit the specification for a particular memory design.
[0036] If a particular memory application requires fast erase and not very stringent retention limits for each particular cell, then such a memory can be designed with a short channel erase time compared to the source erase time. Source erase is inherently more efficient than channel erase at equal applied voltage due to a better coupling factor for the applied voltage. Thus such a design will result in a shorter total erase time, but also in poorer memory retention since the holes generated by the source erase mechanism will have a shorter time to neutralize in the subsequent channel erase part of the erase pulse. Such a design may benefit large density data storage memory in which fast erase/program rates are sought, and data correction provisions like storage of additional parity codes, can be used to correct an inherently weak retention.
[0037] At the other end of the spectrum, if a particular memory requires very good retention but does not pose a stringent limit on the erase time, the time for source erase within an erase pulse can be reduced to as little as 1 ms or less, followed by a long time for channel erase of up to 100 ms or more. In this way, most of the electrons stored on the floating gate of each cell will tunnel out during the channel erase part of the erase pulses, and the hole trapping phenomenon associated with source erase will effectively be avoided at the expense of a longer erase time. This approach may be useful in code storage applications where erasure and reprogramming operations occur rarely and do not require fast time rates, but the preservation of stored data over long periods of time is critical.
[0038] Negative gate erase can be implemented in flash memory by using a row decoder that includes either all P channel wordline driver transistors, or CMOS drivers with N channel pull-down transistors in triple well. In the following, a possible implementation of “negative gate bootstrap” for the memory with P channel wordline drivers will be described. The same idea with small changes may be applied to the memory with triple-well N channel wordline drivers.
[0039] FIG. 8 depicts a design with all P channel driver circuits in the row decoder for a memory device such as memory 200 of FIG. 2 , including pull-up transistor 702 and pull-down transistor 704 . The circuit drives a wordline 703 coupled to memory cells 706 of the memory device. The voltages VH and VL represent respectively the “high” and “low” voltage supply rails. Their absolute values are specific to each memory function like read, program and erase, and their relative difference VH−VL is always positive. The values for the pull-up and pull-down signals, labeled respectively A and B, are specific to the memory function and to the selected or unselected condition of the particular row.
[0040] In particular, all rows of a memory block are selected in the erase function, and thus the signals A and B will assume the same values for all wordlines in the block to be erased. A possible set of such values is:
VH=3.3 V; VL=−10 V; A=3.3 V; B=−10 V
[0041] This would result in a wordline voltage of −8.5 V to −9 V depending on the threshold voltage of the P channel transistors.
[0042] In order to implement the above idea of a “negative bootstrap” for the wordlines in erase mode, the variables VH, VL, A, B in the schematic of FIG. 8 may be set to follow the dynamics in FIG. 7B or FIG. 7C below.
[0043] Capacitive components C ws and C wch in the flash memory array of FIG. 8 represent the capacitance between a wordline and the source of all the memory cells, and respectively, the capacitance between a wordline and the channel of all the memory cells. During an erase, the channel is in accumulation state and thus electrically connected to the common substrate for all the memory cells in a block.
[0044] The falling edge of the source pulse VSSub in FIGS. 7A, 7B and 7 C induces the negative bootstrap (negative overvoltage) on VGSub by capacitive coupling through C ws . If we ignore the parasitic capacitances of the driver transistors, the magnitude of the negative voltage overshoot can be calculated as:
|delta(VGSub)|=VSSub* C ws /( C ws +C wch ).
[0045] Thus, the negative bootstrap will improve as C ws is increased and/or C wch is decreased.
[0046] If erase is implemented as in FIG. 7B , the parasitic capacitance components C gd and C j for all the P channel transistors in the row decoder in FIG. 8 need to be reduced in order to enhance the capacitive coupling of the wordline in the “negative bootstrap” effect. The gate-to-drain parasitic capacitance C gd has a component of overlap of drain diffusion by the gate and another related to the fringing field between drain surface and gate stack sidewall. Both of these components can be reduced with the help of an oxide spacer located between the gate sidewall and the adjoining drain diffusion. A low drain-to-body junction capacitance C j can be obtained by using low doping concentration for the drain diffusion and/or low doping concentration in the channel (N well).
[0047] On the other hand, the dynamics of FIG. 7C can be implemented for erase. Voltages VH and A are reduced in FIG. 7C at the end of the VSSub pulse. In this case all the parasitic capacitances in FIG. 8 with the exception of C gd for pull-down transistor 704 (capacitive coupling between wordline and the signal B) are in fact aiding the coupling for “negative bootstrap” and need not be minimized. The coupling for negative bootstrap can be further increased in such a case by providing an extra capacitor 710 between the VH supply and the wordline in the circuit as shown in FIG. 8 .
[0048] The retention of excess negative voltage VGSub during the channel erase part of the erase pulse is adversely impacted by the drain-to-body leakage of the P channel transistors driving the wordline. This leakage is represented in FIG. 8 by a variable current generator 708 between the source/drain diffusion and the body of the transistor (N well). In practice, an important component of such leakage is known as gate-induced drain leakage (GIDL) and is strongly increasing with the voltage drop between gate and drain. Thus, GIDL appears of concern only for the pull-up P channel transistor 702 in FIG. 8 in which the gate-to-drain voltage drop is large in erase. Such voltage drop is smaller for the erase dynamics according to FIG. 7C , this scheme appears to offer advantages in both coupling and retention for the excess negative gate voltage.
[0049] In terms of transistor structure, the features listed above for reducing the parasitic gate-to-drain capacitance like a gate spacer and/or low doping concentration for the drain diffusion are also conducive to reduced GIDL. FIG. 9 depicts an exemplary P channel MOSFET structure 802 with all the components relevant to the parasitic capacitances C gd , C j shown. In order to minimize parasitic capacitance and decrease GIDL the wordline drive transistors should be fabricated so that lightly doped drain (LDD) regions are present as shown in FIG. 9 so as to minimize parasitic capacitance. In addition a low k dielectric SiO2 gate spacer may be added to reduce parasitic capacitance. Other techniques may likewise be applied to reduce parasitic capacitance as would be familiar to those of ordinary skill in the art.
[0050] Thus, as can be seen from the foregoing, memory devices can be designed to comply with a fixed specified erase time and retention performance. On the other hand, a new kind of memory can be designed in which the respective durations of source erase and channel erase can be made adjustable by way of algorithm codes stored in a special function register or other nonvolatile memory dedicated to such control parameters. In this way, the manufacturer can build a generic memory part and then adjust the duration for either erase mechanism at the time of manufacturing test, or else let the user make such adjustment before or after the device has been assembled in the system for the end use.
CONCLUSION
[0051] A method and apparatus for erasing flash memory has been described. The method includes supplying a negative voltage pulse to the control gate of a memory cell for an erase period, supplying a positive voltage pulse to the source of the memory cell for a period that is shorter in duration than the erase period; and discharging the positive voltage pulse at the end of the second period wherein discharging the positive voltage pulse at the end of the second period effectively increases the magnitude of the negative voltage pulse.
[0052] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiment shown. This application is intended to cover any adaptations or variations of the present invention. Therefore, it is manifestly intended that this invention be limited only by the claims and the equivalents thereof. | Flash memory supporting methods for erasing memory cells using a decrease in magnitude of a source voltage of a first polarity to increase the magnitude of a control gate voltage of a second polarity during an erase period. | 6 |
RELATED APPLICATION DATA
The present application is related to "Magnetic Fluid Thin Film Displays, Monochromatic Light Switch and Tunable Wavelength Filter," Hong, Chin-Yih Rex; Horng, Herng-Er; Yang, Hong-Chang, and Yeung, Wai Bong, Ser. No. 08/835,108, filed concurrently herewith.
FIELD OF THE INVENTION
The present invention comprises methods for producing homogeneous magnetic fluids capable of forming ordered crystalline structures. The invention also comprises methods for generating ordered structures in thin films of such fluids under the influence of externally applied magnetic fields, methods for controlling the structures generated in these films, and magnetic-optical devices based on these ordered structures. These devices include color displays, monochromatic light switches, and tunable wavelength filters.
BACKGROUND
Ferrofluids are a type of magnetic fluid that typically consist of colloidal magnetic particles such as magnetite or manganese-zinc ferrites, dispersed with the aid of surfactants in a continuous carrier phase. The average diameter of the dispersed magnetic particles ranges between 5-10 nm. Each particle has a constant magnetic dipole moment proportional to its size that can align with an external magnetic field.
Ferrofluids experience body forces in homogeneous magnetic fields, that allow their position to be manipulated, and thus enable the construction of devices such as rotary seals, bearings, and related mechanical devices. Ferrofluids also have been used to construct display devices such as those disclosed in U.S. Pat. Nos. 3,648,269 and 3,972,595, that use a magnetic field to capture an opaque magnetic fluid in a predetermined optical pattern. These types of devices usually operate by having an opaque magnetic fluid displace a transparent fluid and thereby produce optical contrast. Such display devices, however, do not generate ordered crystalline structures in the magnetic fluid, and are incapable of generating anything other than a monochromatic image.
Two general methods for producing ferrofluids have been used in the prior art. The first method reduces a magnetic powder to a colloidal particle size by ball-mill grinding in the presence of a liquid carrier and a grinding aid which also serves as a dispersing agent. This approach is exemplified in U.S. Pat. Nos. 3,215,572 and 3,917,538. The second approach is a chemical precipitation technique as exemplified in U.S. Pat. No. 4,019,994. Both of these techniques suffer from the disadvantage that there is heterogeneity in the size distribution of the resulting magnetic particles, the composition of these particles, and/or the interaction forces between the particles. This heterogeneity may produce deleterious effects on the ability of a ferrofluid to form ordered structures under the influence of a magnetic field.
Pattern forming systems of magnetic fluid films under the influence of external magnetic fields have recently attracted much interest. For these studies, a variety of different types of magnetic fluids have been used. For example, the aggregation process and one-dimensional patterns formed in suspensions of latex or polystyrene particles loaded with iron oxide grains under the influence of parallel fields have been studied by M. Fermigier and A. P. Gast, J. Colloidal Interface Sci. 154, 522 (1992), and D. Wirtz and M. Fermigier, Phys. Rev. Lett. 72, 2294 (1994). Quasi two dimensional periodic lattices have been reported to be formed in a phase separated magnetic fluid thin film under the influence of a perpendicular magnetic field. Wang et al., Phys. Rev. Lett. 72, 1929 (1994). FIG. 1 of this paper, however, shows that the resulting structure is disordered. Other investigators have generated more highly ordered two dimensional lattices in thin films of magnetic fluid emulsions or magnetic fluids containing non-magnetic spheres using perpendicular magnetic fields. However, these lattices tend to solidify and therefore are not suitable for applications requiring rapid interconversion between crystalline and amorphous states. See, e.g., Liu et al., Phys. Rev. Lett. 74, 2828 (1995), Skjeltorp, Phys. Rev. Lett. 51, 2306 (1983). Thus there is a recognized need in the art for ferrofluidic compositions that could be used to generate liquid-crystal devices that could be switched by small magnetic fields. See, e.g., da Silva and Neto, Phys. Rev. E. 48, 4483 (1993).
If a ferrofluid composition capable of reversibly forming ordered one dimensional structures or crystalline two dimensional lattices in a thin film under the influence of an external magnetic field could be manufactured, it would be useful for constructing a variety of new and useful liquid-crystal magneto-optical devices. For these reasons, a method is needed for generating homogeneous ferrofluidic compositions capable of reversibly forming ordered one dimensional structures or crystalline two dimensional lattices in a thin film under the influence of an external magnetic field. Also needed is a simple method for determining whether a thin film of a ferrofluidic composition is capable of generating well-ordered one dimensional structures or two dimensional lattices under the influence of external magnetic fields. Finally, it would be desirable to generate magneto-optical devices based on the ordered structures created in thin films of ferrofluidic compositions in response to external magnetic fields. Because the utility of such devices would be enhanced by developing methods for controlling the ordered structures formed in magnetic thin films of ferrofluids under the influence of external magnetic fields, methods for controlling the ordered structures so formed also are needed.
SUMMARY OF THE INVENTION
The present invention is directed to methods for generating homogeneous ferrofluidic compositions that are capable of forming ordered structures when a thin film of the fluid is subjected to an external magnetic field, as well as compositions synthesized according to this method. The method is based on an optimized co-precipitation technique. The invention also provides for methods of generating ordered one dimensional structures or two dimensional lattices in thin films of these ferrofluidic compositions in response to externally applied magnetic fields, as well as methods for determining the ability of a homogeneous magnetic field to form ordered structures. The invention also is directed to the ordered arrays formed in thin films of the homogeneous ferrofluidic compositions upon exposure to an external magnetic field. Also provided are methods for controlling the characteristic spacings of the one dimensional structures or two dimensional lattices by varying parameters such as the strength of the applied magnetic field, the orientation of the field to the film, wherein the angle between the external magnetic field and the plane of the film is 0° to 90°, the rate of change of magnetic field strength, the film thickness, the concentration of magnetic particles in the ferrofluidic composition, or the temperature of the composition. Further, the invention provides for liquid-crystal magnetic-optical devices based on ordered structures created in thin films of ferrofluids and the ability to control the spacings of these structures. These devices include: a light diffraction color display, a monochromatic light diffraction switch that can be turned on or off, a tunable light diffraction wavelength filter, a second type of light diffraction color display that combines the technologies of the first light diffraction color display and the monochromatic light diffraction switch, and a light double refraction color display comprising the magnetic fluid thin film of the present invention and polarizers.
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The file of this patent contains at least one drawing executed in color. Copies of this patent with color drawing(s) will be provided by the Patent and Trademark Office upon request and payment of the necessary fee.
FIG. 1 is a flow chart diagram of the steps for preparation of a homogeneous ferrofluid capable of forming ordered one dimensional structures or two dimensional lattices when a thin film of the fluid is subjected to an external magnetic field.
FIG. 2 illustrates a setup for measuring the properties of ferrofluidic thin films under externally applied magnetic fields.
FIG. 3 illustrates two-dimensional hexagonal arrays with particle columns occupying lattice vertices generated in a homogeneous ferrofluidic thin film in response to an externally applied magnetic field oriented perpendicularly to the plane of the film.
FIG. 4 shows two-dimensional hexagonal arrays formed in films with different thicknesses in response to a perpendicular, 100 Oe magnetic field.
FIG. 5 is a graph showing the relation of the distance between particle columns in two-dimensional hexagonal arrays to magnetic field strength and film thickness.
FIG. 6 is a graph showing the relation of the distance between particle columns in two-dimensional hexagonal arrays to the magnetic field strength and the rate of change of magnetic field strength.
FIG. 7 is a graph relating the distance between particle columns in two-dimensional hexagonal arrays to the magnetic field strength and the volume fraction ratio between the magnetic particle and liquid carrier components of the ferrofluid.
FIG. 8 illustrates the relationship between the periodic spacing of particle chains formed in a homogeneous ferrofluidic thin film and the strength of an external magnetic field that is parallel to the plane of the film.
FIG. 9 illustrates the relationship between the periodic spacing of particle chains formed in a homogeneous ferrofluidic thin film exposed to a parallel external magnetic field as a function of film thickness.
FIG. 10 illustrates a setup used for demonstrating light diffraction and double refraction phenomena generated by ordered structures in homogeneous ferrofluidic thin films.
FIG. 11 shows a spectrum of colors produced by a magneto-optical device in which the thickness of the homogeneous ferrofluidic thin film varies from about 2 to 10 μm. ##EQU1##
FIG. 12 shows different colors produced by a magneto-optical device comprising a homogeneous ferrofluidic thin film as the externally applied magnetic field strength is varied.
FIG. 13 illustrates the cross-section of a homogeneous ferrofluidic thin film for a first type of light diffraction display device.
FIG. 14 illustrates the design of an individual pixel element comprising a homogeneous ferrofluidic thin film, a means for generating a magnetic field, and a means for controlling the strength of the field.
FIG. 15 illustrates a cross section of a homogeneous ferrofluidic thin film for a double refraction display device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The chemical synthesis of magnetite (Fe 3 O 4 ) by co-precipitation of FeSO 4 and FeCl 3 in the presence of NaOH is based on a reaction proposed by W. C. Elmore in 1938. This co-precipitation reaction has been used to generate ferrofluids (also referred to as "magnetic fluids") in which the magnetite particles are coated with a surfactant and dispersed in a continuous phase (i.e., the particles are dispersed in a liquid that is not an emulsion). See, e.g., Fertman, V. E., "Magnetic Fluids Guide Book: Properties and Application," Hemisphere Publishing Corporation, 1989, ISBN-0-89116-956-3 at page 14. While such materials have proved extremely useful for the construction of various mechanical and display devices, they have not been amenable to forming ordered structures in thin films. Ordered structures are regular, periodic arrays of objects, that interact with electromagnetic radiation (e.g., visible light) to generate physical phenomena such as diffraction or polarization. These structures may be ordered in two dimensions (e.g., x and y), or one dimension (e.g., x). The former structures are sometimes also referred to as lattices, crystalline arrays, or 2-dimensional crystals. By carefully tuning the parameters of the co-precipitation reaction and subsequent coating and dispersing steps, we have synthesized improved ferrofluidic compositions capable of reversibly forming ordered structures in thin films under the influence of external magnetic fields.
While not wishing to be bound by any particular theory, it seems likely that improvements in the homogeneity of particle size distribution and/or interaction forces between the particles might be responsible for the ability of these ferrofluidic compositions to form ordered structures. Improvements in interaction force homogeneity in the ferrofluidic compositions of the instant invention may reflect reduced contamination of the compositions by Fe 2 O 3 and/or water.
According to the methods of the present invention, a composite material comprising ultra-fine magnetic particles uniformly dispersed in a continuous liquid phase is prepared by a co-precipitation technique whose controlling parameters were carefully tuned. The magnetic particles are Fe 3 O 4 (magnetite) and result from a chemical reaction between a mixture of FeSO 4 and FeCl 3 and alkali such as NaOH, Fe(OH) 2 , or Fe(OH) 3 . The particles are coated with a layer of surfactant to prevent agglomeration, and are dispersed throughout a continuous liquid carrier phase to form a homogeneous magnetic fluid. FIG. 1 shows a flow chart diagram of the steps used to prepare a homogeneous magnetic fluid according to the present invention.
The general procedure used involves making an aqueous solution of FeSO 4 and FeCl 3 . The temperature of the solution is maintained at 80° C. and is continuously stirred while a sufficient amount of a hydroxide containing base solution such as NaOH, Fe(OH) 2 , or Fe(OH) 3 is rapidly added to keep the pH of the solution between approximately 11 and 11.5. It is important that not more than about 2 minutes elapse between the start of the base addition, and the attainment of the target pH value. The co-precipitation of Fe 3 O 4 occurs over about a 20 minute time period. The formula for this reaction is as follows:
8NaOH+FeSO.sub.4 +2FeCl.sub.3 →Fe.sub.3 O.sub.4 ↓+Na.sub.2 SO.sub.4 +6NaCl+4H.sub.2 O
After about 20 minutes, a surfactant such as oleic acid is added to the solution out of which the Fe 3 O 4 has precipitated. This serves to coat the Fe 3 O 4 particles. If the surfactant added is oleic acid, the pH value drops substantially at first, and an additional amount of base solution is added to keep the pH at a preferred range from about 9.5 to about 10 during the coating process. During the coating process, the temperature of the reaction is maintained at 80° C. This process takes around 30 minutes. At the end of this step, the reaction mix separates into three phases. Prior to proceeding to the next step, the upper layer is removed and discarded, and the middle and bottom layers are retained for use in the next step of the process. The formula of the chemical reactions that occur during the coating process are as follows when oleic acid is used as the surfactant and NaOH is used as the base:
CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COOH+Na.sup.+ OH.sup.- →CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COO.sup.- Na.sup.+ +H.sub.2 O 1.
Fe.sub.3 O.sub.4 +CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COO.sup.- Na.sup.+ →Fe.sub.3 O.sub.4. CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COO.sup.- Na.sup.+ ! 2.
After the coating process has completed (around 30 minutes), an acidification step is carried out to protonate the carboxylate group and thereby replace the Na + counterion with a proton. This is achieved by adding a sufficient amount of an acid such as HCl to the reaction mix as it is stirred to bring to the pH of the mixture down to a range of from around 0 to around 1. This step is carried out at room temperature (from about 20° C. to about 25° C.). The mix is stirred for approximately 20 minutes. During this time, magnetic particles coated with surfactant begin to coagulate. At the end of approximately 20 minutes, the mix phase separates into two layers. The top phase is removed, and the acidification step may be repeated as before an additional two or three times. At the end of each acidification step cycle, the top phase is removed prior to repeating this step. When the top phase no longer contains dark particulate material, the next step may be performed. The formula of the chemical reactions occurring during this replacement step is as follows when HCl is used as the acid:
Fe.sub.3 O.sub.4. CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COO.sup.- Na.sup.+ !+H.sup.+ Cl.sup.- →Fe.sub.3 O.sub.4. CH.sub.3 (CH.sub.2).sub.7 CH═CH(CH.sub.2).sub.7 COO.sup.31 H.sup.+ !+Na.sup.+ Cl.sup.-
The next step is decantation. During this step, de-ionized water is added to remove remaining counter ions such as HCl and NaCl from the surfactant-coated Fe 3 O 4 product. A sufficient amount of de-ionized water at 65° C. is added to the coated Fe 3 O 4 to bring the pH of the suspension to a value between around 4.7 to 5.0. The suspension is stirred as the water is added. After a sufficient amount of de-ionized water has been added, the stirring is stopped and the suspension is allowed to settle. The water is decanted away from the settled Fe 3 O 4 and the product is washed.
Washing is achieved by adding a liquid used as a carrier (e.g., kerosene) to the settled Fe 3 O 4 in a ratio of approximately 1.1 milliliter of kerosene per gram of coated Fe 3 O 4 . The two components are stirred until the solid Fe 3 O 4 is completely suspended in the carrier. This suspension is placed in a centrifuge tube and subjected to a short, low-speed spin carried out at room temperature. We have found that a 10 minute spin at a relative centrifugal force equivalent to about 500×g works well when kerosene is used as the carrier. When the sample is removed from the centrifuge, it will have separated into two phases. The top phase is a dark-colored liquid that contains salt residues and large particles, while the lower phase is a solid that contains magnetic particles coated with surfactant. The top phase is removed, and the coated magnetic particles are dehydrated as completely as is practicable.
We have found that suitable dehydration can be achieved by suspending the particles in acetone, pelleting them with a 30 minute centrifugation at 1800×g, removing the acetone, and drying the particles for 8 to 12 hours in a 65° C. oven. After the particles have been dehydrated, they are dispersed in the carrier, and the fluid is subjected to another short, low-speed spin in a centrifuge. This spin pellets larger or aggregated particles. The liquid sitting above any pellet that may be formed in this spin is the homogeneous magnetic fluid of the present invention. The concentration of magnetic particles in the fluid may be increased by setting the fluid in a 65° C. oven for 8 to 12 hours to evaporate a portion of the carrier.
In addition to the kerosene and oleic acid combination described above, other pairs of carriers and surfactants may be used to generate the compositions of the present invention that are capable of forming ordered structures in thin films. Table 1 sets out representative combinations. In this table, any of the carriers listed in a cell may be used with any of the surfactants listed in the cell in the same row of the table.
TABLE 1______________________________________Carrier/Surfactant Combinations Useful for Generating HomogeneousFe.sub.3 O.sub.4 Magnetic FluidsCarrier Surfactant______________________________________1. kerosene 1. oleic acid2. cyclohexane (C.sub.6 H.sub.12) 2. linoleic acid3. n-octane (C.sub.8 H.sub.18) 3. olive oil, a mixture of:4. n-dodecane (C.sub.12 H.sub.26) ˜9% CH.sub.3 (CH.sub.2).sub.14 COOH,5. n-tetradecane (C.sub.14 H.sub.30) ˜2% CH.sub.3 (CH.sub.2).sub.16 COOH,6. n-hexadecane (C.sub.16 H.sub.34) ˜80% oleic acid,7. n-octadecane (C.sub.18 H.sub.38) ˜10% CH.sub.3 (CH.sub.2).sub.4 CH═CH--CH.sub.2 --8. n-eicosane (C.sub.20 H.sub.42) CH═CH--(CH.sub.2).sub.7 --COOH 4. R(COO)!.sub.2 Zn (where R═CH.sub.3 (CH.sub.2).sub.n, and 4 ≦ n ≦ 5) 5. erucic acidperfluoroeicosane (C.sub.20 F.sub.42) 1. oleic acid 2. perfluoropolyether acid CF.sub.3 CF.sub.2 CF.sub.2 OCF(CF.sub.3)!.sub.5 COOHgas oil, C.sub.12 and above hydrocarbon 1. oleic acid 2. olive oil 3. R(COO)!.sub.2 Zn(where R═CH.sub.3 (CH.sub.2).sub.n, and 4 ≦ n ≦ 5)perfluoro kerosene 1. perfluoropolyether acid 2. oleic acid 3. olive oil2-methoxyethyl ether mixture of R--O--R' (where R or R'═CH.sub.3 (CH.sub.2).sub.n, and 4 ≦ n ≦ 5) and R need not equal R'______________________________________
Characterization of the homogeneous magnetic fluid
Based on the procedure outlined above, a homogeneous magnetic fluid is prepared. X-ray diffraction patterns of the sample can be used to verify the single phase fcc spinel structure expected for an Fe 3 O 4 sample. The X-ray diffraction data can be compared to a standard obtained from the International Center for Diffraction Data compiled by the Joint Committee on Powder Diffraction Standards. The magnetization of the sample is measured using a vibration sample magnetometer such as a VSM Controller Model 4500 available from EG&G Princeton Applied Research. The particle size of the sample is determined from the magnetization, applied field data (M-H data) by fitting it to the Langevin function L(α)=M/M s =(coth α-1/α), where α=M s VH/kT, M is the magnetization of the sample at an applied magnetic field strength, H, M s is the saturated magnetization of the sample, and V is the volume of a particle. Thus, because temperature, M, M s , k and H are known, V can be solved for and the radius of the particle determined. The Langevin function assumes: (1) a uniform particle size; and (2) independent particle behavior. In a magnetic fluid, the particle size may be described by a normal distribution, and interactions between particles occur because the particles generate magnetic dipoles. Thus, the closer the agreement between the empirical M-H curve and the calculated Langevin function, the better the assumptions underlying the Langevin function are met. If a magnet is held near a homogeneous magnetic fluid thin film manufactured according to the methods of the present invention, a light color appears in the film and moves as the magnet is moved due to optical effects created by ordered structures formed in response to the magnetic field. Such colors are not seen in a EMG 909, a commercially available kerosene-based Fe 3 O 4 ferrofluid obtained from Ferrofluidics Corp. (Nashua, N.H.).
Ordered structures in thin films of homogeneous magnetic fluids
A magnetic fluid synthesized according to the methods outlined above may be sealed into a number of glass cells with various cell thicknesses to form fluidic thin films. The thin films of the present invention have preferred thicknesses in the range of from about 1 micron to about 20 microns, and more preferably from about 2 microns to about 6 microns (1 micron=10 -6 m). In one embodiment of the invention, magnetic fields parallel to and perpendicular to the plane of the film may be generated by Helmholtz coils and by a uniform solenoid, respectively. Alternatively, the solenoid may be replaced by Helmholtz coils for application of parallel magnetic fields, if desired. The magnetic field strength of the coils and solenoid may be related to the current supplied to these devices by using a gauss meter to measure the magnetic field. The resulting magnetic fields are uniform, with deviations of field strength in the region of the film less than 1%. To characterize the ordered structures produced by applied magnetic fields in thin films of the homogeneous magnetic fluids, we photographed the films using a Zeiss optical microscope, and the time evolution of the formation of patterns in the films was recorded using a personal computer through a CCD video camera.
FIG. 2 illustrates a setup useful for measuring properties of homogeneous magnetic fluid thin films under externally applied magnetic fields. The power supply used for generating the magnetic fields is computer controlled and is programmed such that the image data is obtained automatically. The program controlling the data acquisition is written such that the field strength and the rate of change of field strength can be adjusted. If desired, a delay time may be programmed prior to capturing image data after the field strength has been changed to ensure the pattern has reached a quasi-steady state.
When a homogeneous magnetic fluid thin film prepared according to the methods of the present invention is subjected to a perpendicularly applied magnetic field (i.e., the field direction is normal to the plane of the film), initial disorder quantum columns form. If the field strength is increased so that it exceeds a critical value, H h , an equilibrium two-dimensional hexagonal structure forms with particle columns occupying lattice vertices. If the field strength is increased to another critical value, H 1 , the pattern changes from a hexagonal structure to a labyrinthine pattern. FIG. 3 illustrates this phenomenon in a 6 μm thin film. In the range of field strength between H h and H 1 , the distance between the particle columns is almost linearly proportional to the inverse of the field strength; the distance between the particle columns is on the order of several microns (FIG. 5). In contrast, commercially available magnetic fluids only generate disordered quantum columns under the influence of perpendicularly applied magnetic fields.
Other parameters affecting the distance between the particle columns include film thickness, L, (FIGS. 4 and 5), the rate of change of the field strength, dH/dt, (FIG. 6), the magnetic particle concentration in the fluid (volume fraction ratio), and temperature, T. The distance between columns is directly proportional to the magnetic film thickness (FIG. 5). An increase in the rate of change of field strength (dH/dt) tends to decrease the distance between columns for the same final field strength. This may be due to a boundary effect. In a plot of the distance (d) between columns (on the ordinate) as a function of field strength (H) (abscissa), a curve generated using a larger rate of field strength change will lie below and to the left of a curve generated using a smaller rate of field strength change. Volume fraction ratio may be adjusted by diluting the magnetic fluid with additional carrier. Decreasing the volume fraction tends to increase the distance between columns, when film thickness and rate of field strength change are held constant. Thus, a plot of distance as a function of field strength at two different volume fractions shows that the d-H curve shifts up and to the right as the volume fraction is reduced. An increase in temperature (T) results in a decrease in the magnetization of the particles, and produces an increase in the distance between columns as all other parameters are held constant.
If a thin film of a homogeneous magnetic fluid of the present invention is subjected to a parallel magnetic field, the magnetic particles in the thin film agglomerate and form chains parallel to the direction of the field. As the field strength is increased, these chains tend to aggregate and form coarse, long chains because of their interaction. A one-dimensional quasi-periodic structure has been observed in thin films of homogeneous magnetic fluid of the present invention. The chains exist in different layers over the thickness of the film. The distance between particle chains is inversely proportional to the field strength (FIG. 8), and proportional to film thickness (FIG. 9).
Magnetic-optical devices using homogeneous magnetic fluid thin films
The present invention also relates to optical phenomena created when magnetic waves pass through or are reflected by the controllable ordered structures produced in homogeneous magnetic fluid thin films of the present invention upon exposure to externally applied magnetic fields. To demonstrate these phenomena, the setup illustrated in FIG. 10 was used to construct and test magnetic-optical devices. The area of the thin film used was 1 cm×4 cm. Helmholtz coils and a uniform solenoid were respectively used to generate parallel and perpendicular magnetic fields. The resulting fields were uniform with a measured deviation of field strength in the vicinity of the thin film of less than 1%. A white light source was used (Intralux 500-1 240 Watt halogen lamp, VOLPI Manufacturing, Inc., U.S.A., lamp operated at approximately 25% maximum power). The light rays were made near parallel by passing them through a telescope. Two optical lenses were used to make the near-parallel light parallel. An aperture was placed between the two lenses to control the size of the light beam. The parallel white light was reflected by a mirror located beneath the thin film. The angle of the mirror to the light beam was adjustable by turning the mirror plane, resulting in a change of the incident angle of the light to the film. Photographic images of the light through the thin film were taken using a CCD camera that was connected to a computer for data acquisition. In addition, a conventional film camera was sometimes used to obtain images of the thin film.
FIG. 11 is a photograph of a drop of a homogeneous magnetic fluid exposed to an externally applied perpendicular magnetic field. The thickness of the drop varies because of surface tension effects. Because the spacing of the ordered arrays formed in response to the external magnetic field vary as a function of film thickness, a spectrum of colors is seen when a source of parallel white light is placed below the film. The scale bar corresponds to 2 mm.
FIG. 12 is a series of photographic images of a homogeneous magnetic fluid thin film that illustrate diffraction of light by the film under the influence of an externally applied perpendicular magnetic field. The scale bar on the figure corresponds to 2 mm. In these images, all the parameters were kept constant, except the current to the solenoid used to generate the magnetic field. The color of the film changes from red to violet as the magnetic field is altered. These images demonstrate that the color of light passing through the thin film can be controlled, and that monochromatic light can be obtained from a thin film with an area on the order of several square centimeters.
A display device comprising a plurality of pixels, each of which comprises a magnetic thin film with an independent electronic circuit for controlling the magnetic field or temperature experienced by the film can therefore be constructed according to the methods of the present invention. By properly adjusting the current in each pixel, a polychromatic image may be displayed.
EXAMPLE 1
Preparation of a homogeneous magnetic fluid composition
500 mls. of an 8 molar solution of NaOH was made by adding 160 g of NaOH (95% grade, Nihon Shiyaku Industries, Ltd.) to a sufficient amount of de-ionized water to bring the final volume to 500 mls. A second solution was made by mixing 0.1 moles of FeSO 4 .7H 2 O (98% grade, Showa Chemicals, Inc.) and 0.2 moles of FeCl 3 .6H 2 O (97% grade, Showa Chemicals, Inc.) in a sufficient volume of de-ionized water to bring the final volume to 600 mls. A glass stirring bar was used to continuously stir the second solution while a sufficient volume of NaOH was added to raise the pH and maintain it between 11 and 11.5, as Fe 3 O 4 precipitated out of the solution. The addition of NaOH was completed in under about 2 minutes. During this step, the temperature was held at 80° C. The precipitation process took about 20 minutes.
50 mls. of oleic acid (Showa Chemicals, Inc.) was added to the solution containing the Fe 3 O 4 precipitate to coat the particles with oleic acid. At first, the pH value dropped substantially, and an additional volume of the NaOH solution was added to keep the pH at around 10 during the coating process. During this procedure, the temperature was maintained at 80° C. The coating process took approximately 30 minutes. At the end of this step, the solution separated into three phases. The upper phase was removed and discarded, and the middle and bottom phases were retained for use in the following step.
A volume of HCl (37.52%, Polin) was added to the retained solution sufficient to bring the pH down to about 1. This step was carried out at room temperature. The solution was stirred for about 20 minutes, as magnetic particles coated with oleic acid began to coagulate. At the end of the 20 minutes, the solution separated into two phases. The top phase, containing a black particulate suspension, was removed, and the entire acidification procedure was repeated as before. Again the top phase was removed and discarded. The black particulate suspension was not observed in the top phase formed following the second acidification step. In some syntheses, this step may have to be repeated an additional one or two times, until the black particulate suspension is no longer observed in the top phase, removing the top phase between repetitions of the process.
After the acidification steps were completed, de-ionized water at 65° C. was added to the retained bottom phase in order to remove remaining HCl and NaCl. The water was added as the material is stirred. A sufficient volume of water was added to raise the pH of the material to around 5. The solid material was allowed to settle and the water was decanted.
The solid material was washed by adding 1.1 ml. of kerosene per gram of solid. This was stirred until the solid material was completely dispersed in the kerosene, and the solution was placed in a centrifuge tube and centrifuged for 10 minutes at around 500×g. This and all other centrifugation steps were carried out at room temperature. After centrifugation, the sample had separated into two layers. The top layer was a dark colored liquid containing salt residues and large particles, and the lower layer was a solid phase which contained magnetic particles coated with oleic acid. The upper phase was removed, and the magnetic particles were dehydrated by suspending the material in acetone, pelleting it by centrifugation for 30 minutes at around 1800×g, removing the acetone, and drying the magnetic particles in a 65° C. oven for 8 to 12 hours. Finally, the dried particles were dispersed into kerosene using a kerosene-to-particle ratio of 2 ml/g. This was centrifuged again at around 500×g for 10 minutes. The supernatant was removed from the test tube and placed in a 65° C. oven for approximately 10 hours to drive off a portion of the kerosene and thereby raise the Fe 3 O 4 concentration. The fluid was removed from the oven and was used to form ordered structures in thin films. Aliquots of this homogeneous magnetic fluid were sealed into glass cells to form magnetic fluid thin films.
An X-ray diffraction pattern for the Fe 3 O 4 sample verified the single phase fcc spinel structure of the sample. The lattice constant was measured to be 8.40 Å. The magnetization of the sample was measured using a vibration sample magnetometer, and a saturation magnetization value of 10.58 emu/g was measured for the homogeneous magnetic fluid. The volume fraction of the homogeneous magnetic fluid was calculated as the ratio of the saturated magnetization of the magnetic fluid to that of the dry Fe 3 O 4 powder. This ratio was 18.9%.
EXAMPLE 2
Two-dimensional ordered structures as a function of applied field strength
The setup illustrated in FIG. 2 was used to examine pattern formation in a thin film of the homogeneous magnetic fluid thin film synthesized in Example 1 in response to an externally applied magnetic field oriented perpendicularly to the plane of the film. In this example, the strength of the applied field was varied. FIG. 3 shows images taken of a 6 μm thick magnetic fluid thin film using a CCD video camera that demonstrate the evolution of the two-dimensional ordered structure pattern from disorder quantum columns (FIG. 3a), to an ordered hexagonal structure (FIGS. 3b and 3c), and to a disordered labyrinthine pattern (FIG. 3d). These images illustrate that the distance between columns was roughly inversely proportional to the field strength in the range between two critical strengths, H h and H 1 .
EXAMPLE 3
Two-dimensional ordered structures as a function of film thickness
In this example, the effect of film thickness on pattern formation was examined. The two-dimensional ordered structures in homogeneous magnetic fluid thin films with different thicknesses were investigated using the setup illustrated in FIG. 2. During this experiment, all parameters remain unchanged except the thickness of the film, which was varied from 10 μm to 2 μm by using glass sample cells having different cell depths. FIG. 4 provides examples of images of thin films of the homogeneous magnetic fluid synthesized in Example 1 taken by the CCD camera using a constant field strength of 100 Oe in which a two-dimensional hexagonal structure had formed in the films under investigation. These images indicate that the distance between columns is roughly proportional to the thickness of the films over the range of film thickness examined.
The results obtained in Examples 2 and 3 show that a two-dimensional hexagonal structure forms in homogeneous magnetic fluid thin films that are subjected to an externally applied perpendicular magnetic field. The distance between columns is closely related to the inverse of the field strength and is roughly proportional to film thickness, at least over the range of thickness shown in Example 3. FIG. 5 plots the distance between columns as a function of film thickness and magnetic field strength.
EXAMPLE 4
Two-dimensional ordered structures as a function of the rate of change of field strength
The effect of the rate of change of the magnetic field strength was investigated, using rates of 5 Oe/s, 50 Oe/s, 100 Oe/s, and 400 Oe/s. FIG. 6 shows the relationship between column distance as a function of field strength using different rates of field strength change (dH/dt). The figure shows that as the rate is increased, the curves are displaced downward and to the left. That is, as the rate of field strength change increases, the distance between the columns decreases.
EXAMPLE 5
Two-dimensional ordered structures as a function of volume fraction ratio
Magnetic fluid samples with varying volume fraction ratios between the magnetic particles and the carrier liquid were made according to the method of Example 1, except in the final dispersing step, the volume of kerosene added was altered to vary the volume fraction ratio of the fluid. FIG. 7 shows that a decrease in the volume fraction ratio produces a shift in the distance versus field strength plots toward the upper right. That is, holding all other parameters constant, a decrease in the volume fraction ratio increases the distance between columns.
In the following two examples, the solenoid was replaced by Helmholtz coils in the setup shown in FIG. 2. As a result, the orientation of the magnetic field applied to the thin film was parallel to the plane of the film.
EXAMPLE 6
One-dimensional ordered structures as a function of applied field strength
In this example, the homogeneous magnetic fluid thin film was subjected to an externally applied magnetic field that was parallel to the plane of the film. As the field was applied, the magnetic particles in the film agglomerated and formed chains in the plane of the thin film oriented along the field direction. These particle chains exist in different layers over the thickness of the film. When the field strength was increased, the chains became periodic and the distance between the chains decreased proportionately. FIG. 8 shows the effect of varying the field strength from 100 Oe to 400 Oe on the distance between the periodic particle chains in the homogeneous magnetic fluid thin film.
EXAMPLE 7
One-dimensional ordered structures as a function of film thickness
In this example, the effect of thin film thickness on the one-dimensional periodic structures formed in response to parallel magnetic fields was examined. The homogeneous magnetic fluid was sealed into glass cells with different cell depths, allowing the effect of film thickness to be investigated. FIG. 9 shows that the distance between particle chains was found to be proportional to the thickness of the thin film in the range of thickness from 10 μm to 2 μm when all other parameters were held constant.
EXAMPLE 8
First type of light diffraction color display
When an applied perpendicular magnetic field reaches a critical value H h , a two dimensional column array is formed in a homogeneous magnetic fluid thin film. Diffraction phenomena occur as a parallel white light ray passes through the film, and constructive and destructive interference occurs as the light rays reach the eyes of a viewer. FIG. 13 is a cross section drawing of arrays formed in a homogeneous magnetic thin film illustrating the light diffraction concept. In this Figure, d is the distance between columns in a two-dimensional column array, θ is the angle formed between the incoming light ray and the direction perpendicular to the plane of the film, θ' is the angle formed between the diffracted rays and the direction perpendicular to the plane of the film, and N is the total number of magnetic particle columns diffracting the light. After diffraction, the intensity of the light, I, is ##EQU2## where ##EQU3## and λ is the wavelength of light. The condition under which the light intensity, I, becomes maximum is the same as that under which the light becomes brightest after diffraction through the film. This condition is ##EQU4## where κ is a non-negative integer.
The angle θ can be designed such that sinθ>>sinθ'. For a fixed angle θ, the color observed by the viewer will not change due to the limited movement of the viewer when the viewer is far away from the film. Meanwhile, the condition of κ=0 will never occur. The condition of κ=1 is the most interesting and important one. Under this condition, d will be related to λ by
d sinθ=λ
If this wavelength λ is within the range of visible light, then the same d will also allow only light with a wavelength of λ/κ for κ=2, 3, . . . to pass through the film. Fortunately, light with these wavelengths are outside the visible spectrum. The reason for this is that the longest wavelength of light visible to the human eye is about 0.7 μm, and so the wavelength of λ/2=0.35 μm. This wavelength is in the ultraviolet region of the electromagnetic spectrum and therefore is not visible to the human eye. Consequently, the viewer will only observe a single wavelength of light.
Of course, there will be dispersion for the intensity, I. The degree of the dispersion δλ must satisfy the condition δλ/λ=1/N. In the case of a two dimensional column array of a homogeneous magnetic fluid thin film, N is very large and depends on the area of the film. Thus, δλ/λ is very small. If the distance between columns d satisfies d=λ/sinθ, a pure monochromatic color will be observed. Fortunately, the distance between the columns in two dimensional column arrays of homogeneous magnetic fluid prepared according to the methods of the present invention is on the order of several micrometers. Therefore, the array is capable of diffracting visible light to produce intensity interference. Furthermore, because the distance d can be manipulated by, e.g., controlling the strength of the externally applied magnetic field, the rate of change of the magnetic field strength (dH/dt), the angle between the magnetic field and the film, the thickness of the homogeneous magnetic fluid thin film, and/or its temperature, the color of the light observed by the viewer can be changed at will.
A display constructed according to the methods of the present invention will comprise many pixels. Each pixel is made of a homogeneous magnetic fluid thin film with an electronic circuit. The electronic circuit is used to drive the change of the column distance in individual pixels, resulting in a change of color of the outgoing light. FIG. 14 is a conceptual drawing of a pixel. As the distance, d, of the pixels in a display device are individually adjusted, the display will generate a polychromatic image.
Diffraction phenomena also will occur in a homogeneous magnetic fluid thin film under the influence of an externally applied parallel magnetic field, according to the diffraction principles set out by Bragg. As the field is applied to the film, the magnetic particles agglomerate and form chains parallel to the plane of the thin film. The distance between chains can be controlled by changes in the field strength. When an incident white light beam forms an angle with the plane of the thin film, chains will reflect the beam. Since these chains are in different layers inside the film, the reflection of light by chains at different layers will interfere, resulting in a very sharp color. Here again, the externally applied magnetic field can be adjusted to obtain the desired colors.
EXAMPLE 9
Monochromatic light diffraction switch
As provided in Example 8, the homogeneous magnetic fluid thin film can be used to create monochromatic light with wavelength λ from white light. Under the same conditions as described in Example 8; i.e., sinθ>>sinθ' the diffraction occurs only when the column distance in the two dimensional column array of the homogeneous magnetic fluid thin film satisfies the condition of d sinθ=λ. That is, under a particular strength of external magnetic field, a monochromatic color of light is diffracted by the film and passes through it to reach the eyes of the viewer. By adjusting the field strength of the externally applied perpendicular magnetic field, one should be able to close or open the light switch. If there is a color dye covering the film, the desired color will appear by opening the switch.
EXAMPLE 10
Tunable wavelength filter by light diffraction
This example also uses the concepts developed in Example 8. The column distance of the hexagonal structure formed in the homogeneous magnetic fluid thin film is adjustable and is around several micrometers. As mentioned in Example 8, one can select any specific electromagnetic wave with a wavelength on the order of the column spacing by adjusting this spacing, d. The design of the homogeneous magnetic thin film and its electronic circuitry are similar to those illustrated in Example 8, except the area of the thin film may be substantially larger.
EXAMPLE 11
Second type of light diffraction color display
The idea of the second type of light diffraction color display is a combination of the technologies used in Example 8 and Example 9. This display consists of a large number of pixels. Each pixel includes three monochromatic light diffraction switches placed adjacent to each other. Each switch is made of a homogeneous magnetic fluid thin film with an accompanying electronic circuit for controlling the distance, d. The light sources for the three switches are red, green, and blue, respectively. The switches are set to allow only the passage of red, green, or blue light, individually.
By properly adjusting the current in the control circuits, one is able to turn the monochromatic light switch on or off, and hence allow none or one of these three colors to pass through its switch. Therefore each pixel of the display will show either black, red, green, blue, or any combination of these three colors. When the currents of the switches comprising the pixels are adjusted individually, the display will generate a colorful RGB (red, green, blue) picture.
EXAMPLE 12
Light double refraction color display
This example is an application of the use of homogeneous magnetic fluid thin films under an external magnetic field oriented parallel to the plane of the thin film. Under the applied field, the magnetic particles agglomerate and form chains in the plane of the film. These chains exist at different layers over the thickness of the film. The magnetic fluid inside the thin film becomes an anisotropic medium due to the directional arrangements of the particle chains.
The light refraction index n.sub.∥, along the direction of the chains will be different from the light refraction index, n.sub.⊥, along the direction perpendicular to the chains. Thus, after traveling a distance, s inside the magnetic fluid, in which s is the thickness of the film, the plane of polarization of a light wave with the electric field parallel to the direction of the chains will be different from that with the electric field perpendicular to the direction of the chains. Denoting these field strengths by E.sub.∥ and E.sub.⊥, they are ##EQU5## where ##EQU6## ω is the frequency of the electromagnetic wave, t is time, and c is the speed of light. These electromagnetic waves interfere due to the different values of n.sub.∥ and n.sub.⊥. This example is an application of control of the interference of two light waves by adjusting the strength of the externally applied magnetic field, resulting in changes in the difference between n.sub.∥ and n.sub.⊥. FIG. 15 illustrates this invention embodied in this e.
In FIG. 15, two polarizers, with their polar axes perpendicular to each other, cover both sides of a homogeneous magnetic fluid thin film. The externally applied magnetic field is chosen such that its field direction forms a 45° C. angle with the polar axes of both polarizers. When light impinges on the polarizer, only light parallel to the direction of the polar axis of the polarizer will be transmitted. Since these two polarizers are perpendicular to each other, the light which passes through the first polarizer can not pass through the second polarizer. However, when there is an anisotropic medium between the two polarizers, the electric field of the incoming light is rotated. Thus some of the light will be able to pass through the second polarizer.
In this example, in external magnetic field is applied parallel to the film, and the magnetic fluid inside the film becomes anisotropic. As a result of the difference created between n.sub.∥ and n.sub.⊥, the plane of polarization of the light will be rotated as it passes through the film. Therefore, some light will be able to pass through the second polarizer and reach the eyes of the viewer. Practically, the intensity of light that passes through both polarizers and the homogeneous magnetic fluid thin film is proportional to ##EQU7## The condition for the maximum intensity is ##EQU8## in which κ is a non-negative integer. In this case, s, the thickness of the film can not be changed by changing the external magnetic field. However, the value of (n.sub.∥ -n.sub.⊥) can be changed by changing, e.g., the strength of the external field. Thus, one is able to obtain light with the desired wavelength by, e.g., adjusting the strength of the external magnetic field. The pixel and the electronic circuit that drives the magnetic field are similar to those shown in Example 8, with the only difference being that, in this example, the magnetic field is parallel to the plane of the homogeneous magnetic fluid film.
The above examples are provided to illustrate the invention but not to limit its scope. Other variants of the invention will be readily apparent to one of ordinary skill in the art and encompassed by the appended claims. All publications, patents, and patent applications cited herein are hereby incorporated by reference. | Methods for preparing homogeneous magnetic fluid compositions capable of forming ordered one dimensional structures or two dimensional lattices in response to externally applied magnetic fields are disclosed. The compositions are prepared using improved co-precipitation methods in which the steps of the procedure have been tuned to reduce sample heterogeneity. Fe 3 O 4 particles are coated with a surfactant and dispersed in a continuous carrier phase to form these homogeneous magnetic fluid compositions. The ability of these compositions to generate ordered structures can be tested by holding a magnet near a thin film of the compositions and observing the formation of colors in the region near the magnet. Methods for controlling the characteristic spacing of the ordered structures formed by the composition also are disclosed. Relevant parameters include the thickness of the film, the strength and orientation of the externally applied magnetic field, the rate of change of field strength, the volume fraction of the magnetic particles dispersed in the continuous phase, and the temperature of the homogeneous magnetic fluid. The homogeneous magnetic fluid composition is useful for the manufacture of liquid crystal devices. The devices take advantage of the serendipitous fact that the spacings in the material are on the order of the wavelength of visible light. A variety of magnetic-optical devices can be constructed that use the ordered structures to diffract, reflect, and polarize light in a controlled and predictable manner. These devices include color displays, monochromatic light switches, and tunable wavelength filters. | 7 |
[0001] This application is based on Provisional Application Ser. No. 61/795,104, filed Oct. 9, 2012, priority of which is hereby claimed.
[0002] This invention relates to a well tool that may be pumped into a well and more particularly to an improved tool that requires a smaller volume of liquid to pump the tool to its desired location.
BACKGROUND OF THE INVENTION
[0003] There are a number of situations in hydrocarbon wells where it is necessary or desirable to position a tool at a predetermined location in the well. In vertical wells, tools are conventionally run on the bottom of a wire line and use gravity to cause the tool to fall into the well. In horizontal wells, gravity can be used in the vertical leg but only for a very short distance into the horizontal leg. It has become customary to pump the tool on the end of a wire line to its desired location in the horizontal leg of a well. Pumping a liquid into the pipe string creates a dynamic pressure differential across the tool thereby propelling it along the horizontal leg. Because the tool is on the end of a wire line, the distance the tool is pumped can be controlled.
[0004] One problem with this approach is that substantial quantities of the pumped liquid, which is usually raw or treated water, are needed because creating a dynamic pressure drop across the tool requires that a large volume of liquid be pumped across the tool. It is not surprising to require twenty barrels of water a minute to propel a tool at an appropriate velocity in the horizontal leg of a hydrocarbon well. The volume required to pump the tool to its desired location is a simple multiplication of the pump rate and the pump time. It is not unusual to consume many hundreds of barrels of water to propel a tool a substantial distance in the horizontal leg of a hydrocarbon well.
[0005] A conventional approach is to provide a more-or-less rigid pump down collar on the exterior of pump down tools as shown in U.S. Printed Patent Applications 20100263876; 20110277989; 20120118561 and 20120145379 to reduce the gap between the outside of the tool and the inside of the pipe string.
[0006] Other disclosures of some interest relative to this invention are found in U.S. Pat. Nos. 2,644,523; 3,346,045; 3,347,196; 4,356,865; 4,392,528; 4,423,783; 4,828,291; 4,961,465; 5,095,980; 5,180,009; 5,209,304; 5,927,402; 6,138,764; 6,460,616; 6,467,541; 6,739,391; 6,973,971; 7,025,142; 7,182,135; 7,261,153; 7,322,421; 7,434,627; 7,686,092 7,753,130 and 8,079,413 and U.S. Printed Patent Application 20050241824.
SUMMARY OF THE INVENTION
[0007] As used herein, upper refers to that end of the tool that is nearest the earth's surface, which in a vertical well would be the upper end but which in a horizontal well might be no more elevated than the opposite end. Similarly, lower refers to that end of the tool that is furthest from earth's surface as measured along the well bore. Although these terms may be thought to be somewhat misleading, they are more normal than the more correct terms proximal and distal ends.
[0008] As disclosed herein, a pump down tool includes a resilient cup on the bottom of the tool that is captivated between a tool body and an anti-rotation device on the extreme bottom end of the tool. The tool body may include a stub having threads extending from its end terminating short of the junction between the stub and the larger tool body. The anti-rotation device may thread onto or slide onto the stub short of the tool body at a position captivating the resilient cup. In some embodiments, the cup may move axially between one position more-or-less abutting the tool body and a second position more-or-less abutting the anti-rotation device.
[0009] It is an object of this invention to provide an improved pump down tool requiring a smaller volume of water to propel the tool to its desired location.
[0010] Another object of this invention is to provide an improved pump down tool incorporating a resilient cup captivated between the tool body and an anti-rotation device on the bottom of the tool.
[0011] These and other objects and advantage of this invention will become more fully apparent as this description proceeds, reference being made to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a partial vertical cross-sectional view of a pump down tool;
[0013] FIG. 2 is an exploded partial view of a resilient cup and its support from FIG. 1 ; and
[0014] FIG. 3 is a view similar to FIG. 2 showing another embodiment of a resilient cup and support.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to FIGS. 1-2 , a pump down tool 10 may comprise, as major components, a body 12 having a passage 13 therethrough, one or more sets of slips 14 , 16 , one or more conical or wedge-shaped sections 18 , 20 , a malleable, rubber, packing element or seal 22 and an anti-rotation device or mule shoe 24 . The body 12 may include an upper section 26 and a lower section 28 connected together in a suitable manner, such as by threads 30 . The tool 10 is illustrated as of a type that can be converted between a bridge plug, a flow back plug, a check valve plug or otherwise by installing or removing a component in an insert 32 . The component may be a plug, a valve ball, a soluble ball or the like as shown in U.S. patent application Ser. No. 12/317,497, filed Dec. 23, 2008, the disclosure of which is incorporated herein by reference.
[0016] The insert 32 may be attached to the upper body 26 by suitable threads 34 and may include internal threads 36 for connection to a conventional setting tool (not shown) connected to a wire line or other work string extending to the surface. The setting tool (not shown) may act in a conventional manner by pushing down on the top of a collar 38 and pulling up on the threads 36 . This shears a pin (not shown) and allows the collar 38 to move downward relative to the slips 14 , 16 thereby expanding the slips 14 , 16 into gripping engagement with the casing 40 .
[0017] The slips 14 , 16 , the wedges 18 , 20 and the packing element 22 may be of a conventional type as shown in U.S. patent application Ser. No. 12/317,497, filed Dec. 23, 2008 so the tool is set in a conventional manner. During setting of the tool 10 , the slips 14 , 16 ride along the wedges 18 , 20 to expand the slips 14 , and fracture them into a number of segments in gripping engagement with the interior of a casing string 40 which may be cemented in a well bore (not shown). At the end of the setting of the tool 10 , the insert 32 fails or breaks at a neck 42 thereby detaching the threads 36 and the setting tool (not shown) so the setting tool and wire line may be removed from the well.
[0018] The anti-rotation device 24 acts to minimize or prevent rotation of the tool when it is being drilled up by interacting with a subjacent tool. This may be accomplished in a number of ways, one of which is to provide angled faces 42 , 44 on the bottom of a body 46 of the anti-rotation device 24 .
[0019] There comes a time when it may be necessary or desirable to drill up the tool 10 . Thus, many of the components of the tool 10 may be easily drillable such as composite materials, aluminum, brass and the like although slips 14 , 16 are often cast iron. The slips 14 , 16 normally fracture into small pieces which are more easily removable and don't necessary have to be drilled up. Those skilled in the art will recognize the tool 10 as heretofore described as being more-or-less conventional.
[0020] A resilient cup 48 may be part of the tool 10 adjacent a lower end thereof and may be captivated between the body 12 and the anti-rotation device 24 . A preferred embodiment of the cup 48 may be a commercially available swab cup of a diameter matched with the I.D. or O.D. of the casing string 40 . In other words, for use in 4½″ casing, a swab cup of that size may preferably be used on the tool 10 .
[0021] It may be preferred to captivate the cup 48 between the anti-rotation device 24 and the body 12 . To this end, the lower body section 28 may include a stub 50 of reduced size providing threads 52 which terminate well short of a flared end 54 of the lower body section 28 . The anti-rotation device 24 may include threads 56 received on the threads 52 and stopping at a distance from the flared end 54 greater than the thickness of the cup 48 . In this manner, the cup 48 may be free to move slightly along the stub 50 so there is no requirement for an exact dimensional tolerance between the anti-rotation device 24 , the lower body section 28 and the cup 48 . A set screw 58 may be used to prevent the anti-rotation device 24 from unthreading from the stub 50 .
[0022] In the alternative, the anti-rotation device 24 may slip over the stub 50 and be pinned in place to captivate the cup 48 . Similarly, the cup 48 may be attached to the stub 50 , or to the anti-rotation device 24 , in any suitable manner, as by extending a fastener (not shown) through a passage 60 in the cup 48 .
[0023] The resilient cup 48 may typically be made of rubber or similar elastomeric material and is sufficiently flexible so a lip 62 stays more-or-less in contact with the interior of the casing string 40 when the tool 10 is horizontal and the lip 60 is distorted by the weight of the tool 10 resting on its side. It will be seen that the lip 62 is formed from converging sides 64 , 66 so that pressure from above spreads the lip 62 into a more secure engagement with the interior of the casing string 40 . Many conventional swab cups include a metal reinforcing rim 68 and such features do not detract from operation of the cup 48 for present purposes. The cup 48 may be concave toward the upper end of the tool 10 so that pressure applied from above may spread or enlarge the diameter of the cup 48 from a size approximating the diameter of the tool 10 in its running in configuration to a size larger than the set diameter of the slips 14 , 16 .
[0024] There is an advantage of the cup 48 being on or near the bottom of the tool 10 rather than on the top. If the cup 48 were above the slips 14 , 16 and the tool 10 were to strike an obstruction while moving through the casing 40 , there is a risk that the shear pin (not shown) will shear off and the tool 10 will set prematurely at a location where it is not wanted.
[0025] When going into the vertical leg of a well, where the tool may be falling by gravity, the resilient cup 48 may abut the inside of the casing 40 but the flexibility and orientation of the resilient lip 62 allows liquid to bypass the resilient cup 48 on its exterior. In other words, the lip 62 may not substantially impede falling of the tool 10 in the vertical leg of a well. In this manner, the tool 10 may fall into the well in much the same manner that a swab falls into a vertical well.
[0026] One of the problems with the prior art devices is that when the tool is horizontal, it is eccentric to the casing, meaning that the gap between the tool and the casing becomes very large on the non-weight bearing side of the tool. This reduces the efficiency of the tool, meaning that a higher pump rate is required to produce the necessary dynamic pressure differential to pump the tool through the horizontal leg of a well. Thus, it is not unusual to require pumping at a rate of 15-20 barrels/minute to propel a tool at a recommended rate of 150-250′/minute. At 200′/minute it takes fifty minutes to pump a tool through a 10,000′ horizontal leg. At a pump rate of 20 bpm, this is 1000 barrels.
[0027] When the tool 10 reaches the horizontal leg of a horizontal well, the weight of the tool 10 tends to compress the cup 48 on the weight bearing side of the tool 10 and move away from the casing interior on the non-weight bearing side. Three factors tend to mitigate the cup 48 from unsealing relative to the casing 40 . First, the cup 48 may have considerable flexibility thereby allowing it to remain more-or-less engaged with the non-weight bearing side of the tool 10 . Second, pressure from above, represented by the arrow 74 , stiffens the cup 48 and pushes the lip 62 on the weight bearing side of the tool 10 toward the casing interior and thereby acts as a centralizer to center the tool 10 in the casing 40 . Pressure from above also biases the non-weight bearing side of the lip 62 toward the casing interior keeping it in more-or-less sealing engagement ith the casing interior.
[0028] It will be seen that the resilient cup 48 prevents most of the liquid pumped into the casing 40 from passing around the tool 10 in an uncontrolled manner. This means that the tool can be pumped to its desired location in the well by pumping into the well a liquid volume substantially equal to the volume of the pipe string from the heel of the horizontal leg to its desired location. This volume is much smaller than is conventionally required. For example, consider a situation of a horizontal well having a 10,000′ long lateral cased with 4½″ O.D., N-80, 11.6 #/ft pipe having a nominal I.D. of 4.000 inches subject to normal manufacturing variations or tolerances. Casing of this size has a volume of 67 linear feet per barrel, so it would take a minimum of 10,000/67 or about 150 barrels of liquid to pump the tool 10 from the heel to the end of the horizontal lateral. This is much smaller than the volume of liquid needed to create a dynamic pressure drop across the tool and propel it 10,000′. To achieve a nominal 150-250′/minute rate of movement of the tool 10 inside the pipe string above, with perfect sealing of the resilient cup 48 , it will be seen that a pump rate of 2.2-3.7 bpm is required—much less than the 15-20 bpm of the prior art.
[0029] In fact, it may be desirable to provide one or more small bypasses 70 may be provided around the resilient cup 48 . Many of the tools 10 are used in conjunction with the fracing of hydrocarbon wells so it is not uncommon to find proppant, such as sand, accumulated in the horizontal leg of such a well. Providing one or more small bypasses around the resilient cup 48 allows a small stream of liquid to disperse any proppant accumulated in front of the tool 10 as it is propelled along the horizontal leg of the well. The bypasses 70 work by diverting part of the pumped liquid in a controlled manner through the lower end of the passage 13 and through a passage 72 in the anti-rotation device 24 as suggested by the arrow 76 . This bypass liquid is sufficient to stir up and disperse any proppant in front of the tool 10 as it is being pumped along the horizontal leg of the well so the tool 10 doesn't have to plow its way through the accumulated proppant. Consequently, a pump rate of 6-9 bpm may be more typical of pump rates with the tool 10 . Thus, to pump the tool 10 through a 10,000′ horizontal leg may require 10-15 bpm less than with a prior art device. Manifestly, the smaller the bypass 70 , the smaller the pumped volume but with less proppant dispersion—both of which are of importance. An optimum size for the bypass 70 is sufficient to barely disperse proppant collecting in the casing 40 , the amount and concentration of which are unknown. Thus, the optimum size of the bypass 70 is normally unknowable and some compromise is in order.
[0030] Another advantage of the bypass 70 is that it allows the tool to be pulled from the well without swabbing the casing 40 . Occasionally, something occurs which makes it desirable to remove the tool 10 from the well without setting it. The bypasses 70 allow the tool 10 to be pulled toward the surface and allow liquid in the casing 40 to pass from above the cup 48 , through the bypass 70 and out the passage 72 without delivering liquid at the surface. Although the size and number of the bypasses 70 will differ depending on the size of the casing 40 , the desired rate of pulling the tool 10 from the well and other factors, two passages of ⅜″ diameter have been found to be sufficient with normal production sized casing, i.e. 4½″ and 5½″ O.D.
[0031] Referring to FIG. 3 , another embodiment of this invention includes a tool 100 including an anti-rotation device 102 on the end of a body section 104 . A resilient cup 106 of somewhat different configuration is captivated between the device 102 and the body section 104 . One or more bypass channels 108 may be provided, either alone or in conjunction with a passage comparable to the passage 70 . The channels 108 pass through threads 110 securing the anti-rotation device 102 to the lower body section 104 . Thus, the threads 110 are interrupted threads but are still of sufficient capacity to secure the anti-rotation device 102 to the lower body section 104 . It will be seen that the bypass channels 108 have the same function as the bypass 70 so a bypass stream flows through the channels 108 , through a slot 112 in the anti-rotation device 102 and out of the bottom of the tool 100 through a passage 114 in the anti-rotation device 102 as suggested by the arrow 116 . A set screw 118 may be provided in the anti-rotation device 102 to prevent it from unthreading from the body section 104 . The cup 106 may be concave toward the upper end of its tool so that pressure applied from above may spread or enlarge the diameter of the cup 106 from a size approximating the diameter of its tool in its running in configuration to a size larger than the set diameter of the slips carried by the tool.
[0032] Although this invention has been described in its preferred forms with a certain degree of particularity, it is understood that the present disclosure of the preferred forms is only by way of example and that numerous changes in the details of operation and the combination and arrangement of parts may be resorted to without departing from the scope of the invention as hereinafter claimed. | A pump down tool includes a resilient cup on the tool exterior to minimize leakage of pumped fluid around the outside of the tool when the tool is pumped into a well. The resilient cup is concave toward an upper end of the tool so it expands upon application of pressure to pump the tool into the well. The resilient cup is capable of expanding to a diameter sealing against the inside of the casing string. A fluid bypass around the resilient cup allows a fraction of the pumped fluid to stir up any proppant lying in the path of the tool thereby allowing the tool to move through a horizontal well without having to plow through the proppant. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a battery power source device for supplying high electric power used for a drive power source for a vehicle.
[0003] 2. Description of Related Art
[0004] Generally, the output of a rechargeable battery is from about 1 to 5 volts. When a high output voltage is necessary for an application such as a power source for the drive of a vehicle, a battery power source device which consists of a large number of rechargeable batteries 1 is required. These rechargeable batteries 1 are connected in series, and arranged in both lengthwise and widthwise directions within a battery box 2 , as shown in a schematic longitudinal sectional view of FIG. 3. In this battery power source device, charge and discharge control is conducted so as to maintain the battery power source device in a state always capable of supplying a required level of electric power.
[0005] Since the temperature of the rechargeable battery 1 increases when it is charged and discharged, it is necessary for a battery power source device to provide cooling to limit such temperature increases. On the other hand, since temperature dependence of the internal resistance of the rechargeable battery 1 becomes vary large when the rechargeable battery 1 is used in a place at low temperatures, difference in individual battery characteristics among the rechargeable batteries 1 becomes large if as much difference in temperature as they are at an ordinary temperature is present among the rechargeable batteries 1 . As a consequence, overall control of the rechargeable batteries 1 is often prevented. Thus, it becomes necessary to quickly increase the temperatures of the individual rechargeable batteries 1 to a temperature where any decrease of battery performance no longer remains a problem. Additionally, the temperatures of the rechargeable batteries 1 should be maintained at a uniform level when such a battery power source device including a large number of the rechargeable batteries 1 is used at low temperatures. In addition, the dependency of the battery characteristics of each rechargeable battery 1 on temperature makes it necessary to maintain the temperatures of the entire arrangement of rechargeable batteries 1 at a uniform level.
[0006] Thus, controlling the temperatures of the individual rechargeable batteries 1 in a conventional battery power source device consists of adopting an arrangement for cooling the individual rechargeable batteries 1 by opening one end of the battery box 2 to form an air inlet opening 3 , providing an air outlet passage 4 on the other end, and providing a fan 7 inside the air outlet passage 4 which is driven to blow air in one direction through the battery box 2 , thereby forcing air E to flow between the individual rechargeable batteries 1 . In addition, when the rechargeable batteries 1 are used in a low temperature, it is known to use a battery heater such as a combustion heater or an electrical heater, installed on the battery box 2 so as to maintain the individual rechargeable batteries 1 at a predetermined temperature (such as one disclosed in Japanese Patent Laid-Open Publication No. Hei. 6-231807).
[0007] However, a problem with the temperature control described above is that, air E having flowed from the air inlet opening 3 flows downstream while absorbing heat from the rechargeable batteries 1 when it passes through between the rechargeable batteries 1 , the temperature of the air E increases as it flows downstream. Thus, while the rechargeable batteries 1 on the side of the air inlet opening 3 are efficiently cooled by exchanging heat with the air E at a low temperature, the rechargeable batteries 1 on the side of the air outlet passage 4 are hardly cooled since they are exposed to the air E heated as a result of the heat exchange with the rechargeable batteries 1 on the upstream side. Consequently, the individual rechargeable batteries 1 are not uniformly cooled. As a result, there is such a problem that a large temperature difference is present between the rechargeable batteries 1 on the side of the air inlet opening 3 and the rechargeable batteries 1 on the side of the air outlet passage 4 .
[0008] On the other hand, when the battery power source device is used at a low temperature, and the heater is installed to heat the rechargeable batteries 1 as described above, an independent cooler is necessary for use of the device at ordinary temperatures. Thus the structure becomes complicated, and as a consequence, the cost increases. As alternative means for increasing the temperatures of the rechargeable batteries without a heater, the rechargeable batteries are placed in a battery box in which a medium such as air does not flow, and the heat from the rechargeable batteries generated by charging and discharging is used to increase the temperatures of the rechargeable batteries. However, in this method, since the heat generation varies among the individual rechargeable batteries due to variation in the internal resistance or the temperature characteristics among the rechargeable batteries, or the heat dissipation varies among the rechargeable batteries due to the placement of the rechargeable batteries within the battery box, it is not possible to maintain the temperatures of the entire arrangement of rechargeable batteries at a uniform level.
SUMMARY OF THE INVENTION
[0009] The present invention has been devised in light of the above-described problems, and has an object of providing a battery power source device including a simple and inexpensive constitution which serves to cool batteries if the temperature is at ordinary temperatures, and quickly increases the battery temperature to a temperature range which does not decrease the battery performance while the temperatures of the individual batteries are maintained uniform if the temperature is low during its use.
[0010] To achieve the object above, a battery power source device according to the present invention includes a battery box for storing a plurality of batteries arranged in a connected state in a battery storage room, an inlet opening for introducing a temperature control medium into the battery storage room, an outlet opening for discharging the medium from the battery storage room to the outside, a medium circulation passage for leading the medium discharged from the outlet opening to the inlet opening for feeding into the battery storage room again, and a medium transport device for forcing the medium flow.
[0011] If this battery power source device is used at low temperatures, since the temperature control medium such as air is introduced into the battery storage room again through the medium circulation passage for circulation after the medium has passed through the battery storage room, and consequently the temperature of the medium has increased due to heat exchange with the individual batteries, it is possible to quickly increases the temperatures of the individual batteries while the temperatures are maintained at a uniform level. In addition, if the battery power source device is used at ordinary temperatures, the individual batteries are cooled efficiently, and thus a proper temperature control effect is provided by discharging the temperature control medium outside from the outlet opening after the medium has flowed from the inlet opening, and has passed through the battery storage room. Thus, though this battery power source device has a simple constitution which includes only the medium circulation passage without a heater or a cooler, it prevents a variation in the temperature characteristics of the individual batteries due to temperature unevenness of the batteries both at low temperatures and at ordinary temperatures. As a result, overall performance brought about by the entire batteries is maintained to a proper state.
[0012] It is preferable that the battery power source device further includes a selector valve mechanism for switching so as to selectively lead the temperature control medium discharged from the outlet opening either to an external outlet passage or the medium circulation passage, and a controller for controlling to switch the selector valve mechanism.
[0013] In the constitution described above, it is preferable that the controller includes a function for controlling to switch the medium transport device so as to reverse the flow direction of the medium in this battery power source device.
[0014] It is preferable that the battery power source device further includes a temperature sensor for detecting the temperature of a battery in the battery storage room, or the temperature of the temperature control medium at a predetermined point in the battery storage room, and that the controller control to switch the medium transport device in accordance with the temperature detected by the temperature sensor.
[0015] It is preferred that the battery power source device further includes another selector valve mechanism for switching so as to selectively lead either the temperature control medium introduced from an inlet passage, or the temperature control medium introduced from the medium circulation passage into the battery storage room, and that the controller control to switch the two selector valve mechanisms in conjunction with each other.
[0016] While novel features of the invention are set forth in the preceding, the invention, both as to organization and content, can be further understood and appreciated, along with other objects and features thereof, from the following detailed description and examples when taken in conjunction with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a schematic longitudinal sectional view showing a battery power source device according to one embodiment of the present invention;
[0018] [0018]FIG. 2 is a characteristic chart showing a relationship between time of the battery operation and a battery temperature while conditions are changed when the battery power source device of the invention, and a battery power source device of comparative example are used at low temperatures; and
[0019] [0019]FIG. 3 is a schematic longitudinal sectional view showing a conventional battery power source device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The following will describe a preferred embodiment of the present invention with reference to the drawings. FIG. 1 is a schematic longitudinal sectional view showing a battery power source device according to one embodiment of the invention. In the drawing, a required number of rechargeable batteries 9 for supplying a necessary output voltage are stored in a battery storage room 10 of a battery box 8 , which is in a rectangular solid shape. The rechargeable batteries 9 are arranged in both lengthwise and widthwise directions, and are electrically connected. In the present embodiment, the rechargeable batteries 9 are placed such that each battery row includes the four rechargeable batteries 9 along a line orthogonal to a flow direction of air E, and the five battery rows exist along the flow direction.
[0021] An inlet duct 12 is connected with an inlet opening 11 , and simultaneously, an outlet duct 14 is connected with an outlet opening 13 in the battery storage room 10 . A circulation duct 17 is provided for communicating an entrance of the outlet duct 14 and an exit of the inlet duct 12 to each other. A selector valve member 18 for switching the flow of the air E between the outlet duct 14 and the circulation duct 17 is provided so as to move between the individual entrances of the outlet duct 14 and the circulation duct 17 . A fan 19 for forcing the air E flow is provided between the outlet opening 13 and the individual entrances of the outlet duct 14 and the circulation duct 17 .
[0022] A temperature sensor 20 for detecting the temperature of the air E is provided at the inlet opening 11 of the battery box 8 . Temperature sensors 21 for respectively detecting the temperatures of the individual rechargeable batteries 9 in the five battery rows arranged along the flow direction are provided in contact with the rechargeable batteries 9 . These temperature sensors 20 and 21 are contact type sensors such as thermistors which detect a temperature based on a change of the resistance. A controller 22 controls to switch the rotation direction of the fan 19 , and simultaneously controls to switch the selector valve member 18 through an actuator 23 in accordance with temperature detection signals supplied from the individual temperature sensors 20 and 21 .
[0023] The following will describe the operation of the battery power source device of the present embodiment. First, when the battery power source device is used at low temperatures, the controller 22 controls the actuator 23 to set the selector valve member 18 to a position indicated by solid lines. As a result, the outlet opening 13 of the battery storage room 10 is shut off from the outlet duct 14 , and communicates to the circulation duct 17 . In this state, the fan 19 is rotated in the forward direction by the controller 22 . Thereby, the air E is sucked from the inlet duct 12 into the battery storage room 10 through the inlet opening 11 , flows through the battery storage room 10 , flows out from the outlet opening 13 , passes through the circulation duct 17 , and then flows into the battery storage room 10 again from the inlet opening 11 . In this way, the air E circulates.
[0024] This flowing air E absorbs heat from the rechargeable batteries 9 while it is flowing through the battery storage room 10 , and is discharged from the outlet opening 13 while its temperature is increased. Then, the air E flows into the battery storage room 10 again from the inlet opening 11 after passing through the circulation duct 17 . The temperature of the air E gradually increases as it repeats this circulation. Thus, the temperatures of the individual rechargeable batteries 9 quickly increase while these temperatures are maintained at a uniform level by the air E whose temperature increases gradually as it circulates.
[0025] The controller 22 always monitors the temperatures of the individual rechargeable batteries 9 in the five rows based on the temperature detection signals supplied from the temperature sensors 21 . When the controller 22 determines that a difference in temperature between the rechargeable battery 9 at the inlet opening 11 and the rechargeable battery 9 at the outlet opening 13 reaches a predetermined value, 3° C. for example, the controller 22 controls to switch the rotation of the fan 19 from the forward direction to the reverse direction. As a result, since the fan 19 operates so as to blow the air E after passing through the circulation duct 17 into the battery storage room 10 from the outlet opening 13 , the air E circulates along the circulation route the same as that for the forward rotation of the fan 19 but in the opposite direction. Consequently, the phenomenon that the temperature at the outlet opening 13 is higher than the temperature at the inlet opening 11 among the rechargeable batteries 9 is avoided, and thus the uniformity of the temperature among the rechargeable batteries 9 increases.
[0026] On the other hand, when the battery power source device is used at ordinary temperatures, the controller 22 controls the actuator 23 to set the selector valve member 18 to a position indicated by a dash-double-dot line. As a result, the outlet opening 13 is shut off from the circulation duct 17 , and communicates to the outlet duct 14 . In this state, the fan 19 is rotated in the forward direction by the controller 22 . As a result, the air E is sucked from the inlet duct 12 into the battery box 8 through the inlet opening 11 , flows through the battery storage room 10 , flows out from the outlet opening 13 , and then discharged outside from the outlet duct 14 . Thereby, the cold air E always flows from the inlet duct 12 into the battery storage room 10 . This flowing air E absorbs the heat from the rechargeable batteries 9 so as to cool the rechargeable batteries 9 while it is passing through the battery storage room 10 , and is discharged outside from the outlet opening 13 through the outlet duct 14 while its temperature is increased. Thus, the individual rechargeable batteries 9 are always cooled efficiently by the cold air E while their temperatures are maintained at a uniform level.
[0027] The controller 22 always monitors the temperatures of the individual rechargeable batteries 9 in the five rows based on the temperature detection signals supplied from the temperature sensors 21 . Simultaneously, the controller 22 monitors the temperature of the air E flowing from the inlet duct 12 based on the detection signal supplied from the temperature sensor 20 . When the controller 22 determines that it is necessary to further equalize the temperatures of the individual rechargeable batteries 9 , the controller 22 controls to switch the rotation of the fan 19 from the forward direction to the reverse direction. As a result, since the fan 19 operates so as to blow the air E sucked from the outlet duct 14 into the battery storage room 10 from the outlet opening 13 , the air E flows along the flow route the same as that for the forward rotation of the fan 19 but in the opposite direction. Consequently, the phenomenon that the temperature at the outlet opening 13 is lower than the temperature at the inlet opening 11 among the rechargeable batteries 9 is avoided, and thus the uniformity of the temperature among the rechargeable batteries 9 increases.
[0028] As described above, the battery power source device uses a simple constitution where a special heater or a cooler is not used, the circulation duct 17 is provided so as to communicate the battery storage room 10 to each other, and the rotation direction of the fan 19 is switched according to the temperature difference between the parts of the rechargeable batteries 9 , or the temperature of the air E. With this constitution, the battery power source device heats or cools a large number of the rechargeable batteries 9 in the battery storage room 10 while the temperatures of the rechargeable batteries 9 are maintained at a uniform level whether the battery power source device is used at low or ordinary temperatures. Thus, the battery power source device prevents the variation of the battery characteristics caused by the change in battery temperatures.
[0029] [0029]FIG. 2 is a characteristic chart showing temperature changes of the rechargeable batteries 9 while conditions such as the flow direction of the air E are changed when the battery power source device is used at low temperatures. This drawing shows results of the temperature changes of the rechargeable batteries 9 for four types of the flow of the air E. Namely, the fan 19 is maintained stationary as a first condition, the fan 19 rotates in the forward direction while the communication between the outlet opening 13 and the circulation duct 17 is shut off by the selector valve member 18 as a second condition, the fan 19 rotates in the forward direction while the communication between the outlet opening 13 and the outlet duct 14 is shut off by the selector valve member 18 as a third condition, and the fan 19 rotates in the forward direction while the communication between the outlet opening 13 and the outlet duct 14 is shut off by the selector valve member 18 , and the rotation direction of the fan 19 is switched when the difference in temperature between the rechargeable batteries 9 on the side of the inlet opening 11 , and the rechargeable batteries 9 on the side of the outlet opening 13 is 3° C. or more as a fourth condition. Therefore, the first and second conditions are similar to those for the conventional battery power source device, and the third and fourth conditions are those for the battery power source device of the embodiment described above.
[0030] Characteristic curves C 11 and C 12 in FIG. 2 respectively show temperature changes of the rechargeable batteries 9 in the battery row at the inlet opening 11 and in the battery row at the center under the first condition. In this case, since the fan 19 is maintained stationary, and thus there are large variations in heat generation and heat dissipation of the rechargeable battery 9 , the temperature of the rechargeable battery 9 in the battery row at the center becomes the highest as the characteristic curve C 12 shows. Namely, there exist the batteries whose temperatures increase very rapidly and the batteries whose temperatures increase very slowly under the first condition. As a result, the uniformity of the battery temperatures becomes very low, and thus a large difference in temperature is generated.
[0031] Characteristic curves C 21 and C 22 respectively show temperature changes of the rechargeable batteries 9 in the battery row at the inlet opening 11 and in the battery row at the outlet opening 13 under the second condition. Under the second condition where the air E flows only in one direction, it was turned out that though the uniformity of the battery temperatures is almost excellent, it is impossible to quickly increase the battery temperature up to a high temperature.
[0032] Characteristic curves C 31 and C 32 respectively show temperature changes of the rechargeable batteries 9 in the battery row at the inlet opening 11 and in the battery row at the outlet opening 13 under the third condition. Characteristic curves C 41 and C 42 respectively show temperature changes of the rechargeable batteries 9 in the battery row at the inlet opening 11 and in the battery row at the outlet opening 13 under the fourth condition. Under the third and fourth conditions which circulate the air E as in the battery power source device of the embodiment described above, it was turned out that the battery temperatures increase quickly while the uniformity of the battery temperatures is maintained. Further, under the fourth condition which switches the flow direction of the air E when the difference in temperature between the rechargeable batteries 9 reaches the predetermined value in addition to circulating the air E, the uniformity of the battery temperatures increases further.
[0033] As the dash-double-dot line in FIG. 1 shows, it is more preferable to provide a selector valve member 24 for switching so as to selectively communicate either the inlet duct 12 or the circulation duct 17 to the inlet opening 11 , and to switch this selector valve member 24 in association with the selector valve member 18 . Namely, both of the selector valve members 18 and 24 are controlled by the controller 22 so as to selectively switch between a state where the entrance and the exit of the circulation duct 17 are closed simultaneously, and a state where the outlet duct 14 and the inlet duct 12 are closed simultaneously. As a result, since the air E is circulated while the introduction of cold air from the inlet duct 12 is prevented when the battery power source device is used at low temperatures, the temperatures of the rechargeable batteries 9 increase quickly. On the other hand, since the entire air E from the inlet duct 12 is prevented from flowing into the circulation duct 17 , and thus efficiently flows into the battery storage room 10 when the battery power source device is used at ordinary temperatures, the rechargeable batteries 9 are efficiently cooled.
[0034] While the embodiment above is described for the case where the cylindrical rechargeable batteries 9 are used, it is apparent that a similar effect is achieved when primary batteries or rechargeable batteries in another shape such as a prismatic shape are used. Also, air E is used as the temperature control medium, and simultaneously the fan 19 is used as the medium transport device in the embodiment, it is possible to properly select to use another temperature control medium or another medium transport device.
[0035] The battery power source device of the present invention has such a constitution that the temperature control medium passes through the battery storage room while the temperature thereof increases by the heat exchange with the batteries, and is introduced into the battery storage room again through the medium circulation passage so as to circulate. Thus, it is possible to increase the temperatures of the individual batteries while the temperatures are maintained at a uniform level, when the battery power source device is used at low temperatures. On the other hand, the individual batteries are efficiently cooled by discharging the temperature control medium outside from the outlet opening after the temperature control medium has flowed from the inlet opening, and then has passed through the battery storage room. Thus, the excellent temperature control effect is achieved when the battery power source device is used at ordinary temperatures. Consequently, though this battery power source device has the inexpensive constitution which simply includes the medium circulation path, the battery power source device prevents the variation of the temperature characteristics of the individual batteries due to unevenness of the individual battery temperatures whether the battery power source device is used at low temperatures or at ordinary temperatures, thereby maintaining excellent overall performance of the entire batteries.
[0036] Although the present invention has been fully described in connection with the preferred embodiment thereof, it is to be noted that various changes and modifications apparent to those skilled in the art are to be understood as included within the scope of the present invention as defined by the appended claims unless they depart therefrom. | A battery power source device is provided for supplying high electric power used for a drive power source for a vehicle. The battery power source device includes a battery box for storing a plurality of batteries arranged in a connected state in a battery storage room, an inlet opening for introducing a temperature control medium into the battery storage room, an outlet opening for discharging the medium from the battery storage room to the outside, a medium circulation passage for leading the medium discharged from the outlet opening to the inlet opening for feeding into the battery storage room again, and a medium transport device for forcing the medium flow. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application No. 60/852,352 filed Oct. 17, 2006, the disclosure of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of Radio Frequency Identification (RFID) tags and in particular relates to a method and apparatus for manufacturing an auxiliary antenna for an RFID tag.
BACKGROUND OF THE INVENTION
[0003] RFID tags are used to associate an object with information stored in the tag such as an identification code. The RFID tag is read via the principle of electromagnetic (EM) communication wherein an interrogator containing a transmitter generates an EM signal that is transmitted via an antenna associated with the interrogator to an antenna associated with the tag. In a passive tag the antenna receives a portion of the transmitted energy and through a rectifier generates DC power for operating a reply generation circuit. The reply generation circuit encodes the information stored in the tag into an EM reply signal that is radiated by the antenna. The radiated signal is received by the interrogator antenna and the information is decoded by the interrogator.
[0004] A typical RFID tag module has a limited read range that may be less than 40 cm. To enhance performance of the tag when it is applied to an object it is known to couple a secondary or auxiliary antenna to the antenna on the tag. The auxiliary antenna may be larger than the tag antenna and may be located on the same object in close proximity to the tag antenna so that it is electromagnetically coupled thereto.
[0005] Prior art methods for manufacturing such range enhancing or auxiliary antennas include etching of suitable conductors such as copper or aluminum on a substrate, and/or depositing conductive ink by means of screen printing, photographic or offset printing processes or the like. However, such manufacturing methods require too many steps and are relatively slow and expensive to apply. They are also not able to be incorporated into a cardboard roll manufacturing process.
SUMMARY OF THE INVENTION
[0006] In accordance with the present invention a process is provided for manufacturing an auxiliary antenna for an RFID tag that at least alleviates the above described disadvantages of the prior art. Further in accordance with the present invention, a process is provided for manufacturing an auxiliary antenna for an RFID tag that may be incorporated into a roll manufacturing process such as a cardboard roll manufacturing process.
[0007] According to one aspect of the present invention there is provided a method of forming on a moving surface an auxiliary antenna for an RFID tag, said method including the steps of:
[0008] providing a webstock of polymeric material including a conductive film; conveying said webstock with said moving surface; and
[0009] applying said conductive film to said moving surface in a shape corresponding to said antenna.
[0010] The moving surface may include cardboard in a roll manufacturing process. The webstock preferably is conveyed between a supply roller and a take up roller.
[0011] The step of applying the conductive film may include cold stamping. Cold stamping may include applying adhesive to the moving surface. The adhesive may be applied substantially in a shape corresponding to the antenna. The adhesive may be applied via an offset printing roller. Cold stamping may include pressing the conductive film to the adhesive via a pressing roller and curing the adhesive with ultra violet light.
[0012] The step of applying the conductive film may include hot stamping. Hot stamping may include applying adhesive to the conductive film and pressing the film to the moving surface via a pressing roller. The pressing roller may have a relief portion substantially in a shape corresponding to the antenna. Hot stamping may include curing the adhesive via application of heat.
[0013] The method of the present invention may include applying an RFID tag over the auxiliary antenna. The RFID tag may include a tag antenna. The RFID tag preferably is applied over the auxiliary antenna such that it is electromagnetically coupled with the tag antenna. The method may include punching the cardboard surface into carton blanks such that the auxiliary antenna is positioned on a side panel of the carton. The method may include embossing each carton blank with fold lines, folding the blank along the fold lines and assembling the blank into a carton.
[0014] According to a further aspect of the present invention there is provided an apparatus for forming on a moving surface an auxiliary antenna for an RFID tag, said apparatus including:
[0015] means for providing a webstock of polymeric material including a conductive film;
[0016] means for conveying said webstock with said moving surface; and
[0017] means for applying said conductive film to said moving surface in a shape corresponding to said antenna.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Preferred embodiments of the present invention will now be described with reference to the accompanying detailed description which refers to the drawings wherein:
[0019] FIG. 1 a is a top, perspective, schematic view of a cold stamping process for manufacturing an auxiliary antenna for an RFID tag in accordance with the present invention;
[0020] FIG. 1 b is a top, perspective, schematic view of a subsequent step in the cold stamping process shown in FIG. 1 a;
[0021] FIG. 1 c is a top, perspective, schematic view of a subsequent step in the cold stamping process shown in FIG. 1 a;
[0022] FIG. 1 d is a top, perspective, schematic view of a subsequent step in the cold stamping process shown in FIG. 1 a;
[0023] FIG. 2 is a side, perspective, cross-sectional view of webstock including conductive film suitable for use with cold stamping in accordance with the present invention;
[0024] FIG. 3 is a side, perspective, cross-sectional view of further webstock including conductive film suitable for use with the cold stamping process of the present invention;
[0025] FIG. 4 is a top, perspective, schematic view of a hot stamping process for manufacturing an auxiliary antenna for an RFID tag in accordance with the present invention;
[0026] FIG. 5 is a side, perspective, cross-sectional view of webstock including conductive film suitable for use with hot stamping in accordance with the present invention;
[0027] FIG. 6 is a side, perspective, cross-sectional view of further webstock including conductive film suitable for use with hot stamping in accordance with the present invention;
[0028] FIG. 7 a is a side, perspective view of an auxiliary antenna and RFID tag applied to a cardboard object in accordance with the present invention;
[0029] FIG. 7 b is a front view of the auxiliary antenna shown in FIG. 7 a; and
[0030] FIG. 7 c is a side, perspective, enlarged view of the RFID tag module shown in FIG. 7 a.
DETAILED DESCRIPTION
[0031] FIG. 1 a shows a cardboard roll manufacturing process including a cold stamping apparatus 10 for manufacturing an auxiliary antenna 20 for an RFID tag 21 . The cold stamping apparatus 10 shown in FIG. 1 a is adapted to apply a relatively thin antenna (approximately not more than about 5 μm) to a cardboard surface 11 in the cardboard roll manufacturing process. The cold stamping apparatus 10 includes an offset printing roll 12 for applying to the surface 11 of the cardboard roll a suitable adhesive 13 in a shape corresponding to the auxiliary antenna. The apparatus 10 includes a roller 14 for supplying continuous webstock 15 including a conductive film 16 . The conductive film 16 is applied to the surface 11 of the cardboard roll by means of a pressing roller 17 and a source 18 of ultra violet (UV) light for irradiating the film prior to being taken up by a roller 19 .
[0032] Pressure applied by roller 17 causes the conductive film 16 to adhere to the adhesive 13 in the shape corresponding to the auxiliary antenna 20 . The adhesive is cured via the UV source 18 . As webstock 15 is pulled away from surface 11 the conductive film peels away from webstock 15 and the webstock excluding portions corresponding to the peeled antennas is taken up by roller 19 .
[0033] An RFID tag module 21 is then positioned and applied over the auxiliary antenna 20 . The carton blank is subsequently punched from the cardboard roll at punching station 22 prior to being embossed with fold lines 28 (refer FIG. 1 b ), folded 29 along the fold lines (refer FIG. 1 c ) and assembled into a carton 30 (refer FIG. 1 d ).
[0034] FIG. 2 shows one example of webstock 15 including conductive film suitable for use with the cold stamping process. The webstock 15 includes a substrate 23 comprising a flexible polymeric material such as polyester (PE), polyethylene terephthalate (PET) or polyethylene napthalate (PEN). A release layer 24 is applied over the substrate 23 to facilitate peeling of subsequent layers from substrate 23 . An insulating layer 25 such as a varnish is applied over the release layer 24 . The insulating layer 25 may be color coded for a purpose as described below. A layer of a first conductive material 26 such as aluminum is applied over the insulating layer 25 . A layer of a second conductive material 27 such as copper is applied over the first conductive material 26 . The conductive layers may be deposited over the insulating layer in any suitable manner and by any suitable means such as by metal evaporation. The relative thickness of the first and second layers of conductive material may vary in the range of 25% to 75%. The relative thickness may be varied to adjust resistivity of the conductive film and for a purpose as described below. The resistivity of the conductive film is preferably in the range of 0.05-0.1 ohms/cm or less.
[0035] FIG. 3 shows another example of webstock 15 including conductive film suitable for use with the cold stamping process. The webstock 15 includes a substrate 33 comprising a flexible polymeric material (PE, PET or PEN), a combined insulating/release layer 34 is applied over the substrate 33 to facilitate peeling thereof from substrate 33 . A layer of a first conductive material 36 (e.g. aluminum) is applied over the insulating/release layer 34 . A layer of a second conductive material 37 (e.g. copper) is applied over the first conductive material 36 .
[0036] The color of the varnish may be defined in accordance with a specific use. The defined color may provide an anti-counterfeiting measure and/or a means for coding products, e.g. the varnish may be colored red for dangerous goods, blue for safe goods, green for perishable goods, etc. Colored varnish may also be used for aesthetic purposes.
[0037] An additional or alternative anti-counterfeiting/coding measure may include adjusting relative thickness of the first and second conductive materials 26 / 36 , 27 / 37 . In one form the relative thickness of the conductive materials may be 75% aluminum and 25% copper. The relative thicknesses of the first and second conductive materials may be detected and/or measured by means of x-ray fluorescence spectroscopy. If a detected and/or measured thickness of the first and second conductive materials does not substantially agree with an expected relative thickness of the conductive materials, the product may be treated as being counterfeit or non-genuine.
[0038] FIG. 4 shows a cardboard roll manufacturing process including a hot stamping apparatus 40 for manufacturing an auxiliary antenna 48 for an RFID tag 49 . The hot stamping apparatus 40 is adapted to apply a relatively thick antenna (approximately at least about 5 μm) to a cardboard surface 41 in the cardboard roll manufacturing process. The hot stamping apparatus 40 includes a roller 42 for supplying continuous webstock 43 including a conductive film 44 overlaid with a heat curing adhesive. The conductive film 44 and adhesive is applied to the surface 41 of the cardboard roll by means of a pressing roller 45 and a source of heat (not shown) prior to being taken up by a roller 46 .
[0039] Pressing roller 45 includes a relief portion 47 in a shape corresponding to the auxiliary antenna 48 . Pressure applied by the relief portion 47 of roller 45 causes conductive film 44 to adhere to the surface 41 in the shape corresponding to the antenna 48 . Adhesive provided on the conductive film 44 is cured by the heat source. As webstock 43 is pulled away from surface 41 , the conductive film peels away from webstock 43 and the webstock excluding portions corresponding to the peeled antennas is taken up by roller 46 .
[0040] An RFID tag module 49 is then positioned and applied over the conductive antenna 48 . The carton blank is subsequently punched from the cardboard roll at punching station 50 prior to being embossed with fold lines, folded and assembled into a carton as described with reference to FIGS. 1 b to 1 d.
[0041] FIG. 5 shows one example of webstock 43 including conductive film suitable for use with the hot stamping process. The webstock 43 includes a substrate 53 comprising a flexible polymeric material such as polyester (PE), polyethylene terephthalate (PET) or polyethylene napthalate (PEN). A release layer 54 is applied over the substrate 53 to facilitate peeling of subsequent layers from substrate 53 . An insulating layer 55 such as a colored varnish is applied over the release layer 54 . The insulating layer 55 may be color coded for a purpose as described above. A layer of a first conductive material 56 such as aluminum is applied over the insulating layer 55 . A layer of a second conductive material 57 such as copper is applied over the first conductive material 56 . The conductive layers may be deposited over the insulating layer in any suitable manner and by any suitable means such as by means of metal evaporation. The relative thickness of the first and second layers of conductive layers may vary in the range of 25% to 75%. The relative thickness may be varied for a purpose as described above. The resistivity of the first and second conductive layers preferably is in the range of 0.05-0.1 ohms/cm or less. A final layer of a heat curing adhesive 58 is applied over the second layer of conductive material 57 .
[0042] FIG. 6 shows another example of webstock 43 including conductive film. The webstock 43 includes a substrate 63 comprising a flexible polymeric material (PE, PET or PEN). A combined insulating/release layer 64 is applied over the substrate 63 to facilitate peeling thereof from substrate 63 . A layer of a first conductive material 66 (e.g. aluminum) is applied over the insulating/release layer 64 . A layer of a second conductive material 67 (e.g. copper) is applied over the first conductive material 66 . A final layer of a heat curing adhesive 68 is applied over the second layer of conductive material 67 .
[0043] FIGS. 7 a to 7 c show RFID tag module 21 , 49 positioned relative to an auxiliary antenna 20 , 48 applied to a side panel 70 of a cardboard box or carton 30 . The RFID tag module 21 , 49 is preferably applied such that it overlaps a portion of a conductive track of the auxiliary antenna 20 , 48 . An enlarged view of the RFID tag module 21 , 49 and auxiliary antenna 20 , 48 is shown in FIG. 7 c . The RFID tag module 21 , 49 includes a U-shaped tag antenna 71 formed over a PET substrate 72 , and an IC chip (not shown) connected to antenna 71 . A layer of adhesive 73 is applied to the underside of substrate 72 . The RFID tag module 21 , 49 is affixed over the insulating layer 34 , 64 (colored varnish) associated with auxiliary antenna 20 , 48 .
[0044] Finally, it is to be understood that various alterations, modifications and/or additions may be introduced into the constructions and arrangements of parts previously described without departing from the spirit or ambit of the invention.
[0045] Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A method is disclosed of forming on a moving surface an auxiliary antenna for an RFID tag. The method includes the steps of providing a webstock of polymeric material including a conductive film, conveying the webstock with the moving surface, and applying the conductive film to the moving surface in a shape corresponding to the auxiliary antenna. The moving surface may include cardboard in a roll manufacturing process. Depending on the thickness of the auxiliary antenna the step of applying the conductive film may include cold or hot stamping. Apparatus for forming an auxiliary antenna for an RFID tag is also disclosed. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62/061,306, filed Oct. 8, 2014, entitled “Reconfigurable Infant Play Yard,” the contents of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a gym that has multiple configurations to allow for use by newborns, infants and even toddlers. In particular, it relates to a children's gym including two support members, an activity bar, and a mat. The mat may be reconfigurable between multiple configurations for different styles of play that allow the gym to grow with the child. The activity bar may further include interactive toys such as hanging elements removably suspended from the activity bar, as well as lights and sounds to further engage the child.
BACKGROUND OF THE INVENTION
[0003] Very young children develop by interacting with their surrounding environment. Sensory stimuli are one of a newborn or infant's first sources of learning (infants learn through audio and visual stimulation related to different fields of experience). For example, seeing bright colors, bold patterns, and moving elements fosters development of visual tracking skills. Listening to music and sounds stimulates auditory skills, while touching materials of varying texture enhances tactile skills. Each of these activities, moreover, encourages these children to use and develop their cognitive skills to differentiate among various sights, sounds, and textures. Consequently, toys for very young children are often developed to create varied interactive, sensory experiences. For example, infant gyms enhance both visual and auditory skills through stimulation by providing an infant an opportunity to use his or her senses while interacting with the gym. Infant gyms provide neurological stimulation, as well as develop an infant's motor and cognitive skills. Specifically, an infant gym with enhanced visual appeal, different textures, and busy activities stimulates the infant's senses, and thus his or her sensory development. Furthermore, infant gyms encourage an infant to kick, reach, and bat at hanging toys, developing motor skills. In addition, the infant's ability to repeatedly make events happen helps an infant understand cause and effect. Increasing interaction with an infant gym is desirable because it increases the infant's potential for learning. However, most infant gyms are only affective at holding an infants attention when the infant is only capable of lying in the supine position, and lose much of their use when the child begins to sit, or ultimately stand. Once infants are able to sit, craw, and/or walk, other forms of entertainment beyond hanging items that they can kick, reach, and bat at while lying in the supine position are desireable to continue to develop the infant's motor and cognitive skills and add value to the consumer. Thus, it is desirable to provide an entertainment device or toy including activities with which a child can interact to develop cognitive and/or motor skills as they grow older.
[0004] The present invention is directed generally to an entertainment device or toy that is capable of being used throughout the growth of the child. What is needed is a gym that is capable of being used during all of the early growth stages of a child, from when a child is only capable of lying in the supine position, to when the child can sit upright unassisted, to when the child is able to stand and walk around. The desired gym may further include one or more interactive features such as hanging elements and ball placement and drop elements that can be utilized in the different configurations.
SUMMARY OF THE INVENTION
[0005] According to one exemplary embodiment, the present invention includes a gym containing a first support member, a second support member, a substantially horizontal member, and a mat. The first and second support members are oriented in a generally vertical orientation and spaced apart from one another. Moreover, the support members each have a top, a bottom, an opening disposed on the top, and an internal passageway in communication with the opening. The substantially horizontal member is coupled to the top of the first support member and the second support member proximate to the upper openings. Furthermore, a toy ball can be placed on the horizontal member and travel towards either of the upper openings. If the ball travels into either of the upper openings, the ball will travel along the internal passageway to the bottom of the support member. Finally, the mat is placeable between the first and second support members, and is be removably coupleable to the first and second support members in multiple configurations to change the orientation and shape of the mat for different types of play as a child grows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates a front view of a first embodiment of a gym in the first configuration according to the present invention.
[0007] FIG. 1A illustrates a front view of the connection of the mat to the first and second support members of the first embodiment of the gym illustrated in FIG. 1 , the gym being configured in the first configuration.
[0008] FIG. 2 illustrates a front view of the first embodiment of the gym illustrated in FIG. 1 , the gym being configured in the second configuration.
[0009] FIG. 2A illustrates a front view of the connection of the mat to the first and second support members of the first embodiment of the gym illustrated in FIG. 2 , the gym being configured in the second configuration.
[0010] FIG. 2B illustrates a perspective view of a second embodiment of the connectors of the mat of the gym illustrated in FIG. 2 , the gym being configured in the second configuration.
[0011] FIG. 2C illustrates a perspective view of a second embodiment of the connectors of the mat illustrated in FIG. 2B connected to the first and second support members of the gym illustrated in FIG. 2 , the gym being configured in the second configuration.
[0012] FIG. 3 illustrates a perspective view of a second embodiment of a gym in the second configuration according to the present invention.
[0013] FIG. 4 illustrates a front view of the first embodiment of the gym illustrated in FIG. 1 , the gym being configured in a third configuration.
[0014] Like reference numerals have been used to identify like elements throughout this disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Illustrated in FIGS. 1, 1A, 2, 2A, 2B, 2C, 3, and 4 is a gym 10 , in accordance with the present invention, that is reconfigurable to provide different play features for a young child. The gym 10 , as illustrated in FIGS. 1, 1A, 2, 2A, 2B, 2C, 3, and 4 , includes a first support member 100 , a second support member 200 , and an arched member 300 connected to both the first support member 100 and the second support member 200 . The first support member 100 includes a first leg 110 , a second leg 130 , and a upper member 170 that extends upwardly from the first and second legs 110 , 130 . The first leg 110 of the first support member 100 has a top portion 112 and a bottom portion 114 where the bottom portion 114 is configured to engage a support surface. The second leg 130 of the first support member 100 also has a top portion 132 and a bottom portion 134 where the bottom portion 134 is configured to engage a support surface. The top portion 112 of the first leg 110 is coupled to the top portion 132 of the second leg 130 , while the bottom portion 114 of the first leg 110 is spaced away from the bottom portion 134 of the second leg 130 . The first leg 110 and the second leg 130 of the first support member 100 together form an archway 150 . Furthermore, the upper member 170 includes a top portion 172 and a bottom portion 174 , where the bottom portion 174 is coupled to the top portions 112 , 132 of the first and second legs 110 , 130 of the first support member 100 .
[0016] Additionally, as illustrated in FIGS. 1, 1A, 2, 2A, 2B, 2C, 3, and 4 , the second support member 200 includes a first leg 210 , a second leg 230 , and a upper member 270 that extends upwardly from the first and second legs 210 , 230 . The first leg 210 of the second support member 200 has a top portion 212 and a bottom portion 214 where the bottom portion 214 is configured to engage a support surface. The second leg 230 of the second support member 200 also has a top portion 232 and a bottom portion 234 where the bottom portion 234 is configured to engage a support surface. Similarly to that of the first support member 100 , the top portion 212 of the first leg 210 is coupled to the top portion 232 of the second leg 230 , while the bottom portion 214 of the first leg 210 is spaced away from the bottom portion 234 of the second leg 230 . The first leg 210 and the second leg 230 of the second support member 200 form an archway 250 identical to the archway 150 formed in the first support member 100 . Furthermore, the upper member 270 includes a top portion 272 and a bottom portion 274 , where the bottom portion 274 is coupled to the top portions 212 , 232 of the first and second legs 210 , 230 of the second support member 200 .
[0017] The top portion 172 of the upper member 170 of the first support member 100 includes an opening 180 (best seen in FIG. 3 ). The upper member 170 further includes a passageway 176 that runs through the interior of the upper member 170 from the opening 180 in the top portion 172 through the bottom portion 174 of the upper member 170 . Furthermore, the first leg 110 of the first support member 100 contains a channel 118 that runs from the top portion 112 of the first leg 110 to the bottom portion 114 of the first leg 110 down the front of the leg 110 . The passageway 176 of the upper member 170 opens into the channel 118 of the first leg 110 creating a continuous pathway from the opening 180 in the top portion 172 of the upper member 170 to the bottom portion 114 of the first leg 110 . A ball 500 that enters the opening 180 in the top portion 172 of the upper member 170 would travel through the passageway 176 of the upper member 170 and then down the channel 118 of the first leg 110 to the bottom portion 114 of the first leg 110 . The bottom portion 114 of the first leg 110 further includes a repositionable gate 120 that, when in the closed position illustrated in FIGS. 1-3 , prevents any balls 500 from exiting the channel 118 of the first leg 110 . The bottom portion 114 of the first leg 110 of the first support member 100 further includes projections 116 positioned on either side of the channel 118 proximate the gate 120 .
[0018] Similar to the upper member 170 of the first support member 100 , the top portion 272 of the upper member 270 of the second support member 200 includes an upper opening 280 (best seen in FIGS. 1, 2, and 4 ). The upper member 270 further includes a passageway 284 that runs through the interior of the upper member 270 from the upper opening 280 in the top portion 272 through the bottom portion 274 of the upper member 270 . Furthermore, the first leg 210 of the second support member 200 contains a channel 218 that runs from the top portion 212 of the first leg 210 to the bottom portion 214 of the first leg 210 down the front of the first leg 210 . The passageway 284 of the upper member 270 opens into the channel 218 of the first leg 210 creating a continuous pathway from the opening 280 in the top portion 272 of the upper member 270 to the bottom portion 214 of the first leg 210 . A ball 500 that enters the opening 280 in the top portion 272 of the upper member 270 would travel through the passageway 284 of the upper member 270 and then down the channel 218 of the first leg 210 to the bottom portion 214 of the first leg 210 . The upper member 270 of the second support member 200 further includes a lower opening 282 that is disposed on the sidewall of the upper member 270 proximate to the bottom portion 214 . The lower opening 282 is in communication with the passageway 284 and the channel 218 , so that a ball 500 placed in the lower opening 282 would also travel down the passageway 284 and into the channel 218 of the first leg 210 . Moreover, the bottom portion 214 of the first leg 210 of the second support member 200 further includes a repositionable gate 220 that, when in the closed position illustrated in FIGS. 1-3 , prevents any balls 500 that travel down the channel 218 from exiting the channel 218 of the first leg 210 . The bottom portion 214 of the first leg 210 of the second support member 200 further includes projections 216 positioned on either side of the channel 218 proximate the gate 220 .
[0019] As best illustrated in FIGS. 1A and 2A , the first support member 100 includes at least three small apertures 122 , 124 , and 136 . Disposed on the first leg 110 of the first support member 100 , proximate to the bottom portion 114 of the first leg 110 , is a first aperture 124 . Similarly, disposed on the second leg 130 of the first support member 100 , proximate to the bottom portion 134 of the second leg 130 , is a second aperture 136 . Additionally, disposed on the first leg 110 of the first support member 100 , proximate to the top portion 112 of the first leg 110 , above the archway 150 , is a third aperture 122 . Mirroring the first support member 100 , the second support member 200 includes at least three small apertures 222 , 224 , and 236 . Disposed on the first leg 210 of the second support member 200 , proximate to the bottom portion 214 of the first leg 210 , is a first aperture 224 . Disposed on the second leg 230 of the second support member 200 , proximate to the bottom portion 234 of the second leg 230 , is a second aperture 236 . Finally, disposed on the first leg 210 of the second support member 200 , proximate to the top portion 212 of the first leg 210 , above the archway 250 , is a third aperture 222 .
[0020] As further illustrated in FIGS. 1, 1A, 2, 2A, 2B, 2C, 3, and 4 , the arched member 300 includes a first end 370 and a second end 380 . The first end 370 of the arched member 300 is coupled to the top portion 172 of the upper member 170 of the first support member 100 proximate the opening 180 in the top portion 172 . Furthermore, the second end 380 of the arched member 300 is coupled to the top portion 272 of the upper member 270 of the second support member 200 proximate the upper opening 280 in the top portion 272 . As further illustrated, the bottom of the arched member 300 includes two lights 330 . In other embodiments, the number of lights 330 may vary, or the arched member 300 may include no lights. The bottom of the arched member 300 also is configured to receive and suspend a first tether 340 , a second tether 350 , and a third tether 360 . Attached to the end of the first tether 340 is a first toy 342 , attached to the end of the second tether 350 is a second toy 352 , and attached to the end of the third tether 360 is a third toy 362 . Other embodiments of the gym 10 may include more or less tethers with toys attached to them.
[0021] FIGS. 1, 1A, 2, 2A, 2B, 2C, 3, and 4 further illustrate that the arched member 300 includes a pair of sidewall members 320 that together define a channel 310 therebetween. The channel 310 is configured to rollingly receive balls 500 . Because the arched member 300 has a curve where the highest point, or apex, of the curve is in the middle of the arched member 300 , a ball 500 placed within the channel 310 of the arched member 300 will roll towards the first side 370 or the second side 380 of the arched member 300 . Because the first side 370 of the arched member 300 is coupled to the top portion 172 of the upper member 170 proximate to the opening 180 , a ball 500 that travels along the channel 310 of the arched member 300 toward the first side 370 of the arched member 300 would roll into the opening 180 , and as explained previously, would eventually travel to the bottom portion 114 of the first leg 110 of the first support member 100 . Similarly, because the second side 380 of the arched member 300 is coupled to the top portion 272 of the upper member 270 proximate to the upper opening 280 , a ball 500 that travels along the channel 310 of the arched member 300 toward the second side 380 of the arched member 300 would roll into the upper opening 280 , and as explained previously, the ball 500 would eventually travel to the bottom portion 214 of the first leg 210 of the second support member 200 .
[0022] Furthermore, illustrated in FIGS. 1, 1A, 2, 2A, 2B, 2C, and 3 is a mat 400 (which may be formed from a softgoods material) that can be positioned between the first support member 100 and the second support member 200 and beneath the arched member 300 . The mat 400 in the embodiments illustrated is substantially rectangular in shape. In other embodiments, the mat 400 may be of a different shape, such as a circle, a square, a triangle, etc. The mat 400 has a first end 460 , a second end 462 opposite the first end 460 , and sides 464 that connect the first end 460 with the second end 462 . Because the mat 400 is in the shape of a rectangle, the sides 464 are longer in length than the first end 460 and the second end 462 . The mat 400 is positioned underneath the arched member 300 and between the first support member 100 and the second support member 200 so that the sides 464 are positioned proximate to the first legs 110 , 210 and the second legs 130 , 230 of the first and second support members 100 , 200 . Moreover, as illustrated, the first end 460 is positioned proximate to the first legs 110 , 210 of the first and second support members 100 , 200 , while the second end 462 is positioned proximate to the second legs 130 , 230 of the first and second support members 100 , 200 . The mat 400 also includes a top surface 440 and a bottom surface 450 (illustrated in FIGS. 2, 2A, 2B, and 2C ). As best shown in FIGS. 1A and 2A , the mat 400 includes a pair of tethers 422 that extend outward from the sides 464 proximate to the first end 460 . The mat 400 additionally includes a second pair of tethers 420 that extend outward from the sides 464 proximate to the second end 462 . In other embodiments, pairs of tethers 420 , 422 may be in another form, such as the connectors 430 illustrated in FIGS. 2B and 2C , where the connectors 430 include tabs 432 . In yet other embodiments, the mat 400 may include fabric loops, string, straps (e.g., straps where the ends are sewn in a T formation to retain the strap within an aperture), plastic or metal buttons or hooks, or other similar attachment means to attach the mat 400 to the first support member 100 and the second support member 200 . In other embodiments, additional pairs of tethers may also be included.
[0023] Turning to FIG. 1 , illustrated is the gym 10 in the first configuration A. In the first configuration A, the mat 400 is placed flat on the support surface with the top surface 440 facing upwards and the bottom surface 450 placed against the support surface. As previously explained, the mat 400 is positioned underneath the arched member 300 and between the first support member 100 and the second support member 200 so that the sides 464 are positioned proximate to the first legs 110 , 210 and the second legs 130 , 230 of the first and second support members 100 , 200 . As best illustrated in FIG. 1A , the mat 400 is secured to the first and second support members 100 , 200 via the tethers 420 , 422 . FIG. 1A illustrates that, when the gym 10 is in the first configuration A, the first tethers 422 are inserted into the first apertures 124 , 224 on the first legs 110 , 210 of the first and second support members 100 , 200 , respectively. Furthermore, the second tethers 420 are inserted into the second apertures 136 , 236 on the second legs 130 , 230 of the first and second support members 100 , 200 , respectively. The insertion of the tethers 420 , 422 into the apertures 124 , 136 , 224 , 236 couples the mat 400 to the first and second support members 100 , 200 . The tethers 420 , 422 may contain ends that are capable of being inserted into the first and second apertures 124 , 136 , 224 , 236 and are configured to prevent the tethers 420 , 422 from accidentally sliding out of engagement with the apertures 124 , 136 , 224 , 236 . The ends of the tethers 420 , 422 may then, when desired, be slid out through the first and second apertures 124 , 136 , 224 , 236 to decouple the tethers 420 , 422 , and subsequently the mat 400 , from the first and second support members 100 , 200 .
[0024] The first configuration A is configured for an infant to lie in the supine position atop the mat 400 between the first and second support members 100 , 200 and underneath the arched member 300 . As previously stated, hanging from the arched member 300 are first tether 340 , second tether 350 , and third tether 360 , which include first toy 342 , second toy 352 , and third toy 362 , respectively. By way of example, the hanging toys 342 , 352 , 362 may include a character comprising a head portion, a torso portion, and/or a leg portion. By way of further example, the characters may be stylized as domestic animals (e.g., a cat or a dog), wild animals (e.g., a raccoon, owl), comic book characters, cartoon characters, and/or humanoid figures. The hanging toys 342 , 352 , 362 may further include various colors, may be made of any suitable material (including teethable material), and may include materials having varying textures. The hanging toys 342 , 352 , 362 may further include noisemakers such as squeakers and rattles, as well as other entertainment features including, but not limited to, spinning portions, mirrors, lights, etc. The tethers 340 , 350 , 360 allow the hanging toys 342 , 352 , 362 to hang from the arched member 300 a distance that would encourage an infant to kick, reach, and bat at the hanging toys 342 , 352 , 362 while the infant is lying in the supine position. Finally, the balls 500 may remain stored in the channels 118 , 218 of the first legs 110 , 210 of the first and second support members 100 , 200 by way of the gates 120 , 220 being positioned in the closed position.
[0025] Turning to FIG. 2 , illustrated is the first embodiment of the second configuration B of the gym 10 . This second configuration B may be utilized by an infant once the infant is able to crawl and sit up without any additional support. In this second configuration, the mat 400 has been folded over so that the second end 462 of the mat 400 is positioned closer to the first end 460 , while also exposing a portion of the bottom side 450 of the mat 400 . Moreover, as best illustrated in FIG. 2A , the mat 400 is secured to the first and second support members 100 , 200 via the tethers 420 , 422 . Similar to the first configuration A, when the gym 10 is in the second configuration B, the first tethers 422 are inserted into the first apertures 124 , 224 on the bottom portion 114 , 214 of the first legs 110 , 210 of the first and second support members 100 , 200 , respectively. However, as illustrated in FIG. 2A , the second tethers 420 are inserted into the third apertures 122 , 222 on the top portion 112 , 212 of the second legs 130 , 230 of the first and second support members 100 , 200 , respectively. As previously explained, the insertion of the tethers 420 , 422 into the apertures 122 , 124 , 222 , 224 couples the mat 400 to the first and second support members 100 , 200 . The ends of the tethers 420 , 422 may be configured to either lock the tethers 420 , 422 into engagement with the apertures 122 , 124 , 222 , 224 or slide out through the apertures 122 , 124 , 222 , 224 to decouple the tethers 420 , 422 from the first and second support members 100 , 200 .
[0026] As illustrated in FIGS. 2 and 2A , with the second pair of tethers 420 coupled to the third apertures 122 , 222 , a portion of the mat 400 proximate to the second end 462 has been lifted off of the support surface and folded over. In this position, the second end 462 is hanging downwards from the coupling of the second pair of tethers 420 to the third apertures 122 , 222 so that the second end 462 of the mat 400 is touching the top surface 440 of the mat 400 . Furthermore, the bottom surface 450 of the mat 400 , proximate the second end 462 is a first pocket 452 , a second pocket 454 , and a third pocket 456 . The pockets 452 , 454 , 456 may be mesh pockets (for example sewn on the bottom surface 450 of the mat 400 ). As illustrated, in the position of the mat 400 when the gym is in the second configuration B, the pockets 452 , 452 , 456 are substantially vertically oriented for the put and take placement of balls 500 into the pockets 452 , 452 , 456 . This second configuration B encourages an infant to sit on the top surface 440 of the mat 400 and remove balls 500 from the channels 118 , 218 of the first legs 110 , 210 of the first and second support members 100 , 200 and place them in the pockets 452 , 452 , 456 .
[0027] FIGS. 2B and 2C illustrate a second embodiment of the mat 400 , the mat 400 being positioned in the second configuration B. Instead of the mat 400 having tethers 420 , as illustrated in FIGS. 2 and 2A , this second embodiment of the mat 400 includes connectors 430 attached to the bottom surface 450 of the mat 400 proximate to the sides 464 . As best illustrated in FIG. 2B , the connectors 430 include a tab 432 and a base 434 . The tab 432 and the base 434 are substantially rigid. As best illustrated in FIG. 2B , the tab 432 is substantially L-shaped. As best illustrated in FIG. 2C , the tabs 432 are inserted into the third apertures 122 , 222 allowing the second end 462 of the mat 400 to be folded over and touching the top surface 440 of the mat 400 . As previously explained, the bottom surface 450 of the mat 400 , proximate the second end 462 has a first pocket 452 , a second pocket 454 , and a third pocket 456 . Moreover, as best illustrated in FIG. 2C , because of the width and rigidity of the bases 434 of the connectors 430 , the bottom surface 450 of the mat 400 forms a shelf-like top surface that extends between the connectors 430 proximate to the pockets 452 , 454 , and 456 .
[0028] Referring to FIG. 3 , illustrated is a second embodiment of a gym 20 with the gym 20 in the second configuration B. As previously discussed, this second configuration B may be utilized by an infant once the infant is able to crawl and sit up without any additional support. Similar to the first embodiment, the second end 462 of the mat 400 has been partially lifted off of the support surface (but not folded over). While not illustrated in FIG. 3 , the second end 462 of the mat 400 is attached to the first support member 100 and the second support member 200 utilizing similar engagement mechanisms to those of the pairs of tethers 420 , 422 and the first and third apertures 122 , 124 , 222 , 224 illustrated in FIG. 2 . With the second end 462 of the mat 400 connected to the first and second support members 100 , 200 , as illustrated in FIG. 3 , the mat 400 forms a curved surface. Moreover, this second embodiment of the gym 20 in the second configuration B includes a lower arched member 600 coupled to the first leg 110 of the first support member 100 and the first leg 210 of the second support member 200 . Opposite of that of the arched member 300 , the lower arched member 600 is curved where the lowest point on the lower arched member 600 is in the middle. However, similar to that of the arched member 300 , the lower arched member 600 has sidewalls 620 that define a channel 610 therebetween configured to receive balls 500 . The infant is encouraged to sit on the mat 400 and throw or place balls 500 into the channel 610 of the lower arched member 600 . Any balls 500 that do not make it into the channel 610 of the lower arched member 600 will be returned to the infant by rolling down the curved mat 400 .
[0029] Turning to FIG. 4 , illustrated is the gym 10 in the third configuration C. This third configuration C may be utilized by an infant once the infant is able to stand and walk without any additional support. As illustrated in FIG. 4 , the mat 400 has been removed from between the first and second support members 100 , 200 and from beneath the arched member 300 . Furthermore, the first toy 342 has been removed from the first tether 340 and coupled to the projections 116 on the bottom portion 114 of the first leg 100 of the first support member 100 , proximate to the gate 120 . In addition, the gate 120 has been repositioned to the open position, allowing any balls 500 that travel down the channel 118 of the first leg 110 to travel out of the first leg 110 of the first support member 100 . Similarly, the third toy 362 has been removed from the third tether 360 and coupled to the projections 216 on the bottom portion 214 of the first leg 200 of the second support member 200 , proximate to the gate 220 . The gate 220 of the second support member 200 has also been repositioned to the open position to allow any balls 500 that travel down the channel 218 and out of the first leg 210 of the second support member 200 .
[0030] As further illustrated, the first toy 342 , when attached to the projections 116 , forms an archway proximate the end of the channel 118 , near the gate 120 of the first support member 100 . The first toy 342 is generally U-shaped with ends 346 that attach to the projections 116 . Moreover, the first toy 342 includes a paddle wheel 344 that spans from one end 346 to the other end 346 . The paddle wheel 344 is configured to spin about a generally horizontal axle. Therefore, when attached to the projections 116 , the paddle wheel 344 is positioned in the pathway of the channel 118 , and any balls 500 that travel out of the channel 118 will strike the paddle wheel 344 , causing the paddle wheel 344 to spin. When the paddle wheel 344 is spun, the first toy 342 may output a noise, such as ratcheting or rattling noises.
[0031] Additionally, the third toy 362 includes an axle 364 with ends 366 that are attached to the projections 216 . The axle 364 of the third toy 362 extends through the body 368 of the third toy 362 , where the body 368 of the third toy 362 may be configured to spin about the horizontal axis of the axle 364 . When the third toy 362 is coupled to the projections 216 of the first leg 210 of the second support member 200 , the body of the third toy 362 is at least partially positioned in the pathway of the channel 218 of the second support member. Therefore, when balls 500 travel down the channel 218 , the balls 500 will strike the body 368 , causing the body 368 of the third toy 362 to spin. When the body 368 is spun, the third toy 362 may output a noise, such as ratcheting or rattling noises.
[0032] When in the third embodiment C, the infant is encouraged to place balls 500 into the channel 310 of the arched member or into the lower opening 282 of the second support member 200 . As previously explained, a ball 500 that travels along the channel 310 of the arched member 300 toward the first side 370 of the arched member 300 would travel into the opening 180 , through the passageway 176 , down channel 118 , and out the first support member 100 while spinning the paddle wheel 344 of the first toy 342 on its way out of the channel 118 . Similarly, a ball 500 that travels along the channel 310 of the arched member 300 toward the second side 380 of the arched member 300 would travel into the upper opening 280 , through the passageway 276 , down the channel 218 , and out of the second support member 200 while spinning the body 368 of the third toy 362 on its way out of the channel 218 . A ball 500 placed into the lower opening 282 would travel through the remainder of the passageway 276 , into the channel 218 , and out of the second support member 200 while also spinning the body 368 of the third toy 362 on its way out of the channel 218 . The first toy 342 and the third toy 362 may be interchangeable in locations. Furthermore, in other embodiments, toys may always be positioned near the bottom portion 114 , 214 of the first legs 110 , 210 of the support members 100 , 200 . Additionally, in other embodiments, additional toys can be placed near the outer and upper portions of support members 100 and 200 that, while not necessarily accessible to the younger baby in the supine position, would increase entertainment options for older toddlers who are able to walk around gym 10 or 20 .
[0033] It is also to be understood that the gym of the present invention, or portions thereof may be fabricated from any suitable material or combination of materials, such as plastic, foamed plastic, wood, cardboard, pressed paper, metal, supple natural or synthetic materials including, but not limited to, cotton, elastomers, polyester, plastic, rubber, derivatives thereof, and combinations thereof. Suitable plastics may include high-density polyethylene (HDPE), low-density polyethylene (LDPE), polystyrene, acrylonitrile butadiene styrene (ABS), polycarbonate, polyethylene terephthalate (PET), polypropylene, ethylene-vinyl acetate (EVA), or the like. Suitable foamed plastics may include expanded or extruded polystyrene, expanded or extruded polypropylene, EVA foam, derivatives thereof, and combinations thereof.
[0034] It is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points or portions of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment of the invention.
[0035] Although the disclosed inventions are illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the scope of the inventions and within the scope and range of equivalents of the claims. In addition, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims. | A children's entertainment structure or play gym includes a first support member, a second support member, an arched member coupled to the top of the first support member and the top of the second support member, and a mat reconfigurable between the first and second support members and beneath the arched member. Moreover, each of the support members has an upper opening and an internal passageway that is in connection with the upper opening that extends through at least a portion of the support member. The upper opening and the passageway are sized and configured to receive and transport balls to the bottom of the support members. The arched member includes a channel that is also configured to receive balls, while allowing them to roll towards the upper openings on the support members. | 0 |
FIELD
[0001] This disclosure pertains to X-ray generators suitable for use as exposure-light sources in, for example, X-ray microlithography systems, and to X-ray microlithography systems comprising the same. More specifically, the disclosure pertains to X-ray generators that produce X-rays from a plasma and that exhibit decreased reflection and scattering from the inner walls of a chamber containing the plasma, thereby reducing temperature increases of components contained in the chamber.
BACKGROUND
[0002] As the diffraction-limitations of optical microlithography (i.e., microlithography performed using a deep-ultraviolet light beam as a lithographic energy beam) have become increasingly burdensome, substantial effort currently has been expended to develop a practical “next-generation lithography” (NGL) system. An especially promising approach involves the use of certain X-ray wavelengths as the lithographic energy beam. In this regard, substantial progress has been made in the use of “soft X-ray” (“SXR”) wavelengths (also termed “extreme UV” or “EUV” wavelengths), typically in the ran effort has been directed to the development of an acceptable EUV-beam source.
[0003] Two types of X-ray sources that show exceptional promise are the so-called “laser-plasma” sources and “discharge-plasma” sources. These sources are especially useful not only for EUV microlithography systems and other EUV-exposure systems, but also in various X-ray-analysis devices. In a laser-plasma X-ray (“LPX”) source a plasma is generated by directing a focused pulsed laser light on a target material inside a vacuum chamber. The target material is highly excited by the pulsed laser light, and X-rays are emitted from the plasma as atoms in the plasma transition to lower energy states. LPX sources are compact and produce X-rays having a brightness rivaling the brightness of X-rays produced by an undulator (synchrotron).
[0004] Discharge-plasma X-ray (“DPX”) sources produce an X-ray-generating plasma by an electrical discharge in the presence of a target material. These sources include “dense plasma focus” (DPF) sources, in which a high-voltage pulse is impressed on electrodes to produce an electrical discharge. The discharge ionizes a working gas (constituting the target material) and generates therefrom a plasma that emits X-rays. DPX sources are compact and low-cost, and produce a high emission yield of X-rays. Other types of DPX sources include hollow-cathode and capillary sources.
[0005] LPX and DPX sources have found particular utility recently as EUV-light sources as used in “reducing” (demagnifying) projection-microlithography systems, especially such systems utilizing a 13-nm EUV beam as the lithographic energy beam. As a result of these and other seminal developments, EUV microlithography is a most promising NGL technology on the threshold of reaching practicality for use in the fabrication of microelectronic devices such as semiconductor integrated circuits, memory devices, and displays.
[0006] Since no known materials exist that can adequately refract EUV radiation, EUV-optical systems must be constructed of reflective optical elements, notably multilayer-film mirrors that exhibit high (currently approximately 70%) reflectivity of incident EUV radiation at perpendicular incidence. For example, for EUV radiation having λ=13 nm, a suitable multilayer film comprises multiple Mo/Si layer pairs (e.g., 45 layer pairs), in which multilayer film the Mo layers are laminated in an alternating manner with the Si layers. The reflection bandwidth (BW) of this type of mirror is approximately ±1%; hence, assuming a median wavelength of 13.5 nm, the bandwidth of reflected EUV light from the multilayer-film mirror is 13.365 nm to 13.635 nm. With this mirror EUV light outside this reflection bandwidth does not contribute to lithographic imaging (pattern-transfer).
[0007] The various plasma X-ray sources discussed above do not exhibit a high conversion efficiency of EUV light relative to input power, especially with respect to the reflection bandwidth of multilayer-film mirrors. For example, with an LPX source in which Xe gas is the target material, the conversion efficiency with which 13-nm EUV light (at 2% BW, emitted at a solid angle of 2π sr) is produced is approximately 0.6%.
[0008] EUV light incident to the illumination-optical system of an EUV microlithography system currently must be at least approximately 50 W to achieve acceptable throughput. This intensity requires that the incident laser light have a power of 15 kW, wherein the solid angle of EUV light from the plasma is πsr. As hinted above, most of the power of the incident laser light is absorbed by the plasma. Also, up to several tens of percent of the incident laser power is consumed as work expended in converting the target material into a plasma. In addition, some of the incident laser power is scattered by the plasma and target material. The remaining power radiates away from the plasma in a broad wavelength range from infrared to X-ray.
[0009] Immediately downstream of the plasma X-ray source is an illumination-optical system, of which the first mirror (referred to as mirror “C1”) typically is configured to gather as much as possible of the EUV light emitted from the plasma X-ray source. Also, the mirror C 1 desirably is made as small as possible so as to simplify fabrication of the mirror. Consequently, the mirror C 1 is disposed in the vicinity of the plasma (e.g., at a distance of 10 to 20 cm from the plasma). If the reflectivity of the multilayer film of the mirror C 1 is approximately 70%, then approximately 15 W of the 50 W of in-band EUV power incident to the mirror C 1 is absorbed by the multilayer film of the mirror C 1 . Most of the broad-bandwidth radiation (infrared to X-ray) outside the reflection bandwidth of the multilayer film is absorbed by the multilayer-film mirror C 1 .
[0010] Absorption of energy, as described above, by the mirror C 1 increases the temperature of the mirror's multilayer film and mirror substrate. As the temperature of the multilayer film is increased in this manner, substantial diffusion occurs at the boundary interfaces between respective individual layers of the multilayer film (e.g., between adjacent Mo and Si layers). Such diffusion decreases the reflectivity of the multilayer film to incident EUV light.
[0011] For example, consider an instance in which the temperature of the multilayer film, disposed 15 cm from the plasma and with an incident laser power of 10 kW, increases to several hundreds of degrees C. If the multilayer film is a Mo/Si multilayer film, boundary diffusion occurs at a marked rate whenever the temperature of the Mo/Si multilayer film exceeds approximately 300° C. Even if the multilayer film does not reach 300° C., if the elevated temperature persists for a sufficiently long period of time, depending upon the circumstances, sufficient boundary diffusion may occur in the Mo/Si multilayer film to significantly reduce its reflectivity and thus shorten the useful life of the mirror.
[0012] The foregoing description highlights the temperature increase of the multilayer-film mirror arising from radiation from the plasma that is directly incident to the mirror. But, under actual conditions, the temperature of the multilayer-film mirror is increased even further as a result of heating caused by indirect radiation from the plasma.
[0013] Plasma X-ray sources, including LPX and DPX sources, must be operated in a vacuum environment in order to generate a plasma and to facilitate propagation of EUV light from the plasma. Consequently, the target material and any discharge electrodes of the source must be connected from outside to inside the vacuum chamber enclosing the source. The vacuum chamber also contains the multilayer-film mirror C 1 . Conventional plasma X-ray sources are contained in respective vacuum chambers made of either stainless steel or aluminum. To facilitate evacuation of the chamber to a high vacuum, the inner surfaces of such chambers have either a metallic luster, without any surficial treatment, or a mirror finish achieved by electrolytic polishing or the like. Infrared through ultraviolet wavelengths of radiation emitted from the plasma are reflected from or scattered by the inner surfaces of the chamber to the mirror C 1 . This “indirect” irradiation of the mirror C 1 contributes to excessive heating of the mirror.
[0014] In addition to the multilayer-film mirror C 1 , other components disposed inside the vacuum chamber include a target-material-discharge member (e.g., a gas-jet nozzle in the case of a Xe-gas-jet LPX), discharge electrodes (for DPX sources), and one or more filters. The filters are used for blocking downstream propagation of infrared, visible, and UV light and transmitting EUV radiation emitted from the plasma. If these wavelengths were not blocked, they would interfere downstream with the transfer-exposure of fine pattern elements. Hence, the filters transmit only the required wavelength range of EUV light. Since common materials readily absorb EUV light, the filters typically are extremely thin, e.g., approximately 150 nm thick. Such thin filters are prone to fracture if an excessive thermal load is imposed on the filter.
[0015] Excessive heating of various components located inside the vacuum chamber, as described above, decreases their performance. For example, the temperature of the gas-jet nozzle used for discharging a stream of Xe target material must be kept low to ensure efficient production by the nozzle of clusters of solid or liquid Xe. It also is necessary to prevent excessive temperature increases of discharge electrodes caused by heat radiating from sources other than the electrical current normally applied to the electrodes, so as to avoid melting the discharge electrodes.
SUMMARY
[0016] In view of the foregoing, the present invention provides, inter alia, X-ray generators exhibiting reduced reflection and scattering of radiation from the inner walls of a chamber containing the plasma, thereby reducing the operational temperature of components located inside the chamber, and lengthening the useful life of the components.
[0017] According to a first aspect of the invention, X-ray generators are provided. An embodiment of the X-ray generator comprises an X-ray source and a vacuum chamber. The X-ray source produces a plasma, from a target material, that emits X-rays. The vacuum chamber is defined by walls and contains the X-ray source. The walls include respective inner surfaces that are configured so that at least a portion of the inner surfaces absorbs incident electromagnetic radiation, produced by the plasma, in a wavelength range from infrared to X-ray radiation. The portion represents a location from which the electromagnetic radiation otherwise would reflect back into the vacuum chamber and heat a component situated inside the vacuum chamber.
[0018] The X-ray source can be, for example, a laser-plasma X-ray source or a discharge-plasma X-ray source.
[0019] By way of example, to confer high reflectivity to the incident electromagnetic radiation, the portion of the inner surfaces can be coated with carbon. The carbon can be selected from the group consisting of carbon black, benzene soot, fullerene, carbon nanotubes, and dried suspensions of colloidal graphite.
[0020] By way of another example, the portion of the inner surfaces can comprise a porous material, such as activated charcoal or porous silicon.
[0021] By way of yet another example, the portion of the inner surfaces can be anodized or comprise a unit of anodized aluminum.
[0022] By way of yet another example, the portion of the inner surfaces can comprise a “brushy” layer comprising, e.g., multiple needle-shaped members, bristle-shaped members, or blade-shaped members. Desirably, these members extend from the inner wall toward the plasma. The needles desirably have respective tapered tips extending toward the plasma. Alternatively, the brushy layer is configured as a “carpet” of glass fibers or bristles, carbon fibers or bristles, metal fibers or bristles, or silicon fibers or bristles, or combinations thereof.
[0023] An X-ray generator according to another embodiment comprises an X-ray source as summarized above and a vacuum chamber defined by walls and containing the X-ray source. At least a portion of the walls is made of a material that is transmissive to incident electromagnetic radiation, from the plasma, in a wavelength range from infrared to ultraviolet. The portion represents a location from which the electromagnetic radiation otherwise would reflect back into the vacuum chamber and heat a component situated inside the vacuum chamber. The portion can be made of a glass material such as, but not necessarily limited to, conventional glass, quartz glass, MgF 2 , and CaF 2 . The portion can include an anti-reflective coating applied to the glass material.
[0024] According to another aspect of the invention, X-ray microlithography systems are provided. An embodiment of such a system comprises any of the X-ray generators summarized above. The system also includes an illumination-optical system situated and configured to direct an X-ray illumination beam from the X-ray generator onto a pattern-defining reticle, thereby forming a patterned beam carrying an aerial image of the pattern. The system also includes a projection-optical system situated and configured to project the patterned beam from the reticle to form an image on a sensitive substrate.
[0025] The foregoing and additional features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 is a schematic elevational section of an X-ray generator according to a first representative embodiment.
[0027] [0027]FIG. 2 is a schematic elevational section of an X-ray generator according to a second representative embodiment.
[0028] [0028]FIG. 3 is an enlargement of detail of several of the needle-shaped members in the brushy layer lining the inner walls of the vacuum chamber of the X-ray generator of FIG. 2.
[0029] [0029]FIG. 4 is a schematic elevational section of an X-ray generator according to a third representative embodiment.
[0030] [0030]FIG. 5 is a schematic elevational diagram of a representative embodiment of a microlithography system including, by way of example, the X-ray generator of FIG. 2.
DETAILED DESCRIPTION
[0031] The invention is described below in the context of representative embodiments that are not intended to be limiting in any way. Although each of the various embodiments comprises a laser-plasma X-ray source, it will be understood that any of various other plasma X-ray sources can be used. Also, even though certain positional relationships (e.g., “top,” “bottom,” “left,” “right,” “upper,” and “lower”) are shown in the figures, it will be understood that these relationships are not intended to be limiting unless specifically stated otherwise.
[0032] A first representative embodiment of an X-ray generator is depicted in FIG. 1. The X-ray generator comprises a vacuum chamber 107 that is connected in a conventional manner to a vacuum pump (not shown) that evacuates the atmosphere inside the vacuum chamber 107 to a vacuum level of several Torr or less. By imposing such a vacuum level inside the vacuum chamber 107 , pulsed laser light 100 can propagate to the target material without being absorbed and/or attenuated by air, and X-ray radiation produced by the plasma 104 will not be damped significantly by absorption.
[0033] The vacuum chamber 107 includes a first window 102 made of glass or other material transmissive to the laser light 100 . A lens 101 is disposed outside the window 102 . Pulsed laser light 100 emitted from a laser (not shown) is focused by the lens 101 through the window 102 on the target material, which produces a plasma 104 . X-rays are emitted from the plasma 104 . Laser light not absorbed by the plasma is transmitted through a second window 110 to outside of the vacuum chamber 107 . Hence, most of the laser light does not strike the inner walls of the vacuum chamber 107 and hence does not contribute to heating of the inside of the vacuum chamber 107 .
[0034] The target material in this embodiment is Xe gas discharged at ultrasonic velocity from a gas-jet nozzle 103 . The gas-jet nozzle 103 is disposed so that it discharges the Xe gas in a direction perpendicular to the plane of the page on which FIG. 1 is drawn. After being used to produce the plasma, spent Xe gas discharged from the gas-jet nozzle 103 is evacuated from the vacuum chamber 107 by a vacuum pump (not shown).
[0035] A multilayer-film, ellipsoidal focusing mirror 105 is disposed near the plasma 104 . The reflective surface of the focusing mirror 105 is coated with multiple alternating layers of Mo and Si to form a multilayer-film interference coating. The multilayer film is configured so as to be highly reflective to incident EUV radiation having a wavelength of λ=13.4 nm. The period length of the multilayer film is changed as required over the reflective surface so as to achieve maximal EUV reflectivity at all points on the reflective surface.
[0036] The rear of the focusing mirror 105 is cooled by a cooling mechanism (not shown but well understood in the art). EUV light 106 reflected by the mirror 105 passes through a filter 109 that blocks infrared, visible, and ultraviolet light and transmits EUV radiation of a particular wavelength. EUV radiation passing through the filter enters a downstream illumination-optical system (not shown, but see FIG. 5, discussed later below). The infrared, visible, and ultraviolet wavelengths that are blocked by the filter 109 are generated by the plasma 104 but otherwise would adversely affect the resolution of fine pattern elements. Hence, the filter 109 only transmits the required wavelength of EUV light.
[0037] In the embodiment of FIG. 1, the inner walls of the vacuum chamber 107 are lined with a film 108 of carbon black. Carbon black is highly absorptive to electromagnetic radiation in the range from infrared to X-ray. “Highly absorptive” in this context means that the subject material absorbs at least 90% of the incident radiation in the range of infrared through ultraviolet. (Absorption of untreated metals to these wavelengths typically is less than several percent.) Consequently, the carbon black film 108 prevents components such as the mirror 105 from being heated by reflected and/or scattered infrared to X-ray radiation from the inner walls of the vacuum chamber 107 .
[0038] Since radiation from the plasma is absorbed at the inner walls by the carbon black coating 108 , the temperature of the walls of the vacuum chamber 107 will experience an increase. If it is necessary to remove this heat, a cooling jacket 111 can be fitted to the exterior, for example, of the vacuum chamber 107 .
[0039] Various materials, other than carbon black, that are highly absorptive to electromagnetic radiation ranging from infrared to X-ray alternatively can be used. Exemplary alternative materials include benzene soot, fullerene, carbon nanotubes, and Aquadag® (an aqueous colloidal suspension of graphite made by, e.g., Macalaster Bicknell). Benzene soot is a soot produced by burning benzene. Further alternatively, any of various porous materials may be used for absorbing incident electromagnetic radiation ranging from infrared to X-ray. Porous materials have innumerable microscopic holes in their surfaces. Light entering the holes is repeatedly reflected and scattered inside the holes by the inner walls of the holes, and thus is prevented from exiting the holes as reflected or scattered light. In other words, the holes behave as ideal black bodies for incident light ranging from infrared to X-ray. An exemplary porous material in this regard is activated charcoal.
[0040] The carbon black coating 108 can be formed by applying carbon black to the inner walls of the vacuum chamber 107 . Alternatively, the inner walls themselves can be modified (without application of a substance to them) so as to confer to the inner walls a high absorptivity to electromagnetic radiation ranging from infrared to X-ray. For example, the inner walls of an aluminum vacuum chamber 107 can be blackened by anodizing or attaching a unit of anodized aluminum.
[0041] Further alternatively, plates or sheets of a material that is highly absorptive to electromagnetic radiation ranging from infrared to X-ray can be adhered to the inner walls of the vacuum chamber 107 . For example, plates or sheets of carbon (as a representative black material) or plates or sheets of porous silicon (as a representative porous material) may be adhered conformably to the inner walls of the vacuum chamber 107 .
[0042] If a porous material is used for lining the inner walls, as discussed above, a high vacuum inside the vacuum chamber 107 probably will not be attainable. However, no problem is posed by an inability to achieve high vacuum so long as the actually attainable vacuum level is sufficient for generating a plasma in the X-ray source and for propagating the EUV light 106 produced by the source. Generally, a vacuum level suitable for meeting these criteria is several tenths of a Torr to several Torr. This range is achievable in a chamber lined with a porous material.
[0043] Porous material (configured as, e.g., sheets) can be applied or adhered to the entire surfaces of the inner walls of the vacuum chamber. Alternatively, the material can be applied or adhered only to those portions of the inner walls at which radiation from the plasma 104 will be incident, or from which heat-producing reflection will occur.
[0044] A second representative embodiment of an X-ray generator is depicted in FIG. 2. The depicted X-ray generator comprises a vacuum chamber 207 , a lens 201 and first window 202 that pass a beam 200 of pulsed laser light, a gas-jet nozzle 203 at which a plasma 204 is formed, an ellipsoidal mirror 205 that produces a reflected beam 206 , a filter 209 through which the reflected beam 206 passes, and a second window 210 . These components are similar to corresponding components in the embodiment of FIG. 1. The X-ray generator of FIG. 2 differs from the embodiment of FIG. 1 mainly in that the embodiment of FIG. 2 comprises a brushy layer 208 of multiple needle-shaped members 211 , rather than the film 108 in the FIG. 1 embodiment, disposed on the inside wall of the vacuum chamber 207 . The tips of the needle-shaped members 211 desirably are oriented toward the plasma 204 .
[0045] Enlarged detail of several needle-shaped members 211 is shown in FIG. 3. Light 212 radiating from the plasma 204 is incident on respective tapered surfaces 213 of tips 214 of the needle-shaped members 208 , from which tapered surfaces the incident light is reflected multiple times toward the bulk mass of the brushy layer 208 . The incident light ultimately is absorbed by the brushy layer 208 , which can absorb light in a broad wavelength band ranging from infrared to X-ray. Thus, the brushy layer 208 behaves as a nearly ideal black body. The material used for fabricating the brushy layer 208 can be metal (e.g., stainless steel or aluminum), glass, carbon, organic material (e.g., organic polymer), or silane material (e.g., silicone polymer).
[0046] The needle-shaped members 211 in FIGS. 2 and 3 appear in the figures as having sharp tips 214 . This depicted configuration is not intended to be limiting because the tips of individual needle-shaped members 211 need not be “sharp” so long as the brushy layer 208 functions in the manner described above. As an alternative to “needle”-shaped configurations, the members 211 can be bristle-shaped or blade-shaped. For example, the brushy layer 208 can be a “carpet” of glass fibers, carbon fibers, metal fibers or bristles, or an array of blade-shaped members.
[0047] A third representative embodiment of an X-ray generator is depicted in FIG. 4. The depicted X-ray generator comprises a vacuum chamber 407 , a lens 401 and first window 402 that pass a beam 400 of pulsed laser light, a gas-jet nozzle 403 at which a plasma 404 is formed, an ellipsoidal mirror 405 that produces a reflected beam 406 , a filter 409 through which the reflected beam 406 passes, and a second window 410 . These components are similar to corresponding components in the embodiments of FIGS. 1 and 2. The X-ray generator of FIG. 4 differs from the embodiment of FIG. 1 mainly in that the embodiment of FIG. 4 comprises a vacuum chamber 407 made of quartz glass. Quartz glass is highly transmissive to light in the range of infrared to ultraviolet. Consequently, by forming the vacuum chamber 407 of quartz glass, the light 406 readily passes through to outside the vacuum chamber 407 and hence is prevented from heating the components inside the vacuum chamber 407 .
[0048] The vacuum chamber 407 can be made of a material, other than quartz glass, exhibiting high transmissivity to light in the range of infrared to ultraviolet.
[0049] Exemplary materials in this regard are conventional glass, magnesium fluoride (MgF 2 ), and calcium fluoride (CaF 2 ).
[0050] The inner walls and/or the outer walls of the vacuum chamber 407 may be coated with an antireflective coating. Such a coating further decreases the amount of light 406 reflected from the walls of the chamber.
[0051] The vacuum chamber 407 may be made entirely of quartz glass. Alternatively, portions of the chamber requiring greater mechanical strength than provided by quartz glass may be formed of metal bonded to the quartz glass used for making the rest of the chamber.
[0052] In the embodiments described above, the respective X-ray generators were described as comprising laser-plasma X-ray (LPX) sources. It will be understood that individual X-ray generators alternatively can be another type of plasma X-ray source, such as a discharge-plasma X-ray source.
[0053] An embodiment of a microlithography system incorporating an X-ray generator 199 as described above is shown in FIG. 5. For convenience, without intending to be limiting in any way, the X-ray generator 199 included with the depicted system is configured according to the embodiment shown in FIG. 2.
[0054] In FIG. 5, the X-ray generator 199 is disposed on “top” of an exposure chamber 50 . The exposure chamber 50 contains an illumination-optical system 56 that receives an EUV beam 206 reflected from the mirror 205 of the X-ray generator 199 . The illumination-optical system 56 comprises one or more condenser mirrors and at least one fly-eye optical system (or analogous feature). The beam of EUV light reflected from the mirror 205 , generally having a circular transverse profile, is directed as an “illumination beam” to the left (in the figure) by the illumination-optical system 56 . In FIG. 5, only parallel rays of light propagating to the illumination-optical system 56 are shown. However, it will be understood that divergent and/or convergent rays of light also can propagate to the illumination-optical system 56 . A vertically mounted reflective mirror 52 receives the illumination beam from the illumination-optical system 56 . The mirror 52 is circular with a concave reflective surface 52 a facing right in FIG. 5. Light of the illumination beam reflected from the mirror 52 is reflected by a light-path-bending mirror 51 toward a reflective reticle 53 . The reticle 53 is horizontally mounted with its EUV-reflective surface facing downward in FIG. 5. The mirror 52 focuses the illumination beam, propagating from the illumination-optical system 56 and reflected by the mirror 51 , onto the reflective surface of the reticle 53 .
[0055] Each of the mirrors 51 , 52 is made from a respective mirror substrate (e.g., quartz) that has been finely machined to form an extremely accurate reflection surface (e.g., item 52 a in FIG. 5). Formed on each reflection surface is a respective multilayer-film coating (e.g., a Mo/Si multilayer-film coating for reflecting EUV radiation of approximately 13-nm wavelength), which can be similar to the multilayer-film coating formed on the reflective surface of the mirror 205 in the X-ray generator 199 . For other illumination-beam wavelengths in the range of 10 nm to 15 nm, the multilayer-film can be formed of other substances such as Ru or Rh as the “high-Z” layer and Si, Be, or B 4 C as the “low-Z” layer.
[0056] A multilayer-film coating also is formed on the reflective surface of the reticle 53 . Formed on the multilayer film of the reticle 53 is an “absorbing-body” layer that is patterned into individual absorbing bodies that, together with spaces between the absorbing bodies, define a reticle pattern to be transfer-exposed from the reticle 53 to a lithographic substrate 59 (e.g., resist-coated semiconductor wafer). The reticle 53 is mounted to a reticle stage 55 that is movable in at least the Y direction. The illumination beam, shaped by the illumination-optical system 56 and reflected by the bending mirror 51 , is illuminated on successive regions of the reticle 53 in a sequential manner, as effected by movements of the reticle stage 55 . EUV light reflected from the reticle 53 constitutes a “patterned beam” that carries an aerial image of the pattern portion in the respective illuminated portion of the reticle 53 .
[0057] The exposure chamber 50 also contains a projection-optical system 57 and the substrate 59 situated downstream of the reticle 53 . The projection-optical system 57 comprises multiple mirrors that demagnify the aerial image carried by the patterned beam by a specified “reduction” factor (e.g., ¼) and form the corresponding actual image on the substrate 59 . The substrate 59 is mounted to a substrate stage 54 that is movable in the X, Y, and Z directions.
[0058] During a microlithographic exposure using the system of FIG. 5, the illumination beam is directed by the illumination-optical system 56 onto the reflective surface of the reticle 53 . Meanwhile, the reticle 53 and substrate 59 are synchronously moved in a scanning manner relative to each other and with respect to the projection-optical system 57 at a specified velocity ratio determined by the reduction factor of the projection-optical system. In this “step-and-scan” manner, the pattern defined on the reticle 53 is transferred to one or more respective dies on the substrate 59 . Individual dies (“chips”) on the substrate 59 have dimensions of, for example, 25 mm×25 mm, and the pattern is formed on the substrate 59 with a line-and-space (L/S) resolution of at least 0.07 μm.
[0059] Whereas the invention has been described in connection with multiple representative embodiments, the invention is not limited to those embodiments. On the contrary, the invention is intended to encompass all modifications, alternatives, and equivalents as may be included within the spirit and scope of the invention, as defined by the appended claims. | X-ray generators are disclosed that produce X-ray radiation from a plasma and that exhibit reduced heating of certain components caused by proximity to the plasma. An embodiment of such an X-ray generator is encased in a vacuum chamber that exhibits reduced reflection and scattering of electromagnetic radiation from the inner walls thereof to components contained in the chamber. Since less reflected radiation reaches the components, the components experience less temperature increase during use. For example, the inner walls can be coated with a film of carbon black that absorbs incident radiation from infrared to ultraviolet. | 7 |
BACKGROUND
[0001] The use of seismic data in the analysis and modeling of subterranean reservoirs containing hydrocarbons and other fluids is known. Typically, such data are gathered through the use of a source of seismic energy and one or more receivers respectively located on a ground or water surface over a subterranean region of interest. The source is used to produce a seismic pulse, burst, or similar energy which travels generally downward and away from the source, into the subterranean material of the region under examination.
[0002] As the seismic pulse encounters a change in material properties, most notably at an interface between one type of subterranean material and another, some of the seismic pulse energy is reflected back toward the surface. The receiver or receivers detect this reflected pulse energy and record corresponding data, often with respect to other parameters of interest such as linear distance from the particular receiver to the source, time-of-flight (i.e., time between emission of source pulse and detected reflection), amplitude of the detected reflection, angle of incidence of the detected reflection relative to the ground (or water) surface plane or some other datum, etc. Thus, the presence of the interface can be detected through later analysis of the detected and recorded pulse reflection data.
[0003] Generally, such pulse reflection and associated parameter data have been used to model, or estimate, the depths of these subterranean material interfaces and to present this information in the form of a cross-sectional elevation plot of the subterranean region of interest. However, such a plot often fails to provide other desirable information regarding the present physical state of a subterranean reservoir containing hydrocarbons or other fluids.
[0004] Therefore, it is desirable to provide a method and apparatus for modeling various other subterranean physical parameters, and to present that model in the form of planar view representation (as well as 3D view presentation) of the subterranean region of interest.
SUMMARY
[0005] One embodiment of the present invention provides for a method of modeling seismic data. The method includes deriving a time-lapse data set from a first seismic data set and a second seismic data set, and deriving a forward-modeled time-lapse data set including a plurality of values. The method further includes sorting the plurality of values into a plurality of bins corresponding to the forward-modeled time-lapse data set, selecting a plurality of optimal values from the plurality of bins, and then mapping the plurality of optimal values using the time lapse data set. The method also includes calibrating the plurality of optimal values. The method further includes plotting the plurality of calibrated optimal values.
[0006] Another embodiment provides for a method of modeling seismic data corresponding to a subterranean reservoir containing hydrocarbons. The method includes calibrating a first seismic data set and a second seismic data set, and then subtracting the calibrated second seismic data set from the calibrated first seismic data set to derive a time-lapse data set. The method further includes deriving a forward- modeled time-lapse data set including a plurality of physical parametric values, sorting the plurality of physical parametric values into a plurality of bins corresponding to the forward-modeled time-lapse data set, and selecting a plurality of optimal physical parametric values from the plurality of bins of physical parametric values. The method also includes mapping the plurality of optimal physical parametric values to a corresponding plurality of subterranean locations using the time-lapse data set, and calibrating the plurality of optimal physical parametric values. The method also includes plotting the plurality of calibrated optimal physical parametric values as a visual representation of the subterranean reservoir containing hydrocarbons.
[0007] Yet another embodiment provides for a computer which includes a processor and a computer-readable storage medium coupled in data communication with the processor. The computer-readable storage medium stores a first data set and a second data set and a plurality of rock physics relationships and a program code. The program code is configured to cause the processor to calibrate each of the first and second data sets, and then to subtract the calibrated second data set from the calibrated first data set to derive a time-lapse data set. The program code is further configured to cause the processor to calculate a forward-modeled time-lapse data set including a plurality of parametric values using selected ones of the plurality of rock physics relationships. The program code is still further configured to sort the plurality of parametric values into a plurality of bins corresponding to the forward-modeled time-lapse data set, and to select a plurality of optimal parametric values from the plurality of parametric values sorted into the plurality of bins. The program code is further configured to cause the processor to map the plurality of optimal parametric values to a corresponding plurality of subterranean locations using the time-lapse data set, calibrate the plurality of optimal parametric values, and to plot the plurality of calibrated optimal parametric values to visually represent at least one spatially distributed physical characteristic of a subterranean reservoir of hydrocarbons.
[0008] These and other aspects and embodiments will now be described in detail with reference to the accompanying drawings, wherein:
DESCRIPTION OF THE DRAWINGS
[0009] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0010] FIG. 1 is a side elevation sectional view depicting a field seismology arrangement in accordance with an embodiment of the present invention.
[0011] FIG. 2 is a flowchart depicting a method of modeling seismic data in accordance with another embodiment of the present invention.
[0012] FIG. 3 is a mapping diagram referring to exemplary data plots 3 A- 3 D in accordance with the present invention.
[0013] FIGS. 3A through 3D are data plots depicting exemplary P-wave and S-wave seismic data collected at times T1 and T2 in accordance with the present invention.
[0014] FIG. 4 is a mapping diagram referring to exemplary data plots 4 A- 4 B in accordance with the present invention.
[0015] FIGS. 4A and 4B are data plots depicting exemplary inverted time-lapse P-wave and S-wave seismic data in accordance with the present invention.
[0016] FIG. 5 is a block diagram depicting a data cube in accordance with an embodiment of the present invention.
[0017] FIG. 6 is a block diagram depicting the data cube of FIG. 5 and a corresponding data array in accordance with an embodiment of the present invention.
[0018] FIG. 7 is a locus plot in accordance with an embodiment of the present invention.
[0019] FIG. 8 is a block diagram depicting data mapping in accordance with an embodiment of the present invention.
[0020] FIG. 9 is a mapping diagram referring to exemplary data plots 9 A- 9 D in accordance with the present invention. FIGS. 9A through 9D are data plots depicting exemplary calibrated and actual (true) saturation and pore pressure values in accordance with the present invention.
[0021] FIG. 10 is a block diagram depicting a data acquisition and processing system in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION
[0022] In representative embodiments, the present teachings provide methods and apparatus for acquiring and processing seismic data corresponding to a subterranean region of interest, typically containing hydrocarbons, and to plot a final processed data set as a graphic representation of time-lapse changes to various selected physical parameters of the subterranean region of interest.
[0023] Turning now to FIG. 1 , a side elevation sectional view depicts a field seismology arrangement 100 in accordance with an embodiment of the present invention. The arrangement 100 includes a source (i.e., emitter) of seismic energy 102 . The source 102 is located on a ground surface 104 over a subterranean region 106 . The source 102 can be defined by any suitable apparatus capable of producing a seismic (acoustic) pulse or vibrational energy which is directed generally into the subterranean region 106 .
[0024] The field seismology arrangement 100 further includes a pair of seismic detectors 108 and 110 , respectively (also known as “receivers”, as for example geophones, or hydrophones when the surface 104 is underwater). Each of the seismic detectors 108 and 110 rests on the ground surface 104 , and is spaced apart from the source 102 by an offset distance 112 or 114 , respectively. Each of the seismic detectors 108 and 110 can be defined by any detection device suitable for detecting and recording seismic energy pulses or reflections (described in detail hereafter) that arrive at the detectors 108 and 110 after passing through the subterranean region 106 .
[0025] The subterranean region 106 includes three different material strata designated as 116 , 118 and 120 , respectively. Each of the material strata 116 , 118 and 120 is respectively defined by a depth D 1 , D 2 and D 3 . Furthermore, the region 106 includes an interface 122 between the material strata 116 and 118 , an interface 124 between the material strata 118 and 120 , and an interface 126 between the material strata 120 and an underlying region 121 . It is assumed that each of the strata 116 , 118 and 120 includes a respective average material incompressibility, fluid content (or lack thereof), and other physical parameters that distinguish it from the other respective material strata.
[0026] Typical operation of the field seismology arrangement 100 is as follows: the source 102 produces a source seismic pulse P 1 of known amplitude A 1 . The source pulse P 1 is directed into the subterranean region 106 and proceeds initially through the material strata 116 , striking the interface 122 at angle of incidence AN 1 . A portion of the energy of pulse P 1 is reflected from the interface 122 back toward the surface 104 , as reflection pulse P 2 , at an angle of reflection AN 1 . The pulse P 2 arrives at surface 104 within detectable vicinity to the seismic detector 108 , having amplitude A 2 upon arrival.
[0027] The seismic detector 108 records data corresponding to the detection of the reflection pulse P 2 . This recorded data can include, for example, a detected amplitude corresponding to amplitude A 2 of the pulse P 2 , the detected angle of reflection (i.e., incidence) AN 1 of the pulse P 2 , the offset distance 112 , the arrival time of the detected pulse P 2 relative to the (known) time of emission of the source pulse P 1 , etc. It will be appreciated that the seismic detector 108 only transitorily “records” data, and that in fact the detector 108 transmits the data to a permanent recording station (not shown) for recording on computer readable media such as a magnetic tape or a hard disk drive.
[0028] As the source pulse P 1 continues into the subterranean region 106 , similar reflection pulses P 3 and P 4 are reflected from interfaces 124 and 126 , respectively. The reflection pulse P 3 is initially reflected from the interface 124 back toward the surface 104 at an angle of AN 2 , and is then refracted at the interface 122 to a new angle of incidence AN 1 . Thus, the reflection pulses P 3 and P 4 arrive at the surface 104 within detectable vicinity of the seismic detectors 108 and 110 , respectively. The seismic detectors 108 and 110 then record data corresponding to the reflected pulses P 3 and P 4 . This recorded data can include any or all of the various characteristics described above in regard to the pulse P 2 .
[0029] The data thus received by the seismic detectors 108 and 110 are recorded and then communicated to a suitable analytical apparatus (i.e., a computer) for analysis by way of the method of the present invention, described in detail hereafter.
[0030] It is to be understood that the field seismology arrangement 100 of FIG. 1 is intended to convey conceptual information regarding the acquisition of seismic data as used in the methods of the present invention, and that a similar field seismology arrangement (not shown) can include any suitable number of seismic energy sources (i.e., source 102 ) and seismic detectors (i.e., detector 108 ) arranged in a linear or matrix pattern on a ground surface (i.e., surface 104 ) or on a water surface in the case where the ground surface 104 is submerged under water. Thus, the field seismology arrangement 100 of FIG. 1 is exemplary of the data acquisition of the present invention and does not represent the only type of such arrangement that can be used, nor does it represent the only type of field conditions under which data acquisition can be performed within the context of the present invention.
[0031] FIG. 2 is a flowchart depicting a method 200 in accordance with the present invention. Simultaneous reference shall be made, as directed, to FIGS. 1 and 3 through 9 D, during the description of the method 200 of FIG. 2 .
[0032] In step 202 , amplitude-versus-offset (hereafter, AVO) field seismic data are acquired through the use of field seismology (e.g., the field seismology arrangement 100 of FIG. 1 ). These AVO data are acquired at a first time T1 and at a later time T2, and are generally collected over a subterranean region of interest such that an area at a given depth (i.e., stratum) is represented. AVO data for both generally planar and volumetric regions of interest can be suitably acquired.
[0033] In step 204 , the AVO data are inverted to seismic impedance data using standard mathematical techniques. As a typical AVO data set is relatively vast, such inversion is generally done by way of electronic computer (see FIG. 10 ). The inverted data sets include P-wave pseudo impedance data (hereafter, IP') and S-wave pseudo impedance data (hereafter, IS'), and are referred to as IP'(T1), IS'(T1), IP'(T2), and IS'(T2).
[0034] In step 205 , the P-wave and S-wave pseudo impedance data IP'(T1), IS'(T1), IP'(T2), and IS'(T2) are calibrated so as to correspond more closely with actual field conditions. This calibration can be performed in a number of different ways; non-limiting examples include: calibrating the pseudo values against like kinds of data (i.e., P-wave and S-wave impedance data) measured at selected well bores; or modeling the pseudo values using rock physics relationships (properties). Combinations of these or other calibration methods can also be used.
[0035] It is to be understood that such calibration is not necessarily linear in nature. In any case, the calibration method yields calibrated P-wave and S-wave impedance data IP (T1), IS (T1), IP(T2), and IS(T2) for the subterranean region under consideration.
[0036] Exemplary plots of such calibrated data IP(T1), IS(T1), IP(T2), and IS(T2) are respectively depicted in FIGS. 3A, 3B , 3 C, and 3 D. Within FIGS. 3A-3D , color is indicative of the signal or seismic wave impedance, with red indicative of seismic wave impedance values at the lower end of the represented scale, and blue used to indicate seismic impedance values at the higher end of the represented scale. The color white (or colorless) is used to indicate mid-scale seismic impedance values.
[0037] As such, FIGS. 3C and 3D each depict the presence of two spot locations where a generally distinct decrease in seismic wave impedance has occurred, relative to the same locations in FIGS. 3A and 3B . These spot decreases (i.e., changes) in seismic wave impedance correspond to physical changes within the subterranean region of interest, such as, for example, changes in porosity, pore pressure, saturation, etc.
[0038] In step 206 , the inverted AVO data matrices derived in step 204 are subtracted in accordance with the two following formulas, thus providing the indicated time-lapse data (i.e., recorded field data):
1) TL(IP) =[IP(T2)- IP(T1)] 2) TL(IS) =[IS(T2)- IS(T1)] It is important to note that time-lapse data required by this embodiment of the present invention need not be seismic impedance (i.e., inverted AVO) data as described above for step 204 . Any time lapse data that can be forward-modeled from a set of physical parameters within the context of the present invention can potentially be used in step 206 . Thus, in another embodiment (not shown) of the present invention, a method using appropriate AVO data acquired in step 202 can dispense with (i.e., skip over) the inverting of step 204 above and proceed directly to the calibrating of step 205 above. Other methods (not shown) in accordance with other embodiments of the present invention can also be used.
[0041] Exemplary plots of such time-lapse data are respectively depicted in FIGS. 4A and 4B . As described above, color is indicative of (i.e., in correspondence to) seismic wave impedance value within FIGS. 4A and 4B . The time-lapse data TL(IP) and TL(IS) derived within step 206 result in a generally more pronounced and distinct indication of physical changes within the subterranean region. As shown in FIGS. 4A and 4B , the two spot locations described above are clearly pronounced, and are assumed to be indicative of a subterranean physical change of interest (i.e., porosity, saturation, etc.), or a combination of such changes.
[0042] In step 208 , selected known rock physics relationships and corresponding formulas are used to compute forward-modeled time-lapse data (i.e., synthetic data) FMTL(lp) and FMTL(ls). Typically, these relationships include such physical parameters as pore pressure, fluid saturation, and rock porosity. Such calculations can be generally represented by the two following formulas:
3) FMTL(IP) =F 1 [TL(Saturation), TL(Pore Pressure), TL(Porosity)] 4) FMTL(IS) =F 2 [TL(Saturation), TL(Pore Pressure), TL(Porosity)] where F1 and F2 are selected rock physics relationships (i.e., formulas) that are functions of the desired physical parameters of porosity, saturation, and pore pressure. Other physical parameters, by way of their associated formulas, can also be considered such as, for example, temperature, salinity, gas-to-oil ratio (GOR), gas gravity, overburden pressure, etc.
[0045] Reference is now made to FIG. 5 . These rock physics calculations are generally used to construct a data cube 300 of the three exemplary parameter types, respectively depicted as TL pore pressure 302 , TL saturation 304 , and TL porosity 306 . The data cube 300 thus includes a plurality of three-dimensional cells 308 , which respectively contain the forward-modeled time-lapse data FMTL(IP) and FMTL(IS) pair values corresponding to the coordinates (i.e., parametric values) of the particular cell 308 . An exemplary cell 310 of the plurality of cells 308 is depicted, which includes corresponding FMTL(IP) and FMTL(IS) data pair contents 312 . The data cube 300 therefore represents a three-dimensional data model of the subterranean region of interest. It is to be understood that if other physical parameters are considered, a corresponding data cube (not shown) can have four or more dimensions.
[0046] It is important to note that any given forward-modeled time-lapse data pair FMTL(IP) and FMTL(IS) can result from more than one corresponding set of physical parameters—that is, more than one cell 308 within the data cube 300 . Typically, any given time-lapse data pair (for example, data pair 312 ) results from several corresponding sets of physical parameters, which can be visualized as rays or arcs of adjacent or near-adjacent, associated cells 308 within the data cube 300 .
[0047] In step 210 , the forward-modeled time-lapse physics data within data cube 300 is sorted. Reference is now made to FIG. 6 . A two-dimensional array 314 including a plurality of data bins 316 is constructed, with each data bin 316 defined by coordinates corresponding to the values of a particular forward-modeled time-lapse data pair (i.e., FMTL(IP) and FMTL(IS)). As described above, any particular forward-modeled time-lapse data pair can correspond to a plurality of derived physical parameters, and therefore several associated physical parameter sets, or vectors, can be sorted into any particular data bin 316 of the array 314 . As depicted in FIG. 6 , an exemplary data bin 318 of the plurality of data bins 316 is depicted, which contains (i.e., includes) an associated physical parameter vector 320 . As depicted in FIG. 6 , Pp' refers to pseudo pore pressure, Sw' refers to pseudo water saturation, and φ (phi) refers to porosity.
[0048] The sorting process is conducted in an exhaustive fashion until all the physical parameter vectors (i.e., 320 ) have been sorted into their respective data bins 316 within the array 314 .
[0049] In step 212 , the contents of each data bin 316 within the array 314 are compared (i.e., searched) to a predetermined, selected parameter value, so as to determine which particular physical parameter vector represents the “optimal” such vector within each data bin 316 . For example, one approach for conducting this search is to compare each of the physical parameter vectors with an average or sample porosity value for the subterranean region under consideration. This comparison value can be predetermined, say, by use of appropriate field instrumentation deployed within a borehole or similar arrangement (not shown). Other search and comparison techniques can be used.
[0050] Reference is now made to FIG. 7 , which is a plot 330 depicting the contents of the data bins 316 of the array 314 , and is provided to assist in an understanding of the optimal value search operation of step 212 of the method 200 . The plot 330 is formatted with a horizontal axis scaled to represent time-lapse pressure values 332 , and a vertical axis scaled to represent time-lapse saturation values 334 . Each of the data bins 316 of the array 314 has its physical parameter vectors plotted as a single locus 336 of values on the plot 330 (that is, there is one plotted locus 336 for each data bin 316 ).
[0051] Within each locus 336 is a selected optimum parameter pair (i.e., vector) value 338 , including corresponding pressure 332 and saturation 334 values, as determined by the comparative search described above. The optimum pressure 332 and saturation 334 parameter pairs 338 are extracted for further use as described hereafter.
[0052] In step 214 , the optimum parameter pairs 338 are mapped to their corresponding locations within the subterranean area under consideration. Steps 210 - 214 are generally referred to as inversion. Reference is now made to FIG. 8 , which depicts a parameter mapping schema 350 in accordance with the present invention. To begin, the time-lapse data pair TL(IP) and TL(IS) from step 206 for each location within the subterranean region under consideration is isolated, one data pair at a time. The data bin 316 within the array 314 that corresponds to the values of an isolated time-lapse data pair is then referenced, and its parameter vector contents considered. The optimal parameter vector 338 within that data bin 316 , as determined in step 212 above, is then extracted from the data bin 316 .
[0053] The desired discrete physical parameters within the optimal parameter vector 338 are then associated with the subterranean location of the original time-lapse data pair TL(IP) and TL(IS). As depicted in FIG. 8 , the time-lapse data pair 312 is associated with a location 352 within the subterranean region corresponding to the original AVO data. Therefore, the particular optimal parameter vector 338 , depicted as a vector 354 , is also associated with the same location 352 . As particularly depicted in FIG. 8 , a pore pressure parameter 356 and a saturation parameter 358 of the vector 354 are associated with the location 352 . These mapped, optimal parameters (i.e., pore pressure 356 and saturation 358 ) are also referred to as pseudo values, and are designated in FIG. 8 as TL Press' and TL Sat', respectively.
[0054] The mapping process of step 214 is generally repeated as described above, until optimal physical parameters are associated with each location within the subterranean region corresponding to the original AVO data.
[0055] In step 216 , the pseudo values (i.e., TL Press' 356 and TL Sat' 358 ) mapped in step 214 above are calibrated so as to correspond more closely with actual field conditions. This calibration can be performed in a number of different ways; non-limiting examples include: calibrating the pseudo values against like kinds of data (i.e., pore pressures and saturations) measured at selected well bores; calibrating the pseudo values against a flow model of the subterranean region of consideration; or modeling the pseudo values against rock physics relationships (properties) in which only pore pressure changes or saturation changes. Combinations of these or other calibration methods can also be used. It is to be understood that such calibration is not necessarily linear in nature. In any case, the calibration method yields calibrated pore pressure and saturation data for the subterranean region under consideration.
[0056] In step 218 , the calibrated data from step 216 above are plotted to provide a 2-dimensional representation of the subterranean region under consideration. Reference is now made to FIGS. 9A-9D . This plot represents the time-lapse change in the physical parameters derived and calibrated as described above in regard to steps 202 - 216 of the method 200 . FIGS. 9A and 9B represent the calibrated saturation and pore pressure data from step 216 above, respectively. FIGS. 9C and 9D represent the actual (true) saturation and pore pressure data, respectively. Once again, the colors red and blue are used to indicate parameter value within the FIGS. 9A-9D . Once the data plotting of step 218 is performed, performance of the method 200 is complete.
[0057] It is to be understood that the method 200 of FIG. 2 represents one embodiment of the present invention, and that other methods (not shown) corresponding to other embodiments of the present invention can also be used. For example, the methods and teachings of the present invention can be used with other kinds of AVO data that can be forward-modeled from a set of physical parameters. The impedance data exemplified in method 200 represents just one of several possible approaches. As described above, under another embodiment of the present invention, for example, the inversion of step 204 described above would be optional.
[0058] Furthermore, other embodiments of the present invention can provide corresponding methods in which the certain steps or operations are performed substantially in parallel with (i.e., concurrent to) other certain steps. For example, another embodiment (not shown; see FIG. 2 ) can provide for the performing of steps 202 through 206 above substantially in parallel with the performing of steps 208 through 212 above, wherein the respective results of these substantially parallel operations (e.g., the time-lapse data set TL(IP) and TL(IS), and the optimum parameter pairs 338 ) are then used to perform steps 214 through 218 . Other methods and other embodiments of the present invention are also possible.
[0059] FIG. 10 is a block diagram depicting a data acquisition and processing system (hereafter, system) 400 in accordance with yet another embodiment of the present invention. The system 400 includes a field seismology arrangement 402 . As depicted in FIG. 10 , the field seismology arrangement 402 includes a plurality of seismic detectors (i.e., receivers) 408 , 410 , and 412 , respectively. The field seismology arrangement 402 is assumed to include at least one source of seismic energy (not shown), and any other elements as required and configured to acquire desired seismic (i.e., AVO or AVA, where AVA is amplitude-versus-angle type seismic data) data corresponding to a subterranean region 414 underlying the field seismology arrangement 402 . The field seismology arrangement 402 is further configured to provide one or more acquired seismic data bundles 416 for processing with the balance of the system 400 as described hereafter.
[0060] The system 400 also includes a computer 418 . The computer 418 includes a processor 420 coupled in data communication with a computer-accessible memory 422 . The memory 422 stores a first seismic data set 424 and a second seismic data set 426 . The first seismic data set 424 is assumed to be received by the computer 418 and stored in the memory 422 , prior to the computer 418 receiving and storing the second seismic data set 426 . It will be appreciated that the data sets 424 and 426 can also be stored in a remote memory device which is accessible by the computer 418 .
[0061] Both the first and second seismic data sets 424 and 426 are delivered to the computer 418 as corresponding seismic data bundles 416 , and can be delivered to the computer 418 by way of any satisfactory means. Non-limiting examples of such delivery means (not shown) can include data cable coupling, transferal by way of optical or magnetic storage media, radio telemetry linking, etc. Those of skill in the instrumentation and related arts can appreciate that any number of satisfactory seismic data 416 delivery means can be utilized within the scope of the present invention, and that further elaboration is not required for purposes herein. The memory 422 further stores a program code 428 that is executable by the processor 420 . The program code 428 is configured to cause to the processor 420 to substantially perform the method 200 of FIG. 2 as described above. The memory 422 also stores a plurality of rock physics relationships 430 , which are selectively accessed and used by the processor 420 during execution of the program code 428 .
[0062] The system 400 also includes a monitor 432 that is coupled in signal communication with the computer 418 . The monitor is configured to provide a user visible data plot 434 under the control of the processor 420 during execution of the program code 428 . The system 400 further includes a printer 436 coupled in signal communication with the computer 418 . The printer 418 is configured to provide a hardcopy data plot 438 under the control of the processor 420 during execution of the program code 428 .
[0063] The computer 418 is further understood to include a plurality of other elements as desired and/or required for normal operation, which are not shown in FIG. 10 . Such elements (not shown) can include, for example, a user keyboard, a user mouse, a power supply, etc. One of skill in the computing arts can appreciate that such elements can be respectively included with the computer 418 and configured as desired, and that further elaboration is not required for an understanding of the present invention.
[0064] Typical normal operation of the system 400 is as follows: The field seismology arrangement 402 acquires the first seismic data set 424 , and at some predetermined period of time thereafter, the field seismology arrangement 402 acquires the second seismic data set 426 . The first and second seismic data sets 424 and 426 are delivered to the computer 418 as respective seismic data bundles 416 , which stores them accordingly within the memory 422 .
[0065] Next, execution of the program code 428 by the processor 420 is initiated by a user (for example, by way of a user keyboard or mouse, not shown). The program code 428 then causes the processor 420 to selectively access the first and second seismic data sets 424 and 426 , as well as the rock physics relationships 430 , which are respectively stored in the memory 422 . The processor 420 then uses the data sets 424 and 426 and the rock physics relationships 430 to carry out (i.e., perform) the method 200 of FIG. 2 substantially as described above, thus deriving a calibrated physical parameter data set corresponding to the first and second seismic data sets 424 and 426 provided by the field seismology arrangement 402 .
[0066] The program code 428 then causes the processor 420 to plot the calibrated physical parameter data set using the monitor 432 and/or the printer 436 , resulting in the visible data plot 434 and/or the hardcopy data plot 438 , respectively. The plot 434 and/or 438 thus provides a visible representation of the selected time-lapse physical characteristics (i.e., porosity, pressure and/or saturation, etc.) of the subterranean region 414 .
[0067] In this way, the system 400 of FIG. 10 provides a substantially automated data acquisition and processing system that performs the method of the present invention and provides resulting 2-dimensional data plots 434 and/or 438 . The system 400 is particularly suitable for use in monitoring and analyzing time-lapse changes in various physical parameters of subterranean regions (i.e., region 414 ) that contain hydrocarbons such as crude oil, natural gas, etc, or other fluids such as water. It is to be understood that three-dimensional volumetric plots (not shown) corresponding to a case of three- dimensional inversion can also be provided under the present invention.
[0068] Furthermore, it is to be understood that while the methods of the present invention described above consider first and second AVO data sets, any number of suitable data sets can also be considered within corresponding other embodiments (hot shown) of the present invention. Within such embodiments (not shown), the methods and teachings of the present invention would typically be applied to any two suitable data sets at a time.
[0069] While the above methods and apparatus have been described in language more or less specific as to structural and methodical features, it is to be understood, however, that they are not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The methods and apparatus are, therefore, claimed in any of their forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | Representative embodiments provide for a computer including a program code configured to cause a processor to invert and thereafter calibrate first and second data sets, subtract the inverted second data set from the inverted first data set to derive a time-lapse data set, calculate a model including a plurality of parametric values, sort the plurality of parametric values into a plurality of bins, select, map and calibrate a plurality of optimal parametric values from the plurality of bins, and plot the plurality of calibrated optimal parametric values to represent at least one physical characteristic of a subterranean reservoir of hydrocarbons. The method includes deriving a time-lapse data set from a first seismic data set and a second seismic data set, deriving a model, sorting the plurality of values into bins, selecting, mapping and calibrating a plurality of optimal values from the bins, and plotting the calibrated values. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to pharmaceutical preparations (i.e., composition) for use as tumor suppressive agents for tumors arising from cancers such as prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial and ovarian cancers, and benign prostate hyperplasia (BPH).
BACKGROUND OF THE INVENTION
[0002] The prostate gland, which is found exclusively in male mammals, produces several components of semen and blood and several regulatory peptides. The prostate gland comprises stroma and epithelium cells, the latter group consisting of columnar secretory cells and basal nonsecretory cells. A proliferation of these basal cells as well as stroma cells gives rise to benign prostatic hyperplasia (BPH), which is one common prostate disease. Another common prostate disease is prostatic adenocarcinoma (CaP), which is the most common of the fatal pathophysiological prostate cancers, and involves a malignant transformation of epithelial cells in the peripheral region of the prostate gland. Prostatic adenocarcinoma and benign prostatic hyperplasia are two common prostate diseases, which have a high rate of incidence in the aging human male population. Approximately one out of every four males above the age of 55 suffers from a prostate disease of some form or another. Prostate cancer is the second most common cause of cancer related death in elderly men, with approximately 96,000 cases diagnosed and about 26,000 deaths reported annually in the United States.
[0003] Studies of the various substances synthesized and secreted by normal, benign and cancerous prostates carried out in order to gain an understanding of the pathogenesis of the various prostate diseases reveal that certain of these substances may be used as immunohistochemical tumor markers in the diagnosis of prostate disease. The three predominant proteins or polypeptides secreted by a normal prostate gland are: (1) Prostatic Acid Phosphatase (PAP); (2) Prostate Specific Antigen (PSA); and, (3) Prostate Secretory Protein of 94 amino acids (PSP94), which is also known as Prostatic Inhibin Peptide (PIP), Human Seminal Plasma Inhibin (HSPI), or β-microseminoprotein (β-MSP), and which is hereinafter referred to as PSP94.
[0004] PSP94 is a simple non-glycosylated cysteine-rich protein, and constitutes one of three predominant proteins found in human seminal fluid along with Prostate Specific Antigen (PSA) and Prostate Acid Phosphatase (PAP). PSP94 has a molecular weight of 10.7 kiloDaltaon (kDa), and the complete amino acid sequence of this protein has already been determined (SEQ ID NO:1). The cDNA and gene for PSP94 have been cloned and characterized (Ulvsback, et al., Biochem. Biophys. Res. Comm., 164:1310, 1989; Green, et al., Biochem. Biophys. Res. Comm., 167:1184, 1990). Immunochemical and in situ hybridization techniques have shown that PSP94 is located predominantly in prostate epithelial cells. It is also present, however, in a variety of other secretory epithelial cells (Weiber, et al., Am. J. Pathol., 137:593, 1990). PSP94 has been shown to be expressed in prostate adenocarcinoma cell line, LNCap (Yang, et al., J. Urol., 160:2240, 1998). As well, an inhibitory effect of exogenous PSP94 on tumor cell growth has been observed both in vivo and in vitro (Garde, et al., Prostate, 22:225, 1993; Lokeshwar, et al., Cancer Res., 53:4855, 1993), suggesting that PSP94 could be a negative regulator for prostate carcinoma growth via interaction with cognate receptors on tumor cells.
[0005] Native PSP94 has been shown to have a therapeutic modality in treating hormone refractory prostate cancer (and potentially other prostate indications).
[0006] Metabolic and immunohistochemical studies have shown that the prostate is a major source of PSP94. PSP94 is involved in the feedback control of, and acts to suppress secretion of, circulating follicle-stimulating hormone (FSH) both in-vitro and in-vivo in adult male rats. PSP94 acts both at the pituitary as well as at the prostate site since both are provided with receptor sites for PSP94. It has been demonstrated to suppress the biosynthesis and release of FSH from the rat pituitary as well as to possibly affect the synthesis/secretion of an FSH-like peptide by the prostate. These findings suggest that the effects of PSP-94 on tumor growth in vivo, could be attributed to the reduction in serum FSH levels.
[0007] Both PSA and PAP have been studied as tumor markers in the detection of prostate disease, but since both exhibit elevated levels in prostates having benign prostatic hyperplasia (BPH), neither marker is specific and therefore they are of limited utility.
[0008] Recently, it has been shown that PSP94 concentrations in serum of patients with BPH or CaP are significantly higher than normal. The highest serum concentration of PSP94 observed in normal men is approximately 40 ng/ml, while in men with either BPH or CaP, serum concentrations of PSP94 have been observed in the range from 300-400 ng/ml. Because there exists some overlap in the concentrations of PSP94 in subjects having normal prostates and patients exhibiting either BPH or CaP, serum levels in and of themselves are of little value.
[0009] A major therapy in the treatment of prostate cancer is androgen-ablation. While most patients respond initially to this treatment, its effectiveness decreases over time, possibly because of the presence of a heterogenous population of androgen-dependant and androgen-independent cells to the androgen treatment, while any androgen insensitive cells present would continue to proliferate unabated.
[0010] Other forms of cancer, which are currently exacting a heavy toll on population are breast cancer in women and cancer of the gastrointestinal tract. Currently, the use of various cancer drugs such as mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin and daunomycin form part of the therapy for treating such cancers. One drawback to such a therapeutic treatment is the presence of adverse side effects due to the drugs in the concentration ranges required for effective treatment.
[0011] Accordingly, it would be advantageous to find a more effective means of arresting the growth of prostate, breast and gastrointestinal cancer cells and tumors, which may be used effectively against both androgen sensitive and androgen insensitive cells.
[0012] In previous work, described in U.S. Pat. No. 5,428,011, we provided pharmaceutical preparations (i.e., compositions) of native human seminal plasma PSP94 for inhibiting in-vitro and in-vivo cancerous prostate, gastrointestinal and breast tumors. The pharmaceutical preparations included native human seminal plasma PSP94 which could be administered in an appropriate dosage form, dosage quantity and dosage regimen to a patient suffering from prostate cancer. In another embodiment, the pharmaceutical preparation included a mixture of human seminal plasma PSP94 and an anticancer drug which may be administered in an appropriate dosage form, dosage quantity and dosage regimen to a patient suffering from, for example gastrointestinal cancer.
[0013] PSP94 sourced from human seminal fluid carries with it significant risk of contamination with infectious agents (e.g., HIV, hepatitis (a, b, or c), and other viruses and/or prions). Even with the use of harsh chemical treatment, total eradication of such agents cannot be guaranteed. Additionally, human seminal fluid is found in limited supply, thus making bulk production of PSP94 very difficult. Therefore, the acceptability of human or even xenogeneic sourced PSP94 may be very difficult for both the regulatory authorities and the marketplace.
[0014] Therefore, the use of recombinant technology for producing PSP94 would represent a significant advancement, as recombinant PSP94 could be produced both free of pathogens and in an unlimited supply. Furthermore, the material would be homogeneous from a single lot source, avoiding batch variation.
SUMMARY OF THE INVENTION
[0015] In its first aspect the present invention relates to a polypeptide or a polypeptide analog selected from the group consisting of the polypeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4, the polypeptide as set forth in SEQ ID NO: 5, and the polypeptide as set forth in SEQ ID NO: 6, a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5. The polypeptide analog mentionned herein may be capable of inhibiting the growth of a tumor or more precisely may be capable of inhibiting the growth of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH).
[0016] In a second aspect, the present invention relates to the use of a polypeptide or a polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), and the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5 and mixture(s) thereof, for inhibiting the growth of a tumor or more precisely for inhibiting the growth of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH).
[0017] In one embodiment of the second aspect of the present invention, the polypeptide or polypeptide analog may be used with an anticancer drug, such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof.
[0018] In an additional embodiment of the second aspect of the present invention, the polypeptide or polypeptide analog may be used with a pharmaceutically acceptable carrier.
[0019] In a further embodiment of the second aspect of the present invention the polypeptide or polypeptide analog may be used with a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of said polypeptide or polypeptide analog.
[0020] It other embodiments of the second aspect of the present invention, the polypeptide or polypeptide analog may be used with an anticancer drug and a pharmaceutically acceptable carrier, with an anticancer drug and a time-release means, with a pharmaceutically acceptable carrier and a time-release means, or with an anticancer drug, a pharmaceutically acceptable and a time-release means. Some examples of an anticancer drug, a pharmaceutically acceptable carrier and a time-release means are described herein.
[0021] In a third aspect, the present invention relates to a method for treating a patient with a tumor or more precisely with prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH), the method comprising administering to the patient a pharmaceutical composition comprising a polypeptide or polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), and the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog selected from the group consisting of a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5 and mixtures thereof. The polypeptide analog mentionned herein may be capable of inhibiting the growth of a tumor or more precisely may be capable of inhibiting the growth of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH).
[0022] The method for treating a patient as described above may result, for example, in the inhibition (e.g., reduction, control, atenuation, prohibition) of the growth of a tumor(s) in a patient suffering for example from prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH). The method described above may be performed, for example, by administering to the patient a pharmaceutical composition comprising a polypeptide, a polypeptide analog, or mixtures thereof of the present invention.
[0023] In one embodiment of the third aspect of the present invention, the polypeptide or polypeptide analog may be used with an anticancer drug, such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof.
[0024] In an additional embodiment of the third aspect of the present invention, the polypeptide or polypeptide analog may be used with a pharmaceutically acceptable carrier.
[0025] In a further embodiment of the third aspect of the present invention the polypeptide or polypeptide analog may be used with a time-release means such as for example, liposomes and polysaccharides for effecting continual dosing of said polypeptide or polypeptide analog.
[0026] It other embodiments of the third aspect of the present invention, the polypeptide or polypeptide analog may be used with an anticancer drug and a pharmaceutically acceptable carrier, with an anticancer drug and a time-release means, with a pharmaceutically acceptable carrier and a time-release means, or with an anticancer drug, a pharmaceutically acceptable and a time-release means. Some examples of an anticancer drug, a pharmaceutically acceptable carrier and a time-release means are described herein.
[0027] In a fourth aspect, the present invention relates to a method for treating a patient with a tumor or more precisely with prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH), the method comprising administering to the patient a pharmaceutical composition including a vector comprising the nucleotide sequence of SEQ ID NO: 9 and a pharmaceutically acceptable carrier or a pharmaceutical composition comprising a polynucleotide selected from the group consisting of a polynucleotide having at least 10 to 285 contiguous residues of SEQ ID NO: 9, and a polynucleotide having at least 10 to 50 contiguous residues of SEQ ID NO: 9, and a pharmaceutically acceptable carrier.
[0028] In one embodiment of the fourth aspect of the present invention, the vector or the polynucleotide may be used with an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof.
[0029] In an additional embodiment of the fourth aspect of the present invention, the vector or the polynucleotide may be used with a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of said vector.
[0030] In further embodiment of the fourth aspect of the present invention, the vector or the polynucleotide may be used with an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof and with a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of said vector or polynucleotide.
[0031] In a fifth aspect, the present invention relates to a pharmaceutical composition for inhibiting (e.g., recuding, controling, atenuating, prohibiting) the growth of a tumor in a patient suffering from prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH), comprising:
[0032] a)a polypeptide or a polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (Polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), the polypeptide as set forth in SEQ ID NO: 6 (Polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and mixture(s) thereof, and;
[0033] b) an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol, taxol derivative, and mixtures thereof.
[0034] In one embodiment of the fifth aspect of the present invention the pharmaceutical composition may further comprise a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of the composition.
[0035] In a sixth aspect, the present invention relates to a pharmaceutical composition for inhibiting the growth of a tumor in a patient suffering from prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH), comprising:
[0036] a) a polypeptide or polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (Polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), the polypeptide as set forth in SEQ ID NO: 6 (Polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and mixture(s) thereof, and;
[0037] b) a pharmaceutically acceptable carrier.
[0038] In one embodiment of the sixth aspect of the present invention the pharmaceutical composition may further comprise a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of the composition.
[0039] In a second embodiment of the sixth aspect of the present invention the pharmaceutical composition may further comprise an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol, taxol derivative, and mixtures thereof.
[0040] In a third embodiment of the sixth aspect of the present invention, the pharmaceutical composition may further comprise a time-release means and an anticancer drug. Examples of time-release means and anticancer drug are described herein.
[0041] In a seventh aspect, the present invention relates to a pharmaceutical composition comprising:
[0042] a) A polypeptide or polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gin), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and mixture(s) thereof, in a therapeutically effective amount, and;
[0043] b) an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol, taxol derivative, and mixtures thereof in a therapeutically effective amount.
[0044] In one embodiment of the seventh aspect of the present invention the pharmaceutical composition may further comprise a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of the composition.
[0045] In an eighth aspect, the present invention relates to a pharmaceutical composition comprising:
[0046] a) a polypeptide or polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and mixture(s) thereof, in a therapeutically effective amount, and;
[0047] b) a pharmaceutically acceptable carrier.
[0048] In one embodiment of the eighth aspect of the present invention the pharmaceutical composition may further comprise a time-release means such as, for example, liposomes and polysaccharides for effecting continual dosing of the composition.
[0049] In a second embodiment of the eight aspect of the present invention, the pharmaceutical composition may further comprise an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol, taxol derivative, and mixtures thereof.
[0050] In a third embodiment of the eight aspect of the present invention, the pharmaceutical composition may further comprise a time-release means and an anticancer drug. Examples of time-release means and anticancer drug are described herein.
[0051] In a ninth aspect, the present invention relates to a pharmaceutical composition for inhibiting (reducing, controling, atenuating, prohibiting) the growth of a tumor in a patient suffering from prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH), comprising a vector comprising the nucleotide sequence of SEQ ID NO: 9 and a pharmaceutically acceptable carrier, or a polynucleotide selected from the group consisting of a polynucleotide having at least 10 to 285 contiguous residues of SEQ ID NO: 9 and a polynucleotide having at least 10 to 50 contiguous residues of SEQ ID NO: 9, and a pharmaceutically acceptable carrier.
[0052] In one embodiment of the ninth aspect of the present invention, the pharmaceutical composition may further comprise an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof.
[0053] In an tenth aspect, the present invention relates to a pharmaceutical composition for inhibiting the growth of a tumor in a patient, comprising a vector comprising the nucleotide sequence of SEQ ID NO: 9 and a pharmaceutically acceptable carrier, or a polynucleotide selected from the group consisting of a polynucleotide having at least 10 to 285 contiguous residues of SEQ ID NO: 9 and a polynucleotide having at least 10 to 50 contiguous residues of SEQ ID NO: 9, and a pharmaceutically acceptable carrier.
[0054] In one embodiment of the tenth aspect of the present invention, the pharmaceutical composition may further comprise an anticancer drug such as, for example, mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol (i.e., paclitaxel), taxol derivative (e.g.,docetaxel, taxane), and mixtures thereof.
[0055] In an eleventh aspect, the present invention relates to a method for treating patients with a disease characterized by elevated levels of FSH comprising administering a pharmaceutical composition in an appropriate dosage form, the pharmaceutical composition comprising a polypeptide or polypeptide analog selected from the group consisting of rHuPSP94 as set forth SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4, the polypeptide as set forth in SEQ ID NO: 5, and the polypeptide as set forth in SEQ ID NO: 6, a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and mixtures thereof, and a pharmaceutically acceptable carrier in a human dose.
[0056] In a twelfth aspect, the present invention relates to the use of a polypeptide or a polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), and the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5 and mixture(s) thereof, for treating patients with a disease characterized by elevated levels of FSH.
[0057] The use of a polypeptide or a polypeptide analog selected from the group consisting of rHuPSP94 as set forth in SEQ ID NO: 2, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), a polypeptide analog of at least five contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog of at least two contiguous amino acids of SEQ ID NO: 2, of SEQ ID NO: 3, of SEQ ID NO: 4, of SEQ ID NO: 5, or of SEQ ID NO: 6, a polypeptide analog consisting of the amino acid sequence X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2 as set forth in SEQ ID NO: 89, wherein X 1 is either glutamic acid (Glu), asparagine (Asn) or aspartic acid (Asp), X 2 is either threonine (Thr) or serine (Ser), and X 3 is either tyrosine (Tyr) or phenylalanine (Phe), a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its amino-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 59 to SEQ ID NO: 88, a polypeptide analog comprising SEQ ID NO: 5 and having an addition of at least one amino acid to its carboxy-terminus, wherein said polypeptide analog comprising SEQ ID NO:5 is selected from the group consisting of SEQ ID NO: 10 to SEQ ID NO: 58, a polypeptide analog comprising two to fifty units of SEQ ID NO: 5, a polypeptide analog comprising two to ten units of SEQ ID NO: 5, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), a polypeptide analog having at least 90% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, a polypeptide analog having at least 70% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5, and a polypeptide analog having at least 50% of its amino acid sequence identical to the amino acid sequence set forth in SEQ ID NO: 5 and mixtures thereof for the manufacture of a medicament for the therapeutic treatment of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, benign prostate hyperplasia (BPH) or a disease characterized by elevated levels of FSH.
[0058] In accordance with the present invention, rHuPSP94 may be used in a dosage range from about 10 micrograms/kg/day to about 4 milligrams/kg/day, in a dosage range from about 500 picograms/kg/day to about 1 milligram/kg/day, in a dosage range from about 5 nanograms/kg/day to about 10 micrograms/kg/day or in a dosage range from about 5 nanograms/kg/day to about 500 nanograms/kg/day.
[0059] In accordance with the present invention, the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4, the polypeptide as set forth in SEQ ID NO: 5, the polypeptide as set forth in SEQ ID NO: 6, and mixtures thereof may be used in a dosage range from about 100 nanograms/kg/day to about 4 milligrams/kg/day.
[0060] In accordance with the present invention, the anticancer drug may be mixed or not with a polypeptide or polypeptide analog or mixtures thereof or it may be given separately, by a different route, or even in a different administration schedule (e.g., a different time or day).
[0061] In accordance with the present invention administration of the composition may be performed by any suitable routes including administration by injection via the intra-muscular (IM), subcutaneous (SC), intra-dermal (ID), intra-venous (IV) or intra-peritoneal (IP) routes or administration at the mucosal membranes including the oral and nasal cavity membranes using any suitable means.
[0062] In accordance with the present invention, the composition may be used to treat gastrointestinal cancer.
[0063] It is known in the art that the proteins or polypeptides of the present invention may be made according to methods present in the art. The polypeptides of the present invention may be prepared for example, from bacterial cell extracts, or through the use of recombinant techniques. Polypeptides of the present invention may, for example, be produced by transformation (transfection, transduction, or infection) of a host cell with all or part of a rHuPSP94 (SEQ ID NO: 2), the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), and the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94) encoding DNA sequence in a suitable expression vehicle. Examples of suitable expression vehicles comprise for example, plasmids, viral particles, artificial chromosomes and phages. The entire expression vehicle, or a part thereof, may be integrated into the host cell genome. In some circumstances, it is desirable to employ an inducible expression vector.
[0064] Any of a wide variety of expression systems may be used to provide the recombinant protein. The precise host cell used is not critical to the invention. Polypeptides of the present invention may be produced in a prokaryotic host (e.g., E. coli or B. subtilis ) or in a eukaryotic host (yeast e.g., Saccharomyces or Pichia Pastoris; mammalian cells, e.g., monkey COS cells, mouse 3T3 cells (Todaro GJ and Green H., J. Cell Biol. 17: 299-313, 1963), Chinese Hamster Ovary cells (CHO) (Puck T T et al., J. Exp. Med. 108: 945-956, 1958), BHK, human kidney 293 cells (ATCC: CRL-1573), or human HeLa cells (ATCC:CCL-2); or insect cells).
[0065] In a yeast cell expression system such as Pichia Pastoris (P. Pastoris), DNA sequence encoding polypeptides of the present invention may be cloned into a suitable expression vector such as the pPIC9 vector (Invitrogen). Upon introduction of a vector containing the DNA sequence encoding all or part of the polypetides of the present invention into the P. Pastoris host cells, recombination event may occur for example in the AOX1 locus. Such recombination event may place the DNA sequence of the various polypetides of the present invention under the dependency of the AOX1 gene promoter. Successful insertion of a gene (DNA sequence) encoding polypeptides of the present invention may result in an expression of such polypeptides that is regulated and/or induced by methanol added in the growth media of the host cell (for reference see Buckholz, R. G. and Gleeson, M. A. G., Biotechnology, 9:1067-1072,1991; Cregg, J. M., et al., Biotechnology, 11:905-910, 1993; Sreekrishna, K., et al., J.Basic Microbiol., 28:265-278, 1988; Wegner, G. H., FEMS Microbiology Reviews, 87:279-284, 1990).
[0066] In mammalian host cells, a number of viral-based expression systems may be utilized. For example, in the event where an adenovirus is used as an expression vector for the polypeptides of the present invention, nucleic acid sequence may be ligated to an adenovirus transcription/translation control complex (e.g., the late promoter and tripartite leader sequence). This chimeric gene may be inserted into the adenovirus genome, for example, by in vitro or in vivo recombination. Insertion into a non-essential region of the viral genome (e.g., region E1 or E3) may result in a recombinant virus that is viable and capable of expressing polypeptides of the present invention in infected hosts.
[0067] Proteins and polypeptides of the present invention may also be produced by plant cells. Expression vectors such as cauliflower mosaic virus and tobacco mosaic virus and plasmid expression vectors (e.g., Ti plasmid) may be used for the expression of polypeptides in plant cells. Such cells are available from a wide range of sources (e.g., the American Type Culture Collection, Rockland, Md.). The methods of transformation or transfection and the choice of expression vehicle are of course to be chosen accordingly to the host cell selected.
[0068] In an insect cell expression system such as Autographa californica nuclear polyhedrosis virus (AcNPV), which grows in Spodoptera frugiperda cells, AcNPV may be used as a vector to express foreign genes. For example, DNA sequence coding for all or part of the polypeptides of the present invention may be cloned into non-essential regions of the virus (for example the polyhedrin gene) and placed under control of an AcNPV promoter, (e.g., the polyhedrin promoter). Successful insertion of a gene (i.e.,DNA sequence) encoding polypeptides of the present invention may result in inactivation of the polyhedrin gene and production of non-occluded recombinant virus (i.e., virus lacking the proteinaceous coat encoded by the polyhedrin gene). These recombinant viruses may be used to infect spodoptera frugiperda cells in which the inserted gene is expressed.
[0069] In addition, a host cell may be chosen for its ability to modulate the expression of the inserted sequences, or to modify or process the gene product in a specific, desired fashion. Such modifications (e.g., glycosylation) and processing (e.g., cleavage) of protein products may be important for the function of the protein. Different host cells have characteristics and specific mechanisms for posttranslational processing and modification of proteins and gene products. Of course, cell lines or host systems may be chosen to ensure desired modification and processing of the foreign protein expressed. To this end, eukaryotic host cells that possess the cellular machinery for proper processing of the primary transcript, glycosylation, and phosphorylation of the gene product may be used. Such mammalian host cells comprise for example, but are not limited to, CHO, VERO, BHK, HeLa, COS, MDCK, 293, and 3T3.
[0070] Alternatively, polypeptides of the present invention may be produced by a stably transfected mammalian cell line. A number of vectors suitable for stable transfection of mammalian cells are available to the public; methods for constructing such cell lines are also publicly available. In one example, cDNA encoding the rHuPSP94 protein may be cloned into an expression vector that includes the dihydrofolate reductase (DHFR) gene. Integration of the plasmid and, therefore, DNA sequence of polypeptides of the present invention, into the host cell chromosome may be selected for by including methotrexate in the cell culture media. This selection may be accomplished in most cell types.
[0071] Specific initiation signals may also be required for the efficient translation of DNA sequences inserted in a suitable expression vehicle as described above. These signals may include the ATG initiation codon and adjacent sequences. For example, in the event where gene or cDNA encoding polypeptides of the present invention, would not have their own initiation codon and adjacent sequences, additional translational control signals may be needed. For example, exogenous translational control signals, including, perhaps, the ATG initiation codon, may be needed. It is known in the art that the initiation codon must be in phase with the reading frame of the polypeptide sequence to ensure proper translation of the desired polypeptide. Exogenous translational control signals and initiation codons may be of a variety of origins, including both natural and synthetic. The efficiency of expression may be enhanced by the inclusion of appropriate transcription enhancer elements, transcription terminators.
[0072] As may be appreciated, a number of modifications may be made to the polypeptides and fragments of the present invention without deleteriously affecting the biological activity of the polypeptides or fragments. Polypeptides of the present invention comprises for example, those containing amino acid sequences modified either by natural processes, such as posttranslational processing, or by chemical modification techniques which are known in the art. Modifications may occur anywhere in a polypeptide including the polypeptide backbone, the amino acid side-chains and the amino or carboxy termini. It will be appreciated that the same type of modification may be present in the same or varying degrees at several sites in a given polypeptide. Also, a given polypeptide may contain many types of modifications. Polypeptides may be branched as a result of ubiquitination, and they may be cyclic, with or without branching. Cyclic, branched and branched cyclic polypeptides may result from posttranslational natural processes or may be made by synthetic methods. Modifications comprise for example, without limitation, acetylation, acylation, addition of acetomidomethyl (Acm) group, ADP-ribosylation, amidation, covalent attachment to fiavin, covalent attachment to a heme moiety, covalent attachment of a nucleotide or nucleotide derivative, covalent attachment of a lipid or lipid derivative, covalent attachment of phosphatidylinositol, cross-linking, cyclization, disulfide bond formation, demethylation, formation of covalent cross-links, formation of cystine, formation of pyroglutamate, formylation, gamma-carboxylation, glycosylation, GPI anchor formation, hydroxylation, iodination, methylation, myristoylation, oxidation, proteolytic processing, phosphorylation, prenylation, racemization, selenoylation, sulfation, transfer-RNA mediated addition of amino acids to proteins such as arginylation and ubiquitination (for reference see, Protein-structure and molecular proterties, 2 nd Ed., T. E. Creighton, W. H. Freeman and Company, New-York, 1993).
[0073] Other type of polypeptide modification may comprises for example, amino acid insertion (i.e., addition), deletion and substitution (i.e., replacement), either conservative or non-conservative (e.g., D-amino acids, desamino acids) in the polypeptide sequence where such changes do not substantially alter the overall biological activity of the polypeptide. Polypeptides of the present invention comprise for example, biologically active mutants, variants, fragments, chimeras, and analogs; fragments encompass amino acid sequences having truncations of one or more amino acids, wherein the truncation may originate from the amino terminus (N-terminus), carboxy terminus (C-terminus), or from the interior of the protein. Analogs of the invention involve an insertion or a substitution of one or more amino acids. Variants, mutants, fragments, chimeras and analogs may have the biological property of polypeptides of the present invention which is to inhibit growth of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH).
[0074] Example of substitutions may be those, which are conservative (i.e., wherein a residue is replaced by another of the same general type). As is understood, naturally occurring amino acids may be sub-classified as acidic, basic, neutral and polar, or neutral and non-polar. Furthermore, three of the encoded amino acids are aromatic. It may be of use that encoded polypeptides differing from the determined polypeptide of the present invention contain substituted codons for amino acids, which are from the same group as that of the amino acid be replaced. Thus, in some cases, the basic amino acids Lys, Arg and His may be interchangeable; the acidic amino acids Asp and Glu may be interchangeable; the neutral polar amino acids Ser, Thr, Cys, Gln, and Asn may be interchangeable; the non-polar aliphatic amino acids Gly, Ala, Val, Ile, and Leu are interchangeable but because of size Gly and Ala are more closely related and Val, Ile and Leu are more closely related to each other, and the aromatic amino acids Phe, Trp and Tyr may be interchangeable.
[0075] It should be further noted that if the polypeptides are made synthetically, substitutions by amino acids, which are not naturally encoded by DNA may also be made. For example, alternative residues include the omega amino acids of the formula NH2(CH2)nCOOH wherein n is 2-6. These are neutral nonpolar amino acids, as are sarcosine, t-butyl alanine, t-butyl glycine, N-methyl isoleucine, and norleucine. Phenylglycine may substitute for Trp, Tyr or Phe; citrulline and methionine sulfoxide are neutral nonpolar, cysteic acid is acidic, and ornithine is basic. Proline may be substituted with hydroxyproline and retain the conformation conferring properties.
[0076] It is known in the art that mutants or variants may be generated by substitutional mutagenesis and retain the biological activity of the polypeptides of the present invention. These variants have at least one amino acid residue in the protein molecule removed and a different residue inserted in its place. For example, one site of interest for substitutional mutagenesis may include but are not restricted to sites identified as the active site(s), or immunological site(s). Other sites of interest may be those, for example, in which particular residues obtained from various species are identical. These positions may be important for biological activity. Examples of substitutions identified as“conservative substitutions” are shown in table 1. If such substitutions result in a change not desired, then other type of substitutions, denominated “exemplary substitutions” in table 1, or as further described herein in reference to amino acid classes, are introduced and the products screened.
[0077] In some cases it may be of interest to modify the biological activity of a polypeptide by amino acid substitution, insertion, or deletion. For example, modification of a polypeptide may result in an increase in the polypeptide's biological activity, may modulate its toxicity, may result in changes in bioavailability or in stability, or may modulate its immunological activity or immunological identity. Substantial modifications in function or immunological identity are accomplished by selecting substitutions that differ significantly in their effect on maintaining (a) the structure of the polypeptide backbone in the area of the substitution, for example, as a sheet or helical conformation. (b) the charge or hydrophobicity of the molecule at the target site, or (c) the bulk of the side chain. Naturally occurring residues are divided into groups based on common side chain properties:
[0078] (1) hydrophobic: norleucine, methionine (Met), Alanine (Ala), Valine (Val), Leucine (Leu), Isoleucine (Ile)
[0079] (2) neutral hydrophilic: Cysteine (Cys), Serine (Ser), Threonine (Thr)
[0080] (3) acidic: Aspartic acid (Asp), Glutamic acid (Glu)
[0081] (4) basic: Asparagine (Asn), Glutamine (Gln), Histidine (His), Lysine (Lys), Arginine (Arg)
[0082] (5) residues that influence chain orientation: Glycine (Gly), Proline (Pro); and
[0083] (6) aromatic: Tryptophan (Trp), Tyrosine (Tyr), Phenylalanine (Phe)
[0084] Non-conservative substitutions will entail exchanging a member of one of these classes for another.
TABLE 1 Preferred amino acid substitution Conservative Original residue Exemplary substitution substitution Ala (A) Val, Leu, Ile Val Arg (R) Lys, Gln, Asn Lys Asn (N) Gln, His, Lys, Arg Gln Asp (D) Glu Glu Cys (C) Ser Ser Gln (Q) Asn Asn Glu (E) Asp Asp Gly (G) Pro Pro His (H) Asn, Gln, Lys, Arg Arg Ile (I) Leu, Val, Met, Ala, Leu Phe, norleucine Leu (L) Norleucine, Ile, Val, Ile Met, Ala, Phe Lys (K) Arg, Gln, Asn Arg Met (M) Leu, Phe, Ile Leu Phe (F) Leu, Val, Ile, Ala Leu Pro (P) Gly Gly Ser (S) Thr Thr Thr (T) Ser Ser Trp (W) Tyr Tyr Tyr (Y) Trp, Phe, Thr, Ser Phe Val (V) Ile, Leu, Met, Phe, Leu Ala, norleucine
[0085] Example of analogs of PCK3145 (SEQ ID NO: 5) exemplified by amino acid substitutions has been illustrated below.
SEQ ID NO: 89 Position 1 5 10 PCK3145 E W Q T D N C E T C T C 15 Y E T X 1 W Q X 2 D X 1 C X 1 X 2 C X 2 C X 3 X 1 X 2
[0086] For example, X 1 could be glutamic acid (i.e., glutamate) (Glu), aspartic acid (aspartate) (Asp), or asparagine (Asn), X 2 could be threonine (Thr) or serine (Ser) and X 3 could be tyrosine (Tyr) or phenylalanine (Phe).
[0087] Amino acids sequence insertions (e.g., additions) include amino and/or carboxyl-terminal fusions ranging in length from one residues to polypeptides containing a hundred or more residues, as well as intrasequence insertions of single or multiple amino acid residues. Other insertional variants include the fusion of the N- or C-terminus of the protein to a homologous or heterologous polypeptide forming a chimera. Chimeric polypeptides (i.e., chimeras, polypeptide analog) comprise sequence of the polypeptides of the present invention fused to homologous or heterologous sequence. Said homologous or heterologous sequence encompass those which, when formed into a chimera with the polypeptides of the present invention retain one or more biological or immunological properties. Examples of homologous sequences fused to PCK3145 (SEQ ID NO: 5) are illustrated below (1 to 79). Such homologous sequences are derived as it is the case for PCK3145, from rHuPSP94 (SEQ ID NO: 2).
1) EWQTDNCETCTCYETE (SEQ ID NO: 10) 2) EWQTDNCETCTCYETEI (SEQ ID NO: 11) 3) EWQTDNCETCTCYETEIS (SEQ ID NO: 12) 4) EWQTDNCETCTCYETEISC (SEQ ID NO: 13) 5) EWQTDNCETCTCYETEISCC (SEQ ID NO: 14) 6) EWQTDNCETCTCYETEISCCT (SEQ ID NO: 15) 7) EWQTDNCETCTCYETEISCCTL (SEQ ID NO: 16) 8) EWQTDNCETCTCYETEISCCTLV (SEQ ID NO: 17) 9) EWQTDNCETCTCYETEISCCTLVS (SEQ ID NO: 18) 10) EWQTDNCETCTCYETEISCCTLVST (SEQ ID NO: 19) 11) EWQTDNCETCTCYETEISCCTLVSTP (SEQ ID NO: 20) 12) EWQTDNCETCTCYETEISCCTLVSTPV (SEQ ID NO: 21) 13) EWQTDNCETCTCYETEISCCTLVSTPVG (SEQ ID NO: 22) 14) EWQTDNCETCTCYETEISCCTLVSTPVGY (SEQ ID NO: 23) 15) EWQTDNCETCTCYETEISCCTLVSTPVGYD (SEQ ID NO: 24) 16) EWQTDNCETCTCYETEISCCTLVSTPVGYDK (SEQ ID NO: 25) 17) EWQTDNCETCTCYETEISCCTLVSTPVGYDKD (SEQ ID NO: 26) 18) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDN (SEQ ID NO: 27) 19) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNC (SEQ ID NO: 28) 20) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQ (SEQ ID NO: 29) 21) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQR (SEQ ID NO: 30) 22) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRI (SEQ ID NO: 31) 23) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIF (SEQ ID NO: 32) 24) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFK (SEQ ID NO: 33) 25) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKK (SEQ ID NO: 34) 26) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKE (SEQ ID NO: 35) 27) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKED (SEQ ID NO: 36) 28) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDC (SEQ ID NO: 37) 29) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCK (SEQ ID NO: 38) 30) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKY (SEQ ID NO: 39) 31) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYI (SEQ ID NO: 40) 32) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIV (SEQ ID NO: 41) 33) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVV (SEQ ID NO: 42) 34) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVE (SEQ ID NO: 43) 35) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEK (SEQ ID NO: 44) 36) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKK (SEQ ID NO: 45) 37) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKD (SEQ ID NO: 46) 38) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDP (SEQ ID NO: 47) 39) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPK (SEQ ID NO: 48) 40) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKK (SEQ ID NO: 49) 41) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKT (SEQ ID NO: 50) 42) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTC (SEQ ID NO: 51) 43) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCS (SEQ ID NO: 52) 44) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSV (SEQ ID NO: 53) 45) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSVS (SEQ ID NO: 54) 46) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSVSE (SEQ ID NO: 55) 47) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSVSEW (SEQ ID NO: 56) 48) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSVSEWI (SEQ ID NO: 57) 49) EWQTDNCETCTCYETEISCCTLVSTPVGYDKDNCQRIFKKEDCKYIVVEKKDPKKTCSVSEWII (SEQ ID NO: 58) 50) SCYFIPNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 88) 51) CYFIPNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 87) 52) YFIPNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 86) 53) FIPNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 85) 54) IPNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 84) 55) PNEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 83) 56) NEGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 82) 57) EGVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 81) 58) GVPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 80) 59) VPGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 79) 60) PGDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 78) 61) GDSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 77) 62) DSTRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 76) 63) STRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 75) 64) TRKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 74) 65) RKCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 73) 66) KCMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 72) 67) CMDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 71) 68) MDLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 70) 69) DLKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 69) 70) LKGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 68) 71) KGNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 67) 72) GNKHPINSEWQTDNCETCTCYET (SEQ ID NO: 66) 73) NKHPINSEWQTDNCETCTCYET (SEQ ID NO: 65) 74) KHPINSEWQTDNCETCTCYET (SEQ ID NO: 64) 75) HPINSEWQTDNCETCTCYET (SEQ ID NO: 63) 76) PINSEWQTDNCETCTCYET (SEQ ID NO: 62) 77) INSEWQTDNCETCTCYET (SEQ ID NO: 61) 78) NSEWQTDNCETCTCYET (SEQ ID NO: 60) 79) SEWQTDNCETCTCYET (SEQ ID NO: 59)
[0088] Other type of chimera generated by homologous fusion includes new polypeptides formed by the repetition of two or more polypeptides of the present invention. The number of repeat may be, for example, between 2 and 50 units (i.e., repeats). In some instance, it may be useful to have a new polypeptide with a number of repeat greater than 50. Examples of new polypeptides formed by the repetition of PCK3145 (SEQ ID NO: 5) are illustrated below (80 to 82). In some instance, SEQ ID NO: 5 units may be separated by a linker or an adaptor of variable length.
80) EWQTDNCETCTCYETEEWQTDNCETCTCYETE (SEQ ID NO: 90) 81) EWQTDNCETCTCYETEEWQTDNCETCTCYETEEWQTDNCETCTCYETE (SEQ ID NO: 91) 82) EWQTDNCETCTCYETEEWQTDNCETCTCYETEEWQTDNCETCTCYETEEWQTDNCETCTCYETE (SEQ ID NO: 92)
[0089] Heterologous fusion includes new polypeptides made by the fusion of polypeptides of the present invention with heterologous polypeptides. Such polypeptides may include but are not limited to bacterial polypeptides (e.g., betalactamase, glutathione-S-transferase, or an enzyme encoded by the E.coli trp locus), yeast protein, viral proteins, phage proteins, bovine serum albumin, chemotactic polypeptides, immunoglobulin constant region (or other immunoglobulin regions), albumin, or ferritin.
[0090] Other type of polypeptide modification includes amino acids sequence deletions (e.g., truncations). Those generally range from about 1 to 30 residues, more preferably about 1 to 10 residues and typically about 1 to 5 residues.
[0091] A host cell transformed or transfected with nucleic acids encoding the polypeptides of the present invention (i.e., vector containing the DNA sequence of the polypeptides of the present invention) or chimeric proteins formed with the polypeptides of the present invention are also encompassed by the invention. Any host cell, which produces a polypeptide analog, mutant, variant, fragment, or chimera having at least one of the biological properties of the present invention is encompassed by the present invention. For example, such host cell may include bacterial, yeast, plant, insect or mammalian cells. In addition, the polypeptides of the present invention may be produced in transgenic animals. Transformed or transfected host cells and transgenic animals may be obtained using materials and methods that are routinely available to one skilled in the art.
DEFINITIONS
General Molecular Biology
[0092] Unless otherwise indicated, the recombinant DNA techniques utilized in the present invention are standard procedures, known to those skilled in the art. Example of such techniques are explained in the literature in sources such as J. Perbal, A Practical Guide to Molecular Cloning, John Wiley and Sons (1984), J. Sambrook et al ., Molecular Cloning: A Laboratory Manual, Cold Spring Harbor Laboratory Press (1989), T. A. Brown (editor), Essential Molecular Biology: A Practical Approach, Volumes 1 and 2, IRL Press (1991), D. M. Glover and B. D. Hames (editors), DNA Cloning: A Practical Approach, Volumes 1-4, IRL Press (1995 and 1996), and F. M. Ausubel et al. (editors), Current Protocols in Molecular Biology, Greene Pub. Associates and Wiley-Interscience (1988, including all updates until present) and are incorporated herein by reference.
[0093] “Polynucleotide” generally refers to any polyribonucleotide or polydeoxyribonucleotide, which may be unmodified RNA or DNA, or modified RNA or DNA. “Polynucleotides” include, without limitation single- and double-stranded DNA, DNA that is a mixture of single- and double-stranded regions, single- and double-stranded RNA, and RNA that is a mixture of single- and double-stranded regions, hybrid molecules comprising DNA and RNA that may be single-stranded or, more typically, double-stranded or a mixture of single- and double-stranded regions. In addition, “polynucleotide” refers to triple-stranded regions comprising RNA or DNA or both RNA and DNA. The term polynucleotide also includes DNAs or RNAs containing one or more modified bases and DNAs or RNAs with backbones modified for stability or for other reasons. “Modified” bases include, for example, tritylated bases and unusual bases such as inosine. A variety of modifications has been made to DNA and RNA; thus “polynucleotide” embraces chemically, enzymatically or metabolically modified forms of polynucleotides as typically found in nature, as well as the chemical forms of DNA and RNA characteristic of viruses and cells. “Polynucleotide” includes but is not limited to linear and end-closed molecules. “Polynucleotide” also embraces relatively short polynucleotides, often referred to as oligonucleotides.
[0094] “Polypeptides” refers to any peptide or protein comprising two or more amino acids joined to each other by peptide bonds or modified peptide bonds (i.e., peptide isosteres). “Polypeptide” refers to both short chains, commonly referred as peptides, oligopeptides or oligomers, and to longer chains generally referred to as proteins. As described above, polypeptides may contain amino acids other than the 20 gene-encoded amino acids.
[0095] As used herein the term “polypeptide analog” relates to mutants, variants, chimeras, fusions, deletions, additions and any other type of modifications made relative to a given polypeptide.
[0096] As used herein, the term “homologous” sequence relates to nucleotide or amino acid sequence derived from the rHuPSP94 DNA sequence or polypeptide.
[0097] As used herein, the term “heterologous” sequence relates to DNA sequence or amino acid sequence of a heterologous polypeptide and includes sequence other than that of PSP94.
[0098] As used herein, the term “tumor” relates to solid or non-solid tumors, metastasic or non-metastasic tumors, tumors of different tissue origin including, but not limited to, tumors originating in the liver, lung, brain, lymph node, bone marrow, adrenal gland, breast, colon, pancreas, prostate, stomach, or reproductive tract (cervix, ovaries, endometrium etc.). The term “tumor” as used herein, refers also to all neoplastic cell growth and proliferation, whether malignant or benign, and all pre-cancerous and cancerous cells and tissues.
[0099] As used herein, the term “polysaccharide” refers to a substance made of two or more saccharide unit and comprise, for example, chitosan, pectin, chondroitin sulfate, cyclodextrin, dextrans, guar gum, inulin, amylose, and locust bean gum.
[0100] As used herein, the term “vector” refers to an autonomously replicating DNA or RNA molecule into which foreign DNA or RNA fragments are inserted and then propagated in a host cell for either expression or amplification of the foreign DNA or RNA molecule. The term <<vector>> mcomprises and is not limited to a plasmid (e.g., linearized or not) that can be used to transfer DNA sequences from one organism to another.
[0101] As used herein, the term “time-release encapsulation means ” refers to controlled or sustained release obtained when a pharmaceutical composition is formulated, for example, with polysaccharides, biocompatible polymers, other polymeric matrices, capsules, microcapsules, microparticles, bolus preparations, osmotic pumps, diffusion devices, liposomes, lipospheres, dry powders, or transdermal delivery systems. Other controlled release compositions of the present invention include liquids that, upon administration to a mammal, form a solid or a gel in situ. Furthermore, the term “time-release encapsulation means” or “time-release means” comprises 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, polycyanoacylates, and crosslinked or amphipathic block copolymers of hydrogels.
[0102] As used herein, “pharmaceutical composition” means therapeutically effective amounts of the agent together with pharmaceutically acceptable diluents, preservatives, solubilizers, emulsifiers, adjuvant and/or carriers. A “therapeutically effective amount” as used herein refers to that amount which provides a therapeutic effect for a given condition and administration regimen. Such compositions are liquids or lyophilized or otherwise dried formulations and include diluents of various buffer content (e.g., Tris-HCl., acetate, phosphate), pH and ionic strength, additives such as albumin or gelatin to prevent absorption to surfaces, detergents (e.g., Tween 20, Tween 80, Pluronic F68, bile acid salts). Solubilizing agents (e.g., glycerol, polyethylene glycerol), anti-oxidants (e.g., ascorbic acid, sodium metabisulfite), preservatives (e.g., thimerosal, benzyl alcohol, parabens), bulking substances or tonicity modifiers (e.g., lactose, mannitol), covalent attachment of polymers such as polyethylene glycol to the protein, complexation with metal ions, or incorporation of the material into or onto particulate preparations of polymeric compounds such as polylactic acid, polyglycolic acid, hydrogels, etc, or onto liposomes, microemulsions, micelles, unilamellar or multilamellar vesicles, erythrocyte ghosts, or spheroplasts. Such compositions will influence the physical state, solubility, stability, rate of in vivo release, and rate of in vivo clearance. Controlled or sustained release compositions include formulation in lipophilic depots (e.g., fatty acids, waxes, oils). Also comprehended by the invention are particulate compositions coated with polymers (e.g., poloxamers or poloxamines). Other embodiments of the compositions of the invention incorporate particulate forms protective coatings, protease inhibitors or permeation enhancers for various routes of administration, including parenteral, pulmonary, nasal and oral routes. In one embodiment the pharmaceutical composition is administered parenterally, paracancerally, transmucosally, transdermally, intramuscularly, intravenously, intradermally, subcutaneously, intraperitonealy, intraventricularly, intracranially and intratumorally.
[0103] Further, as used herein “pharmaceutically acceptable carrier” or “pharmaceutical carrier” are known in the art and include, but are not limited to, 0.01-0.1 M and preferably 0.05 M phosphate buffer or 0.8% saline. Additionally, such pharmaceutically acceptable carriers may be aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Aqueous carriers include water, alcoholic/aqueous solutions, emulsions or suspensions, including saline and buffered media. Parenteral vehicles include sodium chloride solution, Ringer's dextrose, dextrose and sodium chloride, lactated Ringer's orfixed oils. Intravenous vehicles include fluid and nutrient replenishers, electrolyte replenishers such as those based on Ringer's dextrose, and the like. Preservatives and other additives may also be present, such as, for example, antimicrobials, antioxidants, collating agents, inert gases and the like.
[0104] Mutants, Variants and Analogs Proteins
[0105] Mutant polypeptides will possess one or more mutations, which are deletions (e.g., truncations), insertions (e.g., additions), or substitutions of amino acid residues. Mutants can be either naturally occurring (that is to say, purified or isolated from a natural source) or synthetic (for example, by performing site-directed mutagenesis on the encoding DNA or made by other synthetic methods such as chemical synthesis). It is thus apparent that the polypeptides of the invention can be either naturally occurring or recombinant (that is to say prepared from the recombinant DNA techniques).
[0106] A protein at least 50% identical, as determined by methods known to those skilled in the art (for example, the methods described by Smith, T. F. and Waterman M. S. (1981) Ad. Appl.Math., 2:482-489, or Needleman, S. B. and Wunsch, C. D. (1970) J.Mol.Biol., 48: 443-453), to those polypeptides of the present invention are included in the invention, as are proteins at least 70% or 80% and more preferably at least 90% identical to the protein of the present invention. This will generally be over a region of at least 5, preferably at least 20 contiguous amino acids.
[0107] “Variant” as the term used herein, is a polynucleotide or polypeptide that differs from reference polynucleotide or polypeptide respectively, but retains essential properties. A typical variant of a polynucleotide differs in nucleotide sequence from another, reference polynucleotide. Changes in the nucleotide sequence of the variant may or may not alter the amino acid sequence of a polypeptide encoded by the reference polynucleotide. Nucleotide changes may result in amino acid substitutions, additions, deletions, fusion and truncations in the polypeptide encoded by the reference sequence, as discussed herein. A typical variant of a polypeptide differs in amino acid sequence from another, reference polypeptide. Generally, differences are limited so that the sequence of the reference polypeptide and the variant are closely similar overall and, in many regions, identical. A variant and reference polypeptide may differ in amino acid by one or more substitutions, additions, deletions, or any combination therefore. A substituted or inserted amino acid residue may or may not be one encoded by the genetic code. A variant polynuclotide or polypeptide may be a naturally occurring such as an allelic variant, or it may be a variant that is not known to occur naturally. Non-naturally occurring variants of polynucleotides and polypeptides may be made by mutagenesis techniques or by direct synthesis.
[0108] Amino acid sequence variants may be prepared by introducing appropriate nucleotide changes into DNA, or by in vitro synthesis of the desired polypeptide. Such variant include, for example, deletions, insertions, or substitutions of residues within the amino acid sequence. A combination of deletion, insertion and substitution can be made to arrive at the final construct, provided that the final protein product possesses the desired characteristics. The amino acid changes also may alter posttranslational processes such as changing the number or position of the glycocylation sites, altering the membrane anchoring characteristics, altering the intra-cellular location by inserting, deleting or otherwise affecting the transmembrane sequence of the native protein, or modifying its susceptibility to proteolytic cleavage.
[0109] It is to be understood herein, that if a “range” or “group” of substances (e.g. amino acids), substitutents” or the like is mentioned or if other types of a particular characteristic (e.g. temperature, pressure, chemical structure, time, etc.) is mentioned, the present invention relates to and explicitly incorporates herein each and every specific member and combination of sub-ranges or sub-groups therein whatsoever. Thus, any specified range or group is to be understood as a shorthand way of referring to each and every member of a range or group individually as well as each and every possible sub-ranges or sub-groups encompassed therein; and similarly with respect to any sub-ranges or sub-groups therein. Thus, for example,
[0110] with respect to a pressure greater than atmospheric, this is to be understood as specifically incorporating herein each and every individual pressure state, as well as sub-range, above atmospheric, such as for example 2 psig, 5 psig, 20 psig, 35.5 psig, 5 to 8 psig, 5 to 35, psig 10 to 25 psig, 20 to 40 psig, 35 to 50 psig, 2 to 100 psig, etc..;
[0111] with respect to a temperature greater than 100° C., this is to be understood as specifically incorporating herein each and every individual temperature state, as well as sub-range, above 100° C., such as for example 101° C., 105° C. and up, 110° C. and up, 115° C. and up, 110 to 135° C., 115° c. to 135° C., 102° C. to 150° C., up to 210° C., etc.;
[0112] with respect to a temperature lower than 100° C., this is to be understood as specifically incorporating herein each and every individual temperature state, as well as sub-range, below 100° C., such as for example 15° C. and up, 15° C. to 40° c., 65° C. to 95° C., 95° C. and lower, etc.;
[0113] with respect to residence or reaction time, a time of 1 minute or more is to be understood as specifically incorporating herein each and every individual time, as well as sub-range, above 1 minute, such as for example 1 minute, 3 to 15 minutes, 1 minute to 20 hours, 1 to 3 hours, 16 hours, 3 hours to 20 hours etc.;
[0114] with respect to polypeptides, a polypeptide analog consisting of at least two contiguous amino acids of a particular sequence is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog consisting of amino acid 1 and 2, a polypeptide analog consisting of amino acids 2 and 3, a polypeptide analog consisting of amino acids 3 and 4, a polypeptide analog consisting of amino acids 6 and 7, a polypeptide analog consisting of amino acids 9 and 10, a polypeptide analog consisting of amino acids 36 and 37, a polypeptide analog consisting of amino acids 93 and 94, etc.
[0115] with respect to polypeptides, a polypeptide analog consisting of at least five contiguous amino acids of a particular sequence is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog consisting of amino acids 1 to 5, a polypeptide analog consisting of amino acids 2 to 6, a polypeptide analog consisting of amino acids 3 to 7, a polypeptide analog consisting of amino acids 6 to 10, a polypeptide analog consisting of amino acids 9 to 13, a polypeptide analog consisting of amino acids 36 to 40, a polypeptide analog consisting of amino acids 90 to 94, etc.
[0116] with respect to polypeptides, a polypeptide analog comprising a particular sequence and having an addition of at least one amino acid to its amino-terminus is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog having an addition of one amino acid to its amino-terminus, a polypeptide analog having an addition of two amino acid to its amino-terminus, a polypeptide analog having an addition of three amino acid to its amino-terminus, a polypeptide analog having an addition of ten amino acid to its amino-terminus, a polypeptide analog having an addition of eighteen amino acid to its amino-terminus, a polypeptide analog having an addition of forty amino acid to its amino-terminus, a polypeptide analog having an addition of two hundred amino acid to its amino-terminus, etc.
[0117] with respect to polypeptides, a polypeptide analog comprising a particular sequence and having an addition of at least one amino acid to its carboxy-terminus is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog having an addition of one amino acid to its carboxy-terminus, a polypeptide analog having an addition of two amino acid to its carboxy-terminus, a polypeptide analog having an addition of five amino acid to its carboxy-terminus, a polypeptide analog having an addition of twenty amino acid to its carboxy-terminus, a polypeptide analog having an addition of fifty-three amino acid to its carboxy-terminus, a polypeptide analog having an addition of three hundred amino acid to its carboxy-terminus, etc.
[0118] with respect to polypeptides, a polypeptide analog comprising two to fifty units of a particular sequence is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog comprising two units of that particular sequence, a polypeptide analog comprising three units of that particular sequence, a polypeptide analog comprising six units of that particular sequence, a polypeptide analog comprising thirteen units of that particular sequence, a polypeptide analog comprising thirty-five units of that particular sequence, a polypeptide analog comprising fifty units of that particular sequence, etc.
[0119] with respect to polypeptides, a polypeptide analog comprising two to ten units of a particular sequence is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog comprising two units of that particular sequence, a polypeptide analog comprising three units of that particular sequence, a polypeptide analog comprising four units of that particular sequence, a polypeptide analog comprising five units of that particular sequence, a polypeptide analog comprising six units of that particular sequence, a polypeptide analog comprising seven units of that particular sequence, a polypeptide analog comprising eight units of that particular sequence, a polypeptide analog comprising nine units of that particular sequence, and a polypeptide analog comprising ten units of that particular sequence.
[0120] with respect to polypeptides, a polypeptide analog consisting of a sequence of from two to fourteen amino acid units wherein the amino acid units are selected from the group of amino acid units of SEQ ID NO: 5 consisting of glutamic acid (Glu), tryptophan (Trp), glutamine (Gln), threonine (Thr), aspartic acid (Asp), asparagine (Asn), cysteine (Cys), or tyrosine (Tyr), is to be understood as specifically incorporating each and every individual possibility, such as for example, a polypeptide analog of two amino acid units wherein the amino acids are sequentially; Glu and Trp, a polypeptide analog of two amino acid units wherein the amino acids are sequentially; Trp and Glu, a polypeptide analog of three amino acid units wherein the amino acids are sequentially; Trp, Glu, Trp, a polypeptide analog of three amino acid units wherein the amino acids are sequentially; Trp, Trp, Trp, a polypeptide analog of three amino acid units wherein the amino acids are sequentially; Glu, Glu, Trp, a polypeptide analog of three amino acid units wherein the amino acids are, independently of the order; Tyr, Asp, Glu, a polypeptide analog of three amino acid units wherein the amino acids are, independently of the order; Thr, Asp, Asn, a polypeptide analog of three amino acid units wherein the amino acids are, independently of the order; Thr, Thr, Asn, a polypeptide analog of four amino acid units wherein the amino acids are, independently of the order; Glu, Gln, Cys, Asn, a polypeptide analog of four amino acid units wherein the amino acids are, independently of the order; Gln, Gln Cys, Trp, a polypeptide analog of four amino acid units wherein the amino acids are, Cys, Cys, Cys, Cys, a polypeptide analog of fourteen amino acid units wherein the amino acids are, independently of the order; Asn, Asp, Glu, Gln, Trp, Cys, Tyr, Thr, Thr, Asp, Asn, Gln, Thr, Cys, a polypeptide analog of fourteen amino acid units wherein the amino acids are, independently of the order; Asp, Asp, Asp, Asp, Trp, Cys, Cys, Trp, Thr, Thr, Thr, Thr, Thr, Cys, a polypeptide analog of fourteen amino acid units wherein the amino acids are, independently of the order; Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, Tyr, etc.
[0121] with respect to polypeptides, a polypeptide analog having at least 90% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analog having 90% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 91% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 93% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 97% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 99% of its amino acid sequence identical to that particular amino acid sequence, etc.
[0122] with respect to polypeptides, a polypeptide analog having at least 70% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analog having 70% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 71% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 73% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 88% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 97% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 99% of its amino acid sequence identical to that particular amino acid sequence, etc.
[0123] with respect to polypeptides, a polypeptide analog having at least 50% of its amino acid sequence identical to a particular amino acid sequence is to be understood as specifically incorporating each and every individual possibility (excluding 100%), such as for example, a polypeptide analog having 50% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 51% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 54% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 66% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 70% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 79% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 82% of its amino acid sequence identical to that particular amino acid sequence, a polypeptide analog having 99% of its amino acid sequence identical to that particular amino acid sequence, etc.
[0124] and similarly with respect to other parameters such as low pressures, concentrations, elements, etc . . .
[0125] It is also to be understood herein that “g” or “gm” is a reference to the gram weight unit; that “C” is a reference to the Celsius temperature unit; and “psig” is a reference to “pounds per square inch gauge”.
BRIEF DESCRIPTION OF THE DRAWINGS
[0126] [0126]FIG. 1 depicts mass spectrometry analysis of polypeptide 7-21 (SEQ ID NO: 4).
[0127] [0127]FIG. 2 depicts mass spectrometry analysis of polypeptide PCK3145 (SEQ ID NO: 5).
[0128] [0128]FIG. 3 depicts mass spectrometry analysis of polypeptide 76-94 (SEQ ID NO: 6).
[0129] [0129]FIG. 4 a is a graph depicting the in-vitro inhibitory activity of the decapeptide of SEQ ID NO: 3 on PC-3 cells after 9 days of culture.
[0130] [0130]FIG. 4 b is a graph depicting the in-vitro inhibitory activity of the native PSP94 (nPSP94) on PC-3 cells after 9 days of culture.
[0131] [0131]FIG. 5 a is a graph depicting the in-vitro inhibitory activity of the decapeptide of SEQ ID NO: 3 on PC-3 cells after 21 days of culture.
[0132] [0132]FIG. 5 b is a graph depicting the in-vitro inhibitory activity of the native PSP94 (nPSP94) on PC-3 cells after 21 days of culture.
[0133] [0133]FIG. 6 a is a graph depicting the in-vitro inhibitory activity of the decapeptide of SEQ ID NO: 3 on PC-3 cells after 10 days of culture.
[0134] [0134]FIG. 6 b is a graph depicting the in-vitro inhibitory activity of the native PSP94 (nPSP94) on PC-3 cells after 10 days of culture.
[0135] [0135]FIG. 7 depicts a gel showing DNA fragmentation following treatment of PC-3 cells with polypeptide PCK3145 as set forth in SEQ ID NO: 5.
[0136] [0136]FIG. 8 is a graph depicting the results of an apoptosis assay with an ELISA plus kit following polypeptide treatment of PC-3 cells for 72 hours with various concentration of polypeptide 7-21 (SEQ ID NO: 4), polypeptide PCK3145 (SEQ ID NO: 5), polypeptide 76-94 (SEQ ID NO: 6) or native PSP94 (SEQ ID NO: 1).
[0137] [0137]FIG. 9 is a graph depicting in vitro fibroblast cell growth when exposed for 72 hours to various concentration of native PSP94 (nPSP94) (SEQ ID NO: 1) or various concentration of rHuPSP94 (SEQ ID NO: 2) or polypeptide 7-21 (SEQ ID NO: 4), polypeptide PCK3145 (SEQ ID NO: 5), or polypeptide 76-94 (SEQ ID NO: 6).
[0138] [0138]FIG. 10 is a graph depicting the effect of polypeptide 7-21 (SEQ ID NO: 4), polypeptide PCK3145 (SEQ ID NO: 5), polypeptide 76-94 (SEQ ID NO: 6), and polypeptide 61-75 on the in vitro growth of PC-3 cells after 72 hours.
[0139] [0139]FIG. 11 is a graph depicting the effect of polypeptide 22-36 and polypeptide PCK3145 (SEQ ID NO: 5) on in vitro growth of PC-3 cells after 72 hours.
[0140] [0140]FIG. 12 is a graph depicting results of study no. MLL-1 on the anti-tumor efficacy validation of rHuPSP94 (rPSP94) (SEQ ID NO: 2) against Mat Ly Lu (MLL) tumor implanted in nude mice.
[0141] [0141]FIG. 13 is a graph depicting results of study no. MLL-2 on the anti-tumor efficacy validation of rHuPSP94 (rPSP94) (SEQ ID NO: 2) against Mat Ly Lu (MLL) tumor implanted in nude mice.
[0142] [0142]FIG. 14 is a graph depicting tumor volume (tumor growth reduction) in rHuPSP94-treated nude mice.
[0143] [0143]FIG. 15 is a graph depicting tumor volume (tumor growth reduction) in decapeptide (SEQ ID NO: 3)-treated nude mice.
[0144] [0144]FIG. 16 is a graph depicting tumor volume (tumor growth reduction) in control scrambled polypeptide (PB111)-treated mice.
[0145] [0145]FIG. 17 is a graph depicting tumor volume (tumor growth reduction) in native-PSP94 (nPSP94)-treated mice.
[0146] [0146]FIG. 18 is a graph depicting the in vitro inhibitory activity of PCK3145 (SEQ ID NO: 5) on PC-3 cells, after a 72 hours treatment, as measured by MTS (3-(4,5-dimethylthiazol-2-yl)-5-(3-carboxymethoxyphenyl)-2-(4-sulfophenyl)-2H-tetrazolium,inner salt) assay.
[0147] [0147]FIG. 19 is a graph depicting the in vitro inhibitory activity of native PSP94 (SEQ ID NO: 1) and PCK3145 (SEQ ID NO: 5) (GMP grade) on PC-3 cells, after 48 hours of treatment, as measured by MTS assay.
[0148] [0148]FIG. 20 is a graph depicting the in vitro inhibitory activity of PCK3145 (SEQ ID NO: 5) (GMP grade) on PC-3 cells (ATCC), after 72 hours of treatment, as measured by the MTS assay.
[0149] [0149]FIG. 21 is a graph depicting the in vitro inhibitory activity of PCK3145 (SEQ ID NO: 5)(GMP grade) on PC-3 cells (ATCC), after a 48 or 72 hours treatment, as measured by the MTS assay.
[0150] [0150]FIG. 22 is a graph depicting the in vitro inhibitory activity of decapeptide as set forth in SEQ ID NO: 3, polypeptide 7-21 as set forth in SEQ ID NO: 4, polypeptide PCK3145 as set forth in SEQ ID NO: 5, or polypeptide 76-94 as set forth in SEQ ID NO: 6 on PC-3 cells, measured by [ 3 H]-Thymidine uptake assay.
[0151] [0151]FIG. 23 is a graph depicting the in vitro inhibitory activity of decapeptide as set forth in SEQ ID NO: 3, polypeptide 7-21 as set forth in SEQ ID NO: 4, polypeptide PCK3145 as set forth in SEQ ID NO: 5, or polypeptide 76-94 as set forth in SEQ ID NO: 6 on PC-3 cells, measured by [ 3 H]-Thymidine uptake assay.
[0152] [0152]FIG. 24 is a graph depicting the in vitro inhibitory activity of native PSP94 (SEQ ID NO: 1) on PC-3 cells after 72 hours treatment, measured by [ 3 H]-Thymidine uptake assay.
[0153] [0153]FIG. 25 depicts a gel showing DNA fragmentation following treatment of PC-3 cells with PCK3145 (SEQ ID NO: 5) or doxorubicin.
[0154] [0154]FIG. 26 is a graph depicting the in vivo inhibitory activity of PCK3145 (SEQ ID NO: 5) (0.1 μg/kg/day and 10 μg/kg/day) against human PC-3 tumor xenografted in nude mice.
[0155] [0155]FIG. 27 is a graph depicting the in vivo inhibitory activity of PCK3145 (SEQ ID NO: 5) (10 μg/kg/day to 1000 μg/kg/day, administered either via the intra-venous or intra-peritoneal route) against human PC-3 tumor xenografted in nude mice.
[0156] [0156]FIG. 28 is a graph depicting the in vivo inhibitory activity of polypeptide 7-21 (SEQ ID NO: 4), PCK3145 (SEQ ID NO: 5) or polypeptide 76-94 (SEQ ID NO: 6), given at doses of 1 μg/kg/day or 10 μg/kg/day, in Copenhagen rats implanted with Dunning Mat Ly Lu tumors.
[0157] [0157]FIG. 29 is a graph depicting the in vivo inhibitory activity of PCK3145 (SEQ ID NO: 5) or the scrambled polypeptide given at doses of 10 μg/kg/day or 100 μg/kg/day, in Copenhagen rats implanted with Dunning Mat Ly Lu tumors.
[0158] [0158]FIG. 30 is a graph depicting tumor weight at day 18 following PCK3145 (SEQ ID NO: 5) or scrambled polypeptide treatment (10 μg/kg/day or 100 μg/kg/day), in Copenhagen rats implanted with Dunning Mat Ly Lu tumors.
[0159] [0159]FIG. 31 is a graph depicting the efficacy of PCK3145 and taxotere (i.e. docetaxel) combination treatment in Nude mice implanted with PC-3 tumor cells in tumor growth retardation.
DETAILED DESCRIPTION OF THE INVENTION
[0160] The recombinant human rHuPSP94 expressed in yeast is non-glycosylated and has 10 cystein residues. The molecular weight of rHuPSP94 was determined to be 11.5 kDa, compared to 10.7 kDa for its native counterpart.
[0161] Various experimental studies have been carried out in order to determine the efficacy of rHuPSP94 (SEQ ID NO: 2) relative to the native PSP94 secreted by the diseased prostate as tumor suppressive agent. Studies have also been carried out to determine the efficacy of the decapeptide as set forth in SEQ ID NO: 3, the polypeptide as set forth in SEQ ID NO: 4 (polypeptide 7-21), the polypeptide as set forth in SEQ ID NO: 5 (PCK3145), and the polypeptide as set forth in SEQ ID NO: 6 (polypeptide 76-94), as tumor suppressive agents. The tumor suppression activity of the polypeptides of the present invention has been monitored by their ability to reduce or inhibit the growth of prostatic adenocarcinoma both in-vivo and in-vitro. Those results are summarized below.
[0162] Studies were carried out using PC-3 human prostate adenocarcinoma line, which can be maintained both in vivo as a xenograft in nude mice and in vitro as a cell line. In addition, a rat Dunning Mat LyLu prostate tumor, which is a pre-eminent animal model for the study of CaP, was also used. The Dunning tumor is a fast growing, poorly differentiated, transplantable tumor, which can be maintained both in-vivo in the Copenhagen rat and in-vitro as a cell line.
[0163] The following examples are offered by way of illustration and not by way of limitation.
EXAMPLE 1
Preparation of rHuPSP94 (SEQ ID NO: 2) and Polypeptides (SEQ ID NO: 3, SEQ ID NO: 4, SEQ ID NO: 5 and SEQ ID NO: 6)
[0164] Recombinant HuPSP94 was cloned and expressed in Pichia pastoris, and then purified and characterized as follows.
[0165] Materials
[0166] DEAE-cellulose (DE52) was purchased from Whatman (Fairfield, N.J.). Dialysis membranes and the electro chemiluminescence (ECL) detection kit were purchased from Biolynx Canada(Pierce Inc.). Broad-range molecular weight markers and Econo-pack columns fitted with flow adapters were purchased from Bio-Rad Labs Ltd (California). Pellicon device was purchased from Millipore (Massachusetts). Tris-HCl was obtained from ICN. MES ((2-[N-Morpholino]ethanesulfonic acid) hydrate)was obtained from Sigma. Swine anti-rabbit IgG alkaline-phosphatase conjugates was purchased from DAKO (Denmark). Pichia Pastoris expression Kit version G was from Invitrogen(Carlsbad, Calif.). Non-Radioactive High Prime DIG labeling kit® was purchased from Boehringer Mannheim (Indianapolis, Ind.). The MTS (3-(4,5-dimethylthiazol-2-yl)-5-(3-carboxymethoxyphenyl)-2-(4-sulfophenyl)-2H-tetrazolium, inner salt) assays were performed using Cell Titer Aqueous Non radioactive cell proliferation assay kit from Promega (Madison, Wis.). MRX microtiter plate reader was from Dynex technologies (Chantillly, Va.). Rabbit polyclonal antiserum against PSP94 was a gift from the late Dr. A. Sheth. All primers were synthesized by Procyon Biopharma Inc. London, Ontario, Canada.
[0167] Cell Line and Cell Culture
[0168] [0168] P. pastoris host strain GS115 (his4) and all Pichia related products were obtained from Invitrogen. PC-3 (ATCC-# CRL 1435) cell line was obtained from the American Type Cell Culture (ATCC) and maintained in OPTI MEM (minimum essential media) with 10% fetal bovine serum (FBS). All cell culture products were obtained from GIBCO BRL.
[0169] Cloning
[0170] TA cloning vector (pCR TM 2.1) containing human PSP94 cDNA including a 20 amino acid leader sequence described previously (Baijal-Gupta, M., et. al., J. Endocrinol., 165:425-433, 2000) was used to amplify human PSP94 without its leader sequence using appropriate primers. The primers for the polymerase chain reaction (PCR) were designed to contain an EcoRI restriction sites at either end. The 5′ primer used was 5′ -GGG AAG AAT TC T C AT GCT ATT TCA TA-3′ (SEQ ID NO: 7) and the 3′ primer, 5′-TGG ATA TCT GCA GAA TTC GGC-3′ (SEQ ID NO: 8). The +1 start site for PSP94 (at a Serine residue) has been underlined in the 5′ primer described above.
[0171] The PCR included 1 cycle of 12 minutes at 94 ° C., followed by 25 cycles of 1 minute at 94° C., 1 minute at 55° C., 1 minute at 72° C. and a final step of 1 cycle of 10 minutes at 72° C. PCR amplification of the product was performed using BM ExpandTM High Fidelity PCR System. The product was run on a 1.5% agarose gel and the appropriate PCR product was isolated using Pharmacia Sehphaglass Kit (Bandprep). Subcloning of the PSP94 insert was performed in pPIC9 vector (Invitrogen). The EcoRI enzyme was used for the restriction digestion of both the plasmid and the PCR products (thus removing PSP94 signal sequence) followed by ligation and transformation, using DH5α cells. The isolated clones were selected for by ampicillin resistance and inserts were identified by restriction mappings. The constructs were sequenced (Robart's sequencing service, London, Ontario) to identify PSP94 insert with a correct sequence as well as proper orientation and reading frame.
[0172] Screening for Clones Expressing rHuPSP94
[0173] For Pichia pastoris transformation, the spheroplast method was used according to manufacturer's instructions (Invitrogen) using GS115 and KM71 yeast strains. Plasmid pPIC9 with or without the PSP94 insert were linearized using SalI restriction enzyme. Transformed colonies were screened and selected for their ability to produce their own histidine, hence survived on media without histidine. All GS115 transformants scored as Mut + , whereas all KM71 colonies, which did not grow well in the liquid culture, scored as Mut s . Hence a number of GS115 clones were screened for production of the highest levels of rHuPSP94 expression.
[0174] About a hundred clones were selected and grown into 2 ml of culture media until an optical density at 600 nm (OD600) of approximately 6 was reached. Total DNA was isolated for rapid dot blot analysis in order to detect multiple integrations by Southern blot that would possibly correspond to high rHuPSP94 expressing clones. Two hundred microliters of each culture specimens were denatured and blotted (in duplicate) to a positively charged nylon membrane, placed in a dot blot apparatus. The membrane was subsequently air-dried. The membrane was soaked between two sheets of Whatman 3MM paper for 15 minutes in a solution containing 50 mM ethylenediaminetetraacetic acid(EDTA), 2.5% beta-mercaptoethanol (BME), pH 9, followed by an incubation of 24 hours at 37 ° C. with 1 mg/ml Zymolyase 100T, 5 minutes in 0.1 N NaOH, 1.5 M NaCl, 0.015 M sodium citrate pH 7 and two 5 minutes incubation in 2×saline-sodium citrate (SSC). Finally the membrane was baked at 80° C. for 45 minutes and exposed to ultraviolet light (UV) for 15 minutes. Human PSP94 cDNA probe was labeled with the non-radioactive High Prime DIG labeling kit® (Boehringer Mannheim) and was used for hybridization. Hybridization with digoxigenin labeled cDNA probe (25 ng/μl) was done for 2 days at 42° C. in Sodium dodecyl sulfate(SDS) buffer (SDS 7% (w/v); formamide 50% (v/v); 5×SSC; 50 mM sodium phosphate, pH 7.0; N-lauroyl-sarcosine 0.1% (w/v)) and blocking reagent, CSPD® 2% (w/v) (Boehringer Mannheim) was used as the chemiluminescence substrate. All digoxigenin (DIG) labeling procedures were performed according to the manufacturer's instruction. Detection was performed using the Hyper film-ECL product (Amersham Life Science Inc. Arlington Hts, Ill.).
[0175] The clone with the highest signal intensity was used for all flasks shaken cultures.
[0176] Optimization of the Expression of the Protein in Flask Shaken Cultures
[0177] A clone containing the PSP94 construct was selected for high expression of the protein. Colony was grown in 25 ml of basal minimum growth media (BMG) until an OD600 between 2 and 6 was obtained. This clone was further amplified in Baffled Erlenmeyer flasks in a volume of 1 liter of BMG media until the OD600 reached approximately between 2.0 to 6.0. The culture was centrifuged for 15 minutes at 2500×g and the pellet was collected. The induction phase (i.e., induction of expression of rHuPSP94) was carried out by inoculating the cell pellet in basal minimum media (BMM). Growth was performed in Baffled flasks for 6 days, as recommended by Invitrogen. The volume of BMM added varied according to the size of the pellet collected. Five milliliters of 100% methanol were added for each liter of culture. This was performed each day, around the same time, to a final concentration of 0.1% of methanol. A plasmid without the PSP94 insert served as a negative control.
[0178] To determine the optimum time for harvesting rHuPSP94 secreted in the cell culture media, aliquots were taken every 24 hours for 6 days, starting from the first day of induction. Levels of rHuPSP94 protein expression were determined by measuring OD600 and by performing a 15% SDS-PAGE (sodium dodecyl sulfate polyacrylamide gel electrophoresis) stained with Coomassie Brilliant blue or by Western blot analysis using polyclonal antibody against PSP94.
[0179] Sample Preparation
[0180] Culture supernatant of clone showing the highest rHuPSP94 expression, post-induction (e.g., after 96 hours), was centrifuged at 2500×g for 20 minutes. The supernatant was filtered through a 0.8 μm filter and concentrated approximately 10-fold using a Pellicon unit (Millipore). The filtered supernatant was dialyzed against 0.05 mM Tris-HCl buffer, pH 8.0, using a 3500 molecular weight cut-off membrane. An aliquot of the dialyzed supernatant was analyzed by SDS-PAGE and Western blot analysis and the rest was submitted to further purification.
[0181] Culture Conditions for Fermentation
[0182] Fermentation was carried out at the Institute for Biological Sciences, National Research Council (NRC) (Ottawa, Ontario Canada), following manufacturer's instruction (Invitrogen). For example, a fermentation procedure was initiated by inoculating 7.5 liter of media with 625 ml of a starting culture. The growth phase was carried out for approximately 2 days in BMG media until the OD600 reached approximately 0.5. The induction phase was initiated by the addition of methanol (100%), according to the manufacturer's instructions (Invitrogen). The culture was harvested after 95 hours (i.e., after induction with methanol for 67 hours). The final volume of the culture was approximately 13.5 liters.
[0183] Sample Preparation from Fermentation Culture
[0184] The large cell mass was removed by centrifugation. The cell free media collected (9 liters) was further clarified using a 0.2 μm filtration unit (Pellicon). The remaining 8.5 liters containing secreted rHuPSP94 was tested for protein expression and stored at −20° C. for further isolation and purification of the protein.
[0185] Protein Estimation
[0186] The amount of rHuPSP94 protein secreted in the culture supernatant from the flask shaken and the fermentation process was obtained based on estimates of band intensities of samples compared to band intensities of a standard curve obtained by loading known quantities of pure lyophilized PSP94 on a SDS-PAGE. The initial estimate for rHuPSP94 at each step of purification was determined by OD at 280 nm. Quantification of total protein content at the final steps of purification was done by the BCA (bicinchoninic acid) method, using bovine serum albumin (BSA) as standard.
[0187] Lyophilization
[0188] Samples of purified rHuPSP94 were dialyzed against deionized water using a 3000 molecular weight cut-off membrane and were lyophilized.
[0189] SDS-PAGE
[0190] SDS-PAGE was performed using acrylamide at a final concentration of 15% for the separating portion of the gel and acrylamide at a final concentration of 5% for the stacking portion of the gel. The gel contained 0.1% SDS and was performed under reducing conditions. Broad-range molecular weight markers were used for the estimation of molecular weight of the protein. Proteins were stained with Coomassie Brilliant Blue R-250.
[0191] Western Blotting
[0192] For immunoblotting, Mini Trans-Blot Electrophoretic Transfer Cell (Bio Rad) was used with Hi bond-C super membrane (Amersham) and 85 mm blotting papers. Protein samples (0.4 μg) were loaded and separated on SDS-PAGE, as described earlier. Proteins were transferred to the membrane for 2 hours at 4° C., using transfer buffer (25 mM Tris, 192 mM Glycine, pH 8.3 and 20% methanol) and a transfer unit set at 200 milliamperes (mAmp). Membranes were blocked overnight by incubation in 2% (w/v) non-fat dry milk (skim milk) disolved in tris buffer saline (TBS: 500 mM NaCl, 20 mM Tris-HCl, pH 7.5) at room temp (RT). Membranes were washed three times with TBS containing 0.02% (v/v) Tween-20 (this buffer is named TTBS). Membranes were subsequently incubated for 2 hours at RT with anti-PSP94 antibody (1:2000 dilution) diluted in TTBS containing 2% skim milk. Membranes were washed twice with TTBS (5 minutes each washing), and incubated at RT with a secondary antibody (i.e., swine anti-rabbit antibody HRP conjugated) (1:5000 dilution) diluted in TTBS. Membranes were washed twice with 0.02% TTBS (5 minutes each washing). Blots were developed using the ECL detection system, according to manufacturer's instructions, using the Super Signal Substrate, and exposed to a Hyperfilm ECL from Amersham LS for 5 to 20 seconds. Pre-stained molecular weight markers were used for molecular weight estimation.
[0193] Purification of rHuPSP94 using DE52 Column Chromatography
[0194] Following removal of P. pastoris cells from the fermentation culture, supernatant was concentrated approximately ten fold, dialyzed and subjected to anion exchange chromatography. A DE52 column having a bed volume of approximately 40 ml (2.5 cm internal diameter (id)×8 cm height(h)) was equilibrated with 0.05 M Tris-HCl, pH 8.0 (equilibrating buffer). The sample (25 ml) containing 15 to 20 mg of rHuPSP94 protein was applied to the DE52 column at a flow rate of 1 ml/minute.
[0195] Impurities were removed from the column by washing it with 40 to 50 ml of the equilibrating buffer, and monitoring the absorbance at 280 nm. This step was followed by the addition of 100 to 150 ml of 0.05 M Tris-HCl, pH 6.5 to the column until the pH of the wash reached approximately 6.5. The column was further washed with 100 to 150 ml of 0.05 M MES-acetate buffer, pH 6.5, until the absorbance at 280 nm approached zero. Finally rHuPSP94 was eluted from the column with 0.05 M MES-acetate buffer, pH 5.0. Peak fractions were characterized by absorbance at 280 nm, followed by SDS-PAGE and Western blot analysis as described above. Fractions with high absorbance at 280 nm values (0.5 to 1.8) were pooled and dialyzed against water or PBS for storage at −20° C. and/or lyophilization.
[0196] Amino acid Composition
[0197] Amino acid analysis of the DE52 purified flask shaken culture and fermentation cultures was carried out. The Perkin Elmer Biosystems Derivatizer-Analysis system was used with Spheri-5 PTC C-18 5μ column and UV detection at OD254.
[0198] Mass Spectral Analysis
[0199] PSP94 derived polypeptides were synthesized, were found to be in accordance with the required specifications and were analyzed by Mass Spectral Analysis. Mass spectrometry analysis of polypeptide 7-21 (SEQ ID NO: 4), PCK3145 (SEQ ID NO: 5) and polypeptide 76-94 (SEQ ID NO: 6) are represented in FIGS. 1, 2 and 3 respectively.
[0200] Polypeptide samples were analyzed using the PerSeptive Biosystems (Framingham, Mass.), with Voyager-DE MALDI-TOF mass spectrometer using 337 nm light from a nitrogen laser. About 12 to 50 scans were averaged for each analysis.
[0201] Purified samples from the flask shaken culture and fermentation culture were analyzed using the PerSeptive Biosystems (Framingham, Mass.), with Voyager-DE MALDI-TOF mass spectrometer using 337 nm light from a nitrogen laser. About 50 scans were averaged for each analysis. A sample from the native PSP94 was also analyzed under similar conditions for comparison.
EXAMPLE 2
In-vitro Effect of rHuPSP94 on PC-3 Cells (MTS Assay)
[0202] The biological activity of the rHuPSP94 was determined by its growth inhibitory effect on human prostate cancer cells PC-3. Cell proliferation was monitored on PC-3 cells using the MTS/PMS (phenazine methosulfate) kit (Promega), which primarily measures mitochondrial activity of live cells. The basic principle of this method involves the fact that the mitochondrial enzymes of the live cells metabolize the MTS/PMS dyes forming a brown colored precipitate which can be measured as optical density (OD) by absorption at 490 nm in a spectrophotometer. Therefore, the OD values are proportional to the number of living cells. In addition, monitoring of cell morphology was also performed. Cell morphology would be indicative of their health status. For example, viable cells would appear adherent and spread out whereas dead cells would be in suspension in the media and would appear granular and round.
[0203] Results of in vitro effect of rHuPSP94 on PC-3 cells measured by MTS assay are summarized in table 2, below. PC-3 cells (ATCC, Lot AT06) used in these experiments were at a passage number lower or equal to 70 (n≧70). Cells were seeded in Costar 96 well cell culture flat bottom plates in RPMI supplemented media containing 50 μg/ml of bovine serum albumin (BSA) and 0.1 μM FeSO 4 . Peptide was diluted in the same media. Cells were continuously exposed to the polypeptides of the present invention for 72 hours without changing media. Native PSP94 or rHuPSP94 concentrated two fold were directly added to wells and diluted to 1× in order to minimize cell manipulation and avoid detachment.
[0204] The evaluation of growth inhibitory effect of rHuPSP94 on PC-3 cells indicated a substantial reduction in cell numbers (i.e., viability) ranging from 37% to 57% reduction at concentrations of 80 and 120 μg/ml of rHuPSP94 respectively. This effect was observed in 3 out of 4 experiments (Table 2). Results of trypan blue exclusion test demonstrated a cell viability of 62% at 80 μg/ml.
TABLE 2 Experiment % Viability (control = 100%) (μg/ml) no. Sample 40 60 80 120 1 rHuPSP94 72 78 58 43 2 rHuPSP94 63 63 63 68 3 rHuPSP94 95 85 78 ND 4 rHuPSP94 100 52 62 60 5 rHuPSP94 100 98 90 52 % Viability (control = 100%) (μg/ml) Sample 5 10 20 40 80 rHuPSP94 98 84 78 70 55 rHuPSP94 92 95 80 71 59 rHuPSP94 89 69 79 68 65
EXAMPLE 3
In-vitro Effect of rHuPSP94 on PC-3 Cells ([ 3 H]-Thymidine Uptake Assay)
[0205] The in vitro growth inhibition effect of rHuPSP94 was assessed using [ 3 H]-Thymidine uptake assay. [ 3 H]-Thymidine uptake assay involves [ 3 H]-Thymidine incorporation into cellular DNA of actively proliferating cells. It measures the proliferative index of the cells versus the MTS assay, which quantifies the number of lived cells following treatment. Cells were seeded in Costar 96 well cell culture flat bottom plates in RPMI supplemented media containing 50 μg/ml of bovine serum albumin (BSA) and 0.1 μM FeSO 4 . PC-3 cells were exposed to various concentrations of rHuPSP94 for 72 hours and during the final 16 hours of incubation cells were pulsed with 1 μCi of [ 3 H]-Thymidine. The radioactivity in each well of the plate is counted by a beta-counter and is expressed as total counts per minutes (cpm). Results of in vitro effect of rHuPSP94 on PC-3 cells using the 3 [H]-Thymidine uptake assay are summarized in Table 3 and are expressed as percentage of radioactivity measured for treated-cells relative to the radioactivity measured for non-treated cells (for which [ 3 H]-thymidine uptake value was set at 100%).
[0206] Results indicated a 65% reduction in the percentage of cells incorporating [ 3 H]-thymidine following treatment with rHuPSP94 at a concentration of 80 μg/ml for 72 hrs, compared to the non-treated control. Results of a 65% reduction in [ 3 H]-thymidine uptake may also be an indication of a 65% reduction in cell proliferation.
[0207] Comparison was performed between [ 3 H]-Thymidine uptake assay and the MTS assay, in order to evaluate their relative sensitivity. An additional plate was set aside for MTS assay and treated in parallel with the same lot (i.e., batch) of rHuPSP94 as the one used for the [ 3 H]-thymidine uptake assay. Result obtained for the MTS assay demonstrated a 35% reduction in cell viability (65% cells remaining viable) following treatment with rHuPSP94 at a concentration of 80 μg/ml, indicating that the [ 3 H]-Thymidine uptake assay, which was able to measure a 65% reduction in cell proliferation, may be more sensitive than the MTS assay.
TABLE 3 3 [H]-Thymidine Uptake (% of Experiment control) (μg/ml) no. Sample 5 10 20 40 80 1 rHuPSP94 94 101 98 79 35 1 native PSP94 97 98 100 98 77
EXAMPLE 4
In-vitro Effect of Decapeptide and other Polypeptide on PC-3 Cells
[0208] The synthetic decapeptide (SEQ ID NO: 3) has been shown herein to mimic the biological activity of native PSP94 (nPSP94)(SEQ ID NO: 1) and therefore its effect on the PC-3 cells was studied in clonogenicity assay (colony formation). Cells were seeded in Costar 96 well cell culture flat bottom plates in RPMI supplemented media containing 50 μg/ml of bovine serum albumin (BSA) and 0.1 μM FeSO 4 . Clonogenicity was evaluated for PC-3 cells grown in the presence of various concentration of the decapeptide after 9 days of culture (FIG. 4 a ). A parallel experiment was performed with various concentration of nPSP94 using the same experimental conditions (FIG. 4 b ). Other experiments evaluating clonogenicity was performed with the decapeptide (FIG. 5 a ) or nPSP94 (FIG. 5 b ) after 21 days of culture as well as after 10 days of culture (FIG. 6 a : Decapeptide and FIG. 6 b : nPSP94).
[0209] Referring to FIGS. 4 to 6 , the decapeptide (SEQ ID NO: 3) had a similar inhibitory action as nPSP94 (SEQ ID NO: 1) on in-vitro PC-3 cells studied. Results indicated a 40% decrease in colony number for cells incubated with the decapeptide (SEQ ID NO: 3) at a concentration of 1 μg/ml. A decrease in colony number of up to 60% was observed for the decapeptide (SEQ ID NO: 3) at a concentration of 10 μg/ml.
EXAMPLE 5
DNA Fragmentation Assay
[0210] Cell apoptosis result in DNA fragmentation can be evaluated by the presence of a DNA ladder visualized when DNA is run on a 1.2% agarose gel. DNA ladder assay (apoptosis assay) was performed following exposure of PC-3 to various concentrations of the polypeptides for 72 hours. The polypeptides that were used in this particular experiment are polypeptide 7-21 (SEQ ID NO: 4), polypeptide PCK3145 (SEQ ID NO: 5) and polypeptide 76-94 (SEQ ID NO: 6). Visualization of DNA isolated and run on 1.2% agarose gel, demonstrated that every polypeptides tested induced a DNA laddering effect characteristic of apoptosis. This effect was especially evident following treatment with PCK3145 (SEQ ID NO: 5), which is illustrated by FIG. 7. Lane 1 of the gel illustrated in FIG. 7 represents a lambda HindIII digest standard. Lane 2 of the gel illustrated in FIG. 7 represents DNA laddering effect obtained for doxorubicin-treated cells. Lane 3 of the gel illustrated in FIG. 7 represents DNA laddering effect obtained for cells incubated with 40 μg of nPSP94. Lane 4 of the gel illustrated in FIG. 7 represents DNA laddering effect obtained for cells incubated with 20 μg of nPSP94. Lane 5 of the gel illustrated in FIG. 7 represents DNA laddering effect obtained for cells incubated with 22.5 μM of PCK3145 (SEQ ID NO: 5). Lane 6 of the gel illustrated in FIG. 7 represents DNA laddering effect obtained for cells incubated with 45 μM of PCK3145 (SEQ ID NO: 5).
EXAMPLE 6
Apoptosis Assay by Elisa Plus
[0211] The three polypeptides (SEQ ID NO: 4, SEQ ID NO: 5 and SEQ ID NO 6) and native PSP94 used here as a positive control were tested in ELISA plus assay to measure cell death through apoptosis. Briefly, the ELISA plus assay is a sandwich enzyme immunoassay able to measure mono- and oligonucleosomes present in the cytoplasmic fraction of cell lysate using two antibodies, one directed against DNA and the other directed against histones. The apoptotic cell death is characterized by activation of endogenous endonucleases (e.g., calcium- and magnesium-dependant), which cleave double-stranded DNA at the most accessible internucleosomal linker region, generating mono- and oligonucleosomes. The enrichment of mono- and oligonucleosomes in the cytoplasm of the apoptotic cells is due to the fact that DNA degradation occurs several hours before plasma membrane breakdown.
[0212] Four thousand cells were seeded in Costar 96 well cell culture flat bottom plates in RPMI supplemented media containing 50 μg/ml of bovine serum albumin (BSA) and 0.1 μM FeSO 4 . The PC-3 cells were treated with various concentrations (22.5 μM to 90 μM) of polypeptides for 72 hours. Apoptosis assay was done as per manufacturer's instructions using the ApopTag kit (Boeringher Mannheim).
[0213] Results presented in FIG. 8, indicate a dose dependent increase in the apoptotic cell death effect was observed for every polypeptides used (SEQ ID NO: 4, SEQ ID NO: 5 and SEQ ID NO 6). Polypeptide PCK3145 (SEQ ID NO: 5) was more potent than the other polypeptides at 90 μM concentration (FIG. 8).
EXAMPLE 7
Inhibition of Cell-growth by PSP94 Polypeptides (FIGS. 9 to 11 )
[0214] Biological activity of the polypeptides as set forth in SEQ ID NO: 4, SEQ ID NO: 5 and SEQ ID NO 6 was determined by their growth inhibitory effect on human prostate cancer cells PC-3. Native PSP94, rHuPSP94, polypeptide 22-36 and PB111 polypeptide (scrambled polypeptide) were also included in this experiment as controls. Cell proliferation assay was performed on either PC-3 cells or normal fibroblasts (used here as control) using the MTS/PMS kit (Promega). Four thousand cells (FIG. 9 and 10 ) or three thousand (FIG. 11) cells were seeded in Costar 96 well cell culture flat bottom plates in RPMI supplemented media containing 50 μg/ml of bovine serum albumin (BSA) and 0.1 μM FeSO 4 . In addition, monitoring of cell morphology was also performed.
[0215] Results of these experiments are shown in FIGS. 9 to 11 . No cell inhibitory effect was observed following incubation of fibroblasts with various polypeptide concentrations (from 10 to 90 μM) for 72 hours (FIG. 9). However, a significant growth inhibition was observed for polypeptides as set forth in SEQ ID NO: 4 and SEQ ID NO: 6 and more importantly with polypeptide PCK3145 (SEQ ID NO: 5) (FIG. 10). Another experiment was performed using PCK3145 and polypeptide 22-36 at various concentrations on PC-3 cells, grown in OPTI-MEM media. In FIGS. 9 to 11 , the percentage of growth inhibition given for treated cells is evaluated relative to non-treated control cells for which a value of 100% cell survival is given.
EXAMPLES 8 & 9
In-vitro Experiments (FIGS. 12 & 13 )
[0216] Studies MLL-1 and MLL-2 were performed as follows; on day 0, male Copenhagen rats were injected subcutaneously with 5×10 5 Mat LyLu cells per rat. These cells were derived from cultures of Mat LyLu cell line grown in RPMI media containing 10% (v/v) of fetal calf serum in logarithmic phase of growth. Cells were harvested from the culture flasks by trypsinization, were centrifuged at 1200 rotation per minute (rpm) and washed three timed with Hanks balanced salt solution (HBSS). Following washing, cells were counted and adjusted to a concentration of 5×10 6 cells/ml in HBSS. A 0.1 ml volume of tumor cell inoculum containing 5×10 5 cells was administered subcutaneously into the flank region of each rat. Three days after tumor cell implantation (i.e., inoculation), animals were treated daily by a subcutaneous injection of the desired polypeptide until day 13.
[0217] Experiments illustrated in FIG. 12 show the anti-tumor efficacy validation of rHuPSP94 against Mat LyLu (MLL) tumor implanted in nude mice (Protocol based on S. Garde et al.; The Prostate, 22: 225-233, 1993).
[0218] For study MLL-1 (FIG. 12), tumor-implanted nude mice were separated in different groups, each receiving various amount of rHuPSP94 or control reagents. The different groups used in these experiments are illustrated below. Each group contained 8 mice.
[0219] Group 1: Negative control: PBS subcutaneously (s.c.)
[0220] Group 2: Positive control: Doxorubicin at 5 mg/kg intraveanously (i.v.) single bolus on day 3
[0221] Group 3: rHuPSP94 at 1 μg/kg/day (s.c.)
[0222] Group 4: rHuPSP94 at 10 μg/kg/day (s.c.)
[0223] Group 5: rHuPSP94 at 100 μg/kg/day (s.c.)
[0224] A schematic of inoculation is illustrated below; (Tumor cell implantation (T.C.I.), treatment (Tx), measurement (M), day (D)).
[0225] Experiments illustrated in study MLL-2 show the anti-tumor efficacy validation of rHuPSP94 against Mat Ly Lu (MLL) tumor implanted in severe combined immunodeficiency (SCID) mice (Protocol based on S. Garde et al.; The Prostate, 22: 225-233, 1993).
[0226] For study MLL-2 (FIG. 13), tumor-implanted Scid mice were separated in different groups each receiving various amounts of rHuPSP94 or control reagents. The different groups used in these experiments are illustrated below. Each group contained 8 mice.
[0227] Group 1: Negative control: PBS (s.c.)
[0228] Group 2: Positive control: Doxorubicin at 5 mg/kg i.v. single bolus on day 3
[0229] Group 3: rHuPSP94 at 1 μg/kg/day (s.c.)
[0230] Group 4: rHuPSP94 at 10 μg/kg/day (s.c.)
[0231] Group 5: rHuPSP94 at 100 μg/kg/day (s.c.)
[0232] A schematic of inoculation is illustrated below; (Tumor cell implantation (T.C.I.), treatment (Tx), measurement (M), day (D)).
[0233] Results of those two studies indicate a difference in tumor size and growth in Nude vs SCID mice. The tumors grew slower and were smaller in SCID mice. This may be due to some specific factors controlling tumor growth in this mouse strain. Results also show a significant tumor reduction in mice injected with Doxorubicin (positive control). For example, tumor weight reduction in Nude mice (study MLL-1) injected with Doxorubicin was 48% (p=0.006)(p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Tumor weight reduction in SCID mice (study MLL-2) inoculated with Doxorubicin was 82% (p=0.002) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Results indicate also a significant tumor reduction in mice treated with rHuPSP94 at a concentration of 1 μg/kg/day. For example, tumor weight reduction in Nude mice (study MLL-1) treated with rHuPSP94 at a concentration of 1 μg/kg/day was 26% (p=0.042) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Tumor weight reduction in SCID mice (study MLL-2) treated with rHuPSP94 at a concentration of 1 μg/kg/day was 65% (p=0.010) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit).
EXAMPLE 10
In-vivo Experiment using PC-3 Cell Line (FIG. 14 )
[0234] PC-3 human prostate tumor was obtained from ATCC (ATCC 1435). PC-3 cells were grown in RPMI media containing 10% (v/v) of fetal calf serum and were harvested in the logarithmic phase of growth by trypsinization. Cells were centrifuged at 1200 rotation per minute (rpm) and washed three timed with Hanks balanced salt solution (HBSS). Following washing, cells were counted and adjusted to a concentration of 1×10 7 cells/ml in HBSS. A 0.1 ml volume of tumor cell inoculum containing 1×10 6 cells was administered subcutaneously into the two opposite flank region of each Nude mouse (Nu/Nu, BALB/c background). Tumor growth was monitored for approximately 18 days. Once tumor growth has been established (volume of tumor reached a volume of 50 mm 3 ) treatment with rHuPSP94 (SEQ ID NO: 2) was initiated and was performed once a day for 14 days by the subcutaneous route. Based on the assigned treatment groups illustrated in table 4.
TABLE 4 Dose Treatment Test control Dose Level concentration No. of group articles (μg/kg/day) (μg/mg) animal 1 Negative PBS 0 0 8 control 2 Positive Doxorubicin 5000 2500 8 control 3 rHuPSP94 1 0.5 8 4 rHuPSP94 10 5 8 5 rHuPSP94 100 50 8 6 rHuPSP94 1000 500 8
[0235] Results of this experiment (FIG. 14) demonstrated tumor growth reduction in the group of mice treated with rHuPSP94 at a dosage level of 1 μg/kg body weight per day. This reduction was similar to that observed for Doxorubicin (given at 5 mg/kg/day) which is a chemotherapeutic agent used as reference gold standard.
EXAMPLE 11
In-vivo Experiment using PC-3 Cell Line (FIGS. 15 - 17 )
[0236] PC-3 human prostate tumor (ATCC 1435) obtained from ATCC was implanted bilateraly into nude mice and tumor growth was monitored for approximately 18 days. PC-3 cells were injected once subcutaneously into each flank of the mice. Once tumor growth has been established (i.e., volume of tumor reached 0.25 to 0.50 cm 3 ) the treatment with decapeptide (SEQ ID NO: 3), native PSP94 (SEQ ID NO: 1) and control scrambled polypeptide PB111 was initiated and was performed once a day for 14 days by the subcutaneous route based on the treatment groups (randomly assigned) illustrated in table 5.
TABLE 5 Dose Treatment Test and control Dose Level concentration No. of groups articles (μg/kg/day) (μg/mg) animal 1 PBS 0 0 4 (Negative control) 3 Decapeptide 1 0.5 4 (SEQ ID NO: 3) 4 Decapeptide 10 5 4 (SEQ ID NO: 3) 5 Decapeptide 100 50 4 (SEQ ID NO: 3) 6 Decapeptide 1000 500 4 (SEQ ID NO: 3) 7 Native PSP94 1 0.5 4 (SEQ ID NO: 1) 8 Native PSP94 10 5 4 (SEQ ID NO: 1) 10 Native PSP94 100 50 4 (SEQ ID NO: 1) 11 Native PSP94 1000 500 4 (SEQ ID NO: 1) 12 Scrambled 1 0.5 4 polypeptide (PB111) 13 Scrambled 10 5 4 polypeptide (PB111) 14 Scrambled 100 50 4 polypeptide (PB111) 15 Scrambled 1000 500 4 polypeptide (PB111)
[0237] [0237]FIG. 15 represents results obtained for tumor-implanted nude mice treated with the decapeptide (SEQ ID NO: 3) compared to a non-treated control. FIG. 16 represents results obtained for tumor-implanted nude mice treated with scrambled polypeptide PB111 compared to a non-treated control. FIG. 17 represents results obtained for tumor-implanted nude mice treated with native PSP94 (SEQ ID NO: 1) compared to a non-treated control. Results of these experiments (FIGS. 15 - 17 ) indicate a significant (p<0.05) tumor growth reduction in mice treated with the decapeptide (SEQ ID NO: 3) at a dosage level of 10 μg/kg body weight per day.
EXAMPLE 12
Manufacturing and Preparation of Polypeptides
[0238] PSP94 derived polypeptides including PCK3145 (SEQ ID NO: 5) were synthesized using the FMOC and BOC solid phase polypeptide synthesis method (Merrifield, B., Science, 232: 341-347, 1986). Polypeptides were analyzed in order to determine their identity by Mass Spectral Analysis. Polypeptide samples were analyzed using the PerSeptive Biosystems (Framingham, Mass.), with Voyager-DE MALDI-TOF mass spectrometer using 337 nm light from a nitrogen laser. About 50 scans were averaged for each analysis. A sample from the native PSP94 was also analyzed under similar conditions for comparison. Polypeptides were weighed on a Mettler AE 163 micro-balance. The measurements were to nearest 0.1 mg. The polypeptides were reconstituted in 10 mM PBS pH 7.3 to a final concentration of 1 and 5 mg/ml. The polypeptides dissolved relatively well and were filter sterilized through a 0.2 μM syringe filter. Aliquots of 2 ml/tube were made and stored at −80° C.
[0239] The pH of the polypeptides was measured after reconstitution to ensure that possible differences in pH would not be a factor of variation. The pH values of each solution were taken at three concentrations: neat, 100 μg/ml and 12.5 μg/ml. The pH range was approximately from 7.0 to 7.5. This did not make a significant difference in the outcome of the test as cells survive very well within this pH range. To change the concentrations to molar values, the approximate volume of the 1 mg/ml stocks were diluted in PBS pH 7.3. All stocks were made to contain 450 μM polypeptide solutions. When fresh stocks of polypeptide were to be reconstituted, it was done directly to 450 μM concentration in PBS pH 7.3.
[0240] After our initial screening and confirmation of the inhibitory activity of the polypeptide on the growth of the PC-3 cells, a GMP manufactured polypeptide was tested. This polypeptide was weighed and dissolved in PBS and 2 mg/ml stock solution was prepared, sterile filtered through a 0.2 μm syringe filter and stored at in −80° C.
EXAMPLE 13
Effect of PCK3145 on In-vitro PC-3 Cells (MTS Assay (FIGS. 18 - 21 ))
[0241] PCK3145, manufactured as set forth in example 12, was evaluated as a lead candidate product in tumor growth inhibition.
[0242] The biological activity of PCK3145 was determined by its growth inhibitory effect on the human prostate cancer cell line PC-3 using the MTS/PMS kit (Promega). This assay measures the mitochondrial activity of the live cells. The basic principle of this method involves the fact that the mitochondrial enzymes of the live cells metabolize the MTS/PMS dyes forming a brown colored precipitate which can be measured as optical density (OD) by absorption at 490 nm in a spectrophotometer. Therefore, the OD values are proportional to the number of living cells.
[0243] In addition, a visual observation of the cells was also done to check the cell morphology, which could also be indicative of cell growth. The following conditions for MTS assay were used: PC-3 (ATCC, Lot AT06), passage number n≧70, cell line adapted to grow in serum-free OPTI-MEM and in RPMI supplemented with BSA (50 μg/ml) and Ferrous Sulfate (0.1 μM), continuous exposure for up to 72 hours without changing media (i.e., adding PCK3145 at 2×concentration directly to wells and diluting it 1:2 to 1× to minimize cell manipulation and avoid detachment). As indicated in FIG. 18, PCK3145 was assessed at the following concentrations: 12.5, 25, 50, 100, 200, 300 and 400 μg/ml on PC-3 cells (ATCC) grown in supplemented media. The MTS tests were repeated 5 times and a dose dependent inhibitory effect on the growth of PC-3 cells was consistently reproducible demonstrating approximately 40% cell growth inhibition at the highest PCK3145 concentration of 400 μg/ml.
[0244] With the availability of GMP (good manufacturing practice) grade polypeptide the MTS assays were repeated to check the reproducibility and cytotoxicity against PC-3 cells. In parallel PC-3 cells were also treated with the native PSP94 as a reference positive control and with no treatment (negative control, i.e., cont.). FIG. 19 shows the results of the MTS assay where 4000 cells were seeded and exposed to PCK3145 (GMP grade) for 48 hours. A 30% growth inhibitory effect was observed following treatment with PCK3145 at 500 μg/ml. This effect was increased to approximately 40% after 72 hours of exposure (FIG. 20). In a repeat experiment a 48 hours exposure to the polypeptide at 500 μg/ml resulted in only 20-22% growth inhibition, however this effect increased to 30% after 72 hours exposure (FIG. 21). Despite assay to assay variability reflected by the state of cell growth in vitro, polypeptide PCK3145 exhibited a significant cell growth inhibition.
EXAMPLE 14
Effect of PCK3145 on In-vitro PC-3 Cells [ 3 H]-Thymidine Uptake Assay (FIGS. 22 - 24 )
[0245] [ 3 H]-Thymidine uptake assay involves [ 3 H]-Thymidine incorporation into cellular DNA of actively proliferating cells. [ 3 H]-Thymidine uptake assay measures the proliferative index of the cells versus the MTS assay, which quantifies the number of lived cells following treatment. The anti-proliferative effects of PCK3145 and two other synthetic polypeptides derived from the amino and carboxy terminus ends of PSP94 (SEQ ID NO: 4 and NO: 6, respectively) as well as the decapeptide (SEQ ID NO: 3) previously shown to mimic the biological action of native PSP94 were assessed in [H3]-Thymidine uptake assay on PC-3 cells. Two separate experiments were conducted with GMP-grade PCK3145.
[0246] As shown in the FIGS. 22 and 23, polypeptide PCK3145 exhibited a significant proliferation inhibition activity reflected in the percentage of [H3]-Thymidine uptake. In the first experiment, a reduction of nearly 40% in [ 3 H]-Thymidine uptake was observed at PCK3145 concentration of 200 μg/ml. In the second experiment, although a two fold higher concentration of the PCK3145 was used (i.e., 400 μg/ml) only a 25% inhibition was observed. Despite assay to assay variation the overall degree of proliferative inhibitory effect against PC-3 cell was markedly evident with the GMP grade material. Treatment of PC-3 cells with the native PSP94 used as a positive reference standard, exhibited a significant dose dependent reduction in cell proliferation with almost 50% reduction in the [H3]-Thymidine uptake following 72 hours exposure (FIG. 24).
EXAMPLE 15
In Vitro Effect of PCK3145 on PC-3 Cells (Apoptosis-FIG. 25 )
[0247] Apoptosis of PC-3 cells, following a 72 hours exposure to PCK3145 at 500 μg/ml concentration, was evaluated in supplemented media by DNA fragmentation assay. Doxorubicin was used as a reference positive control. Untreated cells and PCK3145-treated cells were harvested and the DNA was isolated. Isolated DNA was run on a 1.2% agarose gel containing Ethidium Bromide (EtBr). As shown in FIG. 25 treatment of PC-3 cells with polypeptide PKC3145 resulted in DNA fragmentation evidenced by the ladder formation seen for fragmented DNA. Lane 1 of the gel illustrated in FIG. 25 represents the DNA marker (100 base pair DNA ladder). Lane 2 of the gel illustrated in FIG. 25 represents a control of untreated PC-3 cells. Lane 3 of the gel illustrated in FIG. 25 represents DNA laddering effect observed for cells treated with doxorubicin at a concentration of 2 μg/ml. Lane 4 of the gel illustrated in FIG. 25 represents DNA laddering effect observed for cells treated with PCK3145 (SEQ ID NO: 5).
EXAMPLE 16
In Vivo Experiments using Human PC-3 Prostate Cancer Cell Line (FIGS. 26 - 27 )
[0248] Studies PC3-6 and PC3-12 (FIGS. 26 - 27 ) are consecutive group experiments designed to characterize the in vivo activity of PCK3145 in the human PC-3 prostate cancer nude mouse xenograft model and to explore relationships between dose, route and schedule of administration and the efficacy parameters of tumor growth (volume).
[0249] PC-3 cells harvested in mid-log phase were inoculated at 5× 10 6 cells per mice via the subcutaneous route in the mice's back area. Tumors grown from this inoculum were excised at approximately day 32 to 35 post-tumor implantation (p.t.i) when tumor volume reached 200-300 MM 3 (i.e., cu mm). The necrotic tissue was removed and the viable tumor mass cut into small pieces (approximately 1 to 3 mm 3 ) were implanted SC in the flank region at two opposite sites of the mouse. Treatment with various concentrations of PCK3145 was initiated at day 3 post-tumor implantation (p.t.i) and was continued daily for 21 days. Subcutaneous injections were done below tumor growth sites. Intra-peritoneal injections were performed in the abdominal region. Intra-venous injections were performed via the lateral tail vein. The experiment was terminated 24 hours after the last treatment. Tumor measurements were taken at Days 11, 14, 16, 18, 20, 22 and 24 post-tumor implantation (p.t.i). Tumor volumes were calculated according to formula (axb 2 ×0.5), where a—is the length of the long diameter, and b—is the width of the perpendicular small diameter.
[0250] Study No: PC3-6 illustrates the efficacy of PCK3145, injected subcutaneously, in tumor growth retardation in Nude mice, which have received PC-3 implants. Mice were separated in different group each receiving various amounts of PCK3145 (SEQ ID NO: 5) or control reagents. The different groups used in these experiments are illustrated in table 6 below. Each group contained 10 mice. Doxorubicin was administered as single bolus intra-venous injection on days 3 and 11 post-tumor implantation (p.t.i).
TABLE 6 Test and Treatment control Dose Level No. of No. of group articles (μg/kg/day) animals tumors 1 Negative PBS 0 10 20 control 2 Positive Doxorubicin 10000 10 20 control 3 PCK3145 0.1 10 20 4 PCK3145 1 10 20 5 PCK3145 10 10 20
[0251] Results of this study (FIG. 26) demonstrated a significant PC-3 tumor growth retardation following treatment with PCK3145 at 10 μg/kg/day. This anti-tumor effect was evidenced by a statistically significant decrease in percentage of tumor growth observed at days 11, 14, 16, 18 , 21 and 24 after tumor implantation with respective p-values ranging from p=0.001 to 0.002, in comparison to the control PBS-treated group (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Doxorubicin, a potent chemotherapeutic agent, was used as reference gold standard and demonstrated a highly significant anti-tumor therapeutic effect. ANOVA analysis of variance, Dunnett's test, Kruskal-Wallis and Dunn's test analysis of data confirmed statistical significance of the observed anti-tumor effect.
[0252] Study No: PC3-12 illustrates the efficacy of PCK3145 in tumor growth retardation in Nude mice, which have received PC-3 implants. Mice were separated in different group each receiving various amounts of PCK3145 (SEQ ID NO: 5) or control reagents. PCK3145 was injected either through intra-venous or intra-peritoneal route. The different groups used in these experiments are illustrated in table 7 below. Each group contained 9 mice.
TABLE 7 Test and Treatment control Dose level No. of No. of groups articles (μg/kg/day) animals tumors 1 Negative PBS 0 9 18 control 2 PCK3145 IV 10 9 18 3 PCK3145 IV 100 9 18 4 PCK3145 IV 500 9 18 5 PCK3145 IV 1000 9 18 6 PCK3145 IP 100 9 18 7 PCK3145 IP 1000 9 18
[0253] Results of this experiment (FIG. 27) demonstrated a significant tumor growth retardation following treatment with PCK3145 at 100 μg/kg/day via the intra-venous route. This effect was statistically significant at days 13, 17 and 20 after tumor implantation when compared by Student's t-test (p-values were p=0.005, 0.025 and 0.011, respectively for each time-point) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). No significant anti-tumor effect was observed following PCK3145 treatment at the other dosage levels of 10, 500 and 1000 μg/kg/day injected via the intra-venous route. However a trend towards significance was observed following treatment with 500 and 1000 μg/kg/day doses of PCK3145. Treatment of mice with PCK3145 at 100 and 1000 μg/kg/day administered via the intra-peritoneal route showed a similar tumor growth retardation trend with statistically less significant difference observed at day 13 p.t.i (p=0.056) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit) at the highest dose of 1000 μg/kg/day (FIG. 27).
[0254] During the course of experimentation using the human PC-3 prostate cancer nude mouse xenograft model, results obtained have suggested that subcutaneous PCK3145 injection of mice at a site (i.e., scruff of the neck) distant from tumor site, might not be efficacious enough and will unlikely may unlikely result in an anti-tumor effect, at least in the experimental conditions tested (doses of PCK3145 tested: 10 μg/kg/day and 100 μg/kg/day). The use of the scruff of the neck as a subcutaneous injection site represents an optimal site for immune response induction rather than a route for therapeutic product administration and as such, selection of this site is expected to be a sub-optimal site for tumor efficacy evaluation.
EXAMPLE 17
In Vivo Experiments using Dunning Rat Mat Ly Lu Prostate Cancer Line (FIGS. 28 - 30 )
[0255] Anti-tumor efficacy evaluation of PCK3145 against Mat Ly Lu (MLL) tumor implanted in Copenhagen rats was performed. (Protocol based on S. Garde et al.; The Prostate, 22: 225-233, 1993). Mat LyLu tumor cells were harvested in mid-log phase from the culture flasks by trypsinization, were centrifuged at 1200 rotation per minute (rpm) and washed three timed with Hanks balanced salt solution (HBSS). Following washing, cells were counted and adjusted to a concentration of 5×10 6 cells/ml in HBSS. A 0.1 ml volume of tumor cell inoculum containing 5×10 5 cells was administered subcutaneously into the flank region of each rat. Treatment started at day 3 post-tumor implantation (p.t.i) by local subcutaneous injection (i.e., in the shaved back area just below tumor implantation site) of various PCK3145 concentrations. This treatment was continued daily for 16 days. Experiments were terminated 24 hours after the last treatment. Tumor measurements were taken at days 7, 9, 11, 14, 16 and 18. Tumor volumes are calculated according to formula (axb 2×0.5 ), where a—is the length of the long diameter, b-width of the perpendicular small diameter. At day 19 tumors of individual rats were excised and weighed.
[0256] Study No: MLL-5 illustrates the efficacy of PCK3145 (SEQ ID NO: 5) compared with polypeptide 7-21 (SEQ ID NO: 4) and polypeptide 76-94 (SEQ ID NO: 6) in tumor growth retardation in Copenhagen rats, which have received Mat Ly Lu implants. Mice were separated in different groups, each receiving various amount of PCK3145 (SEQ ID NO: 5) or control reagents. PCK3145 was injected through the subcutaneous route. The different groups used in these experiments are illustrated in table 8 below. Each group contained 8 mice.
TABLE 8 Test and Treatment control Dose Level No. of No. of groups articles (μg/kg/day) animals tumors 1 Negative PBS 0 8 8 control 2 Polypeptide 10 8 8 7-21 3 Polypeptide 1 8 8 7-21 4 PCK3145 10 8 8 5 PCK3145 1 8 8 6 Polypeptide 10 8 8 76-94 7 Polypeptide 1 8 8 76-94
[0257] Results of this study (FIG. 28) demonstrated a significant anti-tumor effect following administration of PCK3145 at 10 μg/kg/day. This was evidenced by a significant tumor volume reduction at days 11 (p=0.006), 13 (p=0.00001), 16 (p=0.002) and 18(p=0.004), post-tumor cell implantation compared to control PBS-treated group (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). No significant effect was detectable following PCK3145 treatment at 1 μg/kg/day. It was of interest to note that the amino-terminus polypeptide 7-21 also demonstrated comparable anti-tumor effect, which was also observed in the PC-3 nude mouse xenograft model, indicating the possibility of an overlapping active site between the N-terminus and the central regions of the PSP94 protein. This was evidenced by a significant tumor volume reduction observed at day 13 (p=0.05), 16 (p=0.00005), and 18 (p=0.01) in mice treated with polypeptide 7-21) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit).
[0258] Study No: MLL-6 illustrates the efficacy of PCK3145 (SEQ ID NO: 5) in tumor growth retardation in Copenhagen rats, which have received Mat Ly Lu implants. Mice were separated in different group each receiving various amounts of PCK3145 (SEQ ID NO: 5) or control reagents. PCK3145 was injected through the subcutaneous route. The different groups used in these experiments are illustrated in table 9 below. Each group contained 8 mice. Doxorubicin was administered as single bolus via intra-venous injection on day 3 p.t.i.
TABLE 9 Test and Treatment control Dose level No. of No. of groups articles (μg/kg/day) animals tumors 1 (Negative PBS 0 8 8 control) 2 Doxorubicin 5000 8 8 3 PCK3145 10 8 8 4 PCK3145 100 8 8 5 Scrambled 10 8 8 polypeptide 6 Scrambled 100 8 8 polypeptide
[0259] Results of this study (FIGS. 29 and 30) demonstrated a significant dose-dependent anti-tumor effect following administration of PCK3145 at 10 and 100 μg/kg/day. This was evidenced by a significant tumor volume reduction (31% over control) following PCK3145 treatment especially with 100 μg/kg/day at days 14, 16 and 18 post-tumor cell implantation (FIG. 29). The p-value versus negative control-treated group (i.e., scrambled polypeptide (PB111)) was highly significant at p=0.0000062 (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). A moderate extent of growth retardation (marginal statistical significance at p=0.03 versus control PBS-treated group) was also observed following treatment with scrambled polypeptide at a concentration of 100 pg/kg/day (FIG. 29) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Doxorubicin treatment was highly significant resulting in over 80% reduction in tumor volumes. This anti-tumor effect of PCK3145 at 100 μg/kg/day was also reproduced following analysis of the tumor weights data. As shown in FIG. 30, (tumor weight data) a significant reduction in tumor weights (p=0.0003) was observed on day 18 p.t.i (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). This represented a 34% reduction in tumor mass, a 20 gram difference between the control (56.6 g) and PCK3145-treated at 100 μg/kg/day group (37.2 g). This difference in tumor weights was also statistically significant when it was compared to the tumor weights of the control scrambled polypeptide-treated rats given the same dose of 100 μg/kg/day (p=0.003) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit). Comparison of the scrambled polypeptide treated tumor weights with that of control PBS-untreated tumor weights was not statistically significant (p=0.06) (p values measured by unpaired Student's t-test at p<0.05 as cut-off limit).
EXAMPLE 18
Efficacy of PCK3145 and Taxotere Combination Treatment
[0260] In order to test for the efficacy of combination treatment, in tumor growth retardation, PCK3145 and taxotere (i.e., docetaxel) were co-administered in Nude mice previously inoculated with PC-3 tumor cells. Mice were separated in different groups each receiving PCK3145 alone or PCK3145 in combination with taxotere (administered by separate routes) or control reagent (i.e., PBS). In this experiment, the combination treatment was initiated against relatively large tumor burdens. Tumors were allowed to grow beyond the 50 to 60 mm 3 size at which PCK3145 treatment usually becomes inefficient. PCK3145 was injected through intravenous route every other day for 28 days starting from day 1 when 50 to 60 mm 3 size subcutaneous tumors were apparent. Taxotere was injected by intra-peritoneal route at a sub-optimal concentration of 2 mg/kg on days 4 and 11 after subcutaneous tumors were evident. The different groups used in this experiment are illustrated in table 10 below. Each group contained 11 mice.
TABLE 10 Test and Treatment control Dose level No. of groups articles (μg/kg) animals No of tumors 1. Negative PBS 0 11 11 control 2. Positive Taxotere 2000 11 11 control 3. PCK3145 100 11 11 4. PCK3145 + 100 + 11 11 taxotere 2000
[0261] Results of this experiment (FIG. 31) demonstrate a significant tumor growth retardation following combination treatment of PCK3145 and taxotere. This effect is statistically significant at days 19 and 22 post-tumor cell inoculation when compared by Student's t-test (p=0.02 at day 19 and p=0.047 at day 22), (p-values are measured by unpaired Student's t-test at p<0.05 as a cut-off limit) and was markedly better than taxotere administered alone at the same dose of 2 mg/kg (suboptimal dose).
[0262] All publications and patent applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. The citation of any publication is for its disclosure prior to the filing date and should not be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention.
[0263] Although the foregoing invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is readily apparent to those of ordinary skill in the art in light of the teachings of this invention that certain changes and modifications may be made thereto without departing from the spirit or scope of the appended claims.
0
SEQUENCE LISTING
<160> NUMBER OF SEQ ID NOS: 92
<210> SEQ ID NO 1
<211> LENGTH: 94
<212> TYPE: PRT
<213> ORGANISM: Homo sapiens
<300> PUBLICATION INFORMATION:
<301> AUTHORS: Ulvsback, M., Lindstrom, C., Weiber, H., Abrahamson, P.A.,
Lilja, H., and Lundwall, A“
<302> TITLE: Molecular cloning of a small prostate protein, known as
beta-microsemenoprotein, PSP94 or beta-inhibin, and demonstration
of transcripts in non-genital tissues.
<303> JOURNAL: Biochem. Biophys. Res Commun.
<304> VOLUME: 164
<305> ISSUE: 3
<306> PAGES: 1310-1315
<307> DATE: 1989
<308> DATABASE ACCESSION NUMBER: GI 131436
<309> DATABASE ENTRY DATE: 1988-08-01
<400> SEQUENCE: 1
Ser Cys Tyr Phe Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg
1 5 10 15
Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp
20 25 30
Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu Ile Ser
35 40 45
Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp Asn Cys
50 55 60
Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val Glu Lys
65 70 75 80
Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu Trp Ile Ile
85 90
<210> SEQ ID NO 2
<211> LENGTH: 102
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: recombinant human PSP94 (rHuPSP94) produced
from yeast
<400> SEQUENCE: 2
Glu Ala Glu Ala Tyr Val Glu Phe Ser Cys Tyr Phe Ile Pro Asn Glu
1 5 10 15
Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn
20 25 30
Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys
35 40 45
Thr Cys Tyr Glu Thr Glu Ile Ser Cys Cys Thr Leu Val Ser Thr Pro
50 55 60
Val Gly Tyr Asp Lys Asp Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp
65 70 75 80
Cys Lys Tyr Ile Val Val Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser
85 90 95
Val Ser Glu Trp Ile Ile
100
<210> SEQ ID NO 3
<211> LENGTH: 10
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: decapeptide
<400> SEQUENCE: 3
Tyr Thr Cys Ser Val Ser Glu Pro Gly Ile
1 5 10
<210> SEQ ID NO 4
<211> LENGTH: 15
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide 7-21
<400> SEQUENCE: 4
Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu
1 5 10 15
<210> SEQ ID NO 5
<211> LENGTH: 15
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: PCK3145 (polypeptide 31-45)
<400> SEQUENCE: 5
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
1 5 10 15
<210> SEQ ID NO 6
<211> LENGTH: 19
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide 76-94
<400> SEQUENCE: 6
Ile Val Val Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu
1 5 10 15
Trp Ile Ile
<210> SEQ ID NO 7
<211> LENGTH: 26
<212> TYPE: DNA
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Oligonucleotide used in the amplification and
cloning of rHPSP94
<400> SEQUENCE: 7
gggaagaatt ctcatgctat ttcata 26
<210> SEQ ID NO 8
<211> LENGTH: 21
<212> TYPE: DNA
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Oligonucleotide used in the amplification and
cloning of rHPSP94
<400> SEQUENCE: 8
tggatatctg cagaattcgg c 21
<210> SEQ ID NO 9
<211> LENGTH: 285
<212> TYPE: DNA
<213> ORGANISM: Homo sapiens
<300> PUBLICATION INFORMATION:
<301> AUTHORS: Green, C.B., Liu, W.Y. and Kwok, S.C.
<302> TITLE: Cloning and nucleotide sequence analysis of the human beta-
microseminoprotein gene.
<303> JOURNAL: Biochem. Biophys. Res. Commun.
<304> VOLUME: 167
<305> ISSUE: 3
<306> PAGES: 1184-1190
<307> DATE: 1990
<308> DATABASE ACCESSION NUMBER: GI 514370
<309> DATABASE ENTRY DATE: 1995-01-07
<400> SEQUENCE: 9
tcatgctatt tcatacctaa tgagggagtt ccaggagatt caaccaggaa atgcatggat 60
ctcaaaggaa acaaacaccc aataaactcg gagtggcaga ctgacaactg tgagacatgc 120
acttgctacg aaacagaaat ttcatgttgc acccttgttt ctacacctgt gggttatgac 180
aaagacaact gccaaagaat cttcaagaag gaggactgca agtatatcgt ggtggagaag 240
aaggacccaa aaaagacctg ttctgtcagt gaatggataa tctaa 285
<210> SEQ ID NO 10
<211> LENGTH: 16
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 10
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
<210> SEQ ID NO 11
<211> LENGTH: 17
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 11
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile
<210> SEQ ID NO 12
<211> LENGTH: 18
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 12
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser
<210> SEQ ID NO 13
<211> LENGTH: 19
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 13
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys
<210> SEQ ID NO 14
<211> LENGTH: 20
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
polypeptide analog)
<400> SEQUENCE: 14
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys
20
<210> SEQ ID NO 15
<211> LENGTH: 21
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 15
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr
20
<210> SEQ ID NO 16
<211> LENGTH: 22
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 16
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu
20
<210> SEQ ID NO 17
<211> LENGTH: 23
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 17
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val
20
<210> SEQ ID NO 18
<211> LENGTH: 24
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 18
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser
20
<210> SEQ ID NO 19
<211> LENGTH: 25
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 19
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr
20 25
<210> SEQ ID NO 20
<211> LENGTH: 26
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 20
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro
20 25
<210> SEQ ID NO 21
<211> LENGTH: 27
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 21
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val
20 25
<210> SEQ ID NO 22
<211> LENGTH: 28
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 22
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly
20 25
<210> SEQ ID NO 23
<211> LENGTH: 29
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 23
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr
20 25
<210> SEQ ID NO 24
<211> LENGTH: 30
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 24
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp
20 25 30
<210> SEQ ID NO 25
<211> LENGTH: 31
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 25
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys
20 25 30
<210> SEQ ID NO 26
<211> LENGTH: 32
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 26
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
<210> SEQ ID NO 27
<211> LENGTH: 33
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 27
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn
<210> SEQ ID NO 28
<211> LENGTH: 34
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 28
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys
<210> SEQ ID NO 29
<211> LENGTH: 35
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 29
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln
35
<210> SEQ ID NO 30
<211> LENGTH: 36
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 30
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg
35
<210> SEQ ID NO 31
<211> LENGTH: 37
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 31
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile
35
<210> SEQ ID NO 32
<211> LENGTH: 38
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 32
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe
35
<210> SEQ ID NO 33
<211> LENGTH: 39
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 33
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys
35
<210> SEQ ID NO 34
<211> LENGTH: 40
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 34
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys
35 40
<210> SEQ ID NO 35
<211> LENGTH: 41
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 35
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu
35 40
<210> SEQ ID NO 36
<211> LENGTH: 42
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 36
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp
35 40
<210> SEQ ID NO 37
<211> LENGTH: 43
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 37
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys
35 40
<210> SEQ ID NO 38
<211> LENGTH: 44
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 38
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys
35 40
<210> SEQ ID NO 39
<211> LENGTH: 45
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 39
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr
35 40 45
<210> SEQ ID NO 40
<211> LENGTH: 46
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 40
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile
35 40 45
<210> SEQ ID NO 41
<211> LENGTH: 47
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 41
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val
35 40 45
<210> SEQ ID NO 42
<211> LENGTH: 48
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 42
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
<210> SEQ ID NO 43
<211> LENGTH: 49
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 43
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu
<210> SEQ ID NO 44
<211> LENGTH: 50
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 44
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys
50
<210> SEQ ID NO 45
<211> LENGTH: 51
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 45
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys
50
<210> SEQ ID NO 46
<211> LENGTH: 52
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 46
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp
50
<210> SEQ ID NO 47
<211> LENGTH: 53
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 47
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro
50
<210> SEQ ID NO 48
<211> LENGTH: 54
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 48
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys
50
<210> SEQ ID NO 49
<211> LENGTH: 55
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 49
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys
50 55
<210> SEQ ID NO 50
<211> LENGTH: 56
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 50
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr
50 55
<210> SEQ ID NO 51
<211> LENGTH: 57
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 51
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys
50 55
<210> SEQ ID NO 52
<211> LENGTH: 58
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 52
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser
50 55
<210> SEQ ID NO 53
<211> LENGTH: 59
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 53
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val
50 55
<210> SEQ ID NO 54
<211> LENGTH: 60
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 54
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser
50 55 60
<210> SEQ ID NO 55
<211> LENGTH: 61
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 55
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu
50 55 60
<210> SEQ ID NO 56
<211> LENGTH: 62
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 56
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu Trp
50 55 60
<210> SEQ ID NO 57
<211> LENGTH: 63
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 57
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu Trp Ile
50 55 60
<210> SEQ ID NO 58
<211> LENGTH: 64
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 58
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Ile Ser Cys Cys Thr Leu Val Ser Thr Pro Val Gly Tyr Asp Lys Asp
20 25 30
Asn Cys Gln Arg Ile Phe Lys Lys Glu Asp Cys Lys Tyr Ile Val Val
35 40 45
Glu Lys Lys Asp Pro Lys Lys Thr Cys Ser Val Ser Glu Trp Ile Ile
50 55 60
<210> SEQ ID NO 59
<211> LENGTH: 16
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 59
Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
1 5 10 15
<210> SEQ ID NO 60
<211> LENGTH: 17
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 60
Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu
1 5 10 15
Thr
<210> SEQ ID NO 61
<211> LENGTH: 18
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 61
Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr
1 5 10 15
Glu Thr
<210> SEQ ID NO 62
<211> LENGTH: 19
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 62
Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys
1 5 10 15
Tyr Glu Thr
<210> SEQ ID NO 63
<211> LENGTH: 20
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 63
His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr
1 5 10 15
Cys Tyr Glu Thr
20
<210> SEQ ID NO 64
<211> LENGTH: 21
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 64
Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys
1 5 10 15
Thr Cys Tyr Glu Thr
20
<210> SEQ ID NO 65
<211> LENGTH: 22
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 65
Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr
1 5 10 15
Cys Thr Cys Tyr Glu Thr
20
<210> SEQ ID NO 66
<211> LENGTH: 23
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 66
Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu
1 5 10 15
Thr Cys Thr Cys Tyr Glu Thr
20
<210> SEQ ID NO 67
<211> LENGTH: 24
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 67
Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys
1 5 10 15
Glu Thr Cys Thr Cys Tyr Glu Thr
20
<210> SEQ ID NO 68
<211> LENGTH: 25
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 68
Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn
1 5 10 15
Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25
<210> SEQ ID NO 69
<211> LENGTH: 26
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 69
Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp
1 5 10 15
Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25
<210> SEQ ID NO 70
<211> LENGTH: 27
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 70
Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr
1 5 10 15
Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25
<210> SEQ ID NO 71
<211> LENGTH: 28
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 71
Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln
1 5 10 15
Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25
<210> SEQ ID NO 72
<211> LENGTH: 29
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 72
Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp
1 5 10 15
Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25
<210> SEQ ID NO 73
<211> LENGTH: 30
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 73
Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu
1 5 10 15
Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25 30
<210> SEQ ID NO 74
<211> LENGTH: 31
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 74
Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser
1 5 10 15
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25 30
<210> SEQ ID NO 75
<211> LENGTH: 32
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 75
Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn
1 5 10 15
Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25 30
<210> SEQ ID NO 76
<211> LENGTH: 33
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 76
Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile
1 5 10 15
Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu
20 25 30
Thr
<210> SEQ ID NO 77
<211> LENGTH: 34
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 77
Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro
1 5 10 15
Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr
20 25 30
Glu Thr
<210> SEQ ID NO 78
<211> LENGTH: 35
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 78
Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys His
1 5 10 15
Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys
20 25 30
Tyr Glu Thr
35
<210> SEQ ID NO 79
<211> LENGTH: 36
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 79
Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn Lys
1 5 10 15
His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr
20 25 30
Cys Tyr Glu Thr
35
<210> SEQ ID NO 80
<211> LENGTH: 37
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 80
Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly Asn
1 5 10 15
Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys
20 25 30
Thr Cys Tyr Glu Thr
35
<210> SEQ ID NO 81
<211> LENGTH: 38
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 81
Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys Gly
1 5 10 15
Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu Thr
20 25 30
Cys Thr Cys Tyr Glu Thr
35
<210> SEQ ID NO 82
<211> LENGTH: 39
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 82
Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu Lys
1 5 10 15
Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys Glu
20 25 30
Thr Cys Thr Cys Tyr Glu Thr
35
<210> SEQ ID NO 83
<211> LENGTH: 40
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 83
Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp Leu
1 5 10 15
Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn Cys
20 25 30
Glu Thr Cys Thr Cys Tyr Glu Thr
35 40
<210> SEQ ID NO 84
<211> LENGTH: 41
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 84
Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met Asp
1 5 10 15
Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp Asn
20 25 30
Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40
<210> SEQ ID NO 85
<211> LENGTH: 42
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 85
Phe Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys Met
1 5 10 15
Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr Asp
20 25 30
Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40
<210> SEQ ID NO 86
<211> LENGTH: 43
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 86
Tyr Phe Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys Cys
1 5 10 15
Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln Thr
20 25 30
Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40
<210> SEQ ID NO 87
<211> LENGTH: 44
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 87
Cys Tyr Phe Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg Lys
1 5 10 15
Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp Gln
20 25 30
Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40
<210> SEQ ID NO 88
<211> LENGTH: 45
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from rHuPSP94 sequence
(polypeptide analog)
<400> SEQUENCE: 88
Ser Cys Tyr Phe Ile Pro Asn Glu Gly Val Pro Gly Asp Ser Thr Arg
1 5 10 15
Lys Cys Met Asp Leu Lys Gly Asn Lys His Pro Ile Asn Ser Glu Trp
20 25 30
Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40 45
<210> SEQ ID NO 89
<211> LENGTH: 15
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from PCK3145 sequence
(polypeptide analog)
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (1)..(1)
<223> OTHER INFORMATION: Xaa may be glutamic acid, asparagine or
aspartic acid.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (4)..(4)
<223> OTHER INFORMATION: Xaa may be threonine or serine.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (6)..(6)
<223> OTHER INFORMATION: Xaa may be glutamic acid, asparagine, or
aspartic acid.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (8)..(8)
<223> OTHER INFORMATION: Xaa may be glutamic acid, asparagine, or
aspartic acid.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (9)..(9)
<223> OTHER INFORMATION: Xaa may be threonine or serine.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (11)..(11)
<223> OTHER INFORMATION: Xaa may be threonine or serine.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (13)..(13)
<223> OTHER INFORMATION: Xaa may be tyrosine or phenylalanine.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (14)..(14)
<223> OTHER INFORMATION: Xaa may be glutamic acid, asparagine, or
aspartic acid.
<221> NAME/KEY: MISC_FEATURE
<222> LOCATION: (15)..(15)
<223> OTHER INFORMATION: Xaa may be threonine or serine.
<400> SEQUENCE: 89
Xaa Trp Gln Xaa Asp Xaa Cys Xaa Xaa Cys Xaa Cys Xaa Xaa Xaa
1 5 10 15
<210> SEQ ID NO 90
<211> LENGTH: 30
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from PCK3145 sequence
(polypeptide analog)
<400> SEQUENCE: 90
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
20 25 30
<210> SEQ ID NO 91
<211> LENGTH: 45
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from PCK3145 sequence
(polypeptide analog)
<400> SEQUENCE: 91
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu Trp
20 25 30
Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
35 40 45
<210> SEQ ID NO 92
<211> LENGTH: 60
<212> TYPE: PRT
<213> ORGANISM: Artificial Sequence
<220> FEATURE:
<223> OTHER INFORMATION: Polypeptide derived from PCK3145 sequence
(polypeptide analog)
<400> SEQUENCE: 92
Glu Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu
1 5 10 15
Trp Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu Trp
20 25 30
Gln Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr Glu Trp Gln
35 40 45
Thr Asp Asn Cys Glu Thr Cys Thr Cys Tyr Glu Thr
50 55 60 | The invention provides pharmaceutical compositions and method for inhibiting growth of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, or benign prostate hyperplasia (BPH). In one embodiment the pharmaceutical composition includes human rHuPSP94, antigenic portions thereof, and functionally equivalent polypeptides thereof. In another embodiment, the pharmaceutical composition includes a mixture of human rHuPSP94, antigenic portions thereof, and functionally equivalent polypeptides thereof and an anticancer drug which may be administered in an appropriate dosage form, dosage quantity and dosage regimen to a patient suffering from, for example of prostatic adenocarcinoma, stomach cancer, breast cancer, endometrial, ovarian or other cancers of epithelial secretion, benign prostate hyperplasia, or (BPH) gastrointestinal cancer. The anticancer drug of the latter mixture may be one selected from the group of drugs including mitomycin, idarubicin, cisplatin, 5-fluoro-uracil, methotrexate, adriamycin, daunomycin, taxol, taxol derivative, and mixtures thereof. | 2 |
BACKGROUND OF THE INVENTION
Telephone headset amplifiers provide an interface between the telephone and the headset worn by the telephone operator. The headset amplifier receives the audio signal from the telephone, limits the maximum amplitude of the audio signal to improve operator safety, and provides a power output to drive the earphone part of the telephone headset. The headset provides power for the headset microphone, and takes the audio signal from the microphone, switches the gain of the audio signal from the microphone, and drives the gain-switched signal from the microphone into the telephone line through a 4 to 2 wire convertor in the telephone. Sidetone is generated in the 4 to 2 wire convertor enabling the operator to hear through the earphone what he/she is saying into the microphone.
Headset amplifiers can be powered from the a.c. line by an a.c. to D.C. power supply, or they can draw power from the telephone line. Modern headset amplifiers are battery powered, usually by two "AA"-size alkaline cells. Batteries provide a convenient power source for a telephone headset amplifier, but, since they have finite life, powering a telephone headset from batteries can be relatively expensive, and can also present reliability problems. It has proved difficult to train telephone operators to switch the headset amplifier off when the operator leaves the workstation. Failure to switch the amplifier off increases cost, because the batteries continue to provide current while the amplifier is not being used. Failure to switch the amplifier off also reduces reliability, because the batteries of an amplifier left on overnight or over the weekend are less serviceable, which forces the replacement of batteries often enough to become an annoyance.
Gain switching is applied to the microphone output to reduce pickup of extraneous sounds when the operator is not speaking. Additionally, it is desirable to be able to mute the microphone output briefly at times such as when the operator has to sneeze or cough. Known muting circuits tend to cause an annoying click or pop on the transmit linc when the operator operates the mute switch.
Between calls on many telephone systems on which headsets are used continuously there is idle channel noise. The operator must listen to this noise while nobody is speaking on the line. The operator cannot remove or disconnect his/her headset to avoid listening to this noise, because the operator must be ready at all times to deal with incoming calls. Such noise is undesirable since it causes operator fatigue and reduces operator efficiency.
BRIEF DESCRIPTION OF THE INVENTION
A telephone headset amplifier according to the invention includes a line monitor circuit that monitors the activity on the receive telephone line. If the line monitor circuit indicates that there is no activity on the receive line above its threshold, a timer circuit begins to time a time-out time. If the timer reaches the end of its time-out time without there being activity on the line, a control signal generated by the timer changes state. Immediately there is activity on the receive line above the threshold level of the line monitor circuit, the timer is reset and the control signal reverts to its original state.
The control signal from the timer controls the battery saver circuit. The circuitry of the amplifier is contained in a large-scale integration analog integrated circuit that includes a reference voltage line that drives all the current generators in the amplifier. When the control signal changes state, it pulls this reference voltage to ground level, which significantly reduces the current drawn by the amplifier to a few tens of microamps.
The timer derives its time constant by charging a relatively small capacitor with the base current of a high-gain transistor, which enables a time constant of about 3 minutes to be obtained using a 1 μF capacitor.
The line monitor also controls the output level of automatic level control circuit in the earphone driving circuit. The line monitor gradually reduces the output level of the amplifier, and hence the line noise heard by the operator, when the activity on the receive line falls below the threshold of the line monitor. The gradual reduction in output level enables the receive line noise to be reduced without clicks or pops being heard in the earphone.
The headset microphone is amplified by a switched gain amplifier that provides normal amplification, microphone quieting of about 16 dB and microphone muting. The switched gain amplifier is controlled by a manual mute switch, which selects the amplifier's mute condition, and a microphone monitor circuit and threshold circuit that selects between the amplifier's normal and quieting conditions. The amplifier switches between its three gain conditions without causing clicks and pops on its output The input signal is fed with suitable attenuation into one of three identical differential pairs of transistors feeding a common load. One of the pairs of transistors is selected by feeding the current from a single current generator into a selected one of three identical current mirrors, each feeding one of the differential pairs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a telephone headset amplifier according to the invention.
FIG. 2 shows a schematic diagram of the receive line monitor and the timer circuit according to the invention.
FIG. 3 shows a schematic diagram of the automatic level control circuit adapted for providing receive line noise reduction circuit according to the invention.
FIG. 4 shows a schematic diagram of the click-free switched gain amplifier circuit according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
A block diagram of the headset amplifier according to the invention is shown in FIG. 1. The telephone line 3 is connected to the 4 to 2 coupler 5 in the telephone (not shown). The amplifier 1 includes the automatic level control (ALC) amplifier 7 to which the telephone receive lines 6 from the 4 to 2 coupler 5 are differentially connected. The ALC amplifier 7 limits the maximum amplitude of the audio signal from the receive lines. An ALC feedback circuit 9 monitors the output of the earphone driver amplifier 11 and provides the control signal for the ALC amplifier 7, which is typically a transconductance amplifier. The output of the ALC amplifier 7 is connected to the input of the earphone driver amplifier 11, the output of which is connected though the cord 13 to the earphone 15 in the headset 17. Suitable frequency response shaping may be applied in either of the amplifiers 7 or 11.
Also included in the headset 17 is the microphone 19, which is normally an electret microphone powered by the microphone power supply 21. The audio output of the microphone 19 is coupled though the capacitor 23 into the microphone switched gain amplifier 25, the gain of which is controlled by the microphone monitoring circuit 27, and by the manual mute switch 31.
The amplified microphone signal is coupled into the transmit driver 35 which differentially drives the transmit lines 33 into the 4 to 2 coupler 5 in the telephone (not shown), and thence into the telephone line 3.
Each of the active blocks shown has a power supply input (marked with the "+" symbol) which is connected to the power supply 37. The power supply may be powered by the batteries 39 which, in the preferred embodiment, are two "AA"-sized alkaline cells, but could be a greater or lesser number of the same or different sized cells, if desired. The power supply 37 also generates a reference signal, which is connected to the reference input terminal (marked "R") on each of the active blocks of the circuit by the reference line 38. Current generator circuits in the active blocks are connected to the reference line 38.
The circuitry just described is found in known telephone headset amplifiers which suffer from the battery life, microphone muting dicks and pops, and line noise problems discussed above. The headset amplifier 1 according to the invention additionally includes the line monitor 41, which is connected differentially to the receive lines 6. The line monitor 41 monitors the signal level on the receive lines 6 and produces two control signals 43 and 44 at its output. When the signal level on the receive lines 6 is above the threshold level of the line monitor 41, the control signals 43 and 44 are each in one of their two possible states. When the signal level on the receive line 6 is below the threshold level of the line monitor 41, the control signals 44 are each in the other of their two possible states.
The control signal 43 controls the timer 45. When the control signal 43 changes to its state that indicates that activity on the receive line is below the threshold of the line monitor 41, the timer begins timing its time-out time. Any change in state of the control signal 43 resets the timer, and timing starts over again. If the control signal stays in its condition indicating that activity on the receive line is below the threshold of the line monitor 41 for more than the time-out time of the timer, the output of the timer changes state. The output of the timer controls the voltage level on the reference line 38. When the output of the timer 45 is in its normal state. the reference line 38 is at its normal voltage. When the output of the timer 45 changes state, it pulls the level of the reference line 38 down to ground level, which reduces the current drawn by the current generators connected to the reference line 38 to a low level, and consequently reduces the current drawn by the amplifier 1 from the batteries 39.
The control signal 44 from the line monitor 41 is connected to the control circuit 9 of the receive ALC amplifier 7. The control signal 44 controls the current output of the ALC feedback circuit 9 and thus changes the output level of the receive ALC amplifier 7 by a fixed amount, irrespective of the actual output level, which depends on the setting of the manual volume control 51. In the preferred embodiment, the control signal 44 changes the output level of the receive ALC amplifier 7 by about 12 dB.
The telephone headset amplifier 1 according to the invention also includes a microphone mute and quieting circuit, in which the switched gain amplifier 25, the microphone monitoring amplifier 27 and the microphone control circuit 47 together provide click-free switching for microphone quieting and microphone muting. The switched microphone amplifier has three gain states that are selected by the microphone control circuit 47. The microphone control circuit selects the normal gain condition and the -16 dB quieting gain condition depending on whether the signal level at the output of the microphone monitoring amplifier 27 is above or below, respectively, the threshold level set by the microphone control circuit 47. The microphone control circuit 47 also selects a mute condition in the switched gain amplifier 25, in which the output level is reduced by about 60 dB. The mute condition is selected in response to the manual mute switch 31, which overrides the selection of the normal or quieting conditions. The gain of the switched gain amplifier 25 is selected in a way that avoids clicks and pops.
The Battery Saver
The Line Monitor
FIG. 2 shows a detailed schematic of the receive line monitor 41. The figure also shows the timer 45. In the line monitor 41, the receive signal from the receive line 6 (FIG. 1) is applied differenially to the bases 102 and 104 of the transistors 101 and 103, respectively. The transistors 101 and 103 are connected in a long-tail pair configuration supplied by the current generator formed by the transistor 105. The transistors 107 and 109 provide active collector loads for the transistors 101 and 103, respectively. The transistors 107 and 109 are connected in a current mirror arrangement. The resistor 111 (2.5 k) in the emitter of the transistor 109 unbalances the current mirror, creating an input threshold of about 2 mV. This arrangement forms the threshold detector 100.
When the signal level difference between the bases of the transistors 101 and 103 is below the threshold, the collector of transistor 103 feeds current into the base of transistor 113, which holds the transistor 113 on continuously. This holds the transistors 115 and 117 off. The transistor 115 provides the control signal 44 that controls the receive ALC circuit 7 to reduce receive line noise. The transistor 117 provides the control signal 43 that controls the timer 45. When the signal level difference between the bases of the transistors 101 and 103 exceeds the threshold value, the transistor 113 is turned off. This turns the transistor 115 on, and changes the control signal 44 to its low state, and turns the transistor 117 on, which changes the control signal 43 to its low state, resetting the timer 45.
The Timer
The timer 45 is also shown in FIG. 2. To reduce printed circuit board (PCB) area and reduce costs it is desirable to use a small value ceramic capacitor to provide the time constant of the timer, which is required to be of the order of 3 minutes. Ceramic capacitors are small in size and low in cost compared to aluminum or tantalum electrolytic capacitors that are conventionally used to achieve time constants of this length. Ceramic capacitors are also relatively stable with regard to temperature and have low leakage currents, which make the resulting timing more reliable. In this application, the timing does not have to be highly accurate, but the low leakage of the ceramic capacitor used in this application allows a very low charging current to be used, which enables the required time constant to be achieved using a physically small capacitor. The low leakage of the ceramic capacitor enables the timing capacitor 119 to be charged reliably using the base current of a high gain transistor running with a low collector current (in this case the transistor 121). The base current provides a substantially constant charging current of about 5 nA (the current provided by the current source formed by the transistor 123 divided by the current gain of the transistor 121). This allows the required 3 minute delay to be obtained with a 1 μF capacitor.
The actual base current charging the capacitor 119 can vary widely, since the transistor 121 has a specified current gain range of about 3:1. Moreover, the current gain of the transistor 121 is temperature dependent. The time-out time of the timer 45 can vary widely between different samples of the same amplifier, and can vary in one sample of the amplifier depending on the temperature. The time-out time of the timer varies between 1 minute and 5 minutes. Although this variation appears large, it makes little practical difference to the increase in battery life produced by the battery saver circuit because it is small compared with the time that the battery saver circuit keeps the amplifier remains off, i.e., 16 hours overnight, or 64 or 88 hours over a two- or three-day weekend.
When the control signal 43 at the collector of the transistor 117 goes low, even for a short time, indicating that there is activity above the threshold of the threshold detector 100 on the receive line, this causes the transistor 125 to conduct, which turns on the transistors 127 and 129, which both have their bases connected to the collector of the transistor 125. The transistor 127 holds the base of the transistor 125 low, which holds the transistor 125 on. The transistor 125 and the transistor 121 are connected in a long-tail pair configuration which is fed with current by the current generator formed by the transistor 123. The transistor 121 is therefore off.
The transistor 129 discharges the timing capacitor 119 until the voltage across the capacitor reaches a few hundred millivolts, the actual voltage being determined defined by the saturation voltage of the transistor 129. While there is activity on receive line above the threshold of its threshold detector 100, the circuit will stay in this condition. When activity on the receive line falls below the threshold of the threshold detector 100, the control signal 43 on the collector of the transistor 117 goes high, and the current from the current source formed by the transistor 123 is dropped across the resistor 131, which turns the transistor 125, and hence the transistors 127 and 129, off. The transistor 125 turning off turns the transistor 121 on. The base current of the transistor 121 slowly charges the capacitor 119. The voltage on the capacitor 119 rises until it reaches about 2 V be above ground. When the voltage across the capacitor 119 exceeds about 2 V be above ground, the diode 133 and the transistor 135 turn on, which pulls down the 1.2 V reference line 38 (FIG. 1) and significantly reduces the current drawn by the amplifier 1 (FIG. 1).
The timer stays in its set condition until there is activity on the receive line above the threshold of the threshold detector 100. This changes the control signal 43 to its low state, which resets the timer as described above. This in turn switches the transistor 135 off, restores the 1.2 V reference line 38 to its normal voltage, and allows the amplifier to draw its normal current from the battery again.
The timer 45 stays in its reset condition all the time that the control signal 43 is low, as described above. Only when the control signal 43 goes high does the timer 45 begin to time its time-out time. Only if the timer 45 reaches the end of its time-out time without the control signal 43 once more going low, i.e., without there being activity on the receive line above the threshold of the threshold detector 100, does the timer time out and cause the transistor 135 to pull down the 1.2 V reference line 38 which effectively switches the amplifier off. Activity on the receive line above the threshold of the threshold detector 100 immediately causes the control signal 43 to go low, which resets the timer and releases the 1.2 V reference line 38, which switches the amplifier back on.
The 1.2 V reference line 38 is preferably connected to all of the signal processing electronics blocks in the amplifier except the line monitor 41, and the timer 45, which must be connected to a separate 1.2 V reference so that they remain active while the rest of the amplifier electronics is switched off. The microphone power supply 21 and the earphone driver amplifier 11 must be designed so that they switch on and off without causing clicks and pops. Otherwise, they should be left powered continuously. Approximately one hundred microamps of current can be saved by switching off the microphone power supply 21 and the earphone driver amplifier 11. In the preferred embodiment, the battery saver circuit reduces the current drawn from the battery 39 from about 400 μA to about 70 μA.
Receive Line Noise Reduction
In FIG. 1, the ALC control circuit 9 of the receive ALC amplifier 7 provides a control current into the control input of the ALC amplifier that depends on the output level of the earphone driver amplifier 11. The ALC amplifier 7 is preferably a transconductance amplifier. The actual output level of the ALC amplifier 7 is determined by the adjustment of the volume control 51. The ALC control circuit 9 also receives the control signal 44 from the line monitor 41. In FIG. 2, the control signal 44 is provided by the collector of the transistor 115. The control signal 44 is low when the activity on the receive line is above the threshold of the threshold detector 100, and high when the activity on the receive line is below the threshold of the threshold detector 100. The rate of rise control signal 44 is limited by the capacitor 137 and the resistor 139. The relatively gentle rise of the control signal 44 enables the output level of the ALC amplifier 7 to be reduced without clicks or pops.
The ALC control circuit 9 is shown in FIG. 3. The input of the ALC control circuit 9 is fed by the output of the earphone driver amplifier 11. The ALC control circuit produces a current that represents the amplitude of the signal on the output of the earphone driver amplifier 11. In a conventional ALC circuit the ALC control circuit output would be used directly to set the gain of the ALC amplifier, and thus to limit the amplitude of the signal fed to the earphone. In the amplifier according to the invention, the output of the earphone driver amplifier 11 is applied to the base of the transistor 201, the emitter of which is fed by the constant current generator formed by the transistor 203. The emitter of the transistor 201 is connected to the bases of the transistors 205 and 208. The emitters of the transistors 205 and 208 are connected to the bases of the transistors 209 and 212 respectively. The emitters of the transistors 209 and 212 are connected together and via the manual volume control potentiometer 51 (1 M ohm) to ground. The collector of the transistor 209 is connected to the current mirror formed by the transistors 213 and 217, and the collector of the transistor 212 is connected to the current mirror formed by the transistors 216 and 220.
The outputs of the current mirrors are connected together and provide the current output of the ALC amplifier control 9. The current mirror formed by the transistors 216 and 220 is a unity ratio current mirror. whereas the current mirror formed by the transistors 213 and 217 is a 4:1 current mirror. One of the two paths between the input 233 and the output 235 is selected by the switch comprising the transistors 221, 225, and 229, and 224, 228, and 232. Current from the current generator formed by the transistor 203 flows through the transistors 221 and 224, which are in a long-tail pair arrangement. The base of the transistor 221 is connected to the 1.1 V reference 231. The base 237 of the transistor 224 is connected to the control signal 44.
When the activity, on the receive line is above the threshold of the threshold detector 100, the control signal 44 is low. The transistor 224 is on, and, consequently, the transistor 221 is off. Current from the current generator formed by the transistor 203 passes through the transistor 224 into the diode-connected transistor 228. This causes the transistor 232 to conduct, which causes the signal fed into the input 233 to appear on the emitter of the transistor 208. No signal appears on the emitter of the corresponding transistor 205, because the transistor 221, and hence the transistors 225, 229, and 205 are not conducting.
The signal on the base of the transistor 212 causes a current to flow from the collector to the emitter of the transistor. The magnitude of the collector current depends on the setting of the manual volume control 51 and the voltage on the emitter of the transistor 212 (and hence on the input at the input 233.) Increasing the value of the potentiometer 51 decreases the collector current and increases the output level of the ALC amplifier 7. The collector current from the transistor 212 flows into the current mirror formed by the transistors 216 and 220. This is the unity ratio current mirror, so the current from the current mirror and hence the output current fed into the ALC amplifier 7 is subsuntially equal to the collector current of the transistor 212.
When the activity on the receive line falls below the threshold of the threshold detector 100, the control signal 44 goes high. The changing level of the control signal 44 causes the long-tail pair formed by transistors 221 and 224 change state, so that, with the control signal 44 in its high state, the transistor 221 is conducting and the transistor 224 is non-conducting. This causes the signal at the input 233 to appear at the base of the transistor 209, instead of at the base of the transistor 212. The resulting collector current of the transistor 209 is substantially equal to what the collector current of the transistor 212 was before the control signal 44 went high and transistor 212 was switched off (this assumes that the signal of the input 223 is unchanged, and that the manual volume control 51 has not been adjusted). The collector current of the transistor 212 is mirrored by the current mirror formed by the transistors 213 and 217. This current mirror is a 4:1 ratio current mirror, so the output current fed into the ALC amplifier 7 from the collector of the transistor 217 is about four times the collector current of the transistor 209. The current fed into the ALC amplifier 7 is also about four times the current that was fed into the ALC amplifier by the current mirror formed by the transistors 216 and 220 before the control signal 44 went high. This increased current reduces the output level of the ALC amplifier by a factor of 4, or 12 dB.
Switching the current ratio of the current mirror providing the ALC amplifier control signal according to whether the control signal 44 is high or low, i,e., according to the activity on the receive line, changes the operatang point on the combined E/volume control characteristic of the, ALC amplifier 7. When the 4:1 ratio mirror is selected, an ALC amplifier output level some 12 dB lower wiI1 produce the same ALC amplifier control current compared with when the 1:1 ratio current mirror is selected. This effectively reduces the output level of the ALC amplifier by 12 dB without adjusting the manual volume control.
The control signal t4 is taken from the collector of the transistor 115. The transistor 115 is connected to the 1.2 V reference line 38 through the high value (10 Mohm) resistor 139, and the capacitor 137 (0.22 μF) is connected between the collector of the transistor and ground. This causes the control signal 44 to go high relatively slowly, with a time constant of about 2.2 seconds. This means that there is a considerable delay before the control signal 44 rises to 1.1 V, which is the voltage on the base of the transistor 221. Moreover, when the control signal 44 is comparable with the 1.1 V reference voltage on the base of the transistor 221, it is changing slowly, and the transistor 224 turns on gradually, turning the transistor 221 off gradually. The transistors 221 and 224 are on simultaneously, and hence the chain of odd-numbered transistors and the chain of even-numbered transistors connected to the transistors 221 and 224 respectively are also on simultaneously-This causes the current fed into the ALC amplifier 7 to decrease relatively gradually, which enables the output level of the ALC amplifier 7 to be reduced without audible clicks or pops.
When the activity on the receive line exceeds the threshold of the threshold detector 100, the transistor 115 (FIG. 2) switches on and discharges the capacitor 137 rapidly, and the control signal 44 goes low. This rapidly restores the normal gain of the ALC amplifier 7 once there is activity on the receive line. Any clicks and pops that might result from the rapid increase in the ALC amplifier gain are masked by the signal on the receive line, and are thus unnoticeable.
If the activity on the receive line remains below the threshold of the threshold detector 100 for the time out time of the timer 45, the output of the timer changes state and pulls the 1.2 V line down to ground. This switches off the earphone driver ampilfier 11, which effectively mutes the receive line noise. While the 1.2 V line is pulled low, enables the capacitor 137 discharges through the resistor 139, and ensures that, when the ALC amplifier 7 is switched back on when activity on the receive line resumes, it is in its normal gain condition.
Click-free Mute Switching
In FIG. 1, the audio signal from the microphone 19 is ampiflied by the switched gain amplifier 25, the gain of which is selected by the microphone control circuit 47. The switched gain amplifier has three gain conditions: a normal gain condition, a very low gain mute condition, and a -16 dB quieting condition. The very low gain mute condition, the normal gain condition, or the -16 dB quieting condition are all selected in response to the control signal 49 from the microphone monitor circuit 47. The output of the microphone 19 is amplified by the microphone monitoring amplifier 27. When the output of the microphone morntoting amplifier 27 is above the threshold of the microphone monitor circuit 47, the control signal 49 is in one of its states, and the gain of the switched gain amplifier 25 in its normal condition. When the output of the microphone monitoring amplifier 27 is below the threshold of the microphone monitor circuit 47, the control signal 49 is in another of its states, and the gain of the switched gain amplifier is in its quieting condition, which is 16 dB less than in the normal condition. When the manual mute switch 31 is operated, the control signal 49 is an a third of its states, and the switched gain amplifier is in its mute condition.
Details of the switched gain amplifier are shown in FIG. 4. Three identical differential pairs of PNP transistors 313 and 315, 323 and 325, and 333 and 335 drive one current mirror active load formed by the transistors 301 and 303. Only one of the differential pairs of transistors is activated at a time, which switches the gain of the amplifier. One transistor of each differential pair is provided with an emitter-follower input buffer.
The amplifier output 304 is taken from the emitter of the transistor 305, which has the current source (not shown) as its emitter load. The amplifier is configured as a differential amplifier, with the same non-inverting input 309, inverting input 311, and output 304, used for all three gain positions.
Activating the differential pair of transistors 313 and 315 selects the normal gain position of the switched gain amplifier 25. The normal gain of the amplifier is set by the feedback resistor 317, connected between the amplifier output 304 and its inverting input 311, and the resistor 319 connected between the inverting input 311 of the amplifier and ground. The non-inverting input 309 is connected to the base of the transistor 317, which provides an input buffer for the transistor 313. The diode-connected transistor 319 provides a DC level shift between the input and the base of the transistor 313. The serial arrangement of the diode-connected transistor 319 and the transistor 317 is supplied with current by the current generator formed by the transistor 321. The emitter of the transistor 313 is connected to the emitter of the transistor 315 to form a long-tail pair. The base of the transistor 315 is connected to the inverting input 311. The collector of the transistor 313 is connected to the transistor 301, which forms one half of the active load. The collector of the transistor 303 is connected to the transistor 313, which forms the other half of the active load.
The transistors 323, 325, 327, and 329 form an identical stage to that just described. The collectors of the transistors 323 and 325 are connected in the transistors 301 and 303, respectively, of the active load as in the stage just described. The non-inverting input 309 is connected to the base of the transistor 327 via the attenuator formed by the resistors 339 and 341, which attenuates the input by 6 times, or 16 dB. This means that, when the transistors 323 and 315 are selected, the gain of the switched gain amplifier 25 is reduced by about 16 dB.
The transistors 333, 335, 337, and 339 form an identical stage to that just described. The collectors of the transistors 323 and 325 are connected to the transistors 301 and 303, respectively, of the active load. The base of the transistor 337 is connected to ground, instead of to the non-inverting input 309, which prevents the input signal from reaching the output when the transistors 333 and 335 are selected in the mute position. When the mute position is selected, the signal feedthrough is of the order of -60 dB.
The three gain positions of the switched gain amplifier 29 are selected by providing an emitter current to only one of the three identical differential pairs of PNP transistors, 313 and 315, 323 and 325, and 333 and 335. The three pairs of transistors are connected to three identical current mirrors formed by the transistors 343, 345, and 347, respectively. The manual mute switch 31, and the output of the microphone monitoring amplifier 27 are gated together to give priority to the mute switch and connect the input of only one of the three current mirrors to a single current generator formed by the transistor 349.
The base of the transistor 351 is connected to a reference potential and the base of the transistor 353 is connected to the mute switch 31. The base of the transistor 353 is held at ground potential by the resistor 355 and the diode-connected transistor 357. When the mute switch 31 is off, the base of the transistor 353 is held at ground potential, and the transistor 351 is conducting. In this condition, the transistors 359 and 361 select one of the current mirrors 343 or 345 is selected to supply current to the current generator 349.
The base of the transistor 359 is connected to a reference voltage which sets the threshold of the microphone quieting circuit. The base of the transistor 361 is connected to the output of the microphone monitor amplifier 27. When output of the microphone 19, and hence of the microphone monitoring amplifier 27, is low, the transistor 361 does not conduct, and the transistor 359 is conducting. The transistor 359 connects the input of current mirror 345 to the current generator formed by the transistor 349. The output of the current mirror 345 supplies current to the emitters of the transistors 323 and 325. This selects the -16 dB quieting gain condition of the switched gain amplifier, as described above.
When the signal level on the output of the microphone 19, and hence on the output of the microphone monitoring amplifier 27 rises above the threshold set on the base of the transistor 359, this causes the transistor 361 to conduct, and switches the transistor 359 off. The transistor 361 connects the input of the current mirror 343 to the current generator 349. The current output from the current mirror 343 supplies current to the emitters the transistors 313 and 315. This selects the normal gain position of the switched gain amplifier, as described above.
When the mute switch 31 is on, the base of the transistor 353 is pulled up to above the reference voltage on the base of the transistor 351, the transistor 353 is conducting and connects the input of the current mirror 347 to the current generator formed by the transistor 349. The output of the current mirror 347 supplies current to the emitters of the transistors 333 and 335. This selects the mute gain position of the switched gain amplifier, as described above.
By feeding the input signal attentuated by appropriate amounts into one of three identical differential pairs of transistors feeding a common load, and by selecting one of the differential pairs by feeding it with current from a single current generator selectively fed into one of three identical current mirrors, the gain of the switched gain amplifier can be switched without changing the DC level of the output, and hence without clicks or pops. | An amplifier for amplifying a signal received on a telephone line and for providing the amplified signal to a telephone headset. The amplifier draws current from a battery. The current drawn is reduced in the absence of activity on the line. The amplifier includes a timer that generates a first control signal after a time-out time. The timer is reset by a second control signal. A threshold circuit generates the second control signal when the signal on the telephone line is above a threshold level. .[.Finally, a.]. .Iadd.A .Iaddend.circuit, responsive to the first control signal, reduces the current drawn from the power supply. The amplifier may additionally or alternatively include receive line muting. The amplifier includes an automatic level control circuit that receives the signal received on the telephone line and controls the level of the amplified signal provided to the headset to a set level in response to a second control signal. .[.Finally, a.]. .Iadd.A .Iaddend.control circuit generates the second control signal in response to the amplified signal provided to the headset and in response to the inverse of the first control signal. The inverse of the first control signal substantially reduces the set level. Finally, the amplifier includes a microphone amplifier with click-free muting. | 8 |
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/895,558, filed on Mar. 19, 2007, the disclosure of which is incorporated herein by reference as if fully set out at this point.
FIELD OF THE INVENTION
This invention relates to methods of treating starch-based products during processing in the industrial starch separation and extraction industry for achieving optimal microbial decontamination, starch extraction and modification.
BACKGROUND OF THE INVENTION
Starch extraction and modification from raw grain and tuber products is one of the biggest markets in the food, animal feed and industrial starch industries internationally. Each day, thousands of tonnes of starch-based products are processed to extract the starch from it, before converting it to a variety of starch powders, premixes, pastes or liquids for use, inter alia, in beer production, meat and fish products, confectionery, jams and preserves, syrups, paper and cardboard manufacturing, animal and aqua feeds, pet food and many other related applications.
Production of the diverse range of starch-based products requires dedicated adherence to prescribed manufacturing procedures, which often include interventions with substantially noxious and potentially caustic chemical agents for specific manipulation of the molecular features and characteristics of both in-process and end-product starch molecules. These interventions are specifically designed to result in the production of different end products with highly specific and differentiated molecular configurations, which then confer specific and predictable performance when combined in further manufacturing procedures.
These chemical interventions include biocidal remedies to restrict the presence of pathogenic and spoilage micro-organisms which directly impact on the biosecurity of the product produced and thus the capacity to comply with internal as well as customer batch specifications. Optimal decontamination of these starch-based products is a critical factor in determining final product quality, not only from an economic perspective, but particularly from a human and animal safety perspective.
For purposes of this specification, the terms “starch source” or “starch-based products” should be interpreted to include tubers (e.g. potatoes), grains, tapioca and derivative products (e.g. partially processed grains). “Grains” should be interpreted to include nuts, oil seeds, barley, wheat, maize (e.g. waxy and high amylose maize), rye, oats, corn and grains of any other cereal crops from which starch can be extracted.
Industrial Treatment of Starch-Based Products
Industrial starch production encompasses a diverse array of processing procedures for an extensive variety of starch types, all geared towards the production of either pure or derivative starch based products which have been tailored to specific applications and inclusions.
In the grain malting industry, graded barley grains undergo repeated immersion in steep water to increase moisture content from approximately 14% to around 45%. Germination of the embryo within the barley kernel is initiated at around 35% moisture content and the moistened grain is “germinated” for up to 6 days to form what is known as ‘green malt’. This process facilitates optimal enzymatic modification of the starch in the endosperm, but requires termination prior to the endosperm being converted into a starch source required for the developing roots and leaf shoots. Control of the process depends largely on the optimisation of the quality and quantity of the steeping water, the exclusion of overgrowth of microbial contaminants, and the maintenance of optimal temperature and humidity of the germinating grains during the development of the ‘green malt’. Treatment of steep water with biocidal agents to preclude microbial growth and mycotoxin generation must be balanced against the potential adverse impact upon the germinating grains as well as the potential for chemical taint of the starch undergoing enzymatic modification. Thus, water quality remains a critical component for the efficient production of a fundamental ingredient in the brewing process.
In an industrial starch mill, a new shipment of starch-based products is first graded according to, inter alia, colour, size, level of superficial microbial and mycotoxin contamination, and moisture, oil and protein content, after which the starch-based products are weighed and cleaned in a preliminary first stage screening process to remove dust, chaff and foreign materials. The starch-based products are subsequently conveyed to steeping vessels where they undergo steeping in lukewarm steepwater, essentially to permit optimal germ extraction and mobilisation of the endosperm. During steeping these grain products absorb water, which results in softening of the grain husks and an elevation of the moisture level and size of the kernels.
Sulfur dioxide (SO 2 ) is generally added to the steepwater to prevent excessive bacterial growth in this warm environment. The mild acidity of the steepwater also begins to loosen gluten bonds within the starch-based products, thereby initiating the mobilising of the starch molecules.
The softened husks are removed and the grain is coarsely ground to break the grain germ, also known as the embryo, loose from other components, such as the endosperm and fiber. The ground grain is carried in a water slurry to cyclone germ separators where the low density germ is spun out of the slurry and retained for further processing, e.g. extraction of oils, while the germ residue may be used in animal feeds.
The starch-based products undergo a second, more severe grinding stage to release the starch and gluten from the fiber in the kernel. The starch and gluten, which is now referred to as “mill starch”, is separated from the fiber and conveyed to starch separators, while the fiber may be treated further for use in animal feeds. The mill starch slurry is passed through a separator, such as a centrifuge, to separate the low density gluten from the starch. The gluten may be used in animal feeds. The starch slurry is diluted and repeatedly washed to remove any remaining protein traces. The starch slurry is then dried to about 12% moisture content and either (i) sold as unmodified starch; (ii) converted into syrups and dextrose; or (iii) chemically modified into specialty starches by applying different reagents, heat and pressure to change the properties of the unmodified starch.
One of the difficulties associated with starch separation processes concerns the addition of SO 2 to the steepwater during conditioning. Although SO 2 may be a good bacteriostat, it is harmful to humans and can result in severe respiratory conditions. Accordingly, special precautionary measures are required in starch processing facilities to provide for the step of SO 2 addition. Also, microbial contaminants tend to become tolerant after exposure to continuously consistent levels of SO 2 , which may decrease the antimicrobial efficacy of SO 2 over time. Finally, SO 2 may also impart an adverse colour taint to the intermediate and final product, thus requiring an intervention with potent oxidising agents to both neutralise its activity as well as to diminish the associated colour taint.
Moreover, after steeping, it is necessary to eliminate any traces of SO 2 before further processing of the starch slurry, especially where it is intended for human or animal consumption applications. This is usually done by adding an oxidant, notably a peroxide composition such as benzoyl peroxide, to the mill starch slurry for neutralisation of the sulfur dioxide.
However, peroxide is an expensive chemical, which increases production costs. In addition, peroxide is highly corrosive in nature, which not only damages process equipment over time, but also complicates material handling protocols in a starch separation process. Moreover, once peroxide is added to the mill starch, any bacteriostatic efficacy of SO 2 is eliminated, hence creating substantial opportunity for microbial and specifically fungal proliferation and consequential spoilage with an increased potential for mycotoxin generation during downstream processing of the mill starch slurry.
One of the ways in which to modify starches chemically involves reducing the size of a starch polymer through oxidation. This is achieved by mixing sodium hypochlorite (NaOCl) into a starch slurry. Sodium hypochlorite cleaves the complex linkages within a starch polymer, as well as the carbon-to-carbon bonds in a dextrose molecule, to produce large carboxyl and carbonyl groups. These groups reduce the tendency of starch to retrograde, give the starch a stickiness that is beneficial for coating foods and in batters, and make the starches more stable.
Electrochemically Activated Aqueous Compositions
It is well known that production of electrochemically activated (ECA) solutions from diluted dissociative salt solutions involves passing an electrical current through an electrolyte solution in order to produce separable catholyte and anolyte solutions. Those who are engaged in the industry will appreciate that catholyte, which is the solution exiting the cathodal chamber, is an anti-oxidant and normally has a pH in the range of from about 8 to about 13, and an oxidation-reduction (redox) potential (ORP) in the range of from about − 200 mV to about − 1100 mV. The anolyte, which is the solution exiting the anodal chamber, is an oxidant and is generally an acidic solution with a pH in the range from about of between 2 and to about 8, an ORP in the range of from about + 300 mV to about + 1200 mV, and a Free Active Oxidant concentration of ≦300 ppm.
During electrochemical activation of aqueous electrolyte solutions, various oxidative and reductive species are present in solution, for example HOCl (hypochlorous acid); ClO 2 (chlorine dioxide); ClO 2 − (chlorite); ClO 3 − (chlorate); ClO 4 − (perchlorate); OCl − (hypochlorite); Cl 2 (chlorine); O 2 (oxygen); H 2 O 2 (hydrogen peroxide); OH − (hydroxyl); and H 2 (hydrogen). The presence or absence of any particular reactive species in solution is predominantly influenced by the derivative salt and the final solution pH. So, for example, at pH 3 or below, HOCl converts to Cl 2 , which increases toxicity levels. At pH below 5, low chloride concentrations produce HOCl, but high chloride concentrations will produce Cl 2 gas. At pH above 7.5, hypochlorite ions (OCl − ) are the dominant species. At pH>9, the oxidants (chlorites, hypochlorites) convert to non-oxidants (chloride, chlorates and perchlorates) and active chlorine (i.e. defined as Cl 2 , HOCl and ClO − ) is lost due to the conversion to chlorate (ClO 3 − ). At a pH of 4.5-7.5, the predominant species are HOCl (hypochlorous acid), O 3 (ozone), O 2 2− (peroxide ions) and O 2− (superoxide ions).
For this reason, anolyte predominantly comprises species such as ClO; ClO − ; HOCl; OH − ; HO 2 ; H 2 O 2 ; O 3 ; S 2 O 8 2− and Cl 2 O 6 2− , while catholyte predominantly comprises species such as NaOH; KOH; Ca(OH) 2 ; Mg(OH) 2 ; HO − ; H 3 O 2 − ; HO 2 − ; H 2 O 2 − ; O 2 − ; OH − and O 2 2− . The order of oxidizing power of these species is: HOCl (strongest)>Cl 2 >OCl − (least powerful). For this reason anolyte has a much higher antimicrobial and disinfectant efficacy in comparison to that of catholyte or commercially available stabilized chlorine formulations when used at the recommended dosage rates.
SUMMARY OF THE INVENTION
The present invention satisfies the needs and alleviates the problems discussed above. In one aspect, there is provided a method of extracting a starch product from a starch source comprising the steps of: (a) steeping the starch source in a steeping liquid and then (b) extracting the starch product from the starch source. The steeping liquid comprises an aqueous anolyte product having a pH in the range of from about 4.5 to about 7.5 and a positive oxidation-reduction potential of at least + 650 mV. The steeping liquid further comprises non-electrochemically activated water. The aqueous anolyte product is present in the steeping liquid in an amount in the range of from about 1% to about 50% by volume.
Examples of starch sources include, but are not limited to: grain products; tuber products; tapioca; nut products; seed products; derivatives of grain, tuber, tapioca, nut or seed products; and combinations thereof.
In another aspect, there is provided a method of extracting a starch product from a starch source comprising the steps of: (a) steeping the starch source; (b) after step (a), producing from the starch source an intermediate product slurry comprising starch and gluten; and (c) after step (b), at least partially separating the starch and the gluten to produce a starch slurry comprising the starch product. The method further comprises adding an aqueous anolyte product to the intermediate product slurry to produce a treated intermediate slurry, the aqueous anolyte product having, when in undiluted form, a pH in the range of from about 4.5 to about 7.5 and a positive oxidation-reduction potential of at least + 650 mV. This method can also optionally further comprise treating the starch source with sulfur dioxide in step (a). The anolyte is preferably added to the intermediate product slurry in a total amount effective to comprise from about 1% to about 20% by volume of the treated intermediate slurry. In addition, the aqueous anolyte product, when in undiluted form, most preferably has a pH of at least 6.0 and a positive oxidation-reduction potation of at least + 900 mV.
In another aspect, there is provided a method of extracting a starch product from a starch source comprising the steps of: (a) steeping the starch source; (b) after step (a), producing from the starch source an intermediate product slurry comprising starch and gluten; and (c) after step (b), at least partially separating the starch and the gluten to produce a starch slurry comprising the starch product. The method further comprises adding an aqueous anolyte product to the starch slurry to produce a treated starch slurry, the aqueous anolyte product having, when in undiluted form, a pH in the range of from about 4.5 to about 7.5 and a positive-reduction potential of at least + 650 mV.
In another aspect, there is provided a method of starch extraction comprising (i) producing from a starch source an intermediate product slurry comprising starch and gluten and then (ii) at least partially separating the starch and the gluten to produce a starch slurry. The method further comprises the step of adding an aqueous anolyte product having a pH of at least 6.0 and a positive oxidation-reduction potential of at least + 900 mV to (a) the intermediate product slurry, (b) the starch slurry, or (c) to both of the intermediate product slurry and the starch slurry in a manner effective to cause the aqueous anolyte product to be present in the starch slurry in a final concentration in the range of from about 1% to about 35% by volume.
In another aspect, there is provided a method of bleaching a starch product which has been extracted from a starch source. The method comprises the step of contacting the starch product with an aqueous anolyte product having, when in undiluted form, a pH in the range of from about 2 to about 5 and a positive oxidation-reduction potential of at least + 1000 mV.
In another aspect, there is provided a method comprising the step, prior to steeping, of contacting a starch source with an aqueous catholyte product having, when in undiluted form, a pH in the range of from about 8 to about 13 and a negative oxidation-reduction potential of at least − 700 mV.
In another aspect, there is provided a method of modifying a starch product which has been extracted from a starch source. The method comprises the step of contacting the starch product with an aqueous anolyte product having, when in undiluted form, a pH in the range of from about 3.5 to about 7.5, a positive oxidation-reduction potential of at least + 650 mV and a Free Active Oxidant concentration of not more than 300 ppm. The starch product will preferably be contacted with the aqueous anolyte product in an amount and in a manner effective for causing the starch product to have an increased Xylose content. Alternatively, or in addition, the starch product can be contacted with the aqueous anolyte product in an amount and in a manner effective for causing at least some sucrose in the starch product to be broken down to form fructose and glucose. Further, the step of contacting the starch product with aqueous anolyte product can involve forming a dough mixture comprising the starch product and the aqueous anolyte product.
In another aspect, there is provided a method of malting barley comprising the step of germinating the barley in an aqueous steeping liquid comprising (i) an aqueous anolyte product having a pH in the range of from about 4.5 to about 7.5 and a positive oxidation-reduction potential of at least + 650 mV and (ii) non-electrochemically activated water. This method can also further comprise the step of steeping the barley in an aqueous catholyte product having, when in undiluted form, a pH of at least 10 and a negative oxidation-reduction potential of at least − 900 mV.
It is an object of the present invention to provide a new method of treating starch-based products during processing in the industrial starch separation and extraction industry to reduce the presence of superficial bacterial and fungal contaminants that may proliferate during steeping, and thereby to reduce the likelihood of new fungal contamination and thus mycotoxin production, while at the same time replacing biocides that are currently used e.g., sulfur dioxide (SO 2 ).
It is a further object of the invention to introduce a non-toxic remedy for in-process usage during treatment of starch-based products, comprising predominantly HOCl, which is substantially more effective at killing harmful pathogens than hypochlorite or molecular chlorine as may be produced with an Aquachlor device.
It is another object of the invention to provide a superficial method of treating starch-based products that will assist in reducing contamination of the extracted grain germ with spoilage microbes so as to improve keeping quality and limit constituent peroxidation, and thus generation of free fatty acids, which may contribute to rancidity of subsequently extracted oil products.
It is a further object of the invention to introduce a food-grade, aqueous-based biocide for in-process use during the treatment and production of starch-based products, more specifically for downstream control of surface microbial biofilm growth, this with a resultant reduction of recontamination from the same biofilm and associated spoilage and pathogenic microbes.
It is yet a further object of the invention to provide a method of treating starch-based products that will increase the percentage of pharmaceutical grade starch produced from food or industrial grade slurry, or alternatively to increase the percentage of food grade product produced from industrial grade starch slurry.
It is also an object of the invention to provide a method of treating starch-based products to modify starches chemically with an oxidant that exhibits higher oxidation efficiency than the currently used sodium hypochlorite.
It is yet another object of the invention to provide a method of mobilizing polymers of raw starch aggregate by cleaving complex covalent and hydrogen bonded molecular linkages, and thereby to modify the aggregate of starch polymers into highly specific and differentiated molecular configurations and thus commercial products, through a reduced reliance on complex and hazardous chemical interventions.
It is yet another object of the invention to provide a method and a solution for the enhanced antimicrobial biosecurity of intermediate starch based products which may be subjected to unplanned transient or extended in-process storage where unchecked microbial growth would adversely impact upon final product quality.
It is a further object of the invention to provide a method for the safe and effective decontamination of both steeping water and barley grain during a malting process, such method having an additional benefit of effecting a reliably synchronous germination of the barley grains, increasing germination yield per unit grain mass, and the consequent production of an optimally consistent percentage of enzymatically converted starch within the endosperm.
Further features, objects, and advantages of the present invention will be apparent to those of ordinary skill in the art upon examining the accompany figures and upon reading the following Detailed Description of the Preferred Embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a chart showing reduction of microbial contamination of in-process starch in Example 1, using anolyte-treated process water.
FIG. 2 is a chart showing changes in the oxidation-reduction potential (ORP) of anolyte solutions of different dilutions.
FIG. 3 is a chart showing changes in the viscosity of a starch slurry treated with incremental volumes of anolyte in Example 4 versus the resulting change in the percentage of solids.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the invention there is provided an in-process, real-time biocide intervention method and composition for treating grains and starch-based products during processing in the industrial starch separation and extraction industry, the method being capable of producing predominantly pharmaceutical grade starch and being characterized in one aspect that the starch-based products are brought into contact with an electrochemically activated aqueous anolyte solution with a pH in the range of from about 4.5 to about 7.5, an ORP in the range from about + 650 mV to ≧ + 900 mV and a Free Active Oxidant concentration of ≦300 ppm, during steeping and beyond.
The anolyte once added to the various aqueous based phases of the process, will impart distinctive physiochemical attributes such as pH, electrical conductivity, ORP and Free Active Oxidant concentration. These parameters in turn reflect a direct causal relationship with antimicrobial efficacy based on an inverse relationship between microbial bioload and anolyte dilution applied. Thus, these parameters display a direct correlation to the quality of the aqueous phase being treated as well as the dilution at which the anolyte was added.
These parameters can be measured on a real-time basis so as to reliably predict the antimicrobial capacity of the treated aqueous phase.
The anolyte may be produced by electrochemically activating a dilute aqueous saline solution preferably comprising from about 1 to about 9 grams of salt per liter of water. The saline solution will more preferably comprise from about 2 to about 3 grams of salt per liter of water.
The salt will preferably be any inorganic salt. In particular, the salt will preferably be non-iodated sodium chloride (NaCl) or potassium chloride (KCl).
The method may include the step of on-site generation of the anolyte solution, comprising the steps of: electrochemically activating a dilute electrolyte solution in an electrochemical reactor comprising an anodal and a cathodal chamber and being capable of producing separable electrochemically activated aqueous anolyte and catholyte solutions; separately harvesting the catholyte solution; and reintroducing the catholyte solution into the anodal chamber in the absence of any fresh water; and manipulating the flow rate, hydraulic flow configuration and regimen, pressure and temperature of the catholyte through the anodal chamber, so as to produce a preferred anolyte solution that is characterized therein that it predominantly includes the species HOCl (hypochlorous acid), O 3 (ozone), O 2 2− (peroxide ions) and O 2− (superoxide ions), and has a Free Active Oxidant concentration of ≦1000 ppm but preferably in the range of from about 100 to about 500 ppm.
The pH of the anolyte will preferably be in the range of from about 5.5 to about 7.
The method may provide for introducing the anolyte into process steepwater. The anolyte may be introduced into the steepwater at a concentration of up to 50% by volume. Preferably, the anolyte will be introduced into the steepwater at a concentration of less than 20% in corn or maize steeping solutions, and less than 35% in tuber and other grain steeping solutions.
The method may provide for the continuous and/or episodic interventions at single and/or multiple aspects for the treatment of the process water so as to comply with the maintenance of the Oxidation-Reduction Potential (ORP) of the same, this to ensure that the predictive relationship between the minimum microbiocidal and measured oxidant reactivity of the process water is maintained.
The method may include a further step of selectively administering anti-oxidant electrochemically activated aqueous catholyte solution as a pre-steeping wash for superficial mycotoxin neutralization, the catholyte preferably having a pH in the range of from about 8 to about 13, and a negative ORP of more than or equal to − 700 mV (preferably an ORP in the range of from about − 700 mV to about − 1000 mV) for a period of exposure that is commensurate with the degree of mycotoxin elimination required and which is tolerated during commercial scale detoxification appropriate to the industry sector.
The anolyte may be introduced at a temperature as per standard operating conditions. The anolyte will preferably be introduced at a temperature in the range of from about 5° C. to about 45° C.
The method may include the further step of bleaching the separated starch by washing it in an acidic anolyte with a pH in the range of from about 2 to about 5 and an ORP of ≧1000 mV. This distinctive anolyte solution could be applied at any appropriate treatment point after the starch slurry has undergone separation from the raw fiber, gluten and other non-starch components in the “wet mill”. The treatment points would typically comprise bulk holding, transfer vessels or allied reticulation systems prior to further manipulation and/or dehydration, spray and flash drying.
The method also may include the further step of selectively adding anolyte with a pH in the range of from about 6.0 to about 6.5, an ORP of ≧ + 950 mV, and a Free Active Oxidant concentration≦300 ppm to mill starch slurry during downstream processing of the same, as well as to the final extracted starch component, so as continuously to neutralize residual microbial contaminants, as well as to effect a residual disinfection of downstream process equipment for control of potentially recontaminating biofilm growth. The anolyte may be introduced into the mill starch slurry or the final extracted starch component at a concentration of up to 20% by volume. The points of application in the overall process flow will preferably correspond with the targeted microbe biocide contact period as described by the minimum dwell time within the process, itself correlated with the magnitude of anolyte dilution and the minimum levels of microbial decontamination required within the treated starch slurry, this prior to it undergoing further processing and/or dehydration, spray and flash drying.
Typically, large volume batch sizes would require extended processing time and thus protracted storage periods without the bacteriostatic benefits of sulfur dioxide or equivalent agents which would have been neutralised at the time of transfer from the wet mill. Thus the treatment of these slurry types with anolyte immediately after SO 2 or equivalent neutralisation, would be optimal for maintaining a non-tainting, and residual, aqueous based biocidal capacity and capability where optimal microbial control under extended storage periods for the starch slurry may be required.
The invention also extends to the use of electrochemically activated aqueous anolyte solution as a steeping agent during a starch-separation and extraction process, comprising the step of bringing the starch-based products into contact with an anolyte solution with a pH in the range of from about 4.5 to about 7.5 and an ORP in the range of from about + 650 mV to ≧ + 900 mV, by introducing the anolyte into process water.
The invention further includes an electrochemically activated aqueous anolyte solution with a pH in the range of from about 4.5 to about 7.5 and an ORP in the range of from about + 650 mV to ≧ + 900 mV for use as a treatment agent added to the process water used during the steeping and modification of the starch-based products.
The invention also extends to the use of an electrochemically activated aqueous anolyte solution as an oxidant for use in starch modification processes to cleave covalent and hydrogen bonded starch polymer linkages in the aggregate starch molecule, the use comprising the step of bringing an unmodified extracted starch component into contact with an anolyte solution with a pH in the range of from about 3.5 to about 7.5, an ORP in the range of from about + 650 mV to ≧ + 900 mV and a Free Active Oxidant concentration of ≦300 ppm. This heightened capacity to cleave starch polymer bonds is reflected by an increase in the levels of short chain length starch molecules and an equivalent reduction in the viscosity of the anolyte treated starches. These strategic interventions may also employ further increased temperature manipulation to optimize the degree of starch polymer disruption and the equivalent measure of viscosity change.
The invention also includes an electrochemically activated aqueous anolyte solution with a pH in the range of from about 4.5 to about 7.5, an ORP in the range of from about + 650 mV to ≧ + 900 mV, and a Free Active Oxidant concentration of ≦300 ppm, for use as an oxidant during starch modification processes.
The invention includes an electrochemically activated aqueous anolyte solution with a pH in the range of from about 4.5 to about 7.5, an ORP in the range of from about + 650 mV to ≧ + 900 mV, and a Free Active Oxidant concentration≦300 ppm, for use as a treatment agent of process water for the steeping and germination of barley grains during a malting process.
Without limiting the scope thereof, the invention will now further be described and exemplified with reference to the following examples and experimental results.
EXAMPLE 1
Electrochemically activated aqueous solutions were generated on-site at a commercial maize or corn-based starch processing mill. An electrochemically activated aqueous anolyte solution with a pH of 6.5, an ORP of ≧ + 900 mV and a Free Active Oxidant concentration of ≦300 ppm was added into the mill starch slurry upon transfer from the “wet mill” to the final modification and drying infrastructure. The anolyte was added at strategic intervention points along various progressive aspects of the final product modification and dehydration process flow. These intervention points comprised but were not restricted to the starch slurry transfer tanks, the washed starch tanks, the centrifuge transfer tanks, relieved and equivalent centrifuges, centrifuge backwash tanks, countercurrent differential extraction cyclones (Dorrclones), vent boxes, Merco centrifuges and underflow and filtrate tanks. Anolyte was added at a final volumetric inclusion rate of 1% to 2% by volume per total resulting volume at the level of the starch transfer tank immediately after neutralization of sulfur dioxide (SO 2 ), at ≦10% by volume per total resulting volume at the wash starch tanks, and at a rate of ≦35% by volume per total resulting volume in the counter-current extraction cyclones. This equates to a Free Active Oxidant concentration of between 1 and 300 ppm, but preferably a level between 1 and 60 ppm at each of the respective intervention points. In addition, catholyte solutions with a pH of ≦11.0 and a negative ORP of more than or equal to − 800 mV (preferably an ORP in the range of − 800 mV to about − 1000 mV) were used for the mobilization of general organic soiling as well as biofilm removal and general surface cleaning as well as selective pH and anti-oxidant starch manipulation.
TABLE 1
Microbial in-process starch department: Anolyte trials
(immediately prior to beginning treatment):
TPC
Yeast
Moulds
Sample point
cfu/g
Cfu/g
cfu/g
Other
Slurry from milling
—
—
—
—
Slurry storage tank I
>10000
>10000
<10
Bacillus
DC Slurry supply tank
>10000
>10000
<10
Bacillus , NFC
Starch pre-DC
>10000
>10000
<10
Bacillus , Yeast
Starch from the DC
>10000
>10000
<10
Bacillus , Yeast
DC wash water supply
1
0
0
No growth
Tank
Washed starch tank
>10000
>10000
<10
Bacillus , NFC,
Yeasts
Feed tank A
>10000
>10000
<10
Bacillus , NFC,
Yeasts
Feed tank B
>10000
>10000
<10
Bacillus , NFC,
Yeasts
Reineveld A
>10000
>10000
<10
Bacillus , NFC,
Yeasts
Reineveld B
>10000
>10000
<10
Yeasts, NFC
Stirring Pan
>10000
>10000
<10
Yeasts, NFC
Hammer mill inlet/supply
>10000
3840
<10
Yeasts, NFC
Filtrate tank
>10000
>10000
<10
Yeasts, NFC
Legend:
TPC—Total Plate Count,
cfu/gm—colony forming units per gram.
TABLE 2
In-process anolyte dosing (5 hours later):
TPC
Yeast
Moulds
Sample point
cfu/s
cfu/g
cfu/g
Other
Slurry from milling
—
—
—
—
Slurry storage tank 1
3360
4160
<10
Bacillus
DC Slurry supply tank
2160
2880
<10
Bacillus , Yeast
Starch pre-DC
2650
3200
<10
Bacillus , Yeast
Starch from the DC
1120
560
<10
Bacillus , Yeast
DC wash water supply tank
0
0
0
no growth
Washed starch tank
320
10
<10
Bacillus
Feed tank A
1520
1920
<10
Bacillus , NFC
Feed tank B
3040
4080
<10
Bacillus , NFC
Reineveld A
560
360
<10
Bacillus
Reineveld B
6720
>10000
<10
Bacillus , NFC
Stirring Pan
1200
1040
<10
Bacillus , NFC
Hammer mill inlet/supply
50
<10
<10
Bacillus
Filtrate tank
2560
3360
<10
Bacillus , NFC
Legend:
TPC—Total Plate Count,
cfu/gm—colony forming units per gram.
TABLE 3
End of batch specifications: (3 days later)
TPC
Yeast
Moulds
Sample point
cfu/g
cfu/g
cfu/g
Other
Slurry from
410
<10
<10
Bacillus
milling
Slurry storage
—
—
—
—
Tank I
DC Slurry
—
—
—
—
supply tank
Starch pre-DC
—
—
—
—
Starch from
—
—
—
—
the DC
DC wash
—
—
—
—
water supply
tank
Washed starch
10
<10
<10
Bacillus , Yeasts
tank
Feed tank A
—
—
—
—
Feed tank B
300
100
<10
Bacillus
Reineveld A
—
—
—
—
Reineveld B
<10
<10
<10
Bacillus
Stirring Pan
30
<10
<10
Bacillus
Hammer mill
10
<10
<10
Bacillus
inlet/supply
Filtrate tank
>10 000
>10 000
10
Bacillus , NFC,
Yeasts
Continuous administration of anolyte into the starch slurry results in a progressive reduction in the level of microbial contaminants throughout the downstream intermediate and final starch products. Additionally, intervention with the catholyte solutions substantially contributed to the continuous control of cross and recontamination of in-process starch products
EXAMPLE 2
Impact of an Integrated Addition of Electrochemically Activated Anolyte Solution on the Microbial Bioload of Intermediate Starch Products, when Applied Throughout the Process Infrastructure in a Maize Based Starch Milling Plant
Anolyte solutions having an ORP of ≧850 mV, a pH of 6.7, and a Free Active Oxidant concentration of ≦300 ppm were applied, in various volumetric dilutions ranging from 1 to 50 volume %, to the in-process mill starch slurry as a means to progressively decontaminate intermediate and final starch products, as well as to remove residual recontaminating biofilm from downstream process surfaces of the maize or corn starch mill equipment infrastructure.
FIG. 1 provides a graphic representation of the anolyte antimicrobial efficacy results showing the significant reduction of microbial contaminants between the two sampling days (Day 1 and Day 56), as well as the consequential reduction in microbial contamination when the anolyte was added to the slurry after the point of supply from the wet mill. This effect was consistently associated with the strategic intervention with Anolyte throughout the overall process flow.
EXAMPLE 3
Anolyte in the Equivalent Dilutions and at the Prescribed Intervention Points as Detailed in Example 1, was Added to Starch Mill Slurry and the Final Commercial Product was Assessed for Compliance with Internal Microbial Specifications
TABLE 4
Anolyte trials 03 June: Modified starch
Batch no
TPC cfu/g
Yeasts
Moulds
Other
Grade
M3669
90
20
<10
BACILLUS , NFC
FOOD
M3670
1400
740
<10
BACILLUS , NFC
FAIL
M3671
2640
360
<10
BACILLUS , NFC
FOOD
M3672
210
90
<10
BACILLUS , NFC
FOOD
Legend:
TPC—Total Plate Count,
cfu/gm—colony forming units per gram.
TABLE 5
Anolyte trials 07 June: Modified Starch
Batch no
TPC cfu/g
Yeasts
Moulds
Other
Grade
M3681
180
30
<10
BACILLUS
FOOD
M3682
130
20
40
BACILLUS
FOOD
M3685
60
<10
10
BACILLUS
FOOD
Legend:
TPC—Total Plate Count,
cfu/gm—colony forming units per gram.
TABLE 6 Anolyte treatment: White low moisture starch Production rate TPC cfu/g Yeasts Moulds Other Grade 28/Sept. 40 <10 <10 Bacillus Pass - pharma grade 28/Sept. 30 <10 <10 Bacillus Pass - pharma grade 30/Sept. 20 <10 <10 Bacillus Pass - pharma grade 30/Sept. 40 <10 <10 Bacillus Pass - pharma grade 30/Sept. 30 <10 10 Bacillus Pass - pharma grade 01/Oct. 310 20 10 Bacillus Pass - pharma grade 01/Oct. 480 <10 <10 Bacillus Pass - pharma grade 02/Oct. 290 <10 <10 Bacillus Pass - pharma grade 03/Oct. 10 <10 <10 Bacillus Pass - pharma grade Legend: TPC—Total Plate Count, cfu/gm—colony forming units per gram.
Results
Consistent and continuous addition of anolyte solutions to in-process mill starch slurry results in a progressive reduction of microbial contamination of finished product, with a reliable and predictable attainment of the highest grade of commercial product based on the level of microbial contaminants.
EXAMPLE 4
Correlation Between Changes in ORP (Oxidation Reduction Potential), pH and Electrical Conductivity Measurements as a Result of Progressive Dilution, and Antimicrobial Efficacy
Anolyte was generated from two different salt types i.e. Sodium Chloride and Sodium Bicarbonate (ORP≧ − 900 mV and pH 7±0.5) and was diluted with a variety of tap water, distilled water and deionized water. The ORP was measured with a commercial REDOX probe that had been calibrated against a commercial reference solution of 475 mV. (Eutech instruments—Singapore)
FIG. 2 shows that progressive linear dilutions of Anolyte with tap water (S1 and S2) resulted in a non-linear change of the ORP. This disparate relationship is attributed to the buffering capacity of the treated water to limit linear attenuations of electrical charge and affords a reliable measure of predictability of ORP when the anolyte solution has been diluted in water media of different quality.
A commercial strain of Bacillus subtilis was grown on recognized standard culture media and was diluted to the final numerical count using half strength Ringers solution. Anolyte was generated to the specifications as detailed above and diluted in tap water in a non-linear dilution series. Fixed aliquats of microbes ( B. subtilis ) at predetermined bioload strengths were exposed to the various anolyte dilutions as detailed below.
TABLE 7 Correlation between microbial growth as a function of different microbial bioload challenges and anolyte diluted in a non-linear series. (Test micro-organism: Bacillus subtilis ) ORP Anolyte Microbial count - cfu/ml (mV) concentration 10 6 10 5 10 4 10 3 10 2 958 Neat No No No No No growth growth growth growth growth 842 1:10 No No No No No growth growth growth growth growth 784 1:50 Growth Growth No No No growth growth growth 468 1:100 Growth Growth No No No growth growth growth 386 1:1000 Growth Growth Growth Growth Growth 377 1:10 000 Growth Growth Growth Growth Growth Legend - cfu/ml—colony forming units per milliliter of final solution
Conclusion:
Exposure of fixed aliquats of solutions with known microbe numbers to anolyte solutions of different strengths resulted in a reliable correlation between anolyte dilution and microbial viability. There was a direct correlation between the measure of microbial viability and the ORP measurement at the equivalent dilution series as detailed in FIG. 2 and it is thus suggested that ORP is a reliable indicator of microbial viability at different levels of bioload.
EXAMPLE 5
Changes Associated with Incremental Dosing of Anolyte into the Wash Starch Tank at an Industrial Starch Mill
Incremental volumetric dosing of anolyte solutions into the mill starch slurry was undertaken to establish the impact on the physicochemical characteristics of the treated starch.
(Food And Pharmaceutical Grade White Corn Starches at 21Be′)
TABLE 8 Changes in physiochemical parameters of starch slurry when dosed with incremental volumes of anolyte. DB Slurry (kg/h) Viscosity Into (Be) Anolyte Vis- wash Into wash Slurry Added Slurry cosity starch starch in (liter/ out (Be) % tank tank (kg/h) h) (kg/h) out Solids 4522 21.0 12117.8 0 12117.9 21.0 37.320 4522 21.0 12117.8 100 12217.8 20.8 37.016 4522 21.0 12117.8 200 12317.8 20.7 36.716 4522 21.0 12117.8 300 12417.8 20.5 36.420 4522 21.0 12117.8 400 12517.8 20.3 36.129 4522 21.0 12117.8 500 12617.8 20.2 35.843 4522 21.0 12117.8 600 12717.8 20.0 35.561 4522 21.0 12117.8 700 12817.8 19.9 35.283 4522 21.0 12117.8 800 12917.8 19.7 35.010 4522 21.0 12117.8 900 13017.8 19.6 34.741 4522 21.0 12117.8 1000 13117.8 19.4 34.477 4522 21.0 12117.8 1100 13217.8 19.3 34.216 4522 21.0 12117.8 1200 13317.8 19.1 33.959 4522 21.0 12117.8 1300 13417.8 19.0 33.706 4522 21.0 12117.8 1400 13517.8 18.8 33.456 4522 21.0 12117.8 1500 13617.8 18.7 33.211 4522 21.0 12117.8 1600 13717.8 18.6 32.969 4522 21.0 12117.8 1700 13817.8 18.4 32.730 4522 21.0 12117.8 1800 13917.8 18.3 32.495 Legend: DB—Dry Basis mass, Be—‘Baume’ as an indicator of % solids or specific gravity/density.
Results
The incremental addition of anolyte to mill starch slurry did not have an adverse or uncontrolled impact upon the relationship between the viscosity and specific gravity (SG) of the slurry and the percentile of solids present in the same. Changes in SG and viscosity were recognized to be predictable as a direct result of a dilution effect. Anolyte is thus an effective additive to control microbial contaminants at variable inclusion levels without impacting upon the integrity of the predictive ratios of the ingredient parameters recognized in starch production.
EXAMPLE 6
Changes in the Dextrin Components of a Wheat Starch Flour when Exposed to Different Types of Anolyte at Different Stages of Starch Processing
A HPLC (High Pressure Liquid Chromatograph) assay was undertaken to establish the effect on the relative concentrations of various dextrin components of starch polymers after exposing wheat starch at different stages of processing to different types of anolyte.
Commercial white bread flour with a protein content of 11.8% was obtained from a wheat mill and was used as an ingredient in the standard Chorleywood white bread recipe. The water component of the recipe (≦40% by mass of the dough) was either untreated (Code D), treated with Sodium Bicarbonate Anolyte (S2—Code B) at an inclusion rate of 50 vol. % of total or with Sodium Chloride Anolyte (S1—Code C). Untreated flour (Code A) was included to assess the direct impact of untreated or anolyte treated water upon the relative dextrin concentrations.
Wheat grains were either conditioned with untreated tap water (Code A-D) or tap water with a 35 vol. % of total inclusion of Sodium Chloride Anolyte (S1) (Code E-G). These conditioned grains were then milled in accordance with standard commercial milling practices and the flour was submitted as an ingredient to the standard Chorleywood white bread recipe. Anolyte was added to the water component of the bake mix as either 50% of volume (S2) or 35% by volume for S1.
TABLE 9 Fermentable sugar concentration of wheat starch after exposure to two types of anolyte solution Xylose Fructose Sucrose Glucose Code Treatment type μg/g A Mill flour 0.00 6248.30 7959.65 2540.30 B Mill flour + 50% S2 dough 8309.90 5277.85 0.00 14751.95 C Mill flour + 35% S1 dough 35075.90 5046.60 0.00 15610.05 D Mill flour + Tap water dough 0.00 0.00 0.00 3578.10 E 35% S1 conditioned grain 0.00 5801.10 8811.65 2630.70 F 35% S1 conditioned grain + 50% S2 dough 11062.45 5147.90 0.00 23137.75 G 35% S1 conditioned grain + Tap Water 31657.40 5039.45 0.00 17547.65 dough Legend: μg/g—micro grams per gram.
Results:
It is readily apparent that inclusion of anolyte into the mill flour dough mixture results in a substantial increase in the amount of Xylose that is produced, and that the sodium chloride anolyte when added to the mill flour was more effective in the generation of Xylose than was anolyte generated with Sodium Bicarbonate. Additionally it was conclusively demonstrated that the inclusion of the oxidant anolyte solutions in the dough mix resulted in the breakdown of the sucrose component of the dough mix into its constituent Fructose and Glucose molecules (B, C, F & G). In contrast to using flour conditioned with Tap water (A-D), the conditioning of the grain with 35% S1 Anolyte resulted in a substantial increase in Xylose concentration, even when the flour from the anolyte conditioned grain was mixed with tap water (G). Additionally, dry flour derived anolyte conditioned grains, when subjected to HPLC analysis also revealed a significant increase in glucose and fructose sugars, thus substantiating the assertion that anolyte when applied as a conditioning solution or as an ingredient of a dough mix does have the distinctive capability above and beyond that of tap water to modify the profile of fermentable sugars generated during the grain milling and dough production processes.
Additionally, the increased concentrations of Xylose generated from starch polymers after exposure to anolyte, supports the contention that the enhanced positive oxidation reduction potential (ORP) of Anolyte has the capacity to cleave the relatively highly energized covalent bonds between adjacent carbon molecules, in addition to being able to disrupt the hydrogen bonding between the starch polymers normally attributed to an untreated water ingredient.
EXAMPLE 7
Application of Anolyte as a Means to Synchronize the Germination of Barley Seeds in the Malting Process for Beer Production
Commercial barley grains used in the standard malting process were steeped in a variety of solution permutations comprising tap water and anolyte or catholyte and anolyte, and tap water for a 24 hour period. Thirty grains were allocated to each treatment group. The anolyte solution was generated at an ORP of ≧900 mV, a Free Active Oxidant concentration of ≦300 ppm and a pH=6.5, while the catholyte had a negative ORP of more than or equal to − 900 mV (preferably an ORP in the range of − 900 mV and − 1000 mV) and a pH of ≧10.
The concentration of the anolyte used in the aqueous anolyte steeping solution was 50% by volume. In general, the anolyte will preferably be present in the aqueous anolyte steeping solution in an amount in the range of from about 30% to about 100% by volume.
The concentration of the catholyte used in the aqueous catholyte steeping solution was 60% by volume. In general, the catholyte will preferably be present in the aqueous catholyte steeping solution in an amount in the range of from about 40% to about 100% by volume.
The grains of group A were treated with tap water for 24 hours and then irrigated with tap water for 2 days. The grains in group B were soaked in anolyte for 24 hours and then irrigated in anolyte for a further 2 days. Group C were treated with anolyte for 5 hours, Catholyte for 19 hours and then irrigated with tap water for 2 days and finally, group D was irrigated in anolyte for 24 hours with a further 48 hour irrigation with tap water. The grains from each treatment group were evaluated for the measure of consistency of stage of germination after a three day period. At day 7, all root lengths were measured and equated to the root length measures of the germinated grains in the tap water control group (A)
TABLE 10
Changes in germination viability of barley grains
after exposure to Tap Water, Anolyte, Anolyte
and Catholyte and Anolyte and Tap water.
Treatment
Irrigation
Viability
Root length vs
Group
solution
solution
(%)
control
A (Control)
Tap Water
Tap water
80
—
B
Anolyte
Anolyte
3.3
−20%
C
Anolyte +
Tap Water
100
+58%
Catholyte
D
Anolyte
Tap water
96.7
+6.7%
Optimal germination was obtained with a combination of anolyte exposure of 5 hours, catholyte exposure for 19 hours, and tap water irrigation for 48 hours. Excessive exposure of the grains to anolyte resulted in a substantially reduced viability, while exposure to anolyte with subsequent tap water irrigation yielded less significant increases relative to the tap water control grains.
Strategic application of anolyte and catholyte during the first 24 hours of treatment of germinating wheat grains yields a reduced duration to germination, an increased rate of germination, and a greater percentage of viability.
CONCLUSION
The anolyte solution of the invention provides an added benefit in that, in addition to its broad based antimicrobial efficacy, it is able simultaneously to sanitize steeping equipment, such as screw conveyors and hydrators, as well as downstream processing and milling equipment—a simultaneous “in-process” plant and product disinfectant, as it were.
Additionally, we have discovered and shown that ORP is a reliable measure of potential antimicrobial efficacy of the anolyte solutions at different dilution rates and that with a prior knowledge of the extent of microbial bioload (cfu/ml) in a system, the anolyte solution required to eliminate microbial contamination can be accurately titrated on the basis of this relationship.
We have also demonstrated that the elevated ORP's of the electrochemically activated anolyte and catholyte solutions have the capacity to selectively manipulate the starch polymer aggregates and mono-molecules of starch derivatives into highly specific and differentiated molecular configurations of distinctive economic and performance criteria.
Thus, the present invention is well adapted to carry out the objectives and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those of ordinary skill in the art. Such changes and modifications are encompassed within this invention as defined by the claims. | A method of starch extraction, starch modification, and/or malting comprising (a) steeping a starch source in the presence of an aqueous anolyte product, (b) adding an aqueous anolyte product to an intermediate product extraction slurry comprising starch and gluten, (c) adding an aqueous anolyte product to a starch product slurry produced by separating the starch and gluten, (d) contacting an extracted starch product with a type and amount of an aqueous anolyte product effective for modifying the starch product and/or (e) steeping the starch source in the presence of an aqueous catholyte product. | 2 |
BACKGROUND OF THE INVENTION
The present invention generally relates to copper-filled vias in ceramic substrates and, more particularly, to a copper-based paste containing copper aluminate powder in proper particle size and weight proportion for grain size and shrinkage control of the via and thick film copper produced by sintering.
The use of copper-filled vias in ceramic substrates and sintering processes for producing them are well known in the semiconductor packaging art as taught, for example, in U.S. Pat. No. 4,234,367, issued on Nov. 18, 1980 to Lester W. Herron et al. and assigned to the present assignee, the disclosure of which is incorporated by reference herein. Recently, more interest has been focused on the associated problems of the disparity in shrinkage rates between copper and ceramic as well as the onset of via "opens", particularly as via diameters are reduced below 100 μm in high circuit density applications. A discussion of such problems is given in U.S. Pat. No. 4,776,978, issued on Oct. 11, 1988 to Lester W. Herron et al. and assigned to the present assignee, the disclosure of which is incorporated by reference herein.
As set forth in the cited U.S. Pat. No. 4,776,978 patent, metal particles, such as copper, in the via paste undergo sintering with attendant shrinkage of the thick film pattern (also consisting of the paste) during the initial phase of the sintering cycle whereas the ceramic and glass particles (of the ceramic substrate containing the vias) undergo sintering during the intermediate and final phases of the sintering cycle along with their characteristic shrinkage. One method of delaying the onset of sintering of the metal particles until at least the intermediate phase of the sintering cycle is to intersperse the metal particles in the thick film with a high melting point material such as aluminum oxide.
Although the foregoing generalized considerations have been known in the art for some time and have provided the basis for techniques for overcoming previous shrinkage and related problems, more refined and detailed approaches are required to meet the needs of copper-filled vias in ceramic substrates with increasing circuit densities and the concomitant via diameters in the range of about 85 to 100 μm. It is also desirable to provide a copper paste mixture which can be adapted for use with the next generation of ceramic packages which exhibit reduced shrinkage from sintering.
The following references illustrate previous techniques attempting to overcome shrinkage and other problems.
U.S. Pat. No. 4,594,181, issued on Jun. 10, 1986 to Vincent P. Siuta, teaches the dispersal of copper particles in a solution of an organometallic compound in an anhydrous volatile organic solvent towards obtaining a better shrinkage match of copper to ceramic substrate during sintering.
U.S. Pat. No. 4,599,277, issued on Jul. 8, 1986 to James M. Brownlow et al., discloses the addition of an organometallic compound to a metal member such as copper paste which compound undergoes decomposition during sintering to provide a coating such as aluminum oxide on the copper particles towards obtaining better shrinkage match between copper and ceramic substrate during sintering.
Published European Patent Application, Publication No. 0272129, published Jun. 22, 1988 by Hitoshi Suzuki et al., describes a paste composition including a copper powder and an organometallic compound such as an organoaluminate compound, towards obtaining improved adhesion strength of sintered copper to a ceramic substrate.
U.S. Pat. No. 4,906,405, issued on Mar. 6, 1990 to Seiichi Nakatani et al. and Japanese Patent J63095182, issued on Apr. 26, 1988 to Goei Seisakusho KK, teach a paste made of copper oxide, and CuAl 2 O 4 as an additive towards obtaining improved adhesion strength of sintered copper to a ceramic substrate.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a copper paste with appropriate additive to produce copper grain size in the range of about 5 to 15 μm after sintering.
Another object is to provide a copper paste with an appropriate additive to substantially match the shrinkage of the resulting copper material to the shrinkage, if any, during sintering of a ceramic substrate having vias filled with said copper paste.
A further object is to provide a copper paste with an appropriate additive to provide substantially reduced shrinkage after sintering of the copper material in low shrinkage porous ceramic substrates having vias filled with said copper paste.
These and other objects of the present invention, as will be seen from a reading of the following specification, are achieved in a preferred embodiment of the present invention by the provision of a copper paste comprising copper powder, up to about 10 weight percent copper aluminate powder, and the remainder organic material. Use of copper aluminate in one preferred range from about 0.4 to about 1 weight percent provides the dual benefits of grain size control as well as shrinkage matching control of the via copper during sintering.
It is preferred that the size of the copper aluminate particles be in the range of about 3.0 μm or less because the amount of copper aluminate required for grain size control of the sintered Cu varies inversely with copper aluminate particle size.
In a preferred embodiment of the invention, glass-ceramic particles are added to the copper-based paste to provide a shrinkage match during sintering that is substantially identical to that of a glass-ceramic substrate.
DETAILED DESCRIPTION OF THE INVENTION
Multilayered glass-ceramic packages for supporting and interconnecting microelectronic chip devices can be sintered to a peak temperature greater than 950 ° C. Because of the high temperatures, the chip interconnecting copper conductors tend to experience exaggerated grain growth in the vias and in the thick film copper wiring lines.
The growth of large grains in copper is not desirable from the point of view of reliability. The reason for this is that the plasticity of copper varies with the orientation of two neighboring large copper grains and the grains may separate when they are cooled down from high temperature and on subsequent thermal cycling. Inasmuch as the conductor size in both the vias and surface lines is about 70-100 μm, it is desirable to keep the copper grain size after sintering as small as possible, namely about 5-15 μm.
In accordance with a first aspect of the present invention, copper grain size is minimized in a sintering cycles such as the one disclosed in the aforementioned U.S. Pat. No. 4,234,367 patent. Copper grain size is minimized by adding a small amount of copper aluminate powder to copper powder, mixing with suitable organics to form a paste, and then screening the paste using a mask on to a green sheet. The green sheet may comprise a variety of materials including, but not limited to, mullite, borosilicate glass, cordierite glass, ceramic, etc. The cordierite glass ceramic materials, such as that disclosed in Kumar et al. U.S. Pat. No. 4,301,324, the disclosure of which is incorporated by reference herein, are preferred. Preferably, the copper powder has an average particle size of about 5-8 μm and the copper aluminate powder has an average particle size of about 3.0 μm or less.
There are two forms of copper aluminate, namely cupric aluminate (CuAl 2 O 4 ) and cuprous aluminate (CuAlO 2 ). Unless specifically stated otherwise, whenever copper aluminate is mentioned in this specification, it should be understood that copper aluminate is being used in the generic sense to include cupric aluminate and cuprous aluminate, both of which should be considered to be within the scope of the present invention.
When suitable conditions are present in a sintering cycle such as taught in the U.S. Pat. No. 4,234,367 patent, copper aluminate decomposes into copper and alumina according to the following reactions:
CuAl.sub.2 O.sub.4 +H.sub.2 =Cu+Al.sub.2 O.sub.3 +H.sub.2 O
2CuAlO.sub.2 +H.sub.2 =2Cu+Al.sub.2 O.sub.3 +H.sub.2 O
The alumina particles produced by the foregoing decomposition reactions are very small, submicron in size, and are distributed inside the copper matrix. The presence of a small amount of porosity and the small alumina particles inside the copper matrix have been found to inhibit copper grain growth and result in small copper grains after sintering at high temperature in excess of 950° C.
More particularly, the unique use of powdered copper aluminate in the copper paste, in accordance with the present invention, has the special property of yielding grain size control of the sintered copper.
By adding powdered copper aluminate to copper paste, preferably in the range 0.2-1.0% by weight, the sintered copper grain size can be kept small. More importantly, the maximum grain size can be kept under about 20 μm, which improves the reliability of multilayer ceramic packages having copper conductors. It should be noted that by decreasing the particle size of the copper aluminate powder, smaller copper grain sizes can be obtained with lower weight percentage additions of the copper aluminate to the copper paste.
In general terms, grain size control is the predominant effect when the powdered copper aluminate paste additive is present up to about 1 weight percent. Grain size control aids in avoiding opens (breaks) in the sintered copper vias and circuits which have been experienced using other paste additives which produce much larger copper grain sizes after sintering.
It has been found that additions to the sintering paste of copper aluminate up to about 10 weight percent are useful for controlling the shrinkage of the sintered copper. With increasing amounts of copper aluminate, but not greater than about 10 weight percent, the sintered copper becomes porous, i.e., the copper particles continue to shrink microscopically but not on a macro (global) scale. At about 10 weight percent copper aluminate, the copper no longer undergoes shrinkage upon sintering. It is more preferred that the copper aluminate be kept at about 3 weight percent or less since at higher amounts of copper aluminate, the sintered copper has lower strength and increased electrical resistivity.
It has further been found that shrinkage control is possible when there is present, as a minimum, a small but effective amount of copper aluminate. The lower limits have not been determined yet with precision. It is known that about 0.01 weight percent of alumina will induce shrinkage control. It is assumed, therefore, that amounts of copper aluminate (about 0.02 weight percent) that will yield about 0.01 weight percent alumina will also achieve similar shrinkage control, given similar particle sizes. Smaller amounts of copper aluminate are likely to be effective if the particle size of the copper aluminate, now at about 3.0 μm, is reduced further.
As is apparent, the effects of grain size control and shrinkage control may advantageously overlap at small amounts of copper aluminate additions.
It would be most desirable to match or substantially match shrinkage characteristics during sintering of the copper vias and lines with that of a glass-ceramic, particularly a cordierite glass-ceramic, material. Thus, in a preferred embodiment of the invention, there is proposed a copper-based sintering paste comprising copper particles, glass-ceramic particles, copper aluminate, and suitable organic binder materials. Based on volume percent of the inorganic solids, the paste comprises about 90 volume percent copper particles, about 5 to 12 volume percent glass-ceramic particles and about 0.3-1.5 volume percent copper aluminate.
It is preferred that the copper particles have a bimodal distribution. Although a unimodal distribution of the copper particles (preferably having an average particle size of 5-8 μm) will also work well. More preferably, there should be about 60-90 volume percent copper particles having an average particle size of 5 to 6 μm and 0-30 volume percent of copper particles having an average particle size of 1.5 to 2.0 μm. Also preferably, the copper aluminate particles should have an average particle size of 0.7 to 3.0 μm.
It is anticipated that the present invention will have applicability to many glass-ceramic materials. The preferred glass-ceramic materials, however, are the cordierite glass-ceramics disclosed in the Kumar et al. U.S. Pat. No. 4,301,324. The average particle size of the glass-ceramic particles should be about 3.5 μm.
The advantages of the present invention will become more apparent after referring to the following examples.
EXAMPLES
Examples I
A series of samples were prepared comprising copper particles and varying amounts of copper aluminate in order to determine the efficacy of copper aluminate as a grain size control agent.
Batches of copper powder particles (from Metz Metallurgical and Dupont), having an average particle size of 6 μm, were mixed with copper aluminate (CuAl 2 O 4 ), having an average particle size of about 2.5 μm, and various paste additives, including ethyl cellulose resin plus a solvent, wetting agent, and flow control agent. Each batch was dried in an oven at about 100° C. and then milled in a rod mill for 1-2 hours. Thereafter, the paste was pressed into pellets at about 5000 psi. Finally, the pellets were sintered in a sintering cycle such as that disclosed in the above Herron et al. U.S. Pat. No. 4,234,367.
The pellets were examined for grain size and the results are illustrated in Table I. As can be seen, the grain size is markedly reduced when at least 0.2 weight percent copper aluminate is present in the paste.
TABLE I______________________________________Weight % Copper Average Grain Maximum GrainAluminate in Size in Copper Size In CopperPaste (μm) (μm)______________________________________0 18 530 >20 >1000.2 13 550.4 13 410.5 9 180.6 8 150.8 8 191.0 7 14______________________________________
The pellets were also examined for densification, noted as percent of theoretical density, and resistivity. The results are illustrated in Table II. The samples listed in Table II only used the Metz copper powder particles. As can be seen, there is a steady decline in percent theoretical density achieved with increasing amounts of copper aluminate, thus illustrating the ability to control the shrinkage of the sintered copper.
TABLE II______________________________________Weight % Copper % of Theoretical ResistivityAluminate in Paste Density μ-ohm-cm______________________________________0.3 930.4 91 2.21.0 80 2.91.2 76 3.12.0 733.0 6910.0 55______________________________________
Examples II
Samples were prepared comprising copper particles, copper aluminate particles and glass-ceramic particles in order to determine whether it is possible to match the shrinkage characteristics during sintering of a copper paste and a glass-ceramic material.
A batch of copper-based paste was prepared having the following composition, by volume percent of inorganic materials: 10.08 volume percent of copper (from Metz Metallurgical) having an average particle size of 1.5 μm, 79.26 volume percent of copper (from Metz Metallurgical) having an average particle size of 6 μm, 9.9 volume percent of cordierite glass-ceramic particles (average particle size of 3.5 μm) of the composition listed in Table III, and 0.76 volume percent of copper aluminate having an average particle size of 0.6 μm. To this mixture was added various past additions, including ethyl cellulose resin plus a solvent, wetting agent, and flow control agent. The resulting mixture was dried in an oven at about 100° C. and then milled in a rod mill for 1 to 2 hours. Thereafter, the paste was pressed into pellets at about 5000 psi.
TABLE III______________________________________Glass-ceramic in Substrate Glass-paste, weight % Ceramic, weight %______________________________________55.0 SiO.sub.2 55.021.23 Al.sub.2 O.sub.3 21.120.0 MgO 22.31.0 B.sub.2 O.sub.3 1.32.77 P.sub.2 O.sub.5 0.3______________________________________
Next, a batch of glass-ceramic material (average particle size 3.5 μm) representative of glass-ceramic material in substrates was prepared. The composition is also listed in Table III. The glass-ceramic material was prepared in a conventional way such as that disclosed in the Herron et al. U.S. Pat. No. 4,234,367, and then pressed into pellets.
Both sets of pellets were sintered according to the sintering cycle disclosed in the above Herron et al. patent as modified by Farooq et al. U.S. patent application Ser. No. 07/672,517, filed Mar. 20, 1991, the disclosure of which is incorporated by reference herein.
Generally speaking, the sintering cycle proceeds as follows. The temperature was ramped up to 715° C. in an atmosphere of 70% water vapor/30% N 2 followed by binder burnoff in a steam ambient. Subsequently, the atmosphere was replaced with a forming gas atmosphere and then the temperature was ramped up to 975° C. in N 2 . The atmosphere is then changed to a steam ambient and heating at 975° C. continued to complete the second step. The pellets were then cooled down, first in the steam ambient and then in N 2 .
The shrinkage behavior of the pellets was measured during the sintering cycle by a Netzsch dilatometer. It was observed that the glass-ceramic pellets (representing the substrate) began to shrink at about 800° C. and stopped shrinking at about 860° C., while the paste pellets began to shrink at about 800° C. and stopped shrinking at about 890° C. Thus, both sets of pellets exhibited nearly identical shrinkage behavior. According to the invention, therefore, shrinkage matching of paste and substrate materials is obtained.
As is now apparent, the copper-based sintering paste comprising copper aluminate proposed by the present inventors has fulfilled the dual objectives of controlling the grain size in the sintered copper while also altering the shrinkage behavior of the copper particles.
It will be apparent to those skilled in the art having regard to this disclosure that other modifications of this invention beyond those embodiments specifically described here may be made without departing from the spirit of the invention. Accordingly, such modifications are considered within the scope of the invention as limited solely by the appended claims. | A copper-based paste is disclosed for filling vias in, and forming conductive surface patterns on, ceramic substrate packages for semiconductor chip devices. The paste contains copper aluminate powder in proper particle size and weight proportion to achieve grain size and shrinkage control of the via and thick film copper produced by sintering. The shrinkage of the copper material during sintering is closely matched to that of the ceramic substrate. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of PCT International Application No. PCT/JP2010/050831 filed on Jan. 22, 2010 which claims the benefit of priority from U.S. Provisional Application No. 61/146,819 filed on Jan. 23, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical fiber preform manufacturing method for manufacturing an optical fiber having holes extending in a longitudinal direction.
2. Description of the Related Art
Optical fibers having holes extending in a longitudinal direction, so-called microstructure optical fibers, have characteristics that cannot be achieved by optical fibers having a normal structure of confining light with a core and a cladding, and thus are expected to be optical fibers of the next generation. A holey fiber, a hole-assisted fiber, and a photonic bandgap fiber are known as the microstructure optical fibers.
The holey fiber has holes formed around a region that has a substantially uniform refractive index and that is near a center axis, and guides light with a core, which is the region near the center axis in which the holes are not formed. The hole-assisted fiber has holes formed around a core of an optical fiber of a normal structure. The photonic bandgap fiber has a hole formed on a center axis and becoming a core, and has holes cyclically formed around this hole, thereby generating a photonic bandgap to guide light.
A stack-and-draw method and a drilling method are known as methods of manufacturing a preform for a microstructure optical fiber. The stack-and-draw method is a method of manufacturing a preform for a microstructure optical fiber by bundling plural capillary tubes. The hole drilling method is a method of manufacturing a preform for a microstructure optical fiber by forming through-holes in a longitudinal direction of the preform with a drill (see Japanese Patent Application Laid-open No. 2002-321935 and Japanese Patent Application Laid-open No. 2003-342032).
The stack-and-draw method is suitable for arranging many holes in a constant cycle. However, in the stack-and-draw method, capillary tubes need to be prepared as many as the number of holes to be formed, and therefore procurement of parts is difficult. Furthermore, because unintended vacant space is formed between the capillary tubes, characteristics of the optical fiber can become unstable.
The drilling method is suitable for arranging a small number of holes at arbitrary positions in a cross-sectional direction. When a microstructure optical fiber is manufactured, desired optical-fiber characteristics need to be achieved by controlling arrangement positions and shapes of its holes precisely. Therefore, in manufacturing a preform for a microstructure optical fiber, the hole drilling method is used in many cases, particularly when the number of holes to be arranged is small.
However, when the drilling method is used, a hole having a length greater than that of a drill used in the drilling method cannot be formed in one drilling process. Specifically, the length of a drill is about 500 millimeters at most, and thus a hole having a length larger than 500 millimeters cannot be formed in one hole drilling process. Therefore, when the hole drilling method is used, there is a constraint on the length of manufacturable preforms. Accordingly, when the hole drilling method is used, manufacturing large preforms is difficult, and it is difficult to reduce the manufacturing cost of an optical fiber having holes extending in a longitudinal direction.
SUMMARY OF THE INVENTION
It is an object of the present invention to at least partially solve the problems in the conventional technology.
According an aspect of the present invention, an optical fiber preform manufacturing method includes: supporting a drilling jig in a radial direction of a preform that is cylinder-shaped; moving the drilling jig in a longitudinal direction of the preform; and forming a plurality of slits each extending in the longitudinal direction and directed from an outer side of the preform toward a center the preform, and a plurality of holes each extending in the longitudinal direction and connecting with an end of one of the plurality of slits in a depth direction of the one of the plurality of slits.
The above and other objects, features, advantages and technical and industrial significance of this invention will be better understood by reading the following detailed description of presently preferred embodiments of the invention, when considered in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a configuration of an optical fiber preform according to an embodiment of the present invention;
FIG. 2 is a cross-sectional view along a line A-A of the optical fiber preform depicted in FIG. 1 ;
FIG. 3 is a cross-sectional view of a modification of the optical fiber preform depicted in FIG. 1 ;
FIG. 4 is a cross-sectional view of another modification of the optical fiber preform depicted in FIG. 1 ;
FIG. 5A is a conceptual diagram for explaining a manufacturing method of the optical fiber preform depicted in FIG. 1 ;
FIG. 5B is another conceptual diagram for explaining a manufacturing method of the optical fiber preform depicted in FIG. 1 ;
FIG. 6 is still another conceptual diagram for explaining a manufacturing method of the optical fiber preform depicted in FIG. 1 ;
FIG. 7 depicts a relationship between pressure in a hole at the time of stretching an optical fiber preform and circularity of the hole;
FIG. 8A is a schematic diagram of a change in shapes of holes when a pressure in the holes at the time of stretching an optical fiber preform is less than an optimal pressure;
FIG. 8B is a schematic diagram of a change in shapes of holes when a pressure in the holes at the time of stretching an optical fiber preform is at an optimal pressure;
FIG. 8C is a schematic diagram of a change in shapes of holes when a pressure in the holes at the time of stretching an optical fiber preform is greater than a proper value; and
FIG. 9 depicts a relationship between cross-sectional area of a hole after stretching and optimal pressure in the holes at the time of stretching the optical fiber preform.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An optical fiber preform manufacturing method according to an embodiment of the present invention will be explained below with reference to the drawings.
[Configuration of Optical Fiber Preform]
A configuration of an optical fiber preform according to an embodiment of the present invention will be explained first with reference to FIGS. 1 and 2 .
FIG. 1 is a perspective view of the configuration of the optical fiber preform according to the embodiment of the present invention. FIG. 2 is a cross-sectional view along a line A-A of the optical fiber preform depicted in FIG. 1 . As depicted in FIGS. 1 and 2 , the optical fiber preform according to the embodiment of the present invention includes a cylindrical preform 1 , plural slits 2 a to 2 f extending in a longitudinal direction of the preform 1 and formed on an outer peripheral surface of the preform 1 , and plural holes 3 a to 3 f connecting with the slits 2 a to 2 f and extending in the longitudinal direction of the preform 1 .
The preform 1 is formed of silica based glass. Specifically, the preform 1 is formed of a material having a region near a center axis, which has a substantially uniform refractive index. A material having a core having a higher refractive index than that at an outer peripheral portion on the center axis may be used as the preform 1 . The plural slits 2 a to 2 f have a predetermined depth L from the outer peripheral surface of the preform 1 toward a center axis direction of the preform 1 . The plural holes 3 a to 3 f connect with the slits 2 a to 2 f at ends of the slits in a depth direction. While details are described later, preferably, the predetermined depth L is equal to or larger than 2 millimeters and equal to or smaller than 20 millimeters. A width D of each of the slits is preferably equal to or larger than 0.5 millimeter and equal to or smaller than a quarter of a diameter of the holes 3 a to 3 f.
Although the optical fiber preform has only one layer of the preform 1 according to the present embodiment, the optical fiber preform may be a preform having multiple layers of holes by accommodating a preform 1 A in a tubular preform 1 B having slits and holes formed therein as depicted in FIG. 3 . Alternatively, as depicted in FIG. 4 , the preform 1 and a tubular member 5 may be integrated with each other by accommodating the preform 1 in the tubular member 5 such as a glass tube and by fusing the preform 1 with the tubular member 5 .
[Method of Manufacturing a Preform for Optical Fiber]
A method of manufacturing the optical fiber preform depicted in FIG. 1 will be explained with reference to FIGS. 5A and 5B .
FIGS. 5A and 5B are schematic diagrams for explaining the method of manufacturing the optical fiber preform depicted in FIG. 1 . When the optical fiber preform depicted in FIG. 1 is manufactured, as depicted in FIG. 5A , plural slits 2 extending in a longitudinal direction of the preform 1 are first formed on the outer peripheral surface of the preform 1 by using a grindstone or a file, and thereafter a drilling jig 11 having a tubular drill portion 11 a and an arm portion 11 b supporting the drill portion 11 a is set at a longitudinal-direction end of the preform 1 . Next, as depicted in FIG. 5B , the drilling jig 11 is moved along the longitudinal direction of the preform 1 to pass the arm portion 11 b through the slits 2 , thereby forming plural holes 3 connecting with the slits 2 and extending in the longitudinal direction of the preform 1 . Consequently, the optical fiber preform depicted in FIG. 1 is manufactured.
Further, the preform 1 having the holes 3 formed therein is stretched in a longitudinal direction to make an outer diameter of the preform 1 a predetermined size by using a well-known heating method such as a method of heating with a flame, a high-frequency-induction plasma torch, or an electric furnace. A long optical fiber preform may be manufactured by stretching the preform 1 after forming the holes 3 . Because not only the outer diameter of the preform 1 but also diameters of the holes are decreased by stretching the preform 1 , the diameters of the holes drilled by the drilling jig 11 may be large. As a result, formation of the holes 3 by the drilling jig 11 and also cleaning the inside of the holes 3 are facilitated.
As it is clear from the above explanation, according to the optical fiber preform manufacturing method according to the embodiment of the present invention, the plural slits 2 extending in the longitudinal direction of the preform 1 are formed on the outer peripheral surface of the cylindrical preform 1 , the drilling jig 11 is introduced into a predetermined position in the radial direction of the preform 1 via the slits 2 , and the drilling jig 11 is moved in the longitudinal direction of the preform 1 , thereby forming the plural holes 3 connecting with the slits 2 and extending in the longitudinal direction of the preform 1 . That is, in the optical fiber preform manufacturing method according to the embodiment of the present invention, the drilling jig 11 is introduced via the slits 2 which are open faces, and the drilling by the drilling jig 11 is performed. Therefore, according to the optical fiber preform manufacturing method of the embodiment of the present invention, drilling up to an unlimited length is possible in principle, unlike in a conventional drilling method of forming through-holes using a drill, and thus, an optical fiber having holes extending in a longitudinal direction is economically manufacturable.
If, before the stretching, the slits 2 are eliminated to leave only the holes 3 by heating the outer periphery portion of the preform 1 by a well-known heating method such as a method of heating using a flame, a high-frequency-induction plasma torch, and an electric furnace, the preform 1 similar to that formed with through-holes is able to be formed. However, in this case, heating temperature of the preform 1 is preferably within a ±1% range of a softening point temperature of the silica based glass forming the preform 1 . When the heating temperature is low, the shape of the preform 1 does not change, and the slits 2 are not eliminated. On the contrary, when the heating temperature is high, the shape of the holes 3 is changed.
The softening point temperature of the silica based glass is 1800° C. When the actually manufactured preforms 1 were heated at 1773° C., 1782° C., 1800° C., 1818° C., and 1827° C., it was confirmed that the slits 2 were not eliminated at 1773° C., and the slits 2 were eliminated at or above 1782° C. However, when the preform 1 was heated at 1827° C., circularity (=(minimum diameter/maximum diameter)×100) of the holes 3 became 85%. From the above, if aiming only to eliminate the slits 2 , the preform 1 may be heated to or above the softening point temperature of the silica based glass forming the preform 1 , but if aiming to maintain shapes of the holes 3 while eliminating the slits 2 , the preform 1 may be heated to a temperature near the softening point temperature of the silica based glass forming the preform 1 .
When the depth L of the slits 2 is small, the distance between the hole 3 and the outer periphery of the preform 1 becomes short, and this becomes a cause of cracks being generated upon machining. On the contrary, when the depth L of the slits 2 is large, the length of the arm portion 11 b becomes long and precision of positions at which the holes 3 are formed becomes low. When the length of the arm portion 11 b becomes large, load on the arm portion 11 b becomes large, and this becomes a cause of damaging the drilling jig 11 . Therefore, the depth L of the slit 2 is preferably equal to or larger than 2 millimeters and equal to or smaller than 20 millimeters.
When the width D of the slits 2 is small, the arm portion 11 b may contact a sidewall of the slits 2 , and this may become an obstacle upon movement of the arm portion 11 b . On the contrary, when the width D of the slit 2 is large, the holes 3 may be deformed greatly as the slits 2 are eliminated upon heating the outer periphery portion of the preform 1 to eliminate the slits 2 . Therefore, the width D of the slits 2 is preferably equal to or larger than 0.5 millimeter and equal to or smaller than a quarter of a diameter of the holes 3 a to 3 f.
In the present embodiment, although the holes 3 are formed by using the drilling jig 11 depicted in FIG. 5A , the slits 2 and the holes 3 may be simultaneously formed, as depicted in FIG. 6 , by setting, in a longitudinal-direction end of the preform 1 , a drilling jig 21 made of a spherical drill portion 21 a and an arm portion 21 b , such as a file for forming slits, which supports the drilling unit 21 a , and moving the drilling jig 21 along a longitudinal direction of the preform 1 while rotating the drill portion 21 a with the arm portion 21 b as a rotation axis.
When the optical fiber preform is stretched after eliminating the slits 2 , the circularity of holes depends on pressure in the holes at a heat-softened part. FIG. 7 depicts a relationship between pressure in holes and circularity of the holes when a radius r of the holes after stretching is 2 millimeters. When a pressure in the holes is within a range of a region R 1 depicted in FIG. 7 , the outer diameter of the holes 3 decreases in a direction from a center position O of the preform 1 toward an outer periphery and the circularity decreases, as depicted in FIG. 8A . When a pressure in the holes is within a range of a region R 2 depicted in FIG. 7 , the hole 3 keeps its completely round state and the circularity does not decrease greatly, as depicted in FIG. 8B . On the contrary, when a pressure in the holes is within a range of a region R 3 as depicted in FIG. 7 , the outer diameter of the holes 3 increases in a direction from the center position O of the preform 1 toward the outer periphery and the circularity decreases, as depicted in FIG. 8C .
Therefore, when the optical fiber preform is stretched after the slits 2 are eliminated, the pressure in the holes at the heat-softened part needs to be controlled to be at an optimal value. Specifically, when the radius r of the holes after the stretching is to be 2 millimeters, a pressure in the holes at the heat-softened part is preferably set at a value corresponding to the region R 2 depicted in FIG. 7 , that is, at a pressure that is 0.3 kPa to 1 kPa greater than atmospheric pressure. Consequently, the deformation of the holes becomes small, and characteristics of the optical fiber are able to be stabilized.
However, an optimal value of a pressure in the holes changes according to a cross-sectional area of a hole after the stretching as depicted in FIG. 9 . That is, an optimal value of a pressure in the holes becomes smaller when the cross-sectional area of the hole after the stretching becomes larger. Therefore, when the optical fiber preform is stretched, an optimal value of a pressure in the holes needs to be set correspondingly to a targeted value of the cross-sectional area of the hole. A pressure in the holes may be adjusted by a method of sealing both ends of the holes or by a method of supplying an inert gas.
As depicted in FIG. 4 , the preform 1 and a tubular member may be integrated by inserting the preform 1 into the tubular member such as a glass tube, heating the preform 1 to a ±1% range of a softening point temperature of the silica based glass forming the preform 1 to fuse the preform 1 with the tubular member. A heating method of the preform 1 may be, for example, a well-known heating method such as a method of heating using a flame, a high-frequency-induction plasma torch, and an electric furnace. When fusing, by making a clearance between an inner diameter of the tubular member and an outer diameter of the preform 1 about one millimeter, fusing with both ends of the preform 1 open may be performed, without controlling an internal pressure of the holes. The optical fiber may be manufactured by performing fiber-stretching simultaneously with fusing.
A cladding may be further formed around the preform 1 having the holes 3 formed therein. A method of forming the cladding may be, for example, a method of inserting into the tubular member the preform 1 having the holes 3 formed therein and crushing the tubular member, or a method of depositing soot around the preform 1 having the holes 3 formed therein and vitrifying. When the cladding is formed around the preform 1 having the holes 3 formed therein, positions to form the holes 3 and the size of the holes 3 are set in advance by taking into consideration a quantity of the cladding to be formed. When the cladding is formed by the method of crushing the tubular member, an optical fiber may be manufactured by simultaneously performing fiber-stretching.
While embodiments to which the invention made by the present inventors is applied have been explained above, the present invention is not limited to the descriptions and the drawings, which form a part of the disclosure of the present invention according to these embodiments. That is, all of any other embodiments, examples, operational techniques, and the like, which are realized by those skilled in the art based on the present embodiments, are included in the scope of the present invention.
According an embodiment of the present invention, an optical fiber having holes extending in a longitudinal direction is economically manufacturable.
Although the invention has been described with respect to specific embodiments 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 that fairly fall within the basic teaching herein set forth. | An optical fiber preform manufacturing method includes: supporting a drilling jig in a radial direction of a preform that is cylinder-shaped; moving the drilling jig in a longitudinal direction of the preform; and forming a plurality of slits each extending in the longitudinal direction and each directed from an outer side of the preform toward a center the preform, and a plurality of holes each extending in the longitudinal direction and each connecting with an end of one of the plurality of slits in a depth direction of the one of the plurality of slits. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/224,625, filed Mar. 25, 2014, which was a division of U.S. patent application Ser. No. 13/491,045, now U.S. Pat. No. 8,710,344, filed Jun. 7, 2012.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed toward a keyboard with touch sensors for detecting the touch location along the length of an outfitted key as it is being pressed, so as to thereby enable the functionality of the keyboard to be continually reconfigured during play in accordance with the touch location being detected. This reconfiguration can be utilized to enhance that functionality, simplify its use, and substantially reduce the number of keys and keyboard footprint required for its implementation. Such touch detection is particularly applicable to touchscreen, piano-type keyboards; however, it is generally applicable to any keyboard being associated with electronic control, especially where portability is an issue.
[0003] There are numerous piano keyboard apps available for iPads, and similar touchscreen devices. The popularity of these apps can be attributed, at least in part, to the portability of those tablets; however, due to the tiny size of their playing surface as compared to a standard piano keyboard, the number of keys available for playing at any given time, is extremely limited, which presents a serious obstruction to the playing of even the simplest piano arrangements.
[0004] In an attempt to alleviate this functionality obstruction, apps have typically: reduced key width to display additional keys; reduced key length to display multiple key rows; and provided keyboard repositioning swipes during play for revealing normally off-screen keys. While these measures do increase the number of readily available keys, the reduced key size and additionally required swipes have rendered such apps virtually unusable for real-time play.
[0005] Furthermore, since playing even simple arrangements requires a fair amount of skill, keyboards provide preprogrammed buttons for simulating actual playing. While such button pressing does enable beginners to circumvent this learning curve, because it is so far removed from the skills required for piano playing, very little learning is actually accomplished. A keyboard that offered skill simplification rather than complete elimination would be far more advantageous.
[0006] For example, consider the learning curve required for the playing of close, root-position chords, which is relatively small compared to that of advanced chord inversion and voicing. Suppose it were possible to play a close, root-position chord, but then configure the keyboard during play to automatically substitute an advanced chord inversion or voicing before any notes are sounded. This would substantially reduce the learning curve required for advanced playing, but would, at the same time, promote the learning of the basic playing skills.
[0007] To date, there is no such reconfigurable, piano-type keyboard that offers both full functionality and simplified playing, and especially not at a substantially reduced size. As such, there is a recognized need for a tablet-sized, piano-type keyboard, of either the touchscreen or physical variety, that can be continually reconfigured during play, so as to provide such capabilities.
SUMMARY OF THE INVENTION
[0008] The present invention provides touch sensor means for detecting the touch location along the length of an outfitted piano key as it is pressed, so as to then offset the notes of an associated piano keyboard accordingly during play. When such an outfitted key is pressed in combination with other piano keys, the touch location along the length of the outfitted key, and the separation intervals and timing of the key presses, are analyzed to determine the intended chord, such that before any notes are sounded, the notes of the pressed keys are configured for the sounding of that chord. This arrangement enables playing a wide range of notes using just a few keys, so as to provide a substantially reduced-size keyboard with full-sized keys sufficient for real-time playing. This arrangement also enables configuring the note offsets of those pressed keys to conform to a selected musical key, so as to simplify the layout of the keyboard by eliminating its black keys, while still supporting the playing of non-conforming notes. This arrangement further enables applying pitch variation to those note offsets in order to emulate the “string stretching,” “whammy bar,” and “fretless neck” playing techniques for guitars and basses. This arrangement even further enables playing advanced chords in a simplified manner. Finally, this arrangement enables providing a wide assortment of keyboards that can differ in the type, number, size, and functionality of their outfitted keys.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For the purpose of illustrating this invention, there are shown in the accompanying drawings forms that are presently preferred; it being understood that the invention is not intended to be limited to the precise arrangements and instrumentalities shown.
[0010] FIG. 1 is a top view of a first operational state of a first embodiment of an iPad, piano-type, touchscreen keyboard;
[0011] FIG. 2 is a top view of a second operational state of the first keyboard embodiment shown in FIG. 1 ; and
[0012] FIG. 3 is a top view of a third and fourth operational state of the first keyboard embodiment shown in FIGS. 1 and 2 .
[0013] FIG. 4 is a logic diagram of the first keyboard embodiment shown in FIGS. 1 to 3 .
[0014] FIG. 5 is a top view of a second embodiment of an iPad, piano-type, touchscreen keyboard.
[0015] FIG. 6 is a top view of a third embodiment of an iPad, piano-type, touchscreen keyboard.
[0016] FIG. 7 is a top view of a fourth embodiment of an iPad, piano-type, touchscreen keyboard.
[0017] FIG. 8 is a top view of a first operational state of a fifth embodiment of an iPad, piano-type, touchscreen keyboard;
[0018] FIG. 9 is a top view of a second operational state of the fifth keyboard embodiment shown in FIG. 8 ;
[0019] FIG. 10 is a top view of a third operational state of the fifth keyboard embodiment shown in FIGS. 8 and 9 ;
[0020] FIG. 11 is a top view of a fourth operational state of the fifth keyboard embodiment shown in FIGS. 8 to 10 ;
[0021] FIG. 12 is a top view of a fifth operational state of the fifth keyboard embodiment shown in FIGS. 8 to 11 ; and
[0022] FIG. 13 is a top view of a sixth operational state of the fifth keyboard embodiment shown in FIGS. 8 to 12 .
[0023] FIG. 14 is a top view of a sixth embodiment of an iPad, piano-type, touchscreen keyboard.
[0024] FIG. 15 is a top view of a seventh embodiment of an iPad, piano-type, touchscreen keyboard.
[0025] FIG. 16 is a logic diagram of the fifth keyboard embodiment shown in FIGS. 8 to 13 .
[0026] FIG. 17 is a logic diagram of the sixth keyboard embodiment shown in FIG. 14 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] Referring now to the drawings in detail, like reference numerals have been used throughout the various figures to designate like elements.
[0028] A first embodiment of an iPad, piano-type, touchscreen keyboard of the invention is shown in FIGS. 1, 2, and 3 , and is designated generally as 300 . This keyboard 300 is comprised of 7, piano-sized, white keys 120 , 122 , 124 , 126 , 128 , 130 , and 132 arranged across the full portrait screen width. The first white key 120 is divided lengthwise into 15 sections 340 , 342 , 344 , 346 , 348 , 350 , 352 , 354 , 356 , 358 , 360 , 362 , 364 , 366 , and 368 . The corresponding notes 370 , 372 , 374 , 376 , 378 , 380 , 382 , 384 , 386 , 388 , 390 , 392 , 394 , 396 , and 398 , respectively, played by touching those sections are set to the first 15 notes (C3-D-E-F-G-A-B-C4-D-E-F-G-A-B-C5) of the 3-octave note sequence C3-D-E-F-G-A-B-C4-D-E-F-G-A-B-C5-D-E-F-G-A-B of the C Major scale, those 15 notes being initially centered around middle C (C4), so as to currently have a center octave of 4.
[0029] When the first white key 120 is pressed from one of its sections 340 , 342 , 344 , 346 , 348 , 350 , 352 , 354 , 356 , 358 , 360 , 362 , 364 , 366 , or 368 , the remaining white keys 122 , 124 , 126 , 128 , 130 , and 132 will be reconfigured in correspondence with a span of 7 white keys on a standard piano keyboard starting with the note 370 , 372 , 374 , 376 , 378 , 380 , 382 , 384 , 386 , 388 , 390 , 392 , 394 , 396 , or 398 associated with that touched section 340 , 342 , 344 , 346 , 348 , 350 , 352 , 354 , 356 , 358 , 360 , 362 , 364 , 366 , or 368 . As such, if the first white key 120 is progressively pressed from its first section 340 to its last section 368 , the corresponding notes of the 7 keys 120 , 122 , 124 , 126 , 128 , 130 , and 132 will progress from C3-D-E-F-G-A-B to C5-D-E-F-G-A-B.
[0030] In this manner, with just 7 white keys, a 3-octave keyboard can be implemented in a footprint the size of an iPad screen, while retaining the full key size and basic functionality of a standard piano keyboard, as well as enabling all chords to start from the same key, so as to simplify their playing. This keyboard can also be configured to substitute a chord inversion or alternate chord voicing when a standard, root-position chord is pressed, so as to further simplify the playing of chords. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0031] FIG. 1 shows a first operational state of the above keyboard 300 . As such, the corresponding notes 384 , 322 , 324 , 326 , 328 , 330 , 332 played by the touching of the 7 white keys 120 , 122 , 124 , 126 , 128 , 130 , and 132 , respectively, are set to the note sequence C4-D-E-F-G-A-B from the above 3-octave note sequence, starting with the note ‘C4’ 384 associated with the initially last touched section 354 of the first white key 120 .
[0032] FIG. 2 shows a second operational state of the above keyboard 300 . As such, the touching of section 362 accordingly shifts the corresponding notes 392 , 322 , 324 , 326 , 328 , 330 , and 332 played by the touching of the 7 white keys 120 , 122 , 124 , 126 , 128 , 130 , and 132 , respectively, to the note sequence G-A-B-C5-D-E-F from the above 3-octave note sequence, starting with the note ‘G4’ 392 of the currently touched section 362 of the first white key 120 .
[0033] FIG. 2 also shows that the keyboard 300 is further comprised of a pop-up data picker 310 with a control wheel 312 to select the current center octave (4) 314 , and another control wheel 316 to select the current musical key (C Major) 318 . This combination is used to determine the scale and octave range of the above 3-octave note sequence.
[0034] FIG. 3 shows a third operational state of the above keyboard 300 corresponding to an initial center octave of 4 and musical key of C Major. As such, the combination of the 3 touched keys 120 , 124 , and 128 respectively plays the corresponding notes ‘A#3’ 382, ‘D4’ 324, and ‘F4’ 328, where the first note (A#3) 382 does not conform to the current musical key of C Major, but has been programmed to replace the conforming note (B3) normally played by the section 352 , so as to enable, in a limited fashion, the playing of notes outside the set of notes conforming to the current center octave and musical key, while using the same keyboard keys that would normally play only conforming notes.
[0035] FIG. 3 also shows a fourth operational state of the above keyboard 300 . As shown in the figure, there is a first touch position (p 1 ) 334 along the length of the third white key 124 , a subsequent position deviation (Δρ) 336 to a second touch position (p 2 ) 338 along that same key 124 , and a related frequency deviation (Δf) 320 in the pitch of the corresponding note 324 being played by that key 124 , where continued such position deviations will result in continued such frequency deviations for as long as the touching of the key 124 is maintained, thereby enabling emulation of the string stretching, whammy bar, and fretless neck techniques of guitar and bass playing.
[0036] A logic diagram for the above keyboard 300 is shown in FIG. 4 , and is designated generally as 100 . The symbols used in this logic diagram 100 are further explained in the following chart.
[0037] The diagram 100 logic is preset for the musical key ‘Scale’ selector to output a value of ‘Major’, the musical key ‘Tonic’ selector to output a value of ‘C’, and the center ‘Octave’ selector to output a value of ‘4’, which presets the notes of row ‘r-8’, for columns ‘c-1’ through ‘c-7’, to the notes of the C Major key, beginning with note ‘C4’ (namely, C4, D4, E4, F4, G4, A4, and B4). Successive rows above and below r-8 are also preset with the notes of the C Major key, but starting at notes successively above and below ‘C4’, respectively. The note ‘Offset’ selector is initially set to modify the note at ‘r-8’/‘c-7’ by +1 semitone to ‘C5’, and the note at ‘r-7’/‘c-1’ by −1 semitone to ‘A#3’. This provides for the playing of custom chords arrangements, as well as for the playing of chords outside the C Major key, both of which would not otherwise be possible.
[0038] The initial ‘Row’ value being output from the ‘Analyzer’ is internally preset to ‘r-1’ and is not user selectable. This ‘Row’ value causes the notes of ‘r-1’ (namely, C3, D3, E3, F3, G3, A3, and B3), to be output to ‘Synth1’ through ‘Synth7’, respectively.
[0039] With “no keys being initially pressed” as the starting condition, ‘Key1’ 120 through ‘Key7’ 132 each outputs a value of ‘Stop’ (logical 0) to ‘Synth1’ through ‘Synth7’, respectively, a value of logical 0 to the 7-input ‘OR’, and a ‘Y’ value of ‘OFF’ to the ‘Analyzer’. As a result, the output of the 7-input ‘OR’ is set to a value of logical 0, and the output of the rising edge ‘Delay’ is set to a value of ‘Disable’ (logical 0) for the 7 synths, all of which are stopped and disabled from playing due to the values of ‘Stop’ and ‘Disable’ being input.
[0040] Pressing ‘Key3’ 124 causes it to then output a value of ‘Play’ (logical 1) to Synth3′, which is currently loaded with a ‘Note’ of value ‘E3’, but it is also disabled, so it does not yet start playing. The ‘Key3’ 124 press also causes it to output a value of logical 1 to the 7-input ‘OR’, and to output the ‘Y’ value of the pressed point along that key to the ‘Analyzer’, which then internally latches the ‘Y’ value as the ‘Y0’ of ‘Key3’ 124, for comparison with future ‘Y’ values from ‘Key3’ 124. Upon its logical 1 input, the 7-input ‘OR’ outputs a value of logical 1, which triggers the rising edge ‘Delay’ to output a value of ‘Enable’ (logical 1) after a brief delay.
[0041] Additionally pressing ‘Key5’ 128 and ‘Key7’ 132 within the delay time interval causes each key to output a value of ‘Play’ to ‘Synth5’ and ‘Synth7’, respectively, each of which is currently loaded with a ‘Note’ of value ‘G3’ and ‘B3’, respectively, but they are also both disabled, so they do not yet start playing. The ‘Key5’ 128 and ‘Key7’ 132 presses also cause each key to output a value of logical 1 to the 7-input ‘OR’, and to additionally output the ‘Y’ value of its press to the ‘Analyzer’, which then internally latches that ‘Y’ value as the ‘Y0’ of that key, for comparison with future ‘Y’ values from that key.
[0042] If no other keys are pressed before the delay time interval has expired, upon expiration of such, the rising edge ‘Delay’ outputs a value of ‘Enable’ to each synth, which triggers the immediate latching and start of playing of notes ‘E3’, ‘G3’, and ‘B3’ corresponding to ‘Synth3’, ‘Synth5’, and ‘Synth7’, respectively, since those are the only synths inputting a ‘Play’ value from their corresponding key. This effectively plays an E minor chord.
[0043] Alternatively, if the pressing of ‘Key1’ 120 (at a ‘Y’ value corresponding to ‘r-8’) also occurs before the delay time interval has expired, this causes ‘Key1’ 120 to output a value of ‘Play’ to ‘Synth1’, which is currently loaded with a ‘Note’ of value ‘C3’, but it is also disabled, so it does not yet start playing. The ‘Key1’ 120 press also causes the key to output a value of logical 1 to the 7-input ‘OR’, and to output the ‘Y’ value of its press to the ‘Analyzer’, which internally latches that ‘Y’ value as the ‘Y0’ of that key, for comparison with future ‘Y’ values from that key, and which then outputs a ‘Row’ value of ‘r-8’ based on the ‘Y’ value output by ‘Key1’ 120. The ‘Row’ value ‘r-8’ causes notes ‘C4’, ‘D4’, ‘E4’, ‘F4’, ‘G4’, ‘A4’, and ‘C5’ to be output to ‘Synth1’ through ‘Synth7’, respectively, which are all disabled, so no playing occurs. Once the delay time interval has expired, the rising edge ‘Delay’ outputs a value of ‘Enable’ to all synths, which then triggers the immediate latching and start of playing of the notes ‘C4’, ‘E4’, ‘G4’, and ‘C5’ corresponding to ‘Synth1’, ‘Synth3’, ‘Synth5’, and ‘Synth7’, respectively, since those are the only synths inputting a ‘Play’ value from their corresponding key. This effectively plays a C Major chord, with a root note of C4, and a doubling of the root note at C5.
[0044] While a key is being pressed, the ‘Y’ value of the pressed point along the key is continually updated and output to the ‘Analyzer’, where it is compared with the ‘Y0’ value latched for that key when it was initially pressed, and a ‘Pitch Control’ value ‘Y-Y0’ is output to the corresponding synth to control its pitch, thus providing a pitch modulation effect, similar to that of a guitar string bend, string slide, or whammy bar, which can be accomplished simply by sliding one's finger up and down along the key being pressed with that finger.
[0045] When a key is released (possibly ‘Key1’ 120 ), the output to its corresponding synth is set to a value of ‘Stop, and if any key remains pressed, such that the 7-input ‘OR’ output is still set to logical 1, and the rising edge ‘Delay’ output is still set to ‘Enable’, thereby causing all synths to remain enabled, and playing if their corresponding key is pressed, then the synth corresponding to the released key is immediately stopped from playing. Further, the ‘Y’ output of the released key going to the ‘Analyzer’ is set to ‘OFF’. If the released key is, in fact, ‘Key1’, the Y0 value for ‘Key1’ remains latched internally to the ‘Analyzer’, so the ‘Row’ output from the ‘Analyzer’ remains unchanged.
[0046] If a new key (other than ‘Key1’ 120) is pressed before all keys have been released, such that the 7-input ‘OR’ output is still set to logical 1 and the rising edge ‘Delay’ output is still set to ‘Enable’, then the output to its corresponding synth is set to a value of ‘Play’, and its output to the 7-input ‘OR’ is set to a logical 1, which causes the synth to latch and start playing the ‘Note’ corresponding to the newly pressed key, as determined by the current ‘Row’ value from the ‘Analyzer’, and by the column assignment of the pressed key.
[0047] If ‘Key1’ 120 had been released, and is newly pressed (at a ‘Y’ value corresponding to ‘r-3’) before all keys have been released, such that the 7-input ‘OR’ output is still set to logical 1, and the rising edge ‘Delay’ output is still set to ‘Enabled’, that ‘Y’ value is output to the ‘Analyzer’, where it is internally latched as the ‘Y0’ of ‘Key1’, for comparison with future ‘Y’ values from ‘Key1’ 120 . At this same time, the ‘Analyzer’ outputs the corresponding ‘Row’ value of ‘r-3’, thereby causing that row of notes ‘E3’, ‘F3’, ‘G3’, ‘A3’, ‘B3’, ‘C4’, and ‘D4’ to be output to ‘Synth1’ through ‘Synth7’, respectively, immediately after which the ‘Key1’ 120 output to the already enabled ‘Synth1’ is set to a value of ‘Play’, thus causing ‘Synth1’ to latch its loaded ‘Note’ of value ‘E3’ and start playing it. The remaining synths whose corresponding keys are pressed, namely, ‘Synth3’, ‘Synth5’, and ‘Synth7’, continue playing their previously latched notes.
[0048] The ‘Row’ value of ‘r-3’ remains in effect until the next new ‘Key1’ 120 press. Thus, by newly pressing the same keys as before, namely, ‘Key1’ 120 (but now at a new ‘Y’ value corresponding to ‘r-3’, rather than ‘r-8’), ‘Key3’ 124 , ‘Key5’ 128 , and ‘Key7’ 132 , what previously played a modified C Major chord, now plays an E minor 7th.
[0049] When all keys have been released, the outputs of ‘Key1’ 120 through ‘Key7’ 132 , being input to ‘Synth1’ through ‘Synth7’, respectively, are reset to a value of ‘Stop’, which stops from playing any synth that had been playing just prior to the release, and the ‘Y’ outputs of ‘Key1’ 120 through ‘Key7’ 132 , being input to the ‘Analyzer’, are reset to OFF, which then leaves the ‘Row’ output of the ‘Analyzer’ unchanged, such that subsequent key presses would be evaluated by restarting this logic from the “no keys being initially pressed” condition, but now beginning with the current ‘Row’ value being output from the ‘Analyzer’.
[0050] A second embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIG. 5 , and is designated generally as 400 . This keyboard 400 has attributes nearly identical to those of the above keyboard 300 in FIGS. 1, 2, and 3 ; however, it is comprised of 11 , non-sectioned, black and white keys 420 , 422 , 424 , 426 , 428 , 430 , 432 , 434 , 436 , 438 , and 440 in place of the 6 such white keys 322 , 324 , 326 , 328 , 330 , and 332 of the above keyboard 300 .
[0051] The 11 black and white keys 420 , 422 , 424 , 426 , 428 , 430 , 432 , 434 , 436 , 438 , and 440 are equal to the length and 6/11 the width of the above replaced white keys 322 , 324 , 326 , 328 , 330 , and 332 in FIGS. 1, 2, and 3 . The 11 black and white keys 420 , 422 , 424 , 426 , 428 , 430 , 432 , 434 , 436 , 438 , and 440 are further color coordinated with the 11 black and white keys immediately following a C-key on a standard piano keyboard. As such, the operation of the first white key 120 and of the pop-up data picker 310 are as described for the above keyboard 300 , and the corresponding notes 384 , 450 , 452 , 454 , 456 , 458 , 460 , 462 , 464 , 466 , 468 , and 470 of the total of 12 black and white keys 120 , 420 , 422 , 424 , 426 , 428 , 430 , 432 , 434 , 436 , 438 , and 440 are the 12-note sequence of notes (C4-C#-D-D#-E-F-F#-G-G#-A-A#-B) on a standard piano keyboard starting with the note (C4) 384 of the last touched section 354 of the first white key 120 .
[0052] In this manner, with just a single octave of keys, a 3-octave keyboard can be implemented in a footprint the size of an iPad screen, while retaining the full key size and basic functionality of a standard piano keyboard, and enabling all chords of a specific chord type, regardless of their root note, to be played using just the finger position of a C-chord of that chord type, thereby greatly simplifying all chord playing. This keyboard can also be configured to substitute a chord inversion or alternate chord voicing when a standard, root-position chord is pressed, so as to further simplify the playing of chords. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0053] A third embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIG. 6 , and is designated generally as 500 . This keyboard 500 is comprised of a combination of 25, piano-sized, black and white keys 501 to 525 , arranged in a layout typical of the two-octave span of keys centered around middle C (C4) on a standard piano. The keys 501 to 525 are each divided lengthwise into three touch sensor bands 531 to 533 that span the full width of the keyboard 500 , such that, when the keys 501 to 525 are progressively pressed from a touch point within their middle band 532 , their corresponding notes will range from C3 to C5, respectively; however, when the keys 501 to 525 are so pressed from a touch point within their bottom band 531 or top band 533 , their corresponding notes will range from C2 to C4 or C4 to C6, respectively.
[0054] In this manner, using 2 octaves of keys, a 4-octave keyboard can be implemented in a footprint the size of an iPad Pro screen, while retaining the full key size and much of the functionality and the playability of a standard piano keyboard. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0055] A fourth embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIG. 7 , and is designated generally as 600 . In a manner very similar to the above keyboard 500 in FIG. 6 , this keyboard 600 is comprised of a two-octave span of 25 keys 501 to 525 ; however, instead of the three touch sensor bands 531 to 533 of the above keyboard 500 , the keys 501 to 525 are divided lengthwise into seven, more narrow, touch sensor bands 631 to 637 that operate similarly to the three touch sensor bands 531 to 533 , so as to determine the octave of the corresponding note that is played whenever a key is pressed from a specific band.
[0056] However, playing a chord or arpeggio would be very difficult if all keys in such a series had to be pressed from within a single narrow band. Therefore, whenever such a series of key presses is initiated, the first band that is touched remains in effect until all the keys 501 to 525 have been released and remain so for a brief period of time, typically on the order of 0.1 to 0.5 seconds, so that all notes in a given series, regardless of from which of the touch sensor bands 631 to 637 they were pressed, can be played with the same band in effect, and when a new series of key presses is initiated, another of the touch sensor bands 631 to 637 can take effect.
[0057] In this manner, again using 2 octaves of keys, an 8-octave keyboard can now be implemented in a footprint the size of an iPad Pro screen, while retaining the full key size, and virtually all of the functionality and playability, of a standard piano keyboard, but now, with an even wider note span (97 notes vs. 88 notes) than that of a piano. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0058] A fifth embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIGS. 8 to 13 , and is designated generally as 700 . This keyboard 700 is comprised of a combination of 17, piano-sized, black and white keys 701 to 717 , being arranged in a layout typical of a 17-key span starting from any C key on a standard piano. Two white keys 701 and 713 are respectively outfitted with GUI radio button assemblies 720 and 750 , each respectively sectioned lengthwise into 22 , mutually exclusive (in radio button fashion), touch sensors 721 to 742 and 751 to 772 . These two radio button assemblies 720 and 750 are themselves mutually exclusive, such that there can be only one touch sensor 721 to 742 or 751 to 772 in effect at any given time.
[0059] FIG. 8 shows none of the keys 701 to 717 of the above keyboard 700 currently being pressed. As such, if either touch sensor outfitted key 701 or 713 were progressively pressed from within each of its touch sensors 721 to 742 or 751 to 772 , respectively, starting from its bottom touch sensor 721 or 751 , respectively, and progressing to its respective top touch sensor 742 or 772 , the respective corresponding notes for that key 701 or 713 would range from C2 to C5 or C3 to C6. Furthermore, each time a new touch sensor 721 to 742 or 751 to 772 comes into effect, the left touch sensor outfitted key 701 will be configured for that associated note, and the remaining keys 702 to 717 will be immediately reconfigured from that note in accordance with the notes of a standard piano.
[0060] FIG. 9 shows the left touch sensor outfitted key 701 being pressed from its C4 touch sensor 735 (as indicated by the highlighting of that key 701 and the unhighlighting of that touch sensor 735 ), which configures the corresponding note of the key 701 for C4 (as indicated by the display 780 at the top of the key 701 ), and reconfigures the corresponding notes of all keys 701 to 717 for the notes C4 to E5. This configuration remains in effect until the left touch sensor outfitted key 701 is released, and a different touch sensor 721 to 742 or 751 to 772 is subsequently pressed.
[0061] FIG. 10 shows a root position C Major chord being pressed (as indicated by the 3 highlighted keys 701 , 705 , and 708 ). The left touch sensor outfitted key 701 is being pressed from its C4 touch sensor 735 (as indicated by that touch sensor 735 being unhighlighted), which configures the corresponding note of the key 701 for the chord root note C4, and respectively reconfigures the corresponding notes of the 2 remaining pressed keys 705 and 708 for the notes E4 and G4, being located a 3rd and 5th, respectively, above C4 (as respectively indicated by the 2 labels 781 and 783 at the top of those keys 705 and 708 ).
[0062] FIG. 11 shows the right touch sensor outfitted key 713 being pressed from its C5 touch sensor 765 (as indicated by the highlighting of that key 713 and the unhighlighting of that touch sensor 765 ), which configures the corresponding note of the key 713 for C5 (as indicated by the display 783 at the top of the key 713 ), and reconfigures the corresponding notes of all keys 701 to 717 for the notes C4 to E5. This configuration remains in effect until the right touch sensor outfitted key 713 is released, and a different touch sensor 721 to 742 or 751 to 772 is then subsequently pressed.
[0063] FIG. 12 shows a 1st inverted C Major chord being pressed (as indicated by the 3 highlighted keys 705 , 708 , and 713 ). The right touch sensor outfitted key 713 is being pressed from its C5 touch sensor 765 (as indicated by that touch sensor 765 being unhighlighted), which configures the corresponding note of the key 713 for the 1st inverted chord root note C5, and respectively reconfigures the corresponding notes of the 2 remaining pressed keys 705 and 708 for the notes E4 and G4, being located a 3rd and 5th, respectively, above C4 (as respectively indicated by the 2 labels 781 and 783 at the top of those keys 705 and 708 ).
[0064] FIG. 13 shows a 2nd inverted C Major chord being pressed (as indicated by the 3 highlighted keys 708 , 713 , and 717 ). The right touch sensor outfitted key 713 is being pressed from its C5 touch sensor 765 (as indicated by that touch sensor 765 being unhighlighted), which configures the corresponding note of the key 713 for the 2nd inverted chord root note C5, and respectively reconfigures the corresponding notes of the 2 remaining pressed keys 708 and 717 for the notes G4 and E5, located a 5th above C4 and a 3rd above C5, respectively (as respectively indicated by the 2 labels 781 and 783 at the top of those keys 708 and 717 , respectively).
[0065] As follows from the above discussions for FIGS. 8 to 13 , with just 17 keys, a 53-note keyboard can be implemented in a footprint the size of an iPad Pro screen, while retaining the full key size and basic functionality of a standard piano keyboard, as well as enabling all chords of a specific chord type, regardless of their root notes, to be played using just the finger position of a C-chord of that chord type, and further enabling chord inversions to be based around their root notes, so as to substantially simplify all chord playing. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0066] A sixth embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIG. 14 , and is designated generally as 800 . This keyboard 800 is virtually identical in both its form and function to the above keyboard 700 in FIGS. 8 to 13 , except for the fact that two black keys 702 and 714 of this keyboard 800 are each sectioned lengthwise into 22 touch sensors 821 to 842 and 851 to 872 , respectively. The notes associated with each of the touch sensors 821 to 842 and 851 to 872 are respectively one semitone higher than the associated notes of the adjacent touch sensors 721 to 742 and 751 to 772 in FIG. 14 , such that, if the two touch sensor outfitted black keys 702 and 714 were progressively pressed from within each of their touch sensors 821 to 842 and 851 to 872 , respectively, starting from their bottom touch sensors 821 and 851 , respectively, and progressing to their top touch sensors 842 and 872 , respectively, their corresponding notes would respectively range from C#2 to C#5 and C#3 to C#6.
[0067] In this manner, similar to the previously mentioned keyboard 700 , with just 17 piano-sized keys 701 to 717 , the 53-note span, C2 to E6, can be implemented in a footprint the size of an iPad Pro screen, while enabling all chords of a specific chord type, regardless of the chord root note, to be played with just a single finger position, namely, that of a C-chord of that type, which is even easier than on a standard piano keyboard. As would be obvious to one skilled in the art, many other configurations and footprints are possible.
[0068] Furthermore, in view of the additional touch sensor outfitted keys 702 and 714 , knowing the finger position for a relatively easily played chord having a natural root note (e.g., the C Major chord), makes it a simple matter to play the corresponding, more difficult to play, chord with its root note sharpened by one semitone (e.g., the C# Major chord), just by maintaining that finger position and shifting the entire playing hand one semitone to the right, which is exactly how it would be done on a standard piano.
[0069] A seventh embodiment of the above iPad, piano-type, touchscreen keyboard of the invention is shown in FIG. 15 , and is designated generally as 900 . This keyboard 900 is virtually identical in both its form and function to the above keyboard 800 in FIG. 14 , except for the fact that all keys 701 to 717 of this keyboard 900 are of both equal length and equal width. In view of this added keyboard 900 uniformity, the above mentioned one-semitone hand shifts would now be perfectly uniform transitions, regardless of the actual chord, which is even easier than can be done on a standard piano.
[0070] A logic diagram for the above keyboard 700 is shown in FIG. 16 , and is designated generally as 1000 . This logic diagram 1000 uses black-filled arrow tips to designate logic flow along a single wire, and white-filled arrow tips to designate data flow along a multi-wire bus. To minimize the logic diagram 1000 complexity, some multi-function logic elements have been copied to multiple logic diagram 1000 locations, and such copies are indicated by their dashed border. To further minimize the logic diagram 1000 complexity, only five keys 701 , 705 , 708 , 713 , and 717 of the keyboard 700 keys 701 to 717 are shown. The missing keys 702 , 703 , 704 , 706 , 707 , 709 , 710 , 711 , 712 , 714 , 715 , and 716 , as well as their connected logic circuits, are indicated by an ellipsis ( . . . ) placeholder between each of the shown keys 701 , 705 , 708 , 713 , and 717 . Furthermore, for each of the touch sensor outfitted keys 701 and 713 , only three touch sensors, 721 , 735 , and 742 , and 751 , 765 , and 772 , respectively, of their total touch sensors 721 to 742 and 751 to 772 , respectively, are shown.
[0071] Whenever one of the keyboard 700 keys 701 to 717 is pressed, its corresponding note will play as configured according to which of the touch sensor sections 721 to 742 and 751 to 772 is in effect at that time. Whenever a chord is played, if its root note is played from the associated touch sensor 721 to 742 or 741 to 772 of a respective touch sensor outfitted key 701 or 713 , all keys 701 to 717 will then configured correctly for that chord. However, since all keys of a chord are not pressed at precisely the same time, it is likely that the touch sensor outfitted key 701 or 713 would not be the first chord key pressed, such that the actual, first-pressed chord key would then be incorrectly configured for the desired chord.
[0072] As such, if the first-pressed chord key were sounded with an incorrect corresponding note, and then, when a touch sensor outfitted key 701 or 713 is pressed, stopped and resounded with the correct corresponding note, noise will result. Furthermore, depending on the length of time the incorrect note has been sounded before being stopped, that noise could become objectionable. Therefore, it is necessary to delay the sounding of any pressed chord keys until a brief period of time after the first chord key has been pressed, thereby allowing enough time for all chord keys to become pressed in the normal playing of a chord, so that the pressed keys can be configured for the correct corresponding notes of that chord before they are sounded.
[0073] The problem with such a delay is that it will cause a lag in the note sounding, and depending on the magnitude of the delay time, the lag could become noticeable, and even more objectionable than the noise problem. Both of these problems are addressed in the following example.
[0074] Returning now to the logic diagram 1000 , suppose that the keyboard 700 is initially configured with the C4 (middle C) touch sensor 735 of the left touch sensor outfitted key 701 in effect. As such, the keyboard 700 keys 701 to 717 would be configured for the corresponding notes C4 to E5, respectively.
[0075] However, suppose it were now desired to play a C5 Major chord (C5-E5-G5). Since none of the keys 701 to 717 are currently configured for a corresponding note G5, the keyboard 700 would obviously have to be reconfigured to accommodate this new chord. Specifically, if the left touch sensor outfitted key 701 were now pressed from its C5 touch sensor 742 , so as to put that touch sensor 742 into effect, the keyboard 700 keys 701 to 717 would be configured for corresponding notes C5 to E6, respectively, and subsequent pressing of the E5 key 705 and G5 key 708 would complete the C5 Major chord.
[0076] Unfortunately, as discussed above, when playing a chord in the normal fashion, it is impossible to assure that the chord keys will be pressed in a particular order. In the above example, unless the left touch sensor outfitted key 701 is the first pressed, either of the other chord keys 705 or 708 being pressed first would sound their corresponding notes an octave lower than desired for a C5 Major chord. So, rather than sound the chord keys when pressed, a brief delay from the time of the first pressed chord key is needed to assure that all chord keys have been pressed before any corresponding notes are sounded, thereby allowing sufficient time for the keyboard 700 to be correctly configured for a C5 Major chord.
[0077] To implement this logic in logic diagram 1000 , the inputs of a 17-input OR gate 1040 are each connected to the output of one of the 17 keyboard 700 keys 701 to 717 , such that when the first key of the C5 Major chord is pressed, the output of that OR gate 1040 transitions from LOW to HIGH, which triggers its connected one shots 1041 and 1042 and transitions their outputs from LOW to HIGH for 0.05 seconds and 0.10 seconds, respectively, and then back to LOW, which correspondingly transitions the outputs of the connected INV gates 1051 and 1052 , respectively, from HIGH to LOW to HIGH. While the outputs of the INV gates 1051 and 1052 are LOW, the outputs of their connected AND gates 1001 to 1005 and 1006 to 1010 , respectively, are forced LOW, such that no key presses can cause HIGH outputs for the respectively connected AND gates 1001 to 1005 and 1006 to 1010 , thereby preventing their respectively connected latches 1011 to 1015 and 1016 to 1021 from becoming enabled to pass along their data. Therefore, all latches 1010 to 1021 will remain latched during that 0.05 second interval, and no new notes will be passed to their respective synths 1021 to 1025 for playing, thereby preventing any sounding of pressed keys during that time.
[0078] If the C5 touch sensor 742 of the left touch sensor outfitted key 701 has been pressed by the end of that 0.05 second interval, the output of the left radio button assembly 720 , and the bus input of 3-state data bus 1031 , will transition from note C4 (n=14) to note C5 (n=21), and the output of the key 701 will transition from LOW to HIGH, which will transition the S input of its connected NOR latch 1070 , the input and output of its connected H->L delay 1081 , and the connected input of its next connected NOR gate 1080 from LOW to HIGH, and which, since the R input of that NOR latch 1070 is already LOW due to the right touch sensor outfitted key 713 not being pressed and its LOW output being inverted to HIGH by its connected INV gate 1082 so as to thereby force the output of that NOR gate 1080 LOW, will transition the Q output of that NOR latch 1070 , and the D input of its connected D latch 1073 , from HIGH to LOW.
[0079] Since the right touch sensor outfitted key 713 is not pressed and its output is LOW, when the output of the left touch sensor outfitted key 701 transitions from LOW to HIGH, as discussed above, the output of its connected OR gate 1074 will transition from LOW to HIGH, which will trigger the next connected one shot 1075 , such that its output, and the E input of its connected D latch 1073 , will transition from LOW to HIGH for the 0.10 second duration of one shot 1075 , and then back to LOW, which will, in turn, enable that D latch 1073 for that duration so as to pass its above mentioned LOW D input to its Q output, to the OE input of the right 3-state data bus 1032 and thereby disable that 3-state data bus 1032 , and to its connected INV gate 1061 so as to invert it to HIGH at the OE input of the left 3-state data bus 1031 and thereby enable the output of the left 3-state data bus 1031 .
[0080] The Q output of that D latch 1073 , and the outputs of those 3-state data buses 1031 and 1032 , will remain latched LOW, enabled, and disabled, respectively, until such time that the outputs of the touch sensor outfitted keys 701 and 713 are both LOW, and then either outfitted key 701 or 713 is pressed so as to once again trigger the aforementioned connected one shot 1075 .
[0081] With the outputs of the left 3-state data bus 1031 being enabled, as discussed above, note C5 (n=21) will be passed to the input bus of each of its connected D latches 1011 to 1020 , such that, when the output of the above mentioned one shot 1041 returns LOW at the conclusion of its 0.05 second interval, the input and the output of its connected INV gate 1051 will return LOW and HIGH, respectively, so as to then enable the outputs of the next connected AND gates 1001 to 1005 to transition from LOW to HIGH should their respectively connected keys 701 , 705 , 708 , 713 , and 717 be, or become, pressed, thereby enabling their respectively connected D latches 1011 to 1015 . For those D latches 1011 to 1015 that do become enabled, the corresponding note x=n+k (where k is a key-specific integer) will be passed to their respectively connected synths 1021 to 1025 , causing those notes to start sounding.
[0082] As can be seen from the logic diagram 1000 , if the C5 Major chord keys 701 , 705 , and 708 are all pressed within that 0.05 second interval and the touch sensor outfitted key 701 was pressed from the C5 touch sensor 742 , regardless of the order in which the keys 701 , 705 , and 708 were pressed, the C5 Major chord will be sounded. The 0.05 second delay in sounding the C5 Major chord was chosen long enough so as to guarantee that, in most cases, all three chord keys 701 , 705 , and 708 will all have been pressed within that time period, and short enough so as not to cause noticeable lag in the sounding of the chord.
[0083] Obviously, if a slightly longer delay were chosen, it would guarantee that more chord presses would be completed within the longer time period; however, it would also cause more noticeable lag in the sounding of the chord. So, rather than increasing that 0.05 second delay, the slightly longer, 0.10 second interval of the other above mentioned one shot 1042 can be utilized, such that, if prior to the completion of that 0.10 second interval, a different touch sensor comes into effect so as to reconfigure the keyboard 700 keys 701 to 717 , the already started incorrect notes will be stopped, and the reconfigured correct notes will be started. While this 0.10 time period will not add any lag to the sounding of a chord, it must not be made too long or else the starting and stopping of the incorrect notes could cause noticeable noise in the playing of the chord.
[0084] To implement this logic in logic diagram 1000 , at the conclusion of the 0.10 second interval of the aforementioned one shot 1042 , its output, and the input of its connected INV gate 1052 , will return LOW, causing that INV gate 1052 output to return HIGH, thereby enabling the outputs of its connected AND gates 1006 to 1010 to transition from LOW to HIGH should their connected keys 701 , 705 , 708 , 713 , and 717 , respectively, be, or become, pressed, thereby enabling the respectively connected D latches 1016 to 1020 . For those D latches 1016 to 1020 to become enabled, a corresponding note x=n+k (where k is a key-specific integer) will be passed to their respectively connected synths 1021 to 1025 . If those notes are the same as the notes that the synths 1021 to 1025 already started sounding after the 0.05 second one shot 1041 interval, as discussed above, they will be ignored by the synths 1021 to 1025 ; otherwise, for each note that is different, the previously started note will be stopped, and the new note will be started.
[0085] As can be seen from the logic diagram 1000 , if the C5 Major chord keys 701 , 705 , and 708 are all pressed, regardless of the pressing order, within the 0.10 second interval, that interval being long enough to guarantee that all the keys of a normally pressed chord will have been pressed, and if the touch sensor outfitted key 701 was pressed from the C5 touch sensor 742 , then the the corresponding notes of the pressed keys will start sounding 0.05 seconds after the start of the key presses, and the C5 Major chord will be correctly playing, usually by that time, but if not, then definitely by the end of the 0.10 second interval.
[0086] Suppose now, say, 0.30 seconds after the C5 Major chord is released, it were desired to play the first inversion of a C4 Major chord (E4-G4-C5). Since the C5 touch sensor 742 would still be in effect due to the fact that, the Q output of the above mentioned NOR latch 1070 would remain latched LOW when its S input returns LOW and its R input remains LOW, and the C5 touch sensor 742 would, in GUI radio button fashion, remain pressed after its outfitted key 701 has been released if none of its other touch sensors 721 to 741 had since been pressed, none of the keyboard 700 keys 701 to 717 are currently configured for the corresponding notes E4 and G4; therefore, the keyboard 700 would now have to be reconfigured to accommodate this inverted chord.
[0087] Using the same logic as that discussed above for the logic diagram 1000 , if the E4 touch sensor 739 (not shown in the logic diagram 1000 ) of the left touch sensor outfitted key 701 is pressed, that touch sensor 739 would be put into effect, which would reconfigure the keyboard 700 keys 701 to 717 for the corresponding notes E4 to G#5, respectively, and the subsequent, additional pressing of the G4 key 704 and C5 key 709 would play the first inversion of the C4 Major chord.
[0088] This, however, is not how the first inversion of a C4 Major chord would be played on an actual piano keyboard. Rather than the chord being based around its E4 note, as discussed above, it would be based around its C5 note. Once the C5 note is located on a piano, the finger position for the first inversion of a Major chord, which is the same for all Major chords, regardless of their root note, can be readily applied. This eliminates having to remember the bass note (i.e., E4) of such an inversion, which would be different for each of the 12 possible Major chord root notes.
[0089] Implementing such a C5-based first inversion of a C4 Major chord with the logic of logic diagram 1000 requires pressing the right touch sensor outfitted key 713 from its C5 touch sensor 772 , so as to transition the output of the right radio button assembly 750 , and the input of its connected 3-state data bus 1032 with its output still disabled, as discussed above, to note C5 (n=21), and so as to transition the output of that key 713 , the connected input of its OR gate 1074 , and the input of its connected INV gate 1082 from LOW to HIGH, which will transition the output of that INV gate 1082 , and the connected input of its NOR gate 1080 , from HIGH to LOW.
[0090] Since the output of the left touch sensor outfitted key 701 , the connected input of its OR gate 1074 , and the S input of its connected NOR latch 1070 are currently LOW due to that key 701 being released, and since the other input of the above mentioned NOR gate 1080 is currently LOW due to that key 701 having now been released for 0.30 seconds and its resulting HIGH to LOW output transition having already propagated from the input to the output of the connected H->L delay 1081 with its 0.20 second HIGH to LOW transition delay, the aforementioned LOW to HIGH output transition of the right touch sensor outfitted key 713 will additionally transition the output of its connected OR gate 1074 , the input of the next connected one shot 1075 , the output of the aforementioned NOR gate 1080 , the R input and Q output of the aforementioned NOR latch 1070 , and the D input of the NOR latch 1070 connected D latch 1073 from LOW to HIGH.
[0091] The LOW to HIGH transition of the one shot 1075 input will trigger it, and thereby transition its output, and the E input of its connected D latch 1073 , from LOW to HIGH for a duration of 0.10 seconds, which will pass the above mentioned HIGH D input of the D latch 1073 to its Q output, to the OE input of the right 3-state data bus 1032 so as to enable its output, and to the input of the connected INV gate 1061 whose inverted LOW output will be passed to the OE input of the left 3-state data bus 1031 so as to disable its output.
[0092] With the output of the right 3-state data bus 1032 enabled, note C5 (n=21) will be passed to the input buses of the D latches 1011 to 1020 . At this point, the logic to handle the pressing of the E4, G4, and C5 keys 705 , 708 , and 713 , respectively, of the first inversion of a C4 Major chord would correspond with the logic for handling the pressing of the C5, E5, and G5 keys 701 , 705 , and 708 , respectively, of the C5 Major chord, as thoroughly discussed above.
[0093] A logic diagram for the keyboards 800 and 900 of FIGS. 14 and 15 , respectively, is shown in FIG. 17 , and is designated generally as 1100 . The logic of this current logic diagram 1100 is nearly identical to that of the previous logic diagram 1000 in FIG. 16 , but with additional logic to handle the left and right touch sensor outfitted black keys 702 and 714 , respectively, and the left and right black key radio button assemblies 820 and 850 , respectively, that now supplement the left and right touch sensor outfitted white keys 701 and 713 , respectively, and the left and right white key radio button assemblies 720 and 750 , respectively. To similarly reduce the complexity of the current logic diagram 1100 , for each of these two added touch sensor outfitted black keys 702 and 714 , only three touch sensors 821 , 835 , and 842 , and 851 , 865 , and 872 , respectively, of their total touch sensors 821 to 842 and 851 to 872 , respectively, are shown.
[0094] As is shown in the current logic diagram 1100 , rather than the left touch sensor outfitted white key 701 being directly connected, as it was in the previous logic diagram 1000 , to the S input of the NOR latch 1070 and to the input of the H->L delay 1081 , it is now OR'd with the left touch sensor outfitted black key 702 via an OR gate 1181 . Similarly, rather than the right touch sensor outfitted white key 713 being directly connected, as it was in the previous logic diagram 1000 , to the INV gate 1082 , it is now OR'd with the right touch sensor outfitted black key 714 via an OR gate 1182 . As such, with regard to the NOR latch 1070 , H->L delay 1081 , and INV gate 1082 , their logic that was previously controlled by the left touch sensor outfitted white key 701 and by the right touch sensor outfitted white key 713 is now controlled by either the white or black left touch sensor outfitted key 701 or 702 , respectively, and by either the white or black right touch sensor outfitted key 713 or 714 , respectively.
[0095] As is further shown in the current logic diagram 1100 , rather than the left and right white key radio button assemblies 720 and 750 , respectively, being each directly connected, as they were in the previous logic diagram 1000 , to the respective left and right 3-state data buses 1031 and 1032 , they are now multiplexed with the left and right black key radio button assemblies 820 and 850 , respectively, via the left 2:1 MUX 1131 and the right 2:1 MUX 1132 , respectively. The left 2:1 MUX 1131 is controlled by the left touch sensor outfitted keys 701 and 702 via a connected NOR latch 1141 , NOR gate 1151 , H ->L delay 1161 , INV gate 1171 , and D latch 1191 , in the same manner that the right 3-state data bus 1032 was controlled in the previous logic diagram 1000 by the touch sensor outfitted white keys 701 and 713 via the respectively connected NOR latch 1070 , NOR gate 1080 , H->L delay 1081 , INV gate 1082 , and D latch 1073 . Similarly, the right 2:1 MUX 1132 is correspondingly controlled by the right touch sensor outfitted keys 713 and 714 via a connected NOR latch 1142 , NOR gate 1152 , H->L delay 1162 , INV gate 1172 , and D latch 1192 , respectively.
[0096] With this additional logic, it is now possible to play a chord of any type and root note, simply by positioning the fingers for that chord type, positioning the hand for the touch sensor associated with that root note, and then pressing.
[0097] The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the appended claims rather than to the foregoing specification as indicating the scope of the invention. | The present invention provides touch sensor means for detecting the touch location along the length of an outfitted piano key as it is pressed, so as to then offset the notes of an associated piano keyboard accordingly during play. When such an outfitted key is pressed in combination with other piano keys, the touch location along the length of the outfitted key, and the separation intervals and timing of the key presses, are analyzed to determine the intended chord, such that before any notes are sounded, the notes of the pressed keys are configured for the sounding of that chord. This arrangement enables playing a wide range of notes using just a few keys, so as to provide a substantially reduced-size keyboard with full-sized keys sufficient for real-time playing. This arrangement also enables configuring the note offsets of those pressed keys to conform to a selected musical key, so as to simplify the layout of the keyboard by eliminating its black keys, while still supporting the playing of non-conforming notes. This arrangement further enables applying pitch variation to those note offsets in order to emulate the “string stretching,” “whammy bar,” and “fretless neck” playing techniques for guitars and basses. This arrangement even further enables playing advanced chords in a simplified manner. Finally, this arrangement enables providing a wide assortment of keyboards that can differ in the type, number, size, and functionality of their outfitted keys. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of compositions for animal feedstuffs.
STATE OF THE ART
[0002] The most common problem known to affect farm and companion animals is the damage caused by bacterial infections and mycotoxins produced by moulds ingested with their feed. Regarding bacterial infections, and in particular intestinal infections, these often present with severe diarrhoea which can compromise, even to a serious extent, the health of the animal and consequently the revenue of the farm as a whole.
[0003] Regarding mycotoxins produced by moulds, their toxic effects on specific organs and on the physiological functions of animals, and their capacity to cause diseases such as toxicosis, have been known for some years. It is also known that carcinogenic mycotoxins, such as aflatoxins produced by moulds of the Aspergillus strain, can be transferred from cow's or goat's milk to man because they are stable and cannot be eliminated with normal heat treatments. Ocratoxin A is produced by Aspergillus and Penicillium species; if present in the feed, it can cause serious kidney diseases in pigs and in bird species.
[0004] T-2 toxin, produced by Fusarium species, can cause necrosis of the digestive tract of animals.
[0005] It is normally sought to overcome these drawbacks by using short chain organic acids, either alone or in a mixture, such as: formic acid (C 1 H 2 O 2 ), acetic acid (C 2 H 4 O 2 ), propionic acid (C 3 H 5 O 2 ), lactic acid (C 3 H 6 O 2 ), fumaric acid (C 4 H 4 O 4 ), butyric acid (C 4 H 8 O 2 ), citric acid (C 8 H 8 O 7 ) and benzoic acid (C 7 H 6 O 2 ).
[0006] Among the limitations of using said organic acids is their strong corrosive action which can damage any equipment with which they come into contact. Salified forms with ammonium, calcium, sodium or potassium also produce a corrosive action which, though more limited, is nevertheless present.
[0007] There are also certain physiological restrictions to the action of organic acids as such or in salified form when used as antibacterials in the diets of animals; in this respect organic acids are known to require an acidic pH in order to perform the actual antibacterial action, because under these conditions they are present in the undissociated RCOOH form. This undissociated RCOOH form passes through microorganism cell walls and, once inside, is dissociated according to intracellular pH. To maintain its intracellular pH the microorganism expels H + ; the level of dissociated organic acid thus rises and as it does not leave the microorganism, it kills it.
[0008] In the intestines, however, the pH is slightly basic (around 7) so the presence of organic acid in undissociated form is very limited, and consequently the antibacterial function is also very limited.
[0009] In the light of the aforesaid, therefore, there is an evident need to develop new compositions able to counteract the effects of moulds and bacteria present in animal feeds, but which do not exhibit the aforesaid drawbacks.
[0010] The technique of microencapsulating organic acids with lipid substances was developed as a method for delivering organic acid to the intestines and to lower the pH therein, but the results obtained are rather unsatisfactory because of the buffering action of sodium bicarbonate produced by the pancreas as an intestinal pH regulator. Moreover, in addition to not being very effective, this technology is also very costly.
[0011] The antibacterial action of certain fatty acid monoglycerides has been investigated in a number of studies, for example:
[0012] 1. J. Kabara, Dennis M. Swieczkowski, Anthony J, Conley, Joseph P. Truant 1972 FATTY ACIDS AND DERIVATES AS ANTIMICROBIAL AGENTS.
[0013] 2. G. Bergsson, J. Arnfinnsson S. Karlsson, O. Steingrimsson, H. Thormar 1998. IN VITRO INACTIVATION OF CHLAMYDIA TRACHOMATIS BY FATTY ACIDS AND MONOGLYCERIDES.
[0014] 3. G. Bergsson, J. Arnfinnsson, O. Steingrimsson, H. Thormar 2001. IN VITRO KILLING OF CANDIDA ALBICANS BY FATTY ACIDS AND MONOGLYCERIDES.
[0015] 4. H. Thormar, H. Hilmarsson, G. Bergsson 2005. STABLE CONCENTRATED EMULSIONS OF THE 1-MONOGLYCERIDE OF CAPRIC ACID (MONOCAPRIN) WITH MICROBICIDAL ACTIVITIES AGAINST THE FOOD-BORNE BACTERIA CAMPYLOBACTER JEJUNI, SALMONELLA SPP AND ESHERICHIA COLI; PCT/IS 2005/000026 “STABLE CONCENTRATED ANTI-BACTERIAL EMULSIONS OF MONOCAPRIN IN WATER”.
[0016] 5. Hilmarsson, H. Thormar, J. H. Thrainsson, E. Gunnarsson 2006 EFFECT OF GLYCEROL MONOCAPRATE (MONOCAPRIN) ON BROILER CHICKENS: AN ATTEMPT AT REDUCING INTESTINAL CAMPYLOBACTER INFECTION.
[0017] These studies have highlighted a promising but not exhaustive research direction; as far as current knowledge allows, there are no studies which confirm the specifically antibacterial and anti-mould action of compositions of short chain fatty acid monoglycerides combined with glycerol.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 is an aqueous suspension of a composition of the invention shown by electron microscopy.
[0019] FIG. 2 shows untreated feed inoculated with Fusarium.
[0020] FIG. 3 shows feed inoculated with Fusarium and treated with 0.7% Monopropionin 43.
SUMMARY OF THE INVENTION
[0021] The present invention relates to compositions containing C 1 to C 7 fatty acid monoglycerides in percentages between 10% and 90% and glycerol between 10 and 90% by weight (calculated on the total composition weight) as antibacterials and anti-mould agents to be added to cereals, feed, and to general foodstuffs and drinking water intended for the feeding of animals.
DETAILED DESCRIPTION OF THE INVENTION
[0022] It has surprisingly been found that compositions containing C 1 to C 7 organic acid monoglyceride esters combined with glycerol have a strong antibacterial potency both at acidic pH (4.5) and at neutral pH as is present in animal intestines (i.e. pH 7).
[0023] In the compositions of the invention, the organic acid monoglyceride esters as aforedefined are present in amounts between 10% and 90% and the glycerol between 10 and 90% by weight (calculated on the total composition weight); preferably said amounts are between 40%-90%, and 10%-60% respectively.
[0024] The term “C 1 to C 7 organic acids” according to the invention refers preferably to the following acids: formic, acetic, propionic, lactic, butyric, citric, fumaric and benzoic acids.
[0025] Butyric acid and propionic acid are particularly preferred.
[0026] Examples of compositions according to the invention are compositions consisting of:
[0027] (a)
[0000]
monoglyceride ester of butyric acid
42-47%
diglyceride ester of butyric acid
5-8%
triglyceride ester of butyric acid
0.5-2%
glycerol
45-50%
[0028] (b)
[0000]
monoglyceride ester of propionic acid
45-50%
diglyceride ester of propionic acid
8-12%
triglyceride ester of propionic acid
1-3%
glycerol
36-40%
[0029] Specific examples of compositions according to the invention are compositions consisting of:
[0030] (c)
[0000]
monoglyceride ester of butyric acid
45%
diglyceride ester of butyric acid
6%
triglyceride ester of butyric acid
1%
glycerol
48%
[0031] (d)
[0000]
butyric acid monoglycerides
43%
butyric acid diglycerides
6%
butyric acid triglycerides
1%
glycerol
50%
[0032] (e)
[0000]
monoglyceride ester of propionic acid
49%
diglyceride ester of propionic acid
10%
triglyceride ester of propionic acid
2%
glycerol
39%
[0033] (f)
[0000]
propionic acid monoglycerides
43%
propionic acid diglycerides
6%
propionic acid triglycerides
1%
glycerol
50%
[0034] Antibacterial potency values of organic acids alone compared with those of the compositions of the invention are given below in table 1.
[0000]
TABLE 1
Salmonella
Campylobacter
E. coli
typhimurium
jejuni
PRODUCT
CONC. USED
pH
(cfu/ml)
(cfu/ml)
(cfu/ml)
Positive control
7
108 × 10 5
120 × 10 5
431 × 10 5
Positive control
4.5
84 × 10 5
96 × 10 5
201 × 10 5
Propionic acid
1:909
7
54 × 10 4
11 × 10 4
33 × 10 3
Propionic acid
1:909
4.5
13 × 10 4
42 × 10 3
14 × 10 1
Butyric Acid
1:1000
7
106 × 10 4
65 × 10 4
18 × 10 3
Butyric Acid
1:1000
4.5
78 × 10 4
25 × 10 3
2 × 10 1
Monopropionin 43
1:109
7
110 × 10 4
12 × 10 3
79 × 10 5
Monobutyrin 43
1:100
7
75 × 10 4
35 × 10 3
48 × 10 4
Monobutyrin 43
1:100
4.5
47 × 10 4
8 × 10 2
87 × 10 3
Note:
Monopropionin 43 is composed of: 43% propionic acid monoglycerides 6% propionic acid diglycerides 1% propionic add triglycerides 50% glycerol
Note:
Monobutyrin 43 is composed of: 43% butyric acid monoglycerides 6% butyric acid diglycerides 1% butyric acid triglycerides 50% glycerol
[0035] Table 2 compares the in vitro antibacterial action of pure butyric acid, of butyric acid monoglycerides without free glycerol and of a mixture of butyric acid monoglycerides with free glycerol, against Clostridium perfringens. Whereas the mixture of butyric acid monoglycerides and glycerol already exhibits an inhibitory potency (i.e. no growth) in all three replicates at a concentration of 1000 ppm, the butyric acid monoglycerides do not exhibit any inhibitory potency against the bacterium, and butyric acid only exhibits inhibitory action from 3000 ppm.
[0000]
TABLE 2
Bacteria: Clostridium perfringens CP27
Inoculation concentration: 10 5
Medium: Brain Heart Infusion
Incubation time and appearance of growth; + for 24 hr, ++ for
37 hr and +++ for 96 hr - 3 replications for each concentration
Positive
Negative
control
Monobutyrin
Butyric acid
Control
(PC)
ppm
Butyric Acid
43
monoglycerides
+
500
+
+
+
+
+
+
+
++
+
+
+
mean
1000
+
no growth
+
+
no growth
+
+
no growth
+
mean
1500
+
no growth
+
+
no growth
+
+
no growth
+
mean
2000
++
no growth
+
++
no growth
+
++
no growth
+
mean
2500
++
no growth
+
++
no growth
+
++
no growth
+
mean
3000
no growth
no growth
+
no growth
no growth
+
no growth
no growth
+
mean
4000
no growth
no growth
+
no growth
no growth
+
no growth
no growth
+
mean
[0036] Table 3 compares the in vitro antibacterial action of pure acetic acid, of acetic acid monoglycerides without free glycerol and of a mixture of acetic acid monoglycerides with free glycerol against porcine Salmonella typhimurium. Whereas the mixture of acetic acid monoglycerides and glycerol (Monoacetin 42) exhibits an inhibitory potency (i.e. no growth) in all three replicates at a concentration of 10,000 ppm, the acetic acid monoglycerides exhibit inhibitory potency against the bacterium from 25,000 ppm and the acetic acid exhibits inhibitory action from 20,000 ppm.
[0000]
TABLE 3
Bacteria: Porcine Salmonella typhimurium
Inoculation concentration: 10 5
Medium: Brain Heart Infusion
Incubation time and appearance of growth: + for 24 hr, ++ for
37 hr and +++ for 96 hr - 3 replications for each concentration
pH 6
Positive
Negative
Control
Acetic
Monoacetin
Acetic acid
control
(PC)
ppm
acid
42
monoglycerides
+
5000
+
+
+
+
+
+
+
++
+
+
+
Mean
10000
+
no growth
+
+
no growth
+
+
no growth
+
Mean
15000
+
no growth
+
+
no growth
+
+
no growth
+
Mean
20000
no growth
no growth
+
no growth
no growth
+
no growth
no growth
+
Mean
25000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
30000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
40000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
Note:
Monoacetin 42 is composed of: 42% acetic acid monoglycerides 7% acetic acid diglycerides 1% acetic acid triglycerides 50% glycerol
[0037] Table 4 compares the in vitro antibacterial action of pure formic acid, of formic acid monoglycerides without free glycerol and of a mixture of formic acid monoglycerides with free glycerol against porcine Salmonella typhimurium. Whereas the mixture of formic acid monoglycerides and glycerol (Monoformin 42) exhibits an inhibitory potency (i.e. no growth) in all three replicates at a concentration of 5,000 ppm, the formic acid monoglycerides exhibit inhibitory potency against the bacterium from 25,000 ppm and formic acid exhibits inhibitory action from 15,000 ppm.
[0000]
TABLE 4
Bacteria: Porcine Salmonella typhimurium
Inoculation concentration: 10 5
Medium: Brain Heart Infusion
Incubation time and appearance of growth: + for 24 hr, ++ for
37 hr and +++ for 96 hr - 3 replications for each concentration
pH 6
Positive
Negative
Control
Formic
Monoformin
Formic acid
control
(PC)
ppm
acid
42
monoglycerides
+
5000
+
no growth
+
+
+
no growth
+
++
+
no growth
+
Mean
10000
+
no growth
+
+
no growth
+
+
no growth
+
Mean
15000
no growth
no growth
+
no growth
no growth
+
no growth
no growth
+
Mean
20000
no growth
no growth
+
no growth
no growth
+
no growth
no growth
+
Mean
25000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
30000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
40000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
Note:
Monoformin 42 is composed of: 42% formic acid monoglycerides 7% formic acid diglycerides 1% formic acid triglycerides 50% glycerol
[0038] Table 5 compares the in vitro antibacterial action of pure fumaric acid, of fumaric acid monoglycerides without free glycerol and of a mixture of fumaric acid monoglycerides with free glycerol (Monofumarin 41) against E. coli. Whereas the mixture of fumaric acid monoglycerides and glycerol exhibits an inhibitory potency (i.e. no growth) in all three replicates at a concentration of 20,000 ppm, the fumaric acid monoglycerides exhibit inhibitory potency against the bacterium from 60,000 ppm and the fumaric acid exhibits inhibitory action from 90,000 ppm.
[0000]
TABLE 5
Bacteria: E. coli
Inoculation concentration: 10 5
Medium: Brain Heart Infusion
Incubation time and appearance of growth: + for 24 hr, ++ for
37 hr and +++ for 96 hr—3 replications for each concentration
pH 5
Positive
Mono-
Negative
Control
Fumaric
fumarin
Fumaric acid
control
(PC)
Ppm
acid
41
monoglycerides
+
10000
+
+
+
+
+
+
+
++
+
+
+
Mean
20000
+
no growth
+
+
no growth
+
+
no growth
+
Mean
40000
+
no growth
+
+
no growth
+
+
no growth
+
Mean
60000
++
no growth
no growth
++
no growth
no growth
++
no growth
no growth
Mean
80000
++
no growth
no growth
++
no growth
no growth
++
no growth
no growth
Mean
90000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
100000
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
no growth
Mean
Nota:
Monofumarin 41 is composed of: 41% fumaric acid monoglycerides 8% fumaric acid diglycerides 1% fumaric acid triglycerides 50% glycerol
[0039] If preferred, the compositions of the invention can also contain active principles of essential oils (cinnamic aldehyde, thymol, carvacrol) in percentages comprised between 1 and 20% (calculated by weight on the weight of the mixture of other components) as commonly provided for such products for feeding animals, since these active principles are soluble in lipids but insoluble in glycerol.
[0040] It should be noted that when the composition of the invention is dispersed in water, the glycerol surrounds the monoglyceride itself to form drops which incorporate said monoglyceride, they remaining suspended in water (the other optionally added active principles dissolve in the monoglyceride, they also becoming incorporated within the glycerol drop) (see FIG. 1 ).
[0041] The compositions of the invention can be prepared according to the usual fatty acid esterification processes amply described in the literature, but using a large excess of glycerol (never less than 200% by weight on the weight of the fatty acids used) in order to obtain a large amount of monoglycerides with large amounts of free glycerol.
[0042] The compositions of the invention can be added to the animal feed and/or their drinking water in amounts from 0.1 to 1.5%, preferably from 0.3-0.6% calculated by weight on the feed or drink weight.
[0043] The compositions of the invention are particularly indicated for the diets of pigs, chickens, fish, cattle, sheep and companion animals.
EXAMPLE 1
[0044] The esterification reaction takes place in batches of 10,000 kg.
[0045] 3000 kg of butyric acid and 7000 kg of glycerol are introduced into a reactor at ambient temperature.
[0046] The temperature is increased to 140° C., the butyric acid that evaporates being recycled within the reactor by means of a reflux condenser.
[0047] The further raising of the temperature from 140 to 170° C. must be very slow (over about 4 hours) and the reflux condenser temperature must be maintained at 120° C. in order to evaporate the water derived from the esterification reaction while the butyric acid continues to recycle within the reactor.
[0048] At this point the temperature can be raised to 180° C. (but leaving the reflux condenser temperature at 120° C.) and once this temperature has been reached the acidity of the mixture is expected to reach a value less than 1%.
[0049] A vacuum is then applied to distil off any unreacted butyric acid until a final acidity of less than 0.2% is reached.
[0050] The mixture is discharged through a cooler to bring it to ambient temperature.
[0051] A mixture is thus obtained containing 43% monoglyceride ester, 6% diglyceride ester, 1% triglyceride ester, and 50% glycerol.
[0052] Once the esterification reaction is complete the glycerol can be separated if desired by distillation from the thus obtained mono- di- and triglyceride esters to arrive at a 90% monoglyceride concentration.
EXAMPLE 2
[0053] Sixty 5 week old DanBred piglets were assigned to two groups of thirty piglets each: A)—control, and B) treated, divided into 6 pens of ten animals each. After the first 10 days of adaptation in the enclosures, all animals were inoculated orally with Salmonella typhimurium, isolated at the Istituto Zooprofilattico of Forli (Italy) from fecal samples of infected pigs, with a dose equal to 7×10 7 cfu.
[0054] The following day some of the subjects from each pen presented with diarrhoea.
[0055] The symptoms worsened and affected all the subjects over the next three days following infection.
[0056] Fecal samples were collected on the third day following infection; the bacterial count was found to be equal to 165,000 cfu in control group A) and 160,000 cfu in the treated group B). Group B) from the third day after infection was treated with a mixture composed of:
Butyric acid monoglycerides=45% Butyric acid diglycerides=6% Butyric acid triglycerides=1% Glycerol=48%
[0061] administered in the drinking water at a dosage of 0.5% for three days. On the third day after treatment, fecal samples were again collected for bacterial count analysis. The control group A) presented a mean cfu number of 160,000, while in the treated group B) the cfu number was 900. Use of the “butyric acid esters and glycerol” mixture in the stated percentages reduced the cfus of salmonella by 3 log10, with a 3-day administration. This fact confirms the bactericidal effectiveness of the mixture.
EXAMPLE 3
[0062] The present field trial was carried out on an Italian farm with hygiene problems such as very evident ileitis resulting from a Lawsonia intracellularis infection, enteritis from Brachyspira Spp and necrotic enteritis resulting from a Treponema hyodysenteriae infection. 1,027 DanBred pigs weighing about 25 kg (71 days old) were divided into two groups: control group A) and treated group B), composed of 511 and 516 animals respectively.
[0063] The two groups were fed with a feed that was formulated in identical manner except for the following components: the feed of the control group had added Lincomycin, 200 ppm, and Doxicyclin, 250 ppm, for the first 14 days of the trial, and Lincomycin alone for the remaining time. The treated group B) did not receive antibiotics in the feed, only a “butyric acid esters and glycerol” mixture composed as follows:
Butyric acid monoglycerides=45% Butyric acid diglycerides=6% Butyric acid triglycerides=1% Glycerol=48%
[0068] administered to the feed in a quantity of 0.5% to replace 0.5% of the soya oil.
[0069] The trial lasted 63 days. The growth and feeding efficiency results are summarized in the table below.
[0000]
TABLE
Group B) -
Group A) -
Butyric acid esters
Control
and glycerol
Delta
No. of animals
511
516
Age at the start of the trial
71
71
(days)
Age at the end of the trial
134
134
(days)
Average weight at the start
25
25
of the trial (kg)
Average weight at the end of
62.13
63.61
the trial (kg)
No. of dead animals
5
2
−3
No. of rejected animals
3
2
−1
Average daily weight
0.59
0.61
+0.02
increase (kg)
Total feed consumed (kg)
53.570
53.250
−320
Meat produced in kg
19.340
20.200
+860
Feed conversion index
2.76
2.64
−0.12
[0070] Although the fecal analysis of the control group A) showed the presence of Lawsonia, its presence was not found in the treated group B). The diarrhoea episodes were also very much reduced in the treated group B). The growth parameters, the feed conversion index of the treated group B) were comparable, and tendentially better than those of the control group A) whose diet contained the aforesaid antibiotics. The “butyric acid esters and glycerol” mixture enabled the highlighted diseases to be controlled, without the use of antibiotics. The trial has demonstrated the antibacterial effect of the “butyric acid esters and glycerol” mixture with a consequent improvement to intestinal health.
EXAMPLE 4
[0071] Efficacy Test Towards Salmonella Typhimurium in Chickens
[0072] Salmonella Strain
[0073] For the test, a strain of Salmonella typhimurium isolated and identified by the IZSLER section of Forli was used.
[0074] Animals
[0075] SPF (Specific Pathogen Free) chicks were used, 30 animals per test. The chicks were hatched at the IZSLER section of Forli. The subjects were immediately placed into isolation units.
[0076] Diet
[0077] The animals received water from the mains water supply and a commercial starter ad libitum feed. The feed contained added Monobutyrin 43.
[0078] Experimental Protocol
[0079] 4 groups of 30 subjects each were prepared. The diets differed by the different amount of Monobutyrin 43 added to the feed from the first day of life, and were identified as follows: untreated control group: 0%, group 1: 1% in the feed, group 2: 0.3% in the feed. Group 3 received the same feed as the control group up to the 14 th day of life, i.e. until the 7 th day post-infection, and only received feed supplemented with 1.4% Monobutyrin 43 after that day.
[0080] At aged 7 days, all the subjects were infected by the esophageal route with 10 7 cfu of Salmonella typhimurium. 24 hours following infection, cloacal swabs were taken from all the subjects to confirm that Salmonella typhimurium infection had taken hold. At 14, 24 and 35 days of life, 10 subjects in each group were killed.
[0081] The ceca were collected from each animal and the load of Salmonella typhimurium was determined (expressed in cfu/g).
[0082] Laboratory Tests
[0083] The absence of antibodies against S. typhimurium was confirmed by an ELISA test. The cloacal swabs were seeded directly onto Hektoen Enteric Agar and incubated at 37° C. for 24 hours. One gram of intestinal contents was diluted in 9 ml of Ringer's lactate and seeded onto Hektoen Enteric Agar (inoculum volume: 0.1 ml). Colony counting was carried out after 24 hours of incubation at 37° C. For each collection, the geometric means of the bacterial loads of the 10 killed subjects were calculated.
[0084] All the subjects, after one day of life, were found to be seronegative for Salmonella typhimurium. 24 hours after the infection, all the cloacal swabs were found to be positive for S. typhimurium. The results of the determined cecal bacterial loads are shown in the following table.
[0000]
TABLE
CFU in the cecum of chickens infected with Salmonella Typhimurium -10 7
Group 3
Group 1
Group 2
(1.4% in feed
(1% in
(0.3%
from 14 th
Control
feed)
in feed)
day of life)
Day of infection
0
0
0
0
(7 th day of life)
7 th day post-
6,400,000
770,000
2,226,000
6,302,000
infection
Start of
treatment
17 th day post-
25,120,000
213,220
1,242,000
171,120
infection
28 th day post-
(high
>100
300
1,000
infection
mortality)
EXAMPLE 5
[0085] In Vitro Sensitivity Tests towards Filamentous Fungi (Moulds)
[0086] Materials and Methods
[0087] Strains of Aspergillus spp, Penicillium spp and Fusarium spp were utilized for the test, having been isolated and identified during diagnostic activity at the IZSLER section of Forli from complete feeds used in the chicken industry. To prepare the inoculum, mycelium of pure cultures of the tested strains was collected using a swab. The material thus collected was dissolved in a culture broth (BHI—Brain Heart Infusion). 5 ml of the fungal suspension and an equal amount of the product to be tested were placed in contact in a test tube. The test tube was incubated at 20±4° C. for 24 hours.
[0088] After this time period, the fungal suspension was then seeded and enumerated.
[0089] The control suspension was obtained by placing 5 ml of fungal suspension+5 ml of diluent (Ringer's lactate) into a test tube. Reading of the tests was carried out after a 5 day incubation period at 20±4° C.
[0090] The results given in the following table are expressed as cfu/ml
[0000]
TABLE
ASPERGILLUS
PENICILLIUM
FUSARIUM
PRODUCT
spp.
spp.
spp:
Control
450000
97000
310000
Monopropionin 43
20000
1500
90000
Monobutyrin 43
1000
700
3000
Propionic acid
300
<100
300
Ammonium
1000
100
500
propionate
Note:
Monopropionin 43 is composed of: 43% propionic acid monoglycerides 12% propionic acid diglycerides 1% propionic acid triglycerides 28% free glycerol 16% H 2 O
Note:
Monobutyrin 43 is composed of: 43% butyric acid monoglycerides 6% butyric acid diglycerides 1% butyric acid triglycerides 50% glycerol
EXAMPLE 6
[0091] In Vitro Efficacy Test towards Penicilium spp and Fusarium spp
[0092] Materials and Methods
[0093] Strains: strains of moulds isolated and identified by the IZSLER section at Forli were used for the test. The strains were revitalized in BHI broth then enumerated in OGYE agar (after incubation at 20° C. for 5 days)
[0094] Substrate: a complete chicken feed, sterilized in a dry oven at 100° C. for 4 hours, was used.
[0095] Efficacy test: 10 g of feed were inoculated with 2 ml of fungal suspension (in distilled water) to which 70 μl of the product to be tested was added. The mixture thus obtained was kept at ambient temperature. A positive control (infected and untreated) and a negative control (feed only+distilled water) were also prepared.
[0096] On days 7 and 14 following infection, the fungal concentrations in the treated sample and control samples were evaluated.
[0097] The results are given in the table below.
[0000]
TABLE
Concentration of
Concentration of
Concentration of
Concentration of
Concentration of
Concentration of
Fusarium spp.
Fusarium spp.
Fusarium spp.
Penicillium spp.
Penicillium spp.
Penicillium spp.
On day 0
7 days post-
14 days post-
On day 0
7 days post-
14 days post-
PRODUCT
(cfu/g)
infection (cfu/g)
infection (cfu/g)
(cfu/g)
infection (cfu/g)
infection (cfu/g)
Positive control
5,700,000
72,000,000
300,000,000
100,000
30,000,000
200,000,000
Negative control
<100
<100
<100
<100
<100
<100
Monopropionin 43
5,700,000
410,000
250,000
100,000
<100
<100
Note:
Monopropionin 43 is composed of:
43% propionic acid monoglycerides
12% propionic acid diglycerides
1% propionic acid triglycerides
28% free glycerol
16% H 2 O | Described are antibacterial and anti-mould compositions containing high amounts of C 1 to C 7 organic acid mono-glycerides and glycerol, their preparation and their use in animal feedstuffs. | 8 |
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